TC7052 A1 版 QTZ400 (TC7052) Tower crane USER MANUAL CHANGSHA ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY DEVELOPMENT CO ,LTD CUSTOMERS Thanks for your purchase and being one of the users of Zoomli.
TC7052 QTZ400 (TC7052) Tower crane USER MANUAL CHANGSHA ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY DEVELOPMENT CO.,LTD A1 版 CUSTOMERS: Thanks for your purchase and being one of the users of Zoomlion Tower Crane! Go through the instructions for correct operation and maintenance, and always keep at hand for consultation Pay attention to the sentences marked with “Warning, Notice or Precautions ” in this publication, which involves safety of construction Zoomlion has been devoting every effort to the perfect of her products Therefore they are changed without notice If you have any questions, please don't hesitate to contact Zoomlion for further consultation Manufacturer's No Shipped Date Contents Part I Erection of Tower Crane Preface……………… .1.1-1版1.1-11 Foundations & Counter-weight & Center Ballastn……… 1.2-1版1.2-13 Erection 1.3-1版1.3-70 Dismantling 1.4-1版1.4-8 Part II Operation and Maintenance Safety Operation of the Tower Crane 2.1-1版2.1-5 Operation of Mechanisms & Electrical Equipment 2.2-1版2.2-11 Safety Protection Device 2.3-12版2.3-21 Maintenance 2.4-1版2.4-8 Editor版 Proofreader版 Ratifier版 版 TC7052 版版版版版 Part I 版 1.1-1 Installation of Tower Crane Chapter I Preface Model TC7052 tower crane is designed and manufactured by Changsha Zoomlion Heavy Industry Science and Technology Development Co., Ltd according to the Chinese standard of JG/T5037-93 “Classification of Tower Crane” The TC7052 tower crane is a self-climbing multi-purpose machine with a horizontal jib, a trolleying mechanism and an upper slewing mechanism Its characteristics are: 1.1 The performance parameters and technical indicator of the crane are at a leading level in China The Maximum working radius is 70m and the maximum hoisting height is 180m 1.2.The outline of the crane is international fashion model and very perfect, enjoyed by the users 1.3.The crane has many working mode, it is used in different condition Such as: outrigger stationary, undercarriage stationary, anchored to the building and mobile, so that it is applied in different construction projects The hoisting height of the mobile is 74m 版 The hoisting height of the outrigger stationary is 73m The hoisting height of the crane anchored to the building reaches to 180m based on the outrigger stationary , added the tower sections and anchored devices 1.4.The technique of the stepless speed regulated and frequency altering is used in the hoisting mechanism, the trolleying mechanism and the slewing mechanism, so the crane works more smoothly and reliably 1.5.For the convenience of transportation, assembling configures are adopted.The main electric components are used world-renowned products, which service life is 版 times longer than China-made counterparts with less failure, simple maintenance and reliable working 1.6.All equipped safety devices are mechanical or mechanical-electrical integrated products, and adapt to all badly conditions to ensure the crane working reliably 1.7.The design of the crane is based on the actual situations in China and on the safereliable operation principles Greatly absorb and adopt the well-established and reliable advanced technology to enhance its overall technical level at the same time in the world Well-established advanced technology adopted as following: 1)Electric components are made by specialty electronics factories that have brought in the technology of TE company, France; 2)Weight limier, height limiter, radius limiter, slewing limiter, slewing brake, traction brake and similar safety guards are China-made based on the brought in technology; 3)Rope-break-proof device (carriage slip-proof) and axle-break-proof device are used on the carriage 4)Rope pay-off system for hoisting mechanism; 5)Traction rope-tensioning system; 6)anti-drop devices 7)Large-radius hoisting jib suspended by double rigid pull rods, featuring good jib rigidity, light jib weight, small jib cross-section, small wind resistance and nicelooking appearance and several jib lengths, it is satisfied different construction needs 8)Out-hung operator cabin, featuring excellent field of view, spacious interior, it is satisfactory working environment to the operator 9)Advanced inter-active control console, the operator handles the mechanisms easy and services simply 1.8.The design of the crane completely comforms to or is superior to the relevant national standards The crane is suitable for use in such large-sized construction projects as highrise or super high-rise buildings, bridge and water conservancy projects, large-span industrial buildings, large gymnasiums, and high chimneys and silos constructed with slip form 1.9 Technical parameters of the tower crane 1.9.1 Radius and Load Capacity 40m-jib Working radius(m) Hoisting -fall weightQ(t) 4-fall Working radius(m) Hoisting -fall weightQ(t) 4-fall 50m-jib Working radius(m) -fall Hoisting weight(t) 4-fall Working radius(m) Hoisting -fall weight(t) 4-fall 3.5版18.3 20 25 22.51 22 12.5 19.08 35 12.5 38 11.46 40 10.80 11.42 10.29 9.63 3.5版18.1 20 22 12.5 35 12.45 38 11.32 40 10.67 18.8 43 9.80 11.27 10.15 9.50 8.63 25 22.24 25 28 30 33 17.27 15.06 13.84 12.30 25 28 30 33 17.0 45 9.29 14.87 13.67 48 8.61 50 8.20 8.12 7.44 7.03 12.14 60m-jib Working radius(m) Hoisting -fall weight(t) 4-fall Working radius(m) Hoisting -fall weight(t) 4-fall Working radius(m) Hoisting -fall weight(t) 4-fall 70m-jib Working radius(m) Hoisting -fall weight(t) 4-fall Working radius(m) Hoisting -fall weight(t) 4-fall Working radius(m) Hoisting -fall weight(t) 4-fall 3.5版17.9 25 18 20 22 28 30 18.67 25 12.5 16.89 24.93 22.03 14.73 13.53 43 9.71 8.53 45 9.20 8.03 48 8.52 7.35 50 8.12 6.94 22 25 28 30 24.32 12.5 21.48 18.19 16.46 14.34 13.17 33 12.50 12.02 35 12.33 11.16 38 11.21 10.04 40 10.57 9.39 53 7.57 6.39 55 7.23 6.06 58 6.78 5.60 60 6.50 5.33 18 20 3.5版17.6 25 33 12.5 11.69 35 12.02 10.85 38 10.93 9.76 40 10.30 9.12 43 9.46 8.29 45 8.97 7.79 48 8.30 7.13 50 7.90 6.73 53 7.37 55 7.04 58 6.59 60 6.32 63 5.95 65 5.72 68 5.40 70 5.20 6.19 5.87 5.42 5.15 4.77 4.54 4.22 4.03 1.9.2 Technical performance parameters for the whole machine (Table 9-3) Mechanism Group Hoisting M5 Slewing M4 Trolleying M4 KN·m Rated hoisting moment 4000 Working Radius m Minimum 3.5 m Max hoisting height Maximum Outrigger Stationary Anchored 73 Max hoisting capacity Hoisting 180 t 25 Model QP2580 α=2 Fall hoisting capacity(t) Speed m/min Power Trolleying α=4 6.25 12.5 12.5 25 0版80 0版53 0版27 0版40 0版27 0版13.5 kW 63 model BP110 speed m/min 0~100 power Slewing kW 11 model HPW55B.100×3 speed r/min 0~0.72 powerkW 5.5×3 Jacking speed m/min mechanism power kW 0.46 11 pressure MPa Counterweight 70 31.5 length of jib m length of counter-jib weight Total power Operation Temperature m (t) 14.5 kW 40 50 60 70 24 24 24 24 19 24 90.5 () Excluding Erecting Mechanism ℃ -20~+40 28.5 TC7052 版版版版版 版版版版版版版版版 1.2-3 The ground foundation is the precondition to ensure safe operation of the stationary tower crane This foundation must closely comply with the regulations for different geological conditions Reinforced concrete foundations must be adopted Basic requirements as follows: The soil below foundation must be tamped solid Different foundations may be chosen to suit different soil conditions The concrete strength grade must not be lower than C35 The foundation must meet the equations The height of concrete foundation must be no less than 1600mm it is strict to the foundation of Tower Crane with outrigger stationary or anchored, the embedded anchors must be placed into special concrete.Customer can design the foundation by Table (1.2-1) or make it by the foundation drawings The foundation must meet the lower equations: Foundation stability equation: e=(M+Ph·h) / (Pv+Pg) ≤b/3 pressure stress equation: PB=2(Pv+Pg) / 3bl≤[PB] fig1.2.3-4 e eccentricity distance Pg—concrete weight PB—pressure stress [PB]—the ground allowable pressure stress Please refer to related standards about Concrete strength The Foundation has three specifications to applied to different conditions fig 1.2-2a Foundation fig 1.2-2b Foundation 1.2.3 assemble the Embedded Anchor embedded anchor is formed with legs , “K1” shaped parts and connected bar by pins leg “K1” shaped part parts of embedded anchor name numbe r 版kg版 weight leg K1 K1 shaped part connected bar 451 130 42 K1 pins 16 版 pins 2版 2500kg 2.6 ation specific 45×182/220 45×55/93 note every pin including 15×70/86 pin,2 spring pins every pin including 15×70/86 pin,2 spring pins total weight of embedded anchor is 2500 kg 1.2.3.1.Install the Embedded Anchor(fig1.2-3) Embedded anchor is assembled to configure 2.5m×2.5m square through the center of foundation 版 1.2-3 fig 1.2-3 assembled the embedded anchor Placed the embedded anchor into the foundation pit,the foundation is concentric with the embedded anchor, revise the legs,fast the leg with Angle, the diagonal line length tolerance of the embedded anchor should be no more than 2mm, The upper plane tolerance of the four legs should be no more than 2mm (Be sure that the climbing lug on the base section is placed perpendicularly to the building in order to conveniently installing and dismantling the whole tower crane.) Fast the embedded anchor Be sure that the number of re-bars around anchors must not be reduced or cut off If it is difficult to pass through the anchor, the main reinforcing rod can be turned aside Placing concrete,be sure of the upper plane of legs is above 350mm than the upper plane of the foundation and the diagonal line length tolerance of the embedded anchor should be no more than 2mm, The upper plane tolerance of the four legs should be no more than 1/1000 Concrete filling rate around the embedded anchors must be over 95% 1.2.4 Counter-weight 1.2.4.1 General The counter-weight shall be manufactured according to the drawings we have provided Ensuring its overall dimensions and function dimensions, particularly the positions and sizes of hanging holes The counter-weight has two specifications; both are cast with reinforced concrete For specific dimensions, refer to Fig 1.2-4and Fig 1.2-5 TC7052 版版版版版 版版版版版版版版版 1.2-10 fig 1.2-4 5t Counter-weight TC7052 版版版版版 版版版版版版版版版 1.2-13 fig 1.2-5 4.5t counter-weight - Weigh the counter-weight cast with reinforced concrete Permitted weight deviation is 2%, concrete grade no less than C18 In order to obtain the permitted weight deviation, it is possible to change its height according to concrete density 1.2.4 counter-weight configuration jib counter 70m jib table 1.2-2 40m jib 60m jib 50m jib 23m 23m 23m 3×5 0t 2×5 0t 2×5 0t 2×4.5t 2×4.5t 23m -jib counter -weight 3×5 0t 3×4.5t 28.5t total total 24t total 19t 1×4.5t 14.5t total TC7052 版版版版版 版 版 1.3-1 Chapter III Erection 1.3.1 Introduction Customers are required to go through this section to ensure proper and smooth erection of the tower crane 版 According The Characteristics and Hoisting Capacity of Truck Crane and the weight and height of erection units to select the proper truck crane The truck crane selected shall be capable of erecting the tower crane at the shortest time and limited site 1.3.2 版版版版版版版 a The wind speed atop (the highest crane point) should be no greater than 14m/s during crane erection b Strictly follow the erection procedures of tower crane c Properly select the hook point Select the hoisting equipment with proper length and reliable quality to suit the components to be hoisted (refer to Table 1.3-2) 版 d Dismountable pins, nuts and bolts for connecting tower sections and slewing bearing are specially prefabricated parts Customers are not allowed to replace them freely e Stairs, platform and protecting fence should be installed for safe operation f Be sure of the proper length of counter-jib and number of counter-weights according to the length of jib (refer to relevant sections) Jib must be installed after placing one 4.5t counter-weight on the counter-jib It is prohibited to place two pieces or more counter-weight on the counter-jib before installing jib g After jib installation, it is prohibited to hoist any load before placing specified counter-weight on the counter-jib h At the erection position of the tower crane, it must be no less than 1.5m distance between the widest slewing part of the crane and around buildings, and the safe distance between any parts of the crane and overhead power lines shall comply with the stipulations as shown in Table 1.3-1 i Auxiliary hoist equipment, sleepers, cables, rope clips and other ordinary tools should be provided before hand j Reference size for tower crane erection site is shown as Fig 1.3-1 k Drive the trolley to the balance position before jacking Slew the jib to the right front of the in-let beam and then lock the slewing of tower crane by slewing brake No slewing of the jib and no up and down movements of the hoist hook during jacking operation l.Be sure that hoisting (or lowering) tower section should be as close to the tower body as possible Table 1.3-1 Voltage KV Safe distance Vertically Horizontally 版 1.5 1.0 1~15 20~40 60~110 200 3.0 1.5 4.0 2.0 5.0 4.0 6.0 6.0 Weight specifications of crane parts and component Table 1.3-2 Component weight and height weight(kg) h(m) embedded anchor base section tower section 5420 5372/版 7.0 13.3 Climbing frame 14500 25.3 Slewing assembly 13500 16.4 Slewing tower body 3150 19.1 Tower head Counter-jib assembly 5000 29.1 15850 19.6 1st counter-weight 4500 23.3 70m-jib assembly 18870 20.3 60m-jib assembly 17590 20.3 50m-jib assembly 15600 20.3 40m-jib assembly 13510 20.3 name ... 0.46 1.9.4 Overall Dimensions of Tower Crane 1.9.4.1.Overall dimensions of the stationary Tower Crane figure 1.1-1 Overall dimensions of the stationary Tower Crane Working J版mm版 K版mm版 70m 53560... Ratifier版 版 TC7052 版版版版版 Part I 版 1.1-1 Installation of Tower Crane Chapter I Preface Model TC7052 tower crane is designed and manufactured by Changsha Zoomlion Heavy Industry Science and Technology Development... erection of the tower crane 版 According The Characteristics and Hoisting Capacity of Truck Crane and the weight and height of erection units to select the proper truck crane The truck crane selected