MODEL ZQD100
MOBILE TRUCK LOADING EQUIPMENT
FOR SACKED CEMENT
OPERATION MANUAL
The People’s Republic of China
Tangshan Zhongyi Machinery Co., Ltd.
Address：NanKai Road of High-New Technical Area,TangShan,HeBei,China
Telephone：(0086) 0315-3855782 3853580
Fax：(0086) 0315-3857682
Postcode：063020
E-mail：
Contents
Ⅰ. General
Ⅱ. Use and application scope
Ⅲ. Operation principle
Ⅳ. Main construction
Ⅴ.Note to operation
Ⅵ. Safety operation points for attention
Ⅶ. Main technical data
Ⅷ. Installation
Ⅸ. Unloading trial operation
Ⅹ. Maintenance
Ⅺ. Drawings for contour construction
Ⅻ. Annexes
Electric schematic drawings
Ⅰ.General
Model ZQD100 Mobile Truck Loading Equipment for Sacked Cement is a new generation of handling truck loader developed by Zhongyi Company on the basis of advanced technology imported from Germany. This equipment is possessed of high efficiency, saving energy and power, its economic benefit is more than tenfold than truck loading by manpower, its advanced technology and good functions are approved by more users, and it is the 1st selection in truck loaders for sacked cement of modern cement enterprises.
Meanings of model code:
ZQD 100 – L1/ L
Max. Handling length of feeding material m
Stroke of truck loading equipment m
Loading capacity t/h
Code of truck loading equipment
Ⅱ. Use and application scope
1. Use: Model ZQD100 Mobile Truck Loading Equipment for Sacked Cement is a key equipment used in truck loading process of cement producer to load sacked cement. This equipment is possessed of so high automatic degree that one person may complete truck-loading process. This equipment may also be used in industries of chemical fertilizer, grain etc, for handling and track loading of sack packed products.
2. Application scope；
2-1 Mains：AC380v-15%~+10%, 50HZ
2-2 Operation environment；
（1）Temperature：-10~40℃
（2）Relative humidity：<90%
（3）Height above sea level：≤2000m
2-3 Cement sack：accord with GB9774-96 standard
2-4 Truck：max. loading length 12 m
Height of truck is less than 3.8 m
Ⅲ. Operation principle
Sacked cement is handled from crosswise conveyor to the feed belt conveyor of model ZQD100 Mobile Truck Loading Equipment for Sacked Cement through unloading deflector, and then it is further handled by feed belt conveyor and out-feed belt conveyor to the tray at end of out-feed belt conveyor to be unloaded for truck loading. The operator controls unloading positions and stacking height with one hand, and he also adjust unloading height of out-feed conveyor and longitudinal position of whole machine with another hand, thus complete truck loading process.
Only unloading sacked cement from crosswise conveyor drops onto the feed conveyor belt, can truck loading operation be secured during model ZQD100 Mobile Truck Loading Equipment for Sacked Cement travels longitudinally. Each feed conveyor of truck loader may receive unloading bag from one to two crosswise belt conveyors, so the effective length of feed conveyor must be considered during ordering truck loader.
Longitudinal traveling distance of model ZQD100 Mobile Truck Loading Equipment for Sacked Cement,i.g. traveling distance of truck loader must be selected according to type of truck. carriage of truck is normally 7~12 m long, so 7~11 m longitudinal travel distance is enough in selecting truck loader, handling distance of feed belt conveyor is 7~18 m (it is considered according to that an feed conveyor receives sacked cement from one to two crosswise belt conveyors.)
Ⅳ. Main construction
Model ZQD100 Mobile Truck Loading Equipment for Sacked Cement is consisted of 5 parts of cantilever beam, feed conveyor, out-feed conveyor; traveling mechanism and electric control system.
1. Cantilever beam
Cantilever beam is equipped with a electric control cabinet, a set of traveling mechanism, and hoisting-luff device which is connected to feed conveyor and out-feed conveyor at its tail. The hoisting-luff device is used to lift out-feed conveyor up and down.
2. Feed conveyor
Feed conveyor is used to handle sacked cement from crosswise conveyor into the out-feed conveyor, feed conveyor is consisted of drive-device, drive roll, redirecting roll, take-up, and belt etc.
Drive device of feed conveyor is motor-reducer used to drive feed conveyor and out-feed conveyor through sprocket and chain
3. Out-feed conveyor
Out-feed conveyor is used to handle sacked cement from feed conveyor into truck, a hanger and pulley are erected at head end of out-feed conveyor and it is connected to hoisting-luff device on the cantilever beam through wire rope. Out-feed conveyor is lifted up and down for the sake of sacked cement unloading realized hoisting-lutt device. The operator may control operation of truck loader by two sets of pushbutton at left and right at the bead of out-feed conveyor.
4. Traveling mechanism
Traveling mechanism is consisted of main traveling mechanism, auxiliary mechanism, speed reducer and chain transmission mechanism. Planetary cycloid pin gear reducer is selected to drive traveling mechanism through chain transmission that power auxiliary mechanism for traveling foreword or backward.
5. Electric control system
Electric control system is used to control switch, various action and safety protection of each part of the whole truck loader, control cabinet is erected on the cantilever beam and another two pushbutton cases are erected at either side of out-feed conveyor. The lower pushbutton case is erected at a suitable place beneath truck loader for convenient operation by the operator before he steps onto truck loader. Regarding to exact positions of erection and other executing elements, layout of wires, in detail, see electric schematic drawings.
Ⅴ. Note to operation
When the truck parks at loading position waiting for loading, operator may operate the machine by pushing the lower pushbutton. Firstly, push traveling control pushbutton, let the end tray at out-feed conveyor stopped one meter above and ahead of the track, and then push hoisting-luff button, let out-feed conveyor move to a suitable position. This time, the operator may step onto the truck and start the feed conveyor for truck loading. Stacking height of sacked cement may be realized by pushing the luff button that may lift the out-feed conveyor up and down. With the increment of sacked cement on the truck, push the traveling button in succession let track loader moves backward until the truck is fulfilled. When truck loading is completed, shutdown feed conveyor at once and lift higher the out-feed conveyor and turn off the mains, then truck loading is completed.
Ⅵ. Safety operation points for attention
1. Every component must be checked for normal operation during relieving a shift to see whether the upper and lower limits are effective.
2. Hoisting rope of electric hoist must be often checked, if breaking or damage occurs, that must be replaced.
3. Loading conveyor must be lifted to a suitable height by the charging operator before or after vehicle loading that is convenient for driving in or out of the vehicle. Charging operator standing on the conveyor is prohibited during lifting the conveyor.
4. The machine must be shut down to adjust sacked cements if the sacked cement can not normally fall onto the loading conveyer.
5. Brake is not allowed to be adjusted, checked or repaired during truck loader is under operation and retainer can not be used to shut down the machine.
6. Operators must master various safety knowledge, working or standing under loading conveyors are prohibited.
Ⅶ. Main technical data
Main technical data of Model ZQD100 Mobile Truck Loading Equipment for Sacked Cement(see annex table)
Ⅷ. Installation
1. Laying railway track
Laying railway track for truck loader, model P18 apron track is used for tuck loader, immersed irons of 150X100 are prepared along railway track of civil foundation with intervals of 500 mm. The rails are supported by two wedge and the rail is need to be leveled and aligned with a transit and the wedge is welded to the rails by spot welding. Concrete technical requirement: straightness of top surface of rail is less than 1/1500 of total length; two rails must be parallel; inner distance of two rails is 1250 mm; center of rails must be coincident with the center line of the loader, and deviation must be less than 3 mm; relative level error between two rails is less than 1 mm, longitudinal gradient of rails is less than 1/1500 of total length; deviation of connectors is less than 0.5mm.
2. Installation ofModel ZQD100 Mobile Truck Loading Equipment for Sacked Cement
Model ZQD100 Mobile Truck Loading Equipment for Sacked Cement is divided into 3 parts for transportation and erected at site. After it is handled to the site, feed conveyor and cantilever beam is erected on the rails, one end of out-feed conveyor put on the building floor, another end put on the trough position first, and then erect hoisting steel rope. Finally, hoist out-feed conveyor with tripod and connect out-feed conveyor, cantilever beam and feed conveyor with connecting plate, thus the basic installation is completed.
3. Installation of electric devices
Connect wires of various device according to electrical schematic drawings, lifting of out-feed conveyor and traveling of the whole machine are controlled by push the inch button and they are respectively possessed of limit devices. Conveying section of model. ZQD100 Mobile Truck Loading Equipment for Sacked Cement must be concertedly operated (linked or interlocked) with crosswise conveyor and upper handling equipment (terminals are remained in this machine) i.e. only after conveying equipment be started; while conveying section of truck loader is shut down and the upper handling equipment is shut down simultaneously to avoid unloaded sacked cement pile up. Longitudinal limit location of mobile truck loader for sacked cement may be defined according to the location of crosswise conveyor and limit switch may be erected.
Ⅸ. Unloading trial operation
After electrical equipment is installed, unloading trial operation should be conducted as follows;
1. Luffing and lifting functions of out-feed conveyor must be stable; if it travels up to the limit positions, safety devices must act smoothly.
2. Model ZQD100 Mobile Truck Loading Equipment for Sacked Cement must stably move along longitudinal direction. If the limit switch acts when the machine travels up to limited positions, the machine may automatically stop and the blocks must be firmed and stable.
3. There is no misalignment of belt and abnormal noise along conveyors, linked operation of belt conveyors must be stable without abnormal conditions.
4. The above mentioned unloading trial operation must be conducted for more then 5 times.
Ⅹ. Maintenance
1. Conveyor belt must be often checked during operation of model ZQD100 Mobile Truck Loading Equipment for Sacked Cement, if abnormal conditions such as misalignment, looseness etc. occurs, adjustment must be conducted in time.
2. Belt damage by metal or hard matter is strictly forbidden.
3. The machine must be periodically lubricated, bearings of driving roll and redirecting roll may be annually filled with lime grease during maintenance.
4. Lubrications of hoister and cycloidal pin gear reducer motor may be conducted according to original operation manual.
5. In order to secure safety production, Model ZQD 100 Mobile Truck Loading Equipment for Sacked Cement must be protected with fenders around it.
Ⅺ. Drawings for contour construction
Drawings for contour construction see drawings for contour construction and foundation layout of Model ZQD 100-L1/L Mobile Truck Loading Equipment for Sacked Cement.
Ⅻ. Annexes
Technical parameter of ZQD100 Mobile Truck Loading Equipment for Sacked Cement
Descriptions / Unit /Technical parameter
/ RemarksModel / ZQD100-7/7 / ZQD100-7/15 / ZQD100-11/11 / ZQD100-11/18
Suitable matter / Sacked cement (Chemical fertilizer; Grain) / Kg/sacked < 60
Load capacity / t/h / 100 / 100 / 100 / 100
Max. travel distance / m / 7 / 11
Feed conveyer / Width of belt / mm / 650 / 650 / 650 / 650
Length of belt / mm / 15000 / 31000 / 23000 / 37000
Conveying speed / mm/s / 1000 / 1000 / 1000 / 1000
Driving roll diameter / mm / 320 / 320 / 320 / 320
Driving power / Kw / 3 / 3 / 3 / 3
Out-feed conveyer / Width of belt / mm / 650 / 650 / 650 / 650
Length of belt / mm / 16600 / 16600 / 16600 / 16600
Conveying speed / mm/s / 1000 / 1000 / 1000 / 1000
Driving roll diameter / mm / 215 / 215 / 215 / 215
Pitch angle / º / 5--35 / 5--35 / 5--35 / 5--35
Height of moving header / m / 3.15 / 3.15 / 3.15 / 3.15
Speed of moving header / m/min / 8 / 8 / 8 / 8
Power of winding motor / Kw / 3 / 3 / 3 / 3
Running mechanism / Inner distance of two rails / mm / 1250 / 1250 / 1250 / 1250
Running speed / m/min / 11.84 / 11.84 / 11.84 / 11.84
Max. Compressive force of wheel / KN / 12 / 12 / 12 / 12
Recommend rail / P18 / P18 / P18 / P18 / 18kg/m
Motor power / Kw / 1.5 / 1.5 / 1.5 / 1.5
Wheels / Piece / 6 / 10 / 8 / 10
Overall size / Length / m / 16 / 24 / 20 / 27
Width / m / 1.5 / 1.5 / 1.5 / 1.5
Height / m / 1.5 / 1.5 / 1.5 / 1.5
Total installed capacity / kw / 7.5 / 7.5 / 7.5 / 7.5
Supply voltage / V / 380 / 380 / 380 / 380