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Technical Manual

for Compact ZYC 180BS-GB1 Pile Driving

Machine

Changsha Tianwei Engineering Machinery Manufacturing Co.,Ltd

March, 2020
Contents

1.Important Operation Tips ………………………………………………………………………….1


2.Basic Structure And Working principle ……………………………………………………………2
2.1 The Constitution for ZYC Series…………………………………………………………….2
2.2 Working Mechanism …………………………………………………………………………3
2.3 Lifting Mechanism……………………………………………………………………………5
2.4 Center Piling Mechanism …………………………………………………………………….7
2.5 Side piling Mechanism ……………………………………………………………………….8
2.6 Center Clamping Mechanism ………………………………………………………………...9
2.7 Side Clamping Mechanism ………………………………………………………………..10
2.8 Pile Lifting Mechanism……………………………………………………………………...10
2.9 Hydraulic System ………………………………………………………………………….11
2.10 Electrical System ………………………………………………………………………...13
Attachments:
Piling pressure table……………………………………………………………………………….16
Technical parameters………………………………………………………………………………17
Table of main parts………………………………………………………………………………...19
Table for Lubrication …………………………………………………………………………..….20
1 Notice

! Before starting the machine, the operator is obliged to


read the operation manual carefully and act accordingly.

1
2. Basic Structure And Operation Principle

2.1 Structures for ZYC Series


●Structure as Drawing 1 shows:
● Composed of : 1.Movement mechanism 2.Lifting And Leveling Mechanism
3.Center piling mechanism 4.Side piling mechanism 5.Center clamping mechanism
6.Side clamping mechanism 7.Pile lifting mechanism 8.Hydraulic system
9.Electrical system 10.Counterweight

Figure 1

2.2 Movement Mechanism


●Movement Mechanism is as showing figure 2:
2
●Composed of:1.Longitudinal movement mechanism(Long boat) 2.Horizontal
movement mechanism(Short boat)
●Remark:Movement mechanism is working helping by lifting mechanism

Figure 2
2.2.1 Longitudinal movement mechanism(Long Boat)
●Long boat is showing as figure 2:
● Composed of : 1.body 2.longitudinal cylinder 3.movement trolley
4.interlocking cylinder and so on.
●Remark:Two pcs of long boat and lifting mechanism are connected by balls
The rod of two cylinders are hinged with two long boat, and body of cylinder are hinged with
movement trolley.When the rod of lifting cylinder retract, there will be a vertical relative
motion between the body and the long boat .
3
Figure 3

2.2.2 Horizontal Movement Mechanism(Short boat)


●Short boat is showing as figure 4:
●Composed of:1.body 2.horizontal movement part
3.movement trolley 4.rotary base plate and so on.
●Remark:Two pcs of Horizontal movement mechanism and main machine are
connected by center shaft.
●Together with hinged four groups walking wheel frame under the rotary base plate,
two short boat are hanging in the center of the shaft, and around it to do rotation and
swing, so when two horizontal cylinders retract at the same time,they will make
relative movement between main machine and the rotary base plate. If one cylinder
stretches out,the other one draws back, it will cause relative rotation for main
machine and rotary base plate.

4
Figure 4
2.3 Lifting And Leveling Mechanism
●Lifting and leveling mehcniam is showing as Figure 5:
●Composed of:1.outrigger cylinder 2.cantilever beam and so on
●Remark: Four lifting and leveling mechanism and main machine adopt plug-in
connection
●Four outrigger cylinders can do the following movements::
1.When outrigger cylinder stretch out, the short boat will be off the ground .
2.When outrigger cylinder draw back, the long boat will also be off the ground.
●The movement of the whole machine needs the cooperation of lifting and leveling
mechanism.
Summarized as follows:
Longitudinal movement:
Step 1: Outrigger cylinder stretch out→main machine rises up→long boats land to the ground
→short boats rise off the ground→longitudinal cylinders draw back→main machine and
movement trolley turn right until the longitudinal cylinders draw back fully;
Step 2:Outrigger cylinders draw back→the main machine drops down→short boats go down→
outrigger cylinder continue drawing back and long boats rise off the ground→longitudinal
cylinders stretch out to make the long boat moving right until the step finishes, then continue
again→……
5
Horizontal movement:
Step 1:Outrigger cylinders shrink→ the main machine goes down→short boats rise off the
ground; Short boats drop down to the ground→horizontal cylinders draw back at the same time
→movement trolley moves with the rotary base plate and main machine until the horizontal
cylinders draw back fully. The Main machine goes down.
Step 2:Outrigger cylinders stretch→the main machine rises→long boats land to the ground→
short boats rise off the ground→horizontal cylinders stretch out at the same time to make the
short boat rise up until finishing this step. Then continue again→……
Rotary movement:
According to horizontal movement to operate two short boats to realize rotary motions in
different directions.

6
Figure 5

2.4 Center Piling Mechanism


●Center piling mechanism shows as figure 6:
●Composed of :1.four leaders 2.two piling frame and so on
●Four leader are welded with main machine,and it is pin connection between leaders and
piling frame. The jacking cylinder are installed on piling frame which also are
connected with clamping mechanism.When the jacking cylinders stretch out or draw
back, will make the up and down movement for clamping mechanism.the jacking force

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will be passed through the clamping mechanism to the pile to realize piling process.
●The jacking force is as following table:

Figure 6

2.5 Side Piling Mechanism


●Attachable side mechanism with a separate clamping box ,share the same clamps with

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center piling mechanism.
●The piling working can be proceed after the piling frame is installed into the side
piling position, the same principle as the center.
●Remark:Inserted and attachable side piling mechanism are available for some models,
but with the same working principle in different structure.

2.6 Center clamping mechanism


●Structure shows as Figure 7:
1 .Clamping box 2.Clamping jaw 3.Clamping cylinder
●Clamping mechanism connected with the piling cylinder through the connecting hinge
seat.
●Working principle :There are many clamping cylinders with clamping jaws inside the
clamping box,when the cylinder moves,it will drive the clamping jaw stretch in and out,and
press the precast pile.

●Just need changing the different clamping jaw to press the different size and shape of
precast pile.

●Clamping jaw changing rules see the annex.

Figure 7

2.7 Side clamping mechanism


●Most of the side clamping mechanism shares the same with the center clamping
9
mechanism, just need to move the clamping mechanism to the side piling position.
●Remark: Inserted and attachable side piling mechanism are available for some models,
but with the same working principle in different structure.

2.8 Crane system


●The crane is mounted on the static pile driver, see Figure 8:
Mainly composed of :1.Steel wire rope 2.Hook 3.Crane arm
4.Luffing cylinder 5.Hydraulic system 6.Electric System
7.Winch 8.Operation system

Figure 8

2.9 Hydraulic system


●See appendix figure 9 the principle of hydraulic system:
1.Hydraulic system for crane (Figure 9)
2.Hydraulic system for main machine (Figure 10)

10
回转马达 变幅油缸
声光报警器 卷扬马达 伸缩马达

回转保护阀块

13MPa
20Mpa
变幅保护阀块
13MPa

21MPa

24MPa

卷扬保护阀块

回转调速

(20MPa)

回转 变幅 卷扬 伸缩
脚踏阀

Figure 8

11
18 19 20
21 21 22 22

16

夹桩远程调压
8 30
30

13
23
17

24

12 15 25 25 25 25

K
14
30 30 30 30
Figure 10

1.油箱
2.油泵1
3.油泵2
12

4.单向阀
5.回油滤清器
6.压力表
7.主溢流阀
8.溢流阀
9.压桩操纵阀
压桩2 压桩1 档位 10 10.支腿操纵阀
11
29 11.行走操纵阀
9 12.溢流阀
支腿 行走
13.夹桩安全阀
14.压桩安全阀
15.压桩安全阀
16.夹桩缸
17.液控单向阀
6
18.压桩缸2
19.压桩缸1
20.支腿油缸
21.长船油缸
22.短船油缸
23.夹桩压力表
7 24.压桩压力表
4
25.平衡阀
29.夹桩操纵阀
5
30.开关截止阀

2
3

1
泵1 泵2 泵3
3.0 Electrical system
● Appendix figure 11 shows the principle of electric system.
●This system has some security measures for short circuit, overload and phase failure,
ground connection and so on, activating by Y-△.

(驾驶室顶灯)

(吊机驾驶室灯)

(报警灯)

PA

PV
L

24 主机驾驶室灯 EL 24V 5A 1
23 主机驾驶室灯 EL 36V 5A 1
22 变压器 L L500VA-220-36-25 1 输入220V 输出36V 24V
21 电压表 PV 44L1-450V 1
20 选择开关 Q1、2 XB2BD25C 2
19 电流表 PA 44L1-300/5 1
18 信号灯 LA42PD-01R/220VAC 3 按钮自带
17 信号灯 LA42PD-10G/220VAC 3 按钮自带
16 停止按钮 SB1 LA42PD-01R/220VAC 3 红色
15 起动按钮 SB2 LA42PD-10G/220VAC 3 绿色
14 电动机 D2、3 Y225M-4-B5 2 主机油泵电机
13 热继电器 FR2、3 LR2-D5369 2 45KW电机控制

12 接触器 KM 2、3 LC1D15000M7C+LA1DN11C 2 45KW电机控制


11 接触器 KMY2、3 LC1D15000M7C+LA1DN11C 2 45KW电机控制
接触器 KM2、3 LC1D15000M7C+LA1DN11C 45KW电机控制
10 2
9 时间继电器 SJ LADT2 3 JS1 JS2 JS3相同
8 电动机 Y225S-4-B5 1 吊机油泵电机
7 热继电器 FR1 LR2-D4367 1 37KW电机控制

6 接触器 KM LC1D11500M5C+LA1DN11C 1 37KW电机控制


5 接触器 KMY1 LC1D11500M5C+LA1DN11C 1 37KW电机控制
接触器 KM1 LC1D11500M5C+LA1DN11C 1 37KW电机控制
4
3 断路器 QS3、4 NS100N3P100A+STR22ME 3 电机保护

2 小型断路器 QS2 C65a 2P C10A 2 二次回路和空调

1 漏电断路器 QS1 VIGINS400N4PSTR+VIGIMB 1 总开关


序号 名 称 代 号 规 格 数量 备 注

Figure 10

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The design formulas specified for the Pile Driving Force (Unit: KN) and the Pressure of
Hydraulic Oil (Unit: Mpa)

Pile driving force in the table refers to the vertical downward pressing onto the pile in pile
driving. And the pressure of hydraulic oil refers to the dial records showed in the control room
in pile driving (unit: Mpa), which can be also understood as the hydraulic oil pressure in the oil
cylinder without piston rod to in pile driving. The stress state in pile driving illustrated as below:
Total F = F1 + F2 +F3+F4+ G (F1 to F4 stands for the stress on the pile-clamping-box
separately driven by the relevant cylinder. G is the total weight of the pile-clamping-box and
piston rods of oil cylinders), As the two primary jack in cylinders specify for Ф160/110 (the
diameter of cavity without rod is Ф160, the rod diameter Ф110), and two asisstant jacking in
cylinders specifyФ160/110,for then total F = 2 F1 + 2F2 (G = 0KN)
Pile pressing operations can be divided into three according to the manipulation of ways as
below:
1) fast pile driving (Fast piling with the two oil cylinders at meantime, and the hydraulic pipes
connected differential)

2) slow pile driving (slow piling with the two oil cylinders)
Now calculate the pile driving force in the followed two situations:
1) fast pile driving, stated as shown in Figure 2 (fast piling with four jack in cylinders)
Total F = F1 +F4+ G = 2F1 + G
F1 = (P • A1-P • A2)
P stands for oil pressure in the no-rod-cavity of oil cylinder,
A1 is the piston area of oil cylinder without rod in cavity,
A2 is the piston area of oil cylinder with rod in cavity
A1 = 20096X10 - 6 m² A2 =10597.5X10 - 6 m²
η for mechanical efficiency,
Total F = 2 P (A1-A2) +G
= 2P (20096X10 - 6-10597.5X10 - 6) X106 (N)
= 19P (KN)
When P = 1Mpa , F =19KN
…………………
14
When P = 20Mpa, F = 380KN

2) slow pile driving (the two oil cylinders working) as shown in Figure 3:
Total F = F1 + F2 + G = 2F1 + G
F1 = (P • A1-Po • A2)
Po is the oil pressure in the oil returned cavity, while Po = 0.1Mpa
Total F = 2 (P • A1-0.1A2) + G
= 40P-2 (KN)
When P = 1Mpa , F =40.2KN
…………………
When P = 20Mpa, F = 804KN
From the above, the hydraulic oil pressure and the pile driving force
can be calculated on the table as below:
3) slow pile driving 2 (the four oil cylinders working) :
Total F = F1 + F2 + G = 2F1 + 2F2+G= 2(P·A1-0.1A2) · η+2(P·A3-0.1A4) +G
F1=(P·A1﹣Po·A2) F2=(P·A3﹣Po·A4)
A1 and A3 are the piston are without rod,A2 and A4 are piston area with rod.
Total F=(2×P×20096-2×0.1×10597.5)×10-3+(2×P×20096-2×0.1×10597.5)×10-3
=80 P-4(KN)
When P = 1Mpa , F = 80.4KN
…………………
When P = 20Mpa, F = 1608KN
From the above, the hydraulic oil pressure and the pile driving force
can be calculated on the table as above

N
N

P
P P

Po
Po
G
G G

F1 F2
F1 F2 F1 F2
F合
F合 F合
图3
图1 图2
N

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Oil Pressure & the Pile Driving Force
Oil Pile driving Pile driving forc(Ⅱgrade) Pile driving force (Ⅲgrade)
pressure forⅠgradeTwo main jack in Two main jack in cylinder Two main and assistant jack in
(Mpa) cylinder working (KN) working(KN) cylinder working together(KN)
1 19 38 76
2 38 78 156
3 57 118 236
4 76 158 316
5 95 198 396
6 114 238 476
7 133 278 556
8 152 318 636
9 171 358 716
10 190 398 796
11 209 438 876
12 228 478 956
13 247 518 1036
14 266 558 1116
15 285 598 1196
16 304 638 1276
17 323 678 1356
18 342 718 1436
19 361 758 1516
20 380 798 1596
21 399 838 1676
22 418 878 1756
23 437 918 1836
24 456 958 1916
(remarks: Total 4 jacking in cylinder .the diameter for 2pcs of two main jacking in cyliner is Ø160 , and two
asisstant cylinder is Ø160.The fast position refers to the operation in the fast position of the hand lever when
the two main pile cylinders are linked differentially)
1. The first piling grade refers to the operation in the fast position of the hand lever when the two main pile
cyliners are linked differentially, the formula for the pile driving force is : F1=19P (KN)
2. The secondary piling grade refers to two main jacking in cylinder work together , the formula for pile
driving force: F2=40P-2 (KN)
3. The third piling grade refers to two main jacking in cylinder and two asisstant jacking in cylinder work
together,the formula for pile driving force : F3=80P-4(KN)

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Oil Pressure & the Pile Driving Force for side piling
Oil pressure Pile Driving Force(fast position)
(Mpa) (KN)

1 31.9
2 63.7
3 95.6
4 127.5
5 159.4
6 191.2
7 223.1
8 255.0
9 286.8
10 318.7
11 350.6
12 382.4
13 414.3
14 446.2
15 478.1
16 509.9
17 541.8
18 573.7
19 605.5
20 637.4
21 669.3
22 701.1
23 733.0
24 764.9

The formula is : F=2 x A x P(A is the area of cylinder covered by hydraulic oil, P is Mpa)
A=(90 x 90 x 3.14-55 x 55 x 3.14)x10-6 m2=15935.5x10-6 m2

F=2 x A x P = 31871x10-6 x 106 x P(N)=31.9 P (KN)

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Technical parameters

1.1. Capacity of Pile Driving

2.1.1 When two principle pile driving cylinder are working


2.1.1a At the fast speed position with center piling
Maximum pile driving force 456KN
Speed of pile driving 8m/min
2.1.1b At the normal speed position
Maximum pile driving force 1800KN
Max speed of pile driving 3m/min
2.1.2 Depth of pile driving
Maximum depth of each pile driving 1.6m
2.1.1c At the side piling
Maximum pile driving force 700KN
Max speed of pile driving 16m/min
Max depth of each pile driving 1m
2.2.Moving Capacity
Distance of each movement: longitudinal 1.5m
horizontal 0.4m
each turning angle: 150
speed of moving: forward 9m/min
backward 15m/min
left 9m/min
right 15m/min
2.3.Distance of Ascending and Descending 1.45m
2.4. Size of Piles
2.4.1 For center piling:
pipe pile: maximum ø400mm
square pile: maximum □400mm
length of single pile: a) ≥1.5 m,≤8 m(middle pile)
2.4.2For side piling
pipe pile: maximum ø300mm
square pile: maximum □300mm
length of single pile b) ≥1.5 m,≤7m (side pile)
2.5. Hydraulic System
rated pressure: 24(18) MPa
rated flow: 171(93) L/min

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Note: the number outside the brackets for the main engine and the number in the
brackets for the crane。
2.6. Electrical System
rated horsepower: 30X2+22=82kw
rated voltage: 380 V
rated current: 56.8X2+42=155.6A
frequency: 50 Hz
input cable: YCW-3×50+1×10
2.7. Weight
total weight: 120t
heaviest component: 25t
2.8. Dimensions when Working
For center pile driving: length × width × height=6.3m×4m×13m
For side pile driving: length × width × height=7.3m×4m×11m
2.9. Side distance 0.35m
Corner distance 0.7m
2.10. Pressure on Land:
Long boat: 95KN/m2
Short boat: 114KN/m

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Table for Weight of main parts

Marks Meas. L*W*H QTY Unit Weight Total Weight Vol.


Description of Goods &/or Services
& Nos.
(m) (PKGS) (T) (T) (CBM)

BRAND NEW T-WORKS


ZYC120BS-GB1 HYDRAULIC
STATIC PILE DRIVER

1 Main body 8.4*2.2*2.75 1 17 17 50.82

2 Supporting leg 2.2*1.5*0.4 4 0.9 3.6 5.28

3 Counterweight beam 3.55*0.26*0.45 2 0.9 1.8 0.83

4 Cross beam 3*1.3*0.4 2 0.9 1.8 3.12

5 Short boat 2.8×1.8×1.4 2 5 10 14.11

6 Long boat 8.6×0.7×0.7 2 3.5 7 8.43

7 Counterweight beam for side piling 1.4×0.26×0.3 2 0.5 1 0.22

8 Counterweight beam for crane 2.6*0.26*0.5 2 0.6 1.2 0.68

9 Cable 1×1×0.7 1 0.3 0.3 0.70

10 Spare parts kit 1.2×0.6×0.6 1 1 1 0.43

11 Side piling mechanism 2.15*1.2*1.5 1 4 4 3.87

12 F1-counterweight 1.37*0.5*1.1 20 1.9 38 15.07

13 F2-counterweight 1.14*0.57*0.76 6 1.35 8.1 2.96

14 Square counterweight 1.4*0.65*0.8 10 2.6 26 7.28

20
Lubricating Timing Table

Pile Driving Section Crane Section


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

Notes:1. When daubing use ZG-S lubricating fat of graphite calcium base (SY405-65).
2. When using filling gun apply SY1413-80 synthetic lithium base fat.
3. When the ambient temperature is over 200C, use antiwear hydraulic oil N68 and
when the ambient temperature is below 200C, use antiwear hydraulic oil N46

21

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