Zoomlion QTZ250 Operating Instructions Manual
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Zoomlion QTZ250 Operating Instructions Manual

Tower crane
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A 版
TC7525-16D
TC7525-16D VERSION A
QTZ250(TC7525-16D)塔式起重机
QTZ250 (TC7525-16D) Tower Crane
使用说明书
Operating Instructions
ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY CO., LTD.

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  • Page 1 A 版 TC7525-16D TC7525-16D VERSION A QTZ250(TC7525-16D)塔式起重机 QTZ250 (TC7525-16D) Tower Crane 使用说明书 Operating Instructions ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY CO., LTD.
  • Page 2 致用户 CUSTOMERS: 感谢您选购和使用本公司的塔式起重机！ Thanks for your purchase and being one of the users of Zoomlion Tower Crane! 为了使您正确使用与维护该设备，操作前敬请仔细阅读本使用 说明书，并妥善保管，以备查询。 Go through the instructions for correct operation and maintenance, and always keep at hand for consultation. 本使用说明书中标有“注意：”的语句，涉及到施工的安全， 敬请注意。 Pay attention to the sentences marked with “Warning, Notice or Precautions ” in this publication, which involves safety of construction.

  • Page 3: Table Of Contents

    目 录 Contents 第一篇 塔机的安装 Part I Erection of Tower Crane 第一章 概 述 Preface..............1 第二章 基础、平衡重及压重 Foundations & Counter-weight & Centre ....................12 Ballast ................. 22 第三章 立塔 Erection ..............89 第四章 拆塔 Dismantling 第二篇 塔机的使用与维护 Part II Operation and Maintenance 第一章...

  • Page 4: 第一章 概 述 Preface

    Installation of Tower Crane Chapter I 概 述 Preface TC7525-16D 塔式起重机，是中联重科股份有限公司按 JG/T5037-93《塔式 起重机分类》标准设计的新型塔式起重机。 Model TC7525-16D tower crane is designed and manufactured by Zoomlion heavy industry science and technology co., ltd. according to the Chinese standard of JG/T5037-93 “Classification of Tower Crane”. TC7525-16D 塔机为水平起重臂，小车变幅，上回转自升多用途塔机。该机...
  • Page 5 TC7525-16D 塔式起重机 1.2- 基础、平衡重及压重 4、工作速度高，调速性能好，其中起升机构、变幅机构、回转机构采用当 今国际上最先进的变频无级调速方案，工作更加平稳可靠。 It has high working speed and good regulated speed performance. 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.
  • Page 6 TC7525-16D 塔式起重机 1.2- 基础、平衡重及压重 4) 起升机构排绳系统；Rope pay-off system for hoisting mechanism; 5) 牵引绳张紧系统；Traction rope-tensioning system; 6) 顶升防脱装置；Jacking against falling equipment 7) 刚性双拉杆悬挂大幅度起重臂，起重臂刚度好，自重轻，断面小，风阻 小，外形美观，长度有几种变化，满足不同施工需要； 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 nice-looking appearance and several jib lengths, it is satisfied different construction needs.
  • Page 7 TC7525-16D 塔式起重机 1.2- 基础、平衡重及压重 45m 臂 45m Jib 45m 臂起重性能特性 幅度（m） 3.75～19.0 36.7 起重量 二倍率 8.00 7.23 6.30 （t） 四倍率 16.00 11.59 9.29 7.66 7.22 6.46 5.52 50m 臂 50m Jib 50m 臂起重性能特性 幅度（m） 3.75～18.5 35.5 二倍率 8.00 6.97 6.07 5.35 起重量...
  • Page 8 TC7525-16D 塔式起重机 1.2- 基础、平衡重及压重 65m 臂 65m Jib 65m 臂起重性能特性 幅度（m） 3.75～17 32.5 二倍率 8.00 7.35 6.28 起重量 （t） 四倍率 16.00 13.15 10.05 8.01 7.22 6.58 5.51 幅度（m） 起重量 二倍率 5.46 4.80 4.27 3.83 3.45 （t） 四倍率 4.68 4.03 3.49 3.05 2.67 70m 臂...
  • Page 9 TC7525-16D 塔式起重机 1.2- 基础、平衡重及压重...
  • Page 10 TC7525-16D 塔式起重机 1.2- 基础、平衡重及压重...
  • Page 11 TC7525-16D 塔式起重机 1.2- 基础、平衡重及压重...
  • Page 12 TC7525-16D 塔式起重机 1.2- 基础、平衡重及压重...
  • Page 13 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 9.2 整机技术性能参数表（表 9-3） Technical performance parameters for the whole machine (Table 9-3) Table 9-3 表 9-3 起 升 机 构 Hoisting 机构工作级别 回 转 机 构 Slewing Mechanism Group 变 幅 机 构 Trolleying 最大起重力矩 kNm 3840 Rated hoisting moment 最大工作幅度...
  • Page 14 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 9.3 机构技术性能参数(表 9-4) Technical parameters of the mechanisms Table 9-4 表 9-4 单位 型号 Model QP1675 Unit 最大牵引力 44860 Maximum traction of the rope 规格 Specification 35×7-20-1770 钢丝绳 Wire rope 最大线速度 Maximum linear speed m/min 最大转速...
  • Page 15 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 机构型号 Model of Mechanism HPW75F1.130C / HPW75F2.130C 型号 Model YTRVFW132M2-4F1 YTRVFW132M2-4F2 电 机 功 率 Power 7.5×2 Moter 转速 Speed r/min 0~ 1440 型号 Model XX5-130.195CLC-14/12 回 转 减 速 机 传 动 比 Gear Ratio 机...
  • Page 16 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 9.4 整机外型尺寸 Overall dimensions of the crane 9.4.1 独立式整机外型尺寸 Overall dimensions of the stationary crane 图 1.1-1 TC7525-16D 塔式起重机支腿固定独立式外形尺寸 Fig. 1.1-1 Overall dimensions of the TC7525-16D stationary tower crane J(mm) K(mm) L(mm) To slewing center 77100 55110 21000...
  • Page 17 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 9.4.2 附着式整机外形尺寸 Overall dimensions of the crane anchored to the building (Fig.1.1-2) 图 1.1-2 TC7525-16D 塔式起重机支腿固定附着式外形尺寸 Fig. 1.1-2 Overall dimensions for the TC7525-16D stationary tower crane anchored to the building To slewing center R J(mm) K(mm) L(mm) 77100...

  • Page 18: Ballast

    TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 基础、平衡重及压重 第二章 Chapter Ⅱ Foundations, Counter-weight and Center Ballast 1.2.1 支腿固定式地基基础载荷（见图 1.2-1、表 1.2-1） Foundation loading of stationary crane with embedded anchor (Shown as Fig.1.2-1, Table1.2-1) Table 1.2-1 Load 载荷 弯矩 扭矩 垂直力 Bending Torque 工况 水平力...
  • Page 19 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 endurance must not be smaller than the specifications as shown in Fig.1.2-2a, 1.2-2b. —混凝土基础的深度应为 1600 mm。 — The height of concrete foundation must be no less than 1600mm. 图 1.2-2a 地耐力为 0.145Mpa 地基基础图...
  • Page 20 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 图 1.2-2b 地耐力为 0.125Mpa 地基基础图 预埋支腿固定式及其附着式对基础要求比较严格， 其支腿组件要埋入特制的 混凝土内，其基础可根据表 1.2-1 的载荷自行设计，也可根据我们提供的基础图 进行制作。设计基础时要满足抗倾翻稳定性和强度条件，其公式如下：...
  • Page 21 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 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: 混凝土基础抗倾翻稳定性公式如下: Foundation stability equation:...
  • Page 22 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 1.2.3.1 固定支腿尺寸（图 1.2-3）Size of the foundation anchors (Fig. 1.2-3) — 固定支腿必须按混凝土基础中心线对称安装成 2m×2m 的正方形。 — The anchors must be symmetrically embedded at the sides of the centerlines of concrete foundation as a 2m×2m square. 图 1.2-3 固定支腿尺寸 Fig.
  • Page 23 TC7525-16D 塔式起重机 1.2- 基础、 平衡重及压重 —根据施工方便性,当钢筋捆扎到一定程度时，将装配好的固定支腿和基础 节整体吊入钢筋网内。基础节上有踏步的一面应与建筑物垂直。 — According to the construction convenience and the progress of binding rebar, hoist the whole piece of anchors assembled with the base section into rebar net. 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.
  • Page 24 TC7525-16D 使用说明书 1.2.4 防雷保护（图 1.2-5） Lightning Protection(Fig1.2-5) 图 1.2-7 Fig1.2-7 图 1.2-5 Fig1.2-5 注意：不要与建筑物基础的金属加固件连接。 Notes: Not connected with the steel reinforcement of the building foundation. 1.2.5. 平衡重 Counter-weight 1.2.5.1 概述 General — 平衡重应按我们提供的图纸制作。应保证平衡重的外形尺寸及功能尺寸，尤其是 悬挂孔的位置及其尺寸。 --The counter-weight shall be manufactured according to the drawings we have provided. Ensuring its overall dimensions and function dimension, particularly the positions and sizes of hanging holes.
  • Page 25 TC7525-16D 使用说明书 图 1.2-6 Fig. 1.2-6 图 1.2-7...
  • Page 26 TC7525-16D 使用说明书 Fig. 1.2-7 图 1.2-8 Fig. 1.2-8 —用混凝土浇注成形后称重，重量允差 2％，砼标号不低 C20。为得到允差，可按 混凝土密度改变高度尺寸（图 1.2-6、1.2-7、1.2-8 中的尺寸 3340、2500、2084） 。 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 (3340、...
  • Page 27 TC7525-16D 使用说明书 1.2.5.2 平衡重的配置 counter-weight configuration Table 1.2-2 Jib length Counter-jib length 4×4. 0t 3×4. 0t 4×4. 0t 3×4. 0t 2×2.5t 2×2.5t 1×2.5t 1×2.5t Counter-weight 0×1.0t 3×1.0t 0×1.0t 3×1.0t Total 18.0t Total 20.0t Total 18.5t Total 17.5t Jib length Counter-jib length 4×4.

  • Page 28: 第三章 立塔

    TC7525-16D 使用说明书 第三章 立 塔 Chapter Ⅲ Erection 1.3.1 引言 Introduction —用户应熟读本章说明，以便正确迅速架设塔机。 — Customers are required to go through this section to ensure proper and smooth erection of the tower crane. —根据《汽车吊的特性及起重能力》和安装单元的重量和高度选用汽车吊。 —According The Characteristics and Hoisting Capacity of Truck Crane and the weight and height of erection units to select the proper truck crane.
  • Page 29 TC7525-16D 使用说明书 g.装好起重臂后，平衡臂上未装够规定的平衡重前，严禁起重臂吊载。 After jib installation, it is prohibited to hoist any load before placing specified counter-weight on the counter-jib. h.塔机在施工现场的安装位置， 必须保证塔机的最大旋转部分与周围建筑物的距离不 小于 1.5m，塔机任何部位与架空电线的安全距离应符合表 1.3-1 的规定。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.
  • Page 30 TC7525-16D 使用说明书 .整机各部件重量明细表 Weight specifications of crane parts and component Table 1.3-2 Component weight and height Embedd Weight Designation (kg) anchor H(m) Base section 4100 Strengthened section 2150/节 Tower section 1960/节 Climbing frame 5100 Slewing assembly 8700 （ with Operator cab） Slewing tower body 2810 Tower head...
  • Page 31 TC7525-16D 使用说明书 ※注：14a 14b 14c 14d 14e 14f 14g 14h 是安装一块平衡重后剩下的平衡重 Remarks: 14a 14b 14c 14d 14e 14f 14g and 14h refer to the remaining counter-weights after mounting one counter-weight. 1.3.3 塔机的总体布置 General layout of tower crane 1.3.3.1 支腿固定独立式主要组件装配关系（见图 1.3-2） Assembly relation of main components for stationary crane with embedded anchor (Fig.1.3-2) TC7525-16D 支腿固定式独立起升高度为...
  • Page 32 TC7525-16D 使用说明书 1—固定基础 Foundation 2—塔身基础节 Base Tower section 3—塔身加强节 Strengthened Tower section 4—塔身标准节 Tower section 5—爬升架 Climbing frame 6—下支座 Slewing ring support...
  • Page 33 TC7525-16D 使用说明书 7—回转支承 Slewing ring 8—上支座 Upper support 9—司机室 Operator cab 10—起重臂 Jib （a=75m、 b=70m、 c=65m、 d=60m、 e=55m、 f=50m、 g=45m、 h=40m） 11—回转塔身 Slewing tower body 12—塔顶 Tower head 13—平衡臂 Counter-Jib（a=20m） 14—平衡重 Counter-weight（a=21t、b=20t、 c=18.5t、d=17.5t、e=16t、f=14t、g=15t、h=10.5t） 图 1.3-2 Fig.1.3-2 1.3.3.2 附着式主要组件装配关系（参见图 1.3-3）Assembly relation of main components for the tower crane anchored to the building (Fig.1.3-3).
  • Page 34 TC7525-16D 使用说明书 suspension height limit above anchored frame. Item 1.3.3.2.3 (Fig. 1-2) can satisfy both ordinary construction needs and facilitate prefabrication of anchored frames most economically for lower operation cost of the tower crane. 1.3.3.2.1 第一道附着 The 1st anchored-frame attachment (1)第一道附着架以下的塔身高度...
  • Page 35 TC7525-16D 使用说明书 工作高度 Height in use h＞100m，至少要少加一节标准节 Tower sections must be de reduced one section. 即：n0≤12 1.3.3.2.3 支腿固定附着式最经济配置附着架的附着方式 Most economic anchored-frame layout for the stationary crane with embedded anchors 第一次附着后，附着架以上塔机悬出段≤39.3m，塔机最大工作高度 81.3m，自下而 上 1 个基节，1 个加强节，23 个片式标准节。 —After 1 anchoring operation, the tower height above the anchored frame is less than 39.3m, and the maximum working height reaches 81.3m, base tower section from down to up,1...
  • Page 36 TC7525-16D 使用说明书 上 1 个基础节，1 个加强节，67 个片式标准节。 —After 6 anchoring operation, the tower height above the anchored frame is less than 36.3m, and the maximum working height reaches 213.3m, base tower section from down to up,1 Tower leaf-type Tower sections. Strengthened section 第七次附着后，附着架以上塔机悬出段≤36.3m，塔机最大工作高度...
  • Page 37 TC7525-16D 使用说明书 1.3.4.1.1 安装塔身节 Erection of tower sections 1.3.4.1.1.1 结构简述 Structure description 三种塔身节：Two kinds of tower sections: —基础节 BZJL68G22（整体式，与固定基础支腿相连，带安装刀开关箱的角钢，见 图 1.3-5） 。 Base sections (Whole section with angle iron equipped with fitting position of sword switch.Connect to embedded anchors， Fig.1.3-5) —加强节...
  • Page 38 TC7525-16D 使用说明书 图 1.3-5 基础节 Fig 1.3-5 Base Section...
  • Page 39 TC7525-16D 使用说明书 Fig 1.3-6 加强节 BZJL68B2 和标准节 BZJL68B1 Fig 1.3-5b Strengthened section BZJL68B2 and Tower section BZJL68B1 图 1.3-7 塔身通道 A、D、E Fig 1.3-7 channels A、D、E of Tower sections...
  • Page 40 TC7525-16D 使用说明书 表 1.3-1(通道组合表) tab1.3-1（channels configuration） 1+13+1 1+12+1 1+11+1 1+10+1 1+9+1 1+8+1 1+7+1 1+6+1 1+5+1 1+4+1 1+3+1 1+2+1 1+1+1 1+0+1 L+M+N 备注：L 代表基础节，N 代表最高节，M 代表中间节(包括 BZJL68B2 和 L68B1) L—Base Section N—The highest section M—Middle section(BZJL68B2 or BZJL68B1) Tower sections (Fig.1.3-8) 拼装片式标准节...
  • Page 41 TC7525-16D 使用说明书 ○ 每节标准节配有通道，各标准节内均设有供人上下的爬梯，并设有供人休息的平 台。通道与塔身标准节的安装在地面进行，通道组件与塔身标准节配套使用，有 E、D、 A 三种型式（见图 1.3-7） ，E 通道装在最后一节标准节上，如果塔机最终工作高度是经过 若干阶段后到达的，每次加节时都应以 A 型或者 D 型更换最后一节的通道，所有扶梯均 应装在有顶升耳座的塔身侧片上，根据塔身组合高度的不同，通道 E、D、A 的安装均应 按通道组合表（表 1.3-1）的规定组合进行。 Every Tower Section is equipped with channels, flat roof and ladders for human’s resting and pass. The installation of Tower Section and channel has been done on the ground and they must be used relatively.
  • Page 42 TC7525-16D 使用说明书 由爬升架结构、平台、爬梯及液压顶升系统、加强节引进装置等组成，塔机的顶升运 动主要靠此部件完成。 Consists of climbing frame structure, platform, climbing stairs, hydraulic jack system and let-in device for Strengthened section. Jacking of the tower crane is done mainly by this component. 顶升油缸安装在爬升架后侧的横梁上(即预装平衡臂的一侧)，液压泵站放在液压缸一 侧的平台上，爬升架内侧有 16 个滚轮，顶升时滚轮支于塔身主弦杆外侧，起导向支承作 用。 The jacking cylinder (or called climbing jack) is provided on the beam at the rear side of climbing frame (i.e.
  • Page 43 TC7525-16D 使用说明书 1.3.4.1.2.2 吊装爬升架（图 1.3-10）Hoist and install climbing frame (Fig.1.3-10) 将爬升架缓慢套装在加强节外侧。 Pull the climbing frame on the outer side of the Strengthened section gently. 注意：顶升油缸与塔身踏步在同一侧。 Warning: The jacking cylinder and climbing lug on tower section shall be on the same side.
  • Page 44 TC7525-16D 使用说明书 1.3.4.1.3 安装回转支承总成 Install the assembly of slewing ring 1.3.4.1.3.1 结构简述 Structure description 回转支承总成包括下支座、回转支承、上支座、回转机构共四部分，见图 1.3-11。下 下支座下部与加强节 BZJL68B2 支座为整体箱形结构， 及爬升架相连； 中间有两根可拆卸 的引进横梁，用于顶升时标准节的引进；上部与回转支承外圈通过高强度螺栓连接。 The assembly of slewing ring consists of the slewing ring support, slewing ring, upper support and slewing mechanism (shown as Fig. 1.3-11). The slewing ring support is an integrated box structure.
  • Page 45 TC7525-16D 使用说明书 图 1.3-11 Fig 1.3-11 1.3.4.1.3.2 吊装回转支承总成 Hoist and install the assembly of slewing rings 检查与回转支承、下支座、上支座连接用 88 件 10.9 级的 M27 高强螺栓的预紧扭矩 是否达到了 1100N·m。 Inspect M27 high-strength bolts (88 pieces, grade 10.9) connecting the slewing rings, slewing ring support, and upper support to make sure that their pre-tensioned torsion moment are up to 1100Nm.
  • Page 46 TC7525-16D 使用说明书 图 1.3-12 Fig 1.3-12 用特制 Φ55 销轴将下支座与加强节 BZJL68B2 连接牢固，用锁销固定。 Connect with special-made φ55 pins to Strengthened sections BZJL68B2 and slewing ring support, keep their large fastness with the pins . 操作顶升系统， 将液压油缸伸长至基节的下踏步上， 将爬升架顶升至与下支座连接耳 板接触，用销轴和下支座相连。 Operate the jacking system to extrude the hydraulic cylinder to the down pair of climbing lug.
  • Page 47 TC7525-16D 使用说明书 图 1.3-13 Fig.1.3-13 回转塔身为整体框架结构， 上端面分别有用于安装起重臂和平衡臂耳板， 上面用四根 销轴与塔顶相连。 在回转塔身的横梁上安装有起重量限制器， 用以限制各档速度的最大起 重量。 The slewing tower body is an integrated frame structure. Its upper end surface has the ear-plates for mounting the jib and counter-jib respectively. These plates are connected to the tower head by 4 pins.
  • Page 48 TC7525-16D 使用说明书 图 1.3-14 Fig.1.3-14 1.3.4.1.5 安装塔顶 Install the Tower Head 1.3.4.1.5.1 Structure Description 塔顶为四棱锥形结构，顶部有拉板架和起重臂拉板，通过销轴分别与起重臂、平衡臂 拉杆相连，为了安装方便，塔顶上部设有工作平台，工作平台通过螺栓与塔顶连接。塔顶 上部设有起重钢丝绳导向滑轮和安装起重臂拉杆用滑轮， 塔顶后侧主弦下部设有力矩限制 器，并设有带护圈的扶梯，塔顶下端有四个耳板，通过四根销轴与回转塔身连接。 The tower head is a quadrangular cone-shaped structure. On its top, there is provided with the pull plate frame and jib pull plate, which are connected respectively to the counter-jib and the jib through pins.
  • Page 49 TC7525-16D 使用说明书 On each side at the back of the tower head, mount one counter-jib pull rod for the convenient installation of the counter-jib. 将塔顶吊到回转塔身上， 应注意将塔顶垂直的一侧应对准上支座的起重臂方向。 Hoist the tower head onto the slewing tower body. Pay attention to align the vertical side of the tower head to the jib direction of the upper support.
  • Page 50 TC7525-16D 使用说明书 图 1.3-16 Fig.1.3-16 1.3.4.1.6 安装平衡臂总成 Install the counter-jib assembly 1.3.4.1.6.1 结构简述（图 1.3-17）Structure (Fig.1.3-17) 平衡臂是工字钢及角钢组焊成的结构，共两节，用销轴连接。平衡臂上设有栏杆及走 道，还设置了工作平台，平衡臂的一端用两根销轴与回转塔身连接，另一端则用两根组合 刚性拉杆同塔顶连接。尾节装有平衡重、起升机构及扒杆，电气控制箱布置在根部。起升 机构本身有其独立的底架，用 根螺栓固定在平衡臂上。 The counter-jib is welded structure of I-steel and angle steel. It has 2 sections, which are connected by pins. The counter-jib is provided with railings, walkway and working platform. One end of the counter-jib is connected to the tower body by two pins and another end connected to the tower head by two rigidly-combined pull rods.
  • Page 51 TC7525-16D 使用说明书 图 1.3-17 20m 平衡臂臂长 Fig.1.3-17 20m-Length Counter-jib 1.3.4.1.6.2 吊装平衡臂总成 Hoist and Install the Counter-jib Assembly 在地面上根据起重臂长度组装好相应的平衡臂， 将起升机构、 扒杆、 电控箱、 电阻箱、 平衡臂拉杆装在平衡臂上，并固接好。回转机构接上临时电源，将回转支承以上部分回转 到便于安装平衡臂的方位。 Assemble the counter-jib corresponding to the jib length on the ground. Install the hoist mechanism, lifting pole, electric control box, electric resistance box and counter-jib pull rod on the counter-jib and make sure of their solid connection.
  • Page 52 TC7525-16D 使用说明书 图 1.3-18 吊装平衡臂总成 Fig.1.3-18 Hoist and Install the Counter-jib Assembly 吊起平衡臂，用定轴架和销轴将平衡臂与回转塔身固定联接好。 Hoist the counter-jib, connect it to the slewing tower body and fix them by axle-position frame and pins. 平衡臂拉杆示意，见图 1.3-19 所示，将平衡臂逐渐抬高至适当的位置，便于平衡臂 上拉杆与塔顶上平衡臂拉杆顺利相连，将拉杆用销轴铰接，穿好并张开开口销。 平衡臂拉杆，见图 1.3-19 所示，将平衡臂逐渐抬高至适当的位置，见图 1.3-20 所示， 便于平衡臂上拉杆与塔顶上平衡臂拉杆顺利相连，...
  • Page 53 TC7525-16D 使用说明书 上，如图 1.3-21 所示。 Lay down the counter-jib slowly. Lift another 4.0T piece of counter-weight at the furthest position of the counter-jib, as shown in Fig.1.3-20. 1.3-19 平衡臂臂长平衡臂拉杆 Fig.1.3-19 Pull rod of 20m-length counter-jib 图 1.3-20 吊装一块 4.0t 平衡重 Fig.1.3-20 Hoist and install one 4.0t Counter-weight 图...
  • Page 54 TC7525-16D 使用说明书 图 1.3-21 吊装一块 4.0t 平衡重 Fig.1.3-20 Hoist and Install a 4.0t counter- weight 特别注意： Special Notice: 安装平衡重的销轴（2）的挡板（3）必须靠住平衡重（4） 。 Be sure of mounting the baffle (3) of the counter-weight pins (2) against the counter-weight（4）. 安装平衡重的销轴（2）的端面必须超出三角板（1） 。 Be sure of mounting the end face of the counter-weight pin (2) exceeding over the triangle plate (1).
  • Page 55 TC7525-16D 使用说明书 1.3.4.1.7 安装司机室 Installation of operator cab 1.3.4.1.7.1 结构简述（见图 1.3-22）Structure description 司机室为薄板结构，侧置于上支座右侧平台的前端，四周均有大面积的玻璃窗，前上 窗可以开启，视野开阔。司机室美观舒适，内设有联动操纵台。 The cab is a sheet structure, offset at the front on the upper support right side platform. There are large big glass windows on the four sides of the cab. The upper window in front can be opened to obtain a wide field of view.
  • Page 56 TC7525-16D 使用说明书 1.3.4.1.8 安装起重臂总成 Installation of jib assembly 起重臂总成包括起重臂、起重臂拉杆、载重小车、变幅机构，起重臂拉杆安放在起重 臂上弦杆的拉杆固定架上。 The jib assembly consists of the jib, jib pull rods, and trolleying mechanism. The pull rods are placed on the rod-fixing frame on the upper chord rod of the jib. 1.3.4.1.8.1 结构简述（见图...
  • Page 57 TC7525-16D 使用说明书 图 1.3-24 Fig.1.3-24 Jib assembling must closely follow the serial number marks on each jib section. Dislocation and free assembling are not permitted. The jib may be assembled with various jib lengths of 75m, 70m, 65m, 60m, 55m, 50m, 45m and 40m to suit different construction requirements.
  • Page 58 TC7525-16D 使用说明书 1.3.4.1.8.2 吊装起重臂总成 Hoist and install the jib assembly 在塔机附近平整的枕木（或支架）上拼装好起重臂。注意无论组装多长的起重臂， 均应先将载重小车套在起重臂下弦杆的导轨上。 Assemble the jib on the flat sleepers (or supports) near the tower crane. No matter how long a jib is to be assembled, the trolley must at first be installed on the guide rail on the jib lower chord.
  • Page 59 TC7525-16D 使用说明书 将起重臂拉杆按图 1.3-26 所示拼装好后与起重臂上的吊点用销轴铰接，穿好开口销。 放在起重臂上弦杆的定位托架内。 Assemble the hoist jib pull rod as shown in Fig.1.3-26, make its connection to the jib hoist point by pin axle and put in cotter pins. 图 1.3-26 Fig.1.3-26...
  • Page 60 TC7525-16D 使用说明书 检查起重臂上的电路是否完善。 使用回转机构的临时电源将塔机上部结构回转到便于 安装起重臂的方位，按图 1.3-27 挂绳，试吊是否平衡，否则可适当移动挂绳位置，起吊 起重臂总成至安装高度。用定轴架和销轴将回转塔身与起重臂根部联接固定。注意：记 录下吊装起重臂的吊点位置，以便拆塔时使用。 Check the jib circuit for soundness. Switch on the temporary power supply of the slewing mechanism to slew the tower crane superstructure to a position for convenient installation of the jib. Hang up ropes as shown in Fig.1.3-27. Try the ropes for balance. In case of improper balance, move properly the rope-hanging position.
  • Page 61 TC7525-16D 使用说明书 载重小车且载重小车在最小幅度） 见下表。 As for the position of center of gravity during jibs installation with different lengths (incl. long and short pull rods, traveling mechanism, anti-drop device, and trolley at the minimum radius), refer to the Table below. Jib length m Weight t Reference center of gravity m 14.9...
  • Page 62 TC7525-16D 使用说明书 图 1.3-30 平衡重安装位置示意图 Fig.1.3-30 Schematic diagram of counter-weight mounting positio...
  • Page 63 TC7525-16D 使用说明书 1.3.4.3 起升机构绕绳系统 Rope-winding system of hoist mechanism 吊装完毕后，进行起升钢丝绳的穿绕。如图 1.3-31 所示，起升钢丝绳由起升机构卷 筒放出， 经起升机构排绳滑轮， 绕过塔顶导向滑轮向下进入回转塔身上起重量限制器滑轮， 向前再绕到载重小车和吊钩滑轮组， 最后将绳头通过绳夹， 用销轴固定在起重臂头部的防 扭装置。 After installation, wind hoisting ropes. As shown in Fig.1.3-34, the hoisting ropes are released from the wire rope drum, passing through the rope discharging mechanism to go over the guide pulley on tower head down into the pulley of hook weight limiter in the slewing tower.
  • Page 64 TC7525-16D 使用说明书 1.3.4.5 换倍率系统 Fall-change system 换倍率系统包括主小车，副小车、主吊钩以及副吊钩四部分，其 在 起 重 臂上的安 装（见图 1.3-32） ，钢丝绳在主小车、副小车、主吊钩、副吊钩上的绕绳见图 1.3-33。主 小车与副小车的连接与分离便可实现二、四倍率的变换（下面称为变倍率） 。 The automatic fall-change system consists of 4 parts, i.e. the main trolley, the subordinative trolley and main hook, subordinative hook. Their mount on the jib (Fig.1.3-32) rope winding on the main trolley, the subordinative trolley and main hook, subordinative hook (Fig.1.3-33).
  • Page 65 TC7525-16D 使用说明书 to 2-fall, the by-pass switch must at first be turned to the by-pass status to disable the height limiter. After conversion completion, the by-pass switch must be restored to its original status. At the 2 fall working conditions, the suborsinative trolley is fixed at jib root, the subordinative hook with automatic connection device contacts tightly the subordinative trolley.
  • Page 66 TC7525-16D 使用说明书 图 1.3-35 吊钩组图 Fig. 1.3-35 hook 1.3.4.5.1.1 变换前副吊钩与副小车通过销轴 2 连接为一体，静止在起重臂根部，销轴 1 将副小车与起重臂连接在一起，使副小车无法向前变幅行走（见图 1.3-34） 。 Before fall-change, Subordinative hook is fixed at subordinative trolley by pins 2, subordinative trolley is fixed at jib root by pins 1,so subordinative trolley is stopped (fig.1.3-34).
  • Page 67 TC7525-16D 使用说明书 1.3.4.5.2.2 缓慢开动起升机构，使副吊钩上升同时将小车开至起重臂根部，继续上升 副吊钩，使副吊钩顶到副小车，停止起升，插入销轴 1、销轴 2，卸掉销轴 3（图 1.3-34）. Start the hoisting mechanism slowly, rise the subordinative hook, at rhe same time, operate the trolley to the jib root. Rise the subordinative hook continuly, when contact the subordinative trolley,stop it,then insert pin 1 and pin 2, dismantle the pins 3 (Fig. 1.3-34). 1.3.4.5.2.3 开动变幅机构，将主小车往外缓慢变幅。即转换成二倍率工作状态。...
  • Page 68 TC7525-16D 使用说明书 1.3.4.6.2 顶升一般规则 General of jacking operation 1) 顶升前塔机旋转部分必须进行配平。 Keep the crane rotation part in balance. 2) 塔机最高处风速大于 12m/s 时，不得进行顶升作业。 It is prohibited to operate the jacking system when the wind speed at the highest spot exceeding 12m/s. 3) 严禁在顶升系统正在顶起或已顶起时进行吊重（上升或下降） 。 It is prohibited to hoist load (up or down) while the jacking system is in operation or after jacking.
  • Page 69 TC7525-16D 使用说明书 adjusted according to the actual situation in jacking). Remove the pins from 4 legs of slewing ring support, which is for connection to the Tower section. 2) 将液压顶升系统操纵杆推至“顶升方向”，使爬升架顶升至下支座支脚刚刚脱离塔 身的主弦杆的位置； Push the operation handle of the hydraulic jacking system to <<Jacking direction>> to jack the climbing frame to a position where the legs of slewing ring support are just disengaged from the main chord rod of the tower body.
  • Page 70 TC7525-16D 使用说明书 1.3.4.6.4 顶升作业 Jacking operation 1)先将提升装置吊起安装在下支座的引进梁上，再吊起一节标准节，将载重小车开至 （参见图 1.3-37） 顶升平衡位置。 Lift the hoisting equipment to install it on the guide beam of the upper support, and then hoist up one Tower section. Drive the trolley to the jacking position for balance (Fig.1.3-44). The tower crane is now at a balance status.
  • Page 71 TC7525-16D 使用说明书 图 1.3-37 Fig 1.3-37 6)确认两个活动爬爪准确地挂在踏步顶端后，将油缸活塞全部缩回，提起顶升横梁， 重新使顶升横梁顶在爬爪所搁的踏步的圆弧槽内。 Confirm that both movable latches have accurately been pressed on the slots climbing lug and have borne the weight of climbing frame and the parts above it. Retract the piston of cylinder completely. Lift the hanging beam and hang it in the nearest lug slots above again.
  • Page 72 TC7525-16D 使用说明书 added. If several sections are to be added in succession, it will do to follow the above steps again and again. 9）为使下支座顺利地落在塔身顶部，并对准连接销轴孔，在缩回油缸之前，可在下 支座四角的销轴孔内从上往下插入四根（每角一根）导向杆,然后再缩回油缸，将下支座 落下。 Inorder to let slewing ring support matched with the top tower body and holes of pins, four guide rods can be inserted into the slewing ring support, then retract the piston of cylinder, drop the support.
  • Page 73 TC7525-16D 使用说明书 图 1.3-38 附着架布置示意图 Fig.1.3-38 Schematic diagram of anchoring frame layout 1. 撑杆 A Brace Rod A 2. 撑杆 B Brace Rod A 3. 斜撑 Gradient Brace Rods 4. 后梁 Behind Beam 5. 卡箍 B Hoop B 6. 侧梁 Side Beam 7.
  • Page 74 TC7525-16D 使用说明书 图 1.3-39 Fig.1.3-39 注意：附着点的载荷值随着塔机和建筑物的相对位置、附着撑杆布置形式与尺寸、 附着框架以上塔身悬出段的高度值的变化而大幅度变化。因此，塔机附着时，如塔机附 着位置、附着撑杆布置形式与尺寸与图 1.3-39 不符时，请向本公司咨询。切不可盲目套 用表 1.3-3 中的数值自行处理，以免产生重大安全事故。 Attention: Load values at anchoring points vary to a great extent with the relative positions of the tower crane to the building, the strut layout and size, the height of the tower body suspension section over the anchored frame.
  • Page 75 TC7525-16D 使用说明书 connection pedestal fixed to the building. c. 每道附着架的四组附着撑杆应尽量处于同一水平面上。但在安装附着框架和内撑 杆时，若与塔身加强节的某些部位发生干涉，可适当升高或降低附着框架的安装高度。允 许附着框架与连接基座的高度差不大于 200mm。 4 sets of anchoring pull rod on each frame shall be kept at the same horizontal plane. If they are interfered with some positions of the tower body during mounting of anchoring frames and inner pull rods, the height of frames will properly be raised or lowered.
  • Page 76 TC7525-16D 使用说明书 1.3.4.8 投入使用前的工作 Preparations before operation 塔机投入使用前的工作，是为了保证塔机能正确操纵，并在安全条件下运行。这些工 作主要是：对塔机部件的检查及调试各安全装置。 The pre-operation preparations of the tower crane aim at ensuring its correct control and smooth operation at safe conditions. Main preparations are to check tower crane components and to test-run safety devices. 1.3.4.8.1 检查各零部件...
  • Page 77 TC7525-16D 使用说明书 图 1.3-40 Fig.1.3-40 塔机安全装置主要包括： 行程限位器和载荷限制器。 行程限位器有： 起升高度限位器、 回转限位器、幅度限位器。载荷限制器有：起重力矩限制器、起重量限制器。此外还包括 风速仪。 Safety devices for the tower crane mainly include the travel limiter and load limiter. The travel limiter includes the hoisting height limiter, slewing limiter and working radius limiter. The load limiter includes the hoisting moment limiter and hoisting weight limiter. The anemometer is also included.
  • Page 78 TC7525-16D 使用说明书 检查与下支座的连接情况 Check its connection to slewing ring support 检查滚轮、换步顶杆是否灵活可靠，连接是否牢固 爬升架 Check if rollers and lug-changing rods operate smoothly and reliably. Climbing frame 检查走道，栏杆的紧固情况 Check if the walkway and fence are fastened 检查引进小车是否灵活可靠 Check if the trolley moves smoothly and reliably. 检查与回转支承连接的螺栓紧固情况...
  • Page 79 TC7525-16D 使用说明书 检查各安全保护装置是否按本说明书要求调整合格 安全装置 Check safety device for proper adjustment as specified in the Instructions Safety device 检查塔机上所有扶梯、栏杆、休息平台的安装紧固情况 Check all ladders, protection rails and rest platforms for properly fastened. 润滑 根据使用说明书检查润滑情况 Check lubrication conditions according to the operation instructions. Lubrication 1.3.4.8.4 塔机组装好后，应依次进行下列实验（每转移一个工地都必须进行）...
  • Page 80 TC7525-16D 使用说明书 65 m 17.0 m 3.34t 60 m 17.2 m 3.90t 55 m 17.8 m 4.71t 50 m 18.5 m 5.71t 45 m 19.0 m 6.90t 40 m 19.4 m 8.28t 在以上幅度Ⅰ、幅度Ⅱ处以最低安全速度将对应的吊重吊离地面 100～200mm 处， 并在吊钩上逐次增加重量至 1.25 倍，停留 10min，卸载后检查金属结构及焊缝是否出现 可见裂纹、永久变形、连接松动。 Hoist the weight at radius I and radius II from the ground for 100~200mm height at the lowest safe speed.

  • Page 81: 第四章 拆塔

    TC7525-16D 使用说明书 第四章 拆 塔 Chapter Ⅳ Dismantling 1.4.1 拆卸注意事项：Precautions for tower crane dismantle a. 塔机拆出工地之前，顶升机构由于长期停止使用，应对顶升机构进行保养和试运 转。 Conduct maintenance and test-run for the jacking mechanism before moving the tower crane out of the construction site. b. 在试运转过程中，应有目的地对限位器、回转机构的制动器等进行可靠性检查。 Check limiters, slewing mechanism brakes and similar devices for reliability during test-run.
  • Page 82 TC7525-16D 使用说明书 otherwise personal safety accidents will be likely. 拆塔的具体程序 1.4.2 Procedures of Tower dismantling 特别提醒：拆塔是一项技术性很强的工作，尤其是塔身加强节、平衡重、平衡臂、 起重臂的拆卸。如稍有疏忽，就会导致机毁人亡。因此，用户在拆卸这些部件时，需严 格按照本说明书的规定操作。上塔工作人员，必须是经过培训并拿到证书的人员。 Special caution: tower dismantling is a highly technical work, especially the dismantling of the Strengthened sections of tower body, counter-weight, counter-jib and jib. Any slight neglect will cause machine damage, personal injury or death.
  • Page 83 TC7525-16D 使用说明书 5) 拆卸司机室；(亦可待至与回转总成一起拆卸) Dismantle the operator cab (or dismantle it together with the slewing assembly). 6) 拆卸塔顶； Dismantle the tower head. 7) 拆卸回转塔身； Dismantle the slewing tower body. 8) 拆卸回转支座总成； Dismantle the slewing ring assembly. 9) 拆卸爬升架； Dismantle the climbing frame. 10) 拆卸塔身两节加强节及基础节。...
  • Page 84 TC7525-16D 使用说明书 拆卸塔身 1.4.2.1 Lower the tower sections 1.4.2.1.1 将起重臂回转到标准节 BZJL68B1 的引进方向（即爬升架中有开口的一 侧） ，使回转制动器处于制动状态，载重小车停在配平位置（即与安装塔机中顶升加节时 载重小车的配平位置一致，参见图 1.3-36） 。 Slew the jib to the direction for the Tower section let-in (i.e. the opening side of BZJL68B1 climbing frame) to place the slewing brake at a braking status, the tower crane at a balanced jacking status, and the trolley staying at the balanced position (i.e.
  • Page 85 TC7525-16D 使用说明书 1.4.2.1.2 拆掉最上面塔身标准节上下连接销轴，并将提升装置吊钩挂在该标准节 上。 Remove the pins for connection of the topmost section hooked by takeup hook 1.4.2.1.3 伸长顶升油缸，将顶升横梁顶在从上往下数第四个踏步的圆弧槽内，将上 部结构顶起；当最上一节标准节离开第二节标准节顶面 2～5cm 左右，即停止顶升。 Extend the jacking cylinder to place the hanging beam onto the slot of the 4 lug counting from up down, jack the superstructure until the bottom of the trolley is moved to 2~5 cm away from the top section, then stop jacking.
  • Page 86 TC7525-16D 使用说明书 installation height, it is necessary to dismantle at first the counter-weight from the counter-jib. 1.4.2.2 拆卸平衡臂配重 Dismantle counter-weight from counter-jib 将小车固定在起重臂根部，借助辅助吊车拆卸配重。 Fix the trolley at the jib root and use the auxiliary crane to dismantle the counter-weight. 按装配重的相反顺序，将各块配重依次卸下，仅留下一块 4. 0t 的配重块。 Dismantle the counter-weight piece by piece in the sequence opposite to counter-weight mounting.
  • Page 87 TC7525-16D 使用说明书 1.4.2.6 拆卸塔顶 Dismantle tower head 拆卸前，检查与相邻的组件之间是否还有电缆连接。 Before dismantling, check the tower head to see if component-to-component is still connected by power cable. 1.4.2.7 拆卸回转塔身 Dismantle slewing tower 1.4.2.8 拆卸回转总成 Dismantle slewing tower assembly 将爬升架的换步顶杆支承在塔身上， 然后拆掉下支座与爬升架和塔身的连接再用吊索 将回转总成吊起卸下。 Support the lug changing rods of climbing frames on the tower body and then dismantle the connection of the slewing ring support with the climbing frame and tower body.
  • Page 88 TC7525-16D 使用说明书 Dismantle tower struts. 3) 拆卸基节。 Dismantle base sections 4) 拆卸十字梁。 Dismantle cross beams 1.4.3 塔机拆散后的注意事项 Attention after tower crane dismantling 1) 塔机拆散后，由工程技术人员和专业维修人员进行检查、维修保养。 The dismantled crane needs to be checked and maintained by technical personnel and trained maintenance personnel. 2) 对主要受力的结构件应检查金属疲劳、焊缝裂纹、结构变形等情况，检查塔机各...
  • Page 89 TC7525-16D 使用说明书 第二篇 塔机的使用与维护 Part Ⅱ Operation and Maintenance 第一章 塔机安全操纵规程 Chapter Ⅰ Safety Operation 2.1.1 司机与起重工 Crane operator and hoisting signalman 2.1.1.1 必须严格执行 ZBJ80012-89《塔式起重机操作使用规程》的有关规定，司机 与起重工必须是按劳动人事部门有关规定进行考核并取得合格证者。 The trained crane operators and hoisting signalman are required to strictly follow the regulations as specified in The Operating Instructions for Tower Crane. 2.1.1.2 司机必须了解所操作塔机的工作原理，...
  • Page 90 TC7525-16D 使用说明书 Commanding signals, hand gestures and flag signs shall conform to the specifications. 2.1.1.8 司机必须认真做好起重机的使用、维修、保养和交接班的记录工作。 Operators are required to carefully operation and maintenance of the crane, as well as to keep work shift-changing records. 2.1.1.9 严禁司机酒后上机操作。 It is prohibited that the operator is drunk, ill or tired on working. 2.1.2 机械部分及其它...
  • Page 91 TC7525-16D 使用说明书 停机修理或维护保养时，必须切断总电源，不许带电作业。 Switch off the main power supply when the crane operation is to be stopped for repair or maintenance. No operation with power on. 地面、楼台、施工面要设专人指挥塔机作业，与司机联络，必须规定严格的信号或手 势，旗号等，最好采用步话机联络。 Dispatch special persons at the ground, platform and construction work face to direct crane operations and contact the operator.
  • Page 92 TC7525-16D 使用说明书 During crane working, avoid the hoisting hook touching the ground, causing rope on the wire drum in an irregular order. If the hook has to be on the ground, pay attention to drum rope arrangement when it rises again. Make a regular rope arrangement if necessary. 2.1.2.12 紧固在载重小车侧面的吊篮是供维修使用的，...
  • Page 93 TC7525-16D 使用说明书 有漏油现象，要及时处理； The operator is required to carry out routine maintenance and oiling of the speed reducer, pulley, bearing seat and anti-drop device. If oil leakage is found, remove the defect immediately. 2.1.2.18 司机在正式作业之前，必须逐项检查各安全装置的可靠性，绝不允许在安全 装置失灵的情况下勉强作业； Before normal operation, the operator is required to carry out item-by-item checks of various safety guards for reliability.
  • Page 94 TC7525-16D 使用说明书 2.1.2.22 每次顶升加节或降塔减节时，须对加强节的踏步及液压顶升系统的顶升横梁 进行检查。 When adding or lowering down the tower sections every time, it is necessary to check the climbing lugs and the beam of the Climbing Mechanism. 2.1.3 高强度螺栓的使用和检查 Routine check of high-strength bolt 2.1.3.1 高强度螺栓安装前的准备 Preparations of high- strength bolt before tower erecting 塔身和回转总成的高强度连接螺栓使用前必须检查，检查时须用煤油等清洗剂对螺...
  • Page 95 TC7525-16D 使用说明书 中联公司的高强度螺栓均可以多次使用，但必须达到 2.1.3.1 和 2.1.3.2 的要求。 The high-strength bolts can be used many times, but agreed with the requirements of the above item 2.1.3.1 and the item 2.1.3.2. 2.1.4 钢丝绳的检查 Routine check of wire rope 2.1.4.1 起重机械中的钢丝绳是易损件。缺乏维护是钢丝绳寿命短的主要原因之一。 The wire ropes used in hoisting machinery are easily-worn parts. Lack of proper maintenance is one of the causes for their short service life.

  • Page 96: 第二章 机构及电气操作

    TC7525-16D 使用说明书 第二章 机构及电气操作 Chapter Ⅱ Mechanical and Electrical operation 2.1 电气安装与使用 Electrical mounting and operation 2.2.1.1 电气安装 Electrical mounting 2.2.1.1.1 电气安装应在低塔安装完毕后进行， 参看电气原理图， 外部接线图及控制箱 接线图，连接各控制及动力电缆，制动器电缆，及安全装置，接地装置，障碍灯，探照灯， 风速仪。 Electrical erection shall be conducted after completion of tower crane erection at low-level in reference to the electrical principle diagram, external wiring diagram and wiring diagram in control cabinet, connection of controls to the power cable, braking cable, safety devices, earthing devices, aerial lights and anemometer.
  • Page 97 TC7525-16D 使用说明书 Place all cab controls at safe positions. Place the main switch at the power-off position. Finally connect the power cables on the ground. 2.2.1.2 通电调试 Power-on test run 2.2.1.2.1 将地面电源开关合上， 送电到司机室检查三相电源应三相平衡， 且电压应为 380V±10%（地面电网应能提供足够的容量，以保护电机正常启动和运转） 。 Switch on the power switch on the ground to supply power to the operator cab. Check 3-phase power supply for balance.
  • Page 98 TC7525-16D 使用说明书 的开关送电，插座上也有电，可供插风扇之用。 After power supply to the operator cab (before pneumatic switch on), power for the aerial light and lighting in operator cab can be supplied through switches on the control panel. The sockets are also available for fan plugs. 2.2.1.3.2 按启动按扭时，各操作手柄必须归零位，总接触器才可得电自保。...
  • Page 99 TC7525-16D 使用说明书 No free adjustment of the time-delayed relay and over-current relay in the control cabinet, they have been adjusted in the factory as specified. Any component replacements should be conducted according to the instructions for the electrical system. 2.2.2 塔机各机构 Working mechanisms of the tower crane 起重机的工作机构包括：起升机构、回转机构、小车变幅机构及顶升机构，分别简介...
  • Page 100 TC7525-16D 使用说明书 The model of hoist mechanism for the tower crane is QP1675, and the motor (YZPB（F） 280M-8) is a frequency converter motor, equipped with draft fan, with the function of high-speed light-load hoisting and low-speed heavy-load hoisting. The minimum stable speed is smaller than 10m/min to ensure stable hoisting and braking of objects.
  • Page 101 TC7525-16D 使用说明书 回转减速机为脂润滑（000 号润滑脂） ，在维修或油位因渗漏而下降时，应及时补充 润滑脂，保证润滑脂液面达到油位螺塞的位置（减速机上部堵塞） 。 The reducer of the slewing mechanism is lubricated with grease(000# grease), When maintained or the level of oil dropped, supplements grease in time to guarantee the level of grease arrive at the bolt of oil. 1.电动机...
  • Page 102 TC7525-16D 使用说明书 1.电磁盘式制动器 Brake 2.电动机 Motor 3. 卷筒 Drum 4.摆线针轮减速机 Reducer 5.支架 Support 6. 限位器 Limiter 图 2.2-3 变幅机构传动示意图 Fig.2.2-3 Transmission System of Trolley Driving Mechanism 2.2.2.4 顶升机构（图 2.2-4） Climbing Jack (shown as Fig. 2.2-4) 该顶升液压系统由泵站、顶升油缸、高压软管及专用液压油组成，它可顶升和下降塔 机爬升架以上部分，并可使其停留在任何位置，以便塔身加强节的装拆。 The hydraulic system consists of pump station, climbing jack, high-pressure hose and special oil.
  • Page 103 TC7525-16D 使用说明书 2.2.2.4.1 顶升液压系统的主要参数（液压系统原理参见图 2.2-5） （详见顶升液压系统使用 说明书） Main parameters (System principle is shown as Fig. 2.2-5) (Please refer to the operation instructions of hydraulic system) 液压泵站主要技术参数表 Main Parameters of pump station 表 2.2-1 Table 2.2-1 油 Oil Requirement 工作压力 流 量 电机功率...
  • Page 104 TC7525-16D 使用说明书 3) 系统的排气 Air exhausting of the system 启动电机，拧松油缸上 A 口（或 B 口）高压胶管接头，移动手动换向阀 3 的手柄（以 下简称操作手柄）于上升（或下降）位置，使液压油进入管内，将空气从 A 口（或 B 口） 溢出，直至油液从接头处流出且无气泡时为止，然后拧紧高压胶管接头。油缸空载时推动 操作手柄， 让油缸活塞杆全行程上下运动几次， 将油缸内的空气通过油管挤入油箱而排尽。 Unscrew the handle of overflow valve, and then the high-pressure hose-to-port A connector. Move the handle of hand-operated valve to its up position. Start the motor to drive the air out of Port A until the pump noise has become normal and no foam formation from oil liquid.
  • Page 105 TC7525-16D 使用说明书 Keep on screwing down the handle of the overflow valve until the readings on pressure gauge have become stable at 31.5 Mpa. Screw down the locking nut in front of the regulating handle of the high-pressure overflow valve (The overflow valve shall not be adjusted by unauthorized or untrained person).
  • Page 106 TC7525-16D 使用说明书 求，必须用手提过滤机循环过滤 4～6 小时，清洁度指标达到 7～8 级（NAS1638） ，方可 开机使用。 At this time it is a high-pressure hydraulic system with strict requirements of highly cleaned oil, which should be filtered for 4~6 hours by hand –hold filter. The oil cleanness should reach 7～8 ,NAS1638 before starting the system. d.

  • Page 107: 第三章 安全保护装置

    TC7525-16D 使用说明书 第三章 安全保护装置 Chapter Ⅲ Safety Protecting Devices 塔机安全保护装置主要包括：行程限位器和载荷限制器. 行程限位器有：起升高度限位器，回转限位器和幅度限位器； 载荷限制器有：起重力矩限制器，起重量限制器，此外还包括风速仪。 The safety guards of tower crane consist mainly of the travel limiter and load limiter. The former consists of the hook height limiter, slewing limiter and trolley travel limiter. The load limiter consists of the hoist moment limiter and overload limiter.
  • Page 108 TC7525-16D 使用说明书 2.3.1.1.4 拧紧 M5 螺母（螺母一定要拧紧，否则将产生记忆紊乱） ； Screw down M5 nuts (be sure of screwing them down, otherwise foul-up memory will occur). 2.3.1.1.5 空载反复运行数次，验证记忆位置是否准确（有误时重复上述调整） ； Make the mechanism operate under no-load condition again and again several times to check memorized positions for accuracy (repeat the above adjustments in case of deviations) 2.3.1.1.6 确认位置符合要求，紧固...
  • Page 109 TC7525-16D 使用说明书 特别注意：在更换钢绳后一定要重新调整高度或变幅限位器，否则可能导致吊钩冲 顶，钢丝绳张断，造成机毁人亡严重后果。 Especially Note: After changing wire rope, it is necessary to adjust the height limiter or the slewing limiter again. Otherwise the hook may crash the trolley and the wire rope breaks, which will lead to the crane destroying and people death. 2.3.1.3 回转限位器调整方法(调整程序同...
  • Page 110 TC7525-16D 使用说明书 to turn the memory cam (1T) to enable the micro-switch (1WK) for action. (Enable simultaneous overlap of the cam (3T) to the cam (1T) to avoid speed reduction interference before braking). Screw down M5 nuts. Drive the trolley to the position of 220mm away from the jib tip.
  • Page 111 TC7525-16D 使用说明书 Corresponding moment will give warnings and cut off the power for the crane up and trolley outward-travel, thus playing the role in moment limiting protection. 3.2.1 力矩限制器的调整(钢丝绳四倍率) Adjustment of Moment Limiter (wire rope at 4-fall) 3.2.1.1 定码变幅调整 Adjustment of constant load and variable radius of trolley travel: 75m 起重臂长吊重...
  • Page 112 TC7525-16D 使用说明书 load 6.58t～6.9t, he jib length is 60m, hoisting load 6.71t～7.04t, the jib length is 55m, hoisting load 7.02t～7.37t, he jib length is 50m, hoisting load 7.36t～7.73t, he jib length is 45m, hoisting load 7.66t～8.04t, he jib length is 40m, hoisting load 7.86t～8.25t. 上述动作要求重复三次，保持功能稳定。...
  • Page 113 TC7525-16D 使用说明书 jib then loading 7.66t, 40m jib then loading 9.51t), trolley travels outwards from 20m, at the range of 65m～68m radius,（the range is 60m～63m when the jib length is 70m, the range is 55m～58m when the jib length is 65m, the range is 50m～50mwhen the jib length is 60m, the range is 45m～48m when the jib length is 55m, the range is...
  • Page 114 TC7525-16D 使用说明书 小幅度校核：75m 臂长塔机在 25m 幅度处（70m，65m，60m，55 m，50m，45 m 臂长在 30m 处）以正常工作速度起升额定起重量 8.96t（70m 臂长吊重 7.70t ，65m 臂长 吊重 8.01t，60m 臂长吊重 8.17t，55m 臂长吊重 8.54t，50m 臂长吊重 8.94t，45m 臂长吊 重 9.29t，40m 臂长吊重 9.51t） ，力矩限制器不应动作，允许起升。放下重物，然后以慢 速起升 9.4t（70m 臂长吊重 8.08t，65m 臂长吊重 8.41t，60m 臂长吊重 8.58t，55m 臂长吊 重 8.97t，50m 臂长吊重 9.39t，45m 臂长吊重 9.75t，65m 臂长吊重 9.98t） ，力矩限制器应 动作，不能起升。...
  • Page 115 TC7525-16D 使用说明书 Note: 2,4,6,8 are microswitches，1,3,5,7 are screw adjusting devices. 图 2.3-3 起重量限制器 Fig.2.3-3 Hoisting weight limiter 3.3.1 高速档调整 1）吊 8000kg，吊钩以低、高二档速度各升降一次，不允许任何一档产生不能升降现 象; Hoist 8000kg with the hook to travel up and down at low speed and high speed one time each.
  • Page 116 TC7525-16D 使用说明书 16500kg 之间时低速档不能运行。接近小值较为理想。 Repeat all actions mentioned in the Items 1), 2), lifting 16 tons load, and the hoisting mechanism can run at low speed. Lifting the load about 16000～16500kg, the hoisting mechanism cannot run at low speed, at this time, the load gains ground on 16000Kg that is ideal.
  • Page 117 TC7525-16D 使用说明书 图 2.3-4 防扭装置 Fig.2.3-4 Anti-twist Device...

  • Page 118: 第四章 保养与维修

    TC7525-16D 使用说明书 第四章 保养与维修 Chapter Ⅳ Service and Maintenance 为确保安全经济地使用塔机， 延长其使用寿命， 必须做好塔机的保养与维修及润滑工 作。 To ensure safe and economic operation of the tower crane for a longer service life, it must be properly maintained and lubricated. 4.1 塔机的保养 Tower crane maintenance 4.1.1 经常保持整机清洁，及时清扫。...
  • Page 119 TC7525-16D 使用说明书 paint is striped (in 45° oblique strings. Trace the cause immediately and dress the issue in time. 4.1.10 塔身各处 （包括基础节与底架的连接） 的连接螺栓螺母， 各处连接直径大于 Φ20 的销轴等均为专用特制件，任何情况下，绝对不准代用。 Inspect the connecting bolts and nuts of tower sections, including the connection of Undercarriage tower section and undercarriage. The parts with the diameter of connecting pin bolts of more than Φ20 are specially-made, no substitutes shall be replaced under any conditions.
  • Page 120 TC7525-16D 使用说明书 4.2 主要故障及排除方法 Main troubles and troubleshooting 4.2.1 一般性故障及排除 Ordinary troubles, troubleshooting and solution 表 2.2-3 Table 2.2-3 序号 故障现象 故障原因 解决方案 Trouble Troubleshooting Solution 减速器温度过高 润滑油缺少或过多 注意适量增减油量 Reducer temperature Lubrication oil deficient or excessive Properly increase or decrease oil is too hot 主要是润滑脂过量或太少；...
  • Page 121 TC7525-16D 使用说明书 Jacking drop when balance valve of the cylinder head Remove trouble, replaces sealing parts loaded b. 油缸活塞密封损坏 Piston sealing of oil cylinder is damaged 1. 操作手柄没归零 Operation handle not returned to zero 1. 将手柄归零 Return handle to zero. 2.
  • Page 122 TC7525-16D 使用说明书 1. 定子电流, 如大于额定值要减小 负载 Measure stator current, e.g. decrease 1. 负载过大 load if heavier than rated value. Load excessive 2. 按规定进行运行 2. 负载持续及工作不符合规定 Operate as required. Load continuing and work not as specified 3. 测量三相电流, 排除故障 3. 两相运行 Measure 3-phase current to remove 2-phase operation troubles.
  • Page 123 TC7525-16D 使用说明书 减速器中各滚动轴承 钙基润滑脂 Rolling bearings in Calcium-based grease 每工作 160 小时，适当 the reducer. 加油, 每半年清除一次 卷筒轴承 ZG-2 滚动轴承 Grease the bearings each Drum bearing Rolling after they work for 160 Bearing 吊钩止推轴承 hrs，Clean them once 钙基润滑脂 Hook bearings after half a year. 回转支承装置...
  • Page 124 TC7525-16D 使用说明书 工作 200 小时增添部分 液压顶升 清洁油， 工作 2400 小时 泵站 后完全更换油 美国 ESSO 公司 AW46 油箱 Pump Add filtered grease after American ESSO AW46 Oil tank station of working for 200 hrs ， hydraulic and change the grease erection after working for 2400 hrs.
  • Page 125 TC7525-16D 使用说明书 塔机各部件润滑记录表 Table for Parts Lubrication 表 1 Table1 序号 零部件名称 润滑部位名称 润滑剂种类 润滑方法及周期 润滑人 润滑日期 Parts Description Lubricating location Lubricant specifications Lubricating method & duration Lubricated by Lubricating date 每工作一周涂润滑脂一次，每大中修 起升钢丝绳 石墨钙基润滑脂 时煮油。 Hoisting rope 钢丝绳 Graphite Calcium-based grease Grease the rope after working for a Wire rope 变幅钢丝绳...
  • Page 126 TC7525-16D 使用说明书 润滑日期 序号 零部件名称 润滑部位名称 润滑剂种类 润滑方法及周期 润滑人 Lubricating Parts Description Lubricating location Lubricant specifications Lubricating method & duration Lubricated by date 冬季：钙基润滑脂 ZG-2 每工作 1500 小时，换油一次。 Winter：Calcium-based grease ZG-2 电动机轴承 所有电动机 Change the grease after working for Motor bearing All the motors 夏季：钙基润滑脂...
  • Page 127 TC7525-16D 使用说明书 续表 1 Continuation Table 1 序号 零部件名称 润滑部位名称 润滑剂种类 润滑方法及周期 润滑人 润滑日期 Parts Description Lubricating location Lubricant specifications Lubricating method & duration Lubricated by Lubricating date 制动器杠杆系统 每工作 56 小时用油壶加油一次 铰点 各个铰点 机油 Articulated points All the articulated points Machine oil Fill oil after working for 56 hrs of brake lever...
  • Page 128 TC7525-16D 使用说明书 塔机部件检查记录表一 Table 1 for Parts check 表 2 Table 2 序号 零部件名称 检查周期 备注 检查人 检查日期 部件状况及处理方法 Parts Description Checking duration Notes Checked by Checking date Parts state and method to settle 塔身、起重臂、回转支承、起重 臂刚性拉杆、 平衡臂拉杆、 卷筒 联接螺栓、 刹车制动器及换倍率 器等主要关键部位的销轴，...
  • Page 129 TC7525-16D 使用说明书 塔机部件检查记录表二 Table 2 for Parts check 表 3 Table 3 序号 零部件名称 检查周期 备注 检查人 检查日期 部件状况及处理方法 Parts Description Checking duration Notes Checked by Checking date Parts state and method to settle 特别是基础以上的三节塔身节螺栓 （未安装附着架 塔机） 或最上一道附着架附近的上两节下一节塔身 安装高强度螺栓的连接套及附 节螺栓（安装附着架的塔机）以及塔顶和回转塔身 近的母材，塔顶和回转塔身...
  • Page 130 TC7525-16D 使用说明书 续表 3 Continuation Table 3 序号 零部件名称 检查周期 备注 检查人 检查日期 部件状况及处理方法 Parts Description Checking duration Notes Checked by Checking date Parts state and method to settle 先一周二次， 再一周一 次，两周一次，然后一 月一次 Check all bolts 2 times 每年内拆下 2～3 组螺栓检查其变形、腐蚀等情况 高强度螺栓...

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