ZYJ260

ZYJ 260B-Ⅱ Operator’s manual
CONTENTS
1 SAFETY INFORMATION ............................................................................................................. 8
1.1 SAFETY LABELS................................................................................................................ 8
1.2 SAFETY RULES ................................................................................................................ 10
1.3 PREPARATION FOR EMERGENCY ............................................................................... 10
1.4 WEAR SAFETY PROTECTIVE ARTICLES .................................................................... 11
1.5 KEEP MACHINE CLEAN ................................................................................................. 11
1.6 KEEP OPERATOR’S COMPARTMENT CLEAN ............................................................ 11
1.7 MOUNTING AND DISMOUNTING ................................................................................ 11
1.8 MOVE MACHINE SAFELY.............................................................................................. 11
1.9 REQUIREMENT TO THE CONSTRUCTION FIELD ..................................................... 12
1.10 CHECK MACHINE BEFORE START-UP ...................................................................... 13
1.11 OPERATE SAFELY.......................................................................................................... 13
1.12 KEEP AWAY FROM TRANSMISSION PARTS ............................................................. 14
1.13 MAINTAIN SAFELY ....................................................................................................... 14
1.14 BEWARE OF HIGH PRESSURED LIQUIDS................................................................. 14
1.15 BEWARE OF SCALD ...................................................................................................... 15
1.16 AVOID HEATING UP NEAR PRESSURE OIL PIPE ..................................................... 15
1.17 AVOID HEATING UP PIPE WITH PRESSURE OIL ..................................................... 15
1.18 RREMOVE PAINT BEFORE WELDING OR HEATING .............................................. 15
1.19 AVOID FIRE ..................................................................................................................... 16
2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER.......................................... 17
2.1 ADVANTAGES OF SUNWARD PILE DRIVER .............................................................. 17
2.2 COMPARED WITH THOSE BY OTHER FACTORIES................................................... 17
3 BASIC STRUCTURE AND WORK PRINCIPLE ....................................................................... 19
3.1 BASIC STRUCTURE OF ZYJ 260B-Ⅱ............................................................................ 19
3.2 PILING PLATFORM.......................................................................................................... 20
3.2.1 STRUCTURE ........................................................................................................... 20
3.2.2 PILE PRESSING PROCESS .................................................................................... 21
3.3 TRAVEL MECHANISM .................................................................................................... 21
3.3.1 VERTICAL MOTION MECHANISM ..................................................................... 21
3.3.2 LONGITUDINAL MOTION MECHANISM .......................................................... 22
3.3.3 CROSS MOTION AND ROTATION MECHANISM.............................................. 22
3.3.4 CONTINUOUS STEPPING AND ROTATION ....................................................... 23
3.3.5 LONGITUDINAL MOTION.................................................................................... 23
3.3.6 CROSS MOTION ..................................................................................................... 24
3.3.7 ROTATION ............................................................................................................... 24
3.4 HYDRAULIC SYSTEM (FOR PILE PRESSING)............................................................ 25
3.4.1 STRUCTURE ........................................................................................................... 25
3.4.2 WORK PRINCIPLE (SEE APPENDIX FIGURE 1 HYDRAULIC SYSTEM) ...... 27
3.5 SIDE PILING AND CORNER PILING ............................................................................. 29
3.6 ELECTRIC SYSTEM ......................................................................................................... 32
3.6.1 COOLING DEVICE FOR HYDRAULIC OIL ........................................................ 32
3.6.2 HEATING DEVICE FOR HYDRAULIC OIL (FOR NORTH USERS).................. 32
4. OPERATING REGULATIONS ................................................................................................... 33
4.1 CONTROL PANEL............................................................................................................. 33
4.2 PREPARATION BEFORE PRESSING PILE .................................................................... 34
4.3 OPERATION METHOD AND STEPS ............................................................................. 38
4.3.1 START-UP................................................................................................................. 38
4.3.2 POSITIONING PILE ................................................................................................ 38
4.3.3 LEVELING ............................................................................................................... 38
4.3.4 PRESSING PILE ...................................................................................................... 39
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4.3.5 ATTENTION............................................................................................................. 41
4.3.6 CABLES ACCESS PHASE SEQUENCE ................................................................ 41
DUE TO SOME SPECIAL REASON, N MAY CHANGE............................................... 41
4.3.7 OIL COOLING OPERATION .................................................................................. 42
4.3.8 CONNECTING WELDER ....................................................................................... 43
4.4 INSTALLATION AND REPLACEMENT OF CLAMPING JAW .................................... 43
4.4.1 INSTALLATION ...................................................................................................... 43
4.4.2 REPLACEMENT OF CLAMPING JAW................................................................. 45
5ASSEMBLY, DISASSEMBLY, TRANSPORTATION AND MAINTENANCE .......................... 46
5.1 ASSEMBLY ........................................................................................................................ 46
5.2 DISASSEMBLY ................................................................................................................. 50
5.3 TRANSPORTATION ................................................................................................................. 51
5.4 DEBUGGING ..................................................................................................................... 52
5.5 DAILY MAINTENANCE AND TIME MAINTENANCE ................................................ 52
5.6 LUBRICATION DIAGRAM .............................................................................................. 53
5.7 TORQUE FOR STANDARD TIGHTENING PARTS ....................................................... 54
6 CRANE ......................................................................................................................................... 55
6.1ATTENTION ....................................................................................................................... 55
6.2 BASIC STRUCTURE AND WORK PRINCIPLE............................................................. 55
6.2.1 JIB SYSTEM AND ITS EXPANSION..................................................................... 57
6.2.2 WINCH SYSTEM..................................................................................................... 57
6.2.3 SLEWING SYSTEM ................................................................................................ 58
6.2.4 DERRICKING SYSTEM ......................................................................................... 58
6.2.5 HYDRAULIC SYSTEM .......................................................................................... 58
6.2. 6 SAFETY DEVICE ................................................................................................... 60
6.3 CRANE OPERATION ........................................................................................................ 62
6.3.1 PREPARATION BEFORE START-UP..................................................................... 62
6.4 MAINTENANCE................................................................................................................ 63
6.5 PARAMETER ..................................................................................................................... 63
6.6 HYDRAULIC DRAWING ................................................................................................. 66
6.7 ELECTRICAL DRAWING ................................................................................................ 67
7 TROUBLE SHOOTING ............................................................................................................... 68
7.1 COMMON MALFUNCTIONS AND CORRESPONDING SOLUTIONS....................... 68
7.2 REPAIR ............................................................................................................................... 70
8 MAIN TECHNICAL DATA ......................................................................................................... 72
APPENDIX TABLE 8-1 SIGNS IN THIS MANUAL ............................................................. 72
APPENDIX TABLE 8-2 BASIC PARAMETERS ................................................................... 72
APPENDIX TABLE 8-3 OIL PRESSURE AND PILE PRESSING FORCE .......................... 74
APPENDIX TABLE 8-4 ATTACHMENT TOOLS .................................................................. 75
APPENDIX TABLE 8-5 WEARING PARTS........................................................................... 75
APPENDIX TABLE 8-6 CLAMPING JAW COLLOCATION................................................ 76
APPENDIX TABLE 8-7 HYDRAULIC PUMP PRESSURE-FLOW CURVE
ADJUSTMENT LIST ............................................................................................................... 77
APPENDIX TABLE 8-8 HYDRAULIC PARTS FOR MAIN MACHINE.............................. 78
APPENDIX TABLE 8-9 ELECTRIC PARTS FOR MAIN MACHINE .................................. 78
9 APPENDIX FIGURES.................................................................................................................. 79
APPENDIX FIGURE 1 MAIN MACHINE HYDRAULIC SYSTEM ..................................... 79
APPENDIX FIGURE 2 MAIN MACHINE ELECTRIC SYSTEM ........................................ 80
APPENDIX FIGURE 3A CAST IRON COUNTWEIGHT LOCATED .................................... 81
APPENDIX FIGURE 3B BARITE COUNTWEIGHT LOCATED .......................................... 82
10 ABOUT THE MANUFACTURER............................................................................................. 83
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1 SAFETY INFORMATION
1.1 SAFETY LABELS
1.1.1 SAFETY LABELS REQUIRMENTS

 Be sure that you fully understand the correct position and content of labels.
 To ensure that the content of labels can be read properly, be sure that they are in the correct
place and always keep them clean. When cleaning them, do not use organic solvents or
gasoline. These may cause the labels to peel off.
 There are also other labels in addition to the warning signs and safety labels. Handle those
labels in the same way.
 If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the
part numbers for the labels, see this manual or the actual label, and place an order with Sunward distributor.
1.1.2 LOCATION OF SAFETY LABELS
Figure 1-1
1. Caution when machine is working.
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Figure 1-2
2. Caution during pile pressing.
Figure 1-3
3. Caution when machine is removing or rotating.
Figure 1-4
4. Caution when machine is removing or rotating.
Figure 1-5
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5. Caution when crane is working.
Figure 1-6
1.2 SAFETY RULES
 Study the manual carefully and follow the

safety instructions in the labels and in the
manual before operating the machine.
 Always keep the safety labels clean. Replace
any lost or damaged label with a new one. If
the labels or manual book is lost, contact
dealer and indicate the model of machine for
purchase.
 Only qualified operator is permitted to operate
this machine. Keep the machine in good
condition as per this manual.
 Don’t refit machine without authorization. Figure 1-7
Otherwise the performance and lifetime of the
machine 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 Figure 1-8
or monitor), report to person in charge and have
the necessary action taken, do not operate the
machine until the abnormality has been corrected.
All personnel related to operating the machine
should pay attention to prevent accidents from
happening. Always keep a first-aid kit and fire
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extinguisher nearby. Have phone numbers of a

doctor, ambulance, hospital and fire department with
you in case of emergency.
1.4 WEAR SAFETY PROTECTIVE ARTICLES
Before operation, always wear protective

articles when the work so requires, they include:
Skintight work clothes
Hard hat
Safety gloves
Safety glasses, goggles, or veil
Respirator or filtration veil
Earplug or earcap
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
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of movement or under the counterweight.

 While machine moves from soft field to hard
field, the machine should moves at
longitudinal direction and face forward, i.e.
main machine operator faces to the front of
panel.
 Prohibit the machine moving at transverse
direction when it moves from soft field to hard
field.
 When short ship slideway rotates or moves
transversely, assure not to collide with long
ship slideway.
 When controlling longitudinal motion, handles
should be operated at the same time and the
same direction. Any separate and
contra-directional operation should be
prohibited. If one of the longitudinal motion
hydraulic cylinders has extended to the
required position, the other must stop at once
to prevent the damage to the main body.
 Keep the main body horizontal in the
procession of vertical motion in case that these
four vertical motion hydraulic cylinders extend Figure 1-10
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.
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1.10 CHECK MACHINE BEFORE START-UP
Before starting machine every day or every

shift, check the machine according to the contents
in “§4.2 preparation before start-up” of this
manual.
1.11 OPERATE SAFELY
 Keep all the non-workers away from working

range.
 Before piling, enough counterweight should be
loaded; during piling, max hydraulic pressure
should not exceed the rated pressure. Otherwise
the pile driver would be lifted off ground.
 The main machine operator and crane operator
should keep good communication and
observation for each other. Prohibit operating
crane or hoisting objects while the machine
moves or rotates. And also, prohibit the machine
moving or rotating while crane is in operation or
hoisting objects.
 Ensure firm binding while hoisting pile.
 Crane’s winch wire should wrap around the
drum for at least 4 circles.
 When lifting pile, it is prohibited to stand in the
working range of crane.
 Check winch wire and pile lifting wire often and
replace them if any damage occurs.
 Check and screw down the connection bolts at
the crane slewing support every 2 months, the
screwing down torque is 560-600NM. Replace
them with original SUNWARD bolts if any
abnormality occurs.
 Lift rated weight within the limitation of jib
lifting angle to avoid crane jib overloading. Figure 1-11
 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
counterweight during piling.
 Prohibit pushing any handles in the process of
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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
Figure 1-12
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 Figure 1-13
connections.
 Inspect leakage with cardboard, take care to
protect your hand and body against touching
high-pressured liquids.
 If accident occurs, see the doctor at once.
 Any liquid penetrated in skin must be cleaned
14
within few hours. Otherwise it will cause

necrosis.
1.15 BEWARE OF SCALD
 During operation, engine oil, gear oil,

hydraulic oil will become hot. Meanwhile,
engine, hose, pipeline, and other parts will also
become hot. Beware of scald.
 Carry out inspection and maintenance after oil
and parts have been cooled to prevent scald.
1.16 AVOID HEATING UP NEAR PRESSURE OIL PIPE
 If heating up near pressured oil pipe, the

inflammable spray will cause severe burn to
people nearby. Don’t carry out welding, gas
protection welding, or gas cutting near
pressure oil pipe or other inflammable goods.
 If welding, gas protection welding or gas
cutting must be carried out near pressure oil
pipe, mount temporary fireproof jacket to
protect hose or other materials.
1.17 AVOID HEATING UP PIPE WITH PRESSURE OIL
 Not permitted to weld hydraulic oil steel pipe

or hose. Before welding this kind of pipe or
hose, clean it completely with incombustible
solvent.
1.18 RREMOVE PAINT BEFORE WELDING OR HEATING
 Prevent bringing potential poisonous gas and

dust.
 When paint heated up by welding or other
methods, it will bring poisonous gas.
 Remove paint before welding or heating up as
the following methods:
1. Rub out paint with abrasive paper or wheel,
during this work, remember to wear regulated
respirator to prevent inhaling dust.
2. Rub out paint with solvent or paint remover.
After rubbing out, clean paint remover with Figure 1-14
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.
15
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 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’ Figure 1-15
operation, check loosened, twisted,
hardened, or cracked cable and wire.
 Before every shift or after 8 hours’
operation, check lost or damaged
connectors.
 Before operation, tighten, repair, or replace
any loosened or damaged cable, wire and
connector. If the cable or wire is loosened
or twisted, don’t operate the machine.
3. Clean away inflammable materials. Keep the
machine clean every day to prevent fire
16
2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER

SUNWARD Intelligent Equipment Co. Ltd, combining production, teaching and research, is a
new-type enterprise. SUNWARD series hydraulic static press-in pile drives are new kinds of
machine of high efficiency and energy saving.
WORK PRINCIPLE:
In the process of pile pressing, the machine’s weight acts as reaction force to balance the
friction drag from beside the pile and the reaction force from the pile tip, then the pile is pressed in
the ground.
2.1 ADVANTAGES OF SUNWARD PILE DRIVER
The method of using static press-in precast pile is a very particular way of pile foundation
construction. The precast pile is completely pressed into ground by static force. With development
of pile machinery and enhancement of environment-protecting requirement，it has become a
promising way of pile foundation. Compared with other pile foundation construction methods like
impact, vibration or cast, this way has the following advantages:
1. ENVIRONMENT FRIENDLINISS ----The work of construction is quiet and neat, and workers
have less work intension. It’s suitable for urban construction because of the absence of noise,
vibrancy and pollution.
2. HIGH EFFICIENCY ---- Its efficiency is much higher than that of other pile drivers, and it can
finish hundreds meters of pile foundation in a day work (8 hours). It is most suitable for urgent
and large foundation projects.
3. HIGH QUALITY ---- The process of driving pile is similar to testing pile, therefore the rate of
success is almost 100%.
4. UNLIMITED TOTAL LENGTH OF JOINTED PILE ---- The total length of jointed piles is not
limited if pile’s strength allows.
5. LOW COST ---- In all kinds of pile foundation construction methods, the cost of static press-in
technics is one of the most economical types if compared by the cost of carrying capacity per
cubic meter of pile.(equals to that of casting pile when carrying capacity is the same)
2.2 COMPARED WITH THOSE BY OTHER FACTORIES
Customers can choose suitable type according to their practical needs in the range of pressing
force from 800KN to 12000KN. Compared with pile driver made by other factories, SUNWARD
series have the following prominent advantages:
ⅠTECHNIQUE INOVATIONS
In the series products, Sunward has one patent for invention (ZL 93110671.0), three new type
practical patents (patent No. ZL 95236709.2、ZL99249764.7、ZL 99249765.5. These patents got
National Excellence Award and the Ten Most Well Applied Patents Award in Hunan province.
Adopting patent technology highly improves performance of Sunward pile driver:
1. The quasi-constant-power pile driving system is composed of two pairs of hydraulic cylinders
which work orderly in pile-driving and the well-matched hydraulic system makes this kind of
pile drivers superior to other pile drivers of the similar rank, because of its 40% energy saving,
15% increase of speed and more than 40% raised pile driving force.
2. The new type of Step-like moving mechanism can do longitudinal, cross and rotary motion
freely, which makes it easy and agile to aim piles. A two- tier framework with cross and rotary
motion system has a compact structure which is easy to assemble. Specially designed rotary
compensating mechanism and rotary self-return function can largely decrease the resistance of
17
rotation and can reduce time for auxiliary work. Load balancing controller of longitudinal
motion mechanism can largely improve the reliability of vertical motion hydraulic cylinders.
3. The originally designed pile-clamping box is notable for accurate and reliable pile localization.
The pile stress resulting from clamping can be effectively decreased, and the problem of
clamping thin tube pile can also be solved.
4. Among pile drivers of the similar rank, SUNWARD series is the least in width which can
effectively decrease the distance of side pile when in normal pile pressing. The components
are easily disparted and transported.
5. The novel overall layout and special compact mechanism can deal with not only the side pile
near the building wall but also the troublesome corner pile. It improves the adaptability of
SUNWARD pile drivers evidently.
(It should be pointed out that the deed of many domestic factories’ currently copying the
above patents is illegal.)
Ⅱ WELL-CHOSEN OUTSOURCED PARTS TO IMPROVE RELIABILITY
Quality of the outsourced parts is very important to performance of the whole pile driver. In
order to improve the pile driver’ performance, SUNWARD would rather use the outsourced parts
of high price. For example, our oil cylinder is made in well-equipped professional factory
according to our design; hydraulic pump is high pressure auto variable piston pump; crane
windlass and hydraulic motor for rotary are made in Sino-foreign joint venture company with
introduced technique; the balance valve and other key valves are ordered from noted foreign
company.
Ⅲ IMPROVEMENT OF TECHNICS AND THE MANUFACTURE OF EQUIPMENT, ASSURING THE
QUALITY OF PARTS
Sunward pay special attention to the improvement of technics and the manufacture of
equipment .The key structures are made from high quality 16Mn steel plate which is cut with auto
cutter and welded by CO2 gas-proof welding technique. To improve performance of the large
components such as pile-clamping box and guidance beam, location surface and guidance surface
are mechanically machined without cost consideration; and assure the heat-treatment of key parts.
Ⅳ STRONG TECHNIC POWER, UPDATING PRODUCTS QUICKLY
The staff of Dept. of Research and Development is mainly from the Central South University
Mechanical and Electrical Institute. They are of creative talent and spirit. Our institute has a CAD
designing room of several hundreds of square meters and a laboratory of the similar size. We
provide optimum condition for research and development. ZYJ series static pile drivers are all
designed by advanced CAD technique.
In a word, Sunward has created a complete and innovative designing and manufacturing
system which is also capable of quick response to market changes. With the rapid developing pace,
Sunward is leading the world’s static pile driver market.
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3 BASIC STRUCTURE AND WORK PRINCIPLE

3.1 BASIC STRUCTURE OF ZYJ 260B-Ⅱ
FIGURE 3-1 ZYJ260 B-Ⅱ PILE DRIVER

1. Side piling device--- to press side pile 2. Pile driver main cabin--- to protect operator
3. Operating platform--- the main working mechanism
4. Clamping box --- to clamp pile 5. Crane---to lift heavy parts (e.g. pile, counterweight)
6. Vertical motion mechanism--- vertical motion of machine body
7. Cross motion and rotation mechanism---to travel transversely and rotate
8. Longitudinal motion mechanism---to travel longitudinally
9. Counterweight beam---to support counterweight
10. Assistant counterweight beam --- to support counterweight
11. Assistant cantilever--- to support assistant counterweight beam
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12. Electric generator platform--- to place electric generator

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

1- Chief pile pressing cylinder 2- Secondary pile pressing cylinder
3- Pile pressing cross beam 4- Pile pressing upright prop
5- Pile clamping box 6- Pile pressing spherical head 7- Pile pressing seat
FIGURE 3-3 STRUCTURE OF PILE CLAMPING BOX JZX5022
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1- Guide wheel 2- Pile clamping box body 3- Pile clamping cylinder

4- Jaw 5-Guiding device 6-Hydraulic pipeline
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.
NOTE: Before the vertical motion cylinder telescopic, first make sure the cut-off valve
which on the cylinder balancing valve is in open state.
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Figure3-5 Structure of vertical motion mechanism

1-Cantilever 2- Vertical motion cylinder
3.3.2 LONGITUDINAL MOTION MECHANISM

It’s composed of two long ship slideways, two longitudinal motion cylinders joined to it and
four wheel carriers. When the piston of cylinder stretches out or draws back, there is relative
motion between the main body and long ship slideway.
Figure 3- 6 Structure of longitudinal motion mechanism

1- Wheel carrier 2- Longitudinal motion cylinder 3- Linkage cylinder 4- Long ship slideway
3.3.3 CROSS MOTION AND ROTATION MECHANISM

It’s composed of two short ship slideways, two cross motion cylinders, rotary platform, central
axis and return spring mechanism
22
.Figure 3-7 Structure of cross motion and rotation mechanism

1- Short ship slideway 2- Wheel carrier 3- Return spring
4- Central axis hole 5- Rotary platform 6- Cross motion cylinder
3.3.4 CONTINUOUS STEPPING AND ROTATION
Figure 3- 8 Structure of travel mechanism
1- Cross motion cylinder 2- Vertical motion cylinder 3- Longitudinal motion cylinder

4- Long ship slideway 5- Short ship slideway
3.3.5 LONGITUDINAL MOTION
Vertical motion cylinders draw back and short ship slideways support the machine, long ship
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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 down Long ship sideways down
(Long ship sideways longitudinal motion) (main machine body walk)
⑴ Vertical motion cylinders retract

⑵ Longitudinal motion cylinders act
⑶ Vertical motion cylinders extend
⑷ Longitudinal motion cylinders act
Figure 3-9 Longitudinal motion cycle
3.3.6 CROSS MOTION

Vertical cylinders stretch out till long ship slideways touch ground and short ship slideways
leave ground; cross cylinders stretch or draw together, and short ship slideways move; vertical
cylinders draw back till short ship slideways touch ground and long ship slideways leave ground;
cross cylinders stretch or draw together, then body and long ship slideways move transversely.
short ship sideways up short ship sideways up short ship sideways down short ship sideways down
(short ship cross motion) (main machine body walk)
⑴ ⑵ ⑶ ⑷
Long ship sideways down Long ship sideways down Long ship sideways up Long ship sideways up
⑴ Vertical motion cylinders extend

⑵ Transverse motion cylinders act
⑶ Vertical motion cylinders retract
⑷ Transverse motion cylinders act
Figure 3-10 Cross motion cycle
3.3.7 ROTATION
There are five steps to carry out rotation. In every rotation, rotary angle is between 8°-11°.
Rotating procedure (see figure 3-11 and 3-12)
Step 1: Get the pile driver ready.
Step 2: Long ship slideways touch the ground, short ship slideways are lifted, cylinders in
short ship slideways go to the end vis-a-vis.
Step 3: Short ship slideways touch the ground, long ship slideways are lifted, cylinders in
short ship slideways go to the end vis-a-vis( the direction is opposite to that in Step
1). Relative to the original position, the machine body rotates 8°-11°。
Step 4: Long ship slideways touch the ground, short ship slideways are lifted, short ship
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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.
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 act
⑶ Vertical motion cylinders retract
⑷ Transverse motion cylinders act
Figure 3-12 Rotation cycle
3.4 HYDRAULIC SYSTEM (FOR PILE PRESSING)

3.4.1 STRUCTURE
It is mainly composed of two pressure compensation variable pumps, three groups of manual
multidirectional valves，several oil distribution valve blocks and hydraulic cylinders as well as
some other supplementary hydraulic equipment.
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Figure 3-13 Hydraulic cylinders of pile driver

1- Cross motion hydraulic cylinder 2- Longitudinal motion hydraulic cylinder
3- Vertical motion hydraulic cylinder 4- Pile clamping hydraulic cylinder
5- Pile pressing hydraulic cylinder
MULTI-DIRECTIONAL VALVE
Operators use the four operation handles of multi-directional valves to operate the pile driver.
Figure 3-14 Three groups of manual multi-directional valves
1- Multi-directional valve A 2- Multi-directional valve B 3- Multi-directional valve C
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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.
3.4.2 WORK PRINCIPLE (SEE APPENDIX FIGURE 1 HYDRAULIC SYSTEM)

（1） Travel by hydraulic control
Operators use four operating handles of multiunit valve C to control the stepping of pile
driver.
Figure 3-15 Hydraulic system for traveling

1-Multi-directional valve C 2- Walking steel pipe
（2） Hydraulic system for vertical motion
Operators use four operating handles of multiunit valve A to control the vertical motion of
pile driver.
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Figure 3-16 Hydraulic system for vertical motion

1- Multi-directional valve A 2-Vertical motion mechanism
（3） Hydraulic system for clamping pile
Operators use the multiunit valve B to control the job of clamping and releasing pile.
Figure 3-17 Hydraulic system for pile clamping

1- Multi-directional valve B 2- Valve seat 3- Clamping box
（4） Hydraulic system for pressing pile
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Figure3-18 Hydraulic system for pressing pile

1- Multi-directional valve B 2- Valve seat
3- Pipeline 4- Pile pressing hydraulic cylinder
3.5 SIDE PILING AND CORNER PILING

When pressing side or corner pile, use crane to lift the clamping box and pile pressing cross
beam (including pile pressing cylinder) to side pile upright prop and assemble them, then install
them with hydraulic hoses. It can work now. The operating procedures for pressing side pile are
the same with those of when pressing site is in the middle of pile driver.
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Figure 3-19 Side pile frame

1- Pile pressing beam 2- Clamping box 3- Side pile column
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Figure 3-20 Hydraulic system for clamping side pile

1- Multi-directional valve B 2- Valve seat
3- Transition steel pipe 4- Clamping box
Figure 3-21 Hydraulic system for pressing side pile

1- Multi-directional valve B 2- Valve seat 3- Transitional steel pipe 4- Pile pressing platform
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3.6 ELECTRIC SYSTEM

The machine is connected with three phase standard electrical supply AC380V, 50HZ. Three oil
pumps provide power. Two oil pumps with large power adopt the method of Y△ to decrease the
current impact to engine. This electrical system has some security measures for short circuit,
overload and phase failure, electrical leakage, ground connection and so on. During the work, the
temperature of the hydraulic oil can be controlled. For north users, we provide an oil-heating
device (optional)。
Safety rules: to ensure personal safety and equipment safety, the whole machine body
must connect ground firmly and the earth resistance must be kept below 4 ohm. Appendix
figure 2 shows the principle of electrical system.
3.6.1 COOLING DEVICE FOR HYDRAULIC OIL

In hydraulic system long time running, once oil temperature over 60℃ and temperature switch
test it, machine will warn operator to open cooling device. Start filtering pump at first, then open
cooling fan, and open cooling device. After that, buzzer warning will stop.
3.6.2 HEATING DEVICE FOR HYDRAULIC OIL (FOR NORTH USERS)

Hydraulic oil viscosity will be high in low surrounding temperature, which will make hydraulic
pump suck air or increase load, open heating device under this condition. Hydraulic oil
temperature meter will test oil tank temperature automatically. When temperature is less than
-30℃, connecting electric heating circuit; after temperature reaching 35℃, cut off circuit and stop
heating. In hot weather, put heating power switch OFF to prevent miss-heating.
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4. OPERATING REGULATIONS
4.1 CONTROL PANEL
Operators use the push buttons and joy sticks in the control board to operate the machine.
（The joysticks are numbered as S1～S4，Y1～Y4，Z1～Z4）
Figure 4-1 Control panel

Z1、Z2—to control two cross motion cylinders
Z3、Z4—to control two longitudinal motion cylinders
Y2—to control the chief pile pressing cylinder
Y3—to control the secondary pile pressing cylinder
Y4—to control pile clamping hydraulic cylinder
S1～S4—to control four vertical motion cylinders
Y1-to choose piling speed
（Attention ：When piling pressure is higher than 10MPa, it is not allowed to press pile quickly）
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Figure 4-2 Location of push-buttons

1-Socket 2-Pump A on/off 3-Pump B on/off 4-Lubrication pump on/off
5-Buzzer 6-Indoor light 7-Outdoor light 8-Electric fan 9-Oil cooling
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.
11．Simulate piling process. Examine hydraulic system and oil pressure, cylinder and main motion
mechanism. Assure they are at normal.
12．Assure that no abnormal phenomena are found, abnormities have been disposed correctly, and
potential factors of malfunction and security are all cleared up. Then begin piling work.
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4.2.2 ADJUSTMENT OF PRESSURE
Figure 4-3 Location plan of overflow valve
Overflow valve F4 (see Figure 4-3) is used to adjust rated pressure of the hydraulic system.
Set pressure of F4 as follows: After oil pump works normally, push handle Y3 to “(return)”
position, screw down adjustment nut of F4 slowly, watch pile clamping oil pressure meter, when
the oil pressure is increased to Pa, the rated pressure adjustment finishes. Then screw down the
stop screw of adjusting nut.
Overflow valve F6 (see Figure 4-3) is used to set secondary pile pressing pressure Pd, which
can be set according to different needs (see appendix table 8 oil pressure and pile pressing force).
Adjust pressure of valve F6 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 F6; 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 4-4) is used to set main pile pressing pressure. It is set as PF1
≤PF9. Adjust pressure of valve F1 as follows: Start pumps till they run steadily; push the handle
Y1 to the position of “normal pressing”, handle Y2 to the position of “pressing”, after main pile
pressing cylinders stretch to stroke end, gradually screw down adjusting nut of F1; observe the oil
gauge on control panel; when the gauge directs to the needed value, the adjustment is done.
Overflow valve F2 (see Figure 4-4) is used to set quick piling pressure. It is set as value PF2
≤10Mpa. Adjust pressure of valve F2 as follows: Start pumps till they run steadily; push the
handle Y1 to the position of “quick pressing” and handle Y2 to the position of “pile pressing”;
after the piston rod of chief pile pressing cylinders stretch to stroke end, gradually screw down
adjusting nut of F2; observe the oil gauge on control panel; when the gauge directs to 10Mpa, the
adjustment is done.
4.2.3 ADJUSTMENT OF OIL PRESSURE FOR CLAMPING AND RELEASING PILE

Overflow valve F3 (see Figure 4-4) is used to set pile clamping pressure. It is set as PF3≤
PF9. Adjust pressure of valve F3 as follows: Start pumps till it runs steadily; push the handle Y4
to the position of “clamping pile”; gradually screw down adjusting nut of F3; observe the
clamping oil gauge on control panel; when the gauge directs to needed value Pe, the adjustment is
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done. The needed oil pressure for clamping is relevant to material and surface condition of piles.
It should be decided according to practical condition.
If clamping is reliable, the set value should be kept low
Figure 4-4 Location plan of overflow valve

Overflow valve F5 (see Figure 4-3) is used to set pile releasing pressure. Adjust pressure of
valve F5 as follows: Start pumps till it runs steadily; pushes handle Y4 to pile releasing position,
observe pile releasing oil gauge, if the gauge value directs to 5-10Mpa, the adjustment is done. In
the operation, the releasing pressure is permitted to be set more than 5-10Mpa, but it should be
less than pile clamping pressure.
Attention: After any adjustment, please push handle to neutral position.
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4.2.4 ADJUSTMENT OF HYDRAULIC PUMP

Adjust the hydraulic pump of main machine according to the following steps. (See figure 4-5)
Figure 4-5 Main machine hydraulic pump adjustment

（1） Place the handles of 3 multidirectional valves on neutral position, the hydraulic system
unloads (pull any multidirectional valve handle; the machine will start to work).
（2） Screw off plug of pump variable head (see figure 4-6); screw the limitation screw,
adjustment screw of overflow valve F9 as loose as possible.
（3） Start oil pump, the variable head scale pointer should point at the full scale (10) position,
the pump supplies oil at full flux.
（4） Push handle Y3 ( see figure 4-5 ) to “Return” position.
（5） Screw down adjustment screw of overflow valve F9. At the same time, watch the pressure
gauge, the oil pressure will be increased to Pb.
（6） Unscrew the pump’s adjustment sleeve till dial needle of pump variable head begins to
swing, then screw down adjustment sleeve.
（7） Screw down adjustment screw of overflow valve, till oil pressure is increased to Pa.
（8） Screw in pump limitation screw slowly, ensure that the pointer of pump variable head
points at X. Then lock with locknut and screw in plug.
（9） Push handleY3 to neutral position. The adjustment is finished now.
Then the pump’s flow and pressure vary automatically according to the curves of quasi-constant
power characteristics. (See Figure 4-7)
See the appendix table 8-7 for the specific value of Pb, Pa and x.
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Figure 4-6 YCY series hydraulic pump Figure 4-7 Curves of quasi-constant
variable adjustment mechanism power characteristics
Q- Flow P- Pressure
Note: According to different models or customer orders, hydraulic pump models are also different.
The A7V series hydraulic pump pressure-flow curves have been adjusted well in factory, don’t
need the adjustment.
4.3 OPERATION METHOD AND STEPS
4.3.1 START-UP
（1） Turn on the air switch. Turn on the power with key and be sure that all handles of
multidirectional valve are in the neutral (off load position).
（2） First start one pump. After about 7~8 seconds the green indicator light turns on.
（3） Start another pump when the green indicator light turns on. After 7~8 seconds the green
indicator light turns on.
（4） High temperatures in the summer time and machine can turn on the filter pump. If the
cooling performance is poor attention on the cooling fan pump.
（5） Start 3 pumps one by one. Have them work for 3 minutes in the condition of no load. If no
abnormalities happen, continue the following procedures.
（6） Push the handle Y4 to the position of “Releasing pile”. Then oil pressure rises. If the oil
gauge labeled “pile pressing pressure” and “pile clamping pressure” shows the normal
pressure, push Y4 to the neutral. Then the job of start-up is finished.
4.3.2 POSITIONING PILE
Operate four stepping handles Z1~Z4 and four vertical motion handles S1~S4 to ensure
correct pile placement by the pile driver’s rotation, longitudinal and cross motion.
Before pressing pile, operate vertical motion handles S1～S4 to have the piston rods of four
vertical motion cylinders extend and long ship slideways land on the ground, short ship slideways
leave the ground. Then positioning pile is finished.
4.3.3 LEVELING
In order to ensure the verticality of piles, the main body of the pile driver should be kept
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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, 4.2)
Handle Y4 is used to clamp and release pile. When clamping pile, push handleY4 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 handleY4 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 four 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
position and handle Y1 to normally piling position.
（3） “Adding force” refers that two chief piling cylinders and two or four secondary piling
cylinders take part in piling work together. When pile pressing force is balanced by the drag
force on pile driver from the ground (oil pressure for pressing pile reaches Pa(24.5MPa)), the
two or four secondary pile pressing cylinders should be used to add force. Push handleY3
to position of adding force, the secondary cylinders stretch out. Handle Y1 must be in the
position of normal piling and handle Y2 in piling position. After finishing a piling stroke,
push handle Y3 to return position. After the rod draws back, then perform “lifting pile”.
ATTENTION:
When the piston rods of secondary pile pressing cylinders stretch out to add force on pile
clamping box, Y1 must be in the position of “normal pressing”, Y2 in “piling” position.
（4） “Lifting pile” refers to lifting clamping box.. First put Y1 in the middle position, then push
handle Y2 to lifting position. Clamping box is lifted to the highest position. Push Y4 to the
middle position from the position of releasing pile and clamping oil pressure reads zero.
（5） Rapid returning operation: When the chief pressing-in cylinder and a pair or two pairs of
secondary pressing-in cylinder work together, the return operation after pressing a stroke
only need push Y2 to lifting position when Y1 in the middle position. If clamping
stagnation, can accord to the “Lifting pile” operating, that is push the participation cylinder
handle to the lifting state
4.3.4.2 PRESSING PILE PROCEDURES

When piling a set of piles into ground, with the increasing depth and geological change the
pressing force becomes larger and larger. In order to improve efficiency, reduce power
consumption, assure piling quality and protect pile driver, the steps for pressing a set of piles are
to be taken as follows:
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a) The first 1-2 stroke uses “pile pressing” in order to assure the piling verticality and find
out the ground geology.
b) After 1-2 piling stroke, if the oil pressure is lower than 5MPa, use “quick piling” until oil
pressure reaches 10Mpa. Then use “pile pressing” again. Changing from “pile pressing”
to “quick piling”, the displayed pressure value on the gauge will rise. Changing from
“quick piling” to “pile pressing”, the displayed value on the gauge will drop.
c) After 1-2 piling stroke, if the oil pressure is higher than 5 MPa, do not use “quick piling”.
d) If oil pressure reaches Pa (24.5MPa) during piling, then use “adding force”.
e) If oil pressure reaches Pa (24.5MPa) during adding force, then the piling force has
reached rated force, and the job of piling a set of piles has completed.
WARNING：
Before pressing pile, there must be enough counterweight on the pile driver; pile
pressing force should not exceed 260 tf. If the counterweight is not enough or the pile
pressing force is too large, the accident of “lifting machine” will occur. If the electric bell
alarms, which warns that “lifting machine” occurs, immediately push handles Y1, Y2 and
Y3 to middle position. All personnel except operator should leave away from the pile driver
and keep a least distance of 2-3 meters; After the oil pressure gradually drops down to zero
and long ship slideways touch ground, push handle Y4 to position of releasing pile; When
“lifting machine” occurs, absolutely prohibit pushing handle Y4 to releasing pile position
first. If the clamping oil pressure drops during the process of slowly releasing the piling
pressure, it must be done to push handle Y4 to position of clamping pile for load. When
“lifting machine” occurs, it is also prohibited to operate the crane. If the crane has been
lifting objects, the objects should be unloaded. When the accident has been solved, the pile
driver should be paused to find out causes of “lifting machine”. Before continuing work,
measures must be taken to prevent the accident of “lifting machine”.
Sunward shall not be responsible for any legal or economic responsibility caused by
“lifting machine”.
“Lifting machine”------referring to that the main body and long ship slideways are lifted
off ground because of not enough counterweight or piling force exceeding the rated force.
“Machine falling down”---when pressing pile, pile pressing cylinders release piles
abruptly, so that pile driver loses support and falls down suddenly. It can cause serious
injury to personnel and the machine itself.
ATTENTION
1. In normal condition, it is not allowed to pull pile with pile driver. Pulling pile refers to
pulling out the pile that has been pressed into ground. If there is special condition and it
is necessary to pull pile with pile driver, you must make sure that the pulling force is less
than P2tf, the system oil pressure is less than Pa, and weight of pile driver with
counterweight is less than P3tf. Otherwise partial counterweight should be removed.
When pulling pile, short and long ship slideways should be layed down on ground and
nobody is permitted to stand under clamping box. After finishing pulling work, check the
joint seat between chief cylinders and clamping box whether it is normal or not. If pile
driver inclines during pulling pile, the pulling work should immediately be stopped.
2. If piling pressure exceeds 10Mpa, push handle Y2 to middle position to release pressure，
40
then push handle Y4 to the position of releasing pile. If four cylinders work together, the
handle Y3 should also be pushed to middle position to release pressure. After piling oil
pressure gradually drops down, push handle Y4 to position of releasing pile. Otherwise,
great impact would occur! Sunward is free from any responsibility for such incorrect
operation.
3. If pushing handles has to be done or has been done, please remember, at any moment, do
put all handles of multidirectional valve to the middle position to unload, which will help
to save energy, reduce the generation of heat, protect pile driver and assure safety
operation.
4. When working at reconstruction site, especially at the bricks or blocks largely imbedded
stratum, form holes with steel pile first to avoid possible pile break.
4.3.5 ATTENTION
 Pay attention to the verticality of piles and the leveling of machine body during pressing pile.
 Operate handles and buttons gently avoiding rough operation.
 Check at any time whether oil pressure and oil temperature are normal. (The max. oil pressure
should be Pa, oil temperature between 35°～85°). If any abnormalities occurs, stop machine
immediately to dispose abnormalities.
 A set of pile to be inserted into the same location must be completed continuously. If there is a
long break during the process, the pile inserted in ground might solidify with the ground earth.
When piling process resumes, the oil pressure would increase sharply.
 When pile driver moves, rotates, or rises and falls in large range, it must be guided, cooperated
with ground personnel. The operator must keep close watch on the pile driver motion and
communicate with the ground personnel in time. If there is any abnormality, immediately push
the valve to middle position.
 When pile driver moves, rotates, rises or falls, if oil pressure increases, it indicates the related
cylinder has gone to stroke end. Immediately push the valve to middle position.
 While pile driver moves or rotates, the electrical cable should not be pressed by long or short
ship slideway, or blocked by obstacles for which the electrical cable can not move with the pile
driver.
 Electrical cable can neither be grinded by trucks nor covered by objects.
 While pile driver runs, pay attention to the hoses linked to long and short ship slideway, assure
they are not stumbled or blocked by other parts, in case the hose might be pulled broken.
 If a sunk accident occurs while pile driver runs, operator must lay down the long and short ship
slideway to touch the ground, remove the counterweight from pile driver, and then dispose the
accident. The counterweight of inclined side should be removed first.
 When pile pressing cylinders are working, it is prohibited to release pile.
Sinking accident--- It means that pile driver sinks into the ground because the soft ground cannot
support. At that time the pile driver cannot move by itself.
4.3.6 CABLES ACCESS PHASE SEQUENCE

DUE TO SOME SPECIAL REASON, N MAY CHANGE
1. When connecting cable to pile driver，marked with N connected to the zero line.
2. After the three-phase line access, if the pump steering does not meet the requirements, adjusting
41
the phase sequence.
Marked N connecting to zero line
Fig 4-8 Main circuit breaker

4.3.7 OIL COOLING OPERATION
Part 7 in figure 4-2 control Oil cooling fan .
1. Rotating part 7 to the left is close, oil cooling fan can’t work,
2. Rotating part 7 to the right is open, there are two states:
If the Part 6 in fig 4-2 doesn’t start-up, oil cooling fan can’t work;
If the Part 6 in the 4-2 stat-up, oil cooling fan and filter pump working together.
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4.3.8 CONNECTING WELDER
Fig 4-9 Welding protector component

1- Used for protecting ZX 5 series three-phase rectification arc welder, ZX7 inverter welder
and Carbon dioxide air protecting welder
2- Used for BX series AC welder.
3- Air switch
4- Connect three-phase air switch
5- Connect 220V zero line（N）
There is a welding protector electrical assembly in the platform.
a) In part 1, terminal 1, 2, 3 connect to the power. Mark ＋、－ connect to handle.(380V)
b) Part 2 connect to the power of the BX series AC welding machine.（220V）
c) To ensure the safety, only a welder can be used every time.
4.4 INSTALLATION AND REPLACEMENT OF CLAMPING JAW

4.4.1 INSTALLATION
The installation of clamping jaw for round & square pile (see Figure 4-10): fix the inner jaw to
cylinder directly by inner hexagonal bolts. When outer jaw is needed, fix it to jaw seat together
with inner jaw by appropriate inner hexagonal bolts.
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Figure 4-10 Clamping jaw installation for square & round pile
① Pile clamping cylinder base ② Pile clamping cylinder ③ Inner clamping jaw ④ Outer
clamping jaw ⑤ Block plate ⑥ Location pin ⑦ Inner hexagonal screw a--- handling hole
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4.4.2 REPLACEMENT OF CLAMPING JAW

When replacing jaws, remove upper clipping jaws first, then the lower clipping jaws. To
dispart jaws, first attach the lifter hook on clamping jaw, then loosen the joint bolt between jaw
and its seat, and pull the jaw out.
When install jaws, install lower clipping jaws first, then the upper clipping jaws. To install
clamping jaws, first attach the hook on jaw and pull the jaw into the hole of clamping box, then
fix the jaw on its seat with joint bolt and tighten the bolt.
NOTE：Jaw configuration of pile clamping box, see schedule 8-7

WARNING:
1. Prohibit commanding and observation personnel from standing under the clamping box.
2. Reliable lifting equipment is necessary when replacing clamping jaw.
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5ASSEMBLY, DISASSEMBLY, TRANSPORTATION AND

MAINTENANCE
5.1 ASSEMBLY
The first installation and adjustment of pile driver should be carried out under cooperation
and direction of Sunward company’s engineering personnel or the authorized technician. After pile
driver is installed, do maintenance well according to regulations. Adjust and examine the pile
driver according to operation regulations.
a Required disassembly space
1. Space occupied by pile driver itself;
2. Space for transport vehicles going in and out to dump;
3. Space for lifter over 25 tons going in and out to lift components.
b Requirement to the geological conditions of disassembly site：

The plainness and hardness of ground should meet the requirement for truck about 50 tons
and lifter over 25 tons.
Pile Driver Assembling Process：
1. Lift longitudinal motion mechanism to mounting position, see Fig 5-1.
Fig 5-1
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Fig 5-2
2. Running carrier vehicle within largest part to longitudinal motion mechanism center, see fig 5-2
（no carrier vehicle showed in fig）.
3. Lift vertical motion mechanism by crane, mounting related hydraulic pipelines, start pile driver.
Adjusting the position between lifting cylinder bulb and wheel carrier bulb seat in long ship
slideway，connecting them; Run carrier vehicle away. Fig 5-3.
Note：Before assembling，clean impurity in all bulbs and bulb seats.
Fig 5-3
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4. Lift cross motion and rotation mechanism by crane：Lift short ship slideway and turntable to
suitable position, start pile driver, adjusting the position of machine main body, short ship
slideway and turntable by moving longitudinal motion mechanism and vertical motion mechanism,
connecting them; connecting related hydraulic pipelines, fitting ladder. See Fig 5-4.
Fig 5-4 Fig 5-5

5. Lift clamping pile box by crane，adjust its assembling position；then hoist beam, connect
related hydraulic pipes, start pile driver, mounting pile pressing table by moving pile pressing
cylinder, Fig 5-5.
6. Lift counterweight beam by crane，Fig 5-6.
7. Lift counterweight by crane，Fig 5-7.
图 5-6 图 5-7
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Fig 5-8 Fig 5-9
Fig 5-10 Fig 5-11

8. Assembling for side pile and its counterweight：
a) Hoist chief pile pressing beam (include pile pressing cylinder) and pile clamping
box by crane, and installed on the side pile cushion cap.
b) Hoist auxiliary cantilever by crane, see fig 5-9.
c) Hoist auxiliary counterweight beam by crane, see fig 5-10.
d) Hoist auxiliary counterweight by crane, see fig 5-11.
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NOTE: The counterweight placed diagram see §9-figure 3.
5.2 DISASSEMBLY
The disassembling process is inverse of the assembling process.
ATTENTION：
① After disassembling counterweight, unscrew the drain plug on main body, long & short
ship slideway, and drain the water at first. See Fig 5-13.
② During disassembling，all cylinder piston bars must be retracted to prevent damage in
hoisting and shipping period.
③ Before disassembling cross motion and rotation mechanism. Tighten the return spring
bolt to separate the reset spring seat and reset seat；after assembling in construction site, unscrew
the bolts and make spring seat and reset seat touch.
④ All oil tubes should be plugged in time reliably during disassembling.
⑤ In disassembling, outer touching surface should be oil sealed.
⑥ After disassembling, turntable in cross motion and rotation mechanism and short ship
slideway should be fixed.
⑦ Before transportation, draw back the movement parts of crane jib completely, and fix the
retractable jib with 2 bolts on fixed jib. If there is low bridge, tunnel etc：
a) Disassemble the small part in crane higher the cabin top；
b) Disassemble crane slewing support upper part for shipping separately.
Fig 5-12 Water Inlet and Outlet
50
5.3 TRANSPORTATION
 Because of the great weight, use the decomposition transport. The biggest pieces of
transport alone, the rest components flexible locomotive transportation. See Table 5-1
and Figure 5-13.
 Choose sufficient tonnage trailer.
We provided the main detachable parts weight table (See Table 5-1 Parts weight table) for the
user to reference. Convenient for installation, disassembly, lifting, transportation, allocation
of vehicles, and to ensure the safety of transport by road, bridge etc.
Table 5-1 ZYJ260B-ⅡParts weight table
PARTS NAME WEIGHT (TON)

Main machine (without counterweight) About 103.1（include 21.4 tons of sand）
Machine body 22.5
（non-removable）
40
QY12D crane 9.1
Max. parts (include 0.9
（without seat） tons of
Vertical motion 2.1X4=8.4 sand)
mechanism
(include 0.9 tons of sand）
Clamping box JZX5022(ZYJ260B-I 4.1 ( include 0.9 tons of sand)
I)
Pile pressing cylinder and cross beam 3.05X2=6.1
Longitudinal motion mechanism 12.9X2=25.8 ( include 4.8 tons of sand)
Slewing platform 1.4X2=2.8（include
Cross motion 0.9 tons of sand） 30 ( include
mechanism 13.5 tons of
Short ship slideway
13.6X2=27.2 （ include 12.6 sand )
(include cylinder and
wheel carrier) tons of sand）
Counterweight beam 2X2=4（include 1.3 tons of sand）

Auxiliary cantilever and counterweight 0.16X4+0.24X2=1.12
beam
Cast iron F Counterweight 5.02X18=90.36
counterweight
Square 4.81X16=76.96
（ Optional） counterweight
Barite counterweight F Counterweight 4.03X18=72.54
（Optional） Square
2.99 X32=95.68
counterweight
Note:
51
1． The above weight data of all parts is theoretically calculated. The weight data of
outsourced parts is also theoretic. There might be a little difference between practical
weight valve and theoretic weight value. Normally, the percentage error is within ±6%.
2． The cast iron counterweight is calculated as per 6800 Kg/m3.The barite counterweight is
calculated as per 3800 Kg/m3.Customers shall determine the number of square
counterweight to buy according to practical conditions and their need.
3． For ZYJ260B-Ⅱ,the long ship slideway can be filled with 8.1 tons.
FIGURE 5-13 TRANSPORTATION DIMENSION FOR MAX. PARTS OF ZYJ260B-Ⅱ.
5.4 DEBUGGING
See §4 OPERATION REGULATIONS for reference.

5.5 DAILY MAINTENANCE AND TIME MAINTENANCE
1. Examine fixing screw bolts for any looseness. Specially pay attention to those fixing screw
bolts on the pressing cylinders, vertical motion cylinders, crossing motion cylinders and
clamping jaws, as well as the joint screw shaft and screw nuts between cantilever and its seat.
Be sure to keep torque moment symmetrical if there are several fixing screw bolts.
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.
52
5. If it works for the first time, you should change all oil after a month and clear the oil tank.
After that, change oil every half a year. (Be sure to clean used oil in tank, tubes and any units)
6. Keep oil return filter clean. If the return oil manometer shows a pressure over 0.4 MPa, clean
or change the core of the oil-filter. Clean it every month.
7. Screw down every fixing screw bolt on all pipe connections and units every month.
8. If the color of the oil becomes white and muddy, replace the oil. Otherwise the hydraulic
elements will break down earlier than expected.
9. In order to assure the accuracy of the oil gauge, it should be checked periodically. Normally,
interval of check is half of a year. When in another work site or the manometer doesn’t
point at zero, unscrew the oil-filling plug loose (see figure 7-2 ), when the pressure inside
and outside the manometer are the same （it needs about 1 minute）, screw the oil-filling
plug tight, then the manometer can work normally.
10．When replacing new pump, you should fill up oil in leakage pipe, connect the pipe with
leakage coupler (not screw down), start pump, and screw down coupler nuts when oil leaks
from coupler.
5.6 LUBRICATION DIAGRAM
Main machine Crane

Number Number
Parts of Greasing Parts of Greasing
Interval Interval
name greasing style name greasing style
point point
Longitud
inal Wire
16 Grease gun 7days 1 Spreading 7days
motion rope
wheel
Transvers Radius
Grease
e motion 12 Grease gun 7days change 2 7days
gun
wheel shaft
Guide
wheel of Upper
Grease
pile 8 Grease gun 3days wire 1 7days
gun
pressing wheel
box
Spheric
Lower
socket on Change Everyda
8 Spreading wire 1 Spreading
wheel site
wheel y
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 4 Spreading 3days Slewing 1 Grease 30days
53
wheel support gun

track
Wheel Slewing
carrier 4 Spreading 7days wheel 1 Spreading 7days
track gear
Inner
part of Every
16 Grease gun
clamping shift
box
Special Attention：
New machine should be replaces oil sucking filter core after 50working hours; then
replace in every 300working hours or 3 months.
Note：
1． Spread grease with ZG-S graphite calcium-based grease (SY405-65)

2． Injected grease by greasing gun is SY1413-80 lithium-based synthetic grease.
3． 90# gear oil is used to lubricate drum inside（1 liter every time）, replace it at 100
hours operation and at 500 hours operation.
☆ If environment temperature is higher than 20℃, hydraulic oil N68 should be used.
If environment temperature is lower than 20℃, hydraulic oil N46 should be used.
If environment temperature is lower than -20℃, hydraulic oil N32 should be used.
5.7 TORQUE FOR STANDARD TIGHTENING PARTS
Thread size M6 M8 M10 M12 M16 M18 M20 M24 M27 M30
Level 8.8 10 24 44 78 190 260 370 640 950 1300
Torque(N·m)
Level 10.9 12 30 62 110 265 365 520 900 1350 1800
【IMPORTANT NOTES】The following does not belong to the warranty scope:

 Unauthorized increase the system pressure;
 After the shutdown is not closed fan, electric heater or hydraulic oil heater；
 Hanging is not strictly comply with the requirements of the specification；
 Pile driver moving does not ensure long ship slideways or short ship slideways off the
ground，and encounter obstacles in the range of movement；
54
6 CRANE
QY crane is installed in ZYJ hydraulic static pile driver as a pile lifting device, which is an
auxiliary device. The crane’s structure is similar to the superstructure of general hydraulic truck
crane and it is mainly composed of jib system, windlass system, slewing, and hydraulic control
systems.
The superstructure of crane is installed in the machine frame, which is connected with the
inner part of slewing support, while the outer circle of slewing support is connected with the base
of crane. The crane base is welded on the main machine of ZYJ hydraulic static pile driver.
6.1ATTENTION
 The main machine operator and crane operator should keep good communication and
observation for each other. Prohibit operating crane or hoisting objects while the machine
moves or rotates. And also, prohibit the machine moving or rotating while crane is in
operation or hoisting objects.
 Ensure firm binding while hoisting pile.
 Crane’s winch wire should wrap around the drum for at least 4 circles.
 When lifting pile, it is prohibited to stand in the working range of crane.
 Check winch wire and pile lifting wire often and replace them if any damage occurs.
 Check and screw down the connection bolts at the crane slewing support every 2 months,
the screwing down torque is 900NM. Replace them with original SUNWARD bolts if any
abnormality occurs.
 Lift rated weight within the limitation of jib lifting angle to avoid crane jib overloading.
 Before pressing piles, make sure the hook has been separated from the tools for lifting
pile. If not, there will be serious accident of the lifter and pile driver. In some special
condition, if the crane winch has to be used as pile follower, the speed of giving pile must
be higher than the speed of piling.
6.2 BASIC STRUCTURE AND WORK PRINCIPLE
55
Fig 6-1 Crane structure

1-Base 2-Hydraulic pump group 3-Countweight oil tank 4-Winch unit
5-Jib 6- Derricking cylinder 7-Cab 8-Crane platform
9-Lifting hook unit 10-Lifting pile beam
56
6.2.1 JIB SYSTEM AND ITS EXPANSION
Fig 6-2 Jib structure

1-Main jib 2-Flexing jib
Jib system includes main jib, flexing jib, derricking cylinder, and driving system of expansion jib,
etc. When extending or retracting jib, place the jib horizontally and pull out two shafts that fix
expansion jib, then pull the operating handle of multidirectional valve to operate the jib expansion
motor, so that the expansion jib expands relatively to fixed jib.
Note: When extending or retracting jib, the angle between jib and horizon should be less
than 10°. There are two adjustable jib lengths. After the jib length is adjusted, fix the
extendable jib on fixed jib with shaft pin and lock bolt.
Fig 6-3 Telescopic drive system Fig 6-4 Winch Structure
6.2.2 WINCH SYSTEM

Winch system is composed of hydraulic motor, reducer, windlass drum mechanism of brake,
windlass wire and pulley block.
57
6.2.3 SLEWING SYSTEM

Slewing system includes a hydraulic motor, reducer, small gear, and slewing support. The slewing
support is fixed on the machine seat. Hydraulic motor drives small gear via reducer, the small gear
turns around the large gear ring on slewing support, making the crane slew.
Fig 6-5 Slewing Structure

1-Base 2-Slewing mechanism 3-Slewing bearing 4-Crane platform
5-Collecting ring unit
6.2.4 DERRICKING SYSTEM
It is used to change the jib angle.
The amplitude of QY crane is realized by the extension and retraction of cylinder, so that the
horizontal distance between the hook center and slewing center，i.e. the amplitude, changes.
6.2.5 HYDRAULIC SYSTEM
58
Fig 6-6 Hydraulic System Structure
1—winch system 2—slewing mechanism 3—Multiunit valve 4—Crane cabin

5- Pressure meter 6- Expansion motor 7- Balance valve 8-Hydraulic oil tank
9-Hydraulic pump
See figure 6-6 for hydraulic system. (Hydraulic principle diagram see §6.6 crane hydraulic
principle diagram) A hydraulic pump supplies pressure oil; The system pressure is determined by
overflow valve of multidirectional valve, the pressure is set as 18Mpa.
Manual multidirectional valve includes 4 manual control valves, achieving derricking, winch,
slewing, jib extending & retracting, and speed control. Pull multidirectional valve handle and
treadle the pedal to achieve smooth derricking, slewing, and windlassing.
6.2.5.1 Adjustment of hydraulic pump

See Fig 6-7; adjust the pressure of hydraulic pump as per follows.
① Place all the handles in the crane cabin on neutral position, the hydraulic system unloads
(pull any multidirectional valve handle; the machine will be on loading position).
② Screw off plug of pump variable head, adjust the limitation screw, adjusting sleeve,
adjusting screw of overflow valve F1 as loose as possible.
③ Start oil pump, the variable head scale pointer should point at the full scale (10) position
and the pump supplies oil at full flux.
④ Push the control handle of amplitude cylinder (see figure 6-10) to “fall jib” position till
the cylinder retracts to the end (Before you push the handle, take care to watch whether
the movement of jib affects other parts).
⑤ Screw down adjustment screw of overflow valve F1 gradually till oil pressure is
increased to 13Mpa and screw loose the pump adjustment sleeve till the variable head
scale pointer of pump starts to swing. Then lock the adjustment sleeve.
⑥ Continue to screw down the adjustment bolt of overflow valve till the oil pressure
increases to 18Mpa.
59
⑦ Screw down the limitation screw rod of pump gradually till the variable head pointer
points at 7.7 position, then lock with locknut and screw in plug.
⑧ Place the control handle of amplitude cylinder on neutral position.
The adjustment of hydraulic pump is finished now. Then the pump’s flow and pressure vary
automatically according to the curves of quasi-constant power characteristics.
Figure 6-7 Hydraulic variable Figure 6-8 Curves of quasi-constant power

characteristics
adjustment mechanism
In order to meet the requirements of the northeast cold climate, the tank can be selected
northeast configuration, heat the oil. (Fig6-9)
Fig 6-9 The heating control principle diagram of hydraulic oil tank
6.2. 6 SAFETY DEVICE
1. Jib overload protection
Adjust the adjustment screw on derricking hydraulic cylinder equalizer valve (if screw clockwise,
the pressure lower; screw anti-clockwise, the pressure higher). The oil pressure which limits the
jib lifting should not exceed 18Mpa to prevent the jib overload. If the jib falls when windlass
60
loads, which means the jib lifting angle is too small, it should be done to lift the jib and then begin
to windlass.
2. Hook limitation protection

When hook reaches upper limit, the hydraulic system unloads and windlass stops to rise. Its
working theory is as follows: When the hook reaches upper limit, hook assembly props up the
hammer which is wrapped by wire rope, control switch connected with hammer switches on the
electromagnetic valve, then the right position is switched on, overflow valve off-load, the winch
lifting stops; pull down the cancel limit button, the electromagnetic valve gets back to left position,
the hydraulic system works normally, achieving falling hook, and the hook disengages from upper
limit（see fig 6-10）
Fig 6-10 Hook limitation protection

1- Connection box 2- Heavy hammer
3. Torque limitation protection for the jib

The instruments will display different lengths, appropriate inclination angles, lifting weight and
other parameters at real-time. It can also tell the torque limitation weight with the lifted object in
the current position. When the torque limitation weight is reached, it will give prewarning and
warning to alarm operators.
A power switch is installed in the right of instrument panel. After electricity failure, you have to
repeat once the movement of switch-on and switch-off to electrify. It starts to work normally
when buzzer is sounding.
Note: The instrument for torque limitation is optional, if customer needs to buy it, the
requirement should be made clear in the purchase contract.
61
6.3 CRANE OPERATION
Fig 6-11 Control Board
1- Oil pressure gauge for return oil 2-Oil pump on/off 3-Cancel limit button
4- Oil pressure gauge for system oil pressure 5-switch for inside lamps 6-switch for outside
lamps
7-Fan switch 8-Horn 9-Low power 10-Oil temperature gauge (For northern users)
11-Buzzle 12-Oil heating indicating (For northern users)
6.3.1 PREPARATION BEFORE START-UP

① Start oil pump electric engine, and hydraulic system starts to work.
② Start derricking cylinder and rotation motor, roll the jib out from vertical motion
cylinders, and lower it to the horizontal ground with the angle between the jib and the
ground less than 10°.(see figure 6-12)
Fig 6-12 Before jib extends

③ Start expansion motor and extend the expansion jib to needed length, then fix it to fixed
62
jib with pin rolls and bolts.

④ Operate slewing handle to put the crane jib in the position ready for lifting pile; operate
the derricking handle according to lifting weight and put the jib in appropriate height；
Operate windlass handle to lower lifting hook and start to lift pile or other objects. ( see
figure 6-13)
Fig 6-13 Crane in working state
When windlass lifting hook reaches the upper limit, stop the windlass, and operate windlass
handle of multiunit valve to unhitch the hook until lifting hook leaves the upper limit heavy
hammer.
6.4 MAINTENANCE
Proper routine maintenance is extremely important to operator’s personal safety, machine’s

normal running and service lifetime. Please carry out routine maintenance to every machine parts.
(See §5.6 LUBRICATION CHART)
Check often whether there are loose joint bolts in rotary support, hydraulic rotary mechanism and
so on. Tighten loose bolts appropriately. (See §5.7 STANDARD TORQUE TABLE)
Check and solve failure in time. (See §7.1)
6.5 PARAMETER
Table 6-1 MAIN TECHNICAL DATA
Items QY12 Parameters QY16 Parameters

Max. radius-change
65 t·m 90 t·m
moment
Max. lift weight 12 t 16 t
Max. lifting speed (6
10 m/min 10 m/min
wires)
Max. slewing speed 3 r/min 3 r/min
Max elevation 75° 75°
63
Rated pressure for lifting 18 MPa 18 MPa

Lifting flow rate(at full
115 L/min 115 L/min
flow)）
Lifting power 30 Kw 30 Kw
Rated electric current 57 A 57 A
Hydraulic pump model 80YCY14-1B 80YCY14-1B
Electric motor model Y200L-4-30Kw B35 Y200L-4-30Kw B35
Table 6-2A LIFTING ANGLE AND ALLOWABLE LIFTING WEIGHT FOR 12 TONS
Lifting angle Long jib Short jib

Lifting Slewing Lifting Slewing
(°)
weight (t) radius (m) weight (t) radius (m)
0 1.91 16.7 2.74 13.3
20 3.26 15.7 4.43 12.5
30 3.92 14.4 5.25 11.5
40 4.68 12.8 6.20 10.2
50 5.71 10.7 7.49 8.56
60 7.35 8.34 9.54 6.66
65 8.63 7.05 11.14 5.63
70 10.53 5.70 12.00 4.56
75 12.00 4.31 12.00 3.45
76 12.00 4.03 12.00 3.22
77 12.00 3.75 12.00 3.00
78 12.00 3.47 12.00 2.77
Table 6-2B LIFTING ANGLE AND ALLOWABLE LIFTING WEIGHT FOR 16 TONS
(ORDINARY)

(°)
0 1.90 17.2 3.43 12.3
20 3.87 16.2 6.17 11.6
30 4.83 14.9 7.51 10.7
40 5.93 13.2 9.05 9.44
64
50 7.41 11.0 11.11 7.92

60 9.72 8.59 14.32 6.16
65 11.51 7.26 16.00 5.21
70 14.17 5.87 16.00 4.21
75 16.00 4.44 16.00 3.19
76 16.00 4.15 16.00 2.98
77 16.00 3.86 16.00 2.77
78 16.00 3.57 16.00 2.56
Table 6-2C LIFTING ANGLE AND ALLOWABLE LIFTING WEIGHT FOR 16 TONS
(LONG JIB)
(°)
0 1.59 18.17 2.93 13.32
20 3.45 17.1 5.46 12.52
30 4.35 15.74 6.7 11.54
40 5.4 13.92 8.13 10.2
50 6.8 11.68 10.03 8.56
60 8.97 9.09 13 6.66
65 10.67 7.68 15.31 5.63
70 13.18 6.21 16.00 4.56
75 16.00 4.7 16.00 3.45
76 16.00 4.4 16.00 3.22
77 16.00 4.09 16.00 3
78 16.00 3.78 16.00 2.78
Attention: Operate lifting job according to the above table strictly.
65
6.6 HYDRAULIC DRAWING
66
6.7 ELECTRICAL DRAWING
67
7 TROUBLE SHOOTING
7.1 COMMON MALFUNCTIONS AND CORRESPONDING SOLUTIONS
Malfunction Cause Solution

Something dirty between the
Clean the dirty thing, repair
point of the cone and valve seat
or replace it.
or the sealing surface is worn.
The little orifice in the middle of
main valve spool of overflow Clean valve.
valve is blocked.
The main valve spool of
overflow valve is blocked in an Clear and repair.
1. Pressure can not meet
open position and can’t be reset.
needed value or completely
no pressure Oil pressure gauge is destroyed. Change the gauge.
The running direction of Change the running direction
hydraulic pump is wrong. of electrical motor.
The hydraulic pump sucking oil
Add oil or repair oil tube
is not enough
Replace components, and
Hydraulic pump oil-distribution
check whether the leakage oil
tray or backhaul tray worn
pipe unblocked or not.
The orifice in the pilot valve
seat of overflow valve is Clean away such things.
2. Pressure is over the limit blocked and disabled.
(If the pressure exceeds
limit very quickly, stop the The main valve spool of
pile driver at once.) overflow is blocked, so it can’t Clean and repair.
open and overflow.
Oil pressure gauge is damaged.
Change pressure gauge.
The directed value is not correct.
3. The force of clamping Take out of the spool to
can’t be maintained (If Single-direction valve F4 is not check if there is some
above malfunction happens completely sealed. eyewinker or any abrasion.
and can not stop working, Repair or change it.
the method of
The seals of hydraulic cylinder
discontinuous driving
for clamping are worn so that Change the seals.
clamping cylinder during
chambers in cylinders connect.
one pressing stroke can be
adopted. Pipeline leaks. Stop leakage.
4. Pressing pressure can not Oil pressure gauge is damaged.
Change pressure gauge.
meet needed value or The directed value is not correct.
completely no pressure.
The preset pressure value of
system overflow or pressing-in Reset it
overflow is too low
68
Sealing of system overflow

valve or pressing-in overflow
Repair or change it.
valve can not meet requirement
and is not tight.
Seals of pressing cylinder rod
Replace the worn seals.
are damaged.
Clean return oil filter and
Return oil pressure is too high.
pipeline.
Oil is overheated. Refer to item 5.
Remember to push all
handles of multidirectional
The system works too long in
valve to the middle position
the condition of overflowing. Or
of “ Releasing load”. Take
quick press pile in high pressure.
care not to execute quick
piling under high pressure.
Oil pipeline is blocked. Detect and remove.
5. Overheated oil Return oil filter is blocked. Clean and change
Breakdown of the hydraulic
pump. The pump is too hot to Repair the pump.
touch.
The oil level is too low. Fill up hydraulic oil
Hydraulic oil is too dirty or used
Re-filtrate or change oil.
too long.
The leakage at joints is caused
by loose connection or Check and repair, or replace
6. Leakage
contamination or damage of the it.
seal of the joints.
Broken seal ring in the guide
7. Leakage between piston shell, or damage to the mate Replace seals, and refer to
rod and guide shell surface between piston rod and item 8.
guide shell.
Too dirty oil Re-filtrate or change oil.
Eyewinker between seals and
Clean it
dust-proof seal.
8. Piston rod surface pulled
Seals for guide shell are
Change them.
damaged.
Guide shell is damaged. Replace it
When fixing the oil gauge, the
oil-filling plug (safety plug) is
9. Oil pressure gauge being not unscrewed loose so that the
Modify
damaged frequently vent of oil-filling plug can’t link
the atmosphere.（see Figure 7-2）
Detect time delay relay. Correct
10. Electrical elements Reset the interval or change
interval should be 8~10
being frequently burnt relay.
seconds.
69
Start oil pump disobeying the Operate as per regulations

operation regulations in 4.3. strictly.
The oil flow of pump in high
Replace matched pump or
pressure doesn’t match electric
motor.
motor power.
Wheel is not greased. Grease it.
Wheels are deformed. Change the deformed ones.
11. When wheel carrier
(structure as figure7-1) Composite bearing damages. Replace.
moving, wheels sliding on
Wheel axle is deformed or
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
the winch operation handle
switch.
12. It can’t drop hook when 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
components.
circuit
13. Crane hook can’t stop
rising when it passes upper Failure of electromagnetic valve Check and replace concerned
limitation loop and corresponding circuit components.
Overflow valve works
Refer to item 2 to solve.
abnormally
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
70
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. If machine body need weld, first make sure the 24V DC
power supply without 220V AC (the indicator lamp should not light)
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.
71
8 MAIN TECHNICAL DATA

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

Pa Max system oil 25.5 MPa
pressure
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 16.4 MPa
pump at full flux
P1 Largest pile-pressing 62.6 tons
weight
P2 Largest pile-pulling 64 tons
weight
P3 Allowable largest 196 tons
weight of pile driver at
pile- pulling
APPENDIX TABLE 8-2 BASIC PARAMETERS
Item Parameter
Max. pile pressing force（25.5Mpa） 62.6 t
The chief pressing-in Max. pile pressing speed(Pressure 7 m/min
hydraulic cylinder works ＜16Mpa）
separately Min. pile pressing speed（Pressure 4.66m/min
=25.5Mpa）
Max. pile pressing force（25.5Mpa） 260 t
The chief and
Max. pile pressing speed(Pressure 1.69 m/min
secondary pressing-in
＜16Mpa）
hydraulic cylinders work
Min. pile pressing speed（Pressure 1.12 m/min
together
=25.5Mpa）
Pressing-in stroke(once) 0.9 m
Side piling Max. pile pressing force（the chief 60 t
pressing-in cylinder
works,24.5Mpa）
72
Longitudinal stroke（once） ≤3 m
Capability of motion Transverse stroke（once） ≤0.6m
Every rotative angle（once） ≤8◦
Forward ≤5.59 m/min
Backward ≤11.42 m/min
Traveling speed
Left ≤5.59 m/min
Right ≤9.54 m/min
Vertical motion stroke 0.9 m
Length of pile ＞3 m，≤14 m
Ground pressure （ At Long ship slideway 9.9 tf/m2
260t） Short ship slideway 12.1 tf/ m2
Normal pressing position Side pile distance 3100 mm
Side pile distance 940 mm
Side pile position
Corner pile distance 1440 mm
Pile clamping box JZX5022
Pile pressing rated pressure（260tf） 25.5 Mpa
Rated pressure for lifting See the operating manual of
crane
Pile pressing flow rate(at full flow) 172 L/min
Lifting flow rate(at full flow) See the operating manual of
Hydraulic system
crane
For main 63YCY14-1B（1 台）
Hydraulic pump machine 63YCY14-1B F（1 台）
model See the operating manual of
For crane
crane
For main Y2-200L-4-V1 30KW（2 台）
Electric system
Electric motor machine
model See the operating manual of
For crane
crane
Pile pressing power 30KWX2=60 KW
Lifting power See the operating manual of
crane
Voltage 380 V
Current (the whole machine) 145A
Frequency 50 HZ
73
Power cable YCW3X50+2X16

Dimension (LxWxH) (mm) 11872×6200×3141
Weight of main machine 103T±6%
Weight of whole machine (including counterweight) 270T
APPENDIX TABLE 8-3 OIL PRESSURE AND PILE PRESSING FORCE
Pressing pile (tf)

The chief pressing-in cylinder The chief and
Oil pressure works alone the secondary
(MPa) Quick pressure Normal pressing-in
pressure cylinder work
together.
1.0 2.45 5.09 10.18
2.0 4.91 10.18 20.36
3.0 7.36 15.27 30.54
4.0 9.82 20.36 40.72
5.0 12.27 25.45 50.89
6.0 14.73 30.54 61.07
7.0 17.18 35.63 71.25
8.0 19.63 40.72 81.43
9.0 22.09 45.80 91.61
10.0 24.54 50.89 101.79
11.0 27.00 55.98 111.97
12.0 61.07 122.15
13.0 66.16 132.32
14.0 71.25 142.50
15.0 76.34 152.68
16.0 81.43 162.86
16.4 86.52 173.04
18.0 91.61 183.22
19.0 96.70 193.40
20.0 101.79 203.58
21.0 106.88 213.75
22.0 111.97 223.93
23.0 117.06 234.11
24.0 122.15 244.29
25.5 129.78 259.56
74
APPENDIX TABLE 8-4 ATTACHMENT TOOLS
Name and Quantity Remark Name and Quantity Remark

specifications specifications
Double-ended fixed 1unit Round head hammer 1 unit
spanner 5.5-32 2P
Nipper 175 1unit Pipe spammer wrench 1 unit
Inner hexagon spanner 1set Pinch bar D25 X1000 1 unit
3-22
Cross head 1unit Hammer 18 pound 1 unit
screwdriver 150X6
Flat head screwdriver 1 unit Tool box 1 unit
150X6.5X1
Wire cutter 200MM 1 unit Jaw box (for export) 1 unit
Adjustable spanner 1 unit High-sensitivity level 1 unit
300X36 GB4440 gauge
Adjustable spanner 1 unit Pressure gauge 1 unit
450X55 GB4440 Y-100ZT-40MPa
Screw-driver with 1 unit Oil port cover Its quantity and
voltage tester specifications
vary according
Foot operated grease 1 unit Oil port plug
to different
gun
machine model
APPENDIX TABLE 8-5 WEARING PARTS
Name Specification Remark Name Specification Remark

Air filter PAF2-0.02-0.75-10F 8.5X1.8
For
Electric electric
J164-12.5x40x50 25.8X3.55
brush collection
ring
O ring
oil returning For
WY-400X20Q2 seal GB/T 30X3.55
filter core crane
3452.1-82
Oil suction For main
WU-1000x100-J 31.5X3.55
filter machine
oil returning For main
FBX-400X20 33.5X3.55
filter core machine
FUSE φ10X38 2A 85X3.55
φ10X38 R015 RT14 Composite
12
Fuse core 10A washer
Fuse inserts ATS 3A JB982-77 14
Fuse inserts ATS5 18
75
For wheel
SF-2-120115 27
carrier
Crane
SF-1-3240 33
roller
For crane
SF-1-3250 42
jib
Composite
For crane
bearing SF-1-5045 45
jib
For crane
SF-1-50100 48
jib
Wire rope
SF-1-9080F(with For crane For 12T
6X37-13-2000
flange) jib crane
GB/T8918
Wire rope
Wire rope
For wheel For 16T
Friction ring 305070001319 4VX39S+5FC-
carrier crane
15 GB/T 8918
APPENDIX TABLE 8-6 CLAMPING JAW COLLOCATION
Clamping jaw Fixed screws

Pile driver
model Type Quantity Remark Specifications Quantity
（piece） GB70-86 (unit)
200×200 Square pile Used together M16×170 16
8
square jaw with Y30
Square pile 8 Used together M16×145 16
jaw with Y35
250×250 8 Used together M16×60 16
square with Y40
F25
8 Used together M16×150 16
with Y40
Used together M16×60 16
F25 8
with Y45
Used together M16×130 16
8
300×300 with Y40
square Directly
F30
installed in M16×120 16
8
clamping jaw
seat
Directly
350×350 installed in M16×100 16
F35 8
square clamping jaw
seat
Directly
400×400 installed in M16×80 16
F40 8
square clamping jaw
seat
76
Directly
450×450 installed in M16×60
F45 8 16
square clamping jaw
seat
Directly
500×500 F50 8 installed in M16×35
square clamping jaw 16
seat
Used together M16×150
Φ250 round Y25 8 16
with Y40
8 16
with Y40
Φ300 round Y30
8 16
with Y50
8 16
with Y50
Φ350 round Y35 Directly
installed in M16×85
8 16
clamping jaw
seat
8 16
with Y50
Φ400 round Y40 Directly
8 16
clamping jaw
seat
Directly
Φ450 round Y45 8 16
clamping jaw
seat
Directly
installed in M16×35 16
Φ500 round Y50 8
clamping jaw
seat
The above table is for clamping boxes JZX5022
APPENDIX TABLE 8-7 HYDRAULIC PUMP PRESSURE-FLOW CURVE

ADJUSTMENT LIST
Final adjustment Final adjustment

Initial adjustment
pressure Pa(MPa) displacement X
Pump model pressure Pb(MPa)
(Max system (Pump variable
(Start variable)
pressure) indicating position)
63YCY 17 23.5 7.3
77
APPENDIX TABLE 8-8 HYDRAULIC PARTS FOR MAIN MACHINE
Number Code number Parts name

1 Balance valve DFY-B20H
2 F4 Overflow valve MZL5-H32B (with
remote-type coupling)
3 Hydraulic check valve AIY-HC25B
4 Hydraulic Oil drain valve DFY-B25H
5 F1、F2、F3、F5、 F6 Overflow valve MZL7-H25B
6 Plunger pump 63YCY14-1B
7 Plunger pump 63YCY14-1BF
8 Multiunit valve ZS1-L25-4W-GD10
9 Multiunit valve ZS1-L20-4T-GD2
APPENDIX TABLE 8-9 ELECTRIC PARTS FOR MAIN MACHINE
Code Code
Parts name Parts name
number number
Circuit breaker QF
Module plug seat
NMILE-400/3N300
AC30-10A/3
250A
Circuit breaker QF
Fuse seat RT18-32X FU CM1(ZM1)-80L/3300
80A
Circuit breaker DZ67-60 QF
Fuse φ10X38 2A F 40A
Push button SA Circuit breaker DZ47-60 QF
LAY5(39)-11X/2 3P/D20A
Thermal relay NR2-93 FR
Delay relaySK4-222
48-65A
AC contactor KM Auxiliary contactor KM
LC1-0910 AC220V LA1-DN11-C
Contactor CJX4-6511 KM Fuse FU
220V φ10X38 R015 RT14 6A
Lamp for warning HL Lamp 220V-40W HL
against humidity 40W
AC36V
Power cable Fuse inserts ATS 5A FU
YCW3X50+2X16
Fuse φ10X38 R014 FU Fuse inserts ATS 3A FU
RT14 10A
78
9 APPENDIX FIGURES
APPENDIX FIGURE 1 MAIN MACHINE HYDRAULIC SYSTEM
1- Cross motion cylinder 2- Longitudinal motion cylinder 3- Chief pile pressing cylinder
4- Secondary pile pressing cylinder 5- Pile clamping cylinder 6- Vertical motion cylinder
7- Right move 8- Left move 9- Forward 10- Backward 11- Normal pressure 12-
Quick pressure 13- Press pile 14- Lift pile 15- Add force 16- Return 17- Release
pile 18- Pile clamping 19- Back left up 20- Back left down 21- Front left up 22- Front
left down 23- Front right up 24- Front right down 25- Back right up 26- Back right down
79
APPENDIX FIGURE 2 MAIN MACHINE ELECTRIC SYSTEM
80
APPENDIX FIGURE 3a CAST IRON COUNTWEIGHT LOCATED
1- Assistant cantilever 2- Assistant counterweight beam 3- F counterweight

4- Square counterweight 5- Main counterweight beam
81
APPENDIX FIGURE 3b BARITE COUNTWEIGHT LOCATED
1- Assistant cantilever 2- Assistant counterweight beam 3- F counterweight

4- Square counterweight 5- Main counterweight beam
82
10 ABOUT THE MANUFACTURER

Company name: SUNWARD INTELLIGENT EQUIPMENT CO., LTD.
Trade mark:
Address:
16 LiXiang Road, Xingsha economic and technologic development district, Changsha, Hunan.
Tel: 0086-0731-3572642
Maintenance point: our office in some provinces and cities of China
ABOUT THE DISTRIBUTOR
About the distributor
Distributor name:
Address:
Tel:
Fax:
Email:
Service personnel:
Remark：
83

ZYJ260

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ZYJ 260B-Ⅱ Operator’s manual

1.1.1 SAFETY LABELS REQUIRMENTS

1. Caution when machine is working.

4. Caution when machine is removing or rotating.

5. Caution when crane is working.

1.2 SAFETY RULES

 Study the manual carefully and follow the

If you find any abnormalities in the machine

extinguisher nearby. Have phone numbers of a

Before operation, always wear protective

 Do not leave parts or tools lying around the

 Always face the machine when you use the

 While pile driver is moving or rotating,

of movement or under the counterweight.

 Check and assure the construction field meets

1.10 CHECK MACHINE BEFORE START-UP

Before starting machine every day or every

 Keep all the non-workers away from working

jointing piles in case that piles fall down to hurt

 Touching transmission parts may cause GBH.

 Effluent liquids of high pressure will penetrate

within few hours. Otherwise it will cause

 During operation, engine oil, gear oil,

 If heating up near pressured oil pipe, the

 Not permitted to weld hydraulic oil steel pipe

 Prevent bringing potential poisonous gas and

1.19 AVOID FIRE

In order to avoid fire, take the following steps:

2 BRIEF INTRODUCTION TO SUNWARD SERIES PILE DRIVER

3 BASIC STRUCTURE AND WORK PRINCIPLE

FIGURE 3-1 ZYJ260 B-Ⅱ PILE DRIVER

12. Electric generator platform--- to place electric generator

FIGURE 3-2 STRUCTURE OF PILING PLATFORM

FIGURE 3-3 STRUCTURE OF PILE CLAMPING BOX JZX5022

1- Guide wheel 2- Pile clamping box body 3- Pile clamping cylinder

3.2.2 PILE PRESSING PROCESS

（decline）Press pile lift

FIGURE 3-4 PILE PRESSING CYCLE

3.3 TRAVEL MECHANISM

Figure3-5 Structure of vertical motion mechanism

3.3.2 LONGITUDINAL MOTION MECHANISM

Figure 3- 6 Structure of longitudinal motion mechanism

3.3.3 CROSS MOTION AND ROTATION MECHANISM

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

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

Step 1: Get the pile driver ready.

Figure 3-11 Rotating manner

⑴ Vertical motion cylinders extend

Figure 3-12 Rotation cycle

3.4 HYDRAULIC SYSTEM (FOR PILE PRESSING)

Figure 3-13 Hydraulic cylinders of pile driver

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

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

3.4.2 WORK PRINCIPLE (SEE APPENDIX FIGURE 1 HYDRAULIC SYSTEM)

Figure 3-15 Hydraulic system for traveling

Figure 3-16 Hydraulic system for vertical motion

（3） Hydraulic system for clamping pile