JUNTTAN HHK 5/6SL User manual

OPERATOR’S MANUAL
HHK 5/6SL

OPERATOR’S MANUAL
3
OPERATOR’S MANUAL
MANUAL REFERENCE NUMBER: HHK5/6SL212372011
THIS MANUAL COVERS THE OPERATOR’S INSTRUCTIONS OF
JUNTTAN HAMMER
MODEL HHK 5/6SL
SERIAL NUMBER 21237
YEAR OF MANUFACTURE 2011
Manufacturer: JUNTTAN OY
Full address: Matkuksentie 7
FI-70800 KUOPIO
FINLAND
Mail address: PL 1702
FI-70701 KUOPIO
FINLAND
Phone: + 358 10 195 221
Fax: + 358 17 287 4411
Homepage: www.junttan.com
Email: [email protected]
File: Operator's manual HHK 5-6SL 21237
Print date: 23.12.2011
This manual or copy of that should be stored with the hammer. 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. ©2011 Junttan Oy.

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EC Declaration of conformity for machinery
Manufacturer: Junttan Oy
Address: Matkuksentie 7, 70800 Kuopio, FINLAND
Herewith declares that JUNTTAN HHK 5/7SL s/n 21237
HYDRAULIC HAMMER
is in conformity with the provisions of the Machinery
Directive (Directive 2006/42/EC), as amended, and with
national implementing legislation;
is in conformity with the provisions of the following other
EC directives
and furthermore declares that
the following (parts/clauses of) harmonized standards
have been applied
the following (parts/clauses of) national technical
standards and specifications have been used
Kuopio , 23 December 2011
(place) (date)
(signature)
Heikki Ovaskainen, Deputy Managing Director

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Table of contents
1. INTRODUCTION ................................................................... 6
2. SAFETY SECTION................................................................ 7
3. TECHNICAL DESCRIPTION JUNTTAN HAMMER.............. 9
4. SPECIFICATIONS SECTION.............................................. 10
5. CONTROLS......................................................................... 13
6. OPERATING THE HAMMER .............................................. 13
6.1 LIMITATION OF USE OF THE PILING HAMMERS............................ 15
6.2 PRESSURE OF THE HAMMER.......................................................... 15
6.3 HAMMER OPERATION....................................................................... 16
6.3.1 MANUAL HAMMER OPERATION....................................................... 17
6.3.2 CONTINUOUS HAMMER OPERATION.............................................. 18
6.4 LIFTING OF THE HAMMER................................................................ 19
6.5 FUNCTION OF THE HAMMER........................................................... 20
6.5.1 FUNCTION OF THE RETURN FLOW ACCUMULATOR .................... 20
6.5.2 FUNCTION OF THE PRESSURE FLOW ACCUMULATOR................ 20
6.5.3 PERMISSIBLE OPERATING TEMPERATURE OF THE
ACCUMULATOR................................................................................. 21
7. FIELD MAINTENANCE AND REPAIRS ............................. 22
7.1 REPLACING THE DRIVE CAP CUSHION.......................................... 22
7.2 DISMOUNTING OF THE DRIVE CAP................................................. 23
7.3 DISMOUNTING OF THE RAM BLOCK............................................... 23
7.4 DISCONNECTING THE CYLINDER FROM THE FRAME .................. 24
7.5 CHANGING OF THE CYLINDER SEALS............................................ 25
7.6 DISMANTLING THE CYLINDER......................................................... 27
7.7 INSPECTING THE CYLINDER............................................................ 28
7.8 ASSEMBLING THE CYLINDER.......................................................... 29
7.9 MOUNTING OF THE TOP PLATE ...................................................... 37
8. PILING FUNCTION FAULT DETECTION........................... 38
9. LUBRICATION.................................................................... 40
10. ROUTINE SERVICE CHART HAMMERS........................... 41
11. CHECKING THE PRE-CHARGE PRESSURE OF THE
ACCUMULATORS.............................................................. 41
12. TORQUE FOR STEEL BOLTS AND NUTS........................ 42
13. TORQUE FOR HYDRAULIC FITTINGS.............................. 45

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1. INTRODUCTION
Junttan is pioneer in hydraulic piling hammers. First Junttan hydraulic hammers
were built already in the end of 1970’s. Now Junttan hydraulic hammer operate
reliably in all conditions (at temperatures +40 to –30 C°) all over the world.
The extraordinarily versatile Junttan hydraulic hammers are designed for driving
all types of piles; pre-cast concrete, steel tube, sheet or profile and timber.
Impact energy and blow rate can be easily adjusted according to soil conditions
and pile used. The hammer can be operated by the hydraulic system of the rig
or by separate power pack. Easy connect to different systems. The hammer can
be mounted on all kinds of leaders or can be free suspended.
Leader
mounted Free sus
p
ended Flying leader

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2. SAFETY SECTION
Pay special attention to the sections which are identified with
Safety Alert Symbol. Follow the instructions in the safety
message.
DANGER!
DANGER indicates a potentially dangerous
situation which, if not avoided, will result to a
serious personal injury or death.
WARNING!
WARNING indicates a potentially dangerous
situation which, if not avoided, could result to a
serious personal injury or death.
CAUTION!
CAUTION indicates a potentially dangerous
situation which, if not avoided, could result to a
less serious injury or material damage.
NOTICE!
NOTICE sign is used to draw your attention to
situations which, if not avoided, could result to
material damages or the malfunctioning of the
machine.
•You should read and understand all the safety instructions and
operating instructions before you start using, maintaining, lubricating
or repairing the hammer.
•Accidents can be caused by ignorance of instructions, neglect of safety
measures and carelessness.
•Incorrect use, lubrication or repair can be dangerous and lead to
physical injury or damage to the hammer.
•The instructions in these manuals, specifications, illustrations and
drawings are based on the information available at the time of writing.
Information can be changed. These changes may affect the use,
lubrication, service and repair procedures.
•Junttan or its dealer will provide you with up-to-date information
regarding the operation and maintenance of this hammer.
•If the operator’s manual is missing or worn out you can get a new one
from the Junttan or its dealer.
•The hydraulic oil is pressurised during operation. Prior to
disconnecting any parts from the hydraulic system make sure that you
relieve the pressure.
•When connecting hammer to piling machine check stability of the
machine before start piling.
•Keep a minimum distance of 3 metres from any power lines and in the
case of high voltage lines find out the proper safe working distance.
•Do not stand on any mobile parts of the hammer during operation.

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•Do not stand or walk on any steel ropes, hydraulic tubes or hoses.
•Keep a minimum distance of one metre from pressurised tubes and
hoses.
•Do not go under the hammer or any part of it and preferably stay out of
the working radius during operation.
•Do not let outside personnel into the working area.
•No adjustments should be made during operation unless expressly
instructed to do so.
•Keep you hands away from any moving parts.
•In transport the ram block must be locked to the hammer frame.
•When you lift the hammer with shackles use only the indicated lifting
points.
•Store all materials and fluids in properly designed and marked
containers.
•Do not use oil stained or damaged clothing.
•Do not wear objects that may get entangled.
•Wear ear protection during pile driving.
•Use gloves when working with steel ropes.
•Use goggles to protect your eyes.

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3. TECHNICAL DESCRIPTION JUNTTAN HAMMER
JUNTTAN hammer is a hydraulically-powered drop hammer for impact driving.
The cage frame houses the components of the hammer. There are bolted wear
pads on each corner of the ram block which slide along inside the frame
uprights. There is a hole inside the ram block. The ram block is bolted together
with a top plate. There is a rubber plate between the top plate and the ram block
to reduce the effect of the return stress wave during driving. A shaft connects
the top plate to the piston rod of the lifting cylinder through the lifting eye. The
spool valve which controls the lifting cylinder is built into the top end of the
cylinder. The spool valve is operated by a solenoid pilot valve. The position of
the piston rod is sensed with an inductive proximity switch. The lift buffer on the
top plate limits the stroke of the lifting ram during lift. For pile driving the
hammer is placed on the top of the pile. The hammer frame goes down until the
drive cap inside the drive cap housing moves against the rebound ring. In that
position the drive cap is at the end of its stroke and the ram block rests on
cushion.
The main components of the hammer are:
1. frame
2. modular ram block
3. lifting cylinder
4. top plate
5. ram block bolts
6. solenoid valve
7. hydraulic accumulator on the
pressure side for storing energy
8. hydraulic accumulator on the return
side to even pressure surges
9. proximity switch
10.drive cap housing incl. drive cap,
cushion and rebound ring
11.leader guides
12.ram block lifting eye
13.spool valve
14.frame extension

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4. SPECIFICATIONS SECTION
•GENERAL IDENTIFICATION
Type of the hammer: HHK 5/7SL
Serial number: 21237
Name and address of manufacturer: Junttan Oy
Matkuksentie 7
70800 Kuopio
FINLAND
Year of manufacture: 2011
Maximum theoretical characteristic of the hammer:
Ram block weight (5/6SL): 5 000/6 000 kg (11 023/13 228 lb)
Max. drop height: 1 500 mm/59.1 in mm
Max. impact energy (5/6SL): 74/88 kNm (54 613/64 945 lb-ft)
•GENERAL DIMENSIONS
Dimensions refer to the attached illustration
Maximum height (5/6SL): 6 640/7 010 mm (261.4/276 in)
Maximum width: 938 mm/36.9 in
Maximum length: 938 mm/36.9 in
•TYPE OF MOUNTING
Cage type frame and ram block attached to hydraulic cylinder. Built in drive cap.
•HYDRAULIC CYLINDERS
Ram block lifting hydraulic cylinder
- stroke: 1 500 mm/59.1 in
- cylinder tube Ø100 mm/3.9 in
- piston rod Ø75/73 mm/Ø3.0/2.9 in
Maximum working pressure
- with 5 ton weight: 214 bar/3 104 psi
- with 6 ton weight: 267 bar/3 873 psi
- 0,030
- 0,060
+ 0,087
0
,
0

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HYDRAULIC ACCUMULATORS
- pressure side (10 L)
type: elastic bladder in steel case
nitrogen pressure (5/6SL): 121/146 bar (1 755/2 118 psi)/20 °C
- return side (4 L)
type: elastic bladder in steel case
nitrogen pressure: 6 bar/20 °C
Pre-set pressure is stamped to accumulators.
•ELECTRICAL COMPONENTS
Electric pilot valve, inductive proximity sensor.24 VDC
•CUSHION
Ø 600 * 200 mm/Ø23.6*7.9 in, plastic
•REBOUND RING
Ø 878/690 * 100 mm/Ø34.6/27.2*3.9 in * 2, rubber
•HYDRAULIC OIL
Incorrect or dirty hydraulic oil can damage the hammer.
Minimum purity of grade of hydraulic oil: 20/18/15-ISO 4406 (c)
•WEIGHT (WORKING)
Ram block: 6 000 kg 13 228 lb
Frame: 1 600 kg 3 527 lb
Drive cap housing: 750 kg 1 653 lb
Drive cap: 1 000 kg 2 205 lb
Cylinder: 360 kg 794 lb
Guide claws: 170 kg 375 lb
Accumulators: 50 kg 110 lb
Frame extension: 360 kg 794 lb
Total weight (HHK 5SL): 9 300 kg 20 503 lb 10.3 Uston
Total weight (HHK 6SL): 10 600 kg 23 369 lb 11.7 Uston

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MAIN DIMENSIONS

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R31
R30
S34
USB1
S30
S2
S38 S37
S39
S40
S35
S32
S33
S31
S1 H1 S36
H1
R30
S34
S30
S2
S36
S32
S35
S41 S31
S1
R31
5. CONTROLS
USB1 USB memory port
H1 Main current indicator (Power ON/OFF)
R30 Potentiometer for dwell time
R31 Potentiometer for drop height
S1 Power ON/OFF switch
S2 Emergency stop switch
S30 Piling mode switch, manual/continuous switch
S31 Short stroke switch
S32 Piling interruption button
S33 Pile depth measuring button
S34 Single lift/start piling button
S35 Single lift/start piling button
S36 Minimum oil flow switch
S37 Navigation wheel
S38 Back button
S39 Enter button
S40 Alarm indicator light/alarm reset button
S41 Measuring electronics

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6. OPERATING THE HAMMER
If the hammer is connected to the piling rig check the hammer operating
instructions from the piling rig operator’s manual.
During pile driving, the hammer must be supported by the pile in such a way
that the drive cap is in its top position, movement margin is 150 mm. You must
also make sure that the hammer can freely go down with the pile during the pile
driving.
HHKS-HAMMERS:
The cylinder maximum stroke is 1500 mm (59.1 in). Maximum drop height of the
ram block (1300…1500 mm/51.2…59.1 in) is allowed to use only for final blows.
WARNING!
Do not turn the piling mode switch to position 1 or 2 if the hammer is
not resting freely on a pile.
NOTICE!
Junttan Oy recommends that the operator starts pile driving with small
strokes because the cushion is more brittle under lower temperatures.
After a few minutes the cushion is heated up and it is possible to use
normal strokes.
The piston rod of the ram block lifting cylinder is protected against
rust. Clean the piston rod before start piling.
CAUTION!
Use maximum drop height (1300…1500 mm/51.2…59.1 in) only for final
blows. Otherwise the hammer may break.

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6.1 LIMITATION OF USE OF THE PILING HAMMERS
General
As with all machinery there is a limit as to the operational conditions under
which the machinery is expected to function safely, efficiently and longer lasting.
A general definition for the piling hammers limit is described below.
Limitation of use
Under normal piling conditions, the hammer must be stopped when a 10 blows
or more per 25 mm of penetration is recorded, over 6 consecutive
intervals of 25 mm (For example 60 blows per 150 mm).
Continued use of the hammer over this limitation will result in hammer breakage
within a short period of time. The hammer must be stopped immediately. For
more information and guidance please contact your local dealer or
manufacturer before proceeding beyond this limitation.
6.2 PRESSURE OF THE HAMMER
The pressure gauge in the power pack/machine shows the hammer pressure.
The pressure relief valve takes care of the pressure regulation of the hammer.
Regulation of the pressure setting is made by adjusting the screw of the
pressure relief valve. The pressure influences the lifting power of the ram block.
When the pressure is greater than standard values, the hammer begins to
vibrate strongly. Adjust the screw to reduce pressure.

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6.3 HAMMER OPERATION
If the hammer is connected to the piling rig check the hammer operating
instructions from the piling rig operator’s manual.
•Check that there is no person in the hammer working area.
•Check that the hammer is resting on a pile.
•Drive cap is its top position.
DANGER!
Before start operating the hammer check always that there is no
person in the hammer working area.
WARNING!
Do not turn the piling mode switch to position 1 or 2 if the hammer is
not resting on a pile. Check also that there is enough slack in the ropes
of the winches.
If the hammer starts working before you press the single lift buttons
stop working immediately. Find the reason for that and repair it.

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5 1 5515
6.3.1 MANUAL HAMMER OPERATION
•Turn the piling mode switch (1) on the console to position 1 - manual driving.
In this position the hammer hydraulic circuit is pressurized.
•The pressure setting for the hammer used and the ram block is stated in the
specifications manual of the hammer. Make a habit of monitoring that the
hammer circuit pressure stays in the specified range during operation of the
hammer.
•To operate the hammer manually giving single blows, push the ram block
single lift buttons (5) down simultaneously.
•The ram block will be lifted as long as you press the buttons down and
released to drop when you release the button(s).
•When you have lifted ram block manually up and you release your finger
from the single lift button the ram block goes down. Never push the button
when the ram block moves downwards.
•When you stop hammer operation turn the piling mode switch (1) to position
0.

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5 1 5515
6.3.2 CONTINUOUS HAMMER OPERATION
•Turn the drop height dial (3) to minimum and the dwell time (4) dial to
maximum.
•Turn the piling mode switch (1) to position 2.
•To start continuous hammer operation, push the ram block single lift buttons
(5) down simultaneously.
•Increase the drop height as required.
•Adjust the ram block drop height so that the ram block does not touch the top
limit.
•On hard ground and when the pile is against rock the return stress wave
makes the ram block bounce. On such occasions you should increase the
dwell time so that all the bouncing of the ram block stops prior to the next lift.
•In order to get small drop heights turn down the drop height dial, let the
engine speed drop and switch on the minimum oil flow of the pump.
•To stop the continuous hammer operation, turn the piling mode switch to
position 0.
•When you drive piles you should keep the drive cap, the hammer guide
claws and the leads of the ram block always properly creased.
NOTICE!
Adjust the ram block fall height so that the pile maximum movement
downwards during each blow is about the same as drive cap free
movement 80-150 mm.

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6.4 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.
WARNING!
Remove the shackles and ram block locking pin before start piling.

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6.5 FUNCTION OF THE HAMMER
Lifting the ram block
Solenoid valve changes the position of the spool valve so that the upper side of
the piston is released to the tank line and the ram block is raised.
Releasing the ram block
The solenoid valve changes the position of the spool valve so that there is an
equal pressure on both sides of the piston and the ram block falls down freely.
During falling the hydraulic power is stored to the pressure line accumulator.
6.5.1 FUNCTION OF THE RETURN FLOW ACCUMULATOR
The function of the return flow accumulator on the hammer is to smooth down
the return flow on the hose and reduce the vibration of hoses. The return flow
accumulator is pre-filled with nitrogen to a pressure of about 6 bar. If the
pressure of the hydraulic oil too low, the accumulator will not take oil. That
means that the oil returning from hammer tries to flow directly back to the tank
and that causes shaking of hose. If the pressure of hydraulic oil is more than 6
bar a part of the return flow from the hammer will be absorbed to the return flow
accumulator while a part flows back to the tank. When the hammer starts to fall
down the oil, which is in the accumulator, flows back to the tank. The return oil
flow will be more equal than in the case where the hydraulic pressure was too
low. Therefore a certain back pressure is needed for a proper function of the
hammer.
An accumulator on the return side of the power pack/machine will smooth down
the pressure peaks which might cause damages on the hydraulic oil coolers
and other components. It also helps to keep the pressure on the return line of
the hammer on equal level.
6.5.2 FUNCTION OF THE PRESSURE FLOW ACCUMULATOR
The function of the pressure flow accumulator on the hammer is to reserve
energy for lifting the ram block and also reduce the pressure peaks on the
pressure side. The pressure flow accumulator is pre-filled with nitrogen to a
pressure of 30 to 150 bar. Pre-filling pressure depends on the hammer size.
An accumulator on the pressure side of the power pack/machine will work as an
extra energy reservoir and also reduce the pressure peaks on the pressure
side.