English Instruction

ZYC200B-B1Hydraulic Static Pile Driver

Changsha TianweiEngineering Machinery Manufacturing Company Limited

www.t-works.cc

Changsha, Hunan Province

China

1
 Contents

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1 Notice 3

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2 Specifications 4

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3 Main Structure and Working Principle 6
3-1 Composition of ZYC200B-B1 Pile Driver 6
3-2 Pile Driving Mechanism 7
3-3 Side-pile Driving Mechanism 9
3-4 Lifting, Descending and Moving Mechanism 10
3-5 Hydraulic System 10
3-6 Electrical System 14
3-7 Crane 14

□
4 Operation Instructions 16
4-1 Preparation before Starting 16
4-2 Operating Methods and Procedures
4-3 Attention 18

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5 Maintenance and Troubleshooting 20

5-1 Routine and Regular Maintenance 20

5-2 Causes of Common Breakdown and Fixing Methods 20

□
6 Dismantling and Shipment 23

List of Weight Distribution 24

The design formulas specified for the Pile Driving Force 25

Form of Oil Pressure and Pile Driving Pressure 26

Form of Lubricating 27

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 1 Notice

！ Before starting the machine the operator is

obliged to read the manual carefully and act accordingly.

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 □
2 Specifications
2.1. Capacity of Pile Driving
2.1.1 When two principle pile driving cylinder are working
2.1.1a At the fast speed position with center piling

Maximum pile driving force 510KN

Speed of pile driving 11m/min
2.1.1b At the normal speed position
Maximum pile driving force 965.5KN
Max speed of pile driving 5.4m/min
2.1.1c At the third speed position by two primary jack in cylinder and
secondary jack in cylinder
Maximum pile driving force 2000KN
Max speed of pile driving 2.7m/min

2.1.2 Depth of pile driving

Maximum depth of each pile driving 2.0m
2.2.Moving Capacity
Distance of each movement: longitudinal 2.4m
horizontal 0.6m
each turning angle: 150
speed of moving: forward 8.9m/min
backward 15m/min
left 8.9m/min
right 15m/min
2.3.Distance of Ascending and Descending 1.6m
2.4. Size of Piles
2.4.1 For center piling:
pipe pile： maximum ø500mm
square pile： maximum □500mm

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 length of single pile： a) ≥1.5 m，≤12 m（middle pile）
2.4.2For side piling
pipe pile： maximum ø400mm
square pile： maximum □400mm
length of single pile b) ≥1.5 m，≤9m （side pile）
2.5. Hydraulic System
rated pressure： 24(18) MPa
rated flow： 230(115) 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： 30X2+30=97kw
rated voltage： 380 V
rated current： 56.8X2
+56.8=170.4A
frequency： 50 Hz
input cable： YC-3×70+1×25+1×16
2.7. Weight
total weight： 200t
heaviest component： 33t
2.8. Dimensions when Working
For center pile driving:length × width × height＝9.9m×5.9m×7m
2.9. Side distance 0.95m
Corner distance 1.3m
2.10. Pressure on Land：
long boat： 100KN/m2
short boat： 104KN/m2
2.11. Crane
maximum lifting weight： 12t
maximum speed of ascending： 11m/min
maximum rotating speed： 3 r/min

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 Relation between Ascending Angle and the Allowed Lifting Weight

Long boat Short boat

Ascending Angle（°） Lifting Weight（t） Rotating Radius（m） Lifting Weight（t） Rotating Radius（m）
0 2.7 15.2 3.8 11.6
20 3.7 14.3 6.0 11.0
30 4.4 13.1 7.0 10.0
40 5.0 11.5 8.0 9.0
50 5.5 9.6 9.5 7.3
60 8.0 7.4 12.0 5.5
70 11.0 4.9 12.0
75 12.0 3.6 12.0

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)

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 □
3 Structure and Working Principle
3.1 Structure of ZYC200B-B1 Pile Driving Machine
As shown in diagram 1, this machine is made up of 14 large components.

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 1 ZYC200B-B1 Hydraulic Static Pile Driver

3.2 Clamping-type Pile Driving Mechanism

As shown in Diagram 2, the clamping-type pile driving mechanism, as the main working
mechanism is used to clamp piles and drive piles. It consists of hydraulic cylinder for driving
piles, pile clamping box and hydraulic cylinder for clamping piles.
At first, the pistons of 2 pile-driving cylinders move back to raise the pile-driving box to a
higher position, and after pre-made piles are put into the middle holes of pile-driving box,

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the pile-driving cylinders from four directions are working to clamp the piles tight. Then by
manipulating the hand lever of pile-driving valve, the pile-driving cylinders are becoming
longer to produce pressure to drive piles into the foundation. Finally the pile-driving
cylinders release piles and return back. Again the pile-driving cylinders return to raise the
pile-driving box to start another circle of pile-driving. Thus the machine completes
continuously the task of pile-clamping
pile-driving pile-releasing returning pile-clamping …，so as to drive piles
into the foundation one by one.

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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3.3 Side Pile Driving Mechanism
If there is a need of driving side piles and corner piles, side pile driving mechanism is to
be installed at the end of main machine and then a horizontal beam for driving piles and the
pile driving box are fixed with bolts at the proper position on the side pile driving
mechanism so as to drive piles within 0.95 m from the building. See diagram 3 for its
structure.

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

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3.4 Ascending, Descending and Moving Mechanism
See Diagram 4 for its structure and working principle.

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.

3.4.2. Longitudinal Movement Mechanism

It mainly consists of roller shelves, hydraulic cylinders and long boats as shown in the
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.

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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.

3.4.4. Continuous Movement and Revolving

Continuous movement and revolving can be achieved by the above-mentioned three
mechanism, of which a brief account is made as follows according to diagram 4.
Longitudinal Movement
As the oil cylinder on the leg stretches, the machine body rises, the long boat lands and
the short boat takes off.→ When the oil cylinder of the long boat comes back, it makes the
small car and the machine body move to the right until the oil cylinder of the long boat
completely comes back to finish a course.→ When the oil cylinder of the leg comes back,
the machine body descends and the short boat lands. → As the oil cylinder of the leg
comes back further, the long boat takes off. → When the oil cylinder of the long boat
stretches, the long boat moves to the right until a course is made. → As the oil cylinder of
the leg stretches, the machine body rises and the short boat takes off. →……
Horizontal Movement
When the oil cylinder of the leg comes back, the machine body descends，the long boat
takes off and the shoat boat lands. → When the oil cylinder of the short boat comes back, it
makes the small car, the revolving desk and the machine body move until the oil cylinder of
the short boat completes a course. → When the oil cylinder of the leg stretches, the
machine body rises, the long boat lands and the short boat takes off. → When the oil
cylinder of the short boat stretches, it makes the short boat rise until the oil cylinder of the
short boat completes a course. → When the oil cylinder of the leg comes back, the machine
body descends, the long boat takes off and the short boat lands. →……
Revolving Movement
If the cylinders of the two short boats in the front and back are to be operated in the way of
horizontal movement to a different direction, a revolving movement can be achieved.

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3.5 Hydraulic System
3.5.1.General Description
As shown in Diagram 5, it mainly consists of 2 power constant variable pumps, 4
groups of manual universal valves A、B、C、D and 18 hydraulic cylinders which are to fulfill
the mentioned functions. Pump P1、P2 and 3 groups of manual universal valves A、B、C 、
D supply pressure oil for pile driving，and another pump P and manual universal valve D
supply pressure oil for the crane to fulfill lifting tasks.
3.5.2.Adjustment of Hydraulic Pumps
These pumps are already adjusted at the factory according to the power matching
factors, so there is no need to be adjusted by the users. If changing pumps is required, order
must be made stating the power and turns, asking the manufacturer to adjust.

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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。

Diagram 6 Electric System

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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
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.

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 □
4 Operating Instructions
４.1 Preparation before Starting
4.1.1 Check if the steel rope and rope devices of the crane are reliable and durable.
4.1.2 Check if the oil level of the oil tank is normal.
4.1.3 Check if the voltage is normal. （no more than 400V，no less than 350V）.
4.1.4 Check if there is no leakage of electricity.
4.1.5 Check if there is no leakage in hydraulic pipes.

４.２ Operating Procedures

As seen in Diagram 7，on the control panel of operating desk for pile pressing are 3 sets of
operating hand levers with manual universal operation and on the box of electric system are
buttons of electric system controlling. Operators can fulfill the task of pile driving by
operating them. On the control panel of crane operating system are a set of hand levers with
manual universal valves to carry out the lifting task.

Diagram 7 Layout of Panel

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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

５.１ Routine and Regular Maintenance

5.1.1 Lubricate periodically. （For details see the list of lubricating）
5.1.2 Clean the machine every day after work.
5.1.3 Check as often as possible if the bolts are tightened, especially the bolts of pile
driving mechanism, pile clamping mechanism, and ascending and descending
cylinders. If several bolts are used in one point, make sure that the torsion must
be equal.
5.1.4 Pay special attention to the cleaning of hydraulic system and refuel the oil tank
by a specific refueler with a filter no less then 20μ
5.1.5 If the machine is working for the first time, change the oil totally and clean the
oil tank after one month of working. After that change the oil once every six
months in general,（ Before changing oil, be sure to clean the oil tank and
discharge the remaining oil from all the pipes and units as much as possible.）
5.1.6 Be sure to dismantle and assemble the hydraulic units in a clean place without
any dust.
5.1.7 Always keep the returning oil filter clean. If the returning oil pressure meter
shows the value of more than 0.4Mpa, clean it or change the filter wick. Usually
clean it once a month.
5.1.8 Tighten all the joints and bolts once a month.
5.1.9 If the oil is found white, change it immediately otherwise it will damage the
hydraulic elements too earlier.

５.２ Causes of Common Breakdowns and Fixing Methods

A. The pressure cannot reach the required value or there is no pressure at all,
for which the reasons may be as follows:
1. The leading conic valve of the overflowing valve (see Diagram 6) is not sealed
properly. Usually there may be something between the conic point and the valve stand
or the sealing surface is damaged.
2. The small hole of resistance in the main valve wick of the overflowing valve may be

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 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.

B. The pressure is over the rated value.

1. If the pressure is going to be over the rated value soon in working, turn off the
machine.
2. If the small hole of the leading valve stand of the overflowing valve is blocked and
cannot overflow, take it apart and clean it.
3. If the main valve wick of the overflowing valve gets stuck and cannot be opened to
overflow, take it apart and clean it or repair it.
C. The pressure for clamping piles does not sustain for long.
After clamping piles the pressure falls rapidly as seen from the pressure meter so that
piles cannot be clamped firmly, the reasons may be as follows:
1. The hydraulic controlled one way valve F3 is not sealed properly and there may be a
leakage. Take out the valve wick to see if there is anything foreign between the valve
stand and the wick or if it is worn out seriously. Change it or repair it if this is the
case.
2. The seal ring for the piston of the hydraulic cylinder of pile clamping is worn out
and not working properly. Change the seal ring immediately.
D. Overheating of the oil may be caused by:
1. Working for a long time in the state of overflowing；
Note that all the hand levers of universal valves should always be in the neutral

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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.

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 □
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
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.

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 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

Diagram 8 Dimensions of the Largest Part for Shipment

9. Take the electric wire off the pile driver.
10.After arriving at the new work site, the assembling is to be done in the reverse order.
First lay out the long boat as shown in Diagram 9 and then reverse the flatbed car of
the truck in.

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.

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 Weight of Each Individual Item
Qanitity(pc) Unit Total
Name for parts Dimension(L*W*H) weight weight(t)
（t）
Main body 9.2m*3.0m*3.0m 1 26.5 26.5
Supporting leg 2.6m*1.8m*0.72m 4 2 8
Counterweight 4m*0.3m*0.65m 2 1.8 3.6
beam
Cross beam 3.4m*1.4m*0.5m 2 2 4
Short boat 2.55m×3.4m×1.2m 2 4.25 8.5
Main Long boat 10m×0.9m×0.85m 2 6.8 13.6
machine Counterweight 2.3m×0.3m×0.45m 2 0.5 1
beam for side
piling
Counterweight 2.2m*0.3m*0.45m 2 0.6 1.2
beam for crane
cable 0.6m×0.6m×0.5m 1 0.3 0.3
Spare parts kit 1.2m×0.8m×0.8m 1 2.5 2.5
F-counterweight 1.72m×0.5m×1.3m 18 3.4 61.2
F-counterweight 1.72m×0.6m×0.8m 12 2.8 33.6
Square 1.72m×0.5m×0.9m 6 2 12
counterweight

Method for non-dismantling

1、main body:9.9m×3.7m×3.9m weight:56.7T 1pc
（including 2 pcs of short boat,long boat and crane）
2、cross beam：3.4m×1.4m×0.5m weight:2T/pc 2pcs
3、spare parts box：1.2m×0.8m×0.8m weight：2.5T 1pc
4、counterweight beam for crane：2.2m×0.3m×0.5m weight:0.6T/pc 2pcs
5、counterweight beam for side piling：2.3m×0.3m×0.6m weight：0.5T/pc 2pcs
6、counterweight beam:4.0*0.3*0.65m weight：1.8T/pc 2pcs
7、clamping box: 1.7m×1.4m×1.2m weight：5T/pc 1pcs
8、side piling mechanism: 3.2 m×1.4m×1.9m weight：9T/pc 1pcs
8、others :counterweight

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 Oil Pressure & the Pile Driving Force
Oil pressure Pile driving force Pile driving force Pile driving force
(Mpa) （Ⅰgrade） （Ⅱgrade） (Ⅲgrade)
Two primary jack in Two primary jack in Two primary and
cylinder working （KN） cylinder working（KN） secondary jack in cylinder
working together(KN)
1 33.4 52.0 88.3

2 51.8 91.0 186.6

3 70.2 130.0 274.3

4 88.0 169.0 363.2

5 107.0 208.0 451.5

6 125.4 247.0 539.8

7 143.8 286.0 628.1

8 162.2 325.0 716.4

9 180.6 364.0 804.7

10 199.0 403.0 893.0

11 217.4 442.0 981.3

12 235.8 481.0 1069.6

13 254.2 520.0 1157.9

14 272.6 559.0 1246.2

15 291.0 598.0 1334.5

16 309.4 637.0 1422.8

17 327.8 676.0 1511.1

18 346.2 715.0 1599.4

19 364.6 754.0 1687.7

20 383.0 793.0 1776.0

21 401.4 832.0 1864.3

22 419.8 871.0 1952.6

23 438.2 910.0 2040.9

24 456.6 949.0 2129.2

25 475.0 988.0 2217.5

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 (remarks:1.the diameter for 2pcs of pressing cyliner is Ø180, and the first piling grade
refers to the operation in the fast position of the hand lever when the two main pile cylinders
are linked differentially,the formula for the pile driving force: F1=23.8P+50（KN）;
2. the secondary piling grade refers to double primary jack in cylinder work together,the
formula for pile driving force : F2=（49.3P+47.45）（KN）;
3.the third piling grade refers to two primary jack in cylinder and two secondary jack in
cylinder work together,the formula for pile driving force : F3=98.7P+44.9（KN）
)

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The specification for calculation is as below:
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 +F3+F4+ G (F1 to F4 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 primary jack in cylinders specify for Ф180/125 (the
diameter of cavity without rod is Ф180, the rod diameter Ф125), and two secondary jack in
cylinders specifyФ180/125,for then total F = 2 F1 + 2F2+G (G = 50KN)
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 (fast piling with four jack in cylinders)
Total F = F1 +F4+ 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 = 97%
Total F = 2 P (A1-A2) • η + G
= 2P (25434X10 - 6-13168X10 - 6) X97% X106 (N) +50 KN
= 23.8P +50 (KN)
When P = 1Mpa , F = 73.8KN
…………………
When P = 20Mpa, F = 526KN
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 = 97%
Total F = 2 (P • A1-0.1A2) • η + G
= (49.3P +47.45) (KN)
When P = 1Mpa , F = 96.8KN
…………………
When P = 20Mpa, F = 1033.5KN
From the above, the hydraulic oil pressure and the pile driving force
can be calculated on the table as below:
3) slow pile driving 2 (the four oil cylinders working) :

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Total F = F1 + F2 + G = 2F1 + 2F2+G= 2(P·A1-0.1A2) · η+2(P·A3-0.1A4) ·η+G
F1=（P·A1﹣Po·A2）· η F2=（P·A3﹣Po·A4）· η
A1 and A3 are the piston are without rod,A2 and A4 are piston area with rod.
Total F=（2×P×25434-2×0.1×13168.4）×0.97×10-3+（2×P×25434-2×0.1×13168.4）×0.97×10-3+50
=98.7P+44.9（KN）
When P = 1Mpa , F = 143.6KN
…………………
When P = 20Mpa, F = 2019.8KN
From the above, the hydraulic oil pressure and the pile driving force
can be calculated on the table as below

30
 Lubricating

Pile Driving Section Crane Section

Number Number
of of
Way of Way of
Parts to be places Parts to be places
Lubrica Period Lubrica Period
Lubricated to be Lubricated to be
ting ting
lubricat lubricat
ed ed
Longitudinal
& horizontal
16 filling 10 days Steel rope 1 daubing 10 days
moving
wheels
Horizontal lubricating
12 filling 10 days 3 filling 10 days
moving wheel axis
Guiding
Revolving
wheel of pile 8 daubing 3 days 1 daubing 10 days
gear
driving box
Ball socket
for
longitudinal 8 daubing 30 days pulley group 1 filling 10 days
&horizontal
moving
Lifting arm
Central axis 2 daubing 30 days 2 daubing 60 days
stand
Friction
surface of oil cylinder
2 daubing 10 days 4 daubing 60 days
revolving stand
desk
Guiding rail
Revolving
for guiding 4 daubing 10 days 1 filling 60 days
support
wheel

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.

31
 Wearing parts for ZYC200B-GB1
category Parts name model unit QTY 备注
01 Multi-way valve ZFS-H25L-4T pc 1
for crane
02 Multi-way valve ZS1-H32L-4T-2Y pc 1
for piling
03 Multi-way valve ZS1-H25L-5T-A pc 1
for supporting leg
04 Multi-way valve ZS1-H20L-54T pc 1
for movement
05 Balance valve PHY-L20H pc 4
valve 06 Balance valve QY8-12-28 pc 1
01
07 Main relief valve DB30-1-50B/315 pc 1
09 Globe valve DG32 pc 4
10 Remote relief MZL5-H6L pc 1
valve
13 One way valve DG20-1-30B/210Y pc 1
15 One way oil valve SL30PA2-30/2 pc 1
17 Multi-way valve ZS1-H32L-2W pc 1
for clamping
01 pump A7V78 set 3
Moto
r and 02 Rotary mechanism IYH-5000 set 1
pump 03 Hoisting IYJ3B-3000 set 1
02 04 mechanism
Telescopic motor IQM11-0.63 set 1

category Part name model unit QTY Remark

01 Cylinder for GGK1-220/180-1600 pc 4
supproting leg
02 Cylinder for GGK1-125/70-2400 pc 2
long boat
03 Cylinder for GGK1-125/63-600 pc 2
short boat
cyli GGK1-180/125-2000
nder 04 Primary jack in pc 2
03 cylinder
05 Secondary jack GGK1-180/125-2000 pc 2
in cylinder
07 Clamping GGK1-250/180-30 pc 8
cylinder A
09 Transformer GGK1-180/125-1650 pc 2
cylinder
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acce 01 Oil pressure YTN100ZT 40Mp pc 4
ssai gauge
es 02 Oil pressure YTN100ZT 2.5Mp pc 2
04 gauge
03 Level gauge YWZ-250T pc 2
04 Air filter EF7-100 pc 3
05 Oil filter CHL-800×20F pc 1
06 cooler

category Part name model unit QTY remark

elec 01 Electric motor B Y200L-4 B5 set 1
trici 02 residual-current CDM1L-400A pc 1
ty05 circuit breaker
03 moulded case DE20Y-63A pc 2
circuit breaker
04 Time relay ST3P-30 S pc 3
05 Air switch CDB2-125A3P pc 3
06 Ac contactor CJ20-100A 380V pc 9
07 Thermal relay JR36-160/3D 85A pc 3
08 voltmeter 44L1V 450V pc 1
09 ammeter 44L1A 400A pc 1
10 button pc 6

category Part name model unit QTY remark

Oth 01 lever pc 1
ers 02 Spun clamp 400 pc 8
06
03 Spun clamp 350 pc 8
04 Spun clamp 300 pc 8
05 Spun clamp 250 pc 8
06 Square clamp 400 pc 8
07 Square clamp 350 pc 8
08 Square clamp 300 pc 8
09 Square clamp 250 pc 8
10 Square clamp 200 pc 8

33