ZYJ860B－ⅡOperator’s Manual

CONTENTS
1 SAFETY INFORMATION ................................................................................................................................. 3
1.1 SAFETY LABELS .................................................................................................................................... 3
1.1.1 LOCATION OF SAFETY LABELS ............................................................................................. 3
1.1.2 SAFETY LABELS ........................................................................................................................ 3
1.2 SAFETY RULES....................................................................................................................................... 4
1.3 PREPARATION FOR EMERGENCY...................................................................................................... 5
1.4 WEAR SAFETY PROTECTIVE ARTICLES ........................................................................................... 5
1.5 KEEP MACHINE CLEAN........................................................................................................................ 6
1.6 KEEP OPERATOR’S COMPARTMENT CLEAN.................................................................................... 6
1.7 MOUNTING AND DISMOUNTING ....................................................................................................... 6
1.8 MOVE MACHINE SAFELY..................................................................................................................... 6
1.9 REQUIREMENT TO THE CONSTRUCTION FIELD............................................................................. 7
1.10 CHECK MACHINE BEFORE START-UP ............................................................................................. 7
1.11 OPERATE SAFELY ................................................................................................................................ 7
1.12 KEEP AWAY FROM TRANSMISSION PARTS..................................................................................... 9
1.13 MAINTAIN SAFELY.............................................................................................................................. 9
1.14 BEWARE OF HIGH PRESSURED LIQUIDS ........................................................................................ 9
1.15 BEWARE OF SCALD ............................................................................................................................. 9
1.16 AVOID HEATING UP NEAR PRESSURE OIL PIPE........................................................................... 10
1.17 AVOID HEATING UP PIPE WITH PRESSURE OIL ........................................................................... 10
1.18 REMOVE PAINT BEFORE WELDING OR HEATING ...................................................................... 10
1.19 AVOID FIRE ..........................................................................................................................................11
2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER .............................................................. 12
2.1 ADVANTAGES OF SUNWARD PILE DRIVER.................................................................................... 12
2.2 COMPARED WITH THOSE BY OTHER FACTORIES ........................................................................ 12
3 BASIC STRUCTURE AND WORK PRINCIPLE ........................................................................................... 14
3.1 BASIC STRUCTURE OF ZYJ 860B-Ⅱ ................................................................................................. 14
3.2 PILING PLATFORM .............................................................................................................................. 14
3.2.1 STRUCTURE.............................................................................................................................. 14
3.2.2 PILE PRESSING PROCESS ...................................................................................................... 16
3.3 TRAVEL MECHANISM......................................................................................................................... 16
3.3.1 VERTICAL MOTION MECHANISM ....................................................................................... 17
3.3.2 LONGITUDINAL MOTION MECHANISM............................................................................. 17
3.3.3 CROSS MOTION AND ROTATION MECHANISM ................................................................ 18
3.3.4 CONTINUOUS STEPPING AND ROTATION.......................................................................... 18
3.3.5 LONGITUDINAL MOTION ...................................................................................................... 19
3.3.6 CROSS MOTION ....................................................................................................................... 19
3.3.7 ROTATION ................................................................................................................................. 19
3.4 HYDRAULIC SYSTEM ( FOR PILE PRESSING) ............................................................................... 21
3.4.1 STRUCTURE.............................................................................................................................. 21
3.4.2 WORK PRINCIPLE.................................................................................................................... 22
3.5 SIDE PILING AND CORNER PILING (OPTIONAL).......................................................................... 24
3.6 ELECTRIC SYSTEM ............................................................................................................................. 25
4. OPERATING REGULATIONS ....................................................................................................................... 26
4.1 CONTROL PANEL................................................................................................................................. 26
4.2 PREPARATION BEFORE PRESSING PILE......................................................................................... 28
4.2.1 PREPARATION BEFORE START-UP ....................................................................................... 28
4.2.2 OIL PRESSURE ADJUSTING FOR SYSTEM, PILING AND LIFTING PILE(QUICK PILING)
.............................................................................................................................................................. 28
4.3 OPERATION METHOD AND STEPS FOR PILE PRESSING ............................................................. 29
4.3.1 START-UP................................................................................................................................... 29
4.3.2 POSITIONING PILE .................................................................................................................. 30
4.3.3 LEVELING ................................................................................................................................. 30
4.3.4 PRESSING PILE......................................................................................................................... 30
ATTENTION........................................................................................................................................ 32
4.3.5 CABLES ACCESS PHASE SEQUENCE (DUE TO THE SPECIAL REASON, N MAY
CHANGE.) ........................................................................................................................................... 33
4.3.6 OIL COOLING OPERTATION................................................................................................... 34
4.3.6 CONNECTING ELECTRIC WELDING.................................................................................... 34
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4.4 INSTALLATION AND REPLACEMENT OF CLAMPING JAW......................................................... 35

4.4.1 INSTALLATION......................................................................................................................... 35
4.4.2 REPLACEMENT OF CLAMPING JAW ................................................................................... 37
5 ASSEMBLY, DISASSEMBLY, SHIPPING AND MAINTENANCE............................................................... 38
5.1 ASSEMBLY ............................................................................................................................................ 38
5.2 DISASSEMBLY...................................................................................................................................... 42
5.3 TRANSPORTATION .............................................................................................................................. 43
5.4 DEBUGGING ......................................................................................................................................... 44
5.5 DAILY SERVICE AND ROUTINE MAINTENANCE........................................................................... 45
5.6 LUBRICATION DIAGRAM................................................................................................................... 45
5.7 TORQUE FOR STANDARD TIGHTENING PARTS............................................................................. 47
6 TROUBLE SHOOTING ................................................................................................................................... 48
6.1 COMMON MALFUNCTIONS AND CORRESPONDING SOLUTIONS ........................................... 48
6.2 REPAIR ................................................................................................................................................... 51
7 MAIN TECHNICAL DATA.............................................................................................................................. 52
APPENDIX TABLE 7-1 SIGNS IN THIS MANUAL.................................................................................. 52
APPENDIX TABLE 7-2 BASIC PARAMETERS........................................................................................ 52
APPENDIX TABLE 7-3 OIL PRESSURE AND PILE PRESSING PRESSURE ........................................ 54
APPENDIX TABLE 7-4 ATTACHMENT PARTS ....................................................................................... 55
APPENDIX TABLE 7-5 ATTACHMENT TOOLS ...................................................................................... 57
APPENDIX TABLE 7-6 MAIN WEARING PARTS ................................................................................... 57
APPENDIX TABLE 7-7A JAWS COLLOCATION FOR CLAMPING BOX JZX6016BJ ......................... 58
APPENDIX TABLE 7-7B JAWS COLLOCATION FOR CLAMPING BOX JZX6036BJ ......................... 59
APPENDIX TABLE 7-7C CLAMPING JAW COLLOCATION FOR JZX6038BJ..................................... 60
APPENDIX TABLE 7-7D CLAMPING JAW COLLOCATION FOR JZX8016BJ..................................... 61
APPENDIX TABLE 7-7D CLAMPING JAW COLLOCATION FOR JZX5022A ...................................... 61
DIX TABLE 7-8 HYDRAULIC PARTS LIST .............................................................................................. 62
APPENDIX TABLE 7-9 ELECTRICAL PARTS LIST................................................................................. 62
8 APPENDIX FIGURES...................................................................................................................................... 65
APPENDIX FIGURE 1 MAIN MACHINE HYDRAULIC SYSTEM......................................................... 65
APPENDIX FIGURE 2 MAIN MACHINE ELECTRICAL SYSTEM........................................................ 66
APPENDIX FIGURE 3 PILE DRIVER COUNTERWEIGHT .................................................................... 67
9 ABOUT THE MANUFACTURER ................................................................................................................... 68

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1 SAFETY INFORMATION
1.1 SAFETY LABELS

The following warning signs and safety labels are used on this machine.
 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.
1.1.1 LOCATION OF SAFETY LABELS

Figure 1-1
1.1.2 SAFETY LABELS
1. Caution when machine is working.

Figure 1-2
2. Caution during pile pressing.

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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
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
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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.
Otherwise the performance and lifetime of
Fmachine will be affected, or human body hurt
Figure 1-7
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. Figure 1-8
Always follow the precautions below to
prepare for action if any injury or fire should
occur.
 Be sure that fire extinguishers have been
provided and read the labels to ensure that you
know how to use them in emergencies.
 Provide a first aid kit at the storage point and
carry out periodic checks to make sure all
needed things for emergencies are ready.
 Place the phone numbers of doctor, ambulance,
hospital, and fire department near telephone for
easy access in case of emergency.

1.4 WEAR SAFETY PROTECTIVE ARTICLES

Figure 1-9
Before operation, always wear protective
articles when the work so requires, they include:
Skintight work clothes
Hard hat

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Safety gloves
Safety glasses, goggles, or veil
Respirator or filtration veil
Earplug or earcap

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 items into the
operator’s compartment.

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).

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
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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
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

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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 Figure 1-10
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.
 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.

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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.

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 Figure 1-11
moving machine.
 Avoid body and clothing touching transmission
parts.
 Check some parts at regular intervals, repair or
replace, if necessary. (refer to the
“Maintenance and Repair” chapter)
 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 Figure 1-12
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
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,

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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

Figure 1-13
 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 REMOVE 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. Figure 1-14
After rubbing out, clean paint remover with
soap and water. Before welding or heating up,
volatilize the paint remover gas for at least 15
minutes.
ATTENTION
The paint removing work should be operated at
outdoors or well -ventilated site.

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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.
 I
nspect 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, Figure 1-15
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 twisted or damaged
pipeline or hose.
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.

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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 800～12000 KN. 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
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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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3 BASIC STRUCTURE AND WORK PRINCIPLE

3.1 BASIC STRUCTURE OF ZYJ 860B-Ⅱ

FIGURE 3-1 EXPLODED VIEW OF ZYJ 860B-II PILE DRIVER

1.Side piling device-to press side pile(optional) ; 2. Pile driver main cabin---to protect operator；
3. Pile pressing platform---main working mechanism；4. long platform---put generator set；
5. Longitudinal motion mechanism---to travel longitudinally；
6. Vertical motion mechanism---vertical motion of machine body；7. Cross motion and rotation
mechanism---to travel transversely and rotate；8. Pile clamping box-clamping pile;
9. Counterweight beam--- to support counterweight;

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.

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FIGURE 3-2 STRUCTURE OF PILING PLATFORM

1- Secondary pile pressing cylinder; 2- Chief pile pressing cylinder; 3- Pile pressing cross beam;
4- Ball head seat; 5- Pile clamping box; 6- Free bearing; 7-Supporter.

FIGURE 3-3a STRUCTURE OF PILE CLAMPING BOX JZX6016BJ

1- Pile clamping box body; 2-Guide wheel; 3-Pile clamping cylinder; 4- Clamping jaw ;
5-Jaw seat ; 6-Pile clamping block; 7-Connecting block A; 8-Intermediate body ;
9- Connecting block B.

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FIGURE 3-3b STRUCTURE OF PILE CLAMPING BOX JZX6032BJ

1-Hydraulic pipeline; 2- Pile clamping box body 3-Guide wheel
4- Pile clamping cylinder 5- Clamping jaw
★ Remark：Above mentioned two kinds pile clamping box are optional, customer can choose anyone
base on real demand.
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 let 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 raise the box and draw back. 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.
If the needed pressing pressure is over P1, the chief and secondary pile pressing cylinder must
work together

（highest position）
Clamp pile

（decline）Press pile lift

Release pile
（lowest position）

FIGURE 3-4 PILE PRESSING PROCESS

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.

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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.

Fig 3-5 Structure of vertical motion mechanism

1- Cantilever 2- Vertical motion cylinder

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

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1- Wheel carrier; 2- Longitudinal motion cylinder; 3-Linked 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, four wheel carriers, two
turntables, four return springs.

Figure 3-7 Structure of cross motion and rotation mechanism

1- Short ship slideway; 2- Wheel carrier; 3- Return spring;
4- Central axis hole; 5- Turntable; 6- Cross motion cylinder.

3.3.4 CONTINUOUS STEPPING AND ROTATION

Figure 3- 8 Structure of travel mechanism

1- Vertical motion cylinder 2- Short ship slideway 3- Long ship slideway

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4- Longitudinal motion cylinder 5- Cross motion cylinder

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.
short ship sideways down short ship sideways down short ship sideways up short ship sideways up
⑴ ⑵ ⑶ ⑷

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

⑴ Vertical motion cylinders retract

⑵ Longitudinal motion cylinders act
⑶ Vertical motion cylinders extend
⑷ Longitudinal motion cylinders act

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 short ship sideways up short ship sideways down short ship sideways down
(short ship cross motion) (main machine body walk)
⑴ ⑵ ⑶ ⑷

Long ship sideways down Long ship sideways down Long ship sideways up Long ship sideways up

⑴ Vertical motion cylinders extend

⑵ Transverse motion cylinders
⑶ Vertical motion cylinders retract
⑷ 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°.
3.3.7.1 Rotating procedure( see figure 3-11, 3-12)

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Figure 3-11 Rotating manner

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.

short ship sideways up short ship sideways up short ship sideways down short ship sideways down
(short ship move in opposite directions) (main machine body walk)
⑴ ⑵ ⑶ ⑷

Long ship sideways down Long ship sideways down Long ship sideways up Long ship sideways up

⑴ Vertical motion cylinders extend

⑵ Transverse motion cylinders
⑶ Vertical motion cylinders retract
⑷ Transverse motion cylinders

Figure 3-12 Rotation cycle

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3.4 HYDRAULIC SYSTEM ( FOR PILE PRESSING)

3.4.1 STRUCTURE
It is mainly composed of three 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.

Figure 3-13 Location plan of pile driver hydraulic cylinders

1- Longitudinal motion hydraulic cylinder 2- Vertical motion hydraulic cylinder
3- Pile clamping hydraulic cylinder 4- Pile pressing hydraulic cylinder
5- Cross motion hydraulic cylinder
3.4.1.1 MULTI-DIRECTIONAL VALVE
Operators use operation handles of multi-directional valves to operate the pile driver.

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Figure 3-14 Three groups of manual multi-directional valves

1-MULTI-WAY VALVE A 2- MULTI-WAY VALVE B
3- MULTI-WAY VALVE C 4- MULTI-WAY VALVE D

MULTI-WAY VALVE A——It controls the extension and retraction of vertical motion cylinders
to adjust the altitude and level of platform, and to make the short and long ship slideways touch or
leave the ground;
MULTI-WAY VALVE B——It controls the job of pile pressing, pile clamping, pile releasing and
the rise and drop of clamping box;
MULTI-WAY VALVE C——It controls the stepping and rotary motion of pile driver.
MULTI-WAY VALVE D——It controls the job of pile pressing, pile clamping, pile releasing and
the rise and drop of clamping box;

3.4.2 WORK PRINCIPLE

（1） Travel by hydraulic control
Operators use multi-directional valve C to control the stepping of pile driver.

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Figure 3-15 Hydraulic system for traveling

1- Multi-directional valve C 2-Travelling steel pipe

（2） Hydraulic system for vertical motion

Operators use multi-directional valve A to control the vertical motion of pile driver.

Figure 3-16 Hydraulic system for vertical motion

1- Multi-directional valve A 2- Vertical motion steel pipe 3- Vertical motion mechanism

（3） Hydraulic system for clamping pile

Operators use the multiunit valve B to control the job of clamping and releasing pile.

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Figure 3-17 Hydraulic system for pile clamping

1- Multi-way valve B 2-Shuttle valve group 3-40 Multi-way valve
4- Pile pressing valve unit 5- Steel pipe 6-Cylinder 7- Pile clamping box

★ See appendix Fig 1 for hydraulic system.

3.5 SIDE PILING AND CORNER PILING (OPTIONAL)

When pressing side or corner pile, lift the chief pile pressing cylinder to the side piling frame,
have it installed, connect it with hydraulic hoses then it can work. The process of pressing side
pile is similar to that of pressing meso-positon pile.

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Figure 3-18 Side pile frame

1-Pile pressing cylinder 2-Side pile frame 3-Pile clamping box

Figure 3-19 Hydraulic system for clamping side pile

1- Side piling device 2- Pile clamping box 3-Side pile steel pipe
4- Main pile pressing valve block 5-Shuttle valve group 6-Multi-directional valve D

3.6 ELECTRIC SYSTEM

The machine is connected with three phase standard electrical supply AC380V(±5%), 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 safe work, there is alarm system for “floating 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. Check machine
grounding status in every starting machine.

See appendix Fig 2 for electrical drawing.

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
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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.

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～Y5，Z1～Z4, Y1’～Y3’）

Figure 4-1 Main Control Panel in Operating Platform

Z1, Z2—to control two cross motion cylinders
Z3, Z4—to control two longitudinal motion cylinders
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 with quick
pressure.）
Y2—to control the chief pile pressing cylinder
Y3, Y4—to control the secondary pile pressing cylinder
Y5—to control pile clamping hydraulic cylinder

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Figure 4-2 Side Pile Control Panel in Operating Platform

Y1’— to choose piling speed

(Attention：When piling pressure is higher than 10MPa, it is not allowed to press pile with quick
pressure.）
Y2’— o control the chief pile pressing cylinder , Y3’— to control pile clamping hydraulic
cylinder

Fig 4-3 Electrical Buttons Layout

1-Voltmeter 2-Ammeter 3- Pump A on/ off 4- Pump B on/ off
5- Pump C on/ off 6- Filter pump fan on/off 7-Indoor light switch 8- Outdoor light switch
9- Electric fan 10-Oil cooling fan 11-buzzer 12-Warning light
13- Oil heating indicator (for northeast users) 14-oil temperature meter( for northeast users)

NOTE：For different machine model，there may just be reserved holes in corresponding

position.

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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 higher 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.

4.2.2 OIL PRESSURE ADJUSTING FOR SYSTEM, PILING AND LIFTING PILE(QUICK
PILING)

Fig 4-4 Overflow Valves Location

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① Overflow valve F4(see Figure 4-4) is used to adjust rated pressure of the hydraulic system.
Set pressure of F4 as follows: After oil pump works normally, push handle Y3，Y4 to
“(return)” position, screw down adjustment nut of F4 slowly, watch oil pressure meter,
when the oil pressure is increased to Pa(24.5MPa), the rated pressure adjustment finishes.
Then screw down the stop screw of adjusting nut.
② Overflow valve F6, F7 is used to set secondary pile pressing pressure Pd, which can be set
according to different needs ( see Chapter 8 for oil pressure and pile pressing force). Adjust
pressure of valve F6, F7 as follows: Start pumps till they run steadily; push the handle Y1
to the position of “normal pressing “, handle Y3 to the position of “pressing”, and handle
Y3 to “forcing”; after secondary press cylinders stretch to stroke end, gradually screw
down adjusting nut of F6, F7; observe the oil gauge on control panel; when the gauge
directs to the needed value Pd, the adjustment is done.
③ Overflow valve F1 is used to set main pile pressing pressure. It is set as PF1≤PF4. 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
④ Overflow valve F2 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.

⑤ Overflow valve F3 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 Y5 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, 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
⑥ Overflow valve F5 is used to set pile releasing pressure. Adjust pressure of valve F5 as
follows: Start pumps till it runs steadily; push handle Y5 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.
⑦ Overflow valve F8 is used to set pilot control pressure, normally about 4MPa（because
there is no pressure meter in here, operator can adjust it base on experience）.
⑧ Overflow valve F9 is used to set overflow pressure for pump 2, F9=F4, adjust pressure of
valve F9 as follows: after adjusting valve F4, open pump 2, adjust valve F9 base on the
adjusting way for F4.
Attention: After any adjustment, please push handle to neutral position.

4.3 OPERATION METHOD AND STEPS FOR PILE PRESSING

4.3.1 START-UP
（1） Closed cab door.
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（2） 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).
（3） First start one pump, after a few seconds, the green indicator lamp turns on.
（4） If the main cab door doesn’t close, the warning light will work. The buzzer stops when cab door
closed.
（5） Start another pump until the green indicator lamp lights. (The interval is about 8 seconds.)
（6） 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.
（7） Once step on pressure switch, the warning light will buzzer and flash. Operating the
hydraulic push rod in ten seconds. After 10 seconds, the buzzer and flash will finish, it
can not operate.
（8） Once step on pressure switch, the warning light will buzzer and flash, operating the push
rod to perform an action in ten seconds. And warning light will continue to buzzer and
flash.
（9） Once step on pressure switch, the warning light will buzzer and flash, operating push rod
to perform the action about pile- pressing platform in ten minutes. When working with
load, the buzzer will stop but flash continue, when in on-load state, the buzzer will
continue.
（10） Push the handle Y5 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 Y5 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
horizontal, which can be achieved by operating four vertical motion handles S1~S4 and at the
same time observe 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 three handles Y1~Y5 to carry out pile pressing (see§3.4.2 for reference).
Handle Y5 is used to clamp and release pile. When clamping pile, pushes 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, pushes handle Y5 to releasing position. After oil pressure reads zero, push the handle
to middle position.
The combination use of handles Y1, Y2, Y3 and Y4 can perform functions of “quick piling”,
“pressing pile”, “forcing” and “lifting pile”. The former three functions are four modes of pressing
pile. They are different in piling speed and piling force.
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（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） “Forcing” 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 25MPa), the two
secondary pile pressing cylinders should be used to add force. Push handleY3,Y4 to
position of adding force, the two 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,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, Y3,Y4 in the middle position and
Y3,Y4 in the secondary pile pressing cylinders withdraw to the end, then push handle Y2 to
lifting position. Clamping box is lifted to the highest position. Push Y5 to the middle
position from the position of releasing pile and clamping oil pressure reads zero.

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:
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 (25MPa)Pa during piling, then use “adding force”.
e) If oil pressure reaches (25MPa)Pa 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 860T. If the counterweight is not enough or the pile pressing force is too large,
the accident of “floating machine” will occur. If the electric bell alarms, which warns that
“floating machine” occurs, immediately push handles Y1, Y2, Y3 and Y4 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 Y5 to position of releasing pile; When “floating machine” occurs, absolutely prohibit
pushing handle Y5 to releasing pile position first. If the clamping oil pressure drops during the
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process of slowly releasing the piling pressure, it must be done to push handle Y5 to position of
clamping pile for load. When “floating 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 “floating machine”. Before
continuing work, measures must be taken to prevent the accident of “floating machine”.
Sunward shall not be responsible for any legal or economic responsibility caused by “floating
machine”.

“Floating 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
must be done to pull pile with pile driver, you must make sure that the pulling force is
less than P2 (150T, see the appendix table 8-1), the system oil pressure is less than
25MPa, and weight of pile driver with counterweight is less than P3(712T). Otherwise
partial counterweight should be removed. When pulling pile, short and long ship
slideways should be put 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，
then push handle Y5 to the position of releasing pile. If six cylinders work together, the
handle Y3,Y4 should also be pushed to middle position to release pressure. After piling
oil pressure gradually drops down, push handle Y5 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.

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 25MPa, 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
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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.

4.3.5 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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Marked N connecting to zero line

Fig 4-5 Main circuit breaker

4.3.6 OIL COOLING OPERTATION
Part7 in figure 4-2 control Oil cooling fan .
1. Rotating part 7 to the left is close, oil cooling fan can’t work,
2. Rotating part 7 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.

4.3.6 CONNECTING ELECTRIC WELDING

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Fig4-6 Welding protector component

1-Used for ZX 5 series three-phase rectification arc welding machine, ZX7 inverter welding
machine and Carbon dioxide air protecting welding machine.
2-Used for BX series AC welding machine
3- Air switch
4-Connect three-phase air switch
5-Connect 220V zero line（N）

There is welding protector electrical assembly in the platform.

a) In part 1, terminal 1, 2, 3 connect to the power. Mark ＋、－ connect to handle.
b) Part 2 connect to the power of the BX series AC welding machine.（220V）

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. Because of the difference in pile driver model or buyer’s needs, the clamping
box type of corresponding main machine may be different. Operators should handle it according
to different types.
The installation of clamping jaw for thin wall tube pile (see Figure 4-7): 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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Figure 4-7 Clamping jaw installation for thin wall tube pile

①Pile clamping cylinder ②Inner hexagonal screw ③Cylinder flange ④Connection nut
⑤Pulling rod ⑥Inner hexagonal screw ⑦Connection block ⑧Jaw seat
⑨Spring Return installation hole ⑩Pile clamping block ⑾ Inner jaw
⑿ Lifting ring screw hole ⒀ Outer jaw ⒁ Inner hexagonal screw

The installation of clamping jaw for round & square pile(see Figure 4-8): 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 4-8 Clamping jaw installation for square & round pile
① Pile clamping cylinder base ②Inner hexagonal screw ③Block plate
④Pile clamping cylinder ⑤Location pin ⑥Inner clamping jaw
⑦Lifting ring screw hole ⑧Outer clamping jaw ⑨Inner hexagonal screw

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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.
Remark: Detail arrangement for clamping jaws is showed in table 8-7A, 8-7B, 8-7C.
Warning:
Prohibit commanding and observation personnel from standing under the clamping box.
Reliable lifting equipment is necessary when replacing clamping jaw.

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5 ASSEMBLY, DISASSEMBLY, SHIPPING AND MAINTENANCE

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 assembly 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 assembly 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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 ZYJ860B－ⅡOperator’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 slideway and turntable by moving longitudinal motion mechanism and vertical
motion mechanism, connecting them; Connecting related hydraulic pipelines, fitting
ladder. See Fig 5-4.

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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.

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 ZYJ860B－ⅡOperator’s Manual

Fig 5-6

Fig 5-7
8. Assembling for side pile and its counterweight(optional parts)：
a) Hoist side pile by crane，Fig 5-8.

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 ZYJ860B－ⅡOperator’s Manual

Fig 5-8

★ Note：Counterweight fitting is showed in § 9-fig 3.

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.

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Fig 5-12 Water Inlet and Outlet

5.3 TRANSPORTATION

 Because machine weight is very large, it should be shipped after disassembling. The
biggest part should be transported singly，remaining parts is shipped separately. See
Table 5-1and Fig 5-14.
 Choosing trailer within enough load capacity.
The weights of main disparted parts are provided in TABLE 5-1 for user’s reference to facilitate
the job of assembly, disassembly, lifting, transportation and arranging trucks.

Remark：
 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%.
 The counterweight is calculated as per 6800 Kg/m3. Customers shall determine the
number of counterweight to buy according to practical conditions and their need.
 Total weight of water for filling main body, long ship slideway and short ship
slideway is 40 tons.

☆ In cold weather, leave an interspace of 8cm in height when filling water in main
body, long & short ship slideway.

TABLE 5-1 WEIGHTS OF PARTS

PARTS NAME WEIGHT (TON)
Machine body （include parts
Largest part that can not or need not be 38
disassembled）
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Vertical motion mechanism 5.4×4=22

Longitudinal motion mechanism 23.4×2=46.8
Cross motion and rotation mechanism 16.5×2=33
Counterweight beam 6.1×2=12.2
Pile pressing cylinder and beam 6.3×2=12.6
JZX6016BJ 11.4
JZX6036BJ 11.4
Pile clamping box
JZX6038BJ 14.8
JZX8016BJ 14
Main machine(without counterweight) 167
Side pile assembly(optional) 11
Type-F counterweight block 7.1×38=269.3
Square counterweight block 6.9×22=151.8

Fig 5-13 ZYJ860B－ⅡLargest Part Shipping Dimension

5.4 DEBUGGING

See §4 OPERATION REGULATIONS for reference.

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5.5 DAILY SERVICE AND ROUTINE 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 even torque moment if there are several fixing screw bolts. The mounting
bolts of clamping cylinders of thin-wall tube pile clamping box should be tightened again
after the new machine has worked one or two days.
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.( see the table §5-6LUBRICATION DIAGRAM )
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
to zero, unscrew the oil-filling plug loose, 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

Main machine Crane

Number Number
Parts of Greasing Parts of Greasing
Interval Interval
name greasing style name greasing style
point point
Longitud
inal Wire
16 Grease gun 7days 1 Spreading 7days
motion rope
wheel
Transvers Radius
Grease
e motion 12 Grease gun 7days change 4 7days
gun
wheel shaft
Guide 16 Grease gun 3days Upper 1 Grease 7days
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 ZYJ860B－ⅡOperator’s Manual

wheel of wire gun

pile wheel
pressing
box
Spheric Change
Lower
socket on Change
8 Spreading wire 1 Spreading work
wheel site
wheel
carrier site
Center Pulley Grease
4 Spreading 30days 1 7days
shaft block gun
Riding
Friction
wheel of Grease
surface 2 Spreading 3days 1 60days
telescopi gun
of rotary
c jib
Guiding
Slewing Grease
wheel 8 Spreading 3days 1 30days
support gun
track
Wheel Slewing
carrier 4 Spreading 7days wheel 1 Spreading 7days
track gear
Inner
part of Every
16 Grease gun
clamping shift
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.

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5.7 TORQUE FOR STANDARD TIGHTENING PARTS

Thread size M6 M8 M10 M12 M16 M18 M20 M24 M27 M30
Level 8.8 10 24 44 78 190 260 370 640 950 1300
Torque(N·m)
Level 10.9 12 30 62 110 265 365 520 900 1350 1800

【Important Note】Sunward will not be responsible for the warranty under following status.

 Advance system pressure without any approval from Sunward；

 Do not shut down electric fan, electric heater and hydraulic oil heater after stopping
machine；
 Hoisting load who do not follow the operation regulation；
 Short and long ship slideway are not leaving ground in machine moving, and
touching barrier during moving range.

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6 TROUBLE SHOOTING
6.1 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.
open position and can’t be reset.
Oil pressure gauge is destroyed. Change the gauge.
1. Pressure can not meet
needed value or completely The running direction of Change the running direction
no pressure hydraulic pump is wrong. 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.
Leakage in multiple unit valve
and make system pressure can Change multiple unit valve.
not be advanced.
Solenoid valve is not electricity Replace
Foot valve failure Replace
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
pile driver at once.) overflow is blocked, so it can’t Clean and repair.
open and overflow.
Oil pressure gauge is damaged.
Change pressure gauge.
The directed value is not correct.
3. The force of clamping Take out of the spool to
can’t be maintained (If Single-direction valve F4 is not check if there is some
above malfunction happens completely sealed. eyewinker or any abrasion.
and can not stop working, Repair or change it.
the method of
The seals of hydraulic cylinder
discontinuous driving
for clamping are worn so that Change the seals.
clamping cylinder during
chambers in cylinders connect.
one pressing stroke can be
adopted. Pipeline leaks. Stop leakage.

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Oil pressure gauge is damaged.

Change pressure gauge.
The directed value is not correct.
The preset pressure value of
system overflow or pressing-in Reset it
overflow is too low
Sealing of system overflow
4. Pressing pressure can not valve or pressing-in overflow
meet needed value or valve can not meet requirement Repair or change it.
completely no pressure. and is not tight.
Seals of pressing cylinder rod
Replace the worn seals.
are damaged.
Clean return oil filter and
Return oil pressure is too high.
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.
Oil pipeline is blocked. Detect and remove.
5. Overheated oil 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.
The leakage at joints is caused
by loose connection or Check and repair, or replace
6. Leakage
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 Replace seals, and refer to
rod and guide shell surface between piston rod and item 8.
guide shell.
Too dirty oil Re-filtrate or change oil.
Eyewinker between seals and
Clean it
dust-proof seal.
8. Piston rod surface pulled
Seals for guide shell are
Change them.
damaged.
Guide shell is damaged. Replace it

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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
Reset the interval or change
interval should be 8~10
relay.
seconds.
10. Electrical elements Start oil pump disobeying the Operate as per regulations
being frequently burnt 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
tracks Change axle or wheel carrier.
burnt.
The cover press is too tight. Adjust the cover.
12. Multi-way valve works
abnormally Steel ball is abraded or broken. Replace Steel ball

13. Large noise in oil pump Oil inlet is poor sealed and air is
Sealing oil inlet.
running. in.
Air has already been in oil. Replace oil.
Check and repair oil pump,
Oil pump is abraded.
replace abraded parts.
Pile unscrewing pressure is not Adjust overflow valve for
enough. unscrewing pile.
M24 screw in pile clamping box Check and repair parts and
14. Jaw is unscrewed are damaged. replace failure.
difficultly. Abrasion between pile clamping
cylinder and sleeve; gas is too
large and lead to sleeve swing, Treat and solve failures.
sleeve touches face plate and
pile can not be loosened.
Operation is incorrect, pile
clamping handle is not reset to
Correct operation method.
neutral position after clamping
15. Jaw is slip in pile pile.
pressing. Pile clamping pressure is not Adjust pile clamping
enough. pressure.
Jaw abrasion Replace jaw
Leakage in pile clamping
Check and repair cylinder.
cylinder.

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6.2 REPAIR

1. Before examination and repair, long ship and short ship slideway must be laid down on
ground.
2. Only professional personnel are allowed to repair hydraulic system.
3. Any repair is forbidden if hydraulic system pressure still exists.
4. 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.
5. The joints, hose and seals must be the right type as designed.
6. Choose place without dust to dispart and assemble hydraulic elements.
7. 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.
8. 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.
9. If it is necessary to use welding method, things must be done before welding are preparing
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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7 MAIN TECHNICAL DATA

APPENDIX TABLE 7-1 SIGNS IN THIS MANUAL

Signs Meaning Value

Pa System Max. oil pressure 25 MPa

Pd Auxiliary pile pressing oil pressure It depends on real condition.
Pe Pile clamping oil pressure It depends on real condition.
Pb System pressure with pump at full flux 14 MPa
P1 Largest pile-pressing weight 307.5T
P2 Largest pile-pulling weight 150 T

P3 Allowable largest weight of pile driver at 712 T

pile- pulling

APPENDIX TABLE 7-2 BASIC PARAMETERS

Item Parameter

Max. pile pressing force

307.5 tf
(25 MPa)
The chief pressing-in
Max. pile pressing speed
hydraulic cylinder works 7.0 m/min
(oil pressure＜14 MPa)
separately
Min. pile pressing speed
2.2 m/min
(oil pressure =25 MPa)
Max. pile pressing force
615 tf
Two chief and (25 MPa)
secondary pressing-in Max. pile pressing speed
2.0 m/min
hydraulic cylinders work (oil pressure＜14 MPa)
together Min. pile pressing speed
1.3 m/min
(oil pressure =25MPa)
Max. pile pressing force
860 tf
All chief and the (25 MPa)
secondary pressing-in Max. pile pressing speed
1.2 m/min
hydraulic cylinders work (oil pressure＜14 MPa)
together Min. pile pressing speed
0.8 m/min
(oil pressure =25MPa)
Pressing-in stroke 1.8 m
Max. pile pressing force
Side piling 245 tf
(25 MPa)
Longitudinal stroke（once） ≤3.6 m
Capability of motion Transverse stroke（once） ≤0.7 m
Every rotating angle（once） ≤8°
Stepping speed Forward ≤6.67 m/min
Backward ≤10.95 m/min
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Left ≤6.67 m/min

Right ≤9.56 m/min
Vertical motion stroke 1.1 m
Grounding pressure Long ship slideway 15.35 tf/m2
(680 t ) Short ship slideway 20.3 tf/m2
Normal pressing position Side pile distance 4180 mm
After equipped with side Side pile distance 600 mm
piling device Corner pile distance 1160 mm
JZX6016BJ
JZX6036BJ
Pile clamping box( either one is ok)
JZX6038BJ
JZX8016BJ
Pile pressing rated pressure (860 tf) 25 MPa
Rated pressure for lifting 18 MPa
Hydraulic system Pile pressing flow rate(at full flow) 450 L/min
A7V107LV2.0LZFOO(3
Hydraulic pump model sets)

Y225M-4-45KW B35(3
Electric motor model sets)

Pile pressing power 45 Kw×3=135 Kw

Voltage 380 V
Electrical system
Current (the whole machine) 90×3= 270 A
Frequency 50 Hz

Power cable YCW3X70+1X25+1X16

Dimension (LxWxH) (mm) 14300×8680×3280

Max. round pile jaw For 6016 Max. Y60、F40
Max. square pile jaw For 6036 Max. Y60、F60
Max. square pile jaw For 6038 Max. Y60、F60
Max. square pile jaw For 8016 Max. Y80、F50
Weight of main machine 178 T
Weight of whole machine 600 T

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APPENDIX TABLE 7-3 OIL PRESSURE AND PILE PRESSING PRESSURE

Piling Force (tf)

Chief piling cylinder works Chief piling
Oil pressure alone Chief piling cylinder
cylinder +Auxiliary 1
(MPa)
+Auxiliary piling cylinder
Quick piling Normal piling
1piling cylinder + Auxiliary 2
piling cylinder
1.0 6.3 12.3 24.6 34.4
2.0 13.6 24.6 49.2 68.8
3.0 18.9 36.9 73.8 103.2
4.0 25.2 49.2 98.4 137.6
5.0 31.5 61.5 123.0 172.0
6.0 37.8 73.8 147.6 206.4
7.0 44.1 86.1 172.2 240.8
8.0 50.4 98.4 196.8 275.2
9.0 56.7 110.7 221.4 309.6
10.0 63.0 123.0 246.0 344.0
11.0 135.3 270.6 378.4
12.0 147.6 295.2 412.8
13.0 159.9 319.8 447.2
14.0 172.2 344.4 481.6
15.0 184.5 369.0 516.0
16.0 196.8 393.6 550.4
17.0 209.1 418.2 584.8
18.0 221.4 442.8 619.2
19.0 233.7 467.4 653.6
20.0 246.0 492.0 688.0
21.0 258.3 516.6 722.4
22.0 270.6 541.2 756.8
23.0 282.9 565.8 791.2
24.0 295.2 590.4 825.6
25.0 307.5 615.0 860.0

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APPENDIX TABLE 7-4 ATTACHMENT PARTS

No Part No Part Name Qty Remark

COMPOSITE BEARING
1 750502000379 8
SF-2-150113
COMPOSITE BEARING
2 750502000006 2
SF-1-3240
COMPOSITE BEARING
3 750502000010 2
SF-1-3250
COMPOSITE BEARING
4 750502000007 2
SF-1-6050
COMPOSITE BEARING
5 750502000008 2
SF-1-50100
6 750502000319 BEATING COB031 105110 2
7 703202012001 WASHER UNIT 12 JB982 10
8 703202014002 WASHER UNIT 14 JB982 10
9 703202018001 WASHER UNIT 18 JB982 10
10 703202022001 WASHER UNIT 22 JB982 10
11 703202027001 WASHER UNIT 27 JB982 10
12 703202033001 WASHER UNIT 33 JB982 10
13 703202039001 WASHER UNIT 39 JB982 10
14 703202042001 WASHER UNIT 42 JB982 10
15 703202045001 WASHER UNIT 45 JB982 5
16 703202048001 WASHER UNIT 48 JB982 10
O SEAL RING 8.5X1.8 GB/T
17 703201008501 10
3452.1
O SEAL RING 9.5X1.8 GB/T
18 703201009503 10
3452.1
O SEAL RING 25.8X3.55 GB/T
19 703201025802 10
3452.1
O SEAL RING 30X3.55 GB/T
20 703201030001 10
3452.1
O SEAL RING 31.5X3.55 GB/T
21 703201031502 10
3452.1
O SEAL RING 33.5X3.55 GB/T
22 703201033502 10
3452.1
O SEAL RING 53X2.65 GB/T
23 703201053001 10
3452.1
O SEAL RING 69X3.55 GB/T
24 703201069001 10
3452.1
25 730603000194 O SEAL RING 59.4X3.1 5
PRESSURE GAUGE
26 740402000025 1
Y-100ZT-40MPa
HIGH-SENSITIVITY
27 740430000001 1
GRADIENTER QFS
PLUNGER PUMP
28 730201000101 1
A7V107LV1LZFOO

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29 730301000032 CHECK VALVE AIY-HC25B 1

POLIT OVERFLOW VALVE
30 730303900037 1
DB30-2-50B/315
OIL SUCKING FILTER
31 730401000244 1
WU-1000x100-J
32 730403000014 FUSE FBX-400X20 1
CHECK VALVE BLOCK
33 730301000178 1
SYKDXF-500/315
ELECTROMAGNETIC VALVE
34 730305000047 1
4WE6Y-6X/EG24NZ5L
35 720211000006 FUSE φ10X38 2A 10
36 720211000015 FUSE D10X38 R015 RT14 10A 5
37 720211000084 FUSE INSERT ATS 3A 5
38 720211000062 FUSE INSERT ATS5 5
39 720214000032 LAMP(TOP) 1000W PHILIP 2
40 720214000055 LAMP(TOP) 500W PHILIP 2
SCREWDRIVER WITH
41 740254000058 1
VOLTAGE TESTER DL8002
CROSS-HEAD SCREWDRIVER
42 740121000025 1
150X6
SCREWDRIVER 150X6.5X1
43 740121000029 1
GB/T 10639
44 720209000028 CONTACTOR GSC1-6511 220V 3
CONTACTOR CJX4-0910DA
45 720209000039 1
220V
AC CONTACTOR GSC1-0901
46 720209000185 1
220V
47 720209000038 CONTACTOR CJX4-1210 220V 1
PRESSURE SWITCH
48 720212000588 1
P11-011SM14HO DT
PRESSURE SWITCH
49 720212000589 1
P11-011SM14HC DT
50 720235000022 DOOR LIMIT SWITCH TZ-8108 1
BUZZER AD16-22M/K31
51 720410000024 1
AC220V
TEMPERATURE SWITCH
52 720212000377 1
CMRD-09 60
53 305030000611 FRICTION DISK
THREAD LOCKING GLUE
54 760501000001
1262
55 801298020000 LIST

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APPENDIX TABLE 7-5 ATTACHMENT TOOLS

No Part No Tool Name Qty Remark

1 740115000006 DOUBLE-ENDED SPANNER 5.5-32 1

2 740131000010 NIPPER 175 1
3 740104000048 INNER HEXAGON SPANNER 3-22 1
4 740121000003 CROSS-HEAD SCREWDRIVER 75×5 1
CROSS-HEAD SCREWDRIVER
5 740121000004 1
200×8
6 740121000006 CROSS-HEAD SCREWDRIVER 75×5 1
CROSS-HEAD SCREWDRIVER
7 740121000007 1
200×8
8 740131000004 WIRE PLIERS 200mm 1
MOVABLE SPANNER 300×36
9 740103000004 1
GB4440
MOVABLE SPANNER 450×55
10 740103000006 1
GB4440
SCREWDRIVER WITH VOLTAGE
11 740254000002 1
TESTER
12 720214000032 LAMP(TOP) 1000W PHILIP 1
13 720214000055 LAMP(TOP) 500W PHILIP 1
14 740258000015 GREASE GUN(FOOT-TYPE) SD-8 1
15 740210000006 ROUND FACE HAMMER 2P 1
16 845999010000 TOOL BOX 1
17 740131000021 PIPE SPANNER 450 1
18 740239000007 CROWBAR D25X1000 1
19 740210000087 HAMMER 18POUND 1

APPENDIX TABLE 7-6 MAIN WEARING PARTS

Part No Part Name Remark

730402000013 AIR FILTER

FOR HYDRAULIC OIL
730401000244 OIL SUCKING FILTER
TANK
FOR HYDRAULIC OIL
730401000128 OIL RETURN FILTER
TANK
OIL RETURN FILTER FOR COUNTERWEIGHT
730401000023
(MAGNETIC) OIL TANK
305030000806 FRICTION RING FOR WHEEL CARRIER
720222000009 ELECTRIC BRUSH FOR COLLECTING RING

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704105015005 STEEL WIRE ROPE

703201008501 O SEAL RING
703201009503 O SEAL RING
703201025802 O SEAL RING
703201030001 O SEAL RING
703201031502 O SEAL RING
703201033502 O SEAL RING
703201053001 O SEAL RING
703201069001 O SEAL RING
730603000194 O SEAL RING
703203000101 O SEAL RING
703202010002 WASHER UNIT
703202012001 WASHER UNIT
703202014002 WASHER UNIT
703202018001 WASHER UNIT
703202020001 WASHER UNIT
703202022001 WASHER UNIT
703202027001 WASHER UNIT
703202033001 WASHER UNIT
703202042001 WASHER UNIT
703202048001 WASHER UNIT
720211000006 FUSE CORE
720211000013 FUSE CORE
720211000038 FUSE CORE

APPENDIX TABLE 7-7A JAWS COLLOCATION FOR CLAMPING BOX JZX6016BJ

JAW FIXING SCREW

PILE MODE SPEC.
QTY REMARK QTY
L GB/T 70.1
F25
F25 8 Used together with Y40 M16×45 16
SQUARE
F30
F30 8 Used together with Y50 M16×70 16
SQUARE
F35
F35 8 Used together with Y50 M16×45 16
SQUARE
F40
F40 8 Used together with Y50 M16×40 16
SQUARE
Φ250 Y25 8 Used together with Y40 M16×65 16

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SQUARE
Φ300 Used together with
Y30 8 M16×50 16
SQUARE Y40、Y50
Φ350 Used together with
Y35 16 M16×30 32
SQUARE Y40、Y50
Φ400
Y40 16 Used together with Y50 M16×50 32
SQUARE
Φ450
Y45 16 Used together with Y50 M16×30 32
SQUARE
Φ500 Hang on the jaw seat
Y50 16 M16×60 32
SQUARE directly
Φ550
Y55 16 Used together with Y60 M16×30 32
SQUARE
Φ600 Hang on the jaw seat
Y60 16 M16×45 32
SQUARE directly

 The piling force should not exceed 400T if we use clamping box JZX6016BJ for pressing
square pile.

APPENDIX TABLE 7-7B JAWS COLLOCATION FOR CLAMPING BOX JZX6036BJ

JAW FIXING SCREW

PILE SPEC.
MODEL QTY REMARK QTY
GB/T 70.1
Used together with
F30 SQUARE F30 8 M20×160 16
F50
Used together with
F35 SQUARE F35 8 M20×160 16
F50
Used together with
F40 SQUARE F40-45A 8 M20×130 16
F50
Used together with
F45 SQUARE F45 8 M20×130 16
F55
Hang on the jaw
F45 SQUARE F45D 8 M20×110 16
seat directly
Hang on the jaw
F50 SQUARE F50 8 M20×70 16
seat directly
Hang on the jaw
F55 SQUARE F55 8 M20×70 16
seat directly
Hang on the jaw
F60 SQUARE F60 8 M20×50 16
seat directly
Used together with
Φ250 ROUND Y25 8 M20×200 16
Y40
Used together with
Φ300 ROUND Y30 8 M20×200 16
Y40
Used together with
Φ350 ROUND Y35 8 M20×160 16
Y50
Φ400 ROUND Y40 8 Hang on the jaw M20×105 16
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seat directly
Used together with
Φ450 ROUND Y45A 8 M20×130 16
Y55
Hang on the jaw
Φ450 ROUND Y45D 8 M20×110 16
seat directly
Hang on the jaw
Φ500 ROUND Y50 8 M20×70 16
seat directly
Hang on the jaw
Φ550 ROUND Y55 8 M20×70 16
seat directly
Hang on the jaw
Φ600 ROUND Y60 8 M20×50 16
seat directly

APPENDIX TABLE 7-7C CLAMPING JAW COLLOCATION FOR JZX6038BJ

JAW FIXING SCREW

PILE MODE SPEC.
QTY REMARK QTY
L GB/T 70.1
F30 SQUARE F30 8 Used together with F50 M20×200 16
F35 SQUARE F35 8 Used together with F50 M20×180 16
F40 SQUARE F40 8 Used together with F50 M20×160 16
F45 SQUARE F45 8 Used together with F55 M20×130 16
Hang on the jaw seat
F45 SQUARE F45D 8 M20×130 16
directly
Hang on the jaw seat
F50 SQUARE F50 8 M20×110 16
directly
Hang on the jaw seat
F55 SQUARE F55 8 M20×60 16
directly
Hang on the jaw seat
F60 SQUARE F60 8 M20×60 16
directly
Φ300 ROUND Y30 8 Used together with F50 M20×200 16
Φ350 ROUND Y35 8 Used together with F50 M20×180 16
Φ400 ROUND Y40 8 Used together with F50 M20×160 16
Hang on the jaw seat
Φ400 ROUND Y40A 8 M20×110 16
directly
Φ450 ROUND Y45 8 Used together with F55 M20×130 16
Hang on the jaw seat
Φ450 ROUND Y45D 8 M20×130 16
directly
Hang on the jaw seat
Φ500 ROUND Y50 8 M20×110 16
directly
Hang on the jaw seat
Φ550 ROUND Y55 8 M20×60 16
directly
Hang on the jaw seat
Φ600 ROUND Y60 8 M20×60 16
directly

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APPENDIX TABLE 7-7D CLAMPING JAW COLLOCATION FOR JZX8016BJ

JAW FIXING SCREW

PILE SPEC.
MODEL QTY REMARK QTY
GB/T 70.1
F30-35A/ Used together with
F30 SQUARE 12 M16×45 24
B F40 and Y60
F30-35A/ Used together with
F35 SQUARE 12 M16×45 24
B F45 and Y60
Used together with
F40 SQUARE F40A/B 12 M16×210 24
Y60
Used together with
F45 SQUARE F45A/B 12 M16×210 24
Y60
Used together with
F50 SQUARE F50A/B 12 M16×130 24
Y80
Used together with
Φ300 ROUND Y30 10 M16×45 20
Y40 and Y60
Used together with
Φ400 ROUND Y40 20 M16×210 40
Y60
Used together with
Φ500 ROUND Y50 20 M16×190 40
Y60
Used together with
Φ550 ROUND Y55 20 M16×160 40
Y70 and Y80
Hang on the jaw seat
Φ600 ROUND Y60 20 M16×130 40
directly
Used together with
Φ700 ROUND Y70 20 M16×90 40
Y80
Hang on the jaw seat
Φ800 ROUND Y80 20 M16×45 40
directly
ATTENTION：
 The specific collocation of clamping jaw and clamping box model is subject to user’s choice.

APPENDIX TABLE 7-7D CLAMPING JAW COLLOCATION FOR JZX5022A

JAW FIXING SCREW

PILE MOD SPEC.
QTY REMARK QTY
EL GB/T 70.1
F30
F30 8 M16×130 16
SQUARE
F35
F35 8 M16×100 16
SQUARE
F40
F40 8 M16×75 16
SQUARE
F45
F45 8 M16×55 16
SQUARE
F50
F50 8 M16×30 16
SQUARE
Φ250
Y25 4 M16×150 8
ROUND

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Φ300 Used together with

Y30 8 M16×130 16
ROUND Y40
Φ300 Used together with
Y30 8 M16×130 16
ROUND Y50
Φ400 Used together with
Y40 8 M16×80 16
ROUND Y50
Φ400
Y40A 8 M16×85 16
ROUND
Φ450
Y45 8 M16×55 16
ROUND
Φ500
Y50 8 M16×35 16
ROUND

DIX TABLE 7-8 HYDRAULIC PARTS LIST

NO CODE PART NO PART NAME

1 F1、F2、F3、F5、F6、F7 730303000011 OVERFLOW VALVE

2 F4 730303000004 OVERFLOW VALVE
3 F8 730303000064 OVERFLOW VALVE
4 F9 730303000002 OVERFLOW VALVE
5 F10 730301000032 CHECK VALVE
6 F11 730399000010 OIL DRAIN VALVE
7 P1、P2、P3 730201000101 PLUNGER PUMP
8 730302000250 MULTIPLE UNIT VALVE
9 730302000172 MULTIPLE UNIT VALVE
10 730302000048 MULTIPLE UNIT VALVE
11 730302000002 MULTIPLE UNIT VALVE
730302000303 MULTIPLE UNIT VALVE

APPENDIX TABLE 7-9 ELECTRICAL PARTS LIST

PART NO PART NAME QTY CODE REMARK

RESISTANCE
720212000312 1 FOR NORTH
SENSOR
TEMPERATURE
720212000377 1
SWITCH
720238000041 CIRCUIT BREAKER 1
720238000106 CIRCUIT BREAKER 1
SIMULATING
720804000002 1
SOCKET
SIMULATING
720804000012 1
SOCKET
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 ZYJ860B－ⅡOperator’s Manual

TUNGSTEN IODINE
720214000054 2
LAMP
STAINLESS STEEL
720221000011 6 FOR NORTH
HEATING TUBE
720409000037 AUTOMOBILE FAN 1
TUNGSTEN IODINE
720214000053 1
LAMP
DAMP-PROOF
720412000034 1
LAMP
720238000070 CIRCUIT BREAKER 1
720238000080 CIRCUIT BREAKER 3
720209000039 CONTACTOR 2
720203000009 THERMAL RELAY 1
AUXILIARY
720208000005 1
CONTACTOR
720209000038 CONTACTOR 1
720203000010 THERMAL RELA 1
720210000002 FUSE SEAT 6
720211000006 FUSE CORE 3
720211000015 FUSE CORE 1
720211000038 FUSE CORE 2
720238000052 CIRCUIT BREAKER 1
720238000106 CIRCUIT BREAKER 1 FOR NORTH
720238000054 CIRCUIT BREAKER 1 FOR NORTH
FOR FLOATING
720202000017 DC RELAY 1
WARNING
720209000091 AC CONTACTOR 1 FOR NORTH
720209000028 CONTACTOR 9
720203000002 THERMAL RELAY 3
720201000004 DELAY RELAY 3
FLAT PLATE
720406000112 1
POWER SUPPLY
CURRENT
720217000003 1
TRANSFORMER
WALL SOCKET(5
720804000021 1
HOLES 1 OPEN)
SOCKET(ENGLISH
720803000012 1 FOR DOMESTIC
STANDARD)
BUTTON WITH
720237000115 4 FOR OVERSEAS
LAMP
USE 5PCS IN
720237000058 BUTTON SWITCH 6 FLOATING
WARNING
720237000053 BUTTON WITH 1 FOR FLOATING
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LIGHT WARNING
720410000024 BUZZER 1
TEMPERATURE
740431000033 FOR NORTH
METER

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8 APPENDIX FIGURES

APPENDIX FIGURE 1 MAIN MACHINE HYDRAULIC SYSTEM

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APPENDIX FIGURE 2 MAIN MACHINE ELECTRICAL SYSTEM

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APPENDIX FIGURE 3 PILE DRIVER COUNTERWEIGHT

1- Square counterweight 2- F counterweight 3-Counterweight beam

4-Fixed pin 5-Screw 6-Bundling device

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9 ABOUT THE MANUFACTURER

Company name: SUNWARD INTELLIGENT EQUIPMENT CO., LTD.

Trade mark:

Address: No.16 LiXiang Road, Xingsha economic and technologic development district,

Changsha, Hunan.

Contact Tel：0086-0731-83572642 83572717

Consult Hot-line：800-878-6230

Service Hot-line：400-887-8230

Complain Hot-line：400-887-6230

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：

68