Operating Manual for SP800 Full-hydraulic Pile Breakers

SP800 Full-hydraulic Pile Breakers

Operating Manual and

Spare Parts Pictures

Hunan Unimate Heavy industry co.,Ltd

2019

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Preface
You are welcome to use the SP800 Full-hydraulic Pile Breakers of Unimate This
device is independently developed and manufactured by the company after absorbing
advantages of similar products abroad and considering the special conditions and
requirements of bridge engineering.
It is currently the world's most advanced device of the like, which uses a plurality of
hydraulic cylinders to simultaneously squeeze pile from different points on the same
end face, and its working principle is simple, efficient and environmentally friendly.
Without prior notice, Unimate will continuously improve this device, update
documents and technical specifications. Please be informed that the company will not
assume the obligation to improve the device or spare parts sold before.
Your comments and suggestions will be appreciated if you find any deficiencies or
inadequacies in the course of using this device.

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Safety Precautions

· Please read this manual thoroughly before installing, debugging, using and repairing this
device.
· The operator must have been trained strictly and obtained certificate before operating the
device.
· All the provisions of this manual must be strictly followed in the course of use and
maintenance.
· The auxiliary products of this device controlled and managed with safety signs must also
have safety signs. So do the replacing parts during the usage.
· No person is allowed to stand in the working device in the course of the hydraulic Pile
Breakers being installed, debugged, used orrepaired.
· Safety warnings must be carried out before the start of the engineering machine.

says that if neglecting these instructions, improper operations may cause personal
casualty or severe device damage.

says that if neglecting these instructions, improper operations may cause personal
injury or device damage.

says that if neglecting these instructions, improper operations may cause mild personal
injury or device trouble.

says that only qualified personnel are allowed to install and operate this device. In this
manual, qualified personnel are people who are authorized to install, debug, use and
repair the device according to the existing safety regulations and standard.

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

CONTENTS

Chapter 1: Overview of SP800 Full-hydraulic Pile Breakers................................... 4

Chapter 2: Structural Features and Working Principle............................................ 8

Chapter 3: Installation and Operating Instructions................................................ 13

Chapter 4: Safe Operation and Precautions............................................................. 15

Chapter 5: Repair and Maintenance Instructions....................................................15

Chapter 6: SP800 Full- hydraulic Pile Breakers Parts Atlas.................................. 17

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Chapter 1: Overview of SP800 Full-hydraulic Pile Breakers

SP800 Full-hydraulic Pile Breakers is independently developed and manufactured by
Hunan Unimate heavy industry co.,ltd after absorbing advantages of similar products
abroad and considering the special conditions and requirements of bridge engineering.
It is currently the world's most advanced device of the like, which uses a plurality of
hydraulic cylinders to simultaneously squeeze pile from different points on the same
end face, and its working principle is simple, efficient and environmentally friendly.
The operation of the device needs power source which can employ fixed pumping
stations or other mobile engineering machinery equipment. Under normal
circumstances, pumping stations are more often used during the foundation
construction of high-rise building as this combination of equipment needs lower
investment overall but easier to be mobile and thus suitable for the group pile breaking.
Mobile excavators are more often to be used as power source in bridge construction.
Taking down the bucket of the excavator, hanging the hoisting chain of the pile
breaker at the bucket and the big arm connecting shaft, combining these two machines,
and then connecting any hydraulic oil line of excavator to the oil line of oil cylinder of
pile breaker through the balance valve, to drive the cylinder group of pile breaker to
work. This combination of pile breaker moves continently and has a wide working
face, so it is suitable for projects with scattered piles and long work period.
This hydraulic pile breaker can apply to the pile breaking for high-speed rail bridge
projects and civil engineering. There are some pile breaking equipment and manual
pile breaking method at home and abroad, but they are inefficient and expensive and
thus can not meet the requirements of large-scale pile breaking. The operation of this
device has the following features:
1. High efficiency, for example,the length of pile is 1 meter,diameter is
1000mm,concrete grade is C30,as it can break 60 piles by working eight hours
successively, while a worker can only break 2-3 piles by working eight hours;
2. Low noise, as it is full-hydraulic, so it can operate in suburbs with disturbing
people;
3. Longer service life, as its main parts are all made of special materials and process.
It is proven by practice to have 15 years of service life;
4. High modular design, and through changing the number of modules, it is easy to
adjust the diameter of each pile on the site, and it is easy to be operated and
maintained without requiring any special skills;
5. High safety, as the pile breaking is mainly done by manipulators, and there is no
need for worker near the pile, so it is very safe;

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Service environment of SP800 Pile Breaker:

1. The operation of the device needs power source which can employ fixed
pumping stations or other mobile engineering machinery equipment.
2. Hydraulic system pressure is 31.4MPa, the setting value of overflow valve is
34.4MPa, the diameter of main hydraulic pipe is 25mm and of the cylinder tubing
is 20mm;
3. There are uncertain factors for the engineering machinery and the material
composition of pile foundation, and the maximum depth of each pile breaking
construction shall be 0.3m.
4. The number of module, range of pile diameter, tonnage of engineering
machinery needed and total weight of machine when the power source using
engineering machinery are shown in the following table:
Number of 6 7 8 9 10 11 12 13
module
Range of 500- 650- 850- 1050- 1250- 1450- 1650- 1850-
pile
diameter 600 800 1000 1200 1400 1600 1800 2000
(mm)
Tonnage of
engineerin
g 20 22 26 27 30 32 35 36
machinery
(t)
Total pile
breaker 2335 2720 3100 3480 3860 4240 4620 5000
weight
(KG)

The oil pipe of pile breaker shall select corresponding hydraulic oil pipe and coupling
before cutting pile. Before the operation, check whether the hydraulic pipe is well
connected and whether the hydraulic oil pipe and oil cylinder have leakage by engineering
machinery test pressure. Operation can be started only after ensuring the hydraulic pipe
has no oil leakage.

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Chapter 2: Structural Features and Working Principle

SP800 full- hydraulic pile breaker embodies the following structural features:
1. Module-based design with pin connection for easy assembling and maintenance;
2. Hydraulic cylinder piston and alloy head are connected with pin to prevent the piston from
radial force and extend the service life of the cylinder;
3. SP800 full- hydraulic pile breaker is small for easy lifting and transportation.
Section 1: Working Unit
Working unit applies module-based design where modules are connected with each other by pins for
easy assembling and maintenance. Cylinder and cylinder block is linked by high-strength bolts for
easy assembling and maintenance. For the hydraulic pipeline, high-pressure connection and
hydraulic tubing are employed to guarantee the appropriate pressure. Drill rod is made of alloy
materials and given with special heat treatment to ensure the pile breaking can be realized and the
drill rod has a longer service life.
Working unit of SP800 hydraulic pile breaker is arranged as shown Fig. 1:

Fig. 1
1-drill rod; 2-hinge pin; 3-high-pressure rubber hose; 4-guide flange;
5-hydraulic tee; 6-hydraulic connector; 7-cylinder; 8-bow shackle;9-small hinge pin
Module assembling and disassembling unit:
High modularization design is made for easy adaption to individual pile diameter of each field.
Modules are connected with the hinge pin for easy operation and maintenance without any special
skill.

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 Operating Manual for SP800 Full-hydraulic Pile Breakers
Module unit of SP800 pile breaker: as shown below, easy operation can be allowed by simply assembling and
disassembling the hinge pins and small hinge pins when more/less modules are required due to the pipe diameter.
Insert space may differ based on the number of modules (as shown in Fig.2). To assemble two modules, first align
the hole to the hinge pin before inserting the hinge pin, give the gasket and bolt, align the corresponding small
hinge pins hole and insert the small hinge pin to connect and fix the modules, as shown in Fig. 3:

Fig. 2
Qty. of 6 7 8 9 10 11 12 13
Module
No. of 3、11 2、9 1、8 4、11 3、10 7、14 6、13 5、12
Correspondi
ng Hole

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Fig. 3
1- sling bolt; 2-bolt; 3-washer; 4-gasket; 5-small hinge pin;6- screw; 7-hinge pin
Structure of single module of SP800 pile breaker:
Single module of the SP800 pile breaker integrates cylinder, guide flange, drill rod, elastic pin,
tubing coupling, bow shackle, flange bolt, cylinder bolt, etc.
Taking SP800 for example, the cylinder is fixed on the cylinder block by the cylinder bolt; the cover
flange is fixed on the cylinder block by flange bolt; the drill rod is jointed onto the cylinder piston by
the special structure. The drill rod makes movement in the cover flange to realize the hydraulic pipe
breaking. The bolts are assembled to the single module as shown in Fig. 8:

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Fig. 8
1- high-pressure cylinder; 2-module; 3-elastic pin; 4-drill rod; 5-standing bolt; 6-guide flange
Method to change the drill rod:
Have the entire cylinder reached out until the mounting position of the elastic pin exposed, use the
professional tool to knock the elastic pin out and change a new drill rod, knock the elastic pin into
the pin hole to the level (chamfered end of elastic pin into the hole first), as shown in below:

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

1-professional tool; 2-elastic pin; 3-drill rod

Section 2: Lifting Unit
During the operation of the Pile breaker, the working unit is hung on the engineering machinery
through the lifting unit which functions as a connector and lifter. The lifting unit has to bear the
weight of the working unit on the pile breaker as well as tensile force generated during the working
and lifting of pipe head and weight of the pile head, totally up to more than 17 tons.
Lifting unit is arranged as shown in Fig. 9:

Fig. 9
1-sling; 2-chain regulator; 3-chain; 4-chain shackle

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Chapter 3: Installation and Operating Instructions

Unimate is able to manufacture and install corresponding modules and lifting devices based on
customer’s requirements for diameter of cut pile. The pile breaker can be used when delivered to the
customer, which saves the time for pre-operation preparation by the customer.
In most cases, excavator which can be moved conveniently is used as power source during
engineering construction. Remove bucket of the excavator and sling chain of the pile breaker at the
connection shaft of the bucket and the large arm to mechanically combine these two kinds of
equipment together; and then connect the large arm hydraulic circuit of the excavator to cylinder
circuit of the pile breaker with balanced valve to drive cylinder group of the pile breaker to work.

Assembly of hydraulic joint and hydraulic oil pipe in the working unit is shown in the following Fig.
12 (working unit):
Precautions for piping layout:
1. Pipeline shall be kept away from moving parts of the excavator;
2. Pipeline shall be kept away from sharp edge and sharp corner;
3. Schematic diagram of pipe clamp and pipeline is shown in the following Fig. 11:

Pipe clamp

Fig. 11

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Fig. 12
1- Tee coupling A; 2-Tee coupling B; 3-Straight coupling; 4- Flange 5-Screw; 6-High-pressure rubber
hose
The straight coupling is fixed to corresponding female thread in the cylinder with flange and screw
for connection. Torque spanner of inner hexagon spanner is tightened at a moment of 45N.M. Tee
coupling B is connected to the straight coupling and tightened with 32mm torque spanner at a
moment of 180N.M. The hydraulic oil pipe is connected to one side of tee coupling A and tightened
with 32mm torque spanner at a moment of 105N.M. Connect hydraulic cylinder of each module with
tee couplings and straight coupling and then connect with the hydraulic cylinder of engineering
machinery to form a closed loop.
During pile head cutting, after internal diameter of combined cylinder of the pile breaker is adjusted
to corresponding diameter range for the type of pile, the combined cylinder will be directly installed
on the pile surface to be cut with the assistance of excavator; and then position and tightness of
cylinder piston shall be adjusted slightly until the pile surface to be cut is closely clamped by the
combined cylinder. Then system pressure of the excavator shall be adjusted according to the strength
of cast pile concrete and the cylinder shall be pressurized until the concrete pile breaks under strong
pressure. After the pile is cut, broken wasted concrete block shall be directly moved to the spoil yard
by using the pile breaker and then the cylinder shall be released to stack the waste slag tidily.
Precautions for installation:
1: Do not wear gloves while replacing hydraulic pipes and hydraulic joints so as to keep
interface of the hydraulic parts clean! In case the hydraulic pipes can not be replaced in a
timely manner after being removed, standby nuts shall be screwed on temporarily to prevent
foreign matters from entering the pipe coupling!
2: When position of bow shackle of the working unit is changed, hinge pin of the bow shackle
shall be tightened into the threaded hole for the shackle, so as to prevent inclination of the
working unit during lifting due to uneven stress!
3: In case of increase or decrease in quantity of modules as well as removal of hinge pin,copper
rod shall be used for stroking!
4: Empty module shall not be used in case the pile diameter is no larger than 500mm!

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Chapter 4: Safe Operation and Precautions

Before operating the pile breaker, engineering machinery operator shall be able to operate
corresponding engineering machinery skillfully and shall get familiar with operating rules and safety
knowledge on engineering machinery. Detailed precautions are listed as below:
Precautions for operation:
1. Do not get close to the operating pile breaker. Concrete may fall during pile cutting
and the power source operator shall be informed to stop operation before getting close
to the pile breaker!
2. Check whether all hydraulic oil pipes and hydraulic joints are tightened before pile
cutting. Oil pipes and joints with oil leakage observed when hydraulic pipe fittings are
tightened shall be replaced!
3. The working unit shall be free of tapping force and damage; otherwise, its service life
as well as lifetime of the whole machine will be affected. The working unit shall be
cleaned regularly after pile cutting!
4. Any person shall not stay in the operating area of engineering machinery during pile
cutting; otherwise, it will result in severe personal injury!
5. During transportation, transshipment and operation, the cylinder shall be free from
tapping force and great pressure! Soil, sand etc. on the accessories of the cylinder shall
be cleaned regularly when construction is terminated, so as to keep the periphery of
the cylinder clean!
6. Hydraulic pipes and pipe couplings shall be free from tapping force and great pressure
during transportation, transshipment and operation! Especially for operation, if there
is any concrete block falling onto the hydraulic part during operation, concrete on the
hydraulic part shall be removed after operation, so as to protect the hydraulic part
from deformation due to external force and keep the periphery of the hydraulic part
clean!
Pre-operation preparation:
1. The SP800 hydraulic pile breaker shall have a power source before operation and excavator
shall be selected preferentially according to current situation of popularization and
operation of engineering machinery!
2. The SP800 hydraulic pile breaker is equipped with quick-change coupler for hydraulic pipe.
The manufacturer can be informed in advance to manufacture corresponding quick-change
coupler according to model of excavator used by the customer!
3. Customer can also use crane in combination with hydraulic pump station to suspend the pile
breaker at the front end of the crane and connect the hydraulic pump station with the pile
breaker through quick-change coupler!

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Chapter 5: Repair and Maintenance Instructions

The SP800 hydraulic pile breaker can be repaired and maintained easily. When the pile breaker
works continuously for 1 month or cuts 1000 piles, it shall be stopped to check whether each part is
in good condition.
The lifting device shall be firstly checked for damage and crack. Especially for sling chain and chain
shackle, each part shall be checked carefully. If there is any damage or crack, replacement shall be
made immediately!
The working unit shall be checked, especially for drill rod and hydraulic part! Drill rods are direct
working parts and are prone to damage after reaching a certain workload. Make all drill rods stretch
out through pressurization to check the drill rods one by one. If any damage or crack is found,
immediate replacement shall be made. If all drill rods are in good condition, all hydraulic parts shall
also be checked one by one. In case any damage or crack is discovered, immediate replacement shall
be made.
Key points for daily maintenance:
After everyday work, air pump shall be used for cleaning with its air pipe aligning with guide
flanges and gap between drill rods (as shown below). In this way, dust inside guide flanges will be
blown out, which is good for maintenance of drill rod, guide flange and cylinder.

Wind direction

Special tips:

Unimate shall undertake no responsibility for consequences caused by violation of the following
provisions:
Refit and repair the pile breaker at will without permission of the Company;
Remove components & parts from or weld or add components & parts onto the pile breaker without
permission of the Company;
Use drill rods or other accessories which are not supplied or recognized by the Company without its
permission;
Fail to install, use and stop the pile breaker according to requirements of the service and repair
manual;
Fail to maintain the pile breaker timely and effectively according the service and operation manual.

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 Operating Manual for SP800 Full-hydraulic Pile Breakers

Chapter 6: SP800 Full- hydraulic Pile Breakers Parts Atlas

I. SP800 Hydraulic Pile Breakers Parts Atlas
1. Module Assembly SP800.1

NO. CODE DRAWING No. NAME QTY.

1 SP800.1.1 Module welding part 1
2 Bow shackle 3.25t 1
3 Pipe coupling 2
4 Pipe coupling 2
5 Screw M8×25 GB70.1 8
6 Gasket 8 GB93 8
7 Split flange 2
8 SP800.1.3 Cylinder 1
9 SP800.1.2 Flange 1
10 Screw M12×55 GB70.1 12
11

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 Operating Manual for SP800 Full-hydraulic Pile Breakers
2. Pile Breaker SP800

NO. DRAWING No. NAME QTY.

1 Sling chain 1
2 Bolt M10×25 GB5783 12
3 Gasket 10 GB93 12
4 Gasket 10 GB97.1 12
5 SP800-2 Hinge pin 12
6 Screw M8×12 GB70.1 12
7 SP800.2 Hinge pin 12
8 Elastic cylindrical pin 12
9 SP800-1 Alloy head 12
10 Rubber hose 12
11 Rubber hose 12
12 SP800.1 Module assembly 12
13 Pipe coupling 2

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