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Multi Beton - HSPD 120 Ton
Multi Beton - HSPD 120 Ton
Tianwei
Engineering Machinery Manufacturing Limited
Company
Changsha, Hunan Province
China
1
Contents
□
1 Notice 3
□
2 Specifications 4
□
3 Main Structure and Working Principle 6
□
4 Operation Instructions 16
□
5 Maintenance and Troubleshooting 20
□
6 Dismantling and Shipment 23
Form of Lubricating 27
2
1 Notice
3
□
2 Specifications
4
pipe pile: maximum ø250mm
square pile: maximum □250mm
length of single pile b) ≥1.5 m,≤7m (side pile)
2.5. Hydraulic System
rated pressure: 24(18) MPa
rated flow: 171(93) L/min
Note: the number outside the brackets for the main engine and the number in the
brackets for the crane。
2.6. Electrical System
rated horsepower: 18.5X2+22=59kw
rated voltage: 380 V
rated current: 35X2+42=112A
frequency: 50 Hz
input cable: YCW-3×50+1×10
2.7. Weight
total weight: 120t
heaviest component: 21t
2.8. Dimensions when Working
For center pile driving:length × width × height=6.3m×4m×13m
For side pile driving: length × width × height=7.3m×4m×11m
2.9. Side distance 0.45m
Corner distance 0.9m
2.10. Pressure on Land:
long boat: 95KN/m2
short boat: 114KN/m2
2.11. Crane
maximum lifting weight: 8T
maximum speed of ascending: 11m/min
maximum rotating speed: 3 r/min
Relation between Ascending Angle and the Allowed Lifting Weight
Ascending Angle Lifting Weight(t) Rotating Radius(m)
5
(degree)
0 1.4 14
15 3.0 13
30 3.5 12
45 5.0 9
60 7.0 7
75 8.0 4
Note::Be sure to operate the machine as stated in the above form and not to change at will
the adjusted pressure of the relief valve for angle changing. (Here the angle refers to the
angle of lifting arm of the crane to the land)
□
3 Structure and Working Principle
3.1 Structure of ZYC120BS-GB1 Pile Driving Machine
As shown in diagram 1, this machine is made up of 14 large components.
6
1、边桩机构
2、机身
3、驾驶室
4、液压系统
5、夹桩箱
6、电气系统
7、起重机
8、纵移机构
9、横移机构
10、压桩横梁
11、配重
12、顶升机构
1. side piling and corner piling mechanism 2. body 3. operating room 4. hydraulic system 5.
pile clamping box 6. electrical system 7.crane 8. longitudinal moving mechanism
9.horizontal movement 10.piling cross beam 11. counterweight 12. lifting mechanism
1. hydraulic cylinder 2. guiding device 3. pile clamping box 4. oil cylinder for clamping piles
Diagram 2 Clamping-type Pile Driving Mechanism
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structure.
1、边桩机构
2、机身
3、驾驶室
4、液压系统
5、夹桩箱
6、电气系统
7、起重机
8、纵移机构
9、横移机构
10、压桩横梁
11、配重
12、顶升机构
1. side piling and corner piling mechanism 2. body 3. operating room 4. hydraulic system 5.
pile clamping box 6. electrical system 7.crane 8. longitudinal moving mechanism
9.horizontal movement 10.piling cross beam 11. counterweight 12. lifting mechanism
Diagram 3 Side Piling Mechanism
9
1--短船 2--小车 3--回转台 4--升降缸
5--机身 6--复位机构 7--长船 8--纵移液压缸 9--横移液压缸
1. short boat 2. small car 3. rotating desk 4. ascending and descending cylinder 5. machine
body 6. reset device 7. long boat 8. hydraulic cylinder for longitudinal movement 9.
hydraulic cylinder for horizontal movement
Diagram 4 Ascending, Descending and Moving Mechanism
3.4.1. Ascending and Descending Mechanism
It mainly consists of 4 supporting legs as shown in the diagram with either end of the
legs inserted into the machine body and one hydraulic cylinder fixed on each leg. As the
envelopes of oil cylinders which are connected with 4 groups of moving mechanism
stretch, the machine body rises, or vice verse.
Equipped with adjustable oil cylinder lifting mechanism, draw a leg of pins, can make
the lifting mechanism tofold or unfold to be loaded on the trailer easily.the longest width
between two long boat is 3.2m.
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diagram. The piston rods of the two hydraulic cylinders are linked with two long boats and
the two cylinders with the roller shelves of the movement mechanism. When the piston
rods stretch or withdraw, a relative longitudinal movement occurs between the machine
body and the long boat.
3.4.3. Horizontal Movement and the Revolving Mechanism
It mainly consists of the revolving desk, roller shelves for movement, two short boats, two
hydraulic cylinders for horizontal movement, central axis and reset machine as shown in the
diagram.
Two central axes are connected with the machine body universally and the revolving desk as
well as four groups of roller shelves for movement and two short boats are hung on the
central axes, around which they can move. When the two hydraulic cylinders for horizontal
movement stretch at the same time or withdrau at the same time, a relative horizontal
movement occurs between the machine body and the revolving desk. If either cylinder
stretches and the other withdraws, a relative revolving occurs.
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16
1.油箱
2.油泵1
23 夹桩远程调压 19 21 22 3.油泵2
8 18 20
4.回油滤清器
5.压力表
6.主溢流阀
13 7.安全阀
8.溢流阀
17 9.压桩操纵阀
10.支腿操纵阀
11.行走操纵阀
12.溢流阀
13.松桩安全阀
24 14.压桩安全阀
12 15 15.压桩安全阀
25 25 25 25 16.夹桩缸
17.液控单向阀
18.边桩压桩缸
K 19.中桩压桩缸
14 20.支腿油缸
21.长船油缸
22.短船油缸
23.夹桩压力表
24.压桩压力表
25.平衡阀
26.溢流阀
27.转阀
28.支腿伸缩油缸
26 29.夹桩操纵阀
压桩2 压桩1 档位 10 11
29
9
支腿 行走
28
6
7 7
4
3
27
1
P1 P2
13
3.6 Electric System
Diagram 6 shows the electric system of pile driving section.
This electric system is provided with protecting measures such as short circuit
protector。
220V 36V
17 变压器 L BK-500VA 1
16 停止按钮 SB1(1 2)-1 LAY3 3 红色
15 起动按钮 SB1(2 3)-2 LAY3 3 绿色
14 熔断器 FU4 RT14-20/10 1
13 熔断器 FU3 RT14-20/10 1
12 电动机 D3 Y90L-4 1 1.5KW 1500r/min
11 电动机 D1 D2 Y180L-4 1 22KW 1470r/min
10 热继电器 FR3 JR016B-11A 1
9 热继电器 FR1 FR2 JR16B-63A 2
8 接触器 KM3 CJ20-10A 1 德力西集团
7 接触器 KM1 KM2 CJ20-100A 2 德力西集团
6 小型断路器 QS5 DZ47-3P-6A 1 德力西集团
4 小型断路器 QS3 QS4 DZ47-3P-125A 2 德力西集团
序号 名 称 代 号 规 格 数量 备 注
3.7 Crane
It consists of lifting arm system, hoisting system, revolving system and hydraulic
controlling system.
3.7.1. Lifting Arm System and Stretching and Withdrawing of Lifting Arm
The lifting arm system consists of a big arm, stretching arm, 2 parallelly-joined
variable oil cylinders and driving system for stretching lifting arm. When the lifting arm is
working, the arm is placed at level position at first. To get two kinds of length of the arm to
meet different needs, take away the two bolts fixing the movable arm, move the
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multi-directional valve handle so as to control the rotating of the motor for movable arm and
move the movable arm from the fixed arm.
☆ Notice: Be sure to change the length of the lifting arm when the angle of the arm
and the land is less than 10 degrees. After the length of the lifting arm is set, the stretching
arm should be fixed to the big arm with bolts.
3.7.2 Hoisting System
It consists of hydraulic motor, en efficient hoisting roller with built-in speed reducer
and brake, and steel rope and pulleys.
3.7.3 Rotating System
It mainly consists of hydraulic motor for rotating, transmission axis, small gear and
rotating support, which is fixed on the machine base. The upper part of the rotating system is
connected with the crane. The hydraulic motor drives the small gear to rotate, which makes
the big gear rotate, thus the whole machine base including lifting arm and operating desk, etc.
rotate.
3.7.4 Hydraulic System
As shown in Diagram 5, the hydraulic controlling system works in the way that the
hydraulic oil coming from hydraulic pump 3 goes to the crane through rotating joints, and
the oil pressure of the system is controlled by the overflowing valve of the universal valve at
18MPa.
The manual universal valve D is used to control the change of angle of the lifting arm to
the ground, hoisting, rotating, and the stretching and withdrawing of the lifting arm.
15
卷扬马达
回转马达
伸缩马达
阀块B
变幅油缸
阀块A
(18MPa)
回转 变幅 卷扬 伸缩
中心回转接头
泄漏油
回油
回油箱
进油
16
□
4 Operating Instructions
17
4.2.1. Starting
First, switch on the air switch in the distribution cabinet of electricity. Make sure that all
universal valve hand levers are in neutral position of unloading. Then press the button to
start the pile driving motor to make the hydraulic pump groups work and let them run
without loading for 3 minutes. If they are working normally, put the handle for clamping
piles into the position of pile clamping. When the pressure is rising, watch the pressure meter
for system oil pressure on the panel and see if the pressure is 23 Mpa. If the pressure is
normal, put the hand lever for clamping piles into the neutral position.
4.2.2 Locating
Operate the 4 hand levers for movement together with the 4 hand levers for ascending
and descending so as to make longitudinal movement or horizontal movement until
locating the exact position of piles to be driven in.
4.2.3 Leveling
In order to drive piles vertically, be sure to level the machine before driving piles,
which can be done by operating the 4 hand levers for ascending and descending until the
spirit level shows 0 for all directions.
4.2.4 Driving Piles
Pile driving can be done by only operating the four hand levers for driving piles. For
details see the previous parts concerned.
▲ Notice: When there is no need of using hand levers to do a certain task, always
remember to put all the hand levers of universal valves into neutral position of unloading
to save energy and prevent oil from heating.
▲ Notice: When the pressure for driving piles is over 8Mpa,be sure to put the hand
lever for pile driving quickly into pile relief position once or twice for two or three
seconds each time before operating the hand lever for pile relief to relax. After the
pressure for driving piles is relieved, the hand lever can be operated otherwise there is a
large stroke.
▲ Notice:Operate the hand lever for fast driving into the position of fast driving in low
resistance and drive piles fast when there is a big difference of momentum. Otherwise
put it into the position for slow pile driving so as to drive piles with a big force.
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4.2.5 Lifting
(1) Press the button on the electricity distributor to start the motor of oil pump.
(2) Manipulate the rotating hand lever to put the lifting arm of the crane into the
position of lifting piles. According to the weight of the things to be lifted, step down the
foot valve of the operating valves and manipulate the hand lever for the change of the
angle of the lifting arm to the ground as to put the arm at the proper height and then
manipulate the hoisting hand lever to put down the hook so as to be ready to lift piles or
other heavy things.
▲ Notice:The working oil pressure of the crane must be within 18Mpa.
▲ Notice:When the foot valve is not stepped down, the pump of the crane is supplying
oil to the main machine and the hand lever of the crane does not work.
4.3 Notice
4.3.1 Before driving piles, see to it that the hook of the crane is off the steel rope for
tightening piles otherwise it will damage the crane. When lifting piles, make sure
the piles are firmly and securely tightened and there are no people near the area of
piles.
4.3.2 When the angle between the lifting arm and the ground reaches the maximum
degrees allowed and the hook touches the ground, there must be at least 4 rounds of
hoisting steel rope on the roller.
4.3.3 When lifting piles, make sure there are no people standing around the crane. And
there must be a specially assigned person to direct the operation of the crane and pile
driving.
4.3.4 Often check up the hoisting steel rope and the steel rope for lifting piles. If there is
any broken steel wire, change it immediately.
4.3.5 When the lifting arm is at the level position, the lifting weight must be less than the
rated weight(1.2tons),in case the lifting arm is overloaded. When there is alarm for
steel rope over winding, stop lifting.
4.3.6 When piling, do not put your hands or feet into the gaps between piling desk and the
machine body.
4.3.7 When the machine has been stopped working for more than 4 hours, let the machine
running without load for 3 minutes until it is working normally.
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4.3.8 The interval between the starting of the two hydraulic pump motors must be over 8
seconds.
4.3.9 When making longitudinal movement, manipulate the hand lever X3 and X4 at the
same time in the same direction. Do not manipulate only one of them or in two
different directions. When either of the two hydraulic cylinders for longitudinal
movement stretches to the given position, the other must stop stretching otherwise
there will be damage to the machine parts.
4.3.10 When piles are linked by melting, do not manipulate the hand lever at will in case
the pile will fall to hurt people.
4.3.11 In the course of driving piles, often check if the pile is vertical and if the machine
body is level.
4.3.12 Manipulate the hand levers and press buttons gently.
4.3.13 Check if the oil pressure and oil temperature is normal in operation(Maximum oil
pressure for piling is 23Mpa,maximum oil pressure for crane is 18Mpa,and the oil
temperature is 40-80 degrees). Stop to solve the problem if there is anything
abnormal with the machine.
4.3.14 The moving long boat and short boat should be placed on the level ground, without
anything hard between the boat and the ground.
4.3.15 When the machine has stopped working, the short boat should be on the ground and
the long boat is nearly on the ground, with the pile driving box at the lowest position
and turn off the power.
4.3.16 The crane is not allowed to be overloaded. The crane driver must work within the
capacity of the crane and according to the scale on the lifting arm in operation in
order to prevent any accident.
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□
5 Maintenance and Troubleshooting
21
blocked by foreign matter. In this case clean it.
3. The main valve wick of the overflowing valve may get stuck at the on position and
cannot reset. Clean it or get it working properly.
4. The hydraulic pump is turning in the wrong direction. Change the direction of
turning.
5. The hydraulic pump does not take in oil properly ( with some noise). The reason for
this may be that the oil level is too low or there is leakage in the oil-taking pipe. In
this case, refuel or seek where there is a leakage. Or possibly the switch for oil-taking
is not on.
6. The oil distribution plate of the hydraulic pump is worn out. Change the damaged
parts or elements.
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position of unloading if the system is not working.
2. Something has gone wrong with the hydraulic pump which is so hot that hand cannot
touch.(Examine the pump and repair it.)
3. The ambient temperature is too high, therefore stop working and let it cool down.
4. The oil level is too low, so refuel it.
E. Leakage
1. The leakage in the joints are caused by loosening of the joints or foreign matter on
the sealing surface or damage to it.
2. The leakage between the piston rod of hydraulic cylinder and the guiding frame may
result from the damage to the sealing ring in the guiding frame or the damage to the
touching surface of the guiding frame and the piston rod.
□
6 Dismantling and Shipment
When the pile driver is to be transferred from one worksite to another, dismantle it into
6 parts (main body of the machine, pile driving cylinder and horizontal beam, longitudinal
moving mechanism, horizontal moving mechanism, matching weight and matching
weight beam) for the convenience of shipment. The order of dismantling is as follows:
1. Lift away all the matching weights with a crane or the equipped crane in the
machine.
2. Lifting the pile driving box and turn off the motor of the main pump and then put the
4 supporting bolts into the screw nuts. Manipulate the hand lever for pile driving so
as to lower the pile clamping box naturally to the lowest point. Take off the pile
driving cylinder and the connecting axis and then start the motor and manipulate the
hand lever to let the piston rod of pile driving cylinder completely draws inside.
Turn off the motor and turn off the stopping valve in the oil pipe at the bottom of the
pile driving cylinder and then take off the two horizontal beams for pile driving and
the oil cylinder as well as the connecting pipes. The pipes taken apart should be
blocked up.
3. Raise the pile driver and move the machine body to the end of the loang boat and
then lower the machine body to make the short boat land, take off the fastening plate
23
for the central axis so as to take apart the short boat.
4. Raise the machine body and make it move to the other end of the long boat and then
take off the other short boat in the same way as mentioned above.
5. Reverse the transportation car under the machine body and put some cushioning
wood on the car and then let the machine body fall slowly on the wood.
6. Make the ascending and descending cylinder completely withdraw and take off the
connecting axis between the supporting legs and the machine body, turn off the
stopping valve on the oil pipe of the oil cylinder, take apart the hydraulic rubber pipe
and lift the supporting legs from the machine body.
7. Lay the lifting arm at level position between the standing pole of pile driving and the
operating room.
8. When the above mentioned parts are taken apart, the left is called the main machine
shown in Diagram 8, which agrees with the standard of transportation of GB146,
1-83.
8900
4100
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Diagram 9 Layout of the Long Boat in Assembling
☆ Notice:In the above mentioned dismantling process, each oil pipe taken off must
blocked or covered properly at either end with the corresponding covers and blocking
material supplied with the machine.
25
Weight of Each Individual Item
Qanitity(pc) Unit Total
Name for parts Dimension(L*W*H) weight weight(t)
(t)
Main body 8.75m*2.3m*2.65m 1 21 21
Supporting leg 2.2m*1.5m*0.4m 4 0.9 3.6
Counterweight 3.55m*0.26m*0.45m 2 0.9 1.8
beam
Cross beam 3m*1.3m*0.4m 2 0.9 1.8
Main Short boat 2.8m×1.8m×1.4m 2 5 10
machine Long boat 8.6m×0.7m×0.7m 2 3.5 7
Counterweight 2m×0.26m×0.3m 2 0.5 1
beam for side
piling
cable 0.6m×0.6m×0.5m 1 0.3 0.3
Spare parts kit 1.2m×0.8m×0.8m 1 1 1
F-counterweight 1.37m×0.52m×1.1m 18 2.2 39.6
F-counterweight 1.14m×0.57m×1.76m 6 1.35 8
Square 1.45m×0.65m×0.8m 8 2.6 20.8
counterweight
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Oil Pressure & the Pile Driving Force
Oil pressure Pile Driving Force(fast position) Pile Driving Force(second position)
(Mpa) (KN) (KN)
1 34.0 57.3
2 58.0 107.2
3 82.1 157.1
4 106.2 207.0
5 130.2 256.9
6 154.2 306.8
7 178.3 356.7
8 202.3 406.6
9 226.4 456.5
10 250.4 506.4
11 274.4 556.3
12 298.5 606.2
13 322.5 656.1
14 346.6 706.0
15 370.6 755.9
16 394.6 805.8
17 418.7 855.7
18 442.7 905.6
19 466.8 955.5
20 490.8 1005.4
21 514.8 1055.3
22 538.9 1105.2
23 562.9 1155.1
24 587.0 1205.0
(remarks:the diameter for 2pcs of pressing cyliner is Ø180, and the fast position refers to the
operation in the fast position of the hand lever when the two main pile cylinders are linked
differentially)
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The following is the calculating for hydraulic piling pressure:
The design formulas specified for the Pile Driving Force (Unit: KN) and the Pressure of
Hydraulic Oil (Unit: Mpa)
Pile driving force in the table refers to the vertical downward pressing onto the pile in pile
driving. And the pressure of hydraulic oil refers to the dial records showed in the control
room in pile driving (unit: Mpa), which can be also understood as the hydraulic oil pressure
in the oil cylinder without piston rod to in pile driving. The stress state in pile driving
illustrated as below:
Total F = F1 + F2 + G (F1 to F2 stands for the stress on the pile-clamping-box separately
driven by the relevant cylinder. G is the total weight of the pile-clamping-box and piston
rods of oil cylinders), As the two pile driving oil cylinders specify for Ф180/125 (the
diameter of cavity without rod is Ф180, the rod diameter Ф125), and then total F = 2 F1 + G
(G = 10KN)
pile pressing operations can be divided into three according to the manipulation of ways as
below:
1) fast pile driving (Fast piling with the two oil cylinders at meantime, and the hydraulic
pipes connected differential)
2) slow pile driving (slow piling with the two oil cylinders)
Now calculate the pile driving force in the followed two situations:
1) fast pile driving, stated as shown in Figure 2 (hydraulic pipes in
differential connection this time):
Total F = F1 + F2 + G = 2F1 + G
F1 = (P • A1-P • A2) • η
P stands for oil pressure in the no-rod-cavity of oil cylinder,
A1 is the piston area of oil cylinder without rod in cavity,
A2 is the piston area of oil cylinder with rod in cavity
A1 = 25434X10 - 6 m² A2 = 13168X10 - 6 m²
η for mechanical efficiency, value η = 98%
Total F = 2 P (A1-A2) • η + G
= 2P (25434X10 - 6-13168X10 - 6) X98% X106 (N) +10 KN
= 24.04P +10 (KN)
When P = 1Mpa , F = 34KN
…………………
When P = 20Mpa, F = 490.8KN
2) slow pile driving (the two oil cylinders working) as shown in Figure 3:
Total F = F1 + F2 + G = 2F1 + G
F1 = (P • A1-Po • A2) • η
Po is the oil pressure in the oil returned cavity, while Po = 0.1Mpa η = 98%
Total F = 2 (P • A1-0.1A2) • η + G
= (39.4P +9) (KN)
When P = 1Mpa , F = 57.3KN
When P = 20Mpa, F = 1005.4KN
…………………
When P = 24Mpa, F = 1205KN
From the above, the hydraulic oil pressure and the pile driving force
can be calculated on the table as below:
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N
N
P
P P
Po
Po
G
G G
F1 F2
F1 F2 F1 F2
F合
F合 F合
图3
图1 图2
N
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Lubricating
Notes:1. When daubing use ZG-S lubricating fat of graphite calcium base (SY405-65).
2. When using filling gun apply SY1413-80 synthetic lithium base fat.
3. When the ambient temperature is over 200C, use antifriction hydraulic oil N68
and when the ambient temperature is below 200C, use antifriction liquid.
30
list of main parts for ZYC120BS-GB1
31