Tunnel waterproof board laying formwork

Trolley length	L = 3400 mm (car track spacing)
Trolley walking speed	6m/min
Level adjustment amount	none
Hydraulic system working pressure	P=12MPa
Track center distance	8000mm ± 5mm
Maximum stroke of the cylinder	vertical cylinder 300mm

Tunnel waterproof board laying formwork is a non-standard product specially designed and manufactured for the lining of various tunnels and culverts. The whole roll of tarpaulin is hung on the trolley; the bottom end of the tarpaulin is fixed, the tarpaulin can be automatically unfolded, and the tarpaulin can be stopped at any position of the track at any time; and the reverse function is also provided. It can greatly save the labor cost of hanging tarpaulin.

The working process of the tunnel waterproof board laying formwork is carried out in the following steps:

First step

Check whether the tunnel construction conditions meet the design requirements of the tunnel waterproof board laying formwork:

Since the tunnel waterproof board laying formwork is a non-standard equipment, the conditions of use must meet the design requirements before use.

Check whether the road surface elevation and road surface condition meet the design requirements, the road surface elevation: as shown in the figure; the road surface condition: concrete road surface.
Check that all the bolts of the trolley are tight, and check whether the trolley, pulley, winch, etc. are firmly installed.
Check whether the sleepers and rails meet the design requirements;
Check if the circuit meets the design requirements;
Check if the tarpaulin is hung (it will not fall off and can rotate freely).

Second step

Hanging tarpaulin：

The tunnel waterproof board laying formwork walks to the position where the tarpaulin needs to be hung. Hang the tarpaulin in the following steps:

Lift the entire roll of tarpaulin onto the work platform and drive the car to the working platform.
Remove the shaft between the carts and put the tarpaulin on the shaft.
Operate the winch to adjust the trolley to the position of the shaft.
Connect the shaft to the trolley firmly. Tarpaulin installation completed

Third step

Install tarpaulin：

Operate the winch to walk the trolley to the bottom end of the track;
Unfold the tarpaulin, connect and fix the end of the tarpaulin with the tarpaulin reserved by the inverting arch;
Operate the hoist to move the trolley up to the top of the next position that needs to be fixed, and go back some, fix the tarpaulin, and push it in.
Hang up a tarpaulin on the work platform after the tarpaulin is used up.

Fourth step

Walking：

After hanging a lap of tarpaulin, first close the gantry support jack and start the walking motor to walk. Tunnel waterproof board laying formwork should pay attention to the following points when walking:

The tarpaulin of the trolley cannot be connected to the tarpaulin already installed.
Tunnel waterproof board laying formwork must be completely static before you can change direction.

When the slope of the rail is too large, and the trolley is slipping, you can sprinkle some dry sand onto the rail surface to increase the adhesion and make the slip phenomenon disappear.

Repeatedly circling the tarpaulin, installing the tarpaulin, and walking, the entire operation of the Tunnel waterproof board laying formwork was completed.

Precautions：

Before each work cycle, check whether the rail is straight and check the tightness of the rail. Before the trolley is in place, it is necessary to straighten the rails and strictly prevent the phenomenon that the gantry support jacks cannot be supported on the rails.
After each work cycle, check the tightness of the bolts and pins of each part, and re-inspect and tighten the various joints.
The trolley walking mechanism and the jack should be regularly buttered.
The hydraulic system should be free of leakage. The hydraulic oil should be clean. The pressure gauge switch should be opened during operation to observe the fluctuation of pressure at any time.
When the tunnel waterproof board laying formwork is walking, pay attention to obstacles such as air ducts and water pipes on the ground to prevent the towing phenomenon when the trolley is walking.
For the safety of you and others, please operate the trolley according to the specifications and be diligent in maintenance to prevent all accidents.

Electrical part description

It is necessary to introduce a three-phase four-wire power supply, otherwise the leakage circuit breaker will not function as a leakage protection trip.
The green indicator on the panel of the power distribution box is the power indicator.
Oil pump motor thermal relay setting current: 11.6A.

Hydraulic system component table

Hydraulic system component table

NO.	Name	Specification type	Unit	Quantity	Remarks
１	Lifting cylinder	YGJDK-160/90F	article	４
２	Translation cylinder	HSGK-100/55E8501	article	0
3	Multiple way reversing valve	DLF-B15F-T/3C8P	Piece	１
4	Oil pump	PFE-XP-F320CFP	Piece	1
5	Throttle valve	LA-H10L	Piece	4
6	Oil level gauge	YWZ	Piece	1
7	Oil filter	ZV-A40	Piece	1
8	air filter	QVQ3	Piece	1
9	Motor	Y132S-4B3	Piece	1	５.５kw
10	Pressure gauge	Y60	Piece	1	0—25Mpa
11	Pressure gauge switch	KF-L8	Piece	1

Electrical component table

Electrical component table

NO.	Name	Specification model	Unit	Quantity	Remarks
1	Leakage circuit breakers	NM10-100/330-100A	One	1
2	Fuse	RT14	One	2
3	Fuse core	RT14-20	One	2
4	Contactor	JT1-40A/38W	One	2
5	Motor	Y132M2-6	station	4	1.1KW
6	thermal relay	JR36-63 45A	One	1
7	Indicator light	AD11	One	3
8	Button	LA19-11	One	4
9	Distribution box	500x400x200	station	1

Regular maintenance of the trolley

Regular maintenance of the trolley (first-class maintenance)

Job project	Technical requirements and instructions
Walking system	Drive chain and grease
Various bolts	There should be no looseness or slippery phenomenon
Various jacks, cylinders	Should be in the working size position when working
Walking mechanism (when walking)	Smooth transmission, no abnormalities
Check the joystick (no load)	It should be easy to operate, accurate in position and reliable in positioning
Electrical control system	According to the electrical instructions
Hydraulic system
Check the amount of oil in the hydraulic tank	The amount of oil is sufficient
Check each tubing connector	No leakage, no aging
Check oil temperature	The oil temperature is maintained at 30-70 during operation. C

Routine maintenance of the car

Routine maintenance of the car (secondary maintenance for 15 cycles per work)

Job project	Technical requirements and instructions
Complete a maintenance project other than the maintenance work at this level
Jacks, work platforms	The jack rotates flexibly, the hinges must not be deformed, and the working platform should be stable and firm.
Machine
Check each bolt	Should be fastened without slipping
Weld of the gantry and upper arch	No cracking, otherwise it should be repaired
Overall size inspection	Height, width and clearance should be within the tolerance of the drawing design size
Next cycle rail laying inspection	Before each cycle, check whether the rail is horizontal, parallel and accurate, and whether the gauge is accurate. Whether the tunnel lining center and the gauge center are within the error tolerance.
Electrical control section	The working voltage is 380V, the voltage is stable, and no leakage is allowed.
Hydraulic system
Check the hydraulic system control components	Is it in a controllable state
Check each pipe and pipe joint	No leakage
Check system tightness	Eliminate leakage
Cleaning filter	Clean
Detect oil temperature	The oil temperature is at work 30-70^。C

The routine maintenance of the trolley

The routine maintenance of the trolley (three-stage maintenance, 30 cycles per work)

Job project	Technical requirements and instructions
Complete the second guarantee project other than the maintenance work at this level
Electrical control section	The working voltage is 380V, the voltage is stable, and no leakage is allowed.
Hydraulic system
Replace hydraulic oil, oil filter	After cleaning the fuel tank, add anti-wear hydraulic oil
Debug system pressure (under no load)	Ensure that the oil pressure reaches the rated pressure of the pump
Debug lift cylinder base	Should be flexible, the maximum amount of translation must not exceed 80mm

Note:

The whole tunnel waterproof board laying formwork design reference book:

Steel Structure Design Code

Technical Rules for Construction of Railway Bridge Tunnels and Lining Works;

Most parts of the trolley are non-standard parts.
The walking distance of the whole machine is short and the speed is slow. In the tunnel construction, if the deformation of the steel structural parts does not occur, no overhaul is required.

Hydraulic system installation, use, maintenance instructions

1. Inventory all parts and match the packing list.
2. Check if the fuel tank is clean, cover the fuel tank cap, and add 115 liters of clean YA-N46 hydraulic oil from the tank air filter.
3, according to the requirements of the cylinder layout
(1) Before welding the pipe, the burr of the pipe head should be removed, (with a round file), and the high-pressure wind blows the debris inside the pipe.
(2) The welded pipe should be aligned, welded, and not allowed to leak oil.
(3) Pipe the pipe according to the requirements of the pipe, install all the gaskets, rings, and clean the debris in the pipe.
(4) Connect the multi-way reversing valve and cylinder to the pipeline (the mechanical lock cylinder must be connected to the left and right valves of the multi-way reversing valve).
Note: There are no 1, 2 hoses.
1. Jog the motor to check the motor steering and start the oil pump to test each cylinder (the pressure has been adjusted at the factory). If the system pressure is not established (the cylinder does not move), first check whether the joints of the pipes are leaking oil, and if necessary, exclude them. Then adjust the relief valve to see the pressure from the pressure gauge is 12MP. After adjusting, close the pressure gauge switch and pay attention to the oil level.
2. Clean the oil filter element frequently and remove the filter debris. Replace it when it is blocked.
3. After the first refueling, replace the new oil in three cycles, and then change the hydraulic oil condition irregularly. It is recommended to replace the new oil in 30 cycles.

Fault phenomenon	Reason	Approach
The motor does not start properly	1. The circuit fuse is broken 2. The thermal relay normally closed contact JR is not reset 3. Normally closed contact bad contact 4. Poor contact or break between the start and stop buttons	1, replace the fuse 2, reset the contact to close it 3, repair contacts 4, connect the line, repair button point
One of the positive and negative buttons can control the motor and the other cannot control the motor.	1. There is a button contact in the anti-control button. 2. There is an interlocking normally closed contact in the positive and negative control buttons.	1, repair contacts 2, repair the contacts, make it closed
No positive or negative buttons can be activated	1. The reverse contactor coil is damaged. 2. The thermal relay normally closed contact is not reset. 3. Check if the power supply and plug are loose. 4. Check if the stop button is damaged or if its line is connected.	1,replace the contactor coil 2, reset pad relay normally closed contact 3,inspection, replacement 4,inspection, replacement

Tunnel waterproof board laying formwork