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Assembly instructionsRedundant systems in the KBK crane construction kit
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Original assembly instructionsManufacturerDemag Cranes Components GmbHP.O. Box 67
58286 Wetter (Germany)
Telephone +49 (0) 2335 92-0
Telefax +49 (0) 2335 92-7676www.demagcranes.com
Email: [email protected]
Further documents are available for sub-assemblies/components in addition to these assembly instructions. If required, the
corresponding documents are supplied or can be ordered separately, even if special designs or additional options differing
from these assembly instructions are ordered.
Documents1 Ident. no.Technical data/catalogues KBK crane construction kit, project engineering and components 202 976 44
Redundant systems in the KBK crane construction kit 203 334 44
Operating instructions Assembly Adjustment Dimensions Operating instructions/component parts, KBK installations 206 076 44Tab. 1
1) The documents can be ordered from the relevant Demag office.2 211
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Table of contents
Foreword .....................................................................................................................................................................4General........................................................................................................................................................................4
Safety ..........................................................................................................................................................................5General........................................................................................................................................................................5
Intended use................................................................................................................................................................5
Hazards that can be caused by the redundant systems .............................................................................................5
Technical description...................................................................................................................................................6Description ..................................................................................................................................................................6
Transport, packing, scope of delivery, storage............................................................................................................7
Assembly .....................................................................................................................................................................8Track suspensions ......................................................................................................................................................8
Crane suspensions......................................................................................................................................................9
Selection table.............................................................................................................................................................9
Crane suspension on single trolley ...........................................................................................................................10
Crane suspension on double trolley (KBK I, KBK II, KBK III, Aluline) ....................................................................... 12
Redundant system for the single trolley ....................................................................................................................12
Redundant system for the connecting rod.................................................................................................................13
Putting into service for the first time ..........................................................................................................................14Safety instructions when putting into service for the first time...................................................................................14
Inspection regulations ...............................................................................................................................................14
Disassembly, disposal ...............................................................................................................................................15General......................................................................................................................................................................15
11.1
22.1
2.2
2.3
33.1
3.2
44.1
4.2
4.2.1
4.2.2
4.2.3
4.3
4.4
55.1
5.2
66.1
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1 Foreword
1.1 GeneralThe redundant systems in the KBK crane construction kit are supplied as component parts, partly packed in bags.Before beginning assembly, check that the delivery is complete using the enclosed shipping papers. These as
sembly instructions are intended to provide the user with instructions for safe and appropriate assembly.
Every individual given the task of transporting, installing, commissioning, maintaining and repairing the redundant
systems must have read and understood
the assembly instructions,
the safety regulations and
the safety instructions in the individual chapters and sections.
The operating instructions of the installation must be available to the owner / operator at all times in order toprevent operating errors and to ensure smooth and trouble-free operation of our products.
Our KBK crane construction kit document Tab. 1, Page 2provides information on combining individual components and assemblies to create cranes and runways. In particular it includes the technical description of the
KBK systems. The document is a supplement to these assembly instructions.
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2 Safety
2.1 GeneralThe "Safety" chapter provides an overview of all important safety aspects for safe and trouble-free assembly ofthe redundant systems in the KBK crane construction kit.
At the time of their development and manufacture, the redundant systems in the KBK kit were built according togenerally accepted engineering standards and are considered to be safe to operate. However, the redundant sys
tems in the KBK kit may still be a cause of danger if they are not fitted correctly or as intended by suitably trained
personnel.
Knowledge of the contents of the assembly instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to fit the redundant systems in the KBK kit.
Any conversions, modifications or additions to the redundant systems in the KBK kit are prohibited unless approved by Demag in writing.
2.2 Intended useRedundant systems in the KBK kit are used where they are intended to prevent immediate crashes in the case of
broken or loose components.
Please also note the information in the operating instructions of the installation.
No liability for structural modificationsThe manufacturer is not liable for any unauthorised structural modifications which have not been agreed in advance. This also includes incorrect connection of the installation to attached or connected equipment which is not
part of our scope of supplies and services.
2.3 Hazards that can be caused by the redundant systemsA risk assessment has been carried out for the redundant systems. The design and execution based on this analysis corresponds to state-of-the-art engineering principles. However, residual risks remain.
WARNINGCrushing hazard, shearing hazardAdjustment work may be necessary when the redundant systems in the KBK kit are assembled; parts of thebody may be crushed or sheared.Assembly may only be carried out by trained specialist personnel.
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3 Technical description
3.1 DescriptionRedundant systemsRedundant systems prevent immediate crashes in the case of broken or loose components.
Quasi-redundant systemsThe majority of KBK subassemblies are already redundant owing to the assembly structure.
Other components perform additional load bearing functions in the case of an accident, partially at overload, how
ever, without a crash.In principle multiple bolted connections can be considered to be redundant, since in the case of broken or loos
ened bolts the emergency properties of the other bolts are applied.
In the KBK system safety nuts are used which provide a high degree of safety against loosening.
Mode of operationIf a redundant system is triggered (failure of a component), the installation does not necessarily have to be opera
tional by using the redundant components.
It suffices that the accident is noticed and no crash or injury occurs.
Inspection and maintenanceRedundant components are subject to the same inspection and maintenance schedules as the other KBK compo
nents.
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3.2 Transport, packing, scope of delivery, storageSafety instructions
WARNINGFalling partsRisk of injury from falling parts during transport, loading and unloading operations. Do not walk under the suspended load. Keep a sufficient safety distance.
Cordon off a large area around the working zone.
WARNINGDamage caused during transportThe redundant systems in the KBK kit may be damaged or destroyed by inappropriate transport.Transport the assemblies and parts with appropriate care.
Transport inspection Check the delivery to ensure it is complete and for any transport damage immediately on receipt.
If any transport damage is visible from the outside, do not accept the delivery or only on condition. Note thescope of damage in the shipping documents/delivery note of the forwarding company. Lodge a claim.
Lodge a claim for any defects as soon as they are detected, since claims for damages may only be assertedwithin the relevant claim notification periods.
PackingIf no agreement has been made on the return of the packing material, separate the material according to type and
size and make it available for further use or recycling.
Environmental protection:
Always dispose of packing material in an environmentally friendly manner and in accordance with local dis
posal regulations.
Contract a recycling company, where required.
Scope of deliveryIf special designs or additional options are ordered or the latest technical modifications are incorporated, the ac
tual scope of supply may differ from the data and information as well as from the illustrations described here. Ifyou have any questions, please contact the manufacturer.
StorageUntil they are installed, the redundant systems in the KBK kit must only be stored under the following conditions:
Do not store outdoors.
Store in dry and dust-free places, relative air humidity: max. 60%.
Do not expose to aggressive media.
Protect against direct sunlight.
Avoid mechanical vibrations.
Storage temperature: -20 to +70 .
Avoid strong temperature fluctuations (condensation).
Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
protection.
If stored in damp locations, the installation parts must be packed tight and protected against corrosion (desic
cant).
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4 Assembly
4.1 Track suspensions
Fig. 1
Designation KBK 100 KBK I KBK II KBK III AL 120 AL 180Max. SWL 1700 kg
Rope connector completeWeight [kg] 0,5
Part no. 984 428 44
Wire rope 6,5 8x19 + SES SZWeight [kg/m] 0,175
Part no. 583 440 44
Suspension clampWeight [kg] 0,3 0,2 0,8 0,8 0,3 0,8
Part no. 984 550 44 980 260 44 982 260 44 850 260 44 517 770 46 N 517 772 46 N
Tab. 2
The redundant system for the track suspension consists of:
Rope connector (1) with two rope sockets (1a) and rope wedges (1b),
Rope clamps (2),
Rope (3) and
Suspension clamp (4).
The rope is fitted next to the suspension fitting as a catching rope.
The rope connector connects the two rope ends and acts as an additional damping element in the case of dam
age. The rope clamps serve as securing elements.
The wire rope length must be determined in accordance with the required loop length.
Wire rope length = 2 x length of threaded rod + 2 x girder height + Flange width + 500 mm
Tab. 3
First fit the suspension clamp on the rail close to the track suspension fitting max. distance 300 mm.
Then lead one end of the rope over the supporting structure, whereas the second end
- is lead through under the screws of the suspension clamp for KBK I and II
- or, for Aluline and KBK III, is lead through under the suspension clamp.
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Fig. 2
Push the first rope end through the small opening of the rope socket,
place it around the rope wedge and push it through the large open
ing of the same rope socket.
Now press the rope wedge with the rope placed around it into the
rope socket.
The free end must protrude from the rope socket by at least 50 mm.
Carry out the same assembly step with the second rope end on the
other side of the rope socket.
For adjusting the length, make sure that the rope is loose enough to avoid any restriction of the movement of flexible suspensions and that it is lead close enough to reach a max. falling height of 50 mm.
Finally fit the rope clamps on the free ends of the rope. The distance to the rope socket is 20 mm. Tightening
torque 3 5 Nm.
CAUTIONDanger of falling by inappropriate assemblyThe rope clamps must not be fitted in the load-supporting area of the rope.
4.2 Crane suspensions4.2.1 Selection tableCrane runway KBK I KBK II KBK I KBK II KBK I / II KBK I / II KBK III KBK IIICrane KBK I KBK I KBK II KBK II KBK I KBK II KBK III KBK IIIWeight [kg] 0,7 0,8 1,3 1,4 1,0 2,0 4,5 7,5Part no. 517 580 46 N 517 581 46 N 517 582 46 N 517 583 46 N 517 584 46 N 517 585 46 N 517 590 46 N 517 592 46 NOverhang Umin[mm] 70 70 120 120 180 240 155 315Trolley E E E E D D E D
Crane runway AL 120 AL 180 AL 120 AL 180 AL 120 / 180 AL 180 / 120
E = Single trolley
D = Double trolley
Crane AL 120 AL 120 AL 180 AL 180 AL 120 AL 180Weight [kg] 0,8 0,9 1,5 1,6 1,1 2,2Part no. 517 778 46 N 517 779 46 N 517 780 46 N 517 781 46 N 517 782 46 N 517 783 46 NOverhang Umin[mm] 40 40 50 50 150 185Trolley E E E E D D
Tab. 4
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4.2.2 Crane suspension on single trolley
KBK I, KBK II, Aluline
Fig. 3
The redundant system for the crane suspension on KBK I, KBK II, Aluline single trolleys consists of:
Catching plate (1),
Suspension clamp (2) and
Long pin (3) for single trolley.
The standard trolley pin is not needed.For Aluline, first slide the catching plate into the crane girder in such a way that after assembly it is located within
the crane track. Fit the crane suspension fittings to the crane girder in accordance with the operating instructions.
Slide the trolley through the opening of the catching plate (1) and fit the long pin (3) in the trolley. The two roll pins
serve as pin securing elements.Then fix the free end of the catching plate with the suspension clamp (2) on the crane girder between the crane
runways in such a way that the catching plate surrounds the single trolley and the pin without making contact.
CAUTIONWear by inappropriate assemblyIn order to ensure functioning of the redundant system, check after assembly whether free movement of the
crane bridge, the crane suspension fitting and the trolley is ensured.
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KBK III
Fig. 4
Item Designation Item Designation Item Designation1 Catching plate 4 Nut with plate 7 M16 screw2 Washer 30x45x5 5 Washer 17x30x3 8 Suspension clamp
3 M16 nut 6 Washer 17x40x6
Tab. 5
The redundant system for the crane suspension on KBK III single trolleys consists of:
Catching plate and
Suspension clamp with component parts.
First fix the M16 screw (7) in the suspension clamp (8) with a tightening torque of 120 Nm. Observe the sequence
of the washers (5 + 6).
In the second step, pre-assemble the suspension clamp with catching plate (1) without tightening in accordance
with the drawing and then slide it into the crane girder in such a way that it is positioned within the crane track.
Then fit the crane suspension fitting in accordance with the operating instructions.
Connect the trolley with the two installed assemblies by means of the connecting rod. Make sure that the cranesuspension fitting is suspended centrally in the trolley, while you push the catching plate (1) with washer (2)
through one of the two smaller outer openings of the trolley.
The suspension clamp of the redundant system can then be aligned on the crane girder and be tightened with the
M8 screws, tightening torque 25 Nm. Finally fix the nut with plate (4) and the nut (3) on the screw threading and
counter-lock the nuts. The plate should not contact the catching plate.
CAUTIONWear by inappropriate assemblyIn order to ensure functioning of the redundant system, check after assembly whether free movement of thecrane bridge, the crane suspension fitting and the trolley is ensured.
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4.2.3 Crane suspension on double trolley (KBK I, KBK II, KBK III, Aluline)
Fig. 5
Item Designation Item Designation1 Catching bracket 2 Suspension clamp
Tab. 6
The redundant system for the crane suspension on double trolleys consists of:
Catching bracket and
2 suspension clamps.
Before sliding the trolley into the crane runway, first suspend the crane suspension fitting in the double trolley and
then fix it on the crane girder.
In the case of Aluline, make sure that the catching bracket (1) is also pushed into the profile section.Carry out assembly in accordance with the operating instructions.
Then fix the catching bracket on the crane girder in such a way that the centre of the catching bracket is posi
tioned above the centre of the double trolley without making contact. Tightening torques of the suspension clamps
in accordance with the operating instructions.
Finally move the trolley into the crane runway.
CAUTIONWear by inappropriate assemblyIn order to ensure functioning of the redundant system, check after assembly whether free movement of thecrane bridge, the crane suspension fitting and the trolley is ensured.
4.3 Redundant system for the single trolley
Fig. 6 KBK II single trolley with redundant link bar (A), KBK II articulated frame (B), Aluline 180 single trolley with redundant link bar (C), Aluline
180 articulated frame (D)
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Designation KBK I KBK II AL 120 AL 180Redundant link bar
Weight [kg] 0,6 1,0 1,2 2,0
Part no. 517 587 46 N 517 589 46 N 517 774 46 N 517 776 46 N
TrolleyWeight [kg] 0,7 1,2 1,5 2,2
Part no. 980 610 44 982 110 44 855 050 44 855 080 44
Tab. 7
The single trolley is turned into a redundant system by creating a double trolley. This can be done by using the
redundant link bar (1) or via the articulated frame (2).
4.4 Redundant system for the connecting rod
Fig. 7
Item Designation Item Designation1 Single trolley 3 Redundant rope
2 Redundant link bar 4 Articulated frame
Tab. 8
The redundant rope (3) of the chain hoist is either lead through the redundant link bar (2) for single trolleys (1) or
over the articulated frame (4) and fixed in accordance with Fig. 2, Page 9. For application in the crab frame, the
chain hoist can be secured in a similar way.
CAUTIONWear of the redundant rope results in loss of the additional safety function.In order to maintain the function of the redundant system, the following must be observed:
During assembly, make sure that the rope is not damaged by contact with the KBK rail or the edges ofsheet metal parts.
Check the redundant rope for damage at regular intervals and replace it, as required.
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5 Putting into service for the first time
5.1 Safety instructions when putting into service for the first timeWARNING
Unauthorised operationDanger to life and limb if KBK installations are operated without previous inspection.Carry out the inspection only in compliance with all safety regulations.
Please also note the information in the "Operating instructions/Component parts, KBK installations" Tab. 1,
Page 2.
5.2 Inspection regulationsPlease also note the information in the "Operating instructions/Component parts, KBK installations" Tab. 1,
Page 2.
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6 Disassembly, disposal
6.1 GeneralAssembly and disassembly are quite simple owing to the modular design of the crane construction kit.
WARNINGBefore disassembly, follow the safety instructions in the operating instructions of the installation, in particularthose with reference to protecting the ends of rail sections to be disconnected from dropping.
Refer to the operating instructions of the installation for information on removing track sections, trolleys and cur
rent collector trolleys. Other parts are removed in reverse order to assembly.
Waste materials left over from maintenance, repair and disassembly work must be disposed of correctly and ap
propriately in accordance with the relevant regulations and codes of practice.
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dinGermany
The current addresses of the sales offices in Germany and the subsidiaries and
agencies worldwide can be found on the Demag Cranes & Components homepage at
www.demagcranes.com/Contact
Demag Cranes & Components GmbH
PO Box 67 58286 Wetter, Germany
Phone +49 (0)2335 92-0
Fax +49 (0)2335 92-7676
www.demagcranes.com