J&M 66-80 User Manual
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
OPERATING AND MAINTENANCE MANUAL
J&M 66-80
VIBRATORY PILE DRIVER/EXTRACTOR
WITH MODEL 800 POWER PACK
J&M Foundation Equipment
1201 Banksville Road — Pittsburgh, PA 15216
Phone: 412.341.8190 — Fax: 412.341.8192
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
PREFACE
This manual was prepared to acquaint the owner, operator and serviceman with the operation
and maintenance of the vibratory driver/extractor. We suggest that this manual be carefully
studied before operating or undertaking any maintenance work on the unit.
This manual is organized into two major sections.
The first contains routine OPERATING INSTRUCTIONS for the unit and includes a
GENERAL DESCRIPTION section, which presents a basic explanation of the driver/extractor
and its specifications. The MAINTENANCE AND ADJUSTMENT section should be referred
to periodically for normal servicing of equipment. All machines and equipment require
systematic, periodic inspection and maintenance if they are to perform satisfactorily over a
long period of time. The driver/extractor is primarily a vibrating machine and if not given the
best of care, or if improperly used and maintained, it is self-destructive. Therefore, the unit
should receive the same care and maintenance as other high quality construction equipment.
The second category is for parts ordering and it includes both a PARTS LIST and a pictorial
drawing of the assembly, for easier determination of the required part(s). Refer to the
ORDERING PARTS section of the PARTS LIST for more specific procedures regarding parts
ordering. Adherence of the listed procedures will insure receipt of the required part(s) with
the minimal amount of delay or error.
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
WARRANTY
J&M FOUNDATION EQUIPMENT (J&M) STANDARD WARRANTY
J&M warrants new products sold by it to be free from defects in material or workmanship for a
period of 1 year after date of delivery to the first user and subject to the following conditions:
J&M 's obligation and liability under this WARRANTY is expressly limited to repairing or
replacing, at J&M's option, any parts which appear to J&M, upon inspection, to have been
defective in material or workmanship. Such parts shall be provided at no cost to the user, at
the business establishment of J&M or the authorized J&M distributor of the product, during
regular working hours. This WARRANTY shall not apply to component parts or accessories
of products not manufactured by J&M and which may carry the warranty of the manufacturer
thereof, or to normal maintenance (such as engine tune-up) or to normal maintenance parts
(such as oil filters). Replacement or repair parts installed in the product covered by this
WARRANTY are warranted only for the remainder of the warranty, as if such parts were
original components of said product. J&M MAKES NO OTHER WARRANTY, EXPRESS OR
IMPLIED, AND MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS, FOR ANY
PARTICULAR PURPOSE.
J&M’s obligation under this WARRANTY shall not include any transportation charges, cost of
installation, duty, taxes or any other charges whatsoever, or any liability for direct, indirect,
incidental, or consequential damage of delay. If requested by J&M, products or parts for
which a warranty claim is made are to be returned, transportation prepaid to J&M. Any
improper use, including operation after discovery of defective of worn parts, operation beyond
rated capacity, substitution of parts not approved by J&M or any alteration or repair by others
in such manner as in J&M's judgment affects the product materially and adversely shall void
this WARRANTY.
NO EMPLOYEE OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY
IN ANY WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE IS MADE IN
WRITING AND SIGNED BY AN OFFICER OF J&M .
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
TABLE OF CONTENTS
OPERATING INSTRUCTIONS
I. GENERAL DESCRIPTION PAGE
A. General I - 1
B. Vibrator I - 2
C. Hydraulic Clamp I - 2
D. Power Unit I - 2
E. Hoses I - 2
F. Remote-Control Pendant I - 2
G. Specifications I - 3
II. PREPARATION FOR OPERATION
A. General II - 1
B. Safety Precautions II - 1
C. Rigging of Vibrator II - 2
D. Connection of Hydraulic Clamp II - 2
E. Connection of Hydraulic Hoses II - 3
F. Bleeding Hydraulic Clamp Hoses II - 5
G. Filling Vibrator Pressure Hose II - 5
III. OPERATING INSTRUCTIONS
A. Completion of Set-Up and Maintenance III - 2
B. Control Panel III - 2
C. Starting and Warming Up Engine III - 4
D. Warming Hydraulic Oil III - 4
E. Operation of Remote-Control Pendant III - 5
F. Changing Frequency III - 7
G. Shutdown III - 7
IV. MAINTENANCE AND ADJUSTMENTS
A. General IV- 1
B. Daily Maintenance IV- 1
C. 125 Hours (Service Meter Units) IV- 2
D. 250, 500 Hours and Other IV- 2
E. Annual Maintenance IV- 2
F. Maintenance Under Severe Conditions IV- 3
G. Lubrication IV- 4
H. Draining and Filling Hydraulic Oil Reservoir IV- 8
I. Changing Hydraulic Return Filter Elements IV- 9
J. Bolt Torque Information IV-10
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
TABLE OF CONTENTS
OPERATING INSTRUCTIONS (CONTINUED)
V. HYDRAULIC CIRCUITRY PAGE
A. Hydraulic Clamp V- 1
B. Vibrator Drive Motor V- 1
C. Other V- 3
Hydraulic Schematic V- 4
D. Hydraulic Components List V- 5
VI. ELECTRICAL CIRCUITRY
A. Starting Diesel Engine VI- 1
B. Stopping Diesel Engine VI- 1
C. Safety Control System VI- 1
D. Closing Hydraulic Clamp VI- 2
E. Opening Hydraulic Clamp VI- 2
F. Starting Vibrator VI- 3
G. Stopping Vibrator VI- 3
H. Other VI- 3
Electrical Layout VI- 4
Electrical Schematic VI- 5
I. Electrical Components List VI- 6
PARTS LIST
VII. GENERAL DATA
A. Abbreviations VII - 1
B. Screws and Bolts VII- 1
C. Serial Number Locations VII - 2
VIII. ORDERING PARTS
A. Procedure VIII - 1
B. Fitting Description Key VIII - 2
Fitting Style Selector Chart - SC1 VIII - 3
C. Hose Description Code VIII - 4
D. Parts Identification VIII- 5
Parts Lists and Drawings VIII - 6
E. Miscellaneous Accessories VIII -48
F. Recommended Spare Parts VIII -51
G. Recommended Tightening Torque VIII -53
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
I. GENERAL DESCRIPTION
A. GENERAL
The J&M Model 66 is a variable-frequency vibratory pile driver/extractor designed
to drive and extract sheet, pipe, timber and concrete piles, caissons, H-beams, Ibeams and wide-flange beams.
The Model 66 operates in a frequency range of 800 to 1600 vibrations per minute
to provide maximum pile penetration rates in a wide variety of soils. The unit has
an eccentric moment of 6600 inch-pounds (76 kg-M) and produces a maximum
amplitude of 1.23 inch (30mm).
The vibratory driver unit consists of two major components - (1) the vibrator with
attached clamp and (2) the power unit with remote control pendant.
ELASTOMERS
VIBRATION CASE
ECCENTRIC WEIGHTS
CLAMP BODY
DESIEL ENGINE
RADIATOR
OIL COOLER
FUEL TANK
DRIVE & CLAMP PUMPS
I -
DRIVER / EXTRACTOR
MULTI-PUMP DRIVE
POWER UNIT
1
VIBRATION SUPPRRESSOR
HYDRAULIC MOTORS
CLAMP CYLINDER
OIL RESERVOIR
CONTROL PANEL
CLAMP MANIFOLD
(FAR SIDE)
DRIVE MANIFOLD
(FAR SIDE)
REMOTE CONTROL PENDANT
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
I. GENERAL DESCRIPTION
B. VIBRATOR
The vibrator consists of two major components; The vibration case and the
vibration suppressor. The vibration case contains six eccentric weights which
rotate in a vertical plane to create vibration. The eccentric weights are driven by
two hydraulic motors. The vibration suppressor contains a minimum of 24 rubber
elastomers to isolate the vibration case from the crane line. The suppressor is
designed for a maximum line pull of 80 tons (712kN) during extraction.
C. HYDRAULIC CLAMP
The hydraulic clamp attaches the vibrator to the pile. Four types of hydraulic
clamps are available for the Model 66 vibrator. The Model 196 universal clamp
will drive and extract most types of sheet piling, 14" (355mm) H-beams, and wide
flange beams. The Model 122 caisson clamps are used in pairs with either the 7foot (2.13m) or 11-foot (3.35m) caisson beam to drive and extract pipe from
22.25" (565mm)ID to 129.25" (3283mm)OD. The Model 50 wood pile clamp is
designed to drive and extract wood piles from 10” (254mm) OD to 18” (457mm)
OD. The model 165 concrete pile clamp will extract square concrete piles from
18” (457mm) to 24” (610mm).
D. POWER UNIT
The Model 66 vibrator is powered by the J&M Model 950 power pack. The 950
power pack is powered by a Caterpillar 3412DIT diesel engine. The engine
develops 800 horsepower (597kW) at 1900 RPM, and is mounted on a tubular
sub-base which serves as a fuel tank. The Power Unit and Vibrator are operated
from the control panel or remote control pendant. Hydraulic oil is stored in the
reservoir. Oil cooling is accomplished by a air to oil heat exchanger mounted in
front of the engine radiator. All of the above components are contained in a sheet
metal enclosure, with lockable doors, and a central lifting bale. Five hydraulic
pumps are mounted to the engine via a multi-output gear box.
E. HOSES
Three hydraulic hoses, 150 feet (45.7m) in length, connect the power unit to the
hydraulic motors on the vibrator. Two other hydraulic hoses run from the power
unit to the hydraulic clamp.
F.REMOTE-CONTROL PENDANT
The vibrator is operated by the hand-held remote control pendant. The pendant
has 1 palm button, 2 switches and 2 push buttons, 1 with a light. The red palm
button (EMERGENCY STOP) shuts down diesel engine instantly in the event of an
emergency. The (OPEN CLOSE) switch opens and closes the hydraulic clamp.
The light in the (START) button indicates that adequate clamping pressure exists.
The (START) button starts vibration. The (STOP) button stops vibration. The
(THROTTLE) switch raises and lowers the diesel engine speed. Note: Controls
are duplicated on the control panel for use if the pendant becomes damaged.
(See pg.III -6, Section E-g)
I -2
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
I. GENERAL DESCRIPTION
G. SPECIFICATIONS
1. Constant improvement and engineering progress make it necessary that
we reserve the right to make specification changes without notice.
W
L
HH
T
Type ...............................................................Diesel
Engine..............................................CAT 3412DITA
Horsepower (2100 RPM) ...................800 (597kW)
Weight....................................23,000 lbs. (10433kg)
Length [ll]......................................186 in. (472cm)
Width [ww]......................................66 in. (168cm)
Height [hh] ....................................100 in. (254cm)
MODEL 196 CLAMP BODY
(SHOWN)
6666
ll
2. MODEL 66-80 VIBRATOR
(with hydraulic clamp)
Type ........................................................Hydraulic
Eccentric Moment...............6600 In -lbs (50.7kg-M)
Frequency........................................800-1600 VPM
Amplitude ........................................1.23 in. (30mm)
Pile Clamping Force ...................196 Tons (1744kN)
H
Max. Line Pull for
Extraction.....................................80 Tons (712kN)
Suspended Weight with 196 Clamp and
half hoses................................19,200 lbs. (8708kg)
Length [L].........................................97 in. (246cm)
Width [W] .........................................21 in. (55cm)
Throat Width [T]..........................14.25 in. (36cm)
Height with Clamp [HH]............137.75 in. (350cm)
Height without clamp [H] ............99.75 in. (253cm)
3. MODEL 650 POWER UNIT
hh
ww
I -3
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
II. PREPARATION FOR OPERATION
A. GENERAL
When unloading and unpacking the vibratory driver, use extreme care. For your
protection, make a thorough inspection of the unit immediately on delivery. In
case of any damage or shortage, notify the transit agent at once and have the
delivering 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 guide to safety.
Be ever watchful for safety hazards and correct deficiencies promptly.
Use the following safety precautions as a general guide to safe operations:
1. Read this manual thoroughly before operating or working on the equipment.
2. Read and follow any safety instructions in the CATERPILLAR engine
operators manual.
3. Only well trained and experienced personnel should attempt to operate or
maintain this equipment.
4. Never adjust, lubricate or repair the unit when it is in operation, or lifted above
ground level.
5. Never remove, paint over or cover warning or safety labels. If labels become
damaged or unreadable, replace immediately.
6. All personnel should wear approved safety clothing, including HARD HATS,
SAFETY SHOES, SAFETY GLASSES and HEARING PROTECTION when in
the vicinity of this machinery.
7. Do not stand any closer to this equipment than necessary when it is in
operation. Parts may loosen and fall. Never stand under operating, or
elevated, equipment.
8. When maintaining or repairing the equipment, never substitute parts not
supplied, or approved in writing, by J&M.
9. Do not weld, or flame cut, on this equipment.
10. Never use or store flammable liquids on or near the engine.
11. Insure that all lifting equipment, including cranes, wire rope, slings, hooks,
shackles, etc., are properly sized for the worst case loads anticipated during
operations.
12. If there are any questions about the weights, specifications, or performance of
the unit, contact J&M before handling or operating the equipment.
13. If the equipment is to be used for anything other than driving or extracting
plumb piles, contact J&M before using the unit.
14. Check wire rope clips for tightness, and check wire ropes for wear, daily.
15. Insure that ground vibrations will not damage or collapse adjacent structures or
excavations.
16. Remove all tools, parts and electrical cords before starting the unit.
17. When operating in an enclosed area, pipe exhaust fumes outside. Continued
breathing of exhaust fumes may be fatal.
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
II. PREPARATION FOR OPERATION
B. SAFETY PRECAUTIONS (CONTINUED)
18. When servicing batteries, do not smoke or use open flames in the vicinity.
Batteries generate explosive gas during charging. There must be proper
ventilation when charging batteries.
19. When filling fuel tank, do not smoke or use open flame in the vicinity.
20. If abnormal equipment operation is observed, discontinue use immediately and
correct the problem. Do not leave the equipment control pendant (radio
control) unattended.
21. Store oily rags in approved containers, and away from engine exhaust system.
22. Make sure that the vibrator is OFF before starting the power unit engine.
23. Do not adjust, or set, hydraulic pressures higher or lower than those specified
in this manual.
24. Never operate this equipment with hydraulic hoses that are damaged or
“kinked”. Replace damaged hoses immediately.
25. Do not lift, or support, hydraulic hoses with wire rope slings.
26. Never attempt to connect quick disconnects when the power unit is running.
27. Do not pull on, or attempt to move equipment, with hydraulic hoses.
28. Do not attempt to locate hydraulic leaks with your hands. High pressure
hydraulic leaks can penetrate the skin, causing severe damage, blood
poisoning and infection. Do not attempt to repair leaks while the equipment is
in operation.
29. Do not attempt to tighten, or loosen, fittings or hoses when the machine is in
operation.
30. Power unit must always be placed on level, stable, ground.
31. Do not remove power unit heat shields, or operate power unit without heat
shields. Severe fires may result.
32. A properly maintained fire extinguisher, suitable for oil fires, must be kept in
the immediate vicinity of equipment operations.
33. When moving or transporting this equipment, insure that the vehicle or vessel
is of sufficient capacity to handle the load, and that the equipment is properly
tied down.
34. When moving or transporting this equipment, be sure that quick disconnect
dust caps are tight, and that cap safety cables are in place. Be sure that all
equipment parts are tight, or properly secured, before shipment. Unsecured
parts may vibrate loose and fall, during transport, causing injury or property
damage.
35. Keep crane boom, piles, leads, wire rope and other equipment at least
15’ (5M) from electrical power lines, transformers and other electrical
equipment, or at such distance as required by applicable safety codes.
36. Rounded or damaged bolt heads or nuts should be replaced so that proper
torque values may be obtained. Proper torque values are necessary to
prevent parts on this equipment, leads and crane boom from loosening and
falling. Refer to Torque Chart, in this manual, for proper values.
37. Do not use the vibrator clamp to move piles. Loss of hydraulic pressure could
cause piles to fall.
II -1b
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
II. PREPARATION FOR OPERATION
B. SAFETY PRECAUTIONS (CONTINUED)
38. Never clamp vibrator to pile and disconnect the crane line. Loss of hydraulic
pressure could cause vibrator to fall. Lay vibrator down when not in use.
39. When extracting piles, always attach a safety line between pile and crane
hook.
40. When extracting piles, check crane load/radius tables to be sure crane
capacity is adequate for maximum allowable extraction pull.
41. When extracting piles, or any other driving operations, always be sure that the
crane line is aligned with the centerline of the pile. Do not side load crane
boom or vibrator. Dangerous crane boom, or vibrator, damage may result.
42. When extracting piles, do not exceed the capacity of the vibrator suppressor.
Continued operation against the safety stops will cause damage to the crane
boom and the vibrator.
43. Never induce line pull on a vibrator before starting the unit in vibration. Always
start both driving and extraction of piles with a slack line.
44. Keep hands away from clamp jaws.
45. Keep hands away from vibrator suppressor during operation. Clearances may
change causing pinch points.
46. Do not run vibrator unless clamp jaws are closed.
47. Use tag line to control vibrator whenever possible.
48. When driving “batter” piles, insure that the leads, and crane boom, have
sufficient bending strength to handle the worst case load. Consult J&M.
REMEMBER, SAFETY IS EVERYONE’S BUSINESS.
C. RIGGING OF VIBRATOR
A steel wire rope sling must be connected to the lifting pin of the vibration
suppressor. The required strength of this sling depends on the capacity of the
crane and the work to be carried out. A safety factor of five is recommended, (5 x
80 ton). Several turns of a smaller diameter cable will usually last longer than one
turn of a larger diameter cable. Inspect daily for damage to sling or wire rope
clamps.
D. CONNECTION OF HYDRAULIC CLAMP
The vibrator is usually shipped with the hydraulic clamp already attached.
If the clamp is not attached, it will be necessary to attach it to the bottom of the
vibrator. Orient the clamp to the vibrator with the clamp cylinder end (movable
jaw) at the same end of the vibrator at which the hose chute is mounted. All
eleven (1.5-6UNC x 5.00lg) bolts must be in place and torqued to approximately
2800 ft-lbs. (387 Kg-M)
For caisson work, the caisson beam must be attached to the bottom of the vibrator
and tightened as above. Then slide the clamps into position onto the beam.
II -2
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
II. PREPARATION FOR OPERATION
E. CONNECTION OF HYDRAULIC HOSES
1. Connection of hoses at power unit.
a. The vibrator and hydraulic clamp are connected to the power unit by five
hydraulic hoses (Fig. 1).
CAUTION: The power unit must be shut down during connection of the
hydraulic hoses.
b. The hoses connect to the power unit with quick-disconnect couplers.
The hose couplers are arranged to insure correct connections at the
power unit. See the diagram (Fig. 1) below for correct hose connection.
c. Clean couplers with a lint-free cloth before making connections.
d. Make sure that the couplers are fully run up. They should be fully hand
tight. Do not use wrenches to tighten.
950 Power
Unit
Open Clamp Line
Close Clamp Line
Side View
of Vibrator
Attaches Behind
Close Clamp
Open Clamp
Case Drain
Drive Return
Drive Pressure
(Fig. 1)
II -3
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
II. PREPARATION FOR OPERATION
E. CONNECTION OF HYDRAULIC HOSES (CONTINUED)
2. Connection of hoses at vibrator.
a. The vibrator is usually shipped with the hoses attached to the vibrator. If
the hoses have been shipped separately, they must be connected in the
field. Fig. 1 on the previous page shows the correct arrangement of the 5
hoses connecting the power unit to the vibrator.
CAUTION: Starting the vibrator with the hoses reversed will result in low
power or possible ruptured hoses.
b. The vibrator is usually shipped with the hydraulic clamp and hoses
attached. If the clamp has been shipped separately, the two hoses
connecting the clamp to the vibrator must be connected. Fig. 2 shows the
correct arrangement of these hoses. For caisson clamps, four hoses must
be connected. The two connections on the opposite end of the vibrator are
reversed from the positions shown on the drawing below. Both ends are
stamped with an “O”(open) and a “C”(close) to insure correct connection.
The clamp connections are the same.
66 Vibrator
To 950 Power Unit
(See Fig. 1)
Close Clamp
Hose "C"
Open Clamp
Hose "O"
(Fig. 2)
II -4
196 Clamp
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
II. PREPARATION FOR OPERATION
F.BLEEDING HYDRAULIC CLAMP HOSES
1. When the vibrator and hydraulic clamp are shipped with all hoses attached
(between vibrator and clamp and five main hoses connected to the vibrator),
the hoses are usually full of oil and may be used immediately. However, if any
of the clamp hoses are connected at the job site or if air is present in hoses,
they must be bled prior to operation.
2. Read SECTION III - OPERATING INSTRUCTIONS.
3. Start and warm up the diesel engine in accordance with SECTION III-C STARTING AND WARMING UP ENGINE.
4. With the engine warmed-up and running at 1200 RPM, loosen the close -clamp
line at the hydraulic clamp. Turn the clamp switch on the remote-control
pendant to CLOSE. Wait until oil flows from the connection at the hydraulic
clamp. When oil flows without air, tighten the connection.
5. After the line has been bled, alternately turn the clamp switch to CLOSE and
OPEN to insure that the clamp is working properly. It may be necessary to
bleed the line more than once. The open-clamp line may also require
bleeding.
G. FILLING VIBRATOR PRESSURE HOSE
1. The vibrator is usually shipped with the vibrator hydraulic hoses full of oil and
the unit may be used immediately. However, if the pressure hose has been
removed from the vibrator, the hose should be allowed to fill with hydraulic oil
prior to fullspeed operation.
2. Read SECTION III - OPERATING INSTRUCTIONS.
3. Start and warm up the diesel engine in accordance with SECTION III-C STARTING AND WARMING UP ENGINE.
4. With the diesel engine running at 1800 RPM, the Vibrator hoses will fill with oil
in about 10 minutes. Do not press the START button on control pendant.
II -5
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
III. OPERATING INSTRUCTIONS
CONTROL PANEL WITH REMOTE-CONTROL PENDANT
e
a
HYD. FLUID TEMP.
ENGINE OIL
TACHOMETER
b
i
ENG OIL PRESS.
c
ENG WATER TEMP.
PRESS. LOW
ENGINE WATER
TEMP. HIGH
ENGINE
OVER SPEED
ON
STOP START
d
AMMETER
MAIN POWER
g
RETURN
FILTER CLOG
HYD. FLUID
LOW LEVEL
HYD. FLUID
TEMP HIGH
OPEN CLOSE
CLAMP
START
REMOTE - LOCAL
h
STOP
u
f
FORWARD
p
v
BRAKE
t
OPENCLOSE
s
l
k
r
j
m
o
EMERGENCY STOP
OPEN CLOSE
START
n
l
k
EMERGENCY
STOP
STOP
SLOW FAST
j
q
REMOTE - CONTROL
PENDANT
(Fig. 1)
III -1
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
III. OPERATING INSTRUCTIONS
A. COMPLETION OF SET-UP AND MAINTENANCE
1. Complete all preparation as described in Section II.
2. Read Section IV - MAINTENANCE AND ADJUSTMENTS and perform any
required maintenance.
B. CONTROL PANEL
1. The control box (Fig. 1, page III-1) at the side of the power pack contains the
controls and gages for the diesel engine and the vibrator and the OPERATION
AND MAINTENANCE INSTRUCTIONS.
2. Control panel contains the following controls, gages and shutdown indicators.
a. Engine Tachometer
b. Engine Oil Pressure Switch Gage
c. Engine Water Temp Switch Gage
d. Engine Ammeter
e. Hydraulic Oil Temperature Switch Gage
f. Engine Hour Meter
g. Main Power Switch - ON -OFF Switch & Circuit Breaker
h. Engine - ON -OFF-START - Switch for Diesel Engine
i. Engine Shutdown Reset Button - over ride button for engine shutdown
switch. Must be held in until oil pressure exceeds 30 PSI.
j. Vibrator Stop Button
k. Vibrator Start Button - with clamp light.
l. Clamp Switch - open - close.
m. Emergency Stop - pull out to stop engine.
n. Emergency Stop - push to stop engine.
o. Engine Throttle (Manual)
p. Pressure Gage - Forward
q. Engine Throttle (Remote Electric)
r. Pressure Gage - Close Clamp
s. Pressure Gage - Open Clamp
t. Shutdown indicator lights (6) See notes below.
u. Remote - Local Switch
v. Pressure Gage - Brake
Notes: 1. Engine Oil Pressure shutdown indicator - comes on if engine has been
shut down automatically due to engine oil pressure being low.
2. Engine Water Temperature shutdown - comes on if engine has been shut
down automatically due to engine water overheating.
III -2
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
III. OPERATING INSTRUCTIONS
B. CONTROL PANEL (CONTINUED)
3. Engine Overspeed shutdown indicator - comes on if engine has been shut
down automatically due to the engine being run at excessively high RPM.
4. Filter Clogged shutdown indicator - comes on if engine has been shut
down automatically due to the hydraulic oil return filter being clogged.
5. Hydraulic Oil Level Low shutdown indicator comes on if engine has been
shut down automatically due to low hydraulic oil level in the reservoir.
6. Hydraulic Oil Temperature High shutdown indicator - comes on if engine
has been shut down automatically due to high hydraulic oil temperature.
3. The Operating & Maintenance Instructions, on the control box door, are there
as reminders only. They are not intended to substitute for a through
understanding of the Operators Manual.
III -3
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
III. OPERATING INSTRUCTIONS
C. STARTING AND WARMING UP ENGINE
1. Before starting the engine, read the CATERPILLAR OPERATION GUIDE
carefully. Follow the engine starting, operating and maintenance procedures
in that manual.
2. The diesel engine should not be started if the temperature of the hydraulic oil
is below 0°F (-18°C). If ambient temperatures below 0°F (-18°C) are
anticipated, an immersion heater for the hydraulic oil is available. Consult J&M
for details.
3. Turn the MAIN POWER switch on the control panel to on.
4. Pull out the ENGINE THROTTLE about half way. Pressing the button on the
end of the throttle allows rapid throttle adjustment. Turning the throttle allows
fine adjustment. Be sure the EMERGENCY STOP knob is fully pushed in.
5. Press and hold the SHUTDOWN RESET. Turn the ENGINE START switch to
START. Hold SHUTDOWN RESET in until engine oil pressure exceeds 30
PSI (2 BAR).
6. Adjust the throttle until the engine is running at 1500 RPM and allow engine to
warm up for five minutes. After the engine is warmed up, adjust throttle so
engine runs at 2100 RPM's under no load. The engine should hold 1900
RPM's under load.
7. Allow the temperature of the hydraulic oil to come up to at least 30°F (-1°C)
before starting the vibrator.
D. WARMING HYDRAULIC OIL
1. The vibrator should not be operated at full speed if the temperature of the
hydraulic oil is below 60°F (16°C).
2. If temperature is below 60°F (16°C), set the engine at 1500 RPM and press
the START button on the control pendant to start the vibrator. Allow the
vibrator to run until the temperature of the hydraulic oil exceeds 60°F (16°C).
III -4
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
III. OPERATING INSTRUCTIONS
D. WARMING HYDRAULIC OIL (CONTINUED)
3. When the engine is warmed up and hydraulic oil temperature is at least 60°F
(16°C), full speed operation may begin.
4. The hydraulic oil temperature should be monitored with the Hydraulic
Temperature Oil Switch Gage. Oil temperature should never exceed 160°F
(71°C). The engine will automatically shut down if oil temperature exceeds
160°F (71°C).
CAUTION: Do not operate the vibrator if hydraulic oil temperature exceeds 160°F
(71°C) as this may damage hydraulic components.
E. OPERATION OF REMOTE-CONTROL PENDANT
1. The operation of the vibratory driver is controlled by the remote-control
pendant. The pendant is connected to the control cabinet with 50 feet (15m) of
electrical cable to permit operation from any advantageous position near the
vibrator.
2. The pendant has an Emergency Stop palm button, two control buttons, one
with an indicator light, and two switches.
a. To Clamp to Pile:
Position vibratory driver on pile. Turn the clamp switch on the pendant to
CLOSE. The CLAMP light (Start Button) on the pendant will illuminate
when the hydraulic clamp has achieved adequate pressure to permit
vibration to begin. The light should normally come on in a few seconds.
b. To Start Vibration:
Press the START button (lighted).
CAUTION: Do not press the START button until the CLAMP light comes on
indicating adequate clamping pressure.
III -5
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
III. OPERATING INSTRUCTIONS
E. OPERATION OF REMOTE-CONTROL PENDANT (CONTINUED)
c. To Stop Vibration:
Press the STOP button.
The vibrator will stop vibration in a few seconds. If the STOP button does
not stop the vibrator, pressing the Emergency Stop button will shut down
the Power Unit and the vibrator will stop.
d. To unclamp from pile.
Turn the CLAMP switch to OPEN to release the hydraulic clamp so that the
vibrator can be removed from the pile. Hold the CLAMP switch in the
OPEN position for approximately 10 seconds or until a visual check shows
the jaws to be fully open. An electrical interlock prevents the jaw from
opening if the Stop button has not been pressed.
CAUTION: Do not turn the switch to OPEN until a visual check indicates that
vibration has stopped.
e. Remote Electric Throttle
Momentarily turning the electric throttle switch to the FAST position will
increase engine speed (RPM). Turning this switch to the SLOW position
will reduce engine speed.
f. Emergency Stop Palm Button
Pressing the EMERGENCY STOP button will stop the diesel engine and all
vibrator functions will cease.
g. If the remote- control pendant is damaged or the pendant line is cut, you
may still operate the vibrator by using the control switches on the control
panel. (See Fig. 1 on page III-1 items J, K, L). To activate these switches,
find the toggle switch on the bottom of the control panel, labeled
"REMOTE-LOCAL". Turn the switch (item U) to LOCAL and the switches
on the control panel will be functional, and the remote control pendant will
be disabled.
(NOTE: The EMERGENCY STOP button on the pendant is not disabled
during “LOCAL” operation)
h. Radio Remote Control: A Radio frequency Remote Control Unit is available
from J&M for the Model 66-80. This unit allows the operator flexibility to
control the Vibrator at greater distances from the Power Unit without the
inconvenience of the electrical cable. Contact J&M for information and
operating instructions.
III -6
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
III. OPERATING INSTRUCTIONS
F.CHANGING FREQUENCY
1. In order to provide maximum flexibility in achieving optimum pile penetration
and extraction rates, the frequency of the vibratory driver is adjustable.
2. The frequency can be varied from 800 to 1600 vibrations per minute by
changing engine speed. Engine speed is changed with the ENGINE
THROTTLE on the control panel or with the remote electric throttle (FAST /
SLOW) switch on the pendant. Vibration frequency corresponds
approximately to engine speed according to the table shown below.
ENGINE RPM VIBRATOR VPM
20001600
18001400
16001300
14001100
1200900
1000800
G. SHUT DOWN
1. Stop the vibrator.
2. Allow the diesel engine to run for five minutes at 1100 RPM.
3. Reduce engine speed to idle for about thirty seconds.
4. Stop the engine by turning the ENGINE START switch to OFF.
5. Turn MAIN POWER switch to OFF.
6. Check engine crankcase oil level while power unit is setting level.
7. CAUTION: If the diesel engine is shut down while the vibrator is clamped to a
pile, the clamp check valve will keep the vibrator clamped to the
pile. However, system leakage could result in a loss of clamp
pressure over time. Therefore, it is not recommended to leave
the vibrator clamped to a pile when the diesel engine is not
running.
III -7
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
IV. MAINTENANCE AND ADJUSTMENTS
A. GENERAL
Preventive maintenance includes normal servicing that will keep the vibratory
driver, clamp and power unit in peak operating condition and prevent unnecessary
trouble from developing. This servicing consists of periodic lubrication and
inspection of the moving parts and accessories of the unit.
Lubrication is an essential part of preventative maintenance, controlling to a great
extent the useful life of the unit. Different lubricants are needed and some
components in the unit require more frequent lubrication than others. Therefore, it
is important that the instructions regarding types of lubricants and frequency of
their applications be closely followed.
To prevent minor irregularities from developing into serious conditions that might
involve shut-down and major repair, several other services or inspections are
recommended for the same intervals as the periodic lubrications. The purpose of
these services or inspections is to assure the uninterrupted operation of the unit.
Thoroughly clean all lubrication fittings, caps, filler and level plugs and their
surrounding surfaces before servicing. Prevent dirt from entering with lubricants
and coolants. The intervals given in the schedule are based on normal operation.
Perform these services, inspections, etc., more often as needed for operation
under abnormal or severe conditions.
B. DAILY
1. Check the entire unit prior to and during set-up each day or at the beginning of
each shift.
2. Prior to starting the power unit or at the beginning of each shift, check the
following items:
a. Visibly inspect all bolts, nuts and screws including the bolts fastening the
hydraulic clamp to the vibration case to insure they are tight.
IMPORTANT: Vibration loosens bolts. Check carefully.
b. Tighten bolts holding gripping jaws in hydraulic clamp.
c. Grease plunger in hydraulic clamp with any good multi-purpose grease.
d. Check the oil level in the vibration case and add oil if required. The oil
level should be in the middle of the sight glass. Change oil if milky or
contaminated. DO NOT OVERFILL
e. Check the oil level in the hydraulic reservoir and refill if necessary.
CAUTION: It is absolutely imperative that no dirt or other impurities be
permitted to contaminate the hydraulic oil. Any contamination will
drastically shorten the life of the high-pressure hydraulic system.
IV-1
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
IV. MAINTENANCE AND ADJUSTMENTS
B. DAILY (CONTINUED)
f. Visually check all hoses for signs of damage or cuts that might cause hose
failure during operation. Be sure all connections are tight, especially the
quick-disconnect couplers.
g. Visually inspect all suppressor elastomers.
h. Electrical components need no maintenance except periodic wiping with a
clean, dry, lint -free cloth to remove dust.
i. Perform all daily (10 Service Meter Units) maintenance checks and
lubrication in the CATERPILLAR OPERATION GUIDE. For the J&M Model
950 power unit, the HOUR METER on the control panel may be considered
to read Caterpillar's "Service Meter Units".
3. After engine start-up, check the following:
a. Check all hydraulic hoses for leaks. Make sure they hang freely with no
kinks.
b. Check all 5 pumps and all hydraulic manifolds for leaks.
c. Check the filter indicators. The filter indicators on the power unit must be
checked with the diesel engine running at full speed.
C. 125 HOURS (125 Service Meter Units)
1. Every 125 hours drain and refill the vibration case with new lubricant.
2. Perform all maintenance checks and lubrication indicated in the Caterpillar
OPERATION GUIDE.
3. After the first 100 hours, drain and replace the lubricant in the multi-pump
drive, thereafter change every six months or 2000 hours, which ever comes
first.
D. 250, 500 HOURS and Other
1. See Caterpillar OPERATION GUIDE.
E. ANNUALLY
1. Have the hydraulic oil tested by a local hydraulic service center. Replace if
required.
2. See Caterpillar OPERATION GUIDE.
IV-2
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
IV. MAINTENANCE AND ADJUSTMENTS
F. SEVERE CONDITIONS
1. The service intervals specified are based on normal operating conditions.
Operation under unusual conditions require some adjustments in servicing
intervals.
2. When the average temperature is above 80°F (26°C) or below -10°F (-23°C),
reduce service intervals to one half of those specified in Sections C through E.
3. When operating in the presence of dust or sand, reduce service time intervals
by one-half of those specified.
4. When operating in excess of twelve hours per day, reduce service time
intervals by one-half of those specified.
5. When operating in air with high salt or moisture, the servicing intervals need
not usually be changed. However, the unit should be inspected weekly to
determine if additional servicing be required. Also, have hydraulic oil tested
quarterly.
6. During stand-by or inactive period, the servicing intervals may be twice those
specified above. The unit should be exercised every week. Also, refer to the
Caterpillar OPERATION GUIDE.
IV-3
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
IV. MAINTENANCE AND ADJUSTMENTS
G. LUBRICATION
1. Crankcase (Diesel Engine)
a. Follow the engine manufacturer's maintenance schedule and the
lubricating oil specifications outlined in the CATERPILLAR OPERATION
GUIDE.
b. The lubricant shall meet the performance requirements of API Service
Classifications CD or MIL-L-2104C.
c. New engines are shipped with ASHLAND 400M+HDT 15W-40 and the
following multi-grade crankcase oils are recommended for use or
replacement in normal operation (10°F to 90°F) (-12°C to 32°C).
AMOCO 15W-40 300
ARCO 15W-40 Fleet S3 Plus
BORON (BP) 15W-40 Vanellus C Extra
CHEVRON 15W-40 Delo 400
CITGO 15W-40 C500 Plus
CONOCO 15W-40 Fleet Supreme
EXXON 15W-40 XD3
GULF 15W-40 Super Duty Plus
MOBIL 15W-40 Delvac Super
PHILLIPS 15W-40 Super HD II
SHELL 15W-40 Rotella T
SUN 15W-40 Sunfleet Super C
TEXACO 15W-40 Ursa Super Plus
UNION 15W-40 Guardol
VALVOLINE 15W-40 All Fleet
d. For operation in cold weather climate, refer to the CATERPILLAR
OPERATION GUIDE Crankcase Lubricating Oils or contact the nearest
Caterpillar representative. For Cold Weather Recommendations (CAT
bulletin #SEBU5898-06)
2. Vibration Case
The oil level is easily read through the sight glass located at the lower center of
the vibration case opposite the motor side. The proper level is to the middle of
the sight gage. DO NOT OVER FILL Lubricating oil may be added when
necessary through either of the holes in the vibration case top plate after
removing the 1" pipe plugs. To drain the case, remove a 3/4" pipe plug at
either end of the base plate. Tilt the case for complete drainage.
IV-4
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
IV. MAINTENANCE AND ADJUSTMENTS
G. LUBRICATION (CONTINUED)
3. Multi-Pump Drive Adapter
The oil level is easily checked by looking at the sight gage in the center near
the bottom of the multi-pump drive adapter. Lubricating oil should be half way
up the sight gage. If low, lubricating oil may be added by removing the
breather located on the right side of the Multi-pump Drive Adapter. Draining
the lubricating oil may be done by removing the 9/16 socket head pipe plug on
the bottom of the Multi-pump Drive Adapter.
4. The preferred lubricating oil for J&M vibration cases and multi-pump drive
adapters is a “High Moly Oil” (Schaeffer 268). Longer intervals between oil
changes and fewer maintenance hours spent on mechanical service can
generally be realized with this oil.
Therefore, whenever the "first preferred" oil is not available or desired, and an
alternate oil is selected, it will be necessary to test and/or change the oil at
shorter intervals.
Extensive tests have indicated that the use of Schaeffer 268 results in cooler
operation and extended bearing and gear life.
The vibration case and multi-pump drive adapter lubricant installed at the
factory is SCHAEFFER 268 but the following gear lubes may be used when
changing lubricants:
FIRST Preference Group :
SCHAEFFER268
SECOND Preference Group:
MOBIL SHC-634
BORON Gearep 140
CHEVRON Gear Comp. NL460
CITGO Premium MP 85W-140
CITGO Standard MP 85W -140
GULF Lub 85W-140 Lub 85W-140
PHILLIPS SMP 85W-140
SHELL Omala 460 Omala 460
SUN Sunep 1110
IV-5
MODEL 66-80 VIBRATORY DRIVER/EXTRACTOR
IV. MAINTENANCE AND ADJUSTMENTS
G. LUBRICATION (CONTINUED)
THIRD Preference Group (Natural Petroleum Base):
AMOCO Perma Gear EP140
ARCO Pennant NL 460
CONOCO EP 460
EXXON Spartan EP 460
PHILLIPS AP 140
TEXACO Meropa 460
UNIONMP 85W-140
VALVOLINE Gear Lub 85W-140
SCHAEFFER 268 Lubricant is available from J&M in five gallon cans.
See SECTION VIII - ORDERING PARTS, page VIII-48.
5. Hydraulic System
To maintain the maximum operating efficiency in the precision parts of the
hydraulic system, it is extremely important to eliminate factors which can cause
breakdowns or unsatisfactory performance in the system. Among the most
common of these factors are rust, corrosion, contamination and the products of
oil deterioration. Most problems can be minimized or avoided simply by
maintaining a disciplined preventive maintenance program.
Some simple steps to follow as part of that program are:
a. Keep stored oil dry and clean at all times and always store in clean
containers.
b. Always clean tools, spouts, lids, funnels, etc. when used in conjunction with
the transfer of oil.
c. Never put dirty oil into the hydraulic system. Use only clean,
uncontaminated oil of the types recommended below. Never return to the
system any oil which has leaked out.
NOTE: Foreign material in the hydraulic system can drastically effect the life
and operation of many hydraulic component parts.
d. Clean or replace filter elements at the first indication that they are dirty or
ineffective.
Mixing of different manufacturers' hydraulic oil is not recommended. However,
it can be done if the oils are miscible (contain the same base stock and
additives). It may be necessary to contact an oil supplier to determine this.
IV-6
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