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ZYJ 460B-Ⅱ Operator’s manual

CONTENTS 1 SAFETY INFORMATION ................................................................................................................................... 8 1.1 SAFETY LABELS ..................................................................................................................................... 8 1.2 SAFETY RULES...................................................................................................................................... 10 1.3 PREPARATION FOR EMERGENCY..................................................................................................... 10 1.4 WEAR SAFETY PROTECTIVE ARTICLES .......................................................................................... 11 1.5 KEEP MACHINE CLEAN....................................................................................................................... 11 1.6 KEEP OPERATOR’S COMPARTMENT CLEAN................................................................................... 11 1.7 MOUNTING AND DISMOUNTING ...................................................................................................... 11 1.8 MOVE MACHINE SAFELY.................................................................................................................... 12 1.9 REQUIREMENT TO THE CONSTRUCTION FIELD............................................................................ 12 1.10 CHECK MACHINE BEFORE START-UP ............................................................................................ 13 1.11 OPERATE SAFELY ............................................................................................................................... 13 1.12 KEEP AWAY FROM TRANSMISSION PARTS.................................................................................... 14 1.13 MAINTAIN SAFELY............................................................................................................................. 14 1.14 BEWARE OF HIGH PRESSURED LIQUIDS ....................................................................................... 14 1.15 BEWARE OF SCALD ............................................................................................................................ 15 1.16 AVOID HEATING UP NEAR PRESSURE OIL PIPE............................................................................ 15 1.17 AVOID HEATING UP PIPE WITH PRESSURE OIL ............................................................................ 15 1.18 RREMOVE PAINT BEFORE WELDING OR HEATING..................................................................... 15 1.19 AVOID FIRE .......................................................................................................................................... 16 2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER ................................................................ 17 2.1 ADVANTAGES OF SUNWARD PILE DRIVER..................................................................................... 17 2.2 COMPARED WITH THOSE BY OTHER FACTORIES ......................................................................... 17 3 BASIC STRUCTURE AND WORK PRINCIPLE ............................................................................................. 19 3.1 BASIC STRUCTURE OF ZYJ460B-Ⅱ................................................................................................... 19 3.2 PILING PLATFORM ............................................................................................................................... 20 3.2.1 STRUCTURE................................................................................................................................ 20 3.2.2 PILE PRESSING PROCESS ........................................................................................................ 21 3.3 TRAVEL MECHANISM.......................................................................................................................... 22 3.3.1 VERTICAL MOTION MECHANISM ......................................................................................... 22 3.3.2 LONGITUDINAL MOTION MECHANISM............................................................................... 23 3.3.3 CROSS MOTION AND ROTATION MECHANISM .................................................................. 23 3.3.4 CONTINUOUS STEPPING AND ROTATION............................................................................ 24 3.3.5 LONGITUDINAL MOTION ........................................................................................................ 24 3.3.6 CROSS MOTION ......................................................................................................................... 25 3.3.7 ROTATION ................................................................................................................................... 25 3.4 HYDRAULIC SYSTEM ( FOR PILE PRESSING) ................................................................................ 26 3.4.1 STRUCTURE................................................................................................................................ 26 3.4.2 WORK PRINCIPLE (see appendix figure 1 hydraulic system).................................................... 28 3.5 SIDE PILING AND CORNER PILING .................................................................................................. 30 3.6 ELECTRIC SYSTEM .............................................................................................................................. 32 3.6.1 COOLING DEVICE FOR HYDRAULIC OIL............................................................................. 33 3.6.2 HEATING DEVICE FOR HYDRAULIC OIL (FOR NORTH USERS) ...................................... 33 4. OPERATING REGULATIONS ......................................................................................................................... 34 4.1 CONTROL PANEL.................................................................................................................................. 34 4.2 PREPARATION BEFORE PRESSING PILE.......................................................................................... 35 4.2.1 PREPARATION BEFORE START-UP ......................................................................................... 35 4.2.2 ADJUSTMENT OF PRESSURE ............................................................................................... 36 4.2.3 ADJUSTMENT OF OIL PRESSURE FOR CLAMPING AND RELEASING PILE .................. 37 4.2.4 ADJUSTMENT OF HYDRAULIC PUMP................................................................................... 38 4.3 OPERATION METHOD AND STEPS.................................................................................................... 39 4.3.1 START-UP..................................................................................................................................... 39 4.3.2 POSITIONING PILE .................................................................................................................... 39 4.3.3 LEVELING ................................................................................................................................... 39 4.3.4 PRESSING PILE........................................................................................................................... 40 、4.3.5 ATTENTION ............................................................................................................................. 42 4.3.6 CABLES ACCESS PHASE SEQUENCE (DUE TO THE SPECIAL REASON, N MAY CHANGE.) ............................................................................................................................................. 42 6

ZYJ 460B-Ⅱ Operator’s manual 4.3.7 OIL COOLING OPERATION ...................................................................................................... 43 4.4 INSTALLATION AND REPLACEMENT OF CLAMPING JAW.......................................................... 43 4.4.1 INSTALLATION........................................................................................................................... 43 4.4.2 REPLACEMENT OF CLAMPING JAW ..................................................................................... 45 5ASSEMBLY, DISASSEMBLY, TRANSPORTATION AND MAINTENANCE................................................. 46 5.1 ASSEMBLY ............................................................................................................................................. 46 5.2 DISASSEMBLY....................................................................................................................................... 50 5.3 TRANSPORTATION ............................................................................................................................... 51 5.4 DEBUGGING .......................................................................................................................................... 52 5.5 DAILY MAINTENANCE AND TIME MAINTENANCE....................................................................... 52 5.6 LUBRICATION DIAGRAM.................................................................................................................... 53 5.7 TORQUE FOR STANDARD TIGHTENING PARTS ........................................................................................... 54 6 CRANE ............................................................................................................................................................... 55 6.1ATTENTION ................................................................................................................................................ 55 6.2 BASIC STRUCTURE AND WORK PRINCIPLE ................................................................................... 55 6.2.1 JIB SYSTEM AND ITS EXPANSION ......................................................................................... 57 6.2.2 WINCH SYSTEM......................................................................................................................... 57 6.2.4 DERRICKING SYSTEM.............................................................................................................. 58 6.2.5 HYDRAULIC SYSTEM............................................................................................................... 58 6.2. 6 SAFETY DEVICE ....................................................................................................................... 60 6.3 CRANE OPERATION............................................................................................................................ 62 6.3.1 PREPARATION BEFORE START-UP ......................................................................................... 62 6.4 MAINTENANCE..................................................................................................................................... 63 6.5 PARAMETER .......................................................................................................................................... 63 6.6 HYDRAULIC DRAWING....................................................................................................................... 66 6.7 ELECTRICAL DRAWING...................................................................................................................... 67 7 TROUBLE SHOOTING ..................................................................................................................................... 68 7.1 COMMON MALFUNCTIONS AND CORRESPONDING SOLUTIONS ............................................ 68 7.2 REPAIR .................................................................................................................................................... 70 8 MAIN TECHNICAL DATA................................................................................................................................ 72 APPENDIX TABLE 8-1 SIGNS IN THIS MANUAL................................................................................... 72 APPENDIX TABLE 8-2 BASIC PARAMETERS......................................................................................... 72 APPENDIX TABLE 8-3 OIL PRESSURE AND PILE PRESSING FORCE................................................ 74 APPENDIX TABLE 8-4 ATTACHMENT TOOLS ....................................................................................... 75 APPENDIX TABLE 8-5 WEARING PARTS ...................................................................................................... 76 APPENDIX TABLE 8-6A CLAMPING JAW COLLOCATION 1 ................................................................ 76 APPENDIX TABLE 8-6B CLAMPING JAW COLLOCATION 2 ................................................................ 77 APPENDIX TABLE 8-7 HYDRAULIC PUMP PRESSURE-FLOW CURVE ADJUSTMENT LIST ............................... 78 APPENDIX TABLE 8-8 HYDRAULIC PARTS FOR MAIN MACHINE ................................................... 78 APPENDIX TABLE 8-9 ELECTRIC PARTS FOR MAIN MACHINE........................................................ 79 9 APPENDIX FIGURES........................................................................................................................................ 80 APPENDIX FIGURE 1 MAIN MACHINE HYDRAULIC SYSTEM........................................................... 80 APPENDIX FIGURE 2 MAIN MACHINE ELECTRIC SYSTEM .............................................................. 82 APPENDIX FIGURE 3A CAST IRON COUNTWEIGHT LOCATED ......................................................... 83 APPENDIX FIGURE 3B BARITE COUNTWEIGHT LOCATED................................................................ 84 10 ABOUT THE MANUFACTURER ................................................................................................................... 85

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ZYJ 460B-Ⅱ Operator’s manual

1 SAFETY INFORMATION 1.1 SAFETY LABELS 1.1.1 SAFETY LABELS REQUIRMENTS  Be sure that you fully understand the correct position and content of labels.  To ensure that the content of labels can be read properly, be sure that they are in the correct

place and always keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to peel off.  There are also other labels in addition to the warning signs and safety labels. Handle those

labels in the same way.  If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Sunward distributor.

1.1.2 LOCATION OF SAFETY LABELS

Figure 1-1

1.

Caution when machine is working.

8

ZYJ 460B-Ⅱ Operator’s manual

Figure 1-2 2.

Caution during pile pressing.

Figure 1-3 3. Caution when machine is removing or rotating.

Figure 1-4 4. Caution when machine is removing or rotating.

Figure 1-5 9

ZYJ 460B-Ⅱ Operator’s manual 5. Caution when crane is working.

Figure 1-6 1.2 SAFETY RULES  Study the manual carefully and follow the

safety instructions in the labels and in the manual before operating the machine.  Always keep the safety labels clean. Replace

any lost or damaged label with a new one. If the labels or manual book is lost, contact dealer and indicate the model of machine for purchase.  Only qualified operator is permitted to operate

this machine. Keep the machine in good condition as per this manual.  Don’t refit machine without authorization.

Figure 1-7

Otherwise the performance and lifetime of Fmachine will be affected, or human body hurt may be caused. ATTENTION The safety instructions in this book only include the general safety rules of this machine. They do not cover all the possible danger that may occur. If there is any problem, please report to your superior before operating or maintaining the machine. 1.3 PREPARATION FOR EMERGENCY If you find any abnormalities in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to person in charge and have the necessary action taken, do not operate the machine until the abnormality has been corrected. All personnel related to operating the machine should pay attention to prevent accidents from 10

Figure 1-8

ZYJ 460B-Ⅱ Operator’s manual happening. Always keep a first-aid kit and fire extinguisher nearby. Have phone numbers of a doctor, ambulance, hospital and fire department with you in case of emergency. 1.4 WEAR SAFETY PROTECTIVE ARTICLES Before operation, always wear protective articles when the work so requires, they include: Skintight work clothes Hard hat Safety gloves Safety glasses, goggles, or veil Respirator or filtration veil Earplug or earcap Figure 1-9

1.5 KEEP MACHINE CLEAN  If water gets into the electrical system, it is

likely to cause malfunctions or misoperation or electrical leakage. Do not use water or steam to wash electrical parts (sensor, alternator, start motor, voltage changer, contactor and circuit breaker etc.).  If inspection and maintenance is carried out

when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes. Always keep the machine clean. 1.6 KEEP OPERATOR’S COMPARTMENT CLEAN  Do not leave parts or tools lying around the

operator’s compartment.  Do not use cellular telephones inside the

operator’s compartment when driving or operating the machine.  Never bring any dangerous objects such as

flammable or explosive operator’s compartment.

items

into

the

1.7 MOUNTING AND DISMOUNTING  Always face the machine when you use the

steps and hand-holds to enter or leave machine.  Never use any control lever as hand-hold.  Never enter or leave machine when the

machine travels, swings, or digs (lifts). 11

ZYJ 460B-Ⅱ Operator’s manual

1.8 MOVE MACHINE SAFELY  While pile driver is moving or rotating,

prohibit anyone from staying within the range of movement or under the counterweight.  While machine moves from soft field to hard

field, the machine should moves at longitudinal direction and face forward, i.e. main machine operator faces to the front of panel.  Prohibit the machine moving at transverse

direction when it moves from soft field to hard field.  When short ship slideway rotates or moves

transversely, assure not to collide with long ship slideway.  When controlling longitudinal motion, handles

should be operated at the same time and the same direction. Any separate and contra-directional operation should be prohibited. If one of the longitudinal motion hydraulic cylinders has extended to the required position, the other must stop at once to prevent the damage to the main body.  Keep

the main body horizontal in the procession of vertical motion in case that these four vertical motion hydraulic cylinders extend differently (difference should be less than 100mm), which will cause serious damage to the main body. It is prohibited to operate two diagonally placed vertical motion cylinders at the same time.

1.9 REQUIREMENT TO THE CONSTRUCTION FIELD  Check and assure the construction field meets

the pressure ratio requirement. There should not be sharp or hard object of small area in construction field or small protrusion that would block the pile driver’s motion。  The gradient of construction field should not

be larger than 3°. If the construction field has gradient, pile driver should be placed parallel or vertical to the construction field’s descending direction  If

construction field can not meet the requirement for piling, clear up the construction field until the requirement is met, then start piling. In the case of old city rebuilding, especially when there are a lot of 12

Figure 1-10

ZYJ 460B-Ⅱ Operator’s manual small bricks or stones in the ground, clear the work site effectively. 1.10 CHECK MACHINE BEFORE START-UP Before starting machine every day or every shift, check the machine according to the contents in “§4.2 preparation before start-up” of this manual. 1.11 OPERATE SAFELY  Keep all the non-workers away from working

range.  Before piling, enough counterweight should be

loaded; during piling, max hydraulic pressure should not exceed the rated pressure. Otherwise the pile driver would be lifted off ground.  The main machine operator and crane operator

should keep good communication and observation for each other. Prohibit operating crane or hoisting objects while the machine moves or rotates. And also, prohibit the machine moving or rotating while crane is in operation or hoisting objects.  Ensure firm binding while hoisting pile.  Crane’s winch wire should wrap around the

drum for at least 4 circles.  When lifting pile, it is prohibited to stand in the

working range of crane.  Check winch wire and pile lifting wire often and

replace them if any damage occurs.  Check and screw down the connection bolts at

the crane slewing support every 2 months, the screwing down torque is 560-600NM. Replace them with original SUNWARD bolts if any abnormality occurs.  Lift rated weight within the limitation of jib

lifting angle to avoid crane jib overloading.  Before pressing piles, make sure the hook has

been separated from the tools for lifting pile. If not, there will be serious accident of the lifter and pile driver. In some special condition, if the crane winch has to be used as pile follower, the speed of pile follower must be higher than the speed of piling.  Operators shouldn’t put their arms and legs into

the gaps between the pile pressing platform and the main body. 13

ZYJ 460B-Ⅱ Operator’s manual  Prohibit any person from standing under the

counterweight during piling.  Prohibit pushing any handles in the process of

jointing piles in case that piles fall down to hurt any people.  When stop operating, let the short ship slideway

fully touch ground and the long ship slideway touch ground a little. Then lay the clamping box to the bottom on the support beam, shut down power and lock the door. 1.12 KEEP AWAY FROM TRANSMISSION PARTS  Touching transmission parts may cause GBH.  Keep

careful when working around transmission parts to prevent hand, foot, hair and clothes from being entangled in the machine.

Figure 1-11

1.13 MAINTAIN SAFELY Attention of Maintenance:  Understand the maintenance rules before work  Keep the working area clean and dry.  Don’t carry out lubrication or maintenance to

moving machine.  Avoid body and clothing touching transmission

parts.  Check some parts at regular intervals, repair or

replace, if necessary. (refer “Maintenance and Repair” chapter)

to

Figure 1-12

the

 Make sure all parts in good condition and fitted

correctly. Replace wearing or damaged parts. Clean any accumulative lubricant or scraps.  Execute

daily and regular inspection, maintenance, and repair according to this manual book.

1.14 BEWARE OF HIGH PRESSURED LIQUIDS  Effluent liquids of high pressure will penetrate

through skin, causing GBH.  Release pressure before disjoining liquids or

other pipeline to avoid this danger.  Operate control lever many times to release

pressure. Before supercharging, tighten all the connections.  Inspect leakage with cardboard, take care to

14

Figure 1-13

ZYJ 460B-Ⅱ Operator’s manual protect your hand and body against touching high-pressured liquids.  If accident occurs, see the doctor at once.  Any liquid penetrated in skin must be cleaned

within few hours. Otherwise it will cause necrosis. 1.15 BEWARE OF SCALD  During

operation, engine oil, gear oil, hydraulic oil will become hot. Meanwhile, engine, hose, pipeline, and other parts will also become hot. Beware of scald.

 Carry out inspection and maintenance after oil

and parts have been cooled to prevent scald. 1.16 AVOID HEATING UP NEAR PRESSURE OIL PIPE  If heating up near pressured oil pipe, the

inflammable spray will cause severe burn to people nearby. Don’t carry out welding, gas protection welding, or gas cutting near pressure oil pipe or other inflammable goods.  If welding, gas protection welding or gas

cutting must be carried out near pressure oil pipe, mount temporary fireproof jacket to protect hose or other materials. 1.17 AVOID HEATING UP PIPE WITH PRESSURE OIL  Not permitted to weld hydraulic oil steel pipe

or hose. Before welding this kind of pipe or hose, clean it completely with incombustible solvent.

1.18 RREMOVE PAINT BEFORE WELDING OR HEATING  Prevent bringing potential poisonous gas and

dust.  When paint heated up by welding or other

methods, it will bring poisonous gas.  Remove paint before welding or heating up as

the following methods: 1. Rub out paint with abrasive paper or wheel, during this work, remember to wear regulated respirator to prevent inhaling dust. 2. Rub out paint with solvent or paint remover. After rubbing out, clean paint remover with soap and water. Before welding or heating up, 15

ZYJ 460B-Ⅱ Operator’s manual volatilize the paint remover gas for at least 15 minutes. ATTENTION The paint removing work should be operated at outdoors or well -ventilated site. 1.19 AVOID FIRE In order to avoid fire, take the following steps: 1. Check the leakage. The leakage of fuel,

hydraulic oil and lubricant may cause fire.  Use a piece of cardboard to check leakage,

never check leakage with nude hand to prevent pressured oil shooting up, causing injury.

Figure 1-14

 Inspect

hose whether twisted or not, attrition between hose and hard pipe or not, oil cooler damaged or not, and oil cooler connection loosened or not. If necessary, tighten, repair, or replace any clamp, pipe, hose, oil cooler, and flange bolt of oil cooler.

 Don’t twist or knock on high-pressured

pipe.  Don’t

assemble pipeline or hose.

twisted

or

damaged

2. Inspect

the circuit. The short circuit of electrical system may cause fire.  Before

every shift or after 8 hours’ operation, check loosened, twisted, hardened, or cracked cable and wire.

 Before

every shift or after 8 hours’ operation, check lost or damaged connectors.

 Before operation, tighten, repair, or replace

any loosened or damaged cable, wire and connector. If the cable or wire is loosened or twisted, don’t operate the machine. 3. Clean away inflammable materials. Keep the

machine clean every day to prevent fire

16

Figure 1-15

ZYJ 460B-Ⅱ Operator’s manual

2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER SUNWARD Intelligent Equipment Co. Ltd, combining production, teaching and research, is a new-type enterprise. SUNWARD series hydraulic static press-in pile drives are new kinds of machine of high efficiency and energy saving. WORK PRINCIPLE: In the process of pile pressing, the machine’s weight acts as reaction force to balance the friction drag from beside the pile and the reaction force from the pile tip, then the pile is pressed in the ground. 2.1 ADVANTAGES OF SUNWARD PILE DRIVER The method of using static press-in precast pile is a very particular way of pile foundation construction. The precast pile is completely pressed into ground by static force. With development of pile machinery and enhancement of environment-protecting requirement，it has become a promising way of pile foundation. Compared with other pile foundation construction methods like impact, vibration or cast, this way has the following advantages: 1.

ENVIRONMENT FRIENDLINISS ----The work of construction is quiet and neat, and workers

have less work intension. It’s suitable for urban construction because of the absence of noise, vibrancy and pollution. 2.

HIGH EFFICIENCY ---- Its efficiency is much higher than that of other pile drivers, and it can

finish hundreds meters of pile foundation in a day work (8 hours). It is most suitable for urgent and large foundation projects. 3. HIGH QUALITY ---- The process of driving pile is similar to testing pile, therefore the rate of success is almost 100%. 4.

UNLIMITED TOTAL LENGTH OF JOINTED PILE ---- The total length of jointed piles is not

limited if pile’s strength allows. 5. LOW COST ---- In all kinds of pile foundation construction methods, the cost of static press-in technics is one of the most economical types if compared by the cost of carrying capacity per cubic meter of pile.(equals to that of casting pile when carrying capacity is the same) 2.2 COMPARED WITH THOSE BY OTHER FACTORIES Customers can choose suitable type according to their practical needs in the range of pressing force from 800KN to 12000KN. Compared with pile driver made by other factories, SUNWARD series have the following prominent advantages: ⅠTECHNIQUE INOVATIONS

In the series products, Sunward has one patent for invention(ZL 93110671.0), three new type practical patents (patent No. ZL 95236709.2、ZL99249764.7、ZL 99249765.5. These patents got National Excellence Award and the Ten Most Well Applied Patents Award in Hunan province. Adopting patent technology highly improves performance of Sunward pile driver: 1.

The quasi-constant-power pile driving system is composed of two pairs of hydraulic cylinders which work orderly in pile-driving and the well-matched hydraulic system makes this kind of pile drivers superior to other pile drivers of the similar rank, because of its 40% energy saving, 15% increase of speed and more than 40% raised pile driving force.

2.

The new type of Step-like moving mechanism can do longitudinal, cross and rotary motion freely, which makes it easy and agile to aim piles. A two- tier framework with cross and rotary motion system has a compact structure which is easy to assemble. Specially designed rotary 17

ZYJ 460B-Ⅱ Operator’s manual compensating mechanism and rotary self-return function can largely decrease the resistance of rotation and can reduce time for auxiliary work. Load balancing controller of longitudinal motion mechanism can largely improve the reliability of vertical motion hydraulic cylinders. 3.

The originally designed pile-clamping box is notable for accurate and reliable pile localization. The pile stress resulting from clamping can be effectively decreased, and the problem of clamping thin tube pile can also be solved.

4.

Among pile drivers of the similar rank, SUNWARD series is the least in width which can effectively decrease the distance of side pile when in normal pile pressing. The components are easily disparted and transported.

5.

The novel overall layout and special compact mechanism can deal with not only the side pile near the building wall but also the troublesome corner pile. It improves the adaptability of SUNWARD pile drivers evidently.

(It should be pointed out that the deed of many domestic factories’ currently copying the above patents is illegal.) Ⅱ WELL-CHOSEN OUTSOURCED PARTS TO IMPROVE RELIABILITY

Quality of the outsourced parts is very important to performance of the whole pile driver. In order to improve the pile driver’ performance, SUNWARD would rather use the outsourced parts of high price. For example, our oil cylinder is made in well-equipped professional factory according to our design; hydraulic pump is high pressure auto variable piston pump; crane windlass and hydraulic motor for rotary are made in Sino-foreign joint venture company with introduced technique; the balance valve and other key valves are ordered from noted foreign company. Ⅲ IMPROVEMENT OF TECHNICS AND THE MANUFACTURE OF EQUIPMENT, ASSURING THE QUALITY OF PARTS

Sunward pay special attention to the improvement of technics and the manufacture of equipment .The key structures are made from high quality 16Mn steel plate which is cut with auto cutter and welded by CO2 gas-proof welding technique. To improve performance of the large components such as pile-clamping box and guidance beam, location surface and guidance surface are mechanically machined without cost consideration; and assure the heat-treatment of key parts. Ⅳ STRONG TECHNIC POWER, UPDATING PRODUCTS

QUICKLY

The staff of Dept. of Research and Development is mainly from the Central South University Mechanical and Electrical Institute. They are of creative talent and spirit. Our institute has a CAD designing room of several hundreds of square meters and a laboratory of the similar size. We provide optimum condition for research and development. ZYJ series static pile drivers are all designed by advanced CAD technique. In a word, Sunward has created a complete and innovative designing and manufacturing system which is also capable of quick response to market changes. With the rapid developing pace, Sunward is leading the world’s static pile driver market.

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ZYJ 460B-Ⅱ Operator’s manual

3 BASIC STRUCTURE AND WORK PRINCIPLE 3.1 BASIC STRUCTURE OF ZYJ460B-Ⅱ

FIGURE 3-1 ZYJ460 B-Ⅱ PILE DRIVER 1. Side piling device--- to press side pile 2. Pile driver main cabin--- to protect operator 3. Operating platform--- the main working mechanism 4. Clamping box --- to clamp pile

5. Crane---to lift heavy parts ( e.g. pile, counterweight)

6. Vertical motion mechanism--- vertical motion of machine body 7. Cross motion and rotation mechanism---to travel transversely and rotate 8. Longitudinal motion mechanism---to travel longitudinally 9. Counterweight beam---to support counterweight 10. Assistant counterweight beam --- to support counterweight 11. Assistant cantilever--- to support assistant counterweight beam 19

ZYJ 460B-Ⅱ Operator’s manual

3.2 PILING PLATFORM 3.2.1 STRUCTURE Piling platform is machine’s main working mechanism capable of clamping and pressing piles. Its structure is as FIGURE 3-2.

FIGURE 3-2 STRUCTURE OF PILING PLATFORM 1- Chief pile pressing cylinder 2- Secondary pile pressing cylinder 3- Pile pressing cross beam 4- Pile pressing upright prop 5- Pile clamping box 6- Pile pressing spherical head 7- Pile pressing seat

FIGURE 3-3a STRUCTURE OF PILE CLAMPING BOX JZX6014 20

ZYJ 460B-Ⅱ Operator’s manual 1- Pile clamping box body 2- Guide wheel 3- Pile clamping cylinder 4-Jaw 5-Jaw seat 6-Pile clamping block 7-Connection block A 8- Intermediates

9- Connection block B

FIGURE 3-3b STRUCTURE OF PILE CLAMPING BOX JZX6028 1. Hydraulic pipeline 2. Pile clamping box body 3. Guide wheel 4. Pile clamping cylinder

5.Jaw

Attention: These two pile clamping box according to customer requirements, both optionally a. 3.2.2 PILE PRESSING PROCESS When it starts to press precast pile, the chief pile pressing hydraulic cylinder raises the clamping box to the highest position. When the precast pile is put into the central hole in the box, clamping cylinders extend and drive the jaws to clamp the pile. After that，operate the handle of the pile pressing valve to make the chief pressing hydraulic cylinder work and strong hydraulic force will be produced to press the pile into ground. When the clamping box reaches the lowest position, the clamping cylinders draw back and release pile. Then pressing cylinders raise the clamping box to the highest position to start pressing pile again. So the precast pile is pressed into the ground base step by step in the cycle of “clamp pile→ press pile→ release pile→ return→ clamp pile …”. The chief pile pressing cylinder shall work alone if the needed pressing pressure is lower than P1. （See appendix table 8-1）If the needed pressing pressure is over P1, the chief and secondary pile pressing cylinder must work together.

21

ZYJ 460B-Ⅱ Operator’s manual （highest position） Clamp pile

（decline）Press pile

lift

Release pile （lowest position） FIGURE 3-4 PILE PRESSING CYCLE

3.3 TRAVEL MECHANISM It is a step-like traveling mechanism including vertical motion mechanism, longitudinal motion mechanism, cross motion and rotation mechanism. By the three mechanisms, continuous step-like travel can be carried out. 3.3.1 VERTICAL MOTION MECHANISM It is mainly composed of four vertical motion cylinders and four cantilevers. The four cylinder tubes are fixed by the four cantilevers to the machine body, and one end of their rods are jointed with four wheel carriers in long ship slideway. When the piston extends, the main body rises, otherwise it falls. NOTE: Before the vertical motion cylinder telescopic, first make sure the cut-off valve which on cylinder balancing valve is in open state.

Figure3-5 Structure of vertical motion mechanism 1-Cantilever 2- Vertical motion cylinder

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ZYJ 460B-Ⅱ Operator’s manual

3.3.2 LONGITUDINAL MOTION MECHANISM It’s composed of two long ship slideways, two longitudinal motion cylinders joined to it and four wheel carriers. When the piston of cylinder stretches out or draws back, there is relative motion between the main body and long ship slideway.

Figure 3- 6 Structure of longitudinal motion mechanism 1- Wheel carrier 2- Longitudinal motion cylinder 3- Linkage cylinder 4- Long ship slideway

3.3.3 CROSS MOTION AND ROTATION MECHANISM It’s composed of two short ship slideways, two cross motion cylinders, rotary platform, central axis and return spring mechanism

. Figure 3-7 Structure of cross motion and rotation mechanism 23

ZYJ 460B-Ⅱ Operator’s manual 1- Short ship slideway 2- Wheel carrier 3- Return spring 4- Central axis hole 5- Rotary platform 6- Cross motion cylinder

3.3.4 CONTINUOUS STEPPING AND ROTATION

Figure 3- 8 Structure of travel mechanism 1- Cross motion cylinder 2- Vertical motion cylinder 3- Longitudinal motion cylinder 4- Long ship slideway 5- Short ship slideway 3.3.5 LONGITUDINAL MOTION Vertical motion cylinders draw back and short ship slideways support the machine, long ship slideways leave ground；longitudinal cylinders stretch or draw together, and long ship slideways move; vertical motion cylinders stretch out till long ship slideways touch ground and short ship slideways leave ground; longitudinal cylinders stretch or draw together, then body and short ship slideways move longitudinally. ⑴

short ship sideways down ⑵ Long ship sideways up

⑴ ⑵ ⑶ ⑷

short ship sideways down ⑶

short ship sideways up ⑷

short ship sideways up

Long ship sideways up Long ship sideways up Long ship sideways up (Long ship sideways longitudinal motion) (main machine body walk)

Vertical motion cylinders retract Longitudinal motion cylinders act Vertical motion cylinders extend Longitudinal motion cylinders act 24

ZYJ 460B-Ⅱ Operator’s manual

Figure 3-9 Longitudinal motion cycle

3.3.6 CROSS MOTION Vertical cylinders stretch out till long ship slideways touch ground and short ship slideways leave ground; cross cylinders stretch or draw together, and short ship slideways move; vertical cylinders draw back till short ship slideways touch ground and long ship slideways leave ground; cross cylinders stretch or draw together, then body and long ship slideways move transversely. short ship sideways up ⑴

⑵ Long ship sideways down

⑴ ⑵ ⑶ ⑷

short ship sideways up short ship sideways down (short ship cross motion) ⑶ ⑷ Long ship sideways down

Long ship sideways up

short ship sideways down (main machine body walk) Long ship sideways up

Vertical motion cylinders extend Transverse motion cylinders Vertical motion cylinders retract Transverse motion cylinders Figure 3-10 Cross motion cycle

3.3.7 ROTATION There are five steps to carry out rotation. In every rotation, rotary angle is between 8°-11°. Rotating procedure( see figure 3-11 and 3-12) Step 1: Get the pile driver ready. Step 2: Long ship slideways touch the ground, short ship slideways are lifted, cylinders in short ship slideways go to the end vis-a-vis. Step 3: Short ship slideways touch the ground, long ship slideways are lifted, cylinders in short ship slideways go to the end vis-a-vis( the direction is opposite to that in Step 1). If the clearance between short ship slideways and long ship slideways is smaller than the stroke of cylinders, the cylinders just need to go to the end of the clearance. Step 4: Long ship slideways touch the ground, short ship slideways are lifted, short ship slideways and rotary platform rotate around central axis and get back to original place when rubber spring in rotary platform flexes. Step 5: Long ship slideways touch the ground, short ship slideways touch the ground, then return to original position.

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ZYJ 460B-Ⅱ Operator’s manual

Figure 3-11 Rotating manner

short ship sideways up ⑴

⑵

short ship sideways up short ship sideways down short ship sideways down (short ship move in opposite directions) (main machine body walk) ⑶ ⑷

Long ship sideways down Long ship sideways down

⑴ ⑵ ⑶ ⑷

Long ship sideways up

Long ship sideways up

Vertical motion cylinders extend Transverse motion cylinders Vertical motion cylinders retract Transverse motion cylinders Figure 3-12 Rotation cycle

3.4 HYDRAULIC SYSTEM ( FOR PILE PRESSING) 3.4.1 STRUCTURE It is mainly composed of two pressure compensation variable pumps, three groups of manual multidirectional valves，several oil distribution valve blocks and hydraulic cylinders as well as some other supplementary hydraulic equipment.

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ZYJ 460B-Ⅱ Operator’s manual

Figure 3-13 Hydraulic cylinders of pile driver 1- Cross motion hydraulic cylinder

2- Longitudinal motion hydraulic cylinder

3- Vertical motion hydraulic cylinder

4- Pile clamping hydraulic cylinder

5- Pile pressing hydraulic cylinder MULTI-DIRECTIONAL VALVE Operators use the four operation handles of multi-directional valves to operate the pile driver.

Figure 3-14 Three groups of manual multi-directional valves 1- Multi-directional valve A 2- Multi-directional valve B

3- Multi-directional valve C

Multi-directional valve A ---- It controls the extension and retraction of vertical motion cylinders 27

ZYJ 460B-Ⅱ Operator’s manual

to adjust the altitude and level of platform, and to make the short and long ship slideways touch or leave the ground. Multi-directional valve B ---- It controls the job of pile pressing, pile clamping, pile releasing and the rise and drop of clamping box. Multi-directional valve C ---- It controls the stepping and rotary motion of pile driver.

3.4.2 WORK PRINCIPLE (see appendix figure 1 hydraulic system) （1） Travel by hydraulic control Operators use four operating handles of multiunit valve C to control the stepping of pile driver.

Figure 3-15 Hydraulic system for traveling 1-Multi-directional valve C

2- Walking steel

（2） Hydraulic system for vertical motion Operators use four operating handles of multiunit valve A to control the vertical motion of pile driver.

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ZYJ 460B-Ⅱ Operator’s manual

Figure 3-16 Hydraulic system for vertical motion 1- Multi-directional valve A 2- Valve seat 3- Valve seat

4- Vertical motion mechanism

（3） Hydraulic system for clamping pile Operators use the multiunit valve B to control the job of clamping and releasing pile.

Figure 3-17 Hydraulic system for pile clamping 1- Multi-directional valve B

2- Valve seat

（4） Hydraulic system for pressing pile

29

3- Clamping box

ZYJ 460B-Ⅱ Operator’s manual

Figure3-18 Hydraulic system for pressing pile 1- Multi-directional valve B 2- Valve seat 4- Pile pressing hydraulic cylinder 5- Pipeline

3.5 SIDE PILING AND CORNER PILING When pressing side or corner pile, use crane to lift the clamping box and pile pressing cross beam (including pile pressing cylinder) to side pile upright prop and assemble them, then install them with hydraulic hoses. It can work now. The operating procedures for pressing side pile are the same with those of when pressing site is in the middle of pile driver.

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ZYJ 460B-Ⅱ Operator’s manual

Figure 3-19 Side pile frame 1- Pile pressing beam 2- Clamping box 3- Side pile column

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ZYJ 460B-Ⅱ Operator’s manual

Figure 3-20 Hydraulic system for clamping side pile 1- Multi-directional valve B 2- Valve seat C 3- Transition steel pipe 4- Clamping box

Figure 3-21 Hydraulic system for pressing side pile 1- Multi-directional valve B 2- Valve seat A 3- Transitional steel pipe 4- Pile pressing platform 3.6 ELECTRIC SYSTEM The machine is connected with three phase standard electrical supply AC380V, 50HZ. Three oil pumps provide power. Two oil pumps with large power adopt the method of Y△ to decrease the current impact to engine. This electrical system has some security measures for short circuit, overload and phase failure, electrical leakage, ground connection and so on. To ensure machine’s 32

ZYJ 460B-Ⅱ Operator’s manual

safe work, there is alarm system for “lifting machine”( see figure 3-22) Safety rules: to ensure personal safety and equipment safety, the whole machine body must connect ground firmly and the earth resistance must be kept below 4 ohm. Appendix figure 2 shows the principle of electrical system.

3.6.1 COOLING DEVICE FOR HYDRAULIC OIL In hydraulic system long time running, once oil temperature over 60℃ and temperature switch test it, machine will warn operator to open cooling device. Start filtering pump at first, then open cooling fan, and open cooling device. After that, buzzer warning will stop. 3.6.2 HEATING DEVICE FOR HYDRAULIC OIL (FOR NORTH USERS) Hydraulic oil viscosity will be high in low surrounding temperature, which will make hydraulic pump suck air or increase load, open heating device under this condition. Hydraulic oil temperature meter will test oil tank temperature automatically. When temperature is less than -15℃, connecting electric heating circuit; after temperature reaching 35℃, cut off circuit and stop heating. In hot weather, put heating power switch OFF to prevent miss-heating.

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ZYJ 460B-Ⅱ Operator’s manual

4. OPERATING REGULATIONS 4.1 CONTROL PANEL Operators use the push buttons and joy sticks in the control board to operate the machine. （The joysticks are numbered as S1～S4，Y1～Y4，Z1～Z4）

Figure 4-1 Control panel Z1、Z2—to control two cross motion cylinders Z3、Z4—to control two longitudinal motion cylinders Y2—to control the chief pile pressing cylinder Y3—to control the secondary pile pressing cylinder Y4—to control pile clamping hydraulic cylinder S1～S4—to control four vertical motion cylinders Y1-to choose piling speed （Attention ：When piling pressure is higher than 10MPa, it is not allowed to press pile quickly）

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ZYJ 460B-Ⅱ Operator’s manual

Figure 4-2 Location of push-buttons 1- Voltmeter 2-Ammeter 3- Pump 1 on/off 4- Pump 2 on/off 6-Filter pump fan on/off 7-Oil cooling 8- Buzzer 9- Oil temperature meter (for northeast users) 10- Indoor light switch 11- Outdoor light switch 12-Electric fan 13- Oil heating indicating light (for northeast users)

4.2 PREPARATION BEFORE PRESSING PILE 4.2.1 PREPARATION BEFORE START-UP 1．Examine if maintenance and repair meet the requirements. 2．Remove the dirt on the wheel carrier track, spread with clean grease. 3．Examine if the oil level in tank is normal. 4．Detect if the voltage is normal (not larger than 400v and not less than 350v). 5．Detect if there is electric leakage. 6．Detect if there is oil leakage of hydraulic pipeline. 7．Check and tighten the joint bolt between clipping jaw and clipping seat. 8．Check if the ball valve on pump suction port is open. 9. Run the pump one by one, examine if the electric current and oil pressure are normal when every pump works alone. 10.Check if the wire rope is reliable.( if the pile driver is equipped with crane.) 11．Simulate piling process. Examine hydraulic system and oil pressure, cylinder and main motion mechanism. Assure they are at normal. 12．Assure that no abnormal phenomena are found, abnormities have been disposed correctly, and potential factors of malfunction and security are all cleared up. Then begin piling work.

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ZYJ 460B-Ⅱ Operator’s manual

4.2.2 ADJUSTMENT OF PRESSURE

Figure 4-3 Location plan of overflow valve Overflow valve F9 (see Figure 4-3) is used to adjust rated pressure of the hydraulic system. Set pressure of F9 as follows: After oil pump works normally, push handle Y3 to “(return)” position, screw down adjustment nut of F9 slowly, watch pile clamping oil pressure meter, when the oil pressure is increased to Pa, the rated pressure adjustment finishes. Then screw down the stop screw of adjusting nut. Overflow valve F15 (see Figure 4-3) is used to set secondary pile pressing pressure Pd, which can be set according to different needs (see appendix table 8 oil pressure and pile pressing force). 36

ZYJ 460B-Ⅱ Operator’s manual Adjust pressure of valve F15 as follows: Start pumps till they run steadily; push the handle Y1 to the position of “normal pressing “, handle Y2 to the position of “pressing”, and handle Y3 to “add force”; after secondary press cylinders stretch to stroke end, gradually screw down adjusting nut of F15; observe the oil gauge on control panel; when the gauge directs to the needed value Pd, the adjustment is done. Using the same methods setting F16. Overflow valve F1 (see Figure 4-4) is used to set main pile pressing pressure. It is set as PF1 ≤PF9. Adjust pressure of valve F1 as follows: Start pumps till they run steadily; push the handle Y1 to the position of “normal pressing”, handle Y2 to the position of “pressing”, after main pile pressing cylinders stretch to stroke end, gradually screw down adjusting nut of F1; observe the oil gauge on control panel; when the gauge directs to the needed value, the adjustment is done. Overflow valve F2 (see Figure 4-4) is used to set quick piling pressure. It is set as value PF2 ≤10Mpa. Adjust pressure of valve F2 as follows: Start pumps till they run steadily; push the handle Y1 to the position of “quick pressing” and handle Y2 to the position of “pile pressing”; after the piston rod of chief pile pressing cylinders stretch to stroke end, gradually screw down adjusting nut of F2; observe the oil gauge on control panel; when the gauge directs to 10Mpa, the adjustment is done. 4.2.3 ADJUSTMENT OF OIL PRESSURE FOR CLAMPING AND RELEASING PILE Overflow valve F3 (see Figure 4-4) is used to set pile clamping pressure. It is set as PF3≤ PF9. Adjust pressure of valve F3 as follows: Start pumps till it runs steadily; push the handle Y4 to the position of “clamping pile”; gradually screw down adjusting nut of F3; observe the clamping oil gauge on control panel; when the gauge directs to needed value Pe, the adjustment is done. The needed oil pressure for clamping is relevant to material and surface condition of piles. It should be decided according to practical condition. If clamping is reliable, the set value should be kept low.

Figure 4-4 Location plan of overflow valve Overflow valve F13 (see Figure 4-3) is used to set pile releasing pressure. Adjust pressure of valve F13 as follows: Start pumps till it runs steadily; pushes handle Y4 to pile releasing position, observe pile releasing oil gauge, if the gauge value directs to 5-10Mpa, the adjustment is done. In the operation, the releasing pressure is permitted to be set more than 5-10Mpa, but it should be less than pile clamping pressure. Attention: After any adjustment, please push handle to neutral position.

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ZYJ 460B-Ⅱ Operator’s manual

4.2.4 ADJUSTMENT OF HYDRAULIC PUMP Adjust the hydraulic pump of main machine according to the following steps. (see figure 4-5)

Figure

4-5 Main machine hydraulic pump adjustment

（1） Place the handles of 3 multidirectional valves on neutral position, the hydraulic system unloads (pull any multidirectional valve handle, the machine will start to work). （2） Screw off plug of pump variable head ( see figure 4-6) ; screw the limitation screw, adjustment screw of overflow valve F9 as loose as possible. （3） Start oil pump, the variable head scale pointer should point at the full scale (10) position, the pump supplies oil at full flux. （4） Push handle Y3 ( see figure 4-5 ) to “Return” position. （5） Screw down adjustment screw of overflow valve F9. At the same time, watch the pressure gauge, the oil pressure will be increased to Pb. （6） Unscrew the pump’s adjustment sleeve till dial needle of pump variable head begins to swing, then screw down adjustment sleeve. （7） Screw down adjustment screw of overflow valve, till oil pressure is increased to Pa. （8） Screw in pump limitation screw slowly, ensure that the pointer of pump variable head points at X. Then lock with locknut and screw in plug. （9） Push handle Y3 to neutral position. The adjustment is finished now. Then the pump’s flow and pressure vary automatically according to the curves of quasi-constant power characteristics. (see Figure 4-7 ) See the appendix table 8-7 for the specific value of Pb, Pa and x. 38

ZYJ 460B-Ⅱ Operator’s manual

Figure 4-6 YCY series hydraulic pump variable adjustment mechanism

Figure 4-7 Curves of quasi-constant power characteristics Q- Flow P- Pressure

Note: According to different models or customer orders, hydraulic pump models are also different. The A7V series hydraulic pump pressure-flow curves have been adjusted well in factory, don’t need the adjustment. 4.3 OPERATION METHOD AND STEPS 4.3.1 START-UP （1） Turn on the air switch. Turn on the power with key and be sure the all handles of multidirectional valve are in the neutral (off load position). （2） First start one pump. After several seconds the green indicator light turns on. （3） Start another pump when the green indicator light turns on. (The interval is about 8 seconds.) （4） High temperatures in the summer time and machine can turn on the filter pump. If the cooling performance is poor attention on the cooling fan pump. （5） Start 3 pumps one by one. Have them work for 3 minutes in the condition of no load. If no abnormalities happen, continue the following procedures. （6） Push the handle Y4 to the position of “Releasing pile”. Then oil pressure rises. If the oil gauge labeled “pile pressing pressure” and “pile clamping pressure” shows the normal pressure, push Y4 to the neutral. Then the job of start-up is finished. 4.3.2 POSITIONING PILE Operate four stepping handles Z1~Z4 and four vertical motion handles S1~S4 to ensure correct pile placement by the pile driver’s rotation, longitudinal and cross motion. Before pressing pile, operate vertical motion handles S1～S4 to have the piston rods of four vertical motion cylinders extend and long ship slideways land on the ground, short ship slideways leave the ground. Then positioning pile is finished. 4.3.3 LEVELING In order to ensure the verticality of piles, the main body of the pile driver should be kept 39

ZYJ 460B-Ⅱ Operator’s manual horizontal, which can be achieved by operating four vertical motion handles S1~S4 and at the same time observe if the omnidirectional gradienter on the operating panel shows zero. If it shows zero, adjustment is finished. 4.3.4 PRESSING PILE 4.3.4.1 OPERATING METHOD Operate the handles Y1~Y5 to carry out pile pressing.( see§3, 4.2) Handle Y5 is used to clamp and release pile. When clamping pile, push handle Y5 to position of clamping pile. After clamping oil pressure reaches the set value, push the handle to middle position. If clamping oil pressure drops down during pressing pile because of clamping too long, it should be done to push the handle Y5 to clamping position again to get clamping force. To release pile, push handle Y5 to releasing position. After oil pressure reads zero, push the handle to middle position. The combination use of handles Y1,Y2 ,Y3and Y4 can perform functions of “quick piling”, “ pressing pile”, “adding force” and “lifting pile”. The former four functions are four modes of pressing pile. They are different in piling speed and piling force. （1） “Quick piling” refers to that the two chief piling cylinders are switched to special circuit, and press pile quickly at a speed higher than that limited by pump displacement. To perform quick piling, push handle Y2 to pressing pile position and handle Y1 to quick piling position. （2） “Pressing pile” refers to that the two chief piling cylinders take part in piling work at the speed corresponding to pump displacement. To perform piling, push handle Y2 to piling position and handle Y1 to normally piling position. （3） “Adding force” refers that two chief piling cylinders and two or four secondary piling cylinders take part in piling work together. When pile pressing force is balanced by the drag force on pile driver from the ground (oil pressure for pressing pile reaches Pa(24.5MPa)), the two or four secondary pile pressing cylinders should be used to add force. Push handleY3 and Y4 to position of adding force, the secondary cylinders stretch out. Handle Y1 must be in the position of normal piling and handle Y2 in piling position. After finishing a piling stroke, push handle Y3 and Y4 to return position. After the rod draws back, then perform “lifting pile”. ATTENTION: When the piston rods of secondary pile pressing cylinders stretch out to add force on pile clamping box, Y1 must be in the position of “normal pressing”, Y2 in “piling” position. （4） “Lifting pile” refers to lifting clamping box.. First put Y1 in the middle position, then push handle Y2 to lifting position. Clamping box is lifted to the highest position. Push Y4 to the middle position from the position of releasing pile and clamping oil pressure reads zero. （5） Rapid returning operation: When the chief pressing-in cylinder and a pair or two pairs of secondary pressing-in cylinder work together, the return operation after pressing a stroke only need push Y2 to lifting position when Y1 in the middle position. If clamping stagnation, can accord to the “Lifting pile” operating, that is push the participation cylinder handle to the lifting state

4.3.4.2 PRESSING PILE PROCEDURES When piling a set of piles into ground, with the increasing depth and geological change the pressing force becomes larger and larger. In order to improve efficiency, reduce power consumption, assure piling quality and protect pile driver, the steps for pressing a set of piles are to be taken as follows: 40

ZYJ 460B-Ⅱ Operator’s manual a) The first 1-2 stroke uses “pile pressing” in order to assure the piling verticality and find out the ground geology. b) After 1-2 piling stroke, if the oil pressure is lower than 5MPa, use “quick piling” until oil pressure reaches 10Mpa. Then use “pile pressing” again. Changing from “pile pressing” to “quick piling”, the displayed pressure value on the gauge will rise. Changing from “quick piling” to “pile pressing”, the displayed value on the gauge will drop. c) After 1-2 piling stroke, if the oil pressure is higher than 5 MPa, do not use “quick piling”. d)

If oil pressure reaches Pa (24.5MPa)during piling, then use “adding force”.

e) If oil pressure reaches Pa(24.5MPa)during adding force, then the piling force has reached rated force, and the job of piling a set of piles has completed. WARNING： Before pressing pile, there must be enough counterweight on the pile driver; pile pressing force should not exceed 460 tf. If the counterweight is not enough or the pile pressing force is too large, the accident of “lifting machine” will occur. If the electric bell alarms, which warns that “lifting machine” occurs, immediately push handles Y1, Y2 and Y3 to middle position. All personnel except operator should leave away from the pile driver and keep a least distance of 2-3 meters; After the oil pressure gradually drops down to zero and long ship slideways touch ground, push handle Y4 to position of releasing pile; When “lifting machine” occurs, absolutely prohibit pushing handle Y4 to releasing pile position first. If the clamping oil pressure drops during the process of slowly releasing the piling pressure, it must be done to push handle Y4 to position of clamping pile for load. When “lifting machine” occurs, it is also prohibited to operate the crane. If the crane has been lifting objects, the objects should be unloaded. When the accident has been solved, the pile driver should be paused to find out causes of “lifting machine”. Before continuing work, measures must be taken to prevent the accident of “lifting machine”. Sunward shall not be responsible for any legal or economic responsibility caused by “lifting machine”. “Lifting machine”------referring to that the main body and long ship slideways are lifted off ground because of not enough counterweight or piling force exceeding the rated force.

“Machine falling down”---when pressing pile, pile pressing cylinders release piles abruptly, so that pile driver loses support and falls down suddenly. It can cause serious injury to personnel and the machine itself.

ATTENTION 1. In normal condition, it is not allowed to pull pile with pile driver. Pulling pile refers to pulling out the pile that has been pressed into ground. If there is special condition and it is necessary to pull pile with pile driver, you must make sure that the pulling force is less than P2tf, the system oil pressure is less than Pa, and weight of pile driver with counterweight is less than P3tf. Otherwise partial counterweight should be removed. When pulling pile, short and long ship slideways should be layed down on ground and nobody is permitted to stand under clamping box. After finishing pulling work, check the joint seat between chief cylinders and clamping box whether it is normal or not. If pile driver inclines during pulling pile, the pulling work should immediately be stopped. 2. If piling pressure exceeds 10Mpa, push handle Y2 to middle position to release pressure， 41

ZYJ 460B-Ⅱ Operator’s manual then push handle Y4 to the position of releasing pile. If four cylinders work together, the handle Y3 should also be pushed to middle position to release pressure. After piling oil pressure gradually drops down, push handle Y4 to position of releasing pile. Otherwise, great impact would occur! Sunward is free from any responsibility for such incorrect operation. 3. If pushing handles has to be done or has been done, please remember, at any moment, do put all handles of multidirectional valve to the middle position to unload, which will help to save energy, reduce the generation of heat, protect pile driver and assure safety operation. 4. When working at reconstruction site, especially at the bricks or blocks largely imbedded stratum, form holes with steel pile first to avoid possible pile break. 、4.3.5 ATTENTION  Pay attention to the verticality of piles and the leveling of machine body during pressing pile.  Operate handles and buttons gently avoiding rough operation.  Check at any time whether oil pressure and oil temperature are normal. (The max. oil pressure should be Pa, oil temperature between 35°～85°). If any abnormalities occurs, stop machine

immediately to dispose abnormalities.  A set of pile to be inserted into the same location must be completed continuously. If there is a

long break during the process, the pile inserted in ground might solidify with the ground earth. When piling process resumes, the oil pressure would increase sharply.  When pile driver moves, rotates, or rises and falls in large range, it must be guided, cooperated

with ground personnel. The operator must keep close watch on the pile driver motion and communicate with the ground personnel in time. If there is any abnormality, immediately push the valve to middle position.  When pile driver moves, rotates, rises or falls, if oil pressure increases, it indicates the related

cylinder has gone to stroke end. Immediately push the valve to middle position.  While pile driver moves or rotates, the electrical cable should not be pressed by long or short

ship slideway, or blocked by obstacles for which the electrical cable can not move with the pile driver.  Electrical cable can neither be grinded by trucks nor covered by objects.  While pile driver runs, pay attention to the hoses linked to long and short ship slideway, assure

they are not stumbled or blocked by other parts, in case the hose might be pulled broken.  If a sunk accident occurs while pile driver runs, operator must lay down the long and short ship

slideway to touch the ground, remove the counterweight from pile driver, and then dispose the accident. The counterweight of inclined side should be removed first.  When pile pressing cylinders are working, it is prohibited to release pile.

Sinking accident--- It means that pile driver sinks into the ground because the soft ground cannot support. At that time the pile driver cannot move by itself. 4.3.6 CABLES ACCESS PHASE SEQUENCE (DUE TO THE SPECIAL REASON, N MAY CHANGE.) 1. Cable access pile pressing machine, marked with the N connected to the zero line. 2. After the three-phase line access, if the pump steering does not meet the requirements, adjusting the phase sequence.

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ZYJ 460B-Ⅱ Operator’s manual

Marked N connecting to zero line

Fig 4-8 Main circuit breaker

4.3.7 OIL COOLING OPERATION Part 3 in figure 4-2 control Oil cooling fan . 1. Rotating part 3 to the left is close, oil cooling fan can’t work, 2. Rotating part 3 to the right is open, there are two states: If the Part 6 in fig 4-2 didn’t start-up, oil cooling fan can’t work; It the Part 6 in the 4-2 stat-up, oil cooling fan and filter pump working together.

4.4 INSTALLATION AND REPLACEMENT OF CLAMPING JAW 4.4.1 INSTALLATION We produce two types of clamping box, one is round & square clamping boxes, the other is thin-wall tube pile clamping box with cylinder installed vertically. See the following pictures for installation manner. The installation of clamping jaw for thin wall tube pile (see Figure 4-9): fix the inner clamping jaw on clamping jaw seat by inner hexagonal bolts. When outer jaw is needed, fix it together with inner jaw on jaw seat by appropriate inner hexagonal bolts.

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ZYJ 460B-Ⅱ Operator’s manual

Figure 4-9 Clamping jaw installation for thin wall tube pile ①Pile clamping cylinder ②Cylinder flange ③Connection nut ④Pulling rod ⑤Connection block ⑥Outer jaw ⑦Inner jaw ⑧Jaw seat ⑨Pile clamping block ⑩ ⑾ ⑿ Inner hexagonal bolt a—Spring Return installation hole b—Hook bolt hole The installation of clamping jaw for round & square pile(see Figure 4-10): fix the inner jaw to cylinder directly by inner hexagonal bolts. When outer jaw is needed, fix it to jaw seat together with inner jaw by appropriate inner hexagonal bolts.

Figure 4-10 Clamping jaw installation for square & round pile ① Pile clamping cylinder base ② Pile clamping cylinder ③ Inner clamping jaw ④ Outer clamping jaw ⑤ Block plate ⑥ Location pin ⑦ Inner hexagonal screw a--- handling hole

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ZYJ 460B-Ⅱ Operator’s manual

4.4.2 REPLACEMENT OF CLAMPING JAW When replacing jaws, remove upper clipping jaws first, then the lower clipping jaws. To dispart jaws, first attach the lifter hook on clamping jaw, then loosen the joint bolt between jaw and its seat, and pull the jaw out. When install jaws, install lower clipping jaws first, then the upper clipping jaws. To install clamping jaws, first attach the hook on jaw and pull the jaw into the hole of clamping box, then fix the jaw on its seat with joint bolt and tighten the bolt. NOTE：Jaw configuration of pile clamping box ,see schedule 8-7A、8-7B. WARNING: 1. Prohibit commanding and observation personnel from standing under the clamping box. 2. Reliable lifting equipment is necessary when replacing clamping jaw.

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ZYJ 460B-Ⅱ Operator’s manual

5ASSEMBLY, MAINTENANCE

DISASSEMBLY,

TRANSPORTATION

AND

5.1 ASSEMBLY The first installation and adjustment of pile driver should be carried out under cooperation and direction of Sunward company’s engineering personnel or the authorized technician. After pile driver is installed, do maintenance well according to regulations. Adjust and examine the pile driver according to operation regulations. a

Required disassembly space 1.

space occupied by pile driver itself;

2. space for transport vehicles going in and out to dump; 3.

space for lifter over 25 tons going in and out to lift components.

b

Requirement to the geological conditions of disassembly site： The plainness and hardness of ground should meet the requirement for truck about 50 tons and lifter over 25 tons.

Pile Driver Assembling Process： 1. Lift longitudinal motion mechanism to mounting position, see Fig 5-1.

Fig 5-1

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ZYJ 460B-Ⅱ Operator’s manual

Fig 5-2

2. Running carrier vehicle within largest part to longitudinal motion mechanism center, see fig 5-2 （no carrier vehicle showed in fig）. 3. Lift vertical motion mechanism by crane, mounting related hydraulic pipelines, start pile driver. Adjusting the position between lifting cylinder bulb and wheel carrier bulb seat in long ship slideway，connecting them; Running carrier vehicle away. Fig 5-3. Note：Before assembling，clean impurity in all bulbs and bulb seats.

Fig 5-3 4. Lift cross motion and rotation mechanism by crane：Lift short ship slideway and turntable to

suitable position, start pile driver, adjusting the position of machine main body , short ship 47

ZYJ 460B-Ⅱ Operator’s manual slideway and turntable by moving longitudinal motion mechanism and vertical motion mechanism, connecting them; Connecting related hydraulic pipelines, fitting ladder. See Fig 5-4.

Fig 5-4

Fig 5-5

5. Lift clamping pile box by crane，adjust its assembling position；then hoist beam, connect

related hydraulic pipes, start pile driver, mounting pile pressing table by moving pile pressing cylinder, Fig 5-5. 6. Lift counterweight beam by crane，Fig 5-6. 7. Lift counterweight by crane，Fig 5-7.

Fig 5-6

Fig 5-7

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ZYJ 460B-Ⅱ Operator’s manual

Fig 5-8

Fig 5-9

Fig 5-10

Fig 5-11

8. Assembling for side pile and its counterweight： a) Hoist chief pile pressing beam(include pile pressing cylinder) and pile clamping box by crane, and installed on the side pile cushion cap. b) Hoist auxiliary cantilever by crane, see fig 5-9. c) Hoist auxiliary counterweight beam by crane, see fig 5-10. 49

ZYJ 460B-Ⅱ Operator’s manual d) Hoist auxiliary counterweight by crane, see fig 5-11. NOTE: The counterweight placed diagram see §9-figure3

5.2 DISASSEMBLY The disassembling process is inverse of the assembling process. ATTENTION： ① After disassembling counterweight, unscrew the drain plug on main body, long & short ship slideway, and drain the water at first. See Fig 5-13. ② During disassembling，all cylinder piston bars must be retracted to prevent damage in hoisting and shipping period. ③ Before disassembling cross motion and rotation mechanism. Tighten the return spring bolt to separate the reset spring seat and reset seat；after assembling in construction site, unscrew the bolts and make spring seat and reset seat touch. ④

All oil tubes should be plugged in time reliably during disassembling.

⑤

In disassembling, outer touching surface should be oil sealed.

⑥ After disassembling, turntable in cross motion and rotation mechanism and short ship slideway should be fixed. ⑦ Before transportation, draw back the movement parts of crane jib completely, and fix the retractable jib with 2 bolts on fixed jib. If there is low bridge, tunnel etc： a)

Disassemble the small part in crane higher the cabin top；

b)

Disassemble crane slewing support upper part for shipping separately.

Fig 5-12 Water Inlet and Outlet

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ZYJ 460B-Ⅱ Operator’s manual

5.3 TRANSPORTATION 



Because of the great weight, use the decomposition transport. The biggest pieces of transport alone, the rest components flexible locomotive transportation. See Table 5-1 and Figure 5-13. Choose sufficient tonnage trailer.

We provided the main detachable parts weight table (See Table 5-1 Parts weight table) for the user to reference. Convenient for installation, disassembly, lifting, transportation, allocation of vehicles, and to ensure the safety of transport by road, bridge etc.

Table 5-1

ZYJ460B-ⅡParts weight table

PARTS NAME Main machine (without counterweight)

WEIGHT (TON) About 154.5（include 28.6 tons of sand）

Machine body （include parts 34.2 （include that can not or need not be 2.7 tons of disassembled） sand） Max. parts

QY12C crane（without seat）

9.4

Total weight:56.8

QY16D (without seat) (Optional)

10

(include 5.6 tons of sand)

Vertical motion mechanism

3.3X4=13.2 (include 2.9 tons of sand）

Clamping (Alternative)

box JZX6014 JZX6028

Pile pressing cylinder and cross beam Longitudinal motion mechanism Slewing platform

9.79 ( include 1.9 tons of sand) 11.43 ( include 1.6 tons of sand) 3.2X2=6.4 21.6X2=43.2 ( include 10.4

tons of sand)

1.75X2=3.5（1.1 ton of sand）

29.7 ( include 9 Cross motion Short ship slideway 13.1X2=26.2（include 7.9 tons tons of sand ) mechanism (include cylinder and of sand） wheel carrier)

Counterweight beam

2.8X2=5.6（include 2 tons of sand）

Auxiliary cantilever and counterweight 0.24X2+0.15X4=1.1 beam Cast iron F Counterweight counterweight Square counterweight （ Optional） Barite counterweight F Counterweight （Optional）

Square counterweight

6.63X24=159.12 6.41X20=128.2 4.2X24=100.8 3.46 X54=186.84

51

ZYJ 460B-Ⅱ Operator’s manual

Note: 1． The above weight data of all parts is theoretically calculated. The weight data of outsourced parts is also theoretic. There might be a little difference between practical weight valve and theoretic weight value. Normally, the percentage error is within ±6%. 2． The cast iron counterweight is calculated as per 6800 Kg/m3.The barite counterweight is calculated as per 3800 Kg/m3.Customers shall determine the number of square counterweight to buy according to practical conditions and their need. 3． For ZYJ460B-Ⅱ, the main body can be filled with 2 tons of water, long ship slideway can be filled with 10.4 tons, short ship slideway can be filled with 7.4 tons. Total weight of water is 19.8 tons.

FIGURE 5-4 TRANSPORTATION DIMENSION FOR MAX. PARTS OF ZYJ460B-Ⅱ.

5.4 DEBUGGING See §4 OPERATION REGULATIONS for reference. 5.5 DAILY MAINTENANCE AND TIME MAINTENANCE 1. Examine fixing screw bolts for any looseness. Specially pay attention to those fixing screw bolts on the pressing cylinders, vertical motion cylinders, crossing motion cylinders and clamping jaws, as well as the joint screw shaft and screw nuts between cantilever and its seat. Be sure to keep torque moment symmetrical if there are several fixing screw bolts. 52

ZYJ 460B-Ⅱ Operator’s manual

2. Take care to keep the hydraulic system clean. The adding oil of hydraulic system requires special oil adding equipment and the transmissivity of its oil filter should not exceed 20 μ. 3. Lubricate the machine termly. 4. Clean dust and dirty things after work. 5. If it works for the first time, you should change all oil after a month and clear the oil tank. After that, change oil every half a year. (Be sure to clean used oil in tank, tubes and any units) 6. Keep oil return filter clean. If the return oil manometer shows a pressure over 0.4 MPa, clean or change the core of the oil-filter. Clean it every month. 7. Screw down every fixing screw bolt on all pipe connections and units every month. 8. If the color of the oil becomes white and muddy, replace the oil. Otherwise the hydraulic elements will break down earlier than expected. 9. In order to assure the accuracy of the oil gauge, it should be checked periodically. Normally, interval of check is half of a year. When in another work site or the manometer doesn’t point at zero, unscrew the oil-filling plug loose (see figure 7-2 ), when the pressure inside and outside the manometer are the same （it needs about 1 minute）, screw the oil-filling plug tight, then the manometer can work normally. 10．When replacing new pump, you should fill up oil in leakage pipe, connect the pipe with leakage coupler (not screw down), start pump, and screw down coupler nuts when oil leaks from coupler. 5.6 LUBRICATION DIAGRAM Crane

Main machine Parts name

Number of greasing point

Greasing style

Interval

Parts name

Number of greasing point

Greasing style

Interval

Longitud inal motion wheel

16

Grease gun

7days

Wire rope

1

Spreading

7days

Transvers e motion 12 wheel

Grease gun

7days

Radius change shaft

2

Grease gun

7days

Guide wheel of pile 8 pressing box

Grease gun

3days

Upper wire wheel

1

Grease gun

7days

Spheric socket on 8 wheel carrier

Spreading

Change site

Lower wire wheel

1

Spreading

Everyda

Center shaft

Spreading

30days

Pulley block

1

2

53

y Grease gun

7days

ZYJ 460B-Ⅱ Operator’s manual

3days

Riding wheel of 1 telescopi c jib

Grease gun

60days

Spreading

3days

Slewing support

1

Grease gun

30days

Spreading

7days

Slewing wheel gear

1

Spreading

7days

Grease gun

Every shift

Friction surface of rotary

2

Spreading

Guiding wheel track

4

Wheel carrier track

4

Inner part of 16 clamping box Special Attention：

New machine should be replaces oil sucking filter core after 50working hours; then replace in every 300working hours or 3 months. Note： 1． Spread grease with ZG-S graphite calcium-based grease (SY405-65) 2． Injected grease by greasing gun is SY1413-80 lithium-based synthetic grease. 3． 90# gear oil is used to lubricate drum inside（1 liter every time）, replace it at 100 hours operation and at 500 hours operation. ☆

If environment temperature is higher than 20℃, hydraulic oil N68 should be used. If environment temperature is lower than 20℃, hydraulic oil N46 should be used. If environment temperature is lower than -20℃, hydraulic oil N32 should be used.

5.7 Torque for Standard Tightening Parts Thread size Torque(N·m)

M6

M8

M10

M12

M16

M18

M20

M24

M27

M30

Level 8.8

10

24

44

78

190

260

370

640

950

1300

Level 10.9

12

30

62

110

265

365

520

900

1350

1800

【IMPORTANT NOTES】The following does not belong to the warranty scope: 

Unauthorized increase the system pressure;



After the shutdown is not closed fan, electric heater or hydraulic oil heater；



Hanging is not strictly comply with the requirements of the specification； 54

ZYJ 460B-Ⅱ Operator’s manual 

Pile driver moving does not ensure long ship slideways or short ship slideways off the ground，and encounter obstacles in the range of movement；



Before the telescopic of stabilizer cylinder，not sure the check valve of the stabilizer balance valve is in the open state.

6 CRANE QY crane is installed in ZYJ hydraulic static pile driver as a pile lifting device, which is an auxiliary device. The crane’s structure is similar to the superstructure of general hydraulic truck crane and it is mainly composed of jib system, windlass system, slewing, and hydraulic control systems. The superstructure of crane is installed in the machine frame, which is connected with the inner part of slewing support, while the outer circle of slewing support is connected with the base of crane. The crane base is welded on the main machine of ZYJ hydraulic static pile driver.

6.1Attention 

The main machine operator and crane operator should keep good communication and observation for each other. Prohibit operating crane or hoisting objects while the machine moves or rotates. And also, prohibit the machine moving or rotating while crane is in operation or hoisting objects.



Ensure firm binding while hoisting pile.



Crane’s winch wire should wrap around the drum for at least 4 circles.



When lifting pile, it is prohibited to stand in the working range of crane.



Check winch wire and pile lifting wire often and replace them if any damage occurs.



Check and screw down the connection bolts at the crane slewing support every 2 months, the screwing down torque is 520NM. Replace them with original SUNWARD bolts if any abnormality occurs.



Lift rated weight within the limitation of jib lifting angle to avoid crane jib overloading.



Before pressing piles, make sure the hook has been separated from the tools for lifting pile. If not, there will be serious accident of the lifter and pile driver. In some special condition, if the crane winch has to be used as pile follower, the speed of giving pile must be higher than the speed of piling.

6.2

BASIC STRUCTURE AND WORK PRINCIPLE

55

ZYJ 460B-Ⅱ Operator’s manual

Fig 6-1 Crane structure 1-Base 2-Hydraulic pump group 3-Countweight oil tank 6- Derricking cylinder 7-Cab 8-Crane platform 9-Lifting hook unit

56

4-Winch unit 5-Jib 10-Lifting pile beam

ZYJ 460B-Ⅱ Operator’s manual

6.2.1 JIB SYSTEM AND ITS EXPANSION

Fig 6-2 Jib structure 1-Main jib 2-Flexing jib

Jib system includes main jib, flexing jib, derricking cylinder, and driving system of expansion jib, etc. When extending or retracting jib, place the jib horizontally and pull out two shafts that fix expansion jib, then pull the operating handle of multidirectional valve to operate the jib expansion motor, so that the expansion jib expands relatively to fixed jib. Note: When extending or retracting jib, the angle between jib and horizon should be less than 10 °. There are two adjustable jib lengths. After the jib length is adjusted, fix the extendable jib on fixed jib with shaft pin and lock bolt.

Fig 6-3 Telescopic drive system

Fig 6-4 Winch Structure

6.2.2 WINCH SYSTEM Winch system is composed of hydraulic motor, reducer, windlass drum mechanism of brake, 57

ZYJ 460B-Ⅱ Operator’s manual windlass wire and pulley block.

Fig 6-5 Slewing Structure

1-Base 2-Slewing mechanism

3-Slewing bearing

4-Crane platform 5-Collecting ring unit

6.2.4 DERRICKING SYSTEM It is used to change the jib angle. The amplitude of QY crane is realized by the extension and retraction of cylinder, so that the horizontal distance between the hook center and slewing center，i.e. the amplitude, changes.

6.2.5 HYDRAULIC SYSTEM

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ZYJ 460B-Ⅱ Operator’s manual

Fig 6-6 Hydraulic System Structure 1—winch system 2—slewing mechanism 3—Multiunit valve 4—Crane cabin 5- Pressure meter 6- Expansion motor 7- Balance valve 8-Hydraulic oil tank 9-Hydraulic pump

See figure 6-6 for hydraulic system.(Hydraulic principle diagram see §6.6 crane hydraulic principle diagram) A hydraulic pump supplies pressure oil; the system pressure is determined by overflow valve of multidirectional valve, the pressure is set as 18Mpa. Manual multidirectional valve includes 4 manual control valves, achieving derricking, winch, slewing, jib extending & retracting, and speed control. Pull multidirectional valve handle and treadle the pedal to achieve smooth derricking, slewing, and windlassing.

6.2.5.1 Adjustment of hydraulic pump See Fig 6-7, adjust the pressure of hydraulic pump as per follows. ① Place all the handles in the crane cabin on neutral position, the hydraulic system unloads (pull any multidirectional valve handle, the machine will be on loading position). ② Screw off plug of pump variable head, adjust the limitation screw, adjusting sleeve, adjusting screw of overflow valve F1 as loose as possible. ③ Start oil pump, the variable head scale pointer should point at the full scale (10) position and the pump supplies oil at full flux. ④ Push the control handle of amplitude cylinder (see figure 6-10) to “fall jib” position till the cylinder retracts to the end (Before you push the handle, take care to watch whether the movement of jib affects other parts). ⑤ Screw down adjustment screw of overflow valve F1 gradually till oil pressure is increased to 13Mpa and screw loose the pump adjustment sleeve till the variable head scale pointer of pump starts to swing. Then lock the adjustment sleeve. ⑥ Continue to screw down the adjustment bolt of overflow valve till the oil pressure increases to 16Mpa. ⑦ Screw down the limitation screw rod of pump gradually till the variable head pointer 59

ZYJ 460B-Ⅱ Operator’s manual points at 8.0 position, then lock with locknut and screw in plug. ⑧ Place the control handle of amplitude cylinder on neutral position. The adjustment of hydraulic pump is finished now. Then the pump’s flow and pressure vary automatically according to the curves of quasi-constant power characteristics.

Figure 6-8 Curves of quasi-constant power characteristics

Figure 6-7 Hydraulic variable adjustment mechanism

In order to meet the requirements of the northeast cold climate, the tank can be selected northeast configuration, heat the oil.(fig6-9)

Fig 6-9 The heating control principle diagram of hydraulic oil tank

6.2. 6 SAFETY DEVICE 1. Jib overload protection Adjust the adjustment screw on derricking hydraulic cylinder equalizer valve (if screw clockwise, the pressure lower; screw anti-clockwise, the pressure higher). The oil pressure which limits the 60

ZYJ 460B-Ⅱ Operator’s manual jib lifting should not exceed 18Mpa to prevent the jib overload. If the jib falls when windlass loads, which means the jib lifting angle is too small, it should be done to lift the jib and then begin to windlass. 2. Hook limitation protection When hook reaches upper limit, the hydraulic system unloads and windlass stops to rise. Its working theory is as follows: When the hook reaches upper limit, hook assembly props up the hammer which is wrapped by wire rope, control switch connected with hammer switches on the electromagnetic valve, then the right position is switched on, overflow valve off-load, the winch lifting stops; pull the winch control handle to falling position, the process switch on control handle switches off the electromagnetic valve, the electromagnetic valve gets back to left position, the hydraulic system works normally, achieving falling hook, and the hook disengages from upper limit（see fig 6-10）

Fig 6-10 Hook limitation protection 1- Connection box 2- Heavy hammer

3. Torque limitation protection for the jib The instruments will display different lengths, appropriate inclination angles, lifting weight and other parameters at real-time. It can also tell the torque limitation weight with the lifted object in the current position. When the torque limitation weight is reached, it will give prewarning and warning to alarm operators. A power switch is installed in the right of instrument panel. After electricity failure, you have to repeat once the movement of switch-on and switch-off to electrify. It starts to work normally when buzzer is sounding. Note: The instrument for torque limitation is optional, if customer needs to buy it, the requirement should be made clear in the purchase contract.

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ZYJ 460B-Ⅱ Operator’s manual

6.3

CRANE OPERATION

Fig 6-11

Control Board

1- Oil pressure gauge for return oil 2-Oil pump on/off 3-Cancel limit button 4- oil pressure gauge for system oil pressure 5-switch for inside lamps 6-switch for outside lamps 7-Fan switch 8-Horn 9-Low power 10-Oil temperature gauge (For northern users) 11-Buzzle 12-Oil heating indicating (For northern users) 6.3.1 PREPARATION BEFORE START-UP ①

Start oil pump electric engine( the start button is in the main cabin), and hydraulic system starts to work.

②

Start derricking cylinder and rotation motor, roll the jib out from vertical motion cylinders, and lower it to the horizontal ground with the angle between the jib and the ground less than 10°.(see figure 6-12)

Fig 6-12 Before jib extends 62

ZYJ 460B-Ⅱ Operator’s manual

③

Start expansion motor and extend the expansion jib to needed length, then fix it to fixed jib with pin rolls and bolts.

④

Operate slewing handle to put the crane jib in the position ready for lifting pile; operate the derricking handle according to lifting weight and put the jib in appropriate height； operate windlass handle to lower lifting hook and start to lift pile or other objects. ( see figure 6-13)

Fig 6-13 Crane in working state

When windlass lifting hook reaches the upper limit, stop the windlass, and operate windlass handle of multiunit valve to unhitch the hook until lifting hook leaves the upper limit heavy hammer.

6.4 MAINTENANCE Proper routine maintenance is extremely important to operator’s personal safety, machine’s normal running and service lifetime. Please carry out routine maintenance to every machine parts. ( see §5.6 LUBRICATION CHART) Check often whether there are loose joint bolts in rotary support, hydraulic rotary mechanism and so on. Tighten loose bolts appropriately. (see §5.7 STANDARD TORQUE TABLE) Check and solve failure in time.(see §7.1 )

6.5

PARAMETER

Table 6-1 MAIN TECHNICAL DATA

Items Max. radius-change moment

QY12 Parameters

QY16 Parameters

65 t·m

90 t·m

12 t

16 t

Max. lifting speed (6 wires)

10 m/min

10 m/min

Max. slewing speed

3 r/min

3 r/min

Max. lift weight

63

ZYJ 460B-Ⅱ Operator’s manual

Max elevation

75°

75°

18 MPa

18 MPa

115 L/min

115 L/min

Lifting power

30 Kw

30 Kw

Rated electric current

57 A

57 A

80YCY14-1B

80YCY14-1B

Y200L-4-30Kw B35

Y200L-4-30Kw B35

Rated pressure for lifting Lifting flow rate(at full flow)）

Hydraulic pump model Electric motor model

Table 6-2A

LIFTING ANGLE AND ALLOWABLE LIFTING WEIGHT FOR 12 TONS Lifting angle

Table 6-2B

Long jib

Short jib

(°)

Lifting weight (t)

Slewing radius (m)

Lifting weight (t)

Slewing radius (m)

0

1.29

16.65

2.57

11.5

20

2.60

15.61

4.44

10.77

30

3.22

14.33

5.32

9.87

40

3.94

12.60

6.35

8.66

50

4.90

10.47

7.73

7.16

60

6.43

8.00

9.90

5.43

65

7.63

6.66

11.6

4.48

70

9.41

5.26

12.00

3.51

75

12.00

3.83

12.00

2.49

76

12.00

3.54

12.00

2.29

77

12.00

3.24

12.00

2.08

78

12.00

2.95

12.00

1.88

LIFTING ANGLE AND ALLOWABLE LIFTING WEIGHT FOR 16 TONS (ORDINARY)

Lifting angle

Long jib

Short jib

(°)

Lifting weight (t)

Slewing radius (m)

Lifting weight (t)

Slewing radius (m)

0

1.90

17.2

3.43

12.3

20

3.87

16.2

6.17

11.6

30

4.83

14.9

7.51

10.7

40

5.93

13.2

9.05

9.44

50

7.41

11.0

11.11

7.92

64

ZYJ 460B-Ⅱ Operator’s manual

Table 6-2C

60

9.72

8.59

14.32

6.16

65

11.51

7.26

16.00

5.21

70

14.17

5.87

16.00

4.21

75

16.00

4.44

16.00

3.19

76

16.00

4.15

16.00

2.98

77

16.00

3.86

16.00

2.77

78

16.00

3.57

16.00

2.56

LIFTING ANGLE AND ALLOWABLE LIFTING WEIGHT FOR 16 TONS (LONG JIB) Long jib

Lifting angle

Short jib

(°)

Lifting weight (t)

Slewing radius (m)

Lifting weight (t)

Slewing radius (m)

0

1.59

18.17

2.93

13.32

20

3.45

17.1

5.46

12.52

30

4.35

15.74

6.7

11.54

40

5.4

13.92

8.13

10.2

50

6.8

11.68

10.03

8.56

60

8.97

9.09

13

6.66

65

10.67

7.68

15.31

5.63

70

13.18

6.21

16.00

4.56

75

16.00

4.7

16.00

3.45

76

16.00

4.4

16.00

3.22

77

16.00

4.09

16.00

3

78

16.00

3.78

16.00

2.78

Attention: Operate lifting job according to the above table strictly.

65

ZYJ 460B-Ⅱ Operator’s manual

6.6

HYDRAULIC DRAWING

66

ZYJ 460B-Ⅱ Operator’s manual

6.7 ELECTRICAL DRAWING

67

ZYJ 460B-Ⅱ Operator’s manual

7 TROUBLE SHOOTING 7.1 COMMON MALFUNCTIONS AND CORRESPONDING SOLUTIONS Malfunction

Cause

Solution

Something dirty between the Clean the dirty things, repair point of the cone and valve seat or replace it. or the sealing surface is worn. The little orifice in the middle of main valve spool of overflow Clean valve. valve is blocked. The main valve spool of overflow valve is blocked in an Clear and repair. 1. Pressure can not meet open position and can’t be reset. needed value or completely no pressure Oil pressure gauge is destroyed. Change the gauge. The running direction hydraulic pump is wrong.

of Change the running direction of electrical motor.

The hydraulic pump sucking oil Add oil or repair oil tube is not enough Replace components, and Hydraulic pump oil-distribution check whether the leakage oil tray or backhaul tray worn pipe unblocked or not. The orifice in the pilot valve seat of overflow valve is Clean away such things. 2. Pressure is over the limit blocked and disabled. (If the pressure exceeds limit very quickly, stop the The main valve spool of overflow is blocked, so it can’t Clean and repair. pile driver at once.) open and overflow. Oil pressure gauge is damaged. Change pressure gauge. The directed value is not correct. 3. The force of clamping can’t be maintained (If above malfunction happens and can not stop working, the method of discontinuous driving clamping cylinder during one pressing stroke can be adopted.

Take out of the spool to Single-direction valve F4 is not check if there is some completely sealed. eyewinker or any abrasion. Repair or change it. The seals of hydraulic cylinder for clamping are worn so that Change the seals. chambers in cylinders connect. Pipeline leaks.

Stop leakage.

4. Pressing pressure can not Oil pressure gauge is damaged. Change pressure gauge. meet needed value or The directed value is not correct. completely no pressure. The preset pressure value of system overflow or pressing-in Reset it overflow is too low

68

ZYJ 460B-Ⅱ Operator’s manual Sealing of system overflow valve or pressing-in overflow Repair or change it. valve can not meet requirement and is not tight. Seals of pressing cylinder rod Replace the worn seals. are damaged. Return oil pressure is too high.

Clean return oil filter and pipeline.

Oil is overheated.

Refer to item 5.

Remember to push all handles of multidirectional The system works too long in valve to the middle position the condition of overflowing. Or of “ Releasing load”. Take quick press pile in high pressure. care not to execute quick piling under high pressure. 5. Overheated oil

Oil pipeline is blocked.

Detect and remove.

Return oil filter is blocked.

Clean and change

Breakdown of the hydraulic pump . The pump is too hot to Repair the pump. touch. The oil level is too low.

Fill up hydraulic oil

Hydraulic oil is too dirty or used Re-filtrate or change oil. too long. 6. Leakage

The leakage at joints is caused by loose connection or Check and repair, or replace contamination or damage of the it. seal of the joints.

Broken seal ring in the guide 7. Leakage between piston shell, or damage to the mate rod and guide shell surface between piston rod and guide shell. Too dirty oil

8. Piston rod surface pulled

Replace seals, and refer to item 8. Re-filtrate or change oil.

Eyewinker between seals and Clean it dust-proof seal. Seals for damaged.

guide

shell

Guide shell is damaged.

are

Change them. Replace it

When fixing the oil gauge, the oil-filling plug (safety plug) is 9. Oil pressure gauge being not unscrewed loose so that the Modify damaged frequently vent of oil-filling plug can’t link the atmosphere.（see Figure 7-2） Detect time delay relay. Correct 10. Electrical elements Reset the interval or change interval should be 8~10 being frequently burnt relay. seconds. 69

ZYJ 460B-Ⅱ Operator’s manual Start oil pump disobeying the Operate as per regulations operation regulations in 4.3. strictly. The oil flow of pump in high Replace matched pump or pressure doesn’t match electric motor. motor power. Wheel is not greased.

Grease it.

Wheels are deformed. Change the deformed ones. 11. When wheel carrier (structure as figure7-1) Composite bearing damages. Replace. moving, wheels sliding on Wheel axle is deformed or Change axle or wheel carrier. tracks burnt. The cover press is too tight. the process switch mounted on the winch operation handle 12. It can’t drop hook when fails . crane hook reaches upper Failure in electromagnetic valve limitation loop and corresponding circuit. No pressure in overflow valve.

Adjust the cover. Adjust or replace process switch. Replace components.

concerned

Refer to item 1 to solve.

Failure in the limitation switch Check and replace concerned on jib and concerned control components. circuit

13. Crane hook can’t stop rising when it passes upper Failure of electromagnetic valve Check and replace concerned limitation loop and corresponding circuit components. Overflow abnormally

valve

works

Refer to item 2 to solve.

7.2 REPAIR 1. 2. 3. 4. 5. 6. 7.

8.

9.

Before examination and repair, long ship and short ship slideway must be laid down on ground. Only professional personnel are allowed to repair hydraulic system. Any repair is forbidden if hydraulic system pressure still exists. Before electric motor stops, do not pack oil hose or repair leaking joint, do not feel by hand to look for leakage, or the high pressure oil might cut into skin to cause injury. The joints, hose and seals must be the right type as designed. Choose place without dust to dispart and assemble hydraulic elements. When fixing the oil gauge, the oil-filling plug (safety plug) should be screwed loose so that the vent of oil-filling plug can link the atmosphere. During un-using period, screw oil-filling plug tight to prevent filling liquid from leaking. During work time, if it happens that filling liquid level rises or becomes full of gauge, replace the old gauge with a new one. It should be carried out or supervised by qualified electrical worker to examine or repair the electrical system. Also the local manual books of electrical repair and electrical safety should be obeyed. If it is necessary to use welding method, things must be done before welding are preparing 70

ZYJ 460B-Ⅱ Operator’s manual

welding material and filling material, deciding welding method, switching off all electrical power to the pile driver, as well as fire fighting equipment. While welding, electric current is not permitted to get through the vertical cylinder from long ship slideway to platform, nor from platform to long ship slideway. No current is permitted to be conducted by any cylinder nor to get through between rod and cylinder tube. It is not right to conduct electric current by iron joint either. The correct method is to connect the cable directly to the part to be welded. If machine body need weld, first make sure the 24V DC power supply without 220V AC (the indicator lamp should not light)

10. If welding task is carried out near cylinders, the rod part stretching out of cylinder tube must be enclosed up with asbestos cloth in case that welding dregs splash to the rod to damage the cylinder.

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ZYJ 460B-Ⅱ Operator’s manual

8 MAIN TECHNICAL DATA APPENDIX TABLE 8-1 SIGNS IN THIS MANUAL

Signs

Meaning

Value

Pa

Max system oil pressure

25 MPa

Pd

Secondary pressing-in oil pressure

It depends on practical conditions.

Pe

Pile clamping oil pressure

It depends on practical conditions.

Pb

System pressure with pump at full flux

16.4 MPa

P1

Largest pile-pressing weight

153 tons

P2

Largest pile-pulling weight

68 tons

P3

Allowable largest weight of pile driver at pile- pulling

393 tons

APPENDIX TABLE 8-2 BASIC PARAMETERS Item

Parameter

Max. pile pressing force（24.5 Mpa） The

chief

pressing-in Max.

pile

pressing

153.9 t

speed(Pressure ＜ 7.1 /min

hydraulic cylinder works 16Mpa） separately

Min.

pile

pressing

speed 2.34 m/min

（Pressure=24.5Mpa） Max. pile pressing force（24.5 Mpa） 307 t The chief and a pair of Max. pile pressing speed （ Pressure ＜ 1.74 m/min secondary pressing-in 16Mpa） hydraulic cylinders work together

Min.

pile

pressing

speed

(Pressure 1.17 m/min

=24.5Mpa）

The chief and two pairs Max. pile pressing force（24.5 Mpa）

72

461 t

ZYJ 460B-Ⅱ Operator’s manual

of secondary pressing-in Max. pile pressing speed （ Pressure ＜ 1.12 m/min hydraulic cylinders work 16Mpa） together

Min.

pile

pressing

speed

(Pressure 0.75 m/min

=24.5Mpa） Pressing-in stroke(once) Side piling

1.8 m Max. pile pressing force（The chief and the 207 t secondary pressing-in hydraulic cylinders(A group) work together 16.5Mpa）

Capability of motion

Traveling speed

Longitudinal stroke（once）

≤3.6 m

Transverse stroke（once）

≤0.6m

Every rotative angle（once）

≤10◦

Forward

≤5.26 m/min

Backward

≤10.31 m/min

Left

≤5.26 m/min

Right

≤7.95 m/min

Vertical motion stroke

1.0 m

Length of pile

＞3 m，≤14 m

Ground pressure （ at Long ship slideway

11.2 tf/m2

460t）

15.5 tf/ m2

Normal

Short ship slideway pressing Side pile distance

3655 mm

position After equipped with side Side pile distance

1045 mm

piling device

2230 mm

Corner pile distance

JZX6014BJ

Pile clamping box（either one is ok）

JZX6025BJ

Pile pressing rated pressure（460tf）

24.5 Mpa

Rated pressure for lifting

See

the

operating

manual of crane

Hydraulic system

Pile pressing flow rate(at full flow)

219 L/min

Lifting flow rate(at full flow)

See

the

operating

manual of crane For Hydraulic pump model

machine For crane

73

main 80YCY14-1B（1units） 80YCY14-1BF（1units） ）

See

the

operating

manual of crane

ZYJ 460B-Ⅱ Operator’s manual

For Electric motor model

main Y2-225S-4 37KW B5（2

machine

units） See

For crane

the

operating

manual of crane

Pile pressing power

37KWX2=74 KW

Lifting power

See

the

operating

manual of crane Electric system

Voltage

380 V

Current (the whole machine)

145 A

Frequency

50 HZ

Power cable

Southern configuration YCW-3X50+2X16 Northern configuration YHD-3X50+2X16

Dimension (LxWxH) (mm)

13400×7310×3280 154T±6%

Weight of main machine Weight of whole machine (including counterweight)

462T

APPENDIX TABLE 8-3 OIL PRESSURE AND PILE PRESSING FORCE

Oil pressure (MPa)

1.0 2.0 3.0 4.0 5.0 6.0 7.0

Pressing pile (tf) The chief pressing-in cylinder works The chief and the secondary alone pressing-in cylinder work together. Quick Normal pressure Two pairs of A pair of pressure secondary secondary pressing-in pressing-in cylinder cylinder 3.08 6.16 9.24 12.32 15.39 18.47 21.55

6.28 12.57 18.85 25.13 31.42 37.70 43.98 74

12.57 25.13 37.70 50.27 62.83 75.40 87.96

18.85 37.70 56.55 75.40 94.25 113.10 131.95

ZYJ 460B-Ⅱ Operator’s manual 8.0 9.0 10.0 11.0

24.63 27.71 30.79

50.27 56.55 62.83 69.12

100.53 113.10 125.66 138.23

150.80 169.65 188.50 207.35

12.0

75.40

150.80

226.19

13.0

81.68

163.36

245.04

14.0

87.96

175.93

263.89

15.0

94.25

188.50

282.74

16.0

100.53

201.06

301.59

16.4

103.30

206.59

309.89

18.0

113.10

226.19

339.29

19.0

119.38

238.76

358.14

20.0

125.66

251.33

376.99

21.0

131.95

263.89

395.84

22.0

138.23

276.46

414.69

23.0

144.51

289.03

433.54

24.0

150.80

301.59

452.39

24.5

153.94

307.88

461.81

APPENDIX TABLE 8-4 ATTACHMENT TOOLS Name specifications

and Quantity Remark Name specifications

and Quantity Remark

High pressure oil can 1unit

Wire cutter 200MM

Double-ended fixed 1unit spanner 5.5-32

Adjustable spanner 1 unit 300X36 GB4440

Nipper 175

Adjustable spanner 1 unit 450X55 GB4440

1unit

1 unit

Inner hexagon 1set spanner 3-19

Screw-driver voltage tester

Cross head 1unit screwdriver 75X5

Imported grease gun

Cross head 1 unit screwdriver 200X8

Round head hammer 1 unit 2P

Flat head 1 unit screwdriver 75X5

Connection rod 10 1 unit GB3390.4

Flat head 1 unit screwdriver 200X8

Sleeve 17MM

Oil filter device 1 unit LUC-40X10

Oil port cover

Pull rod sleeve

Oil port plug

1 unit

75

with 1 unit 1 unit

1 unit Its quantity and specifications vary according to different machine model

ZYJ 460B-Ⅱ Operator’s manual

APPENDIX TABLE 8-5 wearing parts Name

Air filter Electric brush

Specification

Remark

Specific ation

Name

PAF2-0.02-0.75-10F

12 x 1.9

For electric collectio n ring

J164-12.5x40x50

ring 32 x3.1

O GB1235-76

Magnetic oil returning filter WY-A400X20Q2 core

For crane

40 x3.1

Oil suction filter

For main machine

10

Fuse core

WU-1000x100-J FUSE φ10X38 2A

12

φ10X38 R015 RT14 6A

14

φ10X38 R015 RT14 10A

16

Oil returning WY-400X20Q2 filter core Composite bearing

For main machine For wheel Composite carrier washer

SF-2-120115

Wire rope 6X37-13-2000 For Wire rope

12T

crane

GB/T8918

Wire 4VX39S+5FC-15 8918

Remark

rope For

GB/T

JB982-77

16T

18 20 22 27

crane

6.9x1.8

33

O ring

63x3.55

39

GB3452.1-82

85x3.55

42

437x7

48

APPENDIX TABLE 8-6a CLAMPING JAW COLLOCATION 1

Clamping jaw

Pile driver model

Type

Quantity （piece）

250×250 square

F25

8

300×300 square

F30

8

350×350

F35

8

Fixed screws Remark

Specifications GB70-86

Used together with Y40, M16×45 Y50 Used together M16×70 with Y50 M16×45 76

Quantity (unit) 16

16 16

ZYJ 460B-Ⅱ Operator’s manual square 400×400 square Φ250 round Φ300 round Φ350 round Φ400 round Φ450 round

F40

8

Y25 Y30 Y35 Y40 Y45

8 8 16 16 16

Φ500 round

Y50

16

Φ550 round

Y55

16

Φ600 round

Y60

16

M16×40

16

Used together M16×65 with Y40, M16×50 Y50 M16×30 Used together M16×50 with Y50 M16×30 Directly installed in M16×60 clamping jaw seat Used together M16×30 with Y60 Directly installed in M16×45 clamping jaw seat

16 16 32 32 32 32

32

32

The above table is for clamping boxes JZX6016ZB and JZX6014ZB.

APPENDIX TABLE 8-6b CLAMPING JAW COLLOCATION 2

Pile driver model

Clamping jaw Type

Quantity （piece）

300×300 square

F30-35

8

350×350 square

F30-35

8

400×400 square

F40

8

450×450 square

F45

8

F50

8

F55

8

F60

8

Y25

8

500×500 square 550×550 square 600×600 square Φ250 round

Fixed screws Remark

Specifications GB70-86

Used together with F50 M20×160 Used together with F50 Used together M20×150 with F50 Used together M20×130 with F50 Directly installed in M20×70 cylinder

Used 77

Quantity (unit) 16

16

16

16 16 16

M20×50

16

M20×200

16

ZYJ 460B-Ⅱ Operator’s manual

Φ300 round

Y30

8

Φ350 round

Y35

8

Φ400 round

Y40

8

Φ450 round

Y45

together M20×200 with Y40 Used together M20×160 with Y50 Directly installed in M20×110 cylinder Used together M20×130 with Y55

8

Φ500 round

Y50

8

Φ550 round Φ600 round

Y55 Y60

8 8

Directly installed cylinder

16 16

16

16

M20×70

16

in M20×70

16

M20×50

16

The above table is for clamping boxes JZX6036, JZX6032, JZX6028 and JZX6025. Note: The specific installation of clamping jaw is subject to user’s choice. When clamping box JZX6014 is used to clamp square pile, the pressing force should not exceed 300 tf.

APPENDIX TABLE

8-7 Hydraulic pump pressure-flow curve adjustment list

Pump model

Initial adjustment pressure Pb(MPa) (Start variable)

Final adjustment pressure Pa(MPa) (Max system pressure)

Final adjustment displacement X (Pump variable indicating position)

80YCY

17

23.5

7.3

APPENDIX TABLE 8-8 HYDRAULIC PARTS FOR MAIN MACHINE

78

ZYJ 460B-Ⅱ Operator’s manual

Number

Code number

Parts name

1

F5, F6, F7,F8

Balance valve DFY-B20H

2

F9

Overflow valve MZL5-H32B (with remote-type coupling)

3

F4

Hydraulic check valve AIY-HC25B

4

F14

Hydraulic Oil drain valve DFY-B25H

5

F15、F16

Overflow valve MZL5-H10B

6

Hydraulic pump 80YCY14-1B

7

Plunger pump 80YCY14-1BF

8

Multiunit valve ZS1-L32-4W-GD10

9

Multiunit valve ZS1-L25-4T-GD2

10

Multiunit valve ZS1-L20-4T-GD2

APPENDIX TABLE 8-9 ELECTRIC PARTS FOR MAIN MACHINE

Code Parts name number Circuit seat

Parts name Module plug AC30-10A/3

FU

Fuse φ10X38 2A

F

button SA

LAY5(39)-11X/2

Thermal relay NR2-93

contactor KM

LC1-0910 AC220V contactor CJX4-6511 220V

KM

Lamp for warning HL against humidity 40W AC36V Power cable YCW3X50+2X16 Fuse φ10X38 R015 FU RT14 10A Fuse inserts ATS 5A

Circuit

breaker QF

CM1(ZM1)-80L/3300 80A

Circuit breaker DZ67-60 QF 40A

Circuit breaker DZ47-60 QF 3P/D20A

FR

48-65A

AC

breaker QF

NMILE-400/3N300 250A

Fuse seat RT18-32X

Push

Code number

Delay relaySK4-222 Auxiliary LA1-DN11-C

contactor KM

Fuse φ10X38 R015 RT14 6A

Current

transformer

FU JV

LMZ1-0.5 300/5 Lamp 220V-40W

HL

Fuse inserts ATS 3A

FU

FU

79

ZYJ 460B-Ⅱ Operator’s manual

9 APPENDIX FIGURES

APPENDIX FIGURE 1 MAIN MACHINE HYDRAULIC SYSTEM

80

ZYJ 460B-Ⅱ Operator’s manual

1- Pile clamping cylinder

2- Secondary pile pressing cylinder 2 3- Secondary pile pressing cylinder 1 4- Chief pile pressing cylinder 5- Vertical motion cylinder 6- Longitudinal motion cylinder 7- Cross motion cylinder 8-Right move

9-Left move

13-Back left down

10- Forward

14-Front left up

11- Backward

15-Front left down

16-Front right up

17-Front right down 18-Back right up 19-Back right down 21- Quick pressure 22- Press pile 23- Lift pile 25- Return 1

26- Add force 2

27- Return 2

12-Back left up

20- Normal pressure

24- Add force 1 28- Release pile 29-Pile clamping

81

ZYJ 460B-Ⅱ Operator’s manual

APPENDIX FIGURE 2 MAIN MACHINE ELECTRIC SYSTEM

82

ZYJ 460B-Ⅱ Operator’s manual

APPENDIX FIGURE 3a CAST IRON COUNTWEIGHT LOCATED

1- Assistant cantilever 2- Assistant counterweight beam 3- F counterweight 4- Square counterweight 5- Main counterweight beam

83

ZYJ 460B-Ⅱ Operator’s manual

APPENDIX FIGURE 3b BARITE COUNTWEIGHT LOCATED

1- Assistant cantilever 2- Assistant counterweight beam 3- F counterweight 4- Square counterweight 5- Main counterweight beam

84

ZYJ 460B-Ⅱ Operator’s manual

10 ABOUT THE MANUFACTURER Company name: SUNWARD INTELLIGENT EQUIPMENT CO., LTD. Trade mark: Address: 16 LiXiang Road, Xingsha economic and technologic development district, Changsha, Hunan. Tel: 0086-0731-3572642 Maintenance point: our office in some provinces and cities of China ABOUT THE DISTRIBUTOR About the distributor Distributor name: Address: Tel: Fax: Email: Service personnel: Remark：

85