Operating Instructions

Diesel Hammers

D6 through D280

Hera Hammers
2e Havenstraat 6
1976 CE IJmuiden
The Netherlands

Telephone: + 31 (0)255-531844
Email: info@hera-hammers.com
www.hera-hammers.com
 HERA

1. General information

2. Safety information

3. Technical data
3.1. Conversion factors 3.4 Exhaust / Emission information
3.2 Diesel hammer data (English unit)
3.3 Sound emission values

4. Transport
4.1. General preparation 4.3. Possible cable damage
4.2. Lifting cables – ground support

5. Assembly and mode of operation

5.1 Components of diesel pile hammer 5.6 Assembly and disassembly of the
5.2 Section view upper cylinder extension
5.3 Operating principle 5.7 Safety devices
5.4 Pile driving equipment – general inform.
5.5 Diesel pile hammer conversion for driving
batter piles

6. Starting the Diesel hammer

6.1 Filling lubricant lines 6.6 Tripping device: assembly
6.2 Assembly of pile and helmet cushion 6.7 Fuel supply –bleeding of fuel control
6.3 Guiding for the pile helmet pump and injection valves
6.4 Lifting the pile 6.8 Cleaning of combustion chamber
6.5 Mounting the diesel pile hammer into the 6.9 Start and control
lead system

7. Pile driving instructions

7.1 General information
7.2 Blow energy and regulation- mechanical and hydraulic controlled fuel pump

8. Shutting down – storage

9. Maintenance

10. Servicing & Troubleshooting

HERA IJmuiden Holland

 GENERAL INFORMATION

Thank you for choosing a our Diesel Hammer. This machine will provide the utmost reliability with a
minimum of effort and maintenance on your part.

We appreciate your business and want to continue to deserve it.

YOU CAN RELY ON US !

Prior to assembly Safety indicators

These operating instructions must be read The following symbols are used in these
prior to assembly and prior to putting the unit operating instructions:
into operation. The operating instructions Please read these operating instructions
must be stored at a safe place for later use. carefully. The safety information must be
Confirm on the form enclosed in Appendix A4 observed!
that you have read and fully understood these
operating instructions!

These operating instructions:

 must be used by anyone who assembles, Caution indicates a potentially hazardous
converts, disassembles, operates, situation which, if not avoided may result
maintains or repairs a Diesel pile hammer in minor or moderate injury
 simplify all work in connection with a Diesel

! WARNING !
pile hammer
 inform you about some basics of the
operating mode and use of Diesel pile
hammers Warning indicates a potentially hazardous
 help you with the required calculations situation which, if not avoided could result
 contain important information for the safe in death or serious injury
and proper handling and operation of the
Diesel pile hammer .

The manufacturer will not accept any ! DANGER !

liability, if it is determined that
these operating instructions were not read
Danger indicates an imminantly
or ignored!
hazardous situation, which if not avoided
will result in death or serious injury
Inform the operators about the obligation
to read the operating instructions.
General and special safety information is
contained in Chapter 2 “Safety Regulations”.
Safety information relation to a specific
handling step is shown prior to the description
of this handling step.

2
 GENERAL INFORMATION

Components of Diesel Pile Hammer

The picture below should make you familiar with the diesel hammer components to understand the
following safety information correctly.

starter guides

tripping device

upper end ring

with catch ring groove

lifting ears

trip cam lever

release point
upper cylinder

fuel tank with

lube oil tank

hammer guiding
(for U-type lead)

lifting dog

lower cylinder

lube pump
fuel pump

exhaust ports

injection valve

pump guard
outer end ring
rubber ring
impact block

Important: We do not guarantee pile helmets, striker plates and cushion material !

3
 SAFETY INFORMATION

2. Safety Regulations
destroyed by the impact forces applied by
The safety information is provided to the Diesel pile hammer.
keep the risk for workers and property as
low as possible All other uses such as the deforming or
compacting of materials or the removal of
2.1. Proper and improper use piles constitute an improper use and are thus
The proper use of Diesel pile hammers is not permitted for safety reasons! Danger to
defined as the driving of suitable units into a life!
supporting soil layer. Said units may be
piles, pipes, sheet piles etc. that will not be

! DANGER !

LIFT HAMMER WITH TRIP GEAR AGAINST THE LIFTING

DOGS ONLY AS DESCRIBED IN OPERATING MANUAL.
DO NOTLIFT TRIP GEAR AGAINST TOP OF THE STARTER
GUIDES.

! WARNING !

“WARNING: DO NOT LET TRIP REST ON THE LIFTING DOGS

WHILE HAMMER IS OPERATING”

NEVER PLACE ANY PART OF THE BODY UNDERNEATH THE

HAMMER. ALWAYS SECURE HAMMER BEFORE MOVING
LEADS.
Attach warning notice supplied with hammer in good visible position on piling rig.

! DANGER !

4
 SAFETY INFORMATION

2.2. General Safety Information for

the handling of the Diesel Pile
Hammer.
! DANGER !
Safety is basically a matter of common
You must observe local safety regulations
sense! There are safety regulations that
issued by the respective legislature or by
must be observed at all times! Beyond
unions and similar organizations! Take the
that, each situation exhibits peculiarities
necessary measures with respect to sound
that cannot always be indicated in the
and vibration emissions occurring during the
safety regulations! Always watch for
operation of the Diesel pile hammer.
safety risks and problems! Plan ahead
and take care of problems as early as
Obstacles in the work and transport areas,
possible.
the load capacity of the soil as well as the
safety barriers for public traffic areas must
Please keep these operating instructions for
be taken into account. It is particularly
Diesel pile hammers with the documents for
important to pay attention to changing
the carrier equipment! Keep both at an
weather conditions, wind, decreasing
easily accessible location! Inform the
visibility and changing soil conditions! Stop
operators regarding the obligation to read
work for critical conditions (e.g. storms!).
these operating instructions and about the
Visibility must be sufficient to allow a proper
location where documentation is kept!
operation of the pile-driving equipment by
driver and operator without risking their lives
You must read every page of these
and that of others! Lights must be used for
operating instructions prior to handling the
work carried out under poor visibility
Diesel pile hammer. Observe the safety
conditions or in darkness. The lighting
information and instructions when working
fixtures must provide a brightness of at least
with the Diesel pile hammer. A lack of the
100 lx for the work areas! For transports in
above may endanger your life and that of
darkness, moving equipment must be fitted
other persons!
with lights providing a distance light level of
at least 10 lx (23 feet (7 meters) ahead of
The Diesel pile hammer shall be inspected
the equipment measured in the driving
prior to the first time that it is put into
direction!) Keep a safe distance from
operation and then annually by an expert!
- Earth cables, water pipes, sewage water
Said thorough inspection must be carried
pipes and other pipes located below
out by persons that have participated in an
ground
extensive training program in our facilities.
- Overhangs, edges, slopes and unsafe
Such an expert inspection is also required
soil!
after any structural change! The results of
- High-voltage overhead lines, phone lines
the inspections must be indicated in writing!
and other overhead lines
Prior to beginning your work, ask the
Prior to putting the unit into operation, it will
superintendent about the location of supply
be necessary to determine if the last expert
and disposal pipes and about the safe
inspection was carried out within the last 12
distances to be maintained!
months.
All workers must be healthy and strong
Only properly trained and authorized
enough to meet the physical challenges!
personnel shall work with the diesel pile
Under no circumstances shall a worker be
hammer
allowed to work under the influence of
drugs, alcohol, medications or similar!

5
 SAFETY INFORMATION

! DANGER !

Hard hat, safety gloves, safety boots and Please note that the mixture of fuel, exhaust
suitable work clothes must be worn at all gas, soot and air is at a high pressure blown
times when working with the Diesel pile out of the combustion chamber bolt opening
hammer. Reflective clothing shall be worn if when cleaning the combustion chamber!
conditions warrant this! This reduces the Maintain a safe distance and wear safety
risk of injuries! Ear plugs should also be glasses! Danger of injuries!
worn when operating the Diesel pile
hammer! A permanent hearing impairment Do not touch the Diesel pile hammer
may result otherwise (See Chapter 4 immediately after its operation! Danger of
“Technical Specifications” for Sound burns! Particularly the impact head, exhaust
Emission Data). and components located adjacent to the
combustion chamber must be allowed to
The pile hammer must be fitted with at least cool for a sufficient period!
two fire extinguishers! The fire extinguishers
* must have a minimum capacity of 13 Diesel fuel and lubricants are very
pounds (6 kg), flammable and can explode under certain
* must be suited to extinguish oil and conditions! Diesel fuel, ether and lubricants
electric fires, must be handled carefully! Take appropriate
* must be placed on the same side of the measures to prevent a spilling, igniting,
pile-driving equipment inhalation, swallowing as well as skin or eye
* shall not be placed in areas exposed to a contact with Diesel fuel, ether or lubricants!
high fire risk, The work area of the Diesel pile hammer
* must be placed as close as possible to the must always be well ventilated. Under no
operator and between the operator and the circumstances will smoking or other
area with the greatest fire risk (at a very activities with open flames or sparks be
visible and easily accessible location for allowed during fueling or in storage areas of
remote-controlled Diesel pile hammers), Diesel fuel, ether and lubricants! Diesel fuel,
* must be attached such that they can be ether and lubricants should never be stored
removed without tools! in foodstuff containers! Danger to health
(poisonous, caustic) and the environment!
Familiarize yourself with the location and
handling of the fire extinguishers prior to Exhaust gases forming during operation are
beginning work! poisonous! Do not inhale exhaust gas!
Danger to health!
Maintain a minimum safe distance of 13 Work on a Diesel hammer (maintenance,
feet (4 meters) from the units to be driven repair, converting…) shall be performed
during the operation of the Diesel pile while the hammer is not running! The Diesel
hammer! Make sure that only the excavator pile hammer must rest on the pile or ground
operator, operator and the foreman in or on the lower support device!
charge of the pile-driving work move within
an area of 1.5 times the lead height (or the Avoid touching moving parts! Danger of
height of the excavator/crane)! Close this injury!
area off, if required!

6
 SAFETY INFORMATION

Pay careful attention at any time for

components that come loose and fall from Keep the job site tidy! Danger of injuries!
the Diesel pile hammer, lead, impact head,
pile guiding system or from the pile itself!

2.3. Safety information for the excavator

operator
! DANGER !
Use only excavators/leads/cranes that
exhibit a sufficient load capacity for the
Diesel pile hammer, pile helmet and the
piles!

Make sure the accessories are safely stored

away prior to converting the equipment!
Secure all loose components! Keep the load Never exceed the maximum speed on a
as close as possible to the ground during down slope! Always change – to a lower
the conversion stage! Drive very carefully gear prior to reaching the down slope! You
on a rocky or slippery ground or on a slope! may lose control of the vehicle otherwise!

You must personally make sure that nobody Never leave the driver’s seat when the
will be placed into a dangerous situation vehicle is still moving or the Diesel pile
with the moving of the equipment! Seek the hammer is still in operation! Never leave the
assistance of a helper! Accept signals from vehicle unattended with the motor running!
one person only! No co-driver, please!
You must or must not do the following when
Lights must be turned on in darkness or in you come into contact with a power line
low visibility conditions! carrying a high voltage:

Observe traffic signs and rules when driving - Do not leave the vehicle
on public traffic areas! - Drive the vehicle out of the danger zone, if
possible
Do not hold on to the steering wheel - Warn other persons not to come closer to
column, control console or operating levers or touch the equipment
when entering or leaving the vehicle! This - Arrange for the power to be turned off
may cause accidental motions! Danger of - Leave the vehicle only after the power has
accidents! been turned off!

Always work up or down a slope and not Familiarize yourself with the emergency exit
laterally to the slope! Prevent any actions through the front window!
that could cause the equipment to overturn!
When the equipment nevertheless begins to Report all problems to the foreman in
overturn or slide laterally, it will be charge of the pile-driving work. Make sure
necessary to immediately lower the the necessary repairs are carried out
equipment and point the vehicle down the immediately!
slope!
Check the steel cables daily for wear and
possible damage (see chapter 4.3)
Worn and damaged cables have to be
rreplaced immediately!

7
 SAFETY INFORMATION

2.4. Safety information for the operator

Wear a hard hat, safety boots, safety
gloves, ear plugs, safety glasses and
suitable, possibly reflecting, work clothes ! DANGER !
when working with the Diesel pile hammer!
This reduces the risk of injuries and
prevents permanent hearing and eye equipment into operation! Make sure all
damage! warning signs are placed at the hammer
and easy to read. Do not operate a Diesel
Familiarize yourself with the operating hammer that is damaged or exhibits
instructions for the Diesel pile hammer and operating problems! Inform the foreman in
all of its accessories prior to putting the unit charge of the pile-driving work about
into operation! Make sure you have a damages! All problems must be remedied
complete set of operating instructions! prior starting the hammer.

The Diesel pile hammer shall be operated You must take into account that the
only by trained personnel that have been operation of the Diesel pile hammer causes
authorized by the foreman in charge of the blows, impact forces and vibrations in the
driving work! whole pile hammer structure and in the
immediate vicinity!
Operate the Diesel pile hammer only when
it is in safe working condition! Carry out a Never work under the Diesel pile hammer,
thorough inspection prior to putting the lead or material to be driven! Avoid standing
in the area, in which the material to be
driven touches the ground! Make sure
repairs are carried out only by trained
experts!
2.5. Safety information for the foreman
in charge of the pile driving work

The foreman in charge of the pile-driving Make sure your operating instructions are
work must have been trained with this unit complete!
and must be at least 18 years old. Provide
the operator and excavator operator with Make sure the equipment and associated
information ensuring a safe execution of the attached units are inspected daily for
work! You are responsible for safety and all obvious defects prior to putting them into
events in the work area of the Diesel pile operation! Make sure all warning signs are
hammer! placed and readable Defects are found
most often in the following components: -
Please familiarize yourself with the Diesel pile hammer
operating instructions for the Diesel pile - Tripping device
hammer and all of its accessories prior to - Guiding components
putting the equipment into operation! - Support devices
- Pile helmet and pile guiding system
- Bridle and cables
The pile-driving work cannot be resumed
with a defective unit! Inform the pile-driving
personnel and the superintendent about the sure only properly trained personnel carry
defects! Have the defects remedied prior to out repair work! Do not operate the
putting the equipment into operation! Make equipment until all defects have been fully

8
 SAFETY INFORMATION

remedied Carry out a thorough inspection You must take into account that the
prior to putting the unit into operation. operation of the Diesel pile hammer causes
blows, impact forces and vibrations in the
whole pile hammer structure and in the
Prior to putting the equipment into immediate vicinity!
operation, you must make sure that nobody
is on or below the equipment. Sound the Never work under the Diesel pile hammer,
horn to warn persons of the impending lead or material to be driven! Avoid standing
starting of the diesel hammer! in the area, in which the material to be
driven touches the ground.

! DANGER !
2.6. Assembly, conversion, disassembly,
maintenance, repair

The Diesel pile hammer shall be inspected - At least two persons must be present.
prior to the first time that it is put into Both must be familiar with the operating
operation and then annually by an expert! instructions and must know how to address
Said expert inspection must be carried out safety questions!
by persons that have participated in an - One person must be located at the main
extensive training program in our facilities. operating station to monitor the safety of the
other persons! Said person must have
Assembly, conversion, disassembly, access to an EMERGENCY switch (or
maintenance and repair work shall be shutoff cable for the fuel supply) in all
carried out only by qualified and authorized situations!
personnel!
- An uninterrupted communication must be
The Diesel pile hammer must be shut off possible between the involved persons!
prior to carrying out any work on it! Danger
to life! - The work area must be fully lighted!

Make sure another person cannot put the Maintenance and repair work can be carried
equipment into operation where work is out by one person only, when the pile
carried out! Danger to life! hammer is completely shut off and all
means to put it into operation are blocked!
The following must be observed for repair
and maintenance work.

9
 TECHNICAL DATA

3.1. Conversion Factors

mass 1 t (metric) = 1000 kg 1 kg = 0.001 t (metric)

1 t (metric) = 1.102 t (US) 1 t (US) = 0.9072 t (metric)
1 kg = 2.204 lbs 1 lbs = 0.4536 kg
force 1 kN = 102 kp 1 kp = 0.0098 kN
1 kN ~ 220 Lbf (lb) 1 lbf = 0.0045 kN
energy 1 Nm = 0.102 kpm 1 kpm = 9.81 Nm
1 Nm = 0.7375 ft.lbs 1 ft.lbs 1.356 Nm
distance 1 mm = 0.0393 inch 1 inch = 25.4 mm
1 cm = 0.3937 inch 1 inch = 2.54 cm
1 m = 39.37 inch 1 inch = 0.0254 m
1 m = 3.2808 ft 1 ft = 0.3048 m
1 m = 1.0936 yd 1 yd = 0.9144 m
2 2 2 2
area 1 cm = 0.155 in 1 in = 6.4516 cm
2 2 2 2
1 ft = 0.093 m 1 m = 10.764 ft
3 3 3 3
volume 1 cm = 0.061 in 1 in = 16.38 cm
3 3
1 l = 1000 cm 1 cm = 1.000 ml
1 l = 0.2642 gal 1 gal = 3.785 l
3 3
1 m = 1000 l 1 m = 264.17 gal

3.2. Angle conversion

1
vertical 0
1: 30 = 1.8
1: 15 = 3.8
1: 10 = 5.5
1: 8 = 7.1

11.3
.5

5
0
1: 6 = 9

16.0
= 14.

.4
1: 5 =

= 18

1.8
5 =

11.3
1: 4

=2

6.6
1: 3
1: 3.

=2
.5
1: 2

1: 2

3.6
=3
.5
1:1

45
=
1
1:

10
 TECHNICAL DATA

3.3. Diesel Hammer data

D A

C 4" W 4"
B

B / B1

D1 LH

Model D6-32 D8-22 D12-42 D19-42 D25-32 D30-32

App. piston weight lbs. 1,320 1,770 2,820 4,015 5,515 6,615
Blows per min. 1)
Minimum bl./min. 39 37 37 37 37 37
Maximum bl./min. 52 52 52 52 52 52
Energy per blow 2),
Maximum ft.lbs. 12,570 18,760 29,840 42,480 58,300 69,990
Minimum ft.lbs. 7,090 9,480 15,100 21,510 29,510 35,435
Consumption 3)
Diesel fuel gal./hr. 0.96 1.00 1.2 2.00 2.11 2.64
Lubrication oil gal./hr. 0.06 0.13 0.13 0.16 0.26 0.26
Capacity
Diesel fuel gal. 4.9 5.3 6.3 20.0 17.7 17.7
Lubrication oil gal. 1.3 1.6 1.7 5.0 5.0 5.0
Weight 3)
Hammer lbs. 3,570 4,000 5,730 8,365 12,370 13,472
Hammer with standard guiding lbs. 4,920 5,350 7,100 9,700 14,800 15,900
Dimensions
A – Length ft. 14.1 15.4 15.8 16.8 17.8 17.8
LH – Length , standard ft. 18.0 19.0 19.2 19.2 21.3 21.3
– Length with hydr. start ft. - - - - 22.5 22.5
B – Center to trip inch 13.0 13.0 14.0 14.0 17.5 17.5
B1 – Center to trip cylinder inch - - - 22.0 24.0 24.0
C – Center to pump guard inch 15.0 15.0 15.0 16.0 19.0 19.0
D – Width of hammer Inch 18.3 16.5 19.0 19.5 25.0 25.0
D1 – Width of trip inch 22.1 24.5 24.5 24.5 32.0 32.0
W – Min. lead width inch 21 21 21 21 26 26

1) Depends on fuel pump setting, and kind of soil and kind of pile
2) Potential energy calculated by multiplying piston weight and stroke. The stroke of the ram is a result of the blow rate
3) Consumption and weights are approximate, weight of guiding depends on type and size

11
 TECHNICAL DATA

D A

C 4" W 4"
B

B / B1

D1 LH

Model D36-32 D46-32 D62-22 D80-23 D100-13 D125-32

App. piston weight lbs. 7,940 10,145 13,670 17,640 22,045 27,560
Blows per min. 1)
Minimum bl./min. 37 37 35 36 36 36
Maximum bl./min. 52 52 50 45 45 45
Energy per blow 2),
Maximum ft.lbs. 83,950 107,280 161,640 197,150 246,390 308,025
Minimum ft.lbs. 42,500 54,320 79,200 126,180 157,685 197,135
Consumption 3)
Diesel fuel gal./hr. 3.04 4.23 5.28 6.60 7.93 9.5
Lubrication oil gal./hr. 0.39 0.39 0.53 0.68 0.68 0.95
Capacity
Diesel fuel gal. 23.5 23.5 25.8 40.9 40.9 50
Lubrication oil gal. 4.5 4.5 8.3 8.4 8.4 15.8
Weight 3)
Hammer lbs. 17,375 19,580 27,077 37,275 44,894 53,616
Hammer with standard guiding lbs. 19,900 22,100 29,300 41,200 48,800 -
Dimensions
A – Length ft. 18.3 18.3 22.6 23.6 24.1 25.5
LH – Length , standard ft. 21.3 21.3 24.8 28.1 28.1 27.8
– Length with hydr. start ft. 22.5 22.5 25.8 28.1 28.1 27.8
B – Center to trip inch 19.0 19.0 20.0 26.0 26.0 28
B1 – Center to trip cylinder inch 26.0 26.0 27.0 33.0 33.0 30.5
C – Center to pump guard inch 20.5 20.5 25.5 23.0 23.0 22.5
D – Width of hammer Inch 28.5 28.5 32.5 35.0 35.0 41.0
D1 – Width of trip inch 37.0 37.0 35.5 47.5 47.5 47.5
W – Min. lead width inch 32 32 32 42* 42* 42*

4) Depends on fuel pump setting, and kind of soil and kind of pile
5) Potential energy calculated by multiplying piston weight and stroke. The stroke of the ram is a result of the blow rate
6) Consumption and weights are approximate, weight of guiding depends on type and size

12
 TECHNICAL DATA

D A

C 4" W 4"
B

B / B1

D1 LH

Model D138-32 D160-32 D180-32 D225-22 D250-22 D280-22

App. piston weight lbs. 30,420 35,275 39,680 49,600 55,110 61,720
Blows per min. 1)
Minimum bl./min. 36 36 36 36 36 36
Maximum bl./min. 45 46 46 50 50 50
Energy per blow 2),
Maximum ft.lbs. 340,000 394,250 443,500 564,930 631,300 700,625
Minimum ft.lbs. 217,600 241,470 271,650 292,780 331,870 365,060
Consumption 3)
Diesel fuel gal./hr. 10.2 11.9 13.1 16.9 19.0 21.2
Lubrication oil gal./hr. 0.95 1.32 1.32 1.53 1.53 1.53
Capacity
Diesel fuel gal. 50 63 63 121.5 121.5 121.5
Lubrication oil gal. 15.8 21.1 21.1 26.4 26.4 26.4
Weight 3)
Hammer lbs. 57,360 68,785 75,700 99,840 106,560 113,506
Hammer with standard guiding lbs. 64,000 74,500 82,600 108,215 115,000 121,880
Dimensions
A – Length ft. 25.9 25.8 26.4 26.6 27.1 27.3
LH – Length , standard ft. 27.8 25.8 25.8 30.0 30.6 30.8
– Length with hydr. start ft. 27.8 25.8 25.8 30.0 30.6 30.8
B – Center to trip inch 30.5 33.7 33.7 39.1 39.1 39.1
B1 – Center to trip cylinder inch 31.0 33.7 33.7 39.1 39.1 39.1
C – Center to pump guard inch 22.5 24.5 24.5 33.0 33.0 33.0
D – Width of hammer Inch 41.0 45.5 45.5 53.1 53.1 53.1
D1 – Width of trip inch 47.5 51.2 51.2 52.7 52.7 52.7
W – Min. lead width inch 42* 48* 48* 54* 54* 54*

7) Depends on fuel pump setting, and kind of soil and kind of pile
8) Potential energy calculated by multiplying piston weight and stroke. The stroke of the ram is a result of the blow rate
9) Consumption and weights are approximate, weight of guiding depends on type and size

13
 TECHNICAL DATA

3.4. Sound emission

The amount of noise produced when

driving piles with a Diesel pile hammer For the above reasons it is impossible to
depends on several factors: predict the exact noise level for a particular
construction site
1. Explosion and exhaust noise
The explosion and exhaust noise is not, as The noise levels measured when pile
often supposed, the main source of noise. A driving with a Diesel pile hammer is actually
noise reduction mantle would reduce the somewhat higher than the noise levels
overall sound level only a very small generated by alternate methods of pile
degree. The installation of a noise installation: rotary drilling, percussion
reduction mantle also inhibits proper escape drilling or construction of diaphragm walls,
of the exhaust gases and, therefore,
reduces the fresh air supply for scavenging. But when examining the noise on a
This would impede the proper function of construction site, its is important to compare
the pile hammer. the noise level in relation to the duration of
the noise. If this is done, the noise irritation
2. Noise generated by the piston hitting caused by a Diesel pile hammer will be the
the impact block.
relatively insignificant.
This noise is inside the lower cylinder of the
hammer, so it is not the main source of
The data sheet below was made at the
noise.
Delmag factory test stand on a refusal pile.
3. Noise generated by impact block
hitting the pile helmet. Sound pressure level
Diesel dB(A)
This is where the main noise develops. It Hammer
can be reduced to a large extent by using a at distance from hammer
Type
very “soft” pile helmet cushion. 7m (13 ft) 300m (984 ft)
D6-32
4. Noise generated by the pile helmet 100 73
D8-22
hitting the piles.
D12-42 102 76
This is another main source of noise. In
order to soften the impact it is necessary to D16-32
106 79
use a soft cushion here, too, so that a D19-42
reduction of noise can be achieved. D25-32
110 84
D30-32
5. Noise generated from the piles
D36-32
themselves. 111 85
By taking the above-mentioned measures D46-32
the structure-borne noise generation of the D62-22 114 86
piles can be diminished considerably. Of D80-23 116 88
course, the noise development also D100-13 119 92
depends on the kind of piles used. If steel
piles are used, the noise development will D125/D138 n.a. n.a.
be higher than for concrete piles. Moreover D160/D180 n.a. n.a.
the soil conditions have an effect on the D225～D280 n.a. n.a.
generation of noise. If the soil is rocky, arid,
or hard, there will be more vibration of the Screening the diesel pile hammer and the
piles than if the soil consists of coarse clay. pile was not very successful because the
14
 TECHNICAL DATA
pile hammer performance decreased Screening steel pipe pile and helmets
because of the fouling of the air supply. reduced the sound pressure somewhat, but
was uneconomical.

3.5. Exhaust emission

For diesel hammers a reliable quantitative exhaust research does not exist. Following reasons
don’t allow any warranted statement:
the fuel consumption depends on the driving conditions
the fuel burning depends on the climate conditions
exactly measurements under jobsite conditions require a huge effort and measurement results
will be falsified by imperfect conditions

Calculated emission values based on fuel consumption are theoretical and don’t consider
any driving conditions neither climate nor fuel combustion conditions.
For an estimate of exhaust emission below is given a table with calculation results based on
the fuel consumption.

Diesel Energy Output NMHC + Nox CO PM

hammer type range (kW) (g/kWh) (g/kWh) (g/kWh)
D6-32 22 7.5 (5.6) 5.5 (4.1) 0.6 (0.45)
D8-22 24 7.5 (5.6) 5.5 (4.1) 0.6 (0.45)
D12-42 27 7.5 (5.6) 5.5 (4.1) 0.6 (0.45)
D16-32 30 7.5 (5.6) 5.5 (4.1) 0.6 (0.45)
D19-42 45 7.5 (5.6) 5.5 (4.1) 0.6 (0.45)
D25-32 48 7.5 (5.6) 5.0 (3.7) 0.4 (0.30)
D30-32 60 7.5 (5.6) 5.0 (3.7) 0.4 (0.30)
D36-32 69 7.5 (5.6) 5.0 (3.7) 0.4 (0.30)
D46-32 96 6.6 (4.9) 5.0 (3.7) 0.4 (0.30)
D62-22 120 6.6 (4.9) 5.0 (3.7) 0.4 (0.30)
D80-23 151 6.6 (4.9) 3.5 (2.6) 0.2 (0.15)
D100-13 181 6.6 (4.9) 3.5 (2.6) 0.2 (0.15)
D125-32 220 6.6 (4.9) 3.5 (2.6) 0.2 (0.15)
D138-32 250 6.6 (4.8) 3.5 (2.6) 0.2 (0.15)
D160-32 288 6.6 (4.8) 3.5 (2.6) 0.2 (0.15)
D180-32 325 6.6 (4.8) 3.5 (2.6) 0.2 (0.15)
D225-22 372 6.6 (4.8) 3.5 (2.6) 0.2 (0.15)
D250-22 415 6.6 (4.8) 3.5 (2.6) 0.2 (0.15)
D280-22 450 6.6 (4.8) 3.5 (2.6) 0.2 (0.15)

More environmental fuel types are suitable as replacement for diesel fuel with minor reduction of
diesel hammer performance (see enclosure A2). Attention is required in some case for the
specification of the lubrication oil and additional maintenance.

15
TRANSPORT

4. Transport of Diesel hammer

! WARNING !
4.1. General preparation
4
The Diesel pile hammer shall only be
transported with an installed locking
screw (1) and impact block clamp (3). If
this is omitted, a shift in the center of
gravity could cause sudden movements
of the Diesel pile hammer! The piston
and impact block may accidentally crash
to the other end position! Crushing and
impact danger!

The Diesel pile hammer and its

accessories must be packaged, loaded
and transported carefully to prevent
damage! Check the Diesel pile hammer 1
and all accessories regarding 2
completeness and damages after
delivery! Immediately notify the shipping
agency or the appropriate dealer about
problems!

The following transport safety devices must

be installed prior to transporting the Diesel
pile hammer 3
1 Locking screws. These piston locking
screws prevent moving of the piston during
transport. This prevents sudden shifts in the
center of gravity of the Diesel pile hammer.
Omitting the installation of these bolts may 3 Impact block clamp. The impact block
cause sudden movements as well as clamp prevents a moving of the impact
damages, e.g. to the catch ring! The piston block during transport. Without the impact
safety screws must be screwed in fully and block clamp, the impact block may
tightened! The piston must be in lowered accidentally fall to the other end position!
position! Two piston safety bolts must be Install the impact block clamp as shown in
used for types D80-23 through D100-13 the illustration

2 Exhaust cover. The exhaust covers (2) 4 Protective cap. The protective cap
pieces; 4 pieces for type D80 and above) prevents the entering of water, dust and
prevent the entering of water, dust and foreign bodies. Attach the protective cap
foreign bodies. Screw the exhaust covers with the help of the two chains. Attach the
into the respective thread fitted at the hook located at the end of each chain to the
exhaust respective eyelet.

16
TRANSPORT

4.2. Lifting cables and ground support

Prior to each use, the transport cables must

be inspected visually. Use only approved
cables to transport piles! Immediately
shackle
remove and dispose of damaged cables sling angle
(cable damage in accordance with DIN Lifting padeyes
15020, Sheet 2, Pages 5-4)! Use only steel
cables that exhibit the proper load capacity
and length. (see table below)!

Never walk under suspended

loads! Danger to life!

Minimum required cable diameters for lifting the diesel hammer

(based on maximum safe working for wire rope slings )
Type of diesel Max. total weight 2 steel cable at sling angle approx. min. Shackle Eyelet
pile hammer ( lbs.) sling diameter in (inch) sling length (ft) size Diam.
D6-42 5100
1./2” at 45°
D8-22 5350
5.75
D12-42 7100 9./16” at 45°
D19-42 9700 5./8” at 45°
D25-32 14800 17 ton 1.97”
7./8” at 45° 6.25
D30-32 15900
D36-32 19900
1” at 45° 6.75
D46-32 22100
D62-22 29300 1-1./8” at 45° 7.75
D80-23 41200
1-3./8” at 45° 9.00 2.44”
D100-13 48800
D125-32 53600
1-1./2” at 45° 10.00 25 ton 2.90”
D138-32 64000
D160-32 68800
1-3./4” at 60° 3.22”
D180-32 82600
D225-22 113000 15.00
D250-22 119800 2-1./8” at 60° 40 ton 4”
D280-22 126700

Make sure that the ground for laying down

the diesel hammer is even and level ! You must wear a hard hat, safety gloves,
If you don’t set down the diesel hammer to safety boots and suitable work clothes!
a concrete slab area, use 3” thick wood Danger of injuries!
planks to prevent the hammer sinking into
the ground or tipping over!

17
C
A
UT
I
ON
TRANSPORT

4.3. Possible cable damage

Flattening caused by rolling over

flattening causes increased wire rope breaks
which leads the rope to taken out of service

Constrictions
Replace steel cables exhibiting strong
constrictions!
Possible cable damage

Knots
Replace the steel cable, when many knots have
formed

Breakouts or “contracted loops”

Replace rope

Breaks and Kinks

Replace cable

Corkscrew-like configuration
Replace the steel cable, when X (see illustration)
is larger than or equal to 1/3 of the cable diameter
at the worst damage location!

Basket formation
Steel cable must be replaced even when it
exhibits only a small basket formation !

Loop formation
Replace the cable, when the loop formation of
individual wires causes a substantial change in
the cable structure
Loosening of individual wires
Replace the cable, when loose wires were
caused by rust or wear. When the loosening
effect is caused in another hammer, a decision
regarding the replacing of the cable must be
made on the basis of the wire breaks that are
sure to follow.

18
 ASSEMBLY & MODE OF OPERATION

5. Assembly and Mode of Operation

5.1. Components of Diesel Pile hammer

1 – upper cylinder extension

with catch ring groove
2 – upper cylinder
3 – lifting ears
4 – fuel tank with integrated
lube oil tank
5 – Lifting padeyes
6 – lifting dogs
7 – lubrication lines
8 – locking screw (piston)
9 – trip cam lever engaging point
10 – lubrication pump
11 – fuel / breather line
12 – fuel control pump
13 – injection valve
14 – pump guard
15 – lower cylinder

16 – blow out plug

17 – outer cylinder end ring
18 – rubber ring
19 – impact block
20 – key plate bolts
21 – trip cam lever release point
22 – hammer guides (offset version)
23 – exhaust ports
24 – flange with catch ring groove

A – tripping device
A1 – guide gibs
A2 – lever for activating driving pin
A3 – driving pin
A4 – trip cam lever

19
 ASSEMBLY & MODE OF OPERATION

5.2. Section View of Diesel Pile hammer

2 – upper cylinder
10 – lubrication pump
11 – fuel ventilation line
12 – fuel control pump
18 – rubber ring
19 – impact block
23 – exhaust ports
24 – upper endring with catch ring groove
26 – piston
27 – piston catch ring
28 – cylinder sleeves
29 – inner damping ring

20
 ASSEMBLY & MODE OF OPERATION

5.3. Operating principle

Diesel pile hammers are used to drive piles The atomized Diesel fuel ignites, because
into a supporting soil layer. The mode of the enormous compression causes a
operation is similar to that of a hammer substantial increase in the air temperature
used to drive a nail. of the cylinder volume (working principle of
the Diesel engine). There is an explosion.
The piston activates the pump lever during The explosion causes the following:
its fall. The Diesel fuel is in that manner
sprayed onto the surface of the impact - It drives the pile further into the soil,
block (1). The air in the cylinder is - The piston is driven upward (stroke).
compressed as soon as the piston runs
past the exhaust openings. The strongly The exhaust openings become exposed
increasing compression pressure drives the with the upward driving of the piston. The
piston and the impact head below it on the pressure in the cylinder volume causes
material to be driven. the exhaust gases to be pushed through
the exhaust (3). This reduces the pressure
The following occurs when the hammer in the cylinder to zero.
impacts (2):
The piston continues to move upward.
- The pile is driven into the soil This causes a suction effect (vacuum) in
- The Diesel fuel is atomized the cylinder volume. Said vacuum ensures
that fresh air is suctioned in to purge the
Force cylinder volume (4). This is called
scavenging.

The pump lever is released during the

further upward movement of the piston.
The pump lever returns to its original
position. Diesel fuel is again supplied to
Impact progress the fuel control pump.

Start of impact
and combustion
resistance

phase
soil

Combustion progress

Time
Compression Impact & Explosion Expansion
(1) (2) (3) + (4)
to compression

pile has been pene-

pretension due

compression by

pile & soil have

been released

Compression energy
trated nto soil

Impact energy
impact

Combustion energy
Impact and combustion energy
21
 ASSEMBLY & MODE OF OPERATION

22
 ASSEMBLY & MODE OF OPERATION

5.4. Pile driving equipment – general information

5.4.1. Leadsystems - guiding options

The following indicates and describes

different possibilities to guide the Diesel pile
hammer with a lead. You must consult with
us should you decide on a different guiding
system for the Diesel pile hammer

Following the operating instructions for

the lead! Use only leads with a
sufficiently high capacity and stability!
Danger to life!

U-type lead systems are the most

common and most economical solution for
pile driving, Different U-type lead systems
(see following page) manufactured by us
accomplish different job requirements

23
 ASSEMBLY & MODE OF OPERATION

U-type lead systems

Fixed lead Caisson type or Offshore lead Swinging lead

W Type W max. suitable
inch diesel hammer size
U21 21-1/2 up to D19
U26 26-1/2 up to D30
U32 32-1/2 up to D62
A104-36 42-1/2 up to D100
A104-42 48-1/2 up to D125
A104-48 54-1/2 up to D125
A104-60 66-1/2 up to D160
standard U- leads
Box lead or Pogo lead - type

Standard distance H from the

center of the diesel pile hammer
to the front edge of the guide

H
Type of H
Diesel pile inch
hammer
W
D6-42 15
D8-22 15
European style lead or D12-42 15
drilling rig masts D19-42 15
- hammer guiding is adaptable D25 / D30-32 17-3/8
to various lead dimensions and D36 / D46 –32 19-5/8
lead profiles D62-22 19-5/8
- starting device is directly D80 / D100-13 26
guided at the lead profile D125/D138-32 32
D160/D180-32 40
D225/D250-22 40
D280-22 40
24
 ASSEMBLY & MODE OF OPERATION

5.5. Diesel pile hammer conversion for driving of batter piles

Driving batter piles with a larger inclination  Is the available hammer suited for
than shown below requires a upper cylinder the required batter
extension. This upper cylinder extension  Is it necessary to install the upper
replaces the upper end ring with catch cylinder extension
groove bolted to the upper cylinder.  Is the blow energy still at sufficient
level
Calculate the required batter prior to putting
the equipment into operation. Check
following points using the diagram below:

remaining
blow 100% 96% 93% 90% 82%
energy
D100 with ex
tension 24
D19... D80 w
ith ext
ension

1:5
1:3
D100
1:2
D62 / D80

D19 - D46

D8 / D12 1:1

Blow energy for driving batter piles

11,3

The increased friction of the piston and of

the impact block causes a decrease in the
18.4

blow energy when driving batter piles. The

6
26.

wear on the cylinder and the guiding

components are also increased. The
45

remaining blow energy can be calculated

using the formula shown below.

cos  - 0.1 * sin 

Remaining = x 100
25 blow energy cos  +0.1 * sin 
 ASSEMBLY & MODE OF OPERATION

5.6. cylinder extension Assembly and

Disassembly of the

When required, the upper cylinder section of Replace missing or damaged bolts or
diesel pile hammers D19-42 through D100-13 nuts with new ones!
can be extended. For these Diesel pile
hammers, such an extension is required for a 4. Install the supplied extension for the
batter of more than 1:5. lubricant line!

The disassembly of the extension is the

reverse of the above!

Conversion work can be carried out only on

a safely supported diesel pile hammer in
the lower position in the lead, resting on
Diesel pile hammers D12-42 through
the material to be driven!
D100-13 shall be operated only with
Use a height safety device to prevent a fall
an installed upper end ring or
when climbing up the lead!
extension of the upper cylinder
section!
Conversion work shall only be carried out
If the upper end ring is not mounted the
by qualified and authorized personnel!
piston can jump out of the cylinder when
overstroking. – DANGER TO LIFE !
Hard hat, safety boots and suitable work
clothes must be worn! A life vest must be The catch groove designed with the
worn when working above a water surface! upper endring or the upper cylinder
extension is the point where the the
piston catch ring can snap in to prevent
falling out.

Work stages:

1. Disassemble the upper end ring (24)! To do

so, unscrew all hexagonal bolts of the upper
end ring! Remove the upper end ring by lifting
it upward!

2. Install the supplied extension for the upper

cylinder section (1)!

3. Bolt the extension of the upper cylinder

section (1) to the upper cylinder section (2)!
Use the bolts of the upper end ring. Solidly
tighten the bolts (bolt torque values see
chapter 10.3 “Screwed / bolted connections”)!

26
 ASSEMBLY & MODE OF OPERATION

5.7. Safety devices bridle must be adjusted continuously

to match the driving progress. The
5.7.1 Bridle bridle will be destroyed otherwise!

Unless a legislative body specifically asks for a

certain type of safety device, the Diesel pile
hammer can be secured by other means such
as a bridle.

For small hammers up to the D8 exists a

solution which connects the tripping device
with the upper hammer guiding clips, where a
safety bridle like shown is not needed.

The bridle should never be used to lift the

Diesel pile hammer! The Diesel pile hammer
should only be moved upward using the
tripping device! This is the only way to
ensure safe conditions for the Diesel pile
hammer!

The bridle must be positioned

approximately at the center between the
upper and lower guide prior to putting the
Diesel pile hammer into operation. The

27
STARTING THE DIESEL HAMMER

6. Starting the Diesel hammer

3. Fill the lubricant lines with motor oil using

a squirt can (EO 20, 40 or 50 as a function
of the application temperature; see Chapter
Carefully read and follow Chapter 3 “Safety 11 “Maintenance”)! Keep on filling the
measures” prior to putting the unit into lubricant lines from the bottom with oil, until
operation! oil exits at all connection nozzles!

All installation work required to put the unit 4. Push the lubrication lines back on the
into operation must be carried out by respective connection fittings!
qualified and authorized personnel!
5. Tighten the lubricant clamps again! Make
sure all lubricant lines are solidly attached to
6.1 Filling of lubricant lines with oil the connection fittings (retighten, if
necessary).

6. Put the Diesel pile hammer into a vertical

position (See Chapter 5 “Transport”)!
The lubricant lines of the lubricant
system must always remain filled with 7. Check the lubricant level in the lubricant
lubricant! Otherwise, the Diesel pile tank! The tank must be full!
hammer will be supplied with the
lubricant only after some time has
passed! This will damage the Diesel pile
hammer!

You must wear a hard hat, safety gloves,

safety boots and suitable work clothes!
Danger of injuries!

The lubricant lines of the lubricant system

must be replenished prior to the first putting-
into-operation and after repairs to the
lubrication system:

1. Lay the Diesel pile hammer down in a

horizontal position (see chapter 4 “)

2. Remove the lubricant lines from the Use motor oil SAE 20W or SAE 40W for
lubricant pump (note: D80 through D100 lubrication or see chapter 9 for special
have two (2) lubricant pumps). To do so, cases
loosen the lubricant clamps!
Subsequently pull the lubricant lines from
the connection fitting!
28
STARTING THE DIESEL HAMMER
6.2 Assembly of pile helmet cushions

The pile helmet cushion transfers the impact

from the impact block to the material to be Typical Helmet assembly:
driven. A targeted assembly can dampen 1- striker plate
the impact to a certain degree (See 2- ½” aluminum cushion
Appendix A3 “Reduction factors for different 3- 1” phenolic cushion
pile helmet cushions”). 4- ½” aluminum cushion
5- primary helmet
We recommends a combination plate pile 6- helmet insert for desired pile type
cushion material for several sizes consisting
from: ½” aluminum cushion Ø ¾” cable
1” phenolic cushion or larger to
½” aluminum cushion 1 the hammer lifting
The function of the aluminum plate is taking pad eyes (5)
out the heat from the phenolic cushion plate 2
caused by the impact. 3
4
Ø ½ ” cable
or larger
Assembly 5
1. Place the pile helmet cushion of the
desired arrangement in the pile helmet
Different cushion material has different Ø ¾” cable
dampening properties. Please consult us if 6 or larger
you intend to modify the cushion material.

2. Set the steel striker plate on top of the

cushion. Keep attention that the contact
area of the cushion plate is flat and not
bowed, otherwise your cushion material will
wear out rapidly!

3. Guide the supplied cable section through

the striker plate padeyes and the padeyes
of the helmet

4. Tighten the cables and secure them with

a suitable cable clamp! All bolted connections must be tight!
Loose bolts can cause serious injuries
5. If using a primary helmet set the and property damage!
required pile insert in the receptacle
An incorrect attachment of the pile
6. slide the helmet or primary helmet in the helmet cushion with the steel cable at
lead and attach to the dieselhammer like the pile helmet can cause the striker
shown plate and cushion to fall out! Danger of
an accident!

6.3 Guiding for the pile helmet

29
STARTING THE DIESEL HAMMER

Always guide the pile helmet at the lead and

never at the impact block of the Diesel pile
hammer!

The pile helmet cannot be guided at

the impact block of the Diesel pile
hammer! Otherwise, lateral forces
may cause damage to the impact
block and the cylinder!

30
STARTING THE DIESEL HAMMER
6.4 Lifting of piles

Follow the operating instructions of the You must always wear a hard hat, safety
carrier equipment! gloves, safety boots and suitable
working clothes! You must wear a life
Use only approved steel cables in vest when working over water surface!
accordance with Chapter 4.2 “Transport
cables”! Never pull the material to be driven from the
lead tip! This may cause an overturning of
Observe the following information to the carrier unit or may bend the lead end!
prevent an overturning of the unit and
damage to the lead and material to be Always turn the unit in the direction of the
driven! impact point of the material to be driven!
The inclined pulling force may cause the
unit to overturn!

The material to be driven must always be

lifted in such a manner that

- there is no permanent deformation,

- no cracks form in the material to be driven,
- the material to be driven hangs vertically
after lifting it.

Two cable
pile pick up
One cable
pile pick up

31
STARTING THE DIESEL HAMMER

6.5 Bringing into operating position of diesel pile hammer and pile helmet

Observe the operating instructions of the carrier equipment!

Use only approved steel cables in accordance with Chapter 5.2 “Transport cables”! You must
wear a hard hat, safety gloves, safety boots and suitable work clothes! A lifesaving jacket must
be worn for work above a water surface!

6.5.1. Placing the dieselhammer in swinging lead – lead laying on the ground

- diesel pile hammers up to the D62 can be equipped with channel guiding
- the hammer must be sled in the lead from one side
- before raising up the lead the starting device and the hammer lifting ears must be
connected to the crane winch

6.5.2. Placing the dieselhammer in an offshore lead – lead laying on the ground

guiding
brackets

32
STARTING THE DIESEL HAMMER
- by setting the hammer into the lead pay attention to slide the lead guiding carrier and
the hammer complete to the guiding bell to prevent uncontrolled sliding when lifting up
- after setting the hammer into the lead the backside guiding brackets must be bolted on

6.5.3. Placing the dieselhammer in fixed

lead – lead in vertical position

1. Mount the tripping device (see chapter

8.4.6) to the lead if not guided directly at the
hammer starter guides attached to the 12. Remove the locking screw(s) (piston)
hammer and the impact block clamp (See Chapter
4.1 “Transport safety devices”)!
2. Lift up the tripping device approx. 10ft
(3m) 13. Pull the Diesel pile hammer upward
until the impact block (19) is fully extended
3. Place the Diesel pile hammer in front of and hangs approximately 2 inches (5 cm)
the lead (horizontal position, see chapter above the pile helmet cushion!
4.)!
14. Attach the pile helmet to the lower
4. Place the Diesel pile hammer on wooden cylinder lifting pad eyes (5) as shown in the
blocks! illustration! Use the steel cables and steel
cable clamps from the tool box
5. Remove the transport cables!
15. Slowly lift the Diesel pile hammer using
6. Place the steel cable lops around the the tripping device while guiding the pile
lifting plates (3) and around the hook of the helmet through the lead!
carrier equipment!

6. Carefully pull the Diesel pile hammer to a

vertical position and place the Diesel pile
hammer in front of the lead!

7. Install the two lower and one upper guide

bracket (22)!

8. Lift the Diesel pile hammer 3 feet (1

meter)! Place the guide brackets (22)!

9. Install the second upper guide bracket

(22)!

10. Place the pile helmet below the Diesel

pile hammer!

11. Let the Diesel pile hammer rest on the

pile helmet.

33
STARTING THE DIESEL HAMMER

16. Remove the steel cable loops from the ignored, the unit may be difficult to start
lifting plates (3) and from the hook of the and the fuel lines may become clogged!
lifting equipment! Mixing ratio
Diesel fuel / regular gasoline or engine oil
17. Attach both ends of the 230 feet (70 m)
long control cable (in the tool box) to the outside Summer Winter
eyelets for the control cable of the fuel temperature Diesel fuel Diesel fuel
pump (12)! above -10C
14F 90% / 10% 100% / 0%
18. Attach the 115 feet (35 m) long rope to
the shutoff valve (center eyelet) of the fuel -10C to -14C
pump (12)! 14F to 7F 70% / 30% 100% / 0%
-14C to -20C
7F to -4F 50% / 50% 80% / 20%
-20C to -30C
-4F to -22F - 50% / 50%
Note: regular gasoline tends to pre ignition

6.6. Tripping device

The tripping device is an auxiliary means

- to lift the Diesel pile hammer at the lead,

- to lower the Diesel pile hammer at the
lead,
- to lift the piston when starting the Diesel
pile hammer

The tripping device is operated with the help

of a winch on the carrier equipment or
hydraulically.

Check the tripping device for damage

prior to its installation! Use only tripping
devices that are in good working
condition!
19. Fill the tank with Diesel fuel (See
Appendix A2 “Usable fuels” for alternate
fuels). The filling nozzle of the tank indicates
“Diesel”.
Following the operating instructions for
It is important to use a fuel that is suited the carrier equipment
for the ambient temperature conditions
(See the following table)! If this is

34
STARTING THE DIESEL HAMMER
You must wear a hard hat, safety gloves, You must wear a life vest when working
safety boots and suitable work clothes. over water!

Installation of the tripping device You must keep a distance of at least 13

feet (4 meters) from the Diesel pile
1. Attach the lower and one upper guide hammer!
gibs to the tripping device!
In U- type leads the tripping devices is Lowering the tripping device
guided directly at starter guides mounted to
the diesel pile hammer (see page 1-2) 1. Pull the lever (A2) down to the stop using
the rope and keep it taut! This retracts the
2. Place the steel cable in the rope sheave driving pin (A3) in a vertical position. The
or for smaller hammer types connect the tripping device can move past the lifting
cable directly to the sheave pin! To do so, dogs (6) of the Diesel pile hammer.
you must remove the sheave pin and install
it again when the cable is positioned!
Secure the sheave pin with the safety screw
or cotter pin.

3. Lift the tripping device upward and

make sure it is smoothly sliding

2. Lower the tripping device to the lower

stop (9)! The trip cam lever (A5) is pushed
upward at the trip cam lever engaging point
(9). Pawl (A4) is thus pushed out and into
the lifting groove of the piston weight (26).

4. Attach the rope (in the toolbox) to the

lever (A2)!

Operating mode

35
STARTING THE DIESEL HAMMER
3. Release the cable at the lever (A2)!

Lifting the piston – start the hammer

1. Lower the tripping device as described

The tripping device must always be above!
lowered to the lower stop to ensure that
the pawl projects fully and is locked. If 2. Pull the lever (A2) down to the stop using
this is omitted, the Diesel pile hammer the rope and keep the cable tight! This
may trip prematurely! Danger to life! retracts the driving pin (A3) in vertical
position to pass the lifting dogs. After the
The pulling cable must always hang free! tripping device passing the lifting dogs the
Do not tie the pulling rope to the lead or lever A2 can be released to it’s normal
other places! This may cause the diesel position
pile hammer to crash down! Danger to
life and risk of a damaging tripping 3. Use the cable winch to slowly pull the
device! tripping device upwards! When pulling it
upwards, the piston (26) is also pulled
upward and automatically released at the
upper stop (21).

Lift / lower Diesel pile hammer

1. Lower the tripping device as described

above!

2. Slowly pull the tripping device upward

using the cable winch! Do not pull on the
cable at the lever (A2)! During the lifting
stage, the surfaces of the driving pin (A3)
grasp below the lifting dogs (6) of the Diesel
pile hammer. The Diesel pile hammer now
hangs from the tripping device.

Please be sure the pawl of the starting

device is locked under the lifting groove
of the piston during lifting of the
hammer.

3. Use the cable winch to place the Diesel

pile hammer into the proper position.

4. Set the hammer with helmet assembly on

top of a pile.

36
STARTING THE DIESEL HAMMER

6.7 Control of fuel supply

The fuel pump determines the energy per Mode of operation - Increase fuel supply
blow and thus the drop height of the piston. Pull on the right rope to the stop and
The fuel pump has five settings: release the cable! This switches the fuel
pump to the next higher setting. Repeat this
Indicator pin position - fuel supply
step until the desired setting has been
reached (to the maximum Setting “4”)!
setting I 6 o’clock 49…64%
setting II 8 o’clock 66…77% Decrease fuel supply
Pull on the left rope to the stop and release
setting III 10 o’clock 83...90% the cable! This switches the fuel control
setting IV 12 o’clock 100% pump to the next lower setting. Repeat this
step until the desired setting has been
setting 0 4 o’clock shut off reached (to a maximum setting of “0”).

The settings can be adjusted by three ropes Fuel supply shut-off

attached to the fuel pump. For easier Pull on the center rope to the stop and keep
identify the ropes at night you can mark the the cable taut until the impact hammer is at
ropes with single knots and double knots. rest! This has no effect on the setting of the
fuel pump.
Inspect these ropes carefully as you may Should this rope break, you can succesfully
need to depend on them to shut down the shut down the hammer in two alternate
hammer in the case of an emergency. ways:
The fuel setting can be determined by the - adjust the fuel pump to the “0” position
position of the dowel pin on the switch shaft - while in the position “4” (12 o’clock) pull
of the fuel pump. This dowel pin is normally and hold tight the right rope until the
painted yellow for identification (see chart impact hammer is at rest. The dowel pin
below) will go to the 2 o’clock. This position is
spring loaded. Releasing the rope will
cause the fuel pump to return to position
“4” (12 o’clock)

Bleed fuel pump and injection valves

The fuel pump and the injection valves must
be bled
- prior to the first putting-into-operation
- after repair work
- when the Diesel pile hammer fails to
operate due to a lack of fuel

Let the Diesel pile hammer cool down

fully prior to the bleeding in the event the
Diesel pile hammer stopped working due

37
STARTING THE DIESEL HAMMER
to a lack of fuel! Danger of burns and
fire!

1. Pull the piston upward until the trip cam 6.8 Cleaning the combustion chamber
lever (A5) of the tripping device is located
approximately 8 inches (20 cm) below the The combustion chamber must be cleaned
release point (21) each day prior to the first startup of the
The fuel flow to the fuel pump will Diesel pile hammer. When this is omitted,
blocked, when the piston is too low. The the lubricant that has accumulated in the
fuel flow is released automatically if the combustion chamber would also ignite
piston is above the pump lever and thus during starting. The impact hammer may
is released. bounce to the catch groove (25) and cause
2. Set the fuel pump to Setting “4” (full load)! damage.
3. Unscrew the swivel joint at the injection
valves (Pos. 13, Type D5 through D30: only Take the following steps:
one injection valve) by approximately 2-3
turns! Do not fully unscrew the swivel joint!
4. Activate the pump with the right control
rope (dowel pin position 2 o’clock) until fuel
without bubbles exits at all swivel joints
5. Keep the control rope taut and at the
same time tighten all swivel joints The Diesel pile hammer must rest on a
6. Release the control rope! pile or on the ground (with an
7. Pull on the center rope for approximately appropriate support)! It must never rest
5 seconds! This opens the shutoff valve. Air on a support device. If this is not
can escape into the tank by way of the fuel observed, the support device will be
lines. destroyed and the Diesel pile hammer
8. Release the center rope! comes crashing down! Maintain a
9. Repeat steps 3 through 8 three times! distance of at least 13 feet (4 meters)
from the Diesel pile hammer! Never
stand in front of the Diesel pile hammer
with an open combustion chamber bolt!
Fuel, oil, dirt and material residues will
be ejected at a great pressure! This
could cause injuries to the eyes or skin
as well as burns and poisoning.

1. Set the fuel pump to the setting “0”! To

do so, pull the left control cable as often as
required!

2. Remove the blow out plug (16)! (see

page 6-12)

3. Maintain a safe distance from the Diesel

pile hammer, since dirt and material
residues will be ejected at a high pressure!

C
A
UT
I
ON
38
STARTING THE DIESEL HAMMER
Never stand in front of the combustion hammer. Always stand to the side of it!
chamber opening of the Diesel pile
4. Raise the piston five times using the
tripping device and let the piston drop from 6.9 Start and Control
the release point. These cold blows allow oil
and dirt to escape from the combustion
chamber. ! DANGER !
5. Screw the plug (16) back in.
Thoroughly inspect the whole driving
equipment system prior to putting it into
operation! Check the unit for loose
screws and bolts, cracks, wear, leaks
and damage caused by vandals! Check
the stability of the unit! Make sure all
damages are repaired immediately!
Operate the equipment only after all
damages have been repaired (See
chapter 9 “Maintenance”)!

With the exception of the excavator

operator, operator and the foreman in
charge of the pile driving, make sure no
other person stands within a distance of
1.5 times the lead height. Sound a horn
to warn others of the impending starting
of the unit!

The piston should not bounce into the

catch groove (25). The Diesel pile
hammer must be shut off immediately in
this case! Thereafter, operate the Diesel
pile hammer only:
- after checking or replacing the screws
used to fasten the upper end ring or
upper cylinder extension
- after checking the catch groove
- after checking the catch (piston) ring

You must keep a distance of at least 13

feet (4meters) from the diesel hammer.

39
STARTING THE DIESEL HAMMER
Wear hard hat, ear plugs, safety glasses, appropriate work clothes.
safety gloves, safety boots and
Procedure

1. Set the fuel pump to the setting “0”! To

do so, pull on the left control rope as often
as required

2. Using the tripping device, pull the piston

upward and release it

3. For a pre-driven pile: Set the fuel pump

to the setting “2” after the first blow! To do
so, pull the right control rope twice!
For a newly placed pile: Set the fuel
control pump to the setting “3” after the first
blow! To do so, pull the right control cable
three times!

4. Continuously adjust the fuel injection

quantity by pulling the control cables. Do not
increase the injection quantity faster than
one step per stroke!

40
OPERATION
7. Operation which is resting on a skid, etc. The support
device will be destroyed and the Diesel pile
hammer will come crashing down causing
an accident
4. Never drive piles eccentrically ! This may
7.1 General Information cause damage to the cylinder and guide
components as well as damage and
Follow all safety measures describes in vibrations to the material to be driven!
Chapter 3! The center line of the material to be driven
Operate the Diesel pile hammer and lead only must be in line with the center lien of the
when they are in a perfect technical condition! Diesel pile hammer. This is necessary to
Particularly the guiding components and avoid jarring blows. Jarring blows could
tripping device should show no signs of wear! cause
Danger to life! - cracks in and deformation of the cylinder
- vibrations in and damage to the material
to be driven
- directional deviation for the material to be
driven
Remedy: Use a pile helmet that is guided
at the lead and matches the pile profile!
Use a pile helmet cushion selected in an
You must always wear a hard hat, ear plugs, optimal manner with respect to the material
safety goggles, safety gloves, safety boots to be driven and to the blow energy (See
and suitable work clothes! Chapter 9.2 “Blow energy stages” and
Appendix A3-1 “Reduction factors for
Immediately halt the pile-driving operation
different impact head cushions”)! When it
when a dangerous situation develops (e.g., is impossible to guide the pile helmet at the
when unauthorized persons enter the danger lead, it will be necessary to hold the
zone or in the event of damage)! Operate the material to be driven at the lead with at
Diesel pile hammer only after the dangerous least one pile guide!
situation has been taken care of!
5. increased wear in the guide
componentsRebounding impacts, caused
Do not carry out any repair or maintenance by driving eccentrically, very hard driving of
work on a moving Diesel pile hammer! relatively elastic piles (H-beams, soiral
welded thin wall pipe piles) will lead over
long time to damage of the diesel pile
hammer especially the rubber rings.
6. Stop the Diesel pile hammer if the
1. Never start the Diesel pile hammer unless penetration rate is higher than 150 blows
it is resting on a pile ore a specially per foot. Higher blowrates are possible,
prepared test stand. but it causes higher wear of the diesel pile
2. Never start the Diesel pile hammer with the hammer. We cannot warrant parts if it is
impact block hanging out. The impact of obvious that the choosen hammer for the
the piston would transmitted directly to the job was too small.
cylinder outer endring resulting in damage 7. The piston shall not bounce into the catch
of outer endring and lower cylinder. A groove! This may damage the catch ring
stucking impact block prevents the cylinder piston, catch groove and attachment
from freely drop on the impact head unit screws! The safety of the Diesel pile
(possibly due to defective damping rings)! hammer is thus no longer ensured!
3. Never start a Diesel pile hammer which 8. The combustion chamber must be cleaned
has been disconnected from the lead or each day prior to the first startup of the

41
 OPERATION
Diesel pile hammer. When this is omitted, the material to be driven can also occur
the lubricant that has accumulated in the under the best conditions! Accordingly, it
combustion chamber would also ignite will be necessary for the foreman in
during starting. The impact hammer may charge of the pile driving work to
bounce to the catch groove and cause continuously monitor the pile driving
damage. phase and to have the lead corrected,
9. Make sure the allowable batter is not when required!
exceeded when driving batter piles (See
Chapter 7.2 “Conversion to drive batter Shutting off
piles”)! Make sure the Diesel pile hammer
is maintained regularly and properly Pull the center rope (at the shut off valve) and
10. When using a bridle, the bridle must be keep it tight until the piston is completely at
adjusted continuously to the pile driving rest!
progress! The bridle will be destroyed The Diesel pile hammer can also be shut off
otherwise! The safety against a fall is no by setting the fuel control pump to the setting
longer ensure! “0”! To do so, jerk the left control rope as
often as required
Deviations from the original directions of
7.2 Blow energy

7.2.1.Standard fuel control pump

The blow energy is adjusted to the respective blow conditions by controlling the fuel supply (see
Chapter 6.7 “Fuel supply control”). The blow energy of the respective type at different settings can
be taken from the table shown below!
Type Injection Injection quantity (%) and blow energy* Nm (ft.lbs)
Quantity at setting 4 setting 4 setting 3 setting 2 setting 1
100% ±10% 100% 83…90% 66…77% 49…64%
17,040 Nm 14,500 Nm 12,000 Nm 7,090 Nm
D6-32 1.6 cm3/stroke 12,570 ft.lbs 10,700 ft.lbs 8,850ft.lbs 5,230 ft.lbs
25,400 Nm 21,080 Nm 16,890 Nm 12,853 Nm
D8-22 1.75 cm3/stroke 18,760 ft.lbs 15,570 ft.lbs 10,350ft.lbs 9,480 ft.lbs
40,460 Nm 33,580 Nm 26,700 Nm 20,470 Nm
D12-42 2.10 cm3/stroke 29,840 ft.lbs 24,760 ft.lbs 19,690ft.lbs 15,100 ft.lbs
57,600 Nm 47,810Nm 38,015 Nm 29,160 Nm
D19-42 3.54 cm3/stroke 42,480 ft.lbs 35,260 ft.lbs 28,035 ft.lbs 21,510 ft.lbs
79,040 Nm 71,136Nm 58,490 Nm 40,010 Nm
D25-32 3.90 cm3/stroke 58,300 ft.lbs 52,470ft.lbs 38,830ft.lbs 29,510 ft.lbs
94,890 Nm 85,400Nm 70,220 Nm 48,040 Nm
D30-32 4.70 cm3/stroke 69,990 ft.lbs 62,990ft.lbs 51,790 ft.lbs 35,435 ft.lbs
113,820 Nm 94,470 Nm 75,120 Nm 57,620 Nm
D36-32 5.65 cm3/stroke 83,950 ft.lbs 69,680ft.lbs 55,410ft.lbs 42,500 ft.lbs
145,450 Nm 120,720 Nm 96,000 Nm 73,650 Nm
D46-32 7.15 cm3/stroke 107,280 ft.lbs 89,040ft.lbs 70,805 ft.lbs 54,320 ft.lbs
219,150 Nm 181,895 Nm 145,735 Nm 107,380 Nm
D62-22 8.70 cm3/stroke 161,640 ft.lbs 134,160ft.lbs 107490ft.lbs 79,200 ft.lbs
267,300 Nm 239,770 Nm 196,730 Nm 171,080 Nm
D80-23 10.50 cm3/stroke 197,150 ft.lbs 176,840ft.lbs 145,100ft.lbs 126,180 ft.lbs
334.060 Nm 299,650 Nm 257,895Nm 213,790 Nm
D100-13 12.50 cm3/stroke 246,390 ft.lbs 221, 010ft.lbs 190,210ft.lbs 157,685 ft.lbs

* theoretical values based on blows per minute without considering loss of energy by compression and friction
values for D-125 and D160 are estimated

42
OPERATION

Injection Injection quantity (%) and blow energy* Nm (ft.lbs)

Type Quantity at setting 4 setting 4 setting 3 setting 2 setting 1
100% ±10% 100% 83…90% 66…77% 49…64%
384,860 Nm 338,670 Nm 288,645 Nm 230,910 Nm
D125-32 15.5 cm3/stroke 283,860 ft.lbs 249,800 ft.lbs 212,895 ft.lbs 170,310 ft.lbs
460,900 Nm 410,300 Nm 345,900Nm 274,800 Nm
D138-32 17.0 cm3/stroke 340,000 ft.lbs 302,600ft.lbs 261,800 ft.lbs 217,600 ft.lbs
502,100 Nm 441,850 Nm 376,575 Nm 301,260 Nm
D160-32 21.0 cm3/stroke 370,350 ft.lbs 325,910 ft.lbs 277,760 ft.lbs 222,510 ft.lbs
601,300 Nm 535,200Nm 463,000 Nm 368,300 Nm
D180-32 24.0 cm3/stroke 443,500 ft.lbs 394,700ft.lbs 341,500ft.lbs 271,640 ft.lbs
564,930 Nm 485,800Nm 395,000Nm 292,780 Nm
D225-32 28.0 cm3/stroke 416,600 ft.lbs 358,300ft.lbs 291,300ft.lbs 216,000 ft.lbs
631,300 Nm 536,600 Nm 430,000 Nm 331,870 Nm
D250-22 31.0 cm3/stroke 465,600 ft.lbs 395,750ft.lbs 317,100ft.lbs 244,750 ft.lbs
700,625 Nm 588,500 Nm 476,400 Nm 365,060 Nm
D280-22 34.5 cm3/stroke 516,710 ft.lbs 434,000ft.lbs 351,350 ft.lbs 269,200 ft.lbs

* theoretical values based on blows per minute without considering loss of energy by compression and friction
values for D-125 and D160 are estimated

You must be aware of the following: Applying hydraulic pressure to the control
cylinder inside the fuel pump adjusts the fuel
- The given values are measured values. injection volume to a larger amount At a
Deviations are possible between Diesel pile hydraulic hand pump pressure of 275 to 375
hammers of the same type. psi the maximum hammer performance
- The given blow energy is obtained only for should be reached .
vertical driving work. For batter piles, the That depends on:
blow energy is reduced as a function of the - length and diameter of used hydraulic line
batter (See Chapter 5.5 “Conversion for - pile type and ground conditions
batter piles”). - outside temperature and weather conditions
- The injection quantity is not proportional to
the blow energy, because the fuel is burned Shutting off the diesel pile hammer can be
at different degrees of efficiency. For obtained by:
example: 50% of the injection quantity does - Pulling the line of the shutt off valve at the
not reduce the blow energy by exactly 50%! fuel pump
- Opening the quick relief valve of the
hydraulic pump
7.2.2 Hydraulic controlled fuel pump
The hydraulic controlled fuel pump on the
diesel hammer is step less adjustable from
zero to maximum injection volume The
system consists of :

- hydraulic control cylinder inside the fuel

injection pump
- hydraulic hose
- hydraulic hand pump with reservoir,
pressure gauge and quick relief valve

43
OPERATION

7.3 Offshore lead – Start of Diesel pile hammer

Bridle bar

Lead slings

Trip sling

A
STOP BLOCK

Carrier with
drive plate and
guide shoes

Lead frame with

lower guiding A
bell & guide
shoes

1 2 3 4

44
OPERATION
A economic solution for jobs where fixed or
swinging leads cannot be used is the our
offshore type lead system. Upper pad eye
weld on
Requirements are:
- Pre driven piles or piles guided in a template
or jacket
- The lead size must be chosen to the pile
and hammer size, within a range the lead can Hydraulic cylinder
adapt to the pile size with guide shoes
Safety valve
Procedure for starting the hammer
using bridle bar and trip sling:

1. Lifting the lead with hammer over the pile

2. Lowering the lead down until the hammer
guides run against the stop block at the
lead rails. Lowering the lead further down Lower pad eye
until the trip is sled down to the lower bolt on
position at the hammer and the trip lever
engages
3. Lift the lead up. The trip will slide up at the
trip guiding until it reaches the release
point where the piston is released

T
he minimum distance never should be less
than 1 ft, otherwise there is a risk of
damaging the lead when the diesel pile
hammer impact is directly transferred to The hydraulic start is used most common for
the larger size diesel pile hammers (D46 up)
the lower guiding bell and also to the
with our offshore type leads. After positioning
crane.
the offshore type lead on the pile (3) the
The cable length for lead and tripping
hydraulic cylinder must be extended
device are designed in a way that keeping
the minimum distance is possible completely to lower the tripping device
completely down and engage. Retracting the
4. As soon as the diesel pile hammer started
hydraulic cylinder will lift the piston of the
the lead must be lowered continuously with
diesel pile hammer up to the release point.
the progress of the pile penetration (A) to
After starting the diesel pile hammer the
keep at least the minimum required
distance (1ft) between carrier and lower tripping device should remain in the upper
position.
guiding bell.
For cases with low head room and for driving
batter piles the hydraulic starting device gives
Procedure for starting the hammer the advantage for better controlling of the
using a hydraulic start cylinder start procedure. A safety valve ensures the
position of the tripping device if ever a
We offers the solution for a hydraulic starting hydraulic hose should burst
device of the diesel pile hammer. A hydraulic Information about the required hydraulic
cylinder is attached to the starter guides and power pack you find in chapter 11.1
the tripping device (see picture)
45
 SHUTTING DOWN & STORAGE
8. Shutting down and storage

8.1 Shutting down and leaving in lead

1. Let the Diesel pile hammer rest on the
! WARNING ! material to be driven or on the ground!

2. Let the Diesel pile hammer cool down

The Diesel hammer may be left in the lead completely!
for a temporary shutoff. Always - let the
Diesel hammer rest on the material to be
driven or set to the ground.

Make sure the carrier unit exhibits a

sufficient stability! Take into account a
change in the weather (rain, storm)!
Danger of overturning!

Do not touch the Diesel pile hammer

shortly after operation! Danger of burns!
Let hot components cool for a sufficient
period!

You must wear a hard hat, safety gloves,

safety boots and appropriate work
clothes. You must wear a life vest when
working above a water surface!

Block the danger zone of 1.5 times the

lead height! Use warning signs to
prevent anyone from entering this zone!
Observe local regulations for the
blocking of job sites!

10.2 Removal from the lead

When the Diesel pile hammer will not be

operated for several days, it will be
necessary to remove it from the lead.

Follow the operating instructions of the

carrier equipment! Do not touch the
Diesel pile hammer shortly after
operation! Danger of burns! Let hot
components cool down for a sufficient
period!

Proceed as indicated below:

46
 SHUTTING DOWN & STORAGE
3. Install the piston locking screws, piston
safety, protective hood and exhaust covers 7. Remove the steel cable loops from the
(See Chapter 4.1 “Transport safety”)! lifting ears (3)

4. Remove the ropes from the fuel control 8. Put the carrier equipment out of operation
pump! (See operating instructions for the carrier
equipment)!
5. Taking the hammer out of the lead. Put
the hammer a side in reverse procedure like 9. Secure the job site in accordance with
described in chapter 6.5 local regulations for the blocking off of job
sites!
6. Set the hammer on a stable plain
ground, if necessary use 3” thick wood
planks.

10.3 Storage

Let the Diesel pile hammer fully cool Fuel and lubricants are extremely
down prior to storage! Danger of burns flammable and explosive under certain
and fire! conditions! Drain the tanks only in a well
ventilated area! No smoking or work with
You must wear safety gloves, safety open flames or sparks is allowed during
boots and suitable work clothes. A the draining of the tanks and in storage
suitable breathing apparatus must be areas for fuel, ether and lubricants!
worn, when required.
5. Clean the filters!
The following points must be observed
when storing the Diesel pile hammer: 6. Close the drain openings of the fuel
pump with a rubber plug!
1. Check the Diesel pile hammer for
damages and wear! Have the necessary 7. Remove and clean the piston, impact
repairs carried out immediately! This block, upper and lower cylinder section.
prevents the work from being forgotten. Check all connection elements for a solid fit!

2. Check the tanks and lines of the Diesel 8. Clean and check the tripping device as
pile hammer for leaks and a solid fit! well as the guide components of the Diesel
pile hammer and of the tripping device for
4. Drain the tanks (fuel, oil)! damage and wear .

47
 SHUTTING DOWN & STORAGE

9. Clean and check the pile helmet, - Protective clothing, hard hat, safety gloves
attachment cables, pile helmet cushion and and safety boots
accessories (bridle, support devices) for - Safety goggles and ear plugs,
damage and wear. Pile helmet cushions - Lifesaving vest
made of wood do not store well and are - Height safety devices
thus not to be stored for a long time! The personal safety equipment must meet
local safety regulations!
10. Check the tool box and determine its
completeness and the condition of the parts! 12. Prepare the Diesel pile hammer for
Replace missing or unusable parts with new storage (See “Laying-up”)!
parts! Check the control cables for the
tripping device and fuel pump for damage 13. Protect the Diesel pile hammer against
and wear (replace, if necessary)! the effects of the weather! Cover the Diesel
pile hammer and all accessories (Do not
11. Check the condition and completeness use plastic foil or other coated materials)! If
of protection devices and personal safety possible, storage the Diesel pile hammer in
equipment as an unheated and dry room exhibiting
minimal temperature changes! Do not store
the Diesel pile hammer in direct sunlight!

Laying-up – long time storage

The protective effect is very much a function

of the thickness and viscosity (ductility) of 6. Apply a rust protection oil by brush to
material used. We recommend the use of the guide parts of the Diesel pile hammer
Moly Grease 126 EP#2; it is a thick grease and the tripping device!
that you can apply with a rag or brush.
7. Spray the tank inside with a rust-
1. Disassemble the Diesel pile hammer! inhibiting oil! Then solidly close the tanks!
Observe the installation information
indicated in Chapter 10 “Servicing and 9. Carefully apply grease such as Moly
troubleshooting”! Grease 126 EP#2 by brush to all unpainted
parts (including the holes in the end ring,
2. Remove all dirt and rust from all upper and lower cylinder)
components! Replace worn or damaged
parts! 10. Assemble the Diesel pile hammer and
all transport safety devices! Follow the
3. Touch up the paint! Let the fresh paint assembly information in Chapter 10
dry! “Servicing and troubleshooting” as well as
Chapter 4.1 “Transport safety devices”)!
4. Run a corrosion protection oil through
the fuel and lubricant pump! 11. Apply a rust-inhibiting oil to all metal
tools in the tool box!
5. Lubricate the tripping device and
subsequently apply a rust protection oil to it
by brush.

48
MAINTENANCE
9. Maintenance

Maintenance work must be carried out by Do not touch the Diesel pile hammer after
qualified authorized personnel! operation! Danger of burns! Let hot
components cool down sufficiently!

Place the Diesel pile hammer out of

operation prior to carrying out any You must wear a hard hat, safety gloves,
maintenance work! Make sure the unit safety boots and suitable work clothes. You
cannot be put into operation by other must wear a life vest when working above a
persons during maintenance work! Danger water surface!
to life!

9.1 Daily maintenance

As with every equipment / machinery the 5. Check bolts securing the upper and
Diesel pile hammer does require minor daily lower cylinder together .
inspections to ensure that all bolts and nuts (210 ft.lbs torque)
are tightened securely. Since the hammer 6. Check hollow bolts on lubrication
and it’s accessories are subject to points of upper and lower cylinder
excessive shock and vibration while in use, 7. Check guide gib bolts at the tripping
it is possible that loosening of certain bolts device (210 ft.lbs torque)
can occur. Daily inspection procedures are 8. Each grease nipple at the lower
listed below: cylinder & endring should be given 10-12
shots of grease every one-half hour of
1. Filling of diesel fuel and oil tanks running time This is accomplished by the
should be performed after machine is put standard lever gun with a bottom head
into upright position. Be sure that only attachment, as provided in the hammer’s
clean filtered diesel (#2) fuel is and a good tool box. The grease must be a very high
quality high detergent motor oil are added temperature grease to hold up under the
to the tanks. If contamination from dirt or high heat and friction developed during
water is suspected, flush tanks thoroughly running. We tested many types of grease
and refill. Filling the tanks will reduce the and has concluded: -
possibility of condensation in the fuel and Bel Ray Molylube- Molylube 126 EP#2
lubrication oil. This grease is available in cases
2. Check the bolts securing the guide containing 12 tubes/case and is therefore
clamps / side guides of the hammer (540 easy to store and maintain during non-
ft.lbs torque) use.
3. Check nuts securing the fuel pump & 9. Check for wear at guiding parts
lube pump at the lower cylinder . 10. Check for wear of rubber ring
(210 ft.lbs torque) 11. Check all cables (connected to the
4. Check bolts securing the injection hammer , the tripping device, the
valve at the lower cylinder . helmet)
(210 ft.lbs torque) 12. Clean the combustion chamber

49
MAINTENANCE
9.2 Weekly maintenance Fuel pump is set on “off” (dowel pin at 4
Weekly inspection of the Diesel pile o’clock position)
hammer should include:

 Remove and inspect the rubber ring

(2 pieces). This ring prevents the impact
block from striking the outer endring /
lower cylinder of the hammer while Raise the piston and trip up to the
running. This ring also is instrumental in release point and release the piston.
regulating the amount of air volume the There is sufficient compression if the
machine scavenges, therefore affecting piston after it hitting the impact block is
the compression. If damaged, please thrown upwards through the
advise us. compression and falls back onto the
impact block after three (3) additional
 Bolts securing the outer endring to up and down movements on the air
the lower cylinder. The procedure is cushion. If there is less compression
described in chapter 11.xx. The the piston rings need to be checked
tightness of this bolts should always be
uniform. Running the diesel pile hammer If a diesel pile hammer is continuously
with loose or stretched bolts will result in used with worn out piston rings the
damage to the other bolts, the endring piston face will be damaged and there
and the lower cylinder is a high risk of piston cracks, because
the piston will hit the impact block
 Catch groove and catch piston ring. harder with higher velocity than
When the pile meets strong resistance, designed to do so.
piston travel can increase so much that
the catch ring may be hit the catch
groove in the upper cylinder. If this 9.3 Monthly maintenance
occurs, immediately reduce fuel
injection by lowering the fuel pump  Empty fuel and lube oil tanks
setting. Thus shutting off the hammer. Remove fuel and lube oil lines
Catch groove and catch piston ring must Remove and clean filter nozzles!
always be in perfect condition, otherwise
there is a risk of accident. The catch
groove edge can be re machined by
taking off the upper endring.

 Testing the compression

Only test the compression if the hammer

rests on a driven pile, otherwise there is
a danger of accident!

50
SERVICING & TROUBLESHOUTING

10. Servicing and troubleshooting

10.1 General

Maintenance and repair work must be Do not touch the Diesel pile hammer after
carried out by qualified and authorized operation! Danger of burns! Let hot
personnel! components cool down sufficiently!

Place the Diesel pile hammer out of You must wear a hard hat, safety gloves,
operation prior to carrying out any safety boots and suitable work clothes. You
maintenance and repair work! Make sure must wear a life vest when working over a
the unit cannot be put into operation by water
other persons during maintenance and
repair work! Danger to life!

10.2 Trouble shooting

Problem Possible cause Symptoms Fault / Remedy

Diesel pile Compression too low Impact block drops quickly Defective or stuck piston
hammer when lifting the diesel pile rings
does not hammer Insufficient lubrication at
start Strong blowing effect at impact impact head or piston
block (maintain lubrication intervals
as indicated in chapter 9)
After dropping and without a
fuel supply, piston does
bounce only one or two times
and then sink slowly
Wear grooves in lower cylinder Replace defective or worn
below the exhaust openings parts or have repairs made
Damaged cylinder sleeves by a repair shop authorized
by us
Lower cylinder is out of round
Low soil resistance Soft soil, light or pointed or Drop piston several times
narrow material to be driven, (cold blows) until there is a
Pile runs sufficient penetration
resistance

Oil grease or water in Dull sound, when piston

combustion chamber impacts the impact block
Black smoke (oil or grease in Clean combustion chamber ,
the combustion chamber) and flush fuel tank

White smoke (water in the

fuel)

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SERVICING & TROUBLESHOUTING

Problem Possible cause Symptoms Fault / Remedy

Diesel pile Fuel problems Dull sound, when piston hits the Leaking relief valve (replace
hammer impact block relief valve, clean combustion
does not chamber
start
Black smoke (->too much fuel) Air in fuel pump

Selected setting of fuel control

pump is too high

Fuel pump is not working

properly

Pump element wrong installed in

reverse position, supply opening
must be at the top position
No smoke or little gray smoke Sticking pump element, pump
(-> too little fuel) lever or guide sleeve or setting
value of the pump lever has been
changed

Defective pump element in fuel

pump

Clogged ventilation in diesel tank

plug screw

Defective check valve, suction

valve, injection valves or shut off
valve (replace)

Damaged or clogged fuel lines

(replace or clean)

Dirty fuel tank (clean)

Dirty fuel filter

White or black smoke Water in fuel (clean fuel tank,
(-> water or dirt in fuel) fuel filter and fuel lines, clean
combustion chamber
Lack of lubrication Impact block gets stuck in Too little or incorrect lubricant
cylinder or end ring type
Mechanical Damage to impact areas of Machine impact areas
piston or impact block
Stuck or broken piston rings Replace defective or worn piston
rings

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SERVICING & TROUBLESHOUTING

Problem Possible cause Symptoms Fault / Remedy

Diesel pile Mechanical damage Damaged or deformed upper Replace defective parts or have
hammer cylinder / upper cylinder a repair shop authorized by us
runs extension carry out the necessary repair
irregularly Worn cylinder (out of round) or
piston is not round
Changing soil Material to be driven Make adjustments during the
conditions penetrates at different rates pile driving by regulating the fuel
control pump
Diesel hammer Pre ignition, lower stroke Check the blow rate (If the blow
become too hot rate id higher than 150 blows
(above 600F per foot penetration a larger pile
/300C) hammer must be considered)
Choose the right hammer size
Check compression
Check injection valve and fuel
pump (leaking elements or
valves can cause insufficient
fuel burn)
Diesel pile Fuel problems Clogged fuel filter
hammer
stops Diesel hammer Damaged piston rings
running becomes too hot Damaged injection valve
after a short - Insufficient Pump element jams
time combustion

Tripping Piston is not latched Broken dowel pins at trip cam Replace defective or worn parts
device does lever
not lift the Bent trip cam lever
piston
Damaged bearings of trip cam
axis
Piston is not lifted Rounded edges at piston
lifting groove or pawl
Bent or broken leaf spring at
tripping device
Loose leaf spring bolts Tighten bolts!
Worn guide strips or guide Immediately replace worn guide
sleeves parts
Tripping Cam of the tripping Lack of lubrication at the latch Lubricate (lubrication intervals
device does device does not of the tripping device maintenance chapter 9)
not lift the grasp below the Broken torsion spring on the Replace broken or worn out part
diesel lifting dogs at the driving pin of the tripping
hammer diesel pile hammer device

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SERVICING & TROUBLESHOUTING

10.3 Screwed / bolted connections

Tighten all screwed or bolted connections

prior to the pile-driving work at the :
(1) Upper end ring (cylinder extension)
(2) Upper cylinder
(10) Lubrication pump
(12) Fuel control pump
(13) Injection valve cover
(17) Cylinder end ring
(22) Hammer guides
(A1) Guide gibs

The fasteners used for the diesel hammer

are metric dimensioned, but some guiding
parts are mounted with inch-dimensioned
fasteners.

Immediately replace stretched bolts with

the new ones of the same strength! The
Diesel pile hammer cannot be operated
safely with loose or stretched bolts!

D125/D

D160/D

D225/D
250/D2
D6/D8

D100
D25 /

D36 /

D80 /
D12

D19

D30

D46

D62

138

180

80
1 Upper end ring (cylinder extension) - M16 M24 M24 M24 M24 M24 M24 M24 M24
2 Upper - lower cylinder M24 M24 M24 M24 M24 M36 M36 M36 M36 M36
10 Lubrication pump
12 Fuel control pump M16
13 Injection valve
17 Outer end ring M24 M24 M24 M24 M24 M36 M36 M36 M36 M36
22 Hammer guides M24 M24 M24 M24 M24 M30 M36 M36 M36 M36
A1 Guide gibs for tripping device 7/8”-9 1”-8 1”-8 1”-8 7/8”-9 7/8”-9 1”-8 1”-8 1”-8 1”-8

Thread size Torque* - Grade 10.9 Thread size Torque* - Grade 5

M6 12 ± 3 Nm (9 ± 2 ft lb) 1/4”-20 12 ± 3 Nm (9 ± 2 ft lb)
M8 28 ± 7 Nm (21 ± 5 ft lb) 5/16”-18 25 ± 6 Nm (18 ± 4 ft lb)
M10 55 ± 10 Nm (41 ± 7 ft lb) 3/8”-16 47 ± 9 Nm (35 ± 7 ft lb)
M12 100 ± 20 Nm (75 ± 15 ft lb) 1/2”-13 105 ± 20 Nm (75 ± 15 ft lb)
M14 160 ± 30 Nm (120 ± 22 ft lb) 9/16”-12 160 ± 30 Nm (120 ± 22 ft lb)
M16 240 ± 40 Nm (175 ± 30 ft lb) 5/8”-11 215 ± 40 Nm (160 ± 30 ft lb)
M20 460 ± 60 Nm (340 ± 44 ft lb) 3/4”-10 370 ± 50 Nm (275 ± 37 ft lb)
M22 650 ± 80 Nm (480 ± 60 ft lb) 7/8”-9 620 ± 80 Nm (460 ± 60 ft lb)
M24 800 ± 100 Nm (590 ± 75 ft lb) 1”-8 900 ± 100 Nm (660 ± 75 ft lb)
M30 1600 ± 200 Nm (1180 ± 150 ft lb) 1-1/4”-7 1800 ± 200 Nm (1320 ± 150 ft lb)
M36 2700 ± 300 Nm (2000 ± 220 ft lb) 1-1/2”-6 3100 ± 350 Nm (2280 ± 260 ft lb)

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SERVICING & TROUBLESHOUTING
* fasteners should not be lubricated, except for rust preventive with Mos2
10.4 Guides

Prior to the driving of piles, it will be

necessary to check the wear of the Lead configurations

- guides of the Diesel hammer

- guide gibs of the tripping device
- guides of the pile helmet
- wear strips along the whole lead length!

Lubricating the guide rails of the lead and

the starter guides with a MoS2-containing
multipurpose grease extends the lifetime of
your equipment.
H1

H2
Worn guide parts must be replaced
immediately! Wear strips at the lead that
are too thin must be reinforced
immediately! If this is not done, the
Diesel pile hammer, the helmet or the
tripping device may fall out of the leads!
Danger of accident!

T2
Not only because from a safety standpoint
it is important to have a good guided T1
hammer and pile helmet: The driving
efficiency also depends on how the diesel
hammer is in line with the pile. Our Diesel
hammers have the longest possible
channel-guiding. This accomplishes a good Total guiding clearance
hammer guiding with a relatively large Hammer channel guiding H1 ½”
guiding clearance (which is sometimes H2 ¼”
necessary if slightly bent or worn out leads
Hammer short guiding H1 ¼”
are used)
Short distance hammer guiding needs a H2 ¼”
tighter fit to the lead (less guiding Starter guides T1 ¼“
clearance) T2 ¼“

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SERVICING & TROUBLESHOUTING

10.5 Tripping device

The following items must be checked daily

prior to the driving of the piles and when
problems are suspected:
Worn guide strips must be replaced
- The proper functioning of the trip cam and immediately! When this is not done, the
the lifting mechanism of the tripping device tripping device may jump out of the
guide! Danger of accident!
- The guiding clearance in the guides of the
tripping device Use only spare parts supplied by us! We
cannot guarantee a proper functioning
Lubricate the tripping device weekly with of the tripping device when other spare
Molylube 126 EP#2 (5 strokes with a parts are used!
grease gun per grease nipple)!
Along the whole lead length, the overlap of
the latches between the Diesel pile hammer
and the tripping device must be at least
9/16” (15 mm) greater than the play of the
guide strips

Do not operate the Diesel pile hammer, The play of the guide strips must be less
when the tripping device does not than ¼” or 9/32” (6 mm or 7 mm). If this is
function properly or the overlapping not the case, the guide strips must be
distance between the Diesel pile replaced immediately!
hammer and the tripping device is too
small! Danger of accident!

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SERVICING & TROUBLESHOUTING
Testing the proper operation

The tripping device is considered

inoperative, when one of the following
criteria is not met:

1. Lower the tripping device

2. Make sure the trip cam lever (A5) is

pushed up when the tripping device impacts
the lower support device (9)! At the same
time, pawl (A4) must swing out fully and
must lock!

3. Check the tension and the screw

connection of the plate spring!

4. Pull down on the cable at lever (A2)! The

driving pin (A3) must fully reach its vertical
position!

5. Release the cable at lever (A2)! The

driving pin (A3) must return to fully
horizontal position!

6. Check the proper functioning of the rope

sheave (if used)!

7. Check the tripping device for wear!

Particularly the pawl (A4) with lugs and joint
bolts as well as the driving pin (A3) and the
pawl (A4) should not be rounded or exhibit
visible wear!

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SERVICING & TROUBLESHOUTING

10.6 Pumps Lubricant pump

After each 30 minutes of pile driving work,

check that the upper cylinder section is
properly supplied with the lubricant! The
piston and the upper cylinder section must
Problems with the fuel or lubricant system be covered with a uniform thin lubricant
must be remedied immediately! Such film! The following should be checked as
problems pose an increased fire risk and well:
may cause the destruction of the Diesel pile - Is the lubricant tank empty!
hammer. - Are the lubricant lines clogged or
Use only spare parts supplied by us! We defective? Is the pump lever worn?
cannot guarantee proper functioning of the - Is the lubricant pump contaminated
pumps when other spare parts are used!. or defective.
Following the safety instructions indicated Operate the Diesel pile hammer only after
at the beginning of chapter 10 “Servicing the problems have been remedied!
and troubleshooting Use a motor oil for the appropriate motor
temperature range

Disassembly and cleaning of pumps Fuel control pump

The fuel control pump and lubrication pump
shall be disassembled and cleaned when The control dimension at the fuel control
necessary (See spare parts list)! Remove pump is significant for the fuel quantity
all paraffin and dirt residues! Make sure all supplied with each stroke. A dimension that
moving parts move easily! Replace worn is too long causes an excessive fuel supply
and defective parts! The following steps are to the Diesel pile hammer. Accordingly,
needed to install the sealing surfaces: there is the risk of the piston jumping into
the catch groove. When the control
1. Carefully remove any grease from the dimension is too small (e.g. due to wear at
sealing surfaces as well as from the support the pump lever or guide sleeve), the fuel
surface between the fuel pump and the supply will be too low. The diesel pile
lower cylinder section! Use a suitable
hammer is thus unable to reach the
grease remover! Let the grease remover
evaporate fully! maximum blow energy. Check the control
2. Use a high performance sealant dimension of the fuel control pump as
(Hylomar) or similar (provided in the tool required. Reset the control dimension when
box) for sealing the pumps to the lower it deviates from the nominal dimension!
cylinder 1. Set the fuel control pump to setting”4”
3. Install the pump! (full load)! To do so, pull on the right control
4. Check for leaks! ropes often as required!
2. Measure the control dimension (see pict,)
Depending on the sealant the sealing 3.Compare the measured control dimension
surfaces can be separated several times with the nominal dimension (see table
without applying new sealing mass. No below)!
foreign material should be left on the
sealing surface

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SERVICING & TROUBLESHOUTING
case, replace the pump lever and reset the
4. The control dimension must be reset, control dimension!
when the measured control dimension is
not within the tolerance. This is achieved by
changing the number and thickness of the
shims between the pressure section and
the mushroom! It is generally sufficient to
remove one shim or to use a thinner shim.
The pump lever is worn, when it is no
longer possible to remove shims. In that

5. Check the injection valve! The pistons in

the injection valves must move smoothly
and close well. Replace the injection valves
when this is not the case

Never grind the pressure piece or

mushroom! The supplied fuel quantity can
be measured directly with the test unit for
fuel pumps (see A1-1)

Type Control Supply Fuel control Injection valve Pump element

dimension quantity at full pump order
quantity Order No. Diameter Order
(mm) stroke number
3 (mm) No.
(cm /stroke)
+0.3
D6-32 53.5 1.6 41865 14 22903
+0.3
D8-22 53.5 1.75 41865 14 22903
+0.3
D12-42 54.0 2.10 122469 15 122470
+0.3 1 104675
D19-42 54.6 2.40 170244 16 44015
D25-32 3.90 108780 20 66522
+0.3
D30-32 54.5 4.70 105172 22 66528
+0.3
D36-32 54.0 5.65 105731 24 64804
+0.3
2 63841
D46-32 54.5 7.15 105202 27 64813
+0.3
D62-22 53.5 8.70 100259 2 31 67218
D80-23 10.50 66948 4 32 67207
D100-13 12.50 103964 4 104675 35 14655
D125-32 +0.3 15.5 DH125.04.01 4 39 125.04.01.03
55.0
D138-32 17.0 DH138.04.01 4 41 138.04.01.03

D160-32 21.0 DH160.04.01 4 45 160.04.01.03

DH160.04.07
D180-32 24.0 DH180.04.01 4 48 180.04.01.03
+0.3
D225-22 53.8 28.0 DH125.04.01 4 39 125.04.01.03
+0.3
D250-22 55.0 31.0 DH125.04.01 4 DH225.04.07 39 125.04.01.03
+0.3
D280-22 55.0 34.5 DH138.04.01 4 41 138.04.01.03

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SERVICING & TROUBLESHOUTING
10.7 Filter

Follow the safety instructions indicated

at the beginning of this chapter !

When required, clean the filter of the fuel

and lubricant tanks as described below:

1. Drain the fuel tank!

2. Pull the fuel line from the filter nozzle!
3. Unscrew the filter nozzle!
4. Clean the filter insert!
5. Screw the filter nozzle back in!
6. Push the fuel line again on the filter
nozzle and mount the hose clamp!
7. Fill the fuel tank!
8. Check the filter nozzle for leaks!
9. Clean the filter of the lubricant tank in the
same manner!

10.8 Grease Nipple

Be careful when working on a hot Diesel

pile hammer! Do not touch hot
components! Danger of burns!

The grease nipples and lubrication

openings must be free of dirt and
carbonization and must allow a free flow for
the lubricant. Clogged grease nipples must
be replaced!

Pump fresh grease again in the grease

nipples of the impact block, cylinder end
ring and upper cylinder section after
shutting off the Diesel pile hammer! This
prevents a carbonization of the grease
located in the hot grease nipple!

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SERVICING & TROUBLESHOUTING

10.9 Catch groove and piston catch ring

The material to be driven penetrates slowly

in particularly solid soil or in the case of a
very blunt pile. In such a case, the drop
height of the impact hammer may continue
to increase. You must, in a timely manner,
reduce the fuel supply to prevent the piston
catch ring from bouncing into the catch
groove of the upper cylinder section

The operation of the Diesel pile hammer

must be discontinued immediately, when
the catch piston ring has bounced into the
catch groove of the upper cylinder section!
Check the catch groove and the piston
catch ring! Both must always be in perfect
condition. Machine a damaged catch
groove! Replace damaged catch piston
rings!

10.10 Rubber rings

Rubber rings are components subject to 3. Lift the Diesel pile hammer until the
wear. The service life of damping rings impact block (19) is fully extended!
(operating hours to wear) can vary
tremendously. The service life of the Secure the Diesel pile hammer against a
damping rings is a function of falling down !

- the type of pile-driving work,

- the number of strokes per minute,
- the quality of the maintenance work,
- outside effects (weather, dirt…)

Worn or damaged damping rings shall be

replaced as described below:

Follow the safety instructions indicated

at the beginning of this chapter!

1. Let the Diesel pile hammer rest on the

impact (19)!
2. Remove the impact block safety device,
if present!

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SERVICING & TROUBLESHOUTING
4. Using a screw driver, push the two-piece
outer damping ring (18) out of the groove!
Keep the loose metal guard for the later
installation! Work steps 5 through 19 can be
ignored, when it is necessary to replace
only the two-piece rubber ring (19).
5. Secure the impact block (19) with
wedges against a tilting toward the pile
helmet!
6. Attach the supplied installation plates to
the two-piece cylinder end ring (17)!
7. Screw the installation bolts in the lower
cylinder section (15)!
8. Unscrew all expansion screws of the
cylinder end ring (17)! Keep the expansion
screws at a safe place!

13. Replace the inner damping ring (29)!

14. Let the Diesel pile hammer rest on the
impact flock range (15)!
15. Screw the installation bolts in the lower
cylinder section (15)!
16. Lift the Diesel pile hammer until the
impact block (19) is fully extended!

9. Remove the cylinder end ring (17)! To

do so, screw four expansion screws in the
respective threads (See illustration)! The
width is restricted by the installation bolts.
10. Let the Diesel pile hammer rest on the
impact block flange!
11. Unscrew the installation bolts from the
lower cylinder section (15)!
12. Pull the Diesel pile hammer upward
until the inner damping ring (29) is easy to
replace! Secure the Diesel pile hammer
from falling down!

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SERVICING & TROUBLESHOUTING

The piston rings remain in the cylinder!

Secure the Diesel pile hammer from 10.11 Piston and impact block rings
falling down !

17. Remove the four thrust screws!

18. Screw all expansion screws back in the
cylinder end ring (17)! Follow the torque
data Worn or damaged piston or impact block
19. Remove the installation plates! rings must be replaced as indicated below.
20. Place a new two-piece rubber ring (18)
of the impact block flange! Follow the safety instructions indicated
21. Place the metal guards indicated in at the beginning of this chapter!
work step 4 on the two-piece rubber ring
(18)!

22. Lower the Diesel pile hammer! With its :

self-weight, the Diesel pile hammer presses
the two-piece rubber ring (18) into groove.

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SERVICING & TROUBLESHOUTING

With the Diesel hammers of the types D12

through D100, it will be possible to pull the
piston upward and out after disassembling
the upper end ring. Work steps 18. and 23.
Change accordingly!

1. proceed the steps 1 through 11,

described above

12. Lift the Diesel pile hammer

approximately 3 feet (1 meter)! The cylinder
end ring (17) is kept together with the
installation plates and remains on the
impact head flange. Secure the Diesel pile
hammer from falling !

13. Pull the piston (26) upward with the help

of the tripping device and stop just prior to
reaching the upper stop (21)

The catch lever (A5) must not touch the

upper stop (21)! This may cause a
release of the piston (26) and it may thus
come crashing down! Danger of an
accident!

14. Screw the supplied ring screw into the

piston (26)!

15. Attach a suitable steel cable to the ring

screw and the lifting equipment!

16. Lift the piston approximately 2 inches (5

cm)!

17. Push the catch lever (A5) down using a

pry bar

18. Lower the piston until all piston rings

are easily accessible!

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SERVICING & TROUBLESHOUTING

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SERVICING & TROUBLESHOUTING

19. Remove the piston and impact block

rings using special piston ring installation
pliers (included with the tool chest)!

20. Carefully clean the piston and impact

block ring grooves and apply the special
grease!

21. Install the new piston and impact block

rings using the special piston ring
installation pliers (included in the tool box)!

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SERVICING & TROUBLESHOUTING

22. Place the supplied piston ring

installation band around the piston rings!

23. Carefully pull the piston upward until

you are able to push the pawl (A4) into the
groove of the piston (26) by pressing the
catch lever (A5) upward by hand.

Make sure the piston ring installation strap

does not get stuck, when the piston (26) is
lifted into the cylinder!

24. Let the piston (26) rest on the pawl

(A4)!

25. Remove the cable and ring screw from

the piston (26)!

26. Lower the piston (26) to the lower stop

using the tripping device

27. Place the piston ring installation strap

around the impact block (19)!

28. Slightly raise the Diesel pile hammer to

unlatch the tripping device! Then lower the
Diesel pile hammer! Guide the impact block
(19) during said phase! Make sure the
piston installation strap is not compressed
on the cylinder end ring (17) (Stop the
downward movement at the appropriate
time)!

29. Remove the piston ring installation

band.

30. Install the inner dampening ring and

rubber ring

The Diesel pile hammers of the types

D12 through D100 may be operated only
with the upper end ring or the extension
of the upper cylinder section in place!
Danger of an accident!

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SERVICING & TROUBLESHOUTING

10.12 Compression

Starting difficulties may be caused by a Replace the defective components!

compression that is too low. A major Lubricate the impact block and piston in
decrease in the compression during the accordance with the maintenance schedule
pile-driving work will cause the piston to
reach lower and lower heights. The Diesel The following steps are helpful in case of a
pile hammer will stop in the extreme case. “running” pile:

The compression can be checked as Starting difficulties: Let the piston drop
described below: several times with the fuel supply shutoff
(Setting “0”) (cold blows) until the
penetration resistance is sufficient for the
starting.

You must wear a hard hat, ear plugs,

safety goggles, safety gloves, safety
boots and suitable work clothes!

1. Place the Diesel pile hammer on a hard

pile or a test stand!

2. Set the fuel control pump to setting “0”!

To do so, pull the left control rope as often
as required

3. Pull the piston upward until it trips!

4. Watch the piston! Compression is

sufficient when the piston bounces after
impacting the impact block and comes to
rest after at least another three upward and
downward movements.

Causes for compression that is too low:

- defective or stuck piston rings

- Insufficient lubrication of impact block or
piston
- Grooves in the lower cylinder section
below the exhaust openings
- damaged inner (bearing) ring
- inside diameter of the lower cylinder is out
of round or has grooves (worn out)
- the pile “runs” (soft soil, light, pointed and
narrow material to be driven).

68