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JUNTTAN PM 20L Operator's Manual

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OPERATOR'S MANUAL
JUNTTAN
PM 20L Piling rig s/n 1461

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  • Page 1 OPERATOR’S MANUAL JUNTTAN PM 20L Piling rig s/n 1461...
  • Page 3 This manual or copy of that should be stored in the cabin. All drawings, diagrams and other technical information as well as the technical inventions and possible patents remain the property of JUNTTAN Oy and JUNTTAN Oy has copyright to the contents of this manual unless otherwise indicated. All Rights Reserved. ©2008 / 2013 Junttan Oy.

  • Page 4: Table Of Contents

    JUNTTAN Operator’s manual Table of contents INTRODUCTION SECTION ............7     SAFETY SECTION ..............8     IMPORTANT ASPECTS OF SAFETY ..........8     SAFETY ASPECTS REGARDING THE MACHINE ......8     SAFETY ASPECTS REGARDING THE WORK SITE ..... 9  ...
  • Page 5 JUNTTAN Operator’s manual DAILY OPERATION SECTION ..........57     GENERAL ..................57     COMMISSIONING, STARTING AND STOPPING ......58     6.2.1 STARTING ENGINE ............58     6.2.2 STOPPING ENGINE............59     STABILITY ..................59  ...
  • Page 6 JUNTTAN Operator’s manual   FUELS, LUBRICANTS AND HYDRAULIC FLUIDS ......92   7.2.1   FLUID AND LUBRICANTS CAPACITIES ......92   7.2.2   OIL AND GREASE TYPES ..........93     ROUTINE SERVICING OF THE MACHINE ........95    ...

  • Page 7: Introduction Section

    JUNTTAN Introduction section INTRODUCTION SECTION The Junttan PM 20L piling rig is designed for pile driving. Maximum pile length is 18 m. The construction of the machine is a rotating machinery deck with leader on crawler-mounted undercarriage. The piling leader consists of a leader, basic leader and optional leader extension.

  • Page 8: Safety Section

    Safety section SAFETY SECTION above information IMPORTANT changed. These changes may affect ASPECTS OF the use, lubrication, service and repair procedures. Junttan or its SAFETY dealer will provide with up-to-date information regarding the Pay special attention to the sections operation and maintenance of this which are identified with Safety Alert machine.

  • Page 9: Safety Aspects Regarding The Work Site

    JUNTTAN Safety section Keep all materials and fluids in metre from pressurised tubes and properly designed marked hoses. containers. Do not go under the machine or any Do not keep any loose items on the part of it and preferably stay out of machine or in the cab.

  • Page 10: Personnel Safety

    JUNTTAN Safety section n ATTENTION EMERGENCY There shall be always at least two SYSTEMS persons (operator, helper) when servicing or maintaining the machine The machine has low voltage (24 in the working site. One of them shall VDC) electric system. The ignition supervise the safety of other workers.

  • Page 11: Warning Signs

    JUNTTAN Safety section WARNING SIGNS WARNING KEEP CLEAR There are several warning signs on OF PILE DRIVER this machine. Please read all warning WHEN IN OPERATION signs. Keep signs clean and replace them if the words cannot be read. WARNING...

  • Page 12: Danger Zone

    JUNTTAN Safety section DANGER ZONE Gevarenzone: 24 m + 20 m = 44 m...

  • Page 13: Specifications Section

    JUNTTAN Specifications section SPECIFICATIONS SECTION GENERAL IDENTIFICATION Trade mark of the machine: Junttan PM 20L Type of the machine: Piling rig for impact driving Model: PM 20L Serial number: 1461 Name and address of manufacturer: Junttan Oy PL 1702 70701 KUOPIO...

  • Page 14: Engine

    JUNTTAN Specifications section ENGINE Name of manufacturer: Cummins Type of engine: Turbo-charged diesel Model of engine: QSB6.7 Tier3 Serial number of engine: 21791780 Number of cylinders: 6 (in line) Bore: 104 mm Stroke: 132 mm Rated power: 176 kW/240 hp at 2000 rpm...

  • Page 15: Hydraulic Motors

    JUNTTAN Specifications section HYDRAULIC MOTORS Travel motor and transmission (2) - model: H1CR90-S/Brevini CTU 3700 - type: hydraulic axial piston motor with build in transmission - torque: 70 000 Nm - operating pressure: 300 bar - drive speed: 1,5 km/h...

  • Page 16: Hydraulic Filters

    JUNTTAN Specifications section Horizontal slide cylinder - type: double acting - stroke: 1500 mm Track width adjustment cylinders (2) - type: double acting - stroke: 1000 mm - load holding valve installed Pile arm cylinders (2) - type: double acting...

  • Page 17: Winches

    JUNTTAN Specifications section WINCHES Pile winch (left) - model: - lifting capacity: 8 ton - ropeline specification: Ø22 mm-70 m, 35*7 Compacted 2160 N/mm Hammer winch (right) - model: - lifting capacity: 10 ton - ropeline specification: Ø25 mm-52 m, 6x36-IWRC 1770 N/mm 3.10 SAFETY DEVICES...
  • Page 18 JUNTTAN Specifications section WARNING SIGNS - warning signs are shown in safety section OTHER - safety lever to deactivate controls in the cab - engine emergency stop - sensor for horizontal slide in-position - sensor for leader position on leader lift device...

  • Page 19: Weight (Working)

    JUNTTAN Specifications section 3.11 WEIGHT (WORKING) Base machine with leader: 39 000 kg (net including full fuel and oil tanks, etc.) Counterweight: 7 500 kg Rotary head (JD 1.5): 500 kg Hammer (HHK 3AL): 6 400 kg Hammer (HHK 4AL):...
  • Page 20 JUNTTAN Specifications section Recommended oil brands: Manufacturer Location Neste Mobil Esso Shell Castrol Teboil Engine oil Turbo Delvac Essolube Rimula RX Super Super HPD, XHP, XT 501 Super, Plus Power Delvac HP Super FE Hydraulic oil Hydrauli 46 Flowrex 86,...

  • Page 21: Capacity Tables

    JUNTTAN Specifications section 3.13 CAPACITY TABLES Instructions how to read capacity tables: Tables are calculated for the hammer HHK 3/4A. Counterweight is 7 500 kg. Leader foot is slightly above ground or against hard ground before inclinations. Maximum allowed pile weights are shown in kilograms.
  • Page 22 JUNTTAN Specifications section CAPACITY TABLE, EN996 Machine type: Piling rig Machine model: PM 20L Serial number: 1461 Horizontal slide: Horizontal slide is projected 300, 600, 900 and 1200 mm out. Counterweight: Weight 6 000 kg (include stabilizers). 1. With tracks in full width and on horizontal, level and firm ground.
  • Page 23 JUNTTAN Specifications section Leader length: 18.6 m + cathead 0.85 m and 4 m telescope. Leader sections: 13.8 + 4.8 m Hydraulic hammer: HHK 3AL, total weight 6 400 kg Maximum pile weights in kg Pile 14 m Horizontal slide Max.
  • Page 24 Specifications section CAPACITY TABLE, LEADER FOOT ON THE GROUND Machine type: Piling rig Machine model: PM 20L Serial number: 1461 Horizontal slide: Horizontal slide is projected 300, 600, 900 and 1200 mm out. Counterweight: Weight 6 000 kg (include stabilizers).
  • Page 25 JUNTTAN Specifications section Leader length: 18.6 m + cathead 0.85 m and 4 m telescope. Leader sections: 13.8 + 4.8 m Hydraulic hammer: HHK 3AL, total weight 6 400 kg Maximum pile weights in kg Pile 14 m Horizontal slide Max.
  • Page 26 JUNTTAN Specifications section CAPACITY TABLE, EN996 Machine type: Piling rig Machine model: PM 20L Serial number: 1461 Horizontal slide: Horizontal slide is projected 300, 600, 900 and 1200 mm out. Counterweight: Weight 6 000 kg (include stabilizers). 1. With tracks in full width and on horizontal, level and firm ground.
  • Page 27 JUNTTAN Specifications section Leader length: 18.6 m + cathead 0.85 m and 4 m telescope. Leader sections: 13.8 + 4.8 m Hydraulic hammer: HHK 4AL, total weight 7 700 kg Maximum pile weights in kg Pile 14 m Horizontal slide Max.
  • Page 28 Specifications section CAPACITY TABLE, LEADER FOOT ON THE GROUND Machine type: Piling rig Machine model: PM 20L Serial number: 1461 Horizontal slide: Horizontal slide is projected 300, 600, 900 and 1200 mm out. Counterweight: Weight 6 000 kg (include stabilizers).
  • Page 29 JUNTTAN Specifications section Leader length: 18.6 m + cathead 0.85 m and 4 m telescope. Leader sections: 13.8 + 4.8 m Hydraulic hammer: HHK 4AL, total weight 7 700 kg Maximum pile weights in kg Pile 14 m Horizontal slide Max.
  • Page 30 If you need more information about the capacity of the rig please contact to Junttan or its representative. In order to avoid interruptions in the operation, please allow Junttan enough time to make the necessary calculations.

  • Page 31: Lifting Loads With Pile Winch

    JUNTTAN Specifications section 3.14 LIFTING LOADS WITH PILE WINCH DIAGRAM READING INSTRUCTIONS Diagram shows distance which can be reached for listed forward inclinations to lift loads with the pile winch and what is maximum load weight for appropriate inclination. For example, as shown in diagram below, to lift a load which is placed 7 m far from the center of the rotation, needed forward inclination is 10°...
  • Page 32 JUNTTAN Specifications section Machine type: Piling rig Machine model: Junttan PM 20L Serial number: 1461 Leader length: 18.6 m. The telescope is down. Leader foot is slightly above the ground but it is allowed to be lifted up when needed.
  • Page 33 JUNTTAN Specifications section Machine type: Piling rig Machine model: Junttan PM 20L Serial number: 1461 Leader length: 18.6 m. The telescope is down. Leader foot is slightly above the ground but it is allowed to be lifted up when needed.
  • Page 34 JUNTTAN Specifications section Machine type: Piling rig Machine model: Junttan PM 20L Serial number: 1461 Leader length: 18.6 m. The telescope is down. Leader foot is slightly above the ground but it is allowed to be lifted up when needed.
  • Page 35 JUNTTAN Specifications section Machine type: Piling rig Machine model: Junttan PM 20L Serial number: 1461 Leader length: 18.6 m. The telescope is down. Leader foot is slightly above the ground but it is allowed to be lifted up when needed.

  • Page 36: Ground Pressure

    Maximum ground pressure 350 kPa when Maximum ground pressure 337 kPa when upper carriage is turned 15º against under upper carriage is turned 160º against under carriage. carriage. PM 20L 1461 PM 20L 1461 350 355 350 355 337000 337 kPa...

  • Page 37: Inclinometer

    JUNTTAN Specifications section 3.16 INCLINOMETER See also inclinometer manufacturers operation and installation manual. Safety angle, 30º Sideward inclination Forward and backward inclination 3.16.1 CALIBRATION OF THE INCLINOMETER Check first that the sensor box of the inclinometer is tight on the leader.

  • Page 38: General Section

    JUNTTAN General GENERAL SECTION MAJOR COMPONENTS The construction of the machine is a rotating machinery deck with leader on crawler- mounted undercarriage. The piling leader consists of a leader, basic leader and optional leader extension. The bottom of the leader is connected with the cross joint to the horizontal slide.
  • Page 39 JUNTTAN General Fig. 1...
  • Page 40 JUNTTAN General Fig. 2a...
  • Page 41 JUNTTAN General Fig. 2b Fig. 2c...
  • Page 42 JUNTTAN General...
  • Page 43 JUNTTAN General...

  • Page 44: Controls Section

    JUNTTAN Controls section CONTROLS SECTION GENERAL LAYOUT n DANGER Do not operate the machine unless you are trained and authorized to do so. Unintentional misuse of controls may damage the machine and cause personal injury. Figure 8 illustrates the general layout of the operator's controls and instrumentation in the cab.
  • Page 45 JUNTTAN Controls section...

  • Page 46: Foot Pedals On The Floor

    JUNTTAN Controls section FOOT PEDALS ON THE FLOOR Leader telescope middle: rest position pedal front down: telescope down back down: telescope up Throttle pedal (D) engine rpm...

  • Page 47: Controls On The Right Console

    JUNTTAN Controls section CONTROLS ON THE RIGHT CONSOLE The black arrows in the symbols and beside the control indicate the same direction of the functions. The central rest position is neutral for all levers. The controls on the right console are illustrated Figure 10.
  • Page 48 JUNTTAN Controls section WINCH LEVER Forwards Both winches unwind Backwards Both winches wind up Diagonally The hammer winch unwind/wind up Diagonally The pile winch unwind/wind up Top switch (front) Winches double speed...
  • Page 49 JUNTTAN Controls section SWITCHES Emergency stop Engine emergency stop Ignition switch Key operated P = not connected 0 = engine stop/key remove I = current on II = not connected III = engine start Blow counter Switch 1: Winches/forward inclination cylinder release when using leader lift device, see sections lifting/lowering leader how to use the switch.
  • Page 50 JUNTTAN Controls section Air conditioning Temperature on /off Fresh air Air conditioning, optional...

  • Page 51: Instruments On The Right Console

    JUNTTAN Controls section 5.3.1 INSTRUMENTS ON THE RIGHT CONSOLE...
  • Page 52 JUNTTAN Controls section...

  • Page 53: Switches On The Top Console

    JUNTTAN Controls section SWITCHES ON THE TOP CONSOLE Windshield wipers Roof window wiper Signal horn Hydraulic oil cooler, manual on/off Washer Washer Swing lock Energy measurement system Work lights 10. Work lights 11. Work lights 12. Cabin light 13. Hydraulic pump minimum output 14.

  • Page 54: Controls On The Left Console

    JUNTTAN Controls section CONTROLS ON THE LEFT CONSOLE LATERAL INCLINATION LEVER Diagonally The leader is inclined (raked) to forward the respective side (cylinder is pushed out) Diagonally The leader is inclined (raked) to backward the opposite side (cylinder is pulled in)
  • Page 55 JUNTTAN Controls section SWITCHES Ram block single lift Drop height dial Dwell time dial Oil flow adjusting Piling interruption Short stroke Pre-selection stabilizers Right stabilizer Left stabilizer...

  • Page 56: Signal Lights In The Upper Console

    JUNTTAN Controls section SIGNAL LIGHTS IN THE UPPER CONSOLE when Signal light: ON when Signal light: ON uppercarriage swing the forward inclination lock is used cylinder is released Signal light: ON when the piling mode switch is in position 1 or 2...

  • Page 57: Daily Operation Section

    JUNTTAN Daily operation section DAILY OPERATION SECTION GENERAL These instructions are written for operating the machine on land. Operation on floats is not covered in this manual (always consult the manufacturer or importer before start operating on floats). When entering and exiting the cab use only the accesses provided with handles and steps.

  • Page 58: Commissioning, Starting And Stopping

    JUNTTAN Daily operation section COMMISSIONING, STARTING AND STOPPING There is a separate manual for the engine. The engine may be started and operated only in an area with good ventilation. Indoors and in other closed areas the exhaust gases must be piped outside.

  • Page 59: Stopping Engine

    STABILITY See capacity tables (specifications section). If you need more information about the capacity, contact the manufacturer Junttan Oy, and for more details about the applicable restrictions, see the respective Sections. Operate only on level and firm ground. Use stock mats when the ground is soft. When you are travelling on a slope adjust the position of the leader to vertical in order to maintain balance.

  • Page 60: Moving The Machine Between Work Sites

    JUNTTAN Daily operation section MOVING THE MACHINE BETWEEN WORK SITES 6.4.1 LIFTING OF THE LEADER The machine is designed for lifting and lowering the standard length leader. 6.4.1.1 PREPARATION FOR LEADER LIFTING Drive the machine to even and solid ground. Swing the machinery deck parallel to the undercarriage.

  • Page 61: Testing Releasing Valves Of Forward Inclination Cylinder

    JUNTTAN Daily operation section 6.4.1.2 TESTING RELEASING VALVES OF FORWARD INCLINATION CYLINDER • The forward inclination cylinder is released during leader lifting and lowering. • If there is any rubbish in the releasing valves it is possible that valves do not hold the load.

  • Page 62: Lifting With The Leader Lift Device

    JUNTTAN Daily operation section 6.4.1.3 LIFTING WITH THE LEADER LIFT DEVICE • Switch power to the leader lift device system with the switch (3). • If the signal light (H21) is not on then the horizontal slide and/or the lateral inclination cylinders are not fully in. The leader lift device will only move up if the cylinders are fully in.

  • Page 63: Final Lifting

    JUNTTAN Daily operation section 6.4.1.4 FINAL LIFTING • Lift the leader to the vertical position with the forward inclination cylinder and the lateral inclination cylinders. • Follow the course of the leader foot and, if necessary, lift the leader foot up so that it does not plough into the ground.

  • Page 64: Lowering The Leader

    JUNTTAN Daily operation section 6.4.2 LOWERING THE LEADER 6.4.2.1 PREPARATION FOR LOWERING THE LEADER Drive the machine to even and solid ground. Swing the machinery deck parallel to the undercarriage. Slight ground slope forward (max 5º) is allowed. Ground inclination to the side and backward is forbidden during lowering.

  • Page 65: Lowering The Leader To The Leader Lift Device

    JUNTTAN Daily operation section 6.4.2.2 LOWERING THE LEADER TO THE LEADER LIFT DEVICE n DANGER Always raise the leader lift device fully up (signal light H23 will light on and leader lift device stops moving) before you start lowering the leader with forward inclination cylinder.

  • Page 66: Lowering The Leader Lift Device With The Leader

    JUNTTAN Daily operation section 6.4.2.3 LOWERING THE LEADER LIFT DEVICE WITH THE LEADER • To lower the leader, press simultaneously the “leader lift device down”-button (5) and the “forward incl. cylinder release”-button (2) on the right console. n WARNING Stop the leader lowering if the signal lights are not working properly as told before.

  • Page 67: Daily Operation

    JUNTTAN Daily operation section DAILY OPERATION Daily operation on the work site consists of traveling with the machine and performing various tasks associated with lifting piles off the ground, positioning them and doing the actual driving. The preferred way of doing each step is detailed in the sections below.

  • Page 68: Hauling Of The Pile

    JUNTTAN Daily operation section 6.5.2 HAULING OF THE PILE When piles are brought to the work site they should be positioned so that you can haul them with the machine near to the area where they are to be driven. Ensure that the piles are in the sequence they are needed.

  • Page 69: Lifting Pile To The Leader

    JUNTTAN Daily operation section 6.5.3 LIFTING PILE TO THE LEADER When you have the pile near the machine and the pile is top end towards the machine you can start lifting the pile. • Lifting the pile from the top end.

  • Page 70: Positioning Of The Pile

    JUNTTAN Daily operation section 6.5.4 POSITIONING OF THE PILE • Lift the pile slightly above ground. • Move the machine and swing the machinery deck as needed so that you get as close as possible to the spot where the pile is to be driven.

  • Page 71: Moving Machine On The Working Site

    JUNTTAN Daily operation section 6.5.5 MOVING MACHINE ON THE WORKING SITE • Before moving the machine check the following things: • There is no person in the machine danger zone. • The ground on the working site is level and stable.
  • Page 72 JUNTTAN Daily operation section n WARNING Make sure that there is no person in the danger zone when moving with the machine. Make sure that the ground in the working site is level and stable enough and the border areas are properly marked.

  • Page 73: Working On The Sloping Ground

    JUNTTAN Daily operation section 6.5.6 WORKING ON THE SLOPING GROUND • Before starting the work on the sloping ground check the following things: • There is no person in the machine danger zone. • The ground is level and stable enough and the border areas are marked properly.

  • Page 74: Inclining (Raking) A Pile

    JUNTTAN Daily operation section 6.5.7 INCLINING (RAKING) A PILE n DANGER Pay attention to the capacity table and do not try to exceed the capacity of the machine. Do not use larger inclinations in any direction, nor heavier nor longer piles than is allowed.

  • Page 75: Operating The Hammer

    JUNTTAN Daily operation section 6.5.9 OPERATING THE HAMMER The hammer is operated with - piling mode switch - ram block single lift buttons - drop height dial - the dwell time dial - pump flow adjusting dial - short stroke switch...
  • Page 76 JUNTTAN Daily operation section When you are ready to drive the pile which you have positioned according to the previous sections, release all the controls into their neutral positions. n NOTICE It is recommended to keep the leader foot on ground during hammer operation. This way the vibrations from the impact will not be transmitted to the machine and the leader foot cylinder will not be damaged if the pile suddenly races down.

  • Page 77: Manual Hammer Operation

    JUNTTAN Daily operation section 6.5.9.1 MANUAL HAMMER OPERATION • Check that there is no person in the machine working radius. • Check that the hammer is resting on a pile. • Drive cap is its top position. • Unwind hammer and pile winch ropes enough so that there is no load suspended by the winches.

  • Page 78: Continuous Hammer Operation

    JUNTTAN Daily operation section 6.5.9.2 CONTINUOUS HAMMER OPERATION • Check that there is no person in the machine working radius. • Check that the hammer is resting on a pile. • Drive cap is its top position. • Turn the drop height dial to minimum and the dwell time to maximum.
  • Page 79 JUNTTAN Daily operation section Pile fast sinking in the soft soil: • Sometimes the pile may sink faster if the soil is soft below the pile. • In this case the hammer stroke must be stop with piling interruption switch on the left console.

  • Page 80: Mounting And Dismounting Of Equipment

    JUNTTAN Daily operation section MOUNTING AND DISMOUNTING OF EQUIPMENT When you mount and dismount equipment on the machine ensure that the hydraulic hoses and the ropes do not get tangled with machine parts. Pay attention also to the pile arms, they should be wide open in order not to touch the hammer and other pieces of equipment.

  • Page 81: Lifting Of The Hammer

    JUNTTAN Daily operation section 6.6.2 LIFTING OF THE HAMMER Always use shackles when lifting the hammer. Fasten the ropes to the shackles (four pieces) and lift the hammer up. Know your dimensions and pay attention to the overhang in turns and corners.

  • Page 82: Mounting Of The Cathead

    JUNTTAN Daily operation section 6.6.3 MOUNTING OF THE CATHEAD 1) Attach the lifting rope to the lifting points of the cathead and lift the cathead in place 2) Attach the bolts inside and outside 3) Connect the electric wires Pile rope...

  • Page 83: Leader Shortening

    JUNTTAN Daily operation section 6.6.4 LEADER SHORTENING 1) Loosen the ropes 2) Disconnect the hydraulic hoses (when needed) and electric wires 3) Connect the lifting rope to the lifting points of the leader extension 4) Remove the bolts 5) Remove the leader extension...

  • Page 84: Leader Extension

    JUNTTAN Daily operation section 6.6.5 LEADER EXTENSION 1) Loosen the ropes 2) Disconnect the hydraulic hoses (when needed) and electric wires 3) Connect the lifting rope to the lifting points of the leader extension 4) Lift the leader extension in place...

  • Page 85: Use Of Stabilizers

    JUNTTAN Daily operation section 6.6.6 USE OF STABILIZERS OPTIONAL The rear stabilizers (if they are on place) can be used to lift up the machine with the leader foot to rotate the undercarriage. Also the stabilizers give support to machine when you lift/lower the leader or take backward inclination.

  • Page 86: Transporting And Storing The Machine

    JUNTTAN Daily operation section TRANSPORTING AND STORING THE MACHINE 6.8.1 DRIVING ONTO A TRAILER Check that the trailer is on level and stable ground. Use ramps to drive the machine onto the trailer. Do not exceed the maximum climbing angle (15º) when using ramps. While you are on the ramps you may have to lift the leader slightly so that the cathead does not touch ground.

  • Page 87: Transporting The Machine

    JUNTTAN Daily operation section 6.8.3 TRANSPORTING THE MACHINE During transporting the machine must be secured to the trailer with chains. Attach chains over the tracks. The slewing mechanism lock must be engaged. Follow the regulations for transport. Know your dimensions and pay attention to the overhang in turns and corners.

  • Page 88: Storing The Machine

    JUNTTAN Daily operation section 6.8.4 STORING THE MACHINE When you store the machine and leave it unattended, follow the steps listed below. During storage the machine should be protected from moisture, dust, mechanical damage and vandalism. Park the machine on level and solid ground, out of the way and away from anything moving which might damage it.

  • Page 89: Lifting The Machine

    JUNTTAN Daily operation section 6.8.5 LIFTING THE MACHINE Always use the indicated lifting points when lifting the machine, see picture below. Maximum leader length 12.6 m is shown in the figure. Check center of gravity line position before start lifting.

  • Page 90: Center Of Gravity Of The Machine

    JUNTTAN Daily operation section 6.8.6 CENTER OF GRAVITY OF THE MACHINE Working position - leader in vertical position - leader length 18.6 m (13.8 + 4.8) + cathead - horizontal slide in - counterweight (7 500 kg) fully in - hammer (7 700 kg) on the leader Transport position - leader length 18.6 m (13.8 + 4.8) + cathead...

  • Page 91: Routine Service Section

    JUNTTAN Routine service section ROUTINE SERVICE SECTION SAFETY REGARDING LUBRICATION AND SERVICE When you service the machine, relieve pressure and allow time for cooling of the hydraulic system and engine. Remove the physical forces presented by the load or other machine parts prior to dismounting any component. Remember that the fluids are flammable, the exhaust is toxic and the batteries contain corrosive acid.

  • Page 92: Fuels, Lubricants And Hydraulic Fluids

    JUNTTAN Routine service section FUELS, LUBRICANTS AND HYDRAULIC FLUIDS 7.2.1 FLUID AND LUBRICANTS CAPACITIES Location Type, factory filled Standards Capacity Engine oil Neste turbo LXE API CH-4/SJ, ACEA E5, 17 litres 15W-40 mineral E3, B3, CES 20071 Engine coolant Neste coolant...

  • Page 93: Oil And Grease Types

    JUNTTAN Routine service section 7.2.2 OIL AND GREASE TYPES n ATTENTION Incorrect fuel, oil, grease or fluid can damage the machine. For engine oil specification, see the respective operation and maintenance manual Transmissions oil type: API-GL-5-80/90 SAE 80W/90 VG 150 or VG 220, ISO 3448...
  • Page 94 JUNTTAN Routine service section Recommended oil brands: Manufacturer Location Neste Mobil Esso Shell Castrol Teboil Engine oil Turbo LXE Delvac XHP, Essolube XT Rimula RX Super Super HPD, Delvac HP Super, Super Plus Power Hydraulic oil Hydrauli 46 Flowrex 86,...

  • Page 95: Routine Servicing Of The Machine

    JUNTTAN Routine service section ROUTINE SERVICING OF THE MACHINE Lubricate the machine according to the service chart. The chart also includes other maintenance tasks which you are to perform during daily operation. Also refer to the lubrication charts of the machine. For details of other equipment refer to the respective sections of the lubrication and maintenance manuals.
  • Page 96 JUNTTAN Routine service section JUNTTAN ROUTINE SERVICE CHART PM 20 DAILY OR EVERY 8 HOURS Object: Measure: Engine crankcase oil Check oil level Coolant Check coolant level Hydraulic tank oil Check oil level Machine Walk-Around inspection Lifting devices Walk-Around inspection...
  • Page 97 JUNTTAN Routine service section JUNTTAN ROUTINE SERVICE CHART PM 20 AFTER FIRST 100 HOURS 18. Filter or change the hydraulic oil. 19. Replace the hydraulic oil filter elements. 20. Clean the hydraulic oil tank. 21. Check the pressure settings of the hydraulic system.
  • Page 98 JUNTTAN Routine service section ENGINE MAINTENANCE SCHEDULE General information Perfom maintenance at whichever interval occurs first. At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance. Daily or Refueling - Maintenance check • Air tank and reservoirs - drain •...
  • Page 99 JUNTTAN Routine service section 1. The lubrication oil and lubricating oil filter interval can be adjusted based on application, fuel consumption, gross vehicle weight and idle time. interval is every oil change or 500 hours, or 6 months, whichever . Antifreeze check occurs first.
  • Page 100 JUNTTAN Routine service section Engine crankcase oil Checking the oil level Check the oil level daily. n NOTICE Let the engine be stopped at least for 5 minutes before checking the oil level. Do not overfill. Engine damage can result.
  • Page 101 JUNTTAN Routine service section Coolant Checking the coolant level Check the coolant level daily. • The coolant reservoir is located on the right side of the engine. Open the door. • Coolant level should be seen on the level gauge on the side of the coolant reservoir.
  • Page 102 JUNTTAN Routine service section Hydraulic tank oil Checking the oil level/PM 20 • The hydraulic oil level gauge is located on the left side of the machine. Open the door. • The hydraulic oil level should be at least in the middle of level glass.
  • Page 103 JUNTTAN Routine service section Walk-Around Inspection Check the machine • Check visually upper and lower joints of lateral inclination cylinders and cross joint. • Inspect the lifting point of leader mounted device (hammer, rotary head, vibrator etc.). • Keep a close watch for leaks in cylinders.
  • Page 104 JUNTTAN Routine service section • Check that all covers are firmly in place. • Inspect the steps and handholds for their condition and cleanliness. • Tighten loose bolts. • Inspect the cabin for cleanliness. • Inspect the machine for cleanliness.
  • Page 105 JUNTTAN Routine service section • Check visually the carrier rollers, track rollers, track shoes and idler wheels for wear. • Check visually the track frame slide beams for wear and check the cylinders for leakages. • Tighten loose bolts.
  • Page 106 JUNTTAN Routine service section Cross joint Greasing the cross joint • Grease the cross joint daily. • Lift the leader foot up to grease the upper nipples of the cross joint. • Lower the leader foot against ground to grease the lower nipples of the cross joint.
  • Page 107 JUNTTAN Routine service section Indicators and gauges Checking indicators and gauges • Look for broken gauge lenses, indicator lights and switches. • Start the engine. • Look for inoperative gauges. • Make any needed repairs before start working.
  • Page 108 JUNTTAN Routine service section Emergency stops Inspecting the emergency stops • Check that the emergency stops are in working order before start of each shift. • There are three emergency stops in the machine; one in the cabin and two in front of the machine.

  • Page 109: Hydraulic System

    Routine service section HYDRAULIC SYSTEM The hydraulic system of Junttan rig is an open design and consists of 3 axial piston pumps, which are mounted directly with a clutch and transmission at the flywheel end of the engine. The displacement of main pumps can be adjusted and they have a power regulation.

  • Page 110: The Pressure Settings

    JUNTTAN Routine service section 7.4.1 THE PRESSURE SETTINGS The pressure settings of the relief valves are made by Junttan Oy. The set values can be seen in the hydraulic diagrams. 7.4.2 HYDRAULIC OIL COOLING The oil from the return oil sump goes through two lines to the oil coolers and then through to the return filters.

  • Page 111: Changing The Hydraulic Oil

    JUNTTAN Routine service section 7.4.4 CHANGING THE HYDRAULIC OIL Change or filter the hydraulic oil and clean the tank through manhole (1) after the first 100 operating hours. From then on change or filter the oil and clean the tank after every 1000 hours of operation or at least once a year.

  • Page 112: Airing Of Hydraulic Pumps

    JUNTTAN Routine service section CHANGING THE FILTER ELEMENT OF THE BREATHER Change or clean the filter element of the breather during every oil change (every 1000 hours) or when necessary. 7.4.5 DE-AIRING OF HYDRAULIC PUMPS After the oil change the pump housings have to be de-aired or filled with oil before starting up engine.

  • Page 113: Replacing The Hydraulic Oil Filters

    JUNTTAN Routine service section 7.4.6 REPLACING THE HYDRAULIC OIL FILTERS Refer to Drawings number 451 048 and 451 050. n ATTENTION Absolute cleanliness in the hydraulic system is of utmost importance. It is therefore essential that you adhere to the prescribed intervals for cleaning filter bowls and replacing elements.
  • Page 114 JUNTTAN Routine service section PRESSURE FILTERS IN DRAWING 451 048, filter 3, 4 and 5 The item numbers refer to Drawing number 451 050/1 • Relieve the tank pressure • Remove filter bowl (3) • Remove and discard filter cartridge (1) •...
  • Page 115 JUNTTAN Routine service section...
  • Page 116 JUNTTAN Routine service section 451 050/2...
  • Page 117 JUNTTAN Routine service section LEAK OIL FILTER IN DRAWING 451 048, filter 6 • Relieve the tank pressure by opening the input hose • Remove filter bowl by turning it counter- clockwise • Remove and discard filter element • Check and clean filter bowl •...

  • Page 118: Engine Air Cleaner

    JUNTTAN Routine service section ENGINE AIR CLEANER The air cleaner is situated in the engine compartment on top of the engine. The paper cartridge must be changed when the air cleaner indicator in the cab lights up or at least once a year.

  • Page 119: Draining And De-Airing Of The Fuel Filter And The Water Separator

    JUNTTAN Routine service section 7.6.1 DRAINING AND DE-AIRING OF THE FUEL FILTER AND THE WATER SEPARATOR n WARNING Drain the water and fuel into container, and dispose of it in accordance with local environmental regulations. Draining of the fuel filter: •...
  • Page 120 JUNTTAN Routine service section BACKFLUSHING THE WATER SEPARATOR Backflushing is required when dirt and water block the filter element. The following signs will indicate this: • Loss of engine power • Black smoke may exhaust from the engine • Vacuum gauge will indicate a high restriction reading on the element of the filter.

  • Page 121: Lubrication Of The Slewing Ring

    JUNTTAN Routine service section LUBRICATION OF THE SLEWING RING Lubricate the ball races of the slewing ring and pinion gear after every 40 hours of operation or once a week - more often in tropical and humid conditions. There are lubrication pipes to the ball races of the slewing ring with grease nipples (1) in the hydraulic compartment.

  • Page 122: Changing The Oil Of The Swing Drive Transmission

    JUNTTAN Routine service section 7.9 CHANGING THE OIL OF THE SWING DRIVE TRANSMISSION Make the first oil change after 100 operating hours. Check the oil level weekly and refill if necessary. Fill the oil until the oil reaches the min. level. Change the swing drive transmission oil after every 1000 hours of operation or at least once a year.

  • Page 123: Changing The Oil Of The Track Drive Transmission

    JUNTTAN Routine service section 7.11 CHANGING THE OIL OF THE TRACK DRIVE TRANSMISSION Make the first oil change after 100 operating hours. Check the oil level weekly and refill if necessary. Change the drive transmission oil after every 1000 hours of operation or at least once a year.

  • Page 124: Track Width Adjustment

    JUNTTAN Routine service section 7.12.2 TRACK WIDTH ADJUSTMENT In the transport position the crawler frames are against the middle boy of the undercarriage. In working positions the crawler frames are pushed out. On each side there is a limit bar (1) with a stop.

  • Page 125: Adjustment Of The Track Tension

    JUNTTAN Routine service section 7.12.3 ADJUSTMENT OF THE TRACK TENSION n DANGER Grease is under high pressure. Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track being loosened.

  • Page 126: Track Shoe Bolts

    JUNTTAN Routine service section 7.12.4 TRACK SHOE BOLTS Tighten the track shoe bolts after the first 100 hours of operation and thereafter once a month. The track shoes must be fastened within the exact torque values shown in the following table.

  • Page 127: Winch Service

    Routine service section 7.13 WINCH SERVICE Junttan PM 20 is equipped with two winches in the rear of the machinery deck. The right winch is used for the hammer and the left one is used to lift the pile. The leader winch is for the rotary head.

  • Page 128: Operating Instructions For Steel Ropes

    JUNTTAN Routine service section 7.13.2 OPERATING INSTRUCTIONS FOR STEEL ROPES Correct Correct Wrong PACKING LIFT/HANDLING Steel ropes are delivered according to When you lift and handle steel ropes, make customer’s wishes normally sure that the rope does not get damaged e.g. by bundle, in lattice drum or winded on truck horn.
  • Page 129 JUNTTAN Routine service section n WARNING! - Unwind the rope from the rope drum to the winch drum always to the same direction of rotation. - Exercise special caution during the opening of package. - Careless opening can lead to serious personal injuries.

  • Page 130: Changing Rope To Winch Drum (Bb-Winch)

    JUNTTAN Routine service section 7.13.3 CHANGING ROPE TO WINCH DRUM (BB-WINCH) See pictures 1 – 4. 1. The steel rope is pulled through the opening in the winch drum flange and it is bended to the shackle outside the drum flange.

  • Page 131: Checking Of Steel Ropes

    JUNTTAN Routine service section 7.13.4 CHECKING OF STEEL ROPES In this section are shown some examples of defects which may occur in steel ropes. Check steel ropes daily or at least every week. If you found any noticeable changes in steel ropes contact expert persons to carried out special examination of the ropes.
  • Page 132 JUNTTAN Routine service section Some wire breaks in two strands heavy wear. Change rope Wear of the outer wires and looseness of the wires. Change rope immediately Changes rope diameter. Change rope immediately Flattened rope. Change rope Flattened rope with wire breaks.
  • Page 133 JUNTTAN Routine service section Kinked rope tightened loop. Change rope immediately Bended rope. Change rope Local increase in diameter of rope. Change rope immediately...
  • Page 134 JUNTTAN Routine service section Basket multi-strand construction. Change rope immediately Extrusion of a steel core. Change rope immediately...

  • Page 135: Wear Limits

    JUNTTAN Routine service section Internal corrosion rope. Change rope immediately 7.14 WEAR LIMITS The maximum play for all hydraulic cylinder swivels and shafts is 0.1 - 0.3 mm. The maximum play of guides in the leader is for upper slide 6 mm and for lower slide is 8 mm (left to right and forward to backward) and between leader and basic leader the maximum play is 8 mm.

  • Page 136: Torque For Steel Bolts And Nuts

    JUNTTAN Routine service section 7.15 TORQUE FOR STEEL BOLTS AND NUTS Thread 10.9 12.9 M 10 M 12 M 14 M 16 M 20 M 22 M 24 1050 1270 M 27 1080 1520 1830 M 30 1480 2080 2500...
  • Page 137 JUNTTAN Routine service section Recommended torque values [Nm] Nord-Lock® electro zinc plated / Dacromet with electro zinc plated bolt 8.8 GF = ratio of yield point µg = thread friction µw = washer friction MoS2 GF=0,75 GF=0,75 GF=0,62 Pitch µg=0,12 µw=0,14 µg=0,11 µw=0,12...
  • Page 138 JUNTTAN Routine service section Recommended torque values [Nm] Nord-Lock® electro zinc plated with non-plated bolt 10.9 GF = ratio of yield point µg = thread friction µw = washer friction MoS2 GF=0,71 GF=0,75 Pitch µg=0,14 µw=0,11 µg=0,14 µw=0,10 Range Dim...
  • Page 139 JUNTTAN Routine service section Recommended torque values [Nm] Nord-Lock® electro zinc plated with non-plated bolt 12.9 GF = ratio of yield point µg = thread friction µw = washer friction MoS2 GF=0,71 GF=0,75 Pitch µg=0,14 µw=0,11 µg=0,15 µw=0,10 Range Dim...

  • Page 140: Recommended Torque Values For Hydraulic Fittings

    JUNTTAN Routine service section 7.16 RECOMMENDED TORQUE VALUES FOR HYDRAULIC FITTINGS Notice! Torque values are valid when threads are not lubricated METRIC before installation. Thread mm Lb.ft M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x1.5 M26x1.5 M30x2 M36x2 M42x2 M45x2 M52x2 SAE J514 37º...

  • Page 141: General Fault Detection

    THE ENGINE STALLS AT LOW RPM If the engine consistently stalls at low rpm when load is applied, the setting of the pump angle may have wandered. Contact Junttan. Check the fuel filters. THE SWING WORKS ERRATICALLY If the swing function works erratically check that there is no dirt in the valve which controls the direction of slewing.

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