BSP CG Series User manual

OPERATING MANUAL
MODEL
CG Range
Piling Hammer
BSP International Foundations Ltd.
Claydon Industrial Park
Great Blakenham, Ipswich, Suffolk
IP6 0NL, United Kingdom
www.bsp-if.com
Tel. [phone]
Fax. [phone]

4421 1999 REV - Page 2
CG Range
SERIAL NUMBER ___________________________
OWNER ___________________________
ADDRESS ___________________________
___________________________
___________________________
___________________________
When ordering spare parts please include the following information:
a] Assembly Number
b] Serial Number
c] Part Description
d] Part Number
e] Quantity Required
f] Order Number
Issue
Manual Ref. No. 4421 1999
Date
Revision No.

4421 1999 REV - Page 3
Operating Manual
GENERAL SAFETY 1.1
1.1 Foreword
1.2 Safety at Work
1.3 Noise Data
1.4 Limitations of use
SPECIFICATIONS 2.1
2.1 Hydraulic Circuit
2.2 Hydraulic Supply
2.3 Operating / storage temperature limits
2.4 Options / Weight data
2.5 Hammer lifting points
OPERATING INSTRUCTIONS 3.1
3.1 Connecting Controls
3.2 Control Panel Layout
3.3 Before commencing driving
3.4 Single-Blow Operation
3.5 Tamping
3.6 Automatic Operation
3.7 High-Restart Operation
3.8 Stroke Watch Operation (Energy Monitor)
REGULAR MAINTENANCE 4.1
4.1 Transport
4.2 Initial Set-up for NEW Hammer
4.3 Hydraulic Contamination
4.4 Warming / Purging Oil
4.5 Regular Maintenance Schedule
4.6 Dolly Selection & Replacement
4.7 Vibration Damper

4421 1999 REV - Page 4
Workshop Manual
GENERAL MAINTENANCE 5.1
5.1 Accumulator Pre-Charging
5.2 Accumulator Servicing
5.3 Assembling Cylinder into Cage
5.4 Dropweight to Cylinder Connection
5.5 Assembling Dropweight
5.6 Torque Settings
5.7 Electrical Sensor Installation
FAULT DIAGNOSIS 6.1
6.1 Hammer Will Not Start
6.2 Hammer Will Not Run On AUTOMATIC
6.3 Hammer Stops During Running
6.4 No System Pressure
6.5 No Pilot Pressure
6.6 Slow Blow Rate
6.7 Erratic Stroke
6.8 Excessive Height of Stroke
6.9 Insufficient Height of Stroke
6.10 Hammer Cage lifts with Weight During Stroke
6.11 Weight Remains at Maximum Stroke
6.12 Weight Falls Slowly
6.13 Electrical Sensor Checks
PARTS MANUAL
PARTS LISTS 7.1

4421 1999 REV - Page 5
1. GENERAL SAFETY
1.1 Foreword
The purpose of this Service Manual is to provide equipment owners and operators with all information
necessary for the correct use and maintenance of Hydraulic Hammers.
For pile driving to be safely and efficiently undertaken, rig operators need to be experienced in general
techniques and to have good working knowledge of the mechanical features of the Hydraulic Hammer
and ancillary fittings.
We strongly recommend that this publication be read and understood by all staff concerned before the
hammer is operated in the field.
BSP products are engineered for reliable operation and long life in normal conditions of use; reliability
and life can be extended by careful and regular maintenance following the recommendations in the
maintenance section of this manual.
The manual also contains a fully illustrated Parts List and attention of all users is drawn to the preferred
parts ordering procedure.
A. General Orders
When unloading and unpacking the unit use extreme care. For your protection, make thorough
inspection of the unit immediately on delivery. In case of any damage or shortage notify the
transit agent at once and have the delivery carrier make a notation on the freight bill.
B. Safety Precautions
Safety is basically common sense. There are standard safety rules but each situation has its own
peculiarities which cannot always be covered by rules. Therefore, your experience and common
sense will be your best guides to safety. Be ever watchful for safety hazards and correct
deficiencies promptly. Use the following safety precautions as a general guide so safe
operations:
- Never adjust or repair the unit while it is in operation.
-Remove all tools and electrical cords before starting.
For safety information on the use and handling of diesel fuel and hydraulic mineral oil refer to the
information in the operating manual for the Hydraulic Power Pack
WARNING –The hydraulic system includes nitrogen gas charged accumulators.
Before servicing the hydraulic system, ensure that any retained hydraulic pressure is allowed to
dissipate,
Accumulators are subject to inspection in use according to applicable national regulations
ALL APPLICABLE SAFETY PRECAUTIONS AND RELEVANT SAFETY LEGISLATION SHOULD BE
OBSERVED WHEN OPERATING AND USING HYDRAULIC HAMMERS.
1.2 Safety at Work
NOISE - The use of all types of pile driving equipment will produce noise to varying degrees, which can
be injurious to health.
EAR PROTECTORS - Must be used at all time when in the vicinity of any pile driving operation.
PROTECTIVE CLOTHING - Safety helmets must be worn at all times on construction sites. It is also
recommended that safety boots, safety glasses and fluorescent safety jackets are worn. Life jackets
should be worn in marine sites

4421 1999 REV - Page 6
1.3 Noise Data
Hammer
Sound power level EN996
Sound pressure level @ operator
position –4m from sound source
Measured to EN ISO 11202
4.27.4
Measured
(Lwaeq)
Guaranteed
(Lwaeqd)
A-weighted
(Lpaeq)
C-weighted peak
(Lpcpeak)
CG 180
-
-
-
-
CG 210
126
130
-
-
CG 240
126
130
-
-
CG 300
124
128
-
-
1.4 Limitation of Use
Limitations on Use of Impacting Equipment and Selection of Hammer Size
a) General:
i. It is extremely difficult to avoid overloading a piling hammer and it therefore becomes
impossible to guarantee components against damage or breakage due to overdriving or misuse
of the equipment.
ii. With particular reference to impacting type equipment, driving to an approximate pile
penetration of 10 blows/ 25mm is generally considered to be the limit for economic operation for
any size or model of the hammer.
b) Selection of Hammer Size:
i. Ultimate resistance to penetration should be estimated from ground information and/or test pile
records, as available.
ii. Hammer selection should be based upon the pile penetration per blow during the greater part of
the driving cycle being greater than 5mm (5 blows/25mm), and at final pile penetration of
approximately 2mm (10-12 blows/25mm).
c) Limitation on Use:
i. Except as provided hereunder, a hammer should not be used to drive to a pile penetration
in excess of 10 blows/25mm.
ii. Where piles are to be driven to a level and a known, penetration is required, driving may be
continued beyond the above recommended limit for a maximum period of 3 minutes per pile. If
however during these 3 minutes the rate reaches 25 blows per 25mm (inch) the hammer must
be stopped immediately.
iii. Maximum rake –when used with established BSP raking configurations 1 : 3 (18°)
PLEASE NOTE:
NEVER START THE HAMMER UNTIL THE HAMMER ROPE IS SLACK. THE ROPE MUST REMAIN
SLACK DURING ALL DRIVING OPERATIONS, or IF A SLEDGE IS USED IT IS ALWAYS KEPT IN
CONTACTWITH THE HAMMER USING THE PULL DOWN WINCH. PLEASE READ SECTION 1.4 –
LIMITATIONS OF USE.

4421 1999 REV - Page 7
2. SPECIFICATIONS
2.1 Hydraulic Circuit:
The CG range can be operated from a BSP 250 or 260 Hydropack
To cause the hammer to run:
A] Activate the ‘System Load Valve’ (SLV) to supply oil to the hammer, and charge up the HP
accumulators.
B] Operate the ‘Hammer Control Valve’ (HCV) on the hammer. This moves the spool and directs HP oil
under the piston head to lift the dropweight.
C] During lift some oil from above the cylinder is stored in the LP accumulators. The remainder returns
to tank.
D] Switch the ‘HCV’ off to return the spool to the ‘Fall’ position, the dropweight will fall and the oil from
the LP accumulators will top up the full bore side of the cylinder.

4421 1999 REV - Page 8
2.2 Hydraulic Supply:
The flow and pressures required to operate each hammer in the CG range at rated energy and blow
rate are as follows: The hammers’ will work at lower flow at reduced energy and blow rate.
Model
Ram Weight
Operating
Pressure
Flow
Minimum
Pressure Relief
Setting
(kg)
(bar)
(L/min)
(bar)
CG180
12000
180-210
370
300
CG210
14000
220-250
370
300
CG240
16000
250-280
370
300
CG300
20000
280-300
400
320
2.3 Operating / storage temperature limits
a) Operating
Subject to the use of the appropriate grade of hydraulic oil (refer to the operating manual for
the power source).
Component
Limiting
temp. °C
Comments
Control box / monitor
0
for lower temperature install in operator’s cab
Umbilical
-5
for lower temperature refer to alternative
umbilical construction
Hammer
-10
for temperatures below 0°C the hammer should be
operated at 25% energy for 10minutes after stating
from cold
Hammer
-25
oil must be circulated in hoses and hammer prior to
starting
b) Storage
Minimum temperature -40°C
Hammer to be stored under protective cover.
Hose umbilical, control cable to be removed from hammer and stored under cover.
Control box / monitor to be stored at above 0°C.
c) Maximum ambient temperature
40°

4421 1999 REV - Page 9
2.4 Options / Weight Data
The CG Hammer can be configured to operate suspended from a crane or mounted to a leader.
A pile sleeve with revolving flat cap for use on larger diameter marine tubular piles can be fitted.
Description / Option
“L” (m)
Mass (Kg)
CG180 Basic hammer.
Additional accessories listed
below :
Dolley
Helmet guide assembly
Helmet
Helmet insert
Anvil
1.89
18,500
CG240 Basic hammer.
2.08
21,750

4421 1999 REV - Page 10
Option
Drawing No
“L” (M)
Mass (kg)
12 Tonne Dropweight Assembly
4421 1110
1.17
12,291
16 Tonne Dropweight Assembly
4421 1005
1.50
16,441
2 Tonne Extension Kit
4421 1585
2,900
4 Tonne Extension Kit
4421 1515
4,916

4421 1999 REV - Page 11
Option
Drawing No
Mass (kg)
Pile Guide Assembly
(C/W Drive cap and sleeve to
suit 2M ø Piles)
4421 1305
14,425
Pile Guide Assembly
(C/W Drive cap and sleeve to
suit 900mm ø Piles)
4421 1461
5,600
Helmet Retainer & Damper
Housing Assembly
(picture Shown with 900ø
Helmet)
4421 1045
1,091
Dolley
Dolley –High Temperature
4421 0583
4421 1512
170

4421 1999 REV - Page 12
Option
Drawing No
Mass (kg)
Lifting Tackle Assembly
4421 1281
475
Actuator
4421 2005
750
CG180 Hammer Cage
CG240 Hammer Cage
4421 1584
4421 1415
4041
4287

4421 1999 REV - Page 13
2.5 Hammer lifting points
a) Lifting points for handling hammer for transit
b) Alternative lifting points for handling hammer –vertical operation
Lifting points for 3 leg
Sling / chain for
Horizontal lifting
1 Pad Eye
70ø x 40 Wide
2 Pad Eye
80ø x 30 Wide
Attach Rope to
Lifting Sheave
Lifting points for
Vertical lift only
Attach 2
Ropes / chains
to Top of cage

4421 1999 REV - Page 14
3. OPERATING INSTRUCTIONS
3.1 Connecting Controls

4421 1999 REV - Page 15
SK 7
F 1
F 2
S 1
HIGH
RESTART
RESTART
IMPACT
CABLE
BREAK
CUT-OUT
3.2 Control Panel Layout
The diagram below shows the control panel layout and the connecting leads to the hydraulics, guide
frame and hammer.
Control
F1
S1
F2
12/24v D.C.
O/P to Sensors
System Load Valve
Hammer Control Valve
Stop
Stroke
Dwell
Pump Flow
HAMMER CONTROL
MANUAL LIFT
SK7
Counter
Reset
Test
High Restart
RESTART
Impact
Cable Break
CUT-OUT
Oil Circulate
Device
5 A Fuse
Toggle Switch
0.4 A Fuse
Lamp
Lamp
Lamp
Lamp
Push-button
Potentiometer
Potentiometer
Potentiometer
Rotary Switch
Push-button
7-pole Socket
Display
Push-button
Push-button
Lamp
Lamp
Lamp
Lamp
Lamp
Rotary Switch
Function
Protection on input power supply
Main panel on/off switch
Protection on supply to sensors in hammer
Indicates supply via F1 & S1 is present
Indicates supply to hammer via F2 is present
Indicates SLV (dump valve)is energised
Indicates HCV is energised
Stops power pack engine (& hammer functioning)
Adjusts length of automatic stroke
Adjusts length of pause at impact
Adjust flow from LRB base
HAMMER FUNCTION SELECTOR
Raises Dropweight manually
Alternative connection for monitoring hammer
performance
Blow Totaliser
Zero blow counter
Factory test key
Indicates dropweight sensor operation on hammer
Indicates dropweight sensor operation on hammer
Indicates dropweight sensor operation on hammer
Warning if cable to hammer is broken
Indicates hammer is not engaged on the pile
correctly.
Circulates oil for warming or purging

4421 1999 REV - Page 16
3.3 Before commencing driving
Whenever the hammer is up righted for piling,
it is essential that the dolly assembly is correctly positioned in the drive cap recess
If the hammer is operated with the impact plate or dolly out of position, this will cause damage to the
ram, drive cap and cage
This check can be carried out in either of 2 ways
a) Using the CUT OUT indicator lamp on the control panel
HAMMER CONTROL rotary switch in OFF position
Switch ON 24v power toggle switch
Upright hammer or raise clear of pile so that drive cap rests on its internal stops or is suspended
on its ropes
CUT OUT LAMP SHOULD BE ON
b) Visual inspection of dolly location
Operating the hammer with the dolley out of location will cause major damage to the
hammer
For hammers with enclosed drive cap retainer
These hammers must be fitted with the cast nylon dolley
4421 0583 to reduce risk of the dolley assembly
becoming displaced from the drive cap whenever the
hammer is lowered horizontally to the ground
With hammer upright, the dolley location can be confirmed
through the viewing slot
Dolly Viewing
Aperture
Pile Sleeve
It is essential that the dolley is correctly located in the drive cap recess whenever the hammer is up righted
from the horizontal position.

4421 1999 REV - Page 17
3.4 Single-Blow Operation - (MANUAL)
a] With the control
panel switched on
both power supply
and o/p to sensor
lights will come on.
b] Turn control switch
to ‘MANUAL’ and
flow to 50%
c] Press and hold the
‘Manual Lift’ push-
button.
The SLV and HCV
lamps will come
on.
d] After hydraulic
pressure has built
up the dropweight
will rise.
e] Release the push-
button. The SLV
and HCV lamps
will go out and the
dropweight will fall
f] Repeat as
required.
2
1
3
1
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
bar
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
bar
bar
MAIN DRIVE
PRESSURE
3
HAMMER CONTROL
REMOTE
HIGH
AUTO
TAMP
MANUAL
OFF
RESTART
MANUAL
2
MANUAL LIFT

4421 1999 REV - Page 18
3.5 Tamping Operation:
For small automatic
blows used to input
low energy in the
ground.
a] Turn the control switch
to ‘TAMP’
b] Press the manual lift
button to start the
dropweight moving.
c] Release the push-
button the dropweight
will fall and the SLV
will remain loaded and
the HCV will continue
to pulse
d] Adjust the ‘DWELL’
control to alter the rate
of blows
e] Adjust the Pump flow
to a low rate.
(note: ‘Stroke’ adjust
has no effect)
4
4
2
1
3
3
1
DWELL
MAX.
MIN.
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
100
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
bar
HAMMER CONTROL
OSCILLATE
HIGH
AUTO
TAMP
MANUAL
OFF
RESTART
(NO LEAD)
2
MANUAL LIFT

4421 1999 REV - Page 19
3.6 AUTOmatic Operation:
a] Turn control switch to ‘AUTO’.
Set ‘Stroke’ to 40% ‘Dwell’ to
minimum and Flow to 50%
b] Press manual push-button to
start dropweight moving.
c] The sensor indicators will
show the dropweight is
moving
d] Release the push-button. The
Dropweight will fall. The SLV
remains on, and the HCV
turns off.
e] The next blow is triggered by
the ‘Restart’ sensor as its
indicator lamp goes out.
PUMP FLOW
DWELL
MAX.
MIN.
STROKE
MAX.
MIN.
5
4
3
4
3
1
6
7
2
1
6
NEXT BLOW
TRIGGERED AS
RESTART LAMP
GOES OUT
IMPACT
RESTART
HIGH RESTART
IMPACT
RESTART
HIGH RESTART
IMPACT
RESTART
HIGH RESTART
CABLE BREAK
CUT-OUT
IMPACT
RESTART
HIGH RESTART
CABLE BREAK
CUT-OUT
500
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
O/P TO
SENSORS
12/24v
D.C.
bar
MANUAL LIFT
HAMMER CONTROL
REMOTE
HIGH
AUTO
TAMP
MANUAL
OFF
RESTART
MANUAL
2
7
MAX.
MIN.
5

4421 1999 REV - Page 20
Automatic Continued .
f] The hammer will
continue to run
automatically.
g] The ‘Stroke’ control
adjusts the powered
portion of the stroke
and should be altered
with the flow to give
best hammer
performance.
h] The ‘Dwell’ control
alters the pause
between the restart
sensor triggering and
the HCV activating
g] The ‘Flow’ control
varies the oil delivered
and affects the speed
of lift and over-travel.
DWELL
MAX.
MIN.
STROKE
MAX.
MIN.
RESTART SENSOR
OVER-TRAVEL
STROKE
DWELL
IMPACT
RESTART
HIGH RESTART
CABLE BREAK
CUT-OUT
IMPACT
RESTART
HIGH RESTART
CABLE BREAK
CUT-OUT
IMPACT
RESTART
HIGH RESTART
CABLE BREAK
CUT-OUT
IMPACT
RESTART
HIGH RESTART
CABLE BREAK
CUT-OUT
START
LIFT
OVER-TRAVEL
FALL
IMPACT
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
IMPACT
RESTART
HIGH RESTART
CABLE BREAK
CUT-OUT
SYSTEM
LOAD
VALVE
HAMMER
CONTROL
VALVE
FLOW
MAX.
MIN.