ZYJ240A Operator's Manual

ZYJ240A Operator’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 ......................................................................................................................... 4
1.2 SAFETY RULES....................................................................................................................................... 6
1.3 PREPARATION FOR EMERGENCY...................................................................................................... 6
1.4 WEAR SAFETY PROTECTIVE ARTICLES .......................................................................................... 7
1.5 KEEP MACHINE CLEAN ....................................................................................................................... 7
1.6 KEEP OPERATOR’S COMPARTMENT CLEAN ................................................................................... 7
1.7 MOUNTING AND DISMOUNTING....................................................................................................... 7
1.8 MOVE MACHINE SAFELY .................................................................................................................... 7
1.9 REQUIREMENT TO THE CONSTRUCTION FIELD............................................................................ 8
1.10 CHECK MACHINE BEFORE START-UP ............................................................................................ 9
1.11 OPERATE SAFELY ................................................................................................................................ 9
1.12 KEEP AWAY FROM TRANSMISSION PARTS.................................................................................. 10
1.13 MAINTAIN SAFELY ........................................................................................................................... 10
1.14 BEWARE OF HIGH PRESSURED LIQUIDS ..................................................................................... 10
1.15 BEWARE OF SCALD ...........................................................................................................................11
1.16 AVOID HEATING UP NEAR PRESSURE OIL PIPE ..........................................................................11
1.17 AVOID HEATING UP PIPE WITH PRESSURE OIL...........................................................................11
1.18 RREMOVE PAINT BEFORE WELDING OR HEATING....................................................................11
1.19 AVOID FIRE ......................................................................................................................................... 12
2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER ............................................................... 13
2.1 ADVANTAGES OF SUNWARD PILE DRIVER.................................................................................... 13
2.2 COMPARED WITH THOSE BY OTHER FACTORIES ........................................................................ 13
3 BASIC STRUCTURE AND WORK PRINCIPLE ............................................................................................ 15
3.1 BASIC STRUCTURE OF ZYJ240A....................................................................................................... 15
3.2 PILING PLATFORM .............................................................................................................................. 16
3.2.1 STRUCTURE............................................................................................................................... 16
3.2.2 PILE PRESSING PROCESS ....................................................................................................... 17
3.3 TRAVEL MECHANISM......................................................................................................................... 17
3.3.1 VERTICAL MOTION MECHANISM ........................................................................................ 17
3.3.2 LONGITUDINAL MOTION MECHANISM.............................................................................. 18
3.3.3 CROSS MOTION AND ROTATION MECHANISM ................................................................. 18
3.3.4 CONTINUOUS STEPPING AND ROTATION........................................................................... 19
3.3.5 LONGITUDINAL MOTION ....................................................................................................... 19
3.3.6 CROSS MOTION ........................................................................................................................ 20
3.3.7 ROTATION .................................................................................................................................. 20
3.4 HYDRAULIC SYSTEM( FOR PILE PRESSING) ................................................................................ 22
3.4.1 STRUCTURE............................................................................................................................... 22
3.4.2 WORK PRINCIPLE (see appendix figure 1 hydraulic system)................................................... 24
3.5 SIDE PILING AND CORNER PILING .................................................................................................. 26
3.6 ELECTRIC SYSTEM.............................................................................................................................. 28
4. OPERATING REGULATIONS ........................................................................................................................ 29
4.1 CONTROL PANEL................................................................................................................................. 29
4.2 PREPARATION BEFORE PRESSING PILE......................................................................................... 30
4.2.1 PREPARATION BEFORE START-UP ........................................................................................ 30
4.2.2 ADJUSTMENT OF HYDRAULIC PUMP.................................................................................. 31
4.2.3 ADJUSTMENT OF OIL PRESSURE.......................................................................................... 33
4.2.4 ADJUSTMENT OF OIL PRESSURE FOR CLAMPING AND RELEASING PILE ................. 33
4.3 OPERATION METHOD AND STEPS.................................................................................................... 34
4.3.1 START-UP.................................................................................................................................... 34
4.3.2 POSITIONING PILE ................................................................................................................... 34
4.3.3 LEVELING .................................................................................................................................. 34
1
4.3.4 PRESSING PILE.......................................................................................................................... 34

4.3.5 ATTENTION ................................................................................................................................ 36
4.4 INSTALLATION AND REPLACEMENT OF CLAMPING JAW......................................................... 37
4.4.1 INSTALLATION.......................................................................................................................... 37
4.4.2 REPLACEMENT OF CLAMPING JAW .................................................................................... 39
5 DISASSEMBLY, TRANSPORTATION AND MAINTENANCE ..................................................................... 39
5.1 REQUIREMENTS TO DISASSEMBLY SITE ...................................................................................... 39
5.2 DISASSEMBLY...................................................................................................................................... 39
5.3 ASSEMBLY ............................................................................................................................................ 43
5.4 TRANSPORTATION .............................................................................................................................. 43
5.5 DEBUGGING ......................................................................................................................................... 44
5.6 DAILY MAINTENANCE AND TIME MAINTENANCE...................................................................... 44
5.7 LUBRICATION DIAGRAM................................................................................................................... 45
6 CRANE .............................................................................................................................................................. 46
7 TROUBLE SHOOTING .................................................................................................................................... 47
7.1 COMMON MALFUNCTIONS AND CORRESPONDING SOLUTIONS ........................................... 47
7.2 REPAIR ................................................................................................................................................... 51
8 MAIN TECHNICAL DATA............................................................................................................................... 52
APPENDIX TABLE 8-1 SIGNS IN THIS MANUAL................................................................................... 52
APPENDIX TABLE 8-2 BASIC PARAMETERS......................................................................................... 53
APPENDIX TABLE 8-3 OIL PRESSUAND PILE PRESSING FORCE ...................................................... 55
APPENDIX TABLE 8-4 ATTACHMENT TOOLS ....................................................................................... 56
APPENDIX TABLE 8-5 WEARING PARTS ............................................................................................... 57
APPENDIX TABLE 8-6 CLAMPING JAW COLLOCATION .................................................................... 58
APPENDIX TABLE 8-7 THE TABLE OF OIL PUMP’S PRESSURE VERSUS APPROPRIATE FLOW 58
APPENDIX TABLE 8-8 HYDRAULIC PARTS FOR MAIN MACHINE .................................................. 59
APPENDIX TABLE 8-9 ELECTRIC PARTS FOR MAIN MACHINE....................................................... 60
9 APPENDIX FIGURES....................................................................................................................................... 61
APPENDIX FIGURE 1 MAIN MACHINE HYDRAULIC SYSTEM.......................................................... 61
APPENDIX FIGURE 2 MAIN MACHINE ELECTRIC SYSTEM .............................................................. 62
APPENDIX FIGURE 3 PILE DRIVER COUNTERWEIGHT ..................................................................... 63
APPENDIX FIGURE 4 ELECTRIC SYSTEM FOR WARNING................................................................. 64
10 ABOUT THE MANUFACTURER .................................................................................................................. 65
2
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
3
1.1.2 SAFETY LABELS

1. Caution when machine is working.
Figure 1-2
2. Caution during pile pressing.
Figure 1-3
3. Caution when machine is removing or rotating.
Figure 1-4
4
4. Caution when machine is removing or rotating.
Figure 1-5
5. Caution when crane is working.
Figure 1-6
5
1.2 SAFETY RULES

● Study the manual carefully and follow the
safety instructions in the labels and in the
manual before operating the machine.
● Always keep the safety labels clean. Replace
any lost or damaged label with a new one. If
the labels or manual book is lost, contact dealer
and indicate the model of machine for
purchase.
● Only qualified operator is permitted to operate
this machine. Keep the machine in good
condition as per this manual.
Figure 1-7
● Don’t refit machine without authorization.
Otherwise the performance and lifetime of
Fmachine will be affected, or human body hurt
may be caused.
ATTENTION
The safety instructions in this book only include
the general safety rules of this machine. They do
not cover all the possible danger that may occur. If
there is any problem, please report to your
superior before operating or maintaining the
machine.
1.3 PREPARATION FOR EMERGENCY
If you find any abnormalities in the machine
during operation or maintenance (noise, vibration,
smell, incorrect gauges, smoke, oil leakage, etc.,
or any abnormal display on the warning devices or
monitor), report to person in charge and have the
necessary action taken, do not operate the machine
until the abnormality has been corrected.
Always follow the precautions below to
prepare for action if any injury or fire should
occur.
Figure 1-8
● 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.
6
1.4 WEAR SAFETY PROTECTIVE ARTICLES

Before operation, always wear protective
articles when the work so requires, they include:
Skintight work clothes
Hard hat
Safety gloves
Safety glasses, goggles, or veil
Respirator or filtration veil
Earplug or earcap
1.5 KEEP MACHINE CLEAN Figure 1-9
● 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.
7
● While machine moves from soft field to hard

field, the machine should moves at longitudinal
direction and face forward, i.e. main machine
operator faces to the front of panel.
● Prohibit the machine moving at transverse
direction when it moves from soft field to hard
field.
● When short ship slideway rotates or moves
transversely, assure not to collide with long
ship slideway.
● When controlling longitudinal motion, handles
should be operated at the same time and the
same direction. Any separate and
contra-directional operation should be
prohibited. If one of the longitudinal motion
hydraulic cylinders has extended to the required
position, the other must stop at once to prevent
the damage to the main body.
● Keep the main body horizontal in the
procession of vertical motion in case that these
four vertical motion hydraulic cylinders extend
differently (difference should be less than
100mm), which will cause serious damage to
the main body. It is prohibited to operate two
diagonally placed vertical motion cylinders at
the same time.
1.9 REQUIREMENT TO THE CONSTRUCTION FIELD
● Check and assure the construction field meets
the pressure ratio requirement. There should not
be sharp or hard object of small area in
construction field or small protrusion that
would block the pile driver’s motion。
● The gradient of construction field should not be
larger than 3°. If the construction field has
gradient, pile driver should be placed parallel or
vertical to the construction field’s descending
direction
● If construction field can not meet the
requirement for piling, clear up the construction
field until the requirement is met, then start
piling. In the case of old city rebuilding,
especially when there are a lot of small bricks
or stones in the ground, clear the work site
effectively.
8
1.10 CHECK MACHINE BEFORE START-UP

Before starting machine every day or every
shift, check the machine according to the contents
in “§4.2 preparation before start-up” of this
manual.
1.11 OPERATE SAFELY
● Keep all the non-workers away from working
range.
● Before piling, enough counterweight should be
loaded; during piling, max hydraulic pressure
should not exceed the rated pressure. Otherwise
the pile driver would be lifted off ground.
● The main machine operator and crane operator
should keep good communication and
observation for each other. Prohibit operating
crane or hoisting objects while the machine
moves or rotates. And also, prohibit the
machine moving or rotating while crane is in
operation or hoisting objects.
● Ensure firm binding while hoisting pile.
● Crane’s winch wire should wrap around the
drum for at least 4 circles.
● When lifting pile, it is prohibited to stand in the
working range of crane.
● Check winch wire and pile lifting wire often
and replace them if any damage occurs. Figure 1-10
● Check and screw down the connection bolts at

the crane slewing support every 2 months, the
screwing down torque is 560-600NM. Replace
them with original SUNWARD bolts if any
abnormality occurs.
● Lift rated weight within the limitation of jib
lifting angle to avoid crane jib overloading.
● Before pressing piles, make sure the hook has
been separated from the tools for lifting pile. If
not, there will be serious accident of the lifter
and pile driver. In some special condition, if the
crane winch has to be used as pile follower, the
speed of pile follower must be higher than the
speed of piling.
● Operators shouldn’t put their arms and legs into
the gaps between the pile pressing platform and
the main body.
● Prohibit any person from standing under the
9
counterweight during piling.

● Prohibit pushing any handles in the process of
jointing piles in case that piles fall down to hurt
any people.
● When stop operating, let the short ship
slideway fully touch ground and the long ship
slideway touch ground a little. Then lay the
clamping box to the bottom on the support
beam, shut down power and lock the door.
1.12 KEEP AWAY FROM TRANSMISSION PARTS
● Touching transmission parts may cause GBH.
● Keep careful when working around
transmission parts to prevent hand, foot, hair
and clothes from being entangled in the
machine.
1.13 MAINTAIN SAFELY
Attention of Maintenance:
● Understand the maintenance rules before work
● Keep the working area clean and dry.
● Don’t carry out lubrication or maintenance to
moving machine.
● Avoid body and clothing touching transmission
parts.
● Check some parts at regular intervals, repair or
replace, if necessary. (refer 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
other pipeline to avoid this danger.
● Operate control lever many times to release
pressure. Before supercharging, tighten all the
connections. Figure 1-11
● Inspect leakage with cardboard, take care to
10
protect your hand and body against touching

high-pressured liquids.
● If accident occurs, see the doctor at once.
● Any liquid penetrated in skin must be cleaned
within few hours. Otherwise it will cause
necrosis.
1.15 BEWARE OF SCALD
● During operation, engine oil, gear oil, hydraulic
oil will become hot. Meanwhile, engine, hose,
pipeline, and other parts will also become hot.
Beware of scald.
● Carry out inspection and maintenance after oil
and parts have been cooled to prevent scald.
Figure 1-12
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.
Figure 1-13
1.17 AVOID HEATING UP PIPE WITH PRESSURE OIL
● Not permitted to weld hydraulic oil steel pipe
or hose. Before welding this kind of pipe or
hose, clean it completely with incombustible
solvent.
1.18 RREMOVE PAINT BEFORE WELDING OR HEATING
● Prevent bringing potential poisonous gas and
dust.
● When paint heated up by welding or other
methods, it will bring poisonous gas.
● Remove paint before welding or heating up as
the following methods:
1. Rub out paint with abrasive paper or wheel,
during this work, remember to wear regulated
respirator to prevent inhaling dust.
2. Rub out paint with solvent or paint remover. Figure 1-14
After rubbing out, clean paint remover with
11
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.
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.
● Inspect hose whether twisted or not, attrition
between hose and hard pipe or not, oil cooler
damaged or not, and oil cooler connection
loosened or not. If necessary, tighten, repair, or
replace any clamp, pipe, hose, oil cooler, and
Figure 1-15
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.
12
2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER

Hunan SUNWARD Intelligent Machinery Co. Ltd, combining production, teaching and
research, is a new-type enterprise. SUNWARD series hydraulic static press-in pile drives are new
kinds of machine of high efficiency and energy saving.
WORK PRINCIPLE:
In the process of pile pressing, the machine’s weight acts as reaction force to balance the
friction drag from beside the pile and the reaction force from the pile tip, then the pile is pressed in
the ground.
2.1 ADVANTAGES OF SUNWARD PILE DRIVER
The method of using static press-in precast pile is a very particular way of pile foundation
construction. The precast pile is completely pressed into ground by static force. With development
of pile machinery and enhancement of environment-protecting requirement，it has become a
promising way of pile foundation. Compared with other pile foundation construction methods like
impact, vibration or cast, this way has the following advantages:
1. ENVIRONMENT FRIENDLINISS ----The work of construction is quiet and neat, and workers
have less work intension. It’s suitable for urban construction because of the absence of noise,
vibrancy and pollution.
2. HIGH EFFICIENCY ---- Its efficiency is much higher than that of other pile drivers, and it can
finish hundreds meters of pile foundation in a day work (8 hours). It is most suitable for urgent
and large foundation projects.
3. HIGH QUALITY ---- The process of driving pile is similar to testing pile, therefore the rate of
success is almost 100%.
4. UNLIMITED TOTAL LENGTH OF JOINTED PILE ---- The total length of jointed piles is not
limited if pile’s strength allows.
5. LOW COST ---- In all kinds of pile foundation construction methods, the cost of static press-in
technics is one of the most economical types if compared by the cost of carrying capacity per
cubic meter of pile.(equals to that of casting pile when carrying capacity is the same)
2.2 COMPARED WITH THOSE BY OTHER FACTORIES
Customers can choose suitable type according to their practical needs in the range of pressing
force from 800KN to 12000KN. Compared with pile driver made by other factories, SUNWARD
series have the following prominent advantages:
ⅠTECHNIQUE INOVATIONS
In the series products, Sunward has one patent for invention(ZL 93110671.0), three new
type practical patents (patent No. ZL 95236709.2、ZL99249764.7、ZL 99249765.5. These patents
got National Excellence Award and the Ten Most Well Applied Patents Award in Hunan province.
Adopting patent technology highly improves performance of Sunward pile driver:
1. The quasi-constant-power pile driving system is composed of two pairs of hydraulic cylinders
which work orderly in pile-driving and the well-matched hydraulic system makes this kind of
pile drivers superior to other pile drivers of the similar rank, because of its 40% energy saving,
15% increase of speed and more than 40% raised pile driving force.
2. The new type of Step-like moving mechanism can do longitudinal, cross and rotary motion
freely, which makes it easy and agile to aim piles. A two- tier framework with cross and rotary
13
motion system has a compact structure which is easy to assemble. Specially designed rotary
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.
14
3 BASIC STRUCTURE AND WORK PRINCIPLE

3.1 BASIC STRUCTURE OF ZYJ240A
10
1 2
11 4
9
3
7
Figure 3-1 ZYJ 240A Pile driver structural exploded view
1. Pile driver main cabin---to protect operator 2. Operating platform---where to operate pile
driver 3. Machine body---to support machine 4. Pile pressing platform---main working
mechanism 5. Hydraulic pipeline--to convey hydraulic oil
6. Longitudinal motion mechanism---to travel longitudinally
7. Cross motion and rotation mechanism---to travel transversely and rotate
8. Vertical motion mechanism---vertical motion of machine body
9. Oil pump group---to provide hydraulic power
10. Counterweight---to increase machine’s weight during pressing pile
11. Crane---to lift heavy parts ( e.g. pile, counterweight)
15
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.
2
3
4
FIGURE 3-2 STRUCTURE OF PILING PLATFORM

1- Chief pile pressing cylinder 2- Secondary pile pressing cylinder 3- Guide rack
4- Pile pressing free bearing 5- Pile pressing spherical head 6- Pile clamping box
FIGURE 3-3 STRUCTURE OF PILE CLAMPING BOX

1- Pile clamping box body 2- Clamping jaw 3- Pile clamping cylinder
16
3.2.2 PILE PRESSING PROCESS

When it starts to press precast pile, the chief pile pressing hydraulic cylinder raises the
clamping box to the highest position. When the precast pile is put into the central hole in the box,
clamping cylinders extend and drive the jaws to clamp the pile. After that，operate the handle of
the pile pressing valve to make the chief pressing hydraulic cylinder work and strong hydraulic
force will be produced to press the pile into ground. When the clamping box reaches the lowest
position, the clamping cylinders draw back and release pile. Then pressing cylinders raise the
clamping box to the highest position to start pressing pile again. So the precast pile is pressed into
the ground base step by step in the cycle of “ clamp pile→ press pile→ release pile→ return→
clamp pile …”.
The chief pile pressing cylinder shall work alone if the needed pressing pressure is lower than
P1. （See appendix table 8-1）If the needed pressing pressure is over P1, the chief and secondary
pile pressing cylinder must work together.
（highest position）
Clamp pile
（decline）Press pile lift
Release pile
（lowest position）
FIGURE 3-4 PILE PRESSING CYCLE

3.3 TRAVEL MECHANISM
It is a step-like traveling mechanism including vertical motion mechanism, longitudinal
motion mechanism, cross motion and rotation mechanism. By the three mechanisms, continuous
step-like travel can be carried out.
3.3.1 VERTICAL MOTION MECHANISM
It is mainly composed of four vertical motion

cylinders and four cantilevers. The four cylinder
tubes are fixed by the four cantilevers to the machine
body, and one end of their rods are jointed with four
wheel carriers in long ship slideway. When the piston
extends, the main body rises, otherwise it falls.
FIGURE3-5 STRUCTURE OF VERTICAL

MOTION MECHANISM
1- Cantilever 2- Vertical motion cylinder
17
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.
4
1
FIGURE 3-6 STRUCTURE OF LONGITUDINAL MOTION MECHANISM

1- Long ship slideway 2- Wheel carrier 3- Longitudinal motion cylinder
4- Linkage cylinder（optional）
3.3.3 CROSS MOTION AND ROTATION MECHANISM
It’s composed of two short ship slideways, two cross motion cylinders, rotary platform,
central axis and return spring mechanism.
FIGURE 3-7 STRUCTURE OF CROSS MOTION AND ROTATION MECHANISM
1- Short ship slideway 2- Rotary platform 3- Return spring
4- Wheel carrier 5- Lifting hook 6- Central axis hole
18
3.3.4 CONTINUOUS STEPPING AND ROTATION
FIGURE 3- 8 STRUCTURE OF TRAVEL MECHANISM
1- Cross motion cylinder 2- Vertical motion cylinder 3- Longitudinal motion cylinder

4- Long ship slideway 5- short ship slideway
3.3.5 LONGITUDINAL MOTION
Vertical motion cylinders draw back and short ship slideways support the machine, long ship
slideways leave ground；longitudinal cylinders stretch or draw together, and long ship slideways
move; vertical motion cylinders stretch out till long ship slideways touch ground and short ship
slideways leave ground; longitudinal cylinders stretch or draw together, then body and short ship
slideways move longitudinally.
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 ship 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
19
3.3.6 CROSS MOTION

Vertical motion 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 3-12)
Step1: Get the pile driver ready.
Step 2: Long ship slideways touch the ground, short ship slideways are lifted, cylinders in
short ship slideways go to the end vis-a-vis.
Step 3: Short ship slideways touch the ground, long ship slideways are lifted, cylinders in
short ship slideways go to the end vis-a-vis( the direction is opposite to that in Step 1). If the
clearance between short ship slideways and long ship slideways is smaller than the stroke of
cylinders, the cylinders just need to go to the end of the clearance.
Step 4: Long ship slideways touch the ground, short ship slideways are lifted, short ship
slideways and rotary platform rotate around central axis and get back to original place when
rubber spring in rotary platform flexes.
Step 5: long ship slideways touch the ground, short ship slideways touch the ground, then
return to original position.
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FIGURE 3-11 ROTATING MANNER
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 two pressure compensation variable pumps, three groups of manual
multidirectional valves，several oil distribution valve blocks and hydraulic cylinders as well as
some other supplementary hydraulic equipment.
FIGURE 3-13 LOCATION OF PILE DRIVER HYDRAULIC CYLINDERS

1- Vertical motion hydraulic cylinder 2- Cross motion hydraulic cylinder
3- Longitudinal motion hydraulic cylinder 4- Amplitude cylinder
5- Pile pressing hydraulic cylinder 6- Pile clamping hydraulic cylinder
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3.4.1.1 MULTI-DIRECTIONAL VALVE

Operators use the four operation handles of multi-directional valves to operate the pile driver.
1
3 2
FIGURE 3-14 THREE GROUPS OF MANUAL MULTI-DIRECTIONAL VALVES
1- Multi-directional valve C 2- Multidirectional valve B 3- Multi-directional valve A
4- Operating handle
Multi-directional 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-directional valve B ------ It controls the job of pile pressing, pile clamping, pile releasing
and the rise and drop of clamping box.
Multi-directional valve C ------ It controls the stepping and rotary motion of pile driver.
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3.4.2 WORK PRINCIPLE (see appendix figure 1 hydraulic system)
3.4.2.1 Travel by hydraulic control

Operators use four operating handles to control the stepping of pile driver.
FIGURE 3-15 HYDRAULIC SYSTEM FOR TRAVELING

1- Multi-directional valve C 2- Valve seat 3- Cross motion cylinder 4- Longitudinal motion
cylinder 5- Longitudinal motion mechanism 6- Cross motion mechanism
3.4.2.2 Hydraulic system for vertical motion
Operators use four operating handles to control the vertical motion of pile driver.
FIGURE 3-16 HYDRAULIC SYSTEM FOR VERTICAL MOTION

1- Multi-directional valve A 2- Valve seat 3- Vertical motion cylinder
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3.4.2.3 Hydraulic system for clamping pile
Operators use the multi-unit valve B to control the job of clamping and releasing pile.
FIGURE 3-17 HYDRAULIC SYSTEM FOR PILE CLAMPING

1- Multi-directional valve B 2- Valve seat 3- Pile clamping box 4- Pile clamping cylinder
3.4.2.4 Hydraulic system for pressing pile
FIGURE3-18 HYDRAULIC SYSTEM FOR PRESSING PILE

1- Multi-directional valve B 2- Valve seat 3- Pile pressing hydraulic cylinder
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3.5 SIDE PILING AND CORNER PILING
When pressing side or corner pile, use crane to lift the clamping box and pile pressing guide
rack (including pile pressing cylinder) to side pile free bearing and assemble them, then install
them with hydraulic hoses. It can work now. The operating procedures for pressing side pile are
the same with those of when pressing site is in the middle of pile driver.
FIGURE 3-19 SIDE PILE FRAME

1- Pile pressing hydraulic cylinder 2- Guide rack 3- Pile clamping box
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FIGURE 3-20 HYDRAULIC SYSTEM FOR PRESSING SIDE PILE

1- Multi-directional valve B 2- Valve seat A 3- Side pile transitional valve
4- Pile pressing hydraulic cylinder
FIGURE 3-21 HYDRAULIC SYSTEM FOR CLAMPING SIDE PILE

1- Multi-directional valve B 2- Valve seat C 3- Joint 4- Pile clamping box
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3.6 ELECTRIC SYSTEM
The machine is connected with three phase standard electrical supply AC380V, 50HZ. The oil
pump groups provide power. The 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 “lifting machine”( see figure 3-22)
Safety rules: to ensure personal safety and equipment safety, the whole machine body must
connect ground firmly and the earth resistance must be kept below 4 ohm. Appendix figure 2 shows
the principle of electrical system.
3.6.1 LIFTING MACHINE WARNING

Sunward developed special lifting machine warning
device according to use character of static pilling machine，
test pressure in each position(four lifting cylinders) to confirm
lifting machine phenomenon during work. When pressure is
less than setting value, alarm device will warn through
electric bell or buzzer to remind operator lifting machine
happening and need to solve the phenomenon。
To make sure lifting machine alarm device in good
condition, it need to check sensors in pilling oil way and four
mast foot cylinders and connection wires frequently ；
Meanwhile, operation platform is set
test button to confirm wire Figure 3-22 Alarm sensor for “lifting machine”
connection；and operation platform

is also set rotating switch and signal light, when alarm device warn by mistake or check failure,
close the switch then electric bell and buzzer will stop warning and red signal light
flash(assembled with test button) to show alarm device closed abnormally; it need to check
failure and solve it then open rotating switch to alarm device in stand-by status(See 4.3.4）
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4. OPERATING REGULATIONS
4.1 CONTROL PANEL
Operators use the push buttons and joy sticks in the control board to operate the machine.
（The joysticks are numbered as S1～S4，Y1～Y4，Z1～Z4）
图 4- 1 操作台面板布置图
FIGURE 4-1 CONTROL PANEL

Z1、Z2—to control two cross motion cylinders
Z3、Z4—to control two longitudinal motion cylinders
Y2—to control the chief pile pressing cylinder
Y3—to control the secondary pile pressing cylinder
Y4—to control pile clamping hydraulic cylinder
S1～S4—to control four vertical motion cylinders
Y1-to choose piling speed（attention ：When piling pressure is higher than 10MPa, it is not
allowed to press pile with quick pressure.）
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FIGURE 4-2 LOCATION OF PUSH-BUTTONS

1- Muffler switch ( to shut off electric bell when alarming against “lifting machine”
2- Axial flow fan switch 3- Outdoor light switch 4-Indoor light switch
5- Pump 3 running indicating light 6- Pump 3 start indicating light
7- Pump 2 indicating light 8- Pump 2 start indicating lamp
9- Pump 1 running indicating light
10- Pump 1 start indicating light 11-Electric alarming bell button
12- Cool-down start button 13- Cool-down stop button
14- Pump 3 start button 15- Pump 3 stop button
16- Pump 2 start button 17- Pump 2 stop button 18- Pump 1 start button
19- Pump 1 stop button
A- Volt gauge B- Amperemeter
NOTE：For different machine model，there may just be reserved holes in corresponding
pisiton.
4.2 PREPARATION BEFORE PRESSING PILE
4.2.1 PREPARATION BEFORE START-UP
① Examine if maintenance and repair meet the requirements.
② Remove the dirt on the wheel carrier track, spread with clean grease.
③ Examine if the oil level in tank is normal.
④ Detect if the voltage is normal (not larger than 400v and not less than 350v).
⑤ Detect if there is electric leakage.
⑥ Detect if there is oil leakage of hydraulic pipeline.
⑦ Check and tighten the joint bolt between clipping jaw and clipping seat.
⑧ Check if the ball valve on pump suction port is open.
⑨ Run the pump one by one, examine if the electric current and oil pressure are normal when
every pump works alone.
⑩ Check if the wire rope is reliable.( if the pile driver is equipped with crane.)
⑪ Simulate piling process. Examine hydraulic system and oil pressure, cylinder and main motion
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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 ADJUSTMENT OF HYDRAULIC PUMP
Adjust the chief hydraulic pump according to the following steps（see Figure 4-3）.
FIGURE 4-3 MAIN MACHINE HYDRAULIC PUMP ADJUSTMENT
（1） Place the handles of 3 multidirectional valves on neutral position, the hydraulic system
unloads (pull any multidirectional valve handle, the machine will start to work).
（2） Screw off plug of pump variable head ( see figure 4-4) ; screw the limitation screw,
adjustment screw of overflow valve F9 as loose as possible.
（3） Start oil pump, the variable head scale pointer should point at the full scale (10) position,
the pump supplies oil at full flux.
（4） Push handle Y3 ( see figure 4-3 ) to “Return” position.
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（5） Screw down adjustment screw of overflow valve F9. At the same time, watch the pressure
gauge, the oil pressure will be increased to Pb.
（6） Unscrew the pump’s adjustment sleeve till dial needle of pump variable head begins to
swing, then screw down adjustment sleeve.
（7） Screw down adjustment screw of overflow valve, till oil pressure is increased to Pa.
（8） Screw in pump limitation screw slowly, ensure that the pointer of 63YCY pump variable
head points at 7.2. Then lock with locknut and screw in plug.
（9） Push handle Y3 to neutral position. The adjustment is finished now. Then the pump’s flow
and pressure vary automatically according to the curves of quasi-constant power
characteristics. (see Figure 4-5 )
See the appendix table 8-7 for the specific value of Pb, Pa and x.
FIGURE 4-4 HYDRAULIC PUMP FIGURE 4-5 CURVES OF QUASI-CONSTANT

ADJUSTMENT MECHANISM POWER CHARACTERISTICS
Q- Flow P- Pressure
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4.2.3 ADJUSTMENT OF OIL PRESSURE

Overflow valve F9 (see Figure 4-6) is used to adjust rated pressure of the hydraulic system.
Set pressure of F9 as follows: After oil pump works normally, push handle Y3 to “(return)”
position, screw down adjustment nut of F9 slowly, watch pile clamping oil pressure meter, when
the oil pressure is increased toPa, the rated pressure adjustment finishes. Then screw down the stop
screw of adjusting nut.
Overflow valve F15(see Figure 4-6) is used to set secondary pile pressing pressure Pd, which
can be set according to different needs ( see appendix table 8-3 oil pressure and pile pressing
force). Adjust pressure of valve F15 as follows: Start pumps till they run steadily; push the handle
Y1 to the position of “normal pressing “, handle Y2 to the position of “pressing”, and handle Y3 to
“add force”; after secondary press cylinders stretch to stroke end, gradually screw down adjusting
nut of F15; observe the oil gauge on control panel; when the gauge directs to the needed value Pd,
the adjustment is done.
Overflow valve F1 ( see Figure 4-7) is used to set main pile pressing pressure. It is set as PF1
≤PF9. Adjust pressure of valve F1 as follows: Start pumps till they run steadily; push the handle
Y1 to the position of “normal pressing”, handle Y2 to the position of “pressing”, after main pile
pressing cylinders stretch to stroke end, gradually screw down adjusting nut of F1; observe the oil
gauge on control panel; when the gauge directs to the needed value 5 MPa, the adjustment is done.
Overflow valve F2 (see Figure 4-7) is used to set quick piling pressure. It is set as value PF2
≤10Mpa. Adjust pressure of valve F2 as follows: Start pumps till they run steadily; push the
handle Y1 to the position of “quick pressing” and handle Y2 to the position of “pile pressing”;
after the piston rod of chief pile pressing cylinders stretch to stroke end, gradually screw down
adjusting nut of F2; observe the oil gauge on control panel; when the gauge directs to 10Mpa, the
adjustment is done.
4.2.4 ADJUSTMENT OF OIL PRESSURE FOR CLAMPING AND RELEASING PILE

Overflow valve F3 (see Figure 4-7) is used to set pile clamping pressure. It is set as PF3≤
PF9. Adjust pressure of valve F3 as follows: Start pumps till it runs steadily; push the handle Y4 to
the position of “clamping pile”; gradually screw down adjusting nut of F3; observe the clamping
oil gauge on control panel; when the gauge directs to needed value Pe, the adjustment is done. The
needed oil pressure for clamping is relevant to material and surface condition of piles. It should be
decided according to practical condition. If clamping is reliable, the set value should be kept low.
Overflow valve F13 (see Figure 4-6) is used to set pile releasing pressure. Adjust pressure of
valve F13 as follows: Start pumps till it runs steadily; push handle Y4 to pile releasing position,
observe pile releasing oil gauge, if the gauge value directs to 5-10Mpa, the adjustment is done. In
the operation, the releasing pressure is permitted to be set more than 5-10Mpa, but it should be less
than pile clamping pressure.
Attention: After any adjustment, please push handle to neutral position.
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4.3 OPERATION METHOD AND STEPS

4.3.1 START-UP
（1） Turn on the air switch. Turn on the power with key and be sure the all handles of
multidirectional valve are in the neutral (off load position).
（2） First start one pump. The green indicator light turns on.
（3） Start another pump when the green indicator light turns off and the red indicator light turns
on. (The interval is about 8 seconds.)
（4） 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.
（5） Push the handle Y4 to the position of “Releasing pile”. Then oil pressure rises. If the oil
gauge labeled “pile pressing pressure” and “pile clamping pressure” shows the normal
pressure, push Y4 to the neutral. Then the job of start-up is finished.
4.3.2 POSITIONING PILE
Operate four stepping handles Z1~Z4 and four vertical motion handles S1~S4 to ensure
correct pile placement by the pile driver’s rotation, longitudinal and cross motion.
Before pressing pile, operate vertical motion handles S1～S4 to have the piston rods of four
vertical motion cylinders extend and long ship slideways land on the ground, short ship slideways
leave the ground. Then positioning pile is finished.
4.3.3 LEVELING
In order to ensure the verticality of piles, the main body of the pile driver should be kept
horizontal, which can be achieved by operating four vertical motion handles S1~S4 and at the
same time observe if the omnidirectional gradienter on the operating panel shows zero. If it shows
zero, adjustment is finished.
4.3.4 PRESSING PILE
4.3.4.1 OPERATING METHOD
Operate the handles Y1~Y4 to carry out pile pressing. see§3, 3.2 Piling Platform for
reference）
Handle Y4 is used to clamp and release pile. When clamping pile, push handle Y4 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 Y4 to clamping position again to get clamping force. To release
pile, push handle Y4 to releasing position. After oil pressure reads zero, push the handle to middle
position.
The combination use of handles Y1, Y2 and Y3 can perform functions of “quick piling”,
“ pressing pile”, “adding force” and “lifting pile”. The former three functions are three modes of
pressing pile. They are different in piling speed and piling force.
（1） “Quick piling” refers to that the two chief piling cylinders are switched to special circuit,
and press pile quickly at a speed higher than that limited by pump displacement. To perform
quick piling, push handle Y2 to pressing pile position and handle Y1 to quick piling
position.
（2） “Pressing pile” refers to that the two chief piling cylinders take part in piling work at the
speed corresponding to pump displacement. To perform piling, push handle Y2 to piling
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position and handle Y1 to normally piling position.

（3） “Adding force” refers that two chief piling cylinders and two secondary piling cylinders
take part in piling work together. When pile pressing force is balanced by the drag force on
pile driver from the ground (oil pressure for pressing pile reaches Pa), the two secondary
pile pressing cylinders should be used to add force. Push handleY3 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 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 and Y3 in the middle position
and 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 Y4 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”.
If oil pressure reaches Pa during piling, then use “adding force”.
d) If oil pressure reaches Pa during adding force, then the piling force has reached rated
piling 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 240 tf. If the counterweight is not enough or the pile pressing force is too
large, the accident of “lifting machine” will occur. If the electric bell alarms, which warns that
“lifting machine” occurs, immediately push handles Y1, Y2 and Y3 to middle position. All
personnel except operator should leave away from the pile driver and keep a least distance of 2-3
meters; After the oil pressure gradually drops down to zero and long ship slideways touch ground,
push handle Y4 to position of releasing pile; When “lifting machine” occurs, absolutely prohibit
pushing handle Y4 to releasing pile position first. If the clamping oil pressure drops during the
process of slowly releasing the piling pressure, it must be done to push handle Y4 to position of
clamping pile for load. When “lifting machine” occurs, it is also prohibited to operate the crane. If
the crane has been lifting objects, the objects should be unloaded. When the accident has been
solved, the pile driver should be paused to find out causes of “lifting machine”. Before continuing
work, measures must be taken to prevent the accident of “lifting machine”.
35
Sunward shall not be responsible for any legal or economic responsibility caused by “lifting
machine”.
“Lifting machine”------referring to that the main body and long ship slideways are lifted
off ground because of not enough counterweight or piling force exceeding the rated force.
“Machine falling down”---when pressing pile, pile pressing cylinders release piles
abruptly, so that pile driver loses support and falls down suddenly. It can cause serious
injury to personnel and the machine itself.
ATTENTION
1. In normal condition, it is not allowed to pull pile with pile driver. Pulling pile refers to
pulling out the pile that has been pressed into ground. If there is special condition and it
must be done to pull pile with pile driver, you must make sure that the pulling force is
less than P2tf (see the appendix table 8-1), the system oil pressure is less than Pa, and
weight of pile driver with counterweight is less than P3tf. Otherwise partial
counterweight should be removed. When pulling pile, short and long ship slideways
should be layed down on ground and nobody is permitted to stand under clamping box.
After finishing pulling work, check the joint seat between chief cylinders and clamping
box whether it is normal or not. If pile driver inclines during pulling pile, the pulling
work should immediately be stopped.
2. If piling pressure exceeds 10Mpa, push handle Y2 to middle position to release pressure，
then push handle Y4 to the position of releasing pile. If four cylinders work together, the
handle Y3 should also be pushed to middle position to release pressure. After piling oil
pressure gradually drops down, push handle Y4 to position of releasing pile. Otherwise,
great impact would occur! Sunward is free from any responsibility for such incorrect
operation.
3. If pushing handles has to be done or has been done, please remember, at any moment, do
put all handles of multidirectional valve to the middle position to unload, which will help
to save energy, reduce the generation of heat, protect pile driver and assure safety
operation.
4. When working at reconstruction site, especially at the bricks or blocks largely imbedded
stratum, form holes with steel pile first to avoid possible pile break.
4.3.5 ATTENTION
● Pay attention to the verticality of piles and the leveling of machine body during pressing pile.
● Operate handles and buttons gently avoiding rough operation.
● Check at any time whether oil pressure and oil temperature are normal. (The max. oil pressure
should be Pa, oil temperature between 35°～85°). If any abnormalities occurs, stop machine
immediately to dispose abnormalities.
● A set of pile to be inserted into the same location must be completed continuously. If there is a
long break during the process, the pile inserted in ground might solidify with the ground earth.
When piling process resumes, the oil pressure would increase sharply.
● When pile driver moves, rotates, or rises and falls in large range, it must be guided, cooperated
36
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.
4.4 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 4-8): 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 4-8 CLAMPING JAW INSTALLATION FOR THIN WALL TUBE PILE
①Pile clamping cylinder ②Cylinder flange ③Connection nut ④Pulling rod
⑤Connection block ⑥Outer jaw ⑦Inner jaw ⑧Jaw seat ⑨Pile clamping block
⑩ ⑾ ⑿ Inner hexagonal bolt a—Spring Return installation hole b—Hook bolt hole
The installation of clamping jaw for round & square pile(see Figure 4-9): 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 4-9 Clamping jaw installation for square & round pile
① Pile clamping cylinder base ② Pile clamping cylinder ③ Inner clamping jaw ④ Outer
clamping jaw ⑤ Block plate ⑥ Location pin ⑦ Inner hexagonal screw a--- handling hole
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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.
Prohibit commanding and observation personnel from standing under the clamping box.
Reliable lifting equipment is necessary when replacing clamping jaw.
5 DISASSEMBLY, TRANSPORTATION AND MAINTENANCE

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.
5.1 REQUIREMENTS TO DISASSEMBLY SITE
a Required disassembly space
1. space occupied by pile driver itself;
2. space for transport vehicles going in and out to dump;
3. space for lifter over 25 tons going in and out to lift components.
b Requirement to the geological conditions of disassembly site：

The plainness and hardness of ground should meet the requirement for truck about 50 tons
and lifter over 25 tons.
5.2 DISASSEMBLY
Before being transported to another construction site, the pile driver shall be disassembled to
seven parts (main body, pile pressing cylinders, pile pressing cross beam, counterweight beam,
longitudinal motion mechanism, cross motion mechanism, and counterweight), so as to facilitate
transportation.
The disassembling shall be carried out in the following sequence:
1. Move away all the counterweight and counterweight beam with lifter.
2. Unscrew the drain plug on main body, long & short ship slideway, and drain the water (see
figure 5-1).
3. Lift the clamping box up till it’s above the upper surface of the main body and put below it two
1.5m light steel rails (see figure 5-1). Then lay the clamping box gently on the rails. After that,
disassemble the joint shaft between clamping box and chief pressing cylinder, and have the rod
draw back completely.
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4. Disassemble the pressing cylinder.

5. Lift the pile driver, move the main body to the end of the long ship slideway, and then descend
the main body and land short ship slideway on the ground, screw off the nut on this end of the
central shaft which plugs into the rotation platform of the short ship slideway. Then you can
disassemble the short ship slideway.
Attention: Before disassembling, the screw bolt of return spring should be tightened
appropriately so as to pull off the spring seat from return seat. After assembling in another
field, loose the screw to make the spring seat and return seat touch again.
6. Lift the main body to move to the other end of the long ship slideway. Disassemble the other
short ship slideway with the same method.
7. The flat board truck goes back under the main body. Place bed timbers and let the main body
slowly lies on them. Disassemble the joints of the four vertical motion cylinders and the stepping
wheel carrier and then disassemble the long ship slideway.
ATTENTION: Cylinders in long ship slideways draw back. Reduce the exposure of rod as
much as possible in case that the rod might be damaged by bump during lift and transport.
（ The tonnage of pile driver’s crane is small, therefore the long ship slideway should be
lifted by crane of larger tonnage.）
8. Draw back the vertical motion cylinders completely. Pull out the joint bolt between main body
and cantilever. Then remove cantilever and vertical motion cylinders (see figure 5-2). If it is a
swing arm pile driver, it is also feasible to rotate the cantilever and vertical motion cylinders in a
certain angle rather than disassemble them, and transport them together with main machine on
condition that it is not over the permitted transportation weight. ( see figure 5-2).
9. Disassemble power cables in the pile driver.
ATTENTION: Before transportation, draw back the movement parts of crane jib completely, and
fix the retractable jib with 2 bolts on fixed jib, then lower it on the four bearing platforms of pile
pressing platform. In transportation, if there is low bridge or tunnel along the route, there are two
solutions:
1. Disassemble the parts which is higher than cabin roof.
2. Disassemble the parts above crane’s slewing support and transport them separately. The
remaining part is the max. parts of main machine. Its dimension is as figure 5-2.
40
FIGURE 5-1 WATER INLET AND OUTLET
FIGURE 5-2 TRANSPORTATION SIZE FOR MAX. PARTS
41
TABLE 5-1 WEIGHTS OF PARTS
PARTS NAME WEIGHT (ton)

Main machine ( without counterweight) About 102（ include 20.9 tons of sand）
Machine body （ include the 29.2（include 9 tons of
parts that cannot or need not be sand）
assembled）
Vertical motion mechanism 2.1X4=8.4（ include 0.8 Total weight: 53.5
Max. parts tons of sand）（ include 9.8 tons of
sand）
Crane 7.39
Clamping box 3.46
Guide rack 2.5X2=5
Pile pressing cylinder 0.56X4=2.24
Longitudinal motion mechanism 10.7×2 =21.4（include 4 tons of sand）
Rotation platform 1.5X2=3 （ include 0.6
Cross motion tons of sand） 20.3（include 5.6 tons of
mechanism Short ship slideway 8.65X2=17.3（include 5 sand
tons of sand）
Counterweight beam 1.57X2=3.14（include 0.576 tons of sand）
Assistant cantilever（optional） 0.78X2=1.56（include 0.9 tons of sand）
Square counterweight (buyer prepares) 3.88X10=38.8
Main F counterweight (buyer prepares， 4.5X20=90
necessary)
Note:
1． The above weight data of all parts is theoretically calculated. The weight data of
outsourced parts is also theoretic. There might be a little difference between practical
weight valve and theoretic weight value. Normally, the percentage error is within ±6%.
2． The counterweight is calculated as per 6800 Kg/m3. Customers shall determine the
number of square counterweight to buy according to practical conditions and their need.
3． Machine body can be filled with 3.2 tons of water, long ship slideway can be filled with
4.5 tons, short ship slideway can be filled with 3 tons. Total weight of water is 10.7 tons.
☆ In cold weather, leave an interspace of 8cm in height when filling water in main body,
long & short ship slideway.
During disassembly, stop up the oil port with cover or plug when removing any oil
pipe.
42
5.3 ASSEMBLY
After arriving at the new construction site, place the long ship slideway as figure 5-6, then
drive the truck in. The sequence of assembling is the reverse of disassembling. After pile driver is
installed in the new construction site, carry out maintenance and repair well, readjust and
reexamine it.
ATTENTION
There is a big reinforcing screw bolt in every joint seat where vertical motion cylinder cantilever is
fixed. During assembly, assure to screw the big screw nuts as tightly as possible.
5.4 TRANSPORTATION
Transport the disassembled parts.

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.
FIGURE 5-4 THE LAYOUT OF LONG SHIP SLIDEWAY FOR ASSEMBLY
43
5.5 DEBUGGING
See §4 OPERATION REGULATIONS for reference.
5.6 DAILY MAINTENANCE AND TIME MAINTENANCE
① Examine attachment bolts for any looseness. Specially pay attention to those attachment bolts
on the pressing cylinders, vertical motion cylinders, longitudinal and cross 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 bolts. The mounting blots of
clamping cylinder of thin tube pile clamping box should especially be tightened again after
the new machine works 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.
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. If change the work site or pressure meter does not point to
zero, unscrew the oil filling plug loose (see figure 7-2) until the pressure inside and outside
the pressure meter are the same (wait about 1 minute), then screw the oil filling plug tight and
pressure meter can be used now.
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.
44
5.7 LUBRICATION DIAGRAM
Main machine Crane

Number Number
Parts of Greasing Parts of Greasin
Interval Interval
name greasing style name greasing g style
point point
Longitud
inal Grease Wire Spreadin
16 7days 1 7days
motion gun rope g
wheel
Transvers Radius
Grease Grease
e motion 12 7days change 2 7days
gun gun
wheel shaft
Guide
wheel of Upper
Grease Grease
pile 8 3days wire 1 7days
gun gun
pressing wheel
box
Spheric
Lower
socket on Change Spreadin Everyda
8 Spreading wire 1
wheel site g y
wheel
carrier
Center Pulley Grease
2 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 4 Spreading 3days 1 30days
support gun
track
Wheel Slewing
Spreadin
carrier 4 Spreading 7days wheel 1 7days
g
track gear
Inner
part of Grease Every
16
clamping gun shift
box
45
Remark：
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.
Note:
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.
6 CRANE
QY crane is installed in ZYJ hydraulic static pile driver as a pile lifting device, which is an
auxiliary device. The crane’s structure is similar to the superstructure of general hydraulic truck
crane and it is mainly composed of jib system, windlass system, slewing, and hydraulic control
systems.
The superstructure of crane is installed in the machine frame, which is connected with the
inner part of slewing support, while the outer circle of slewing support is connected with the base
of crane. The crane base is welded on the main machine of ZYJ hydraulic static pile driver.
See the provided operating manual of crane for detailed information.
46
7 TROUBLE SHOOTING
7.1 COMMON MALFUNCTIONS AND CORRESPONDING SOLUTIONS
Malfunction Cause Solution

Something dirty between the Clean the dirty things, repair
point of the cone and valve seat or replace it.
or the sealing surface is worn.
The little orifice in the middle of
main valve spool of overflow Clean valve.
valve is blocked.
The main valve spool of
1. Pressure can not meet overflow valve is blocked in an Clear and repair.
needed value or completely open position and can’t be reset.
no pressure Oil pressure gauge is destroyed. Change the gauge.
The running direction of Change the running direction
hydraulic pump is wrong. of electrical motor.
The hydraulic pump sucking oil
is not enough Add oil or repair oil tube
Replace components, and
Hydraulic pump oil-distribution check whether
tray or backhaul tray worn the leakage oil
pipe unblocked or not.
The orifice in the pilot valve
2. Pressure is over the limit seat of overflow valve is Clean away such things.
(If the pressure exceeds blocked and disabled.
limit very quickly, stop the
pile driver at once.) The main valve spool of
overflow is blocked, so it can’t Clean and repair.
open and overflow.
Oil pressure gauge is damaged.
The directed value is not correct. Change pressure gauge.
3. The force of clamping Single-direction valve F4 is not Take out of the spool to
check if there is some
can’t be maintained (If completely sealed. eyewinker or any abrasion.
above malfunction happens Repair or change it.
The seals of hydraulic cylinder
and can not stop working, for clamping are worn so that Change the seals.
the method of chambers in cylinders connect.
discontinuous driving
clamping cylinder during
Pipeline leaks. Stop leakage.
one pressing stroke can be
adopted.
4. Pressing pressure can not Oil pressure gauge is damaged. Change pressure gauge.
The directed value is not correct.
meet needed value or The preset pressure value of
completely no pressure. system overflow or pressing-in Reset it
overflow is too low
Sealing of system overflow
valve or pressing-in overflow
Repair or change it.
valve can not meet requirement
and is not tight.
47
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
The system works too long in handles of multidirectional
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
dust-proof seal. Clean it
8. Piston rod surface pulled
Seals for guide shell are
damaged. Change them.
Guide shell is damaged. Replace it
When fixing the oil gauge, the
oil-filling plug (safety plug) is
9. Oil pressure gauge being
not unscrewed loose so that the Modify
damaged frequently
vent of oil-filling plug can’t link
the atmosphere.（see Figure 7-2）
10. Electrical elements Detect time delay relay. Correct Reset the interval or change
interval should be 8~10
being frequently burnt relay.
seconds.
Start oil pump disobeying the Operate as per regulations
operation regulations in 4.3. strictly.
48
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.
11. When wheel carrier Wheels are deformed. Change the deformed ones.
(structure as figure7-1) Replace.
Composite bearing damages.
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.
the process switch mounted on
Adjust or replace process
12. It can’t drop hook when the winch operation handle switch.
fails .
crane hook reaches upper
Failure in electromagnetic valve Replace concerned
limitation loop and corresponding circuit. components.
No pressure in overflow valve. Refer to item 1 to solve.
Failure in the limitation switch
Check and replace concerned
on jib and concerned control
13. Crane hook can’t stop circuit components.
rising when it pass upper Failure of electromagnetic valve Check and replace concerned
loop and corresponding circuit components.
limitation
Overflow valve works
Refer to item 2 to solve.
abnormally
49
FIGURE 7-1 WHEEL CARRIER
FIGURE 7-2 OIL PRESSURE GAUGE
50
7.2 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.
⑩ 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.
⑪ 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.
51
8 MAIN TECHNICAL DATA

APPENDIX TABLE 8-1 SIGNS IN THIS MANUAL
Signs Meaning Value for ZYJ240A

Pa System oil pressure 23.2 Mpa
Pd Secondary pressing-in It depends on practical
oil pressure conditions.
Pe Pile clamping oil It depends on practical
pressure conditions.
Pb System pressure with 13 Mpa
pump at full flux
P1 Chief pile pressing-in 120 tons
pressure
P2 Largest pile-pulling 62 tons
weight
P3 Allowable largest 180 tons
weight of pile driver at
pile- pulling
52
APPENDIX TABLE 8-2 BASIC PARAMETERS
Item Parameter
Max. pile pressing force（23.2 Mpa） 120 tf
The chief pressing-in Max. pile pressing speed(Pressure ＜ 13 5.48 m/min
hydraulic cylinder works Mpa）
separately Min. pile pressing speed （ Pressure=23.2 1.5 m/min
Mpa）
Max. pile pressing force（23.2 Mpa） 240 tf
The chief and the
Max. pile pressing speed （ Pressure ＜ 13 1.32 m/min
secondary pressing-in
Mpa）
hydraulic cylinders work
Min. pile pressing speed (Pressure = 23.2 0.76 m/min
together
Mpa）
Pressing-in stroke 1.6 m
Side piling Max. pile pressing force（23.2 Mpa） 120 tf
Longitudinal stroke（once） ≤3 m
Capability of motion Transverse stroke（once） ≤0.6m
Every rotative angle（once） ≤8◦
Forward ≤4.4 m/min
Backward ≤8.9 m/min
Stepping speed
Left ≤4.4 m/min
Right ≤7.4 m/min
Vertical motion stroke 0.9 m
Length of pile 3 m＜L＜12 m
Ground pressure Long ship slideway 10 tf/m2
Short ship slideway 12.5 tf/ m2
（at 240 t）
Normal pressing Side pile distance 3100 mm
position
After equipped with side Side pile distance 800mm
piling device Corner pile distance 1345 mm
Model JZX5022A
Pile clamping box Optional circle pile clamping jaw Y25-Y50
Optional square pile clamping jaw F25- F50
53
Pile pressing rated pressure（240 tf） 23.2 Mpa

Rated pressure for lifting See the operating
manual of crane
Pile pressing flow rate(at full flow) 148 L/min
Lifting flow rate(at full flow) See the operating
Hydraulic system
manual of crane
For main 40YCY14-1B (1 unit)
machine 63YCY14-1B(1 unit)
Hydraulic pump model
See the operating
For crane
manual of crane
For main Y180L-4 （1 unit）

machine Y160L-4（1 unit）
Electric motor model
See the operating
For crane
manual of crane
Pile pressing power 22kW+15kW=37 kW
Electric system Lifting power See the operating
manual of crane
Voltage 380 V
Current (the whole machine) 42+30+42 =114 A
Frequency 50 HZ
Power cable YCW-3X35+2X16
Dimension (LxWxH) (mm) 10000×6200×3120
Weight of main machine 102T±6%
Weight of whole machine (including counterweight) About 243.8 T
54
APPENDIX TABLE 8-3 OIL PRESSUAND PILE PRESSING FORCE
Piling force
Oil pressure
(tf)
(MPa) Chief piling cylinder Chief and secondary cylinder

Quick pressure Normal pressure together
1 2.5 5.2 10.4
2 5.0 10.4 20.8
3 7.5 15.6 31.1
4 10.0 20.8 41.5
5 12.5 26.0 51.9
6 15.0 31.1 62.3
7 17.5 36.3 72.7
8 20.0 41.5 83.0
9 22.5 46.7 93.4
10.0 25.0 51.9 103.8
11.0 57.1 114.2
12.0 62.3 124.6
13.0 67.5 135.0
14.0 72.7 145.3
15.0 77.9 155.7
16.0 83.0 166.1
17.0 88.2 176.5
18.0 93.4 186.9
19.0 98.6 197.2
20.0 103.8 207.6
21.0 109.0 218.0
22.0 114.2 228.4
23.0 119.4 238.8
23.2 120.4 240.8
55
APPENDIX TABLE 8-4 ATTACHMENT TOOLS
Parts name and Quantit Remark Parts name and Quantit Remark
specifications y specifications y
High pressure oil can 1 Wire cutter 200MM 1
Double-ended fixed 1 Adjustable spanner 1
spanner 5.5-32 300X36 GB4440
Nippers 175 1 Adjustable spanner 1
450X55 GB4440
Inner hexagon 1 Screw-driver with 1
spanner 3-19 voltage tester
Cross head 1 Greasing gun 1
screwdriver 75X5
Cross head 1 Round head hammer 1
screwdriver 200X8 2P
Flat head 1 Extension rod 1
screwdriver 75X5 10 GB3390.4
Flat head 1 Bushing 17MM 1
screwdriver 200X8
Filter press 1 Oil port cover Quantity and
LUC-40X10 specifications
vary according
Pull rod sleeve 1 Oil port plug
to different
machine
models.
56
APPENDIX TABLE 8-5 WEARING PARTS
Name Specification Remark Name Specification Remark
Air filter PAF2-0.02-0.75-10

GB1235-76 10x1.9 O ring
F
Electric For electric
J164-12.5x40x50 12
brush collection ring
Magnetic oil
returning WY400x20Q2 For crane 14
filter core
RT18φ10x38
Fuse 16
（500V，2A）
Oil
returning FBX-1000x20 Composite 18
washer
filter core
JB982-77
For wheel
Bearing SF-2-120120 22
carrier
Wire rope GB1102-74-6x19-1
27
4-2000
6.3x1.8 33
O ring
GB3452.1-8 63x3.55 39
2
85x3.55 42
57
APPENDIX TABLE 8-6 CLAMPING JAW COLLOCATION
Clamping jaw Fixed screws

Pile driver
Type Quantity Remark Specificatio Quantity
model
（piece） ns GB70-86 (unit)
200×200 square Installed in F30
F20-35 8 M16×50 16
300×300 square F30 8 Directly installed M16×120 16
in cylinder
350×350 square F35 8 M16×100 16
400×400 square F40 8 M16×80 16
450×450 square F45 8 M16×55 16
500×500 square F50 8 M16×30 16
Φ250 round Y25 4 Together with M16×155 8

Y40
Φ300 round Y30 8
M16×130 16
Φ300 round Y30A 8 Together with
Y50
Φ400 round Y40 8 M16×80 16
Φ400 round Y40A 8 Directly installed M16×85 16
in cylinder
Φ450 round Y45 8 M16×55 16
Φ500 round Y50 8 M16×35 16
Note: The specific installation of clamping jaw is subject to user’s choice.
APPENDIX TABLE 8-7 THE TABLE OF OIL PUMP’S PRESSURE VERSUS

APPROPRIATE FLOW
Initial set
Final set pressure Final displacement x
pressure Pb
Pa（MPa）（the indicated
Oil pump model （MPa）
（max system position by pump
（the flux starts
pressure） variable head）
to chang）
63YCY 13 23.2 6.0
40YCY 13 23.2 5.6
58
APPENDIX TABLE 8-8 HYDRAULIC PARTS FOR MAIN MACHINE
Number Code number Parts name

1 F5, F6, F7, F8 Hydraulic one-way valve 23Y-10B
2 F13 Overflow valve MZL5-H10B
3 F4 Hydraulic one-way valve AIY-HC25B
4 F9 Overflow valve MZL5-H25B
5 Multiunit valve ZS1-L20-4T-GD2
6 Multiunit valve ZS1-L32-4W-GD10
7 P1 Oil pump 63YCY
8 P2 Oil pump 40YCY
9 F10 Straight check valve DIF-L32H1
10 F11 Straight check valve DIF-L32H1
59
APPENDIX TABLE 8-9 ELECTRIC PARTS FOR MAIN MACHINE
Parts name Quantity Code Parts name Quantity Code

number number
Voltage transformer 1 Circuit breaker 1 QF
JDZ2-1 380/100 NMILE-400/3N300
250A
Amperemeter 44L1-A 1 A Circuit breaker 2 QF
300/5A CM1-100L/3300 63A
Voltmeter 44L1-450V 1 V Circuit breaker 1 QF
380/100 CM1-100L/3300 32A
Module plug seat 1 Circuit breaker 1 QF
AC30-10A/3 DE15LE-40/4901 40A
Fuse seat RT18-32X 11 FU Circuit breaker 2 QF
DZ15-100/3902 63A
Fuse φ10X38 2A 20 F Circuit breaker 1 QF
DZ47-3P/AD 20A
Push button 3 SB Delay relaySK4-222 2
LAY39-11/R
Push button 3 SB Auxiliary contactor 2 KM
LAY39-11/G LA1-DN11-C
Push button 5 SA Axial flow fan150FY2-D 1 M
LAY5(39)-11X/2 220V-30W
Thermal relay NR2-93 1 FR Connector 1 X
23-32A JH6-35/18+6/25
Thermal relay NR2-93 1 FR Flexible metal tubingφ15 25
40A
Intermediate relay 2 K Flexible metal tubingφ25 5 FU
JZC4(CA2-D)-22/36V
Control transformer 1 TC Flexible metal tubingφ32 12
JBK-250VA
380/36V
AC contactor 3 KM Hose couplerφ15 20 JV
LC1-0910 AC36V
Contactor 3 KM Hose couplerφ25 2
CJX4-5011d/380v
Contactor 3 KM Hose couplerφ32 10
CJX4-4011d/380v
Lamp for warning 1 HL Power cable 100
against humidity 40W YCW3X50+2X16
AC36V
Indicator light 2 HL Lamp bulb36V-40W 1 HL
XDY2-36V red
Indicator light 2 HL Tungsten iodine lamp 3 HL
XDY2-36V green bracket for strip
lamp220V 1000W
Tungsten iodine lamp 3 HL
220V-1000W
60
9 APPENDIX FIGURES
APPENDIX FIGURE 1 MAIN MACHINE HYDRAULIC SYSTEM
1- Vertical motion cylinder 2- Pile clamping cylinder 3- Secondary pile press cylinder
4- Chief pile press cylinder 5- Longitudinal motion cylinder 6- Cross motion cylinder
7- Right back up 8- Right front up 9- Left front up 10- Left back up 11- Release pile
12- Add force 13- Press pile 14- Normal pressure 15, 16- Forward 17,18- Right
19- Right back down 20- Right front down 21- Left front down 22- Left back down 23- Clamp pile
24- Return 25- Lift pile 26- Quick pressure 27,28- Backward 29,30- Left
61
APPENDIX FIGURE 2 MAIN MACHINE ELECTRIC SYSTEM
62
APPENDIX FIGURE 3 PILE DRIVER COUNTERWEIGHT
1- Assistant cantilever 2- Assistant counterweight 3- F counterweight

4- Square counterweight 5- Main counterweight beam
Note: The parts number 1 assistant cantilever and number 2 assistant counterweight are optional.
Some pile drivers may have no such parts because of customer’s different order.
63
APPENDIX FIGURE 4 ELECTRIC SYSTEM FOR WARNING
64
10 ABOUT THE MANUFACTURER

Company name: HUNAN SUNWARD INTELLIGENT MACHINERY CO., Ltd.
Trade mark:
Address:
16 LiXiang Road, Xingsha economic and technologic development district, Changsha, Hunan.
Tel: 0086-0731-3572642
Maintenance point: our office in some provinces and cities of China
ABOUT THE DISTRIBUTOR
About the distributor
Distributor name:
Address:
Tel:
Fax:
E-mail:
Service personnel:
Remark:
65

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ZYJ240A Operator’s manual

4.3.4 PRESSING PILE.......................................................................................................................... 34

1.1.2 SAFETY LABELS

4. Caution when machine is removing or rotating.

1.2 SAFETY RULES

1.4 WEAR SAFETY PROTECTIVE ARTICLES

● While machine moves from soft field to hard

1.10 CHECK MACHINE BEFORE START-UP

● Check and screw down the connection bolts at

counterweight during piling.

protect your hand and body against touching

soap and water. Before welding or heating up,

2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER

3 BASIC STRUCTURE AND WORK PRINCIPLE

3.2 PILING PLATFORM

FIGURE 3-2 STRUCTURE OF PILING PLATFORM

FIGURE 3-3 STRUCTURE OF PILE CLAMPING BOX

3.2.2 PILE PRESSING PROCESS

（decline）Press pile lift

FIGURE 3-4 PILE PRESSING CYCLE

It is mainly composed of four vertical motion

FIGURE3-5 STRUCTURE OF VERTICAL

1- Cantilever 2- Vertical motion cylinder

3.3.2 LONGITUDINAL MOTION MECHANISM

FIGURE 3-6 STRUCTURE OF LONGITUDINAL MOTION MECHANISM

FIGURE 3-7 STRUCTURE OF CROSS MOTION AND ROTATION MECHANISM

1- Short ship slideway 2- Rotary platform 3- Return spring

4- Wheel carrier 5- Lifting hook 6- Central axis hole

3.3.4 CONTINUOUS STEPPING AND ROTATION

FIGURE 3- 8 STRUCTURE OF TRAVEL MECHANISM

1- Cross motion cylinder 2- Vertical motion cylinder 3- Longitudinal motion cylinder

⑴ Vertical motion cylinders retract

FIGURE 3-9 LONGITUDINAL MOTION CYCLE

3.3.6 CROSS MOTION

⑴ Vertical motion cylinders extend

FIGURE 3-10 CROSS MOTION CYCLE

Step1: Get the pile driver ready.

FIGURE 3-11 ROTATING MANNER

⑴ Vertical motion cylinders extend

3.4 HYDRAULIC SYSTEM( FOR PILE PRESSING)

FIGURE 3-13 LOCATION OF PILE DRIVER HYDRAULIC CYLINDERS

3.4.1.1 MULTI-DIRECTIONAL VALVE

FIGURE 3-14 THREE GROUPS OF MANUAL MULTI-DIRECTIONAL VALVES

1- Multi-directional valve C 2- Multidirectional valve B 3- Multi-directional valve A

3.4.2 WORK PRINCIPLE (see appendix figure 1 hydraulic system)

3.4.2.1 Travel by hydraulic control

FIGURE 3-15 HYDRAULIC SYSTEM FOR TRAVELING

FIGURE 3-16 HYDRAULIC SYSTEM FOR VERTICAL MOTION

3.4.2.3 Hydraulic system for clamping pile

FIGURE 3-17 HYDRAULIC SYSTEM FOR PILE CLAMPING

FIGURE3-18 HYDRAULIC SYSTEM FOR PRESSING PILE

3.5 SIDE PILING AND CORNER PILING

FIGURE 3-19 SIDE PILE FRAME

FIGURE 3-20 HYDRAULIC SYSTEM FOR PRESSING SIDE PILE

FIGURE 3-21 HYDRAULIC SYSTEM FOR CLAMPING SIDE PILE

3.6 ELECTRIC SYSTEM

3.6.1 LIFTING MACHINE WARNING

connection；and operation platform

FIGURE 4-1 CONTROL PANEL

FIGURE 4-2 LOCATION OF PUSH-BUTTONS

mechanism. Assure they are at normal.

FIGURE 4-3 MAIN MACHINE HYDRAULIC PUMP ADJUSTMENT