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Operating instructions/component parts

1. Item no Index Component designation Item no Index Component designation 1 Straight section 39 Hexagon nut for suspension rod 2 Track joint bolt set 40 Ball head suspension rod 3 Conductor joint set 41 Suspension rod Conductor connector 42 Track suspension clamp Joint connector a Ball socket 4 Curved section b Suspension clamp side section pressure clamp 5 Drilling jig drill c Bolt 6 Internal buffer stop 43 Spring clip 7 End cap 44 Ball head bolt End cap bolted connection 45 Suspension short not adjustable End cap for busbar 46 V type upper suspension bracket e ergo end cap 47 V type suspension bracket 8 Powerfeed end cap a Filler plate for sloping surface 9 Line powerfeed 48 Suspension rod strainer 10 Power pick up guide 49 Hinged block 11 Maintenance section 50 Coupling for suspension rod b Reinforcing section 51 Packing plate for upper suspension bracket Protective cover 52 KBK II M10 suspension clamp d Swivel lock pin 53 Trolley attachment bracket with pin f Clamp 54 Pin g Center busbar section 55 Trolley h Warning plate a Side cheek 12 Current collector housing b Travel roller a DEL protective frame c Supporting washer e Engaging stirrup for
2. A B C KA DQM A 2 QS o gt o Lo o 0 o o o o o 2 q N Gi 43490344 xml eps Fig 51 A Long link bar required B TAA approach dimen C Consider overall height Tab 37 211 259 44 110414 211 259 44 110414 5 12 2 5 Fitting DRF 200 Position of the shims A B A Coupling sido D B Eye bolt side a Shims oN O Tab 38 TLL HL HL 43 El my U WARNING a Risk of damage to the machine if incorrectly fitted Pay special attention to correct arrangement of the dis ae tance washers and shims as shown in gt Fig 52 Page 59 Fig 52 and gt Fig 53 Page 59 Assembly of RF friction wheel travel drive with KBK Aluline trolleys 69a 69f 69c 69d 69e 69b 69d 70e 70f 70 70b 70d 42612245 xml eps Fig 53 1 2 3 4 5 6 Remove the 2 pins 69b and 69f of trolley 69a Connect the trolley to the friction wheel travel drive 70 using longer pin 69b Connect eye bolt 70e which guides the spring to the trolley using short pin 69f Undo nuts 70d to loosen dished washer pack 70b Slide the friction wheel travel drive into the KBK Aluline profile section Set the length of the dished washer pack to L 76 mm se
3. a Hinged block b RF hinged block c Articulated spacer bar Tab 41 Articulated spacer bar examples a b ee gt e A oo gt e 138 A 138 75 L 243 A 138 75 yx E d e Oe A E He L243 A 143 80 Vx o Os 42608151_xml eps Fig 58 Articulated spacer bar examples a Spacer bar on single trolley for b Spacer bar on double trolley for c Spacer bar on RF trolley one or Aluline A12 A16 Aluline A12 A16 both sides for Aluline A12 A16 d Spacer bar on single trolley for e Spacer bar on double trolley for f Spacer bar on DRF 200 friction Aluline A18 A22 Aluline A18 A22 wheel travel drive one or both sides for Aluline A18 A22 Tab 42 63 64 Spacer bar for Aluline A18 A22 straight track components a b 20 20 A 65 20 65 A 65 20 TE T tt ola o E o ela to lo seas O O 1 ee E ee 1 E 19 4 4 42608149_xml eps Fig 59 Spacer bar for Aluline A18 A22 straight track components a Spacer bar with one open end b Spacer bar with two open ends Tab 43 Examples of spacer bars for Aluline A18 A22 straight track components a px 265 65 42608152_xml eps Fig 60 Examples of spacer ba
4. Lubrication of articulated joints resin free grease 2 2 Straight and curved sec tions Dirt accumulation Wear on the track Wear of edges in rail section gap Rail gap width Aluline A12 A16 23 0 5 mm Aluline A18 A22 31 0 5 mm Replacement is necessary when the measured values are exceeded 2 3 Track bolted joint Bolted connections retighten as required fit of the adjusting pins Alignment of track joints End caps track buffers buffers on trolleys and cranes Secure attachment wear replace if worn Shock absorbers Secure attachment wear replace if worn Conductor rail system Supporting section Deposits Fixed point Maximum vertical and horizontal misalignment of 1 mm 3 2 Busbars Wear Burnt spots Corrosion Tight fit in PVC supporting channel 3 3 Busbar connectors Correct and tight fit of busbar connector and PVC supporting channel 3 4 Suspension Attachment 3 5 Power pick up guides Maximum horizontal misalignment 1 mm Attachment 3 6 Power feed Cable connection Fit of plug connectors 3 7 End cap Attachment 3 8 Isolating section Wear Dirt deposits Current collector trolley Sliding contacts and arms Wear max 7 mm up to the insulation Contact pressure Centring Mobility Attachment 4 2 Terminal strip
5. Crane trolley travel drive assembly and adjustment Crane girder suspension distance l as specified as for crane runway Easy movement and no unwanted forces at connections between components Component connections secured e g BoClip pin retaining device Buffers buffer plates Function check Power supply control Trailing cable moves easily and is not twisted Safe and reliable current collector contact Terminal designations arrangement of the phases All installation control fittings are firmly attached Leads cables laid properly Switches microswitches correct fuse links 5 Finalisation Inspection of the installation with the customer Demonstration of installation functions under realistic conditions verification of cycle times if required Acceptance and handover verified by signature Instruction of the operating personnel Hand over complete documentation Forward any changes to the design department so that the actual status of the installation is documented Tab 9 25 26 5 5 Component designations The components of the crane construction kit are all numbered The component item numbers are used to identify them in some of the texts in these operating instructions A list of all item numbers is provided below
6. 66 5 12 8 Buffer and impact plate on A18 A22 single trolley 43495944 xml eps Fig 63 The following parts can be attached direct to a A18 A22 single trolley e the stop plate e the rubber buffer e the cellular plastic buffer The assembly to be installed on the trolley can be pre assembled and introduced into the gap from above The nut is retained in position by its shape and the assembly can be secured Tighten the rubber buffer by hand Tighten the cellular plastic buffer and stop plate to a tightening torque of 45 Nm 211 259 44 110414 211 259 44 110414 5 13 5 13 1 5 13 1 1 Cable power supply lines Aluline power supply Fitting the trailing cable power supply 42612346_xml eps Fig 64 A power supply system between mains connection and hoist appliance consists of mains on off switch isolator 88 Fig 70 Page 70 fuses with inserts if required flat cable 84 cable sliders 85 or cable trolleys 86 cable clamps at rail end 83 on crane girder 80 Fig 66 Page 68 on crab frame 81 gt Fig 67 Page 69 on trolley for RF 82 Fig 68 Page 69 round cable for wiring on the crane bridge The following items of equipment are included in the basic electrical equipment for standard KBK electrics equipment sets terminal boxes and their fittings connecting cables
7. The hoist unit load handling attachment and load must be flexibly suspended Rigid connections cause uncon trolled forces to be transmitted and lead to fatigue fracture 73 5 14 3 Load bar for D BP Aluline A12 A16 42786846_xml eps Fig 75 Item Designation Item Designation Item Designation Load bar fixed point connector A pre fitted on the left as standard b vvaener E Supporting washers d Balancer e Protective tube AD 27 or AD 36 f Hose clip set 2 Tab 49 1 Position load bar a and secure it to rope balancer d Pay attention to the position of shims c 2 Connect the trolleys not included in the scope of delivery of the load bar Fit hose clip set 2 f 3 Secure protective hose e AD 27 or AD 36 for the supply lines 5 14 4 Handling device Depending on the model and size the handling equipment is fitted to a mounting plate which is bolted to the crab frame This work can be carried out when the crab is installed and before it is installed Refer to gt Tightening torques Page 24 for the tightening torques 74 211 259 44 110414 211 259 44 110414 5 15 Maker s plate and load capacity plate WARNING A 5 16 Overload Danger to life and limb Higher loads than those specified on the load capacity plate must not be handled The load capacity specified on
8. 2 2 2 3 Safety General information on safety The Safety chapter provides an overview of all important safety aspects for optimum protection of personnel as well as safe and trouble free operation of the installation When it is placed on the market the installation is built according to genetrally accepted engineering standards and is considered to be safe to operate It may still be a cause of danger if it is not used correctly or as intended by suitably trained personnel Knowledge of the contents of the operating instructions are one of the requirements necessary to protect person nel from hazards and to avoid malfunctions and therefore to operate the installation safely and reliably Any conversions modifications or additions to the installation are prohibited unless approved by Demag in writing Safety signs on the installation Any pictograms signs or labels on the installation must be obeyed and must not be removed Pictograms signs or labels that are damaged or no longer legible must be replaced immediately 43229046_xml eps Fig 1 Example Capacity plate Intended use The installation may only be used as intended and in compliance with the requirements for the owner and the following limitations as specified in these operating instructions Any other use may result in a danger to life and limb and or cause damage to the machine and or load e KBK suspension monorails suspension cranes are only inten
9. Cable connection 4 3 Connection cable Broken strands Insulation Strain relief 211 259 44 110414 211 259 44 110414 Item no Component Details to be checked Inspection intervals in months 3 6 12 44 Travel wheels and guide Wear tightness mobility rollers 4 5 Coupling Attachment m 5 Trolleys crabs and cranes 5 1 Trolley and trolley for Smooth operation wear and damage to the wheels 7 DRF 200 RF 125 Retaining pins m Suspension bolt wear max 1 mm n Side cheek wear max 0 5 mm Must be replaced when dimension value is exceeded Smooth running and wear of support rollers Sealing cover of guide rollers load bars crane trolleys crab frames n Wear of link bars coupling elements spacer bars n Free movement n Secure fit of the split sleeves Bolted connections between KBK Ergo n Trolley and end carriage End carriage and L shaped steel crossbar for fitting the mast mast bolted connection to L shaped steel crossbars 5 2 DRF 200 RF 125 friction see friction wheel drive operating instructions n n wheel travel drives Friction wheel contact pressure 5 3 Hoist unit See hoist unit operating instructions n 5 4 Current collector trolley See item 4 6 Electrical equipment on trolleys crabs 6 1 Contactor control Burnt contactor contacts m 6 2 Run up limit switch Swi
10. D MN DEMAS Operating instructions component parts KBK Aluline uspension So NS a 2 CSS o NS CACA AY XC VL Y Q A AS Qs a A ANNE VL wie VE J L EN y VE y cc gt o y Original operating instructions Manufacturer Terex MHPS Corp 29201 Aurora Road Cleveland Ohio 44139 Telephone 440 248 2400 Fax 440 248 3086 Internet http Awww demag us com Further documents are available for sub assemblies components in addition to these operating instructions The correspond ing documents are supplied as necessary or can be ordered separately also for special designs or if additional options are ordered which differ from these operating instructions Owner Where in use Crane type Year of manufacture Load capacity Crane serial number Chain hoist model code Chain hoist serial number Drawing number Operating voltage Control voltage Frequency Wiring diagram number Contactor control direct control Supplier Assembled by Signature Date Tab 1 i The metric system is used in this document and all figures are shown with a comma as the decimal separator 211 259 44 110414 211 259 44 110414 Table of contents 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 2 1 2 2 2
11. Structural dimensions for cranes crane runways and suspension monorails as well as load capacities and span dimensions are specified in the approval drawing and in the test and inspection booklet Hoist unit Please refer to the hoist document for all technical data such as dimensions weights permitted loads and tem perature ranges Control system A direct or contactor control system is used for control purposes In suspended operating position the control pendant is rated to IP65 according to DIN VDE Noise emission sound pressure level Please refer to the hoist unit or travel drive operating instructions Transport packing scope of delivery storage Safety instructions WARNING A Falling parts Risk 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 WARNING A Damage caused during transport The KBK installation may be damaged or destroyed by inappropriate transport Attach lifting and handling equipment only at the correspondingly marked points Transport inspection e Check the delivery to ensure it is complete and for any transport damage immediately on receipt e f any transport damage is visible from the outside do not accept the delivery or only on condition Note the scope of damage in the shipping documents delivery note of the forwarding compa
12. cable entries twist type cable entry glands nuts connecting elements wire end sleeves cable lugs sockets Ensure that the flat cable is not twisted along its length during assembly Firmly tighten all nuts and bolts at the cable fixing points 1 Select a cable length such that no additional tensile forces can act on the cable except where cable carriers cable sliders 85 or cable trolleys 86 are fitted Space the cable carriers at equal distances along the length of the cable The distance between the cable supports should be approx twice the length of the required sag of the cables Tighten the nuts on the cable trolleys so that flat cable 84 does nat slip through the cable supports Place the cable supports in track section 1 67 68 5 13 1 2 5 13 1 3 Connect the cable trolleys with strain relief cords to obtain good running characteristics Fix the cords in the trolley bore holes The cord length must be shorter than the cable Fitting the trailing cable power supply to cable trolleys with snap locks 86d A L 86e 86a 0009 43212345_xml eps Fig 65 Fitting buffer stops designed to be used only once Multiple use e g in the case of incorrect fitting is not possible il Note that cable brackets 86d and cable straps 86e are e Pulla cable strap 86e through the two lower slots of cable bracket support 86d e Space o
13. 211 259 44 110414 5 7 7 3 End cap with buffer shock absorber 43491044 xml eps End cap with buffer e Place pre assembled end cap c on profile section a in such a way that the buffer points into the rail section Insert the T head bolts into the slots of the rail section e Tighten nuts b with a tightening torque of 25 Nm Shock absorbers e Fit in the same way as for the cap with buffer 41 42 5 8 5 8 1 5 8 2 5 8 3 Internal conductors General In addition to the information given in gt Assembling a runway Page 28 attention must be paid to the details in the following sections Track section bolted joint 43208845_xml eps Fig 27 Connect the track sections as shown The busbar joint set consists of busbar connectors 3a and joint connector 3b Powerfeed end cap 43496244 _xml eps Fig 28 e All necessary parts for powerfeed end cap 8 are contained in the terminal box Assemble as shown above e Connect the conductors to the correct phases L1 to L4 211 259 44 110414 211 259 44 110414 5 8 4 5 8 5 End cap 43209345_xml eps Fig 29 Example KBK II R end cap Slide end cap 7b onto the busbar at the end of the track Then close the track with end cap with buffer 7 Curre
14. a ei a ee ee eb a tias 87 Required tests and inSPecti ns tc licita 87 S W P measures for achieving safe Working Periods ooocccnonnnnnncccnnonnnnonananonrnc cnn cnn norn cnn nan crrrnnnrrrrnnnnnrrrrrrnr 87 Maintenance schedule tica Ai 89 MAINTENANCE WORK ea a 91 General remarks on Maintenance WOKK ooconncccnnncnioccccnnonnnnnonnn ono nc nnnnn rn rr 91 Removing and replacing rail SECtIONS oonnnnninnnnnicnnnnnnnnnnncnnnacccnnrnn rro cnn rca rr 92 Crane suspension fittings with sliding shell track SUSPENSION fittidQS oooooonnnicnnnnnnnnnncnnnnncccnnnnnnnnrrccnnnrncnnnrrnnnn nn 92 Electric cabling and WiTIOD AE 92 Hoists units and travel drives ii A A A ish aah ele 92 Removing trolleys and similar items from long or closed trACKS eee ceeeeeeeseeeeceneeeeeeeeeeeeeeeeeeaeeeseeeeeeseeeeenaeeseeeaees 93 IKBIK Ee O ii ada 93 MAlTUNCIIONS lt lt caia a deg paa li A e eee hc Se add Ads iaa lis 94 9 1 10 10 1 11 11 1 11 2 Safety instructions in the event Of malfunctions eee ce cece eeeee cece cence eect e ee eeeee ae cee e ee aaaeeeeeeseaaeaeeeeecaeaeeeesesesaeeeeeeeees 94 Disassembly dispoSal cito ai datada dali 95 General information on disassembly diSpOSAl ooooocccononicinnccnnnocccnnonnnononnnnnnrncc nan nn nr nnn nn 95 Spare Parts oi anisi onn a aeee a EE a E a Aa aE a Ana Ea Aaa Aa N EENE Aaea aeae NAA E AAA aa aE aaan E daaa aak 96 General information ON Spare PartS nnciinnicinnnc
15. a travel unit can also be removed at a rail joint e Open a rail joint as described in gt Removing and replacing rail sec Bolted connection Size Tightening torque Nm KBK Aluline A12 A16 45 Trolley end carriage KBK Aluline A18 A22 130 End carriage stiffener plate 80 End carriage L shaped steel crossbar for fitting the mast 80 KBK Aluline A12 A16 10 Track suspension clamps KBK Aluline A18 A22 25 Suspension clamp 120 Tab 54 93 94 9 Malfunctions 9 1 Safety instructions in the event of malfunctions WARNING Inappropriate fault elimination Danger to life and limb Risk of damage to the machine Faults may only be eliminated by qualified instructed personnel Definition of personnel Page 9 in compli ance with the safety regulations DANGER Live components Danger to life and limb Work on electric equipment may only be carried out by qualified specialist personnel gt Definition of person nel Page 9 in compliance with the safety regulations Switch off the electric power supply before starting work The mains connection or isolating switch must be pro tected against unauthorized or accidental restoration of the power supply by means of a padlock WARNING Risk of burns Risk of burns from contact with the motors after operation of the installation Do nat touch hot motor housings Allow the motor to cool down before elmininating the fault Condu
16. 1x hose clip set 1 22 5 interval e for PG21 AD27 h KBK cable trolley with 2x hose clip set 1 Clamp section f for PG29 AD36 j Upper nut k Lower nut Tab 47 Hose clip set 1 can be used to attach hoses to all KBK cable trolleys which have M6 threaded pins at a distance of 58 mm apart Up to two hose clips can be fitted to a cable trolley Adjustment is possible at intervals of 22 5 if retaining plates a are used Hose clip sets have a clamping range for hose diameters from 18 mm to 36 mm 1 Turn upper nuts j up to fit hose clip set 1 to a KBK cable trolley 2 Raise retaining plate a and screw nuts k onto the ends of the threaded pins 3 Push retaining plate a against lower nuts k 4 Turn upper nuts j against it from above Hose clip set 2 a b c d e f max 12 ite N 36 41854246_xml eps Fig 74 a Retaining plate c d Clamp section f for PG29 AD36 b 22 5 interval e for PG21 AD27 g M6x25 hexagon head bolts Tab 48 Hose clip set 2 can be used to attach hoses to brackets or walls Adjustment is possible at intervals of 22 5 if retaining plates a are used Hose clip sets have a clamping range for hose diameters from 18 mm to 36 mm The enclosed M6x25 hexagon head bolts g are suitable for a clamping range up to 12 mm 211 259 44 110414 211 259 44 110414
17. 5 14 Suspending the hoist 5 14 1 Safety instructions for suspending the hoist WARNING A DANGER A Overload Danger to life and limb if the components are overloaded Select the correct load capacity for the hoist unit to ensure that the installation is not overloaded Incorrect direction of movement Danger to life and limb if the direction of movement is wrong The control devices must be checked for correct and proper operation following work on the main power supply and before work begins If the phases are not correctly connected the switching elements and limit switches may not function as intended The control device e g control pendant must be marked in such a way that the direction of movement is clear and distinct The arrow symbol on the switching elements must correspond to the direction of movement 5 14 2 Chain hoist If the KBK installation is operated with a Demag chain hoist the corresponding chain hoist assembly and operat ing instructions see Tab 2 Page 7 must be observed In particular the safety instructions must be observed and followed Attach the hoist correctly as follows 1 The hoist unit must be suspended in such a way that the opening for the electric supply line on the hoist unit points in the longitudinal direction of the track 2 Position the eyebolt between the trolley side plates insert the pin and secure it WARNING A Danger of falling load Premature wear of the KBK installation
18. Buffers Spring clips and split sleeves on suspensions Split sleeve retainer for pins on trolleys traverses crab frames limit switches BoClip retainer for pins on trolleys traverses crab frames limit switches Power supply Trailing cable power supply Integrated conductor line External busbar Power supply components and attachments Powerfeed end cap Maintenance section Current collector trolley Crane runway Track elements straight sections Joint bolts nternal buffer stop End cap with buffer nformation plates Suspension monorail Track elements straight sections Bolted connection rail connection nternal buffer stop End cap with buffer nformation plates Track suspension Suspension from structural beams Short suspension fitting Suspension from U bolt Suspension from ceiling rail sections Suspension from solid ceilings Track suspension from sloping superstructure stiffeners V type suspension arrangement V type suspension stiff ener arrangement Components for ceiling suspension Miscellaneous See relevant documents Further KBK Aluline crane construction kit documents gt Tab 2 Page 7 Tab 7 21 22 5 1 5 2 DANGER Assembly General assembly information These instructions enable the owner to install re install or replace KBK components and assembl
19. always be tightly bolted together with these sub assemblies KBK Ergo trolleys must not be used as single trolleys For KBK Aluline A18 A22 ergo the end carriages are provided with connection bore holes Buffer plates spacer bars drive units etc can be connected to the connection bore holes of the end carriages Assemble tandem crane end carriages from two single girder crane end carriages and one spacer bar KBK Aluline ergo A18 A22 trolley The distance between the counter pressure roller and the bottom edge of the profile section can be adjusted on KBK Aluline ergo A18 A22 trol leys The counter pressure roller and the load bearing rollers inside the pro o Y o file section should not be in contact with the rail at the same time The LO o counter pressure roller must be adjusted in such a way that there is an nd air gap of approx 0 5 mm when there is no load on the trolley This can be adjusted by loosening the bolt via the hexagon socket on A the eccentric axle 43495844 mieps Tighten the bolt again after adjustment Tightening torque 10 Nm Fig 41 51 5 12 2 Travel drives 5 12 2 1 General A B 42607946_xml eps Fig 42 Item Designation Item Designation Item Designation A RF 100 travel drive B RF 125 trolley C DRF 200 travel drive pneumatically driven el
20. clamps and the hinges of hinge sockets must be well greased Use resin free anti friction bearing grease lubricants containing molybdenum disulphide MoS must not be used The free movement of joints ball head rods hinged block short suspension hangers crane suspen sion fittings must not be restricted Lifting appliances load handling devices and loads must be flexibly suspend ed from the trolleys Rigid connections cause uncontrolled forces to be transmitted and lead to fatigue fracture Check that the cranes do not tilt when the load is suspended from an overhang section Ensure that all attachment points are freely accessible for inspections and servicing or that free access can be provided The control device e g control pendant must be marked in such a way that the direction of movement is clear and distinct The arrow symbol on the switching elements must correspond to the direction of movement A clearance check must be carried out after completing assembly Check for e smooth travel over track joints e safe and reliable current collector contact e smooth running of the trailing cable e safety distances to adjacent parts of the building machinery and similar items 75 76 6 Putting into service for the first time 6 1 Safety instructions when putting into service for the first time The installation may only be handed over when its safety has been verified by means of a corresponding check gt Checks on enterin
21. eeeeeceseeeeeeneeee cence eeaaeeeeeaeeeseeeeeesaeeeseaeenseneees 33 Upper suspension brackets A B and Suu eee eecceceeneeeeneeeeeneeeeeaeeeseeaeeeeeeeeeaaeeeseeaeeesaeeeeeaaeeseeaeessneeeesaeeesenaeeseeeeees 34 Transverse and longitudinal lateral stiffeners V type stiffeners oo eee eeeeeeeeeeeeeeeeeenaeeeeeeeeeeseeeseaaeeseeaeeeenaeeeseaas 36 KBK Aluline ergo track SUSPENSIONS 00 0 eee cence a E a E a A E A ea 38 Connectingtrack SECtONS circadiano 38 General remarks on connecting track sections ooooonniccccnnnccnnoninnnnccnnnrnnrnnnnn nn nor r nan rn rr 38 Track section bolted Joti A A AA eae eee 39 Buffer stop end cap With DU A A A a A Io 40 O 40 Internal butfer Stop ii de et ee Pe eel 40 End cap with buffer Shock absorber ccceecececce cee a aa e aa i a a alaaa 41 Internal conductors a SS ee 42 E A eee eee A i en eee 42 Track section bolted Joti A ee on ete ai Se he ce 42 Powert ed 6nd Gap ia Bea a ieee dee ee 42 EE Cicas siastoveas evhaiepaduaesQeptavies epiatceasa antes athes vaunted ahi esas gate E el eae 43 Current coll ctor trolley hi A Se Se ee en ee ee 43 Retrofitting CONGUCLONS tritio 44 External busbar iii ee Si ee Sen Ve i o aL aa aaa 44 US ee sacs ies sey dives in en reine EEN r E Ea eee ala 44 DGL Pro compact c nd ctor lihe sennie eed ee cite hich A Beit ete 44 Assembling SUSPENSION CANES ci pesgedsdulseeeetibeesendebsbebeeeseerseyeeeeees 45 Preparation WORK coito AO Ai 45 Single girder cr
22. ergo current collector trolley d Retaining ring Coupling e Ergo trolley 13 Emergency stop emergency off f Travel wheel 14 Manufacturer s plate g Socket head bolt 15 Capacity plate h Sleeve 16 Name plate i Crossbar 20 Track switch j Hexagon bolt 21 Turntable k Lock nut 22 Drop section Washer 23 Latching device m Washer 25 Upper suspension bracket n Split sleeve 26 Upper suspension clamp s Brake tape 27 U bolt 56 Pre assembled double trolley 28 Roof truss 57 Load bar 29 Anchor bolt sets 58 Load bar suitable for curves 30 Complete suspension with suspension rod 59 Load bar for travel on straight track 31 Complete suspension short adjustable 60 Load bar 600 with trolleys e ergo suspension fitting 61 Single trolley link 32 Packing plate 62 Rigid crane end carriage 33 Lock nut a Connecting member 34 Wall fixture b Clamp connection 35 Floor slab e Ergo crane end carriage 36 Cover for floor fixture plate 63 Frame for Aluline double girder crane 37 Split sleeve 64 Light duty trolley steel 38 Suspension rod drilling jig 65 Light duty trolley plastic Tab 10 211 259 44 110414 211 259 44 110414 Item no Index Component designation Item no Index Component designation 66 Traverse for double girder crane 90 Switch mounting plate 67 Raised crane traverse 91 Cable brack
23. immediately e To actuate the emergency stop press the button until it reaches the end stop It then locks automatically and the hoist unit is shut down e To unlock the actuated emergency stop turn the pushbutton in the direction of the arrows clockwise and re lease it Following an emergency stop do not switch the installation on again until a trained person is satisfied that e the cause which led to actuation of this function has been rectified and e continued operation of the machine constitutes no further hazard 83 84 7 5 7 5 1 7 5 2 7 5 3 Taking the equipment out of operation Taking the equipment out of service when faults occur The machine must be switched off immediately if the following faults occur e f electric devices and cables as well as parts of the insulation are damaged e Brake and safety device failure Taking the equipment out of service at the end of the shift The following measures must be taken when finishing work or leaving the working area e Position the hoist unit outside the travel area Deposit any load handling attachments such as grabs or magnets e Run the crane to the rest position if grabs or magnets are fitted e Actuate the emergency stop e Switch the hoist unit power supply off at the mains connection or isolating switch Taking the equipment out of service for maintenance and repairs 1 Switch off the mains connection switch or isolating switch before commencing maintena
24. must not be welded or drilled Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly manner 8 4 Regular inspections 8 4 1 Required tests and inspections WARNING Non compliance with operating and maintenance regulations Danger to life and limb Required tests and inspections must be carried out An annual inspection e g as specified in German accident prevention regulations UVV BGV D8 Sec tion 23 2 and BGV D6 1 must be carried out Adjustment maintenance and inspection activities and inspection deadlines including specifications con cerning the replacement of parts assemblies prescribed in the operating instructions must be observed This work may only be carried out by specialist personnel Cranes and equipment must be inspected by a specialist at least once a year Regular inspections mainly consist of a visual inspection and a function check which should include a check to determine the condition of compo nents and equipment regarding damage wear corrosion and any other safety devices Regular inspections must be carried out in accordance with BGV D6 and BGG 905 Principles for the inspection of cranes in Germany The results of inspections must be entered in a test and inspection booklet It may be necessary to remove parts in order to inspect wearing parts Load bearing media and suspensions must be inspected along their entire length including those parts which cannot
25. nsion of threaded rods ii A a e aN 30 U bolts cast into solid ceilings atsean ias 30 Suspension from ceiling SECtION FAIS 0 eee cece cence an a n A A R a a 31 5 7 2 7 5 7 2 8 5 7 2 9 5 7 2 10 5 7 2 11 5 7 2 12 5 7 3 5 7 3 1 5 7 3 2 5 7 4 5 7 5 5 7 6 5 7 6 1 5 7 6 2 5 7 7 5 7 7 1 5 7 7 2 5 7 7 3 5 8 5 8 1 5 8 2 5 8 3 5 8 4 5 8 5 5 8 6 5 9 5 9 1 5 9 2 5 10 5 10 1 5 10 2 5 10 2 1 5 10 2 2 5 10 3 5 10 4 5 11 5 12 5 12 1 5 12 2 5 12 2 1 5 12 2 2 5 12 2 3 5 12 2 4 5 12 2 5 5 12 3 5 12 4 5 12 5 5 12 6 5 12 7 5 12 8 5 13 5 13 1 5 13 1 1 Fastening upper suspension bracket A with threaded rods and counterplates to solid ceilings 31 Floor fixture platesnei Se siet e a deen ieee 31 Suspension with anchor bolt connection eee ee eee cence sent ee eect ee ceeeeeeaaeeeeeeeaeecaeeeesaaeeseeeeeeeaeeeseaaeseeeeeesseeeensaeeeeeneees 32 Suspension from inclined Steelworks scc escciesecneeecteccuseecvhendennscceevevhceasbectivedadeestihevtacdebeubstecsdocetvedenvnendivecsisdvsesevhlectes 32 Short suspension arrangement with height adjustment 2 eee eee ee center eeeeeeesaeeeseeaeeesaaeeseeaaeeseeeeeesneeeseaeeseeeeees 32 Vertical s spension from U Sections cit de ae ee ie ai 33 Special attachments for suspensions to technical data sheet 203 072 44 ooo eeeeceeeneeeeenneeeeeeeeeeneeeeeaeeeeeeees 33 Upper suspension bracket H for ceiling section rails Halfen ee eee
26. shown without motor and tensioning element i Ensure that the slots in split sleeves point outwards since otherwise they cause wear Fitting the pressure cylinder 43491344_xml eps Fig 46 Item Designation Item Designation Item Designation a Trolley j Connecting element m Fork head pin e Supporting washers k Spacer sleeves for short pins n Retaining plate g Short pin Tab 33 1 Remove short pin g from trolley a 2 Connect connecting element j and the trolley using short pin g The arrangement of connecting element j supporting washers e and spacer sleeves k can be seen in gt Fig 46 Page 54 3 Adjust the distance between fork head pin m and retaining plate n of the tensioning element factory set ting 40 mm 4 Ensure that there is no pressure in the cylinder 5 Slide the friction wheel travel drive into the KBK profile section Ensure that the slots in split sleeves point outwards since otherwise they cause wear 211 259 44 110414 211 259 44 110414 Fitting a counterweight 42638445 _xml eps Fig 47 Item Designation Item Designation a Counterweight b Disengaging cylinder Tab 34 RF 100 PN travel drives fitted with disengaging cylinder b and an articulated link bar require a counterweight a e Assemble the component parts for the counterweight a e Fit counterweight a to the side cheek of the RF 100 PN tr
27. span dimension D Height difference between the crane runway tracks 1 o of Ix however max 5 mm Tab 27 Only carefully assembled crane runways will guarantee smooth and problem free long and cross travel and a long trolley service life Danger resulting from incorrect assembly There is a risk that the crane and trolley may move under their own weight Unloaded crane tracks must not exceed the limit values given above If these values are exceeded the crane and trolley may move along the tracks under their own weight The crane runway suspended as described Assembling a runway Page 28 may have to be aligned Suitable for this are e levelling instrument e spirit level e transparent plastic tube filled with water to replace the spirit level e install a loaded trolley and observe the way it travels The threaded suspension rods with spring clip allow the following height adjustments to be made 9 mm for KBK Aluline A12 A16 classic 14 mm for KBK Aluline A18 A22 classic Ensure that all threaded suspension rods hang vertically and equally bear the deadweight of the crane runway After any adjustment there must be no vertical play in the threaded rods Suspension rod strainers 48 enable stiffeners to be aligned Fig 20 Page 36 30 mm for KBK Aluline A12 A16 40 mm for KBK Aluline A18 A22 Following adjustment of the stiffener there must be no vertical play in the threaded rods Following alignment check that the
28. stop 45 Nm KBK Aluline A12 A16 suspension KBK Aluline A12 A16 trolley fittings 85 Nm KBK Aluline A18 A22 bolted connection M12 80 Nm KBK Aluline A18 A22 trolley fittings M16 120 Nm KBK Aluline A18 A22 suspension Tab 8 Loose connections Loose connections are a danger to life and limb and a risk of damage to the machine Metal nuts featuring a locking element self locking nuts are mainly used for KBK installations They must not be replaced by normal nuts Self locking nuts must be replaced when they have been tightened and untightened five times Assembly checklist Order no Responsible for assembly Name Date Dept 1 Documents Installation assembly drawing circuit diagrams Operating maintenance instructions function description gt Tab 2 Page 7 Shipping lists schedule assembly checklist Test and inspection booklets conformity declaration gt Tab 2 Page 7 Verification of support structure foundation suitability 211 259 44 110414 211 259 44 110414 2 Tools Toolbox standard with set of HSSE drills Voltage tester extension cable Hand drill hand saw G clamps Torque wrench Suspension rod drilling jig part no 982 017 44 Spirit level hose water level laser Spray paint can 1 kg paint brush thinners Depending on the site Scaffolding ladders forkli
29. the crane bridge must match the load capacity of the hoist unit The load capacity plates must be attached to both sides of the crane bridge The permitted load capacity must be specified on the bottom block of monorail traveling hoists One maker s plate must be attached to each traveling hoist unit and one to each crane bridge For push travel hoist units the maker s plate on the hoist is sufficient Apply the adhesive load capacity and maker s plates to the track and press them firmly onto the rail section Safety and warning information in the form of signs labels and markings on the crane installation must not be removed or defaced They must be maintained in complete and legible condition Inspection following assembly WARNING A Falling parts Danger to life and limb if parts to be fitted are dropped Keep out of the danger zone at all times Keep a sufficient safety distance Wear protective equipment Check that spring clips are correctly fitted to the suspensions The spring clip must pass through the holes in the suspension rod and ball head suspension rod Only then is the connection secured against loosening If the sus pension rod and ball head suspension rod can be turned the spring clip is not correctly fitted Check to ensure that pin connections are correctly fitted The slots in split sleeves must face outwards otherwise they will cause wear The ball sockets of upper suspension brackets suspension
30. trolleys of the cranes and monorail hoists can be moved freely by hand over the entire length of the rail section without jamming KBK Aluline ergo 211 259 44 110414 211 259 44 110414 5 12 5 12 1 Any deviations from the specified crane span dimension must be smaller for KBK Aluline ergo than for KBK Alu line classic perm 1 mm Turn the threaded pin to adjust the height of a rigid suspension Height differences of 4 mm Aluline A12 A16 and 12 mm Aluline A18 A22 can be compensated After adjusting the height use the counter nut to secure the threaded pin against turning Following alignment check that the trolleys of the cranes and monorail hoists can be moved freely by hand over the entire length of the rail section without jamming Trolleys electric travel drives Trolleys trolley combinations 43490744 _xml eps Fig 40 If a single trolley link is used for KBK Aluline A18 A22 single trolleys replace the pin of the trolley with the longer pin of the single trolley link Fit the trolley pin in the vacant hole in the link Assemble tandem crane end carriages from two single girder crane end carriages and one spacer bar To make up multiple trolleys from single trolleys and load bars and or traverses remove the relevant pins Replace and secure the pins after assembly KBK Aluline ergo trolleys KBK Ergo trolleys are provided with bore holes to connect end carriages and crab frames They must
31. 10414 5 12 2 4 Fitting an RF 125 with an E22 drive E Ud CU 43211745_xml eps Fig 50 Please also refer to the E11 E34 DC travel drive document gt Tab 2 Page 7 1 2 10 Remove the pins from the trolley Connect rocker assembly 135 with tractor trolley 69 Use the long collared pin of the rocker assembly The long support pin of the trolley is not needed Place the flat head on the side to which the drive is to be attached Insert the spacer sleeves Undo the nut on the pressure spring to allow the rocker assembly to swing down Connect the fork section with the bolt to the tractor trolley using the short pin Ensure that the distance wash ers are correctly fitted Swing the rocker assembly back up into position and hand tighten the pressure spring and nut Slide the friction wheel travel drive into the KBK rail Open the E 22 drive Slide the drive shaft into the hub of the friction wheel and secure the drive using the bolts provided Tension the pressure spring to a length of 47 mm Refer to the E11 E34 DC travel drive document gt Tab 2 Page 7 for electrical connection and commis sioning The crane enclosure can be attached to the rocker assembly using the relevant mounting plate 57 Beware of collisions
32. 16 A18 and A22 Profile sections with internal conductor rails are designated KBK R All KBK components are produced as standardized series assemblies Standardized connection dimensions guarantee simple conversion or extension of your crane installation regard less of when it was made The simple pin and bolted connections between the individual elements facilitate rapid assembly All components and assemblies of the crane construction kit are described and their dimensions are specified in the KBK Aliline crane construction kit document and in the technical data sheets see gt Tab 2 Page 7 This document contains a general description of the crane construction kit information for project drafting and selec tion tables for suspension monorails and cranes It also includes part numbers and details for ordering these parts The possible sub assemblies and components used in a KBK installation are listed below Please refer to the KBK Aluline crane construction kit document for further information see Tab 2 Page 7 Example of a single girder crane 43490544_xml eps Fig 3 Item Designation Item Designation Item Designation 1 Track suspension 3 Crane bridge 5 Control system 2 Crane runway 4 Traveling hoist Tab 4 18 211 259 44 110414 19 VLVOLL V 6SZ LLZ 20 4 2 KBK suspension monorail suspension crane components Traveling hoist The traveling hoist assembly can co
33. 3 2 4 2 5 2 6 2 7 2 8 2 9 3 1 3 2 3 3 3 4 3 5 3 6 4 1 4 2 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 7 1 5 7 2 5 7 2 1 5 7 2 2 5 7 2 3 5 7 2 4 5 7 2 5 5 7 2 6 GONG Tal fetes stat nites nectar obli diia de ti 7 KBK MOUSE A A aa ade 7 KBK GOCUMONTS ia a A an 7 Symbols signal WOKS ci A and 7 Information on the operating instructions ooooonnnccninnninnncccnnnanonnncnnnn non cnnnn nn cnn nn n rana arrancar r ren rca nnnnann rra 8 Liability and Warranty ii 9 COP YTIQNE Aree ida ideada 9 Use of Spare parts cria A A Aire 9 Definition of Pers OM eliminarse 9 Test and inspection booklet viii daa 10 Aftersales SERVICE uc A A lcd io 10 A Hie ee eee RO E ei eee eR I ee 11 General information on Safety iii docs 11 Safety sighsS on the installation comicios it 11 Intended Use nenien a a A A dr 11 Hazards that can be caused by the installati0D oo nnoinnnnnncccnnnncconncncnnorcccnn arc rr nnrrnn nr arranco 12 Responsibility O the Qwnen ici A A aia 13 Operating personnel requirementS oonnconncccnnoncconoconanonnnonan ono nono cnn nan nr nn rn 14 Personal protection equipe diria da AA A le i eel 14 Em rgency stop Vi a 15 Regular InSpections ai iia a Si a AAA Ses Sees ee 15 Technicalidata omitido tian a aadi aae RE 16 KBK runwaySs crane girderS ci dea 16 Hoist Unit it A A A AA ad Oi sh es IA cas 16 Control SEM A eas AA ee ee a ee 16 Noise emission SOUNC pressure level oo eee cence eeeneeeceee
34. 44 KBK suspensions upper suspension bracket H S clamp S V 203 072 44 DS 1 winch 203 123 44 KBK Aluline crane construction kit 203 813 44 Technical data catalogues KBK anchor bolt connection 203 276 44 Redundant systems in the KBK crane construction kit 203 334 44 DCL Pro conductor line 203 751 44 DKK conductor line 202 540 44 DCL arrangement on KBK 203 510 44 DRF 200 travel drive 214 395 44 Operating instructions component DC Pro 1 15 chain hoist 214 741 44 parts DC Com chain hoist 214 802 44 D BP rope balancers 214 421 44 KBK disengaging device 206 854 44 id Adjustment Dimen Ey E34 DC travel drive 1 214 810 44 E11 E34 DC travel drive Il circuit diagrams 211 229 44 Test and inspection booklet KBK installations only in German 206 020 44 Tab 2 1 3 Symbols signal words Important safety information and instructions are marked by corresponding symbols and signal words in these in structions The safety instructions must be followed Exercise particular caution to ensure that accidents injuries and dam age are avoided in such cases Locally applicable accident prevention regulations and general safety regulations must also be followed The following symbols and instructions warn against possible injuries or damage and are intended to assist you in your work DANGER This symbol indicates an immediate hazard which can result in serious injury or death Follow these instructions at all times and be particularly careful a
35. 50_xml eps Fig 2 Position of emergency stop 13 The installation is fitted with an emergency stop device 13 to prevent damage and injuries This is located on the control unit The emergency stop operating function must be checked regularly Regular inspections The owner of the installation may be obliged to carry out regular inspections by national industrial safety legisla tion and regional regulations In Germany this is specified by the accident prevention regulations for winches hoists and towing devices BGV D8 and the accident prevention regulations for cranes BGV D6 for example These specify that e the installation must be inspected before it is put into operation e the installation must be inspected regularly e the elapsed share of the theoretical safe working period must be calculated e arecord of tests and inspections must be kept The owner is obliged to ensure that the installation complies with the latest rules and regulations and to observe new regulations at all times If no comparable inspection regulations or requirements apply at the place where the installation is operated we recommend compliance with the above mentioned regulations 15 16 3 1 3 2 3 3 3 4 3 5 Technical data KBK runways crane girders Please refer to our KBK ALuline crane construction kit document for all technical data such as dimensions weights permitted loads and temperature ranges see gt Tab 2 Page 7
36. 59 44 110414 211 259 44 110414 On sloping superstructures the surface may only be inclined to the extent that the horizontal position of the pin axis is maintained The V type upper suspension brackets must be secured against slipping by means of stops if tensile forces act on steel sections in the longitudinal direction If the V type upper suspension bracket is not fitted to steel sections the packing plate must be used V type suspension bracket assembly V type suspension brackets are rigidly connected to the profile section with the plates The V type hinged suspension bracket is designed for a maximum of three suspension rod connections suspension rod strainer or hinged end piece On a V type suspension arrangement the rods are fitted to the outer holes on a lateral stiffener to the center and one outer hole The V type hinge can be adjusted in the suspension bracket to any an gle in relation to the track however the pin axis must always be per pendicular to the suspension rod axis hy at Fig 21 Further assembly of lateral stiffeners See also Fig 20 Page 36 1 Attach hinged end piece 49 to the V type upper suspension bracket To do this remove the pin and secure it again after assembly 2 Screw threaded rod 41 into hinged end piece 49 until spring clip 43 can be pushed through the hole in the hinged end piece and through the hole in the suspension rod 3 Screw the follo
37. Disengaging cylinder x 265 295 with control Tab 30 The friction wheel is pressed against the bottom flange of the rail by means of a pneumatic cylinder only when the motor is also supplied with compressed air This enables the connected trolley to be moved by hand when no pressure is applied The drive is controlled pneumatically or electrically and is mainly intended to be used as a starting help Motor technical data Travel speed Rated speed Output Operating Recommended Air demand at 4 bar CDF Max displacea pressure operating pres ble load sure m min m min Ww bar bar Vs Kg approx 10 50 20 80 3 6 approx 4 45 50 500 Tab 31 Fitting the travel drive 42613245_xml eps Fig 45 53 54 Item Designation Item Designation Item Designation a Trolley c Link bar e Supporting washers b Long pin d Spacer sleeves for long pin f Friction wheel travel drive Tab 32 1 Remove the longer of the 2 pins b from trolley a on the coupling side 2 Connect the trolley to friction wheel travel drive f using pin b 3 The arrangement of link bar c supporting washers e and spacer sleeves d can be seen in gt Fig 45 Page 53
38. a dangerous contact voltage in the sense of the safety regulations Donotremove any safety equipment or render it inoperative by modifications WARNING Crushing hazard There is a risk of injury due to parts of the body being crushed sheared or clothing or hair becoming entangled Protective devices must be provided if the installation is fitted at a suspension height within normal reach WARNING Crushing hazard Body parts can be crushed when loads are lifted lowered or moved Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered WARNING Suspended load Falling parts Danger to life and limb if lifted loads are dropped Keep out of the danger zone at all times 211 259 44 110414 211 259 44 110414 2 5 Keep a sufficient safety distance Never step under a suspended load Certain work and practices are prohibited when using the machine as they may involve danger to life and limb and result in lasting damage to the installation Observe the safety instructions in the sections e gt Assembly Page 22 e gt Putting into service for the first time Page 76 e gt Operation Page 79 e gt Maintenance work Page 85 Responsibility of the owner Information on safety at work refers to the regulations of the European Union that apply when the installation is manufactured The owner is obliged to ensure that the specified industrial safety measures comply with t
39. ab 25 Assemble as for Frame for double girder crane 48 211 259 44 110414 211 259 44 110414 5 10 4 Crane traverse for KBK Aluline ergo double girder crane 43491244 xml eps Fig 37 Example KBK Aluline ergo 180 Crab frame Slide traverse a with trolleys b into the crane girder and position it Align the crane taking overhangs into consideration Tighten the bolts of pressure plates c with the correct tightening tor que Aluline A12 and A16 10 Nm Aluline A18 and A22 25 Nm 42611945 xml eps Fig 38 Item Designation Item Designation Item Designation A Aluline A12 A16 B Aluline A18 A22 up to 1200 kg C Aluline A18 A22 up to 2600 kg Tab 26 e Complete the crab frame with the trolleys e Slide the trolleys over the axles and or support plates e Secure the trolleys with pins and pin retainers 49 50 5 11 CAUTION Track and crane alignment oj 2000 n Z Es 2 x lt 1 X wi d 2 l le E 40479647_xml eps Fig 39 Dimen Designation sion Cc Height difference between runway suspension points 10 mm but not more than C 2 mm over 2 m ly Distance between track suspension points A Permissible limits of crane span KBK Aluline classic gt A max Ix 12 mm A min Ik 12 mm KBK Aluline ergo gt A max x 1 mm A min 1 mm lkr Crane
40. ae ae filiales bl 67 211 259 44 110414 211 259 44 110414 5 13 1 2 5 13 1 3 5 13 1 4 5 13 1 5 5 13 1 6 5 13 2 5 14 5 14 1 5 14 2 5 14 3 5 14 4 5 15 5 16 6 1 6 2 6 3 6 4 7 1 7 2 7 2 1 7 2 2 7 3 7 3 1 7 3 2 7 3 3 7 4 7 5 7 5 1 7 5 2 7 5 3 8 1 8 2 8 3 8 4 8 4 1 8 4 2 8 5 8 6 8 6 1 8 6 2 8 6 3 8 6 4 8 6 5 8 6 6 8 6 7 Fitting buffer StOpS voii Sond eed nicer ph ania a rel net aerials ae EI eee Gee i soe Moe 68 Fitting flat cablesiscrwes ctecssn nates sn ietietnind Gas ARE Ata 68 Fitting round Cable siiecsscrek aie Ail wae Sis ee ev eee Se es Se kt 69 Terminal DOK soria Aa 70 Isolating MA A eel 70 Pneumatic power supply Gi iia 71 Suspending the OS A dank a E ee talas 73 Safety instructions for suspending the hOiSt ooocoonnconnccnononcconocacnn ano no nan nnnnn nn cnn non rra rr rn 73 Chal NOIST onnan na a N a tone 73 Load bar for D BPoiiit see ies A A Se ed es St Se 74 Handling dEViCG ciseorecsecaceeyebdsteee aehechas niebed id de aiid Gees 74 Maker s plate and load capacity plate oo eee cece ecenee teens ee eeeaeeeseaaeeeaeeeeesaeeeseeaaeeceeeeeseeeseeeeeseneeesenaeeeeenaeeseeeeees 75 Inspection following assembly sasesana wienen hara eaaa Ape ice 75 Putting into service for the first time oononninnnnninnnnnnnnnnnnnnnonncnnncn cnn nn rr rr nro 76 Safety instructions when putting into service for the firSttiMe o nocnnnnnnninnnnonnnccnnnoncnno conan nrrr cnn raro rr 76 In
41. afety in structions in the working sections of these operating instructions The operating instructions must be available to operating personnel at all times to prevent operating errors and to ensure smooth and trouble free operation of our products They must be kept in the immediate vicinity Complete machine Based on Machinery Directive 2006 42 EC the KBK suspension monorail suspension crane installation is also designated as a machine in the sense of a complete machine in the following For a KBK suspension monorail suspension crane installation delivered ready for operation in the sense of a com plete machine we confirm conformity with the requirements of Directive 2006 42 EC by means of the attached EC declaration of conformity Partly completed machinery These instructions provide the manufacturer of a KBK suspension monorail suspension crane installation with in formation on e basic technical information e some typical risks e the assembly and operation of the KBK suspension monorail suspension crane installation The instructions contained in this document may be used as the basis for the risk assessment and operating in structions which must be compiled by the manufacturer of the installation in compliance with the Machinery Direc tive For operation of the installation the manufacturer of the installation must provide additional operating instructions as the result of the risk assessment as required and inform the o
42. aintenance repairs The specified inspection and maintenance intervals gt Maintenance schedule Page 89 apply to normal KBK installation operating conditions All wearing parts must be checked in the course of the annual inspection If routine maintenance reveals that the intervals are too long they should be adapted to the specific operating conditions Electric components Only fuse links with the specified amperage and tripping characteristics may be used in the electric circuits De fective fuse links must not be bridged Pay attention to the following when working on machinery or machine equipment 1 Wear personal protection equipment 2 Before starting any maintenance work switch off the mains connection switch and protect it against unau thorized or accidental reconnection to the power supply by locking it with a padlock 3 Only carry out maintenance work on the crane when the load has been removed 4 Mark off the working area with a red white safety chain or safety tape and warning signs 5 Ensure that there is sufficient freedom of movement Keep the working area clean and tidy Loose parts or tools left lying around may cause accidents 6 Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out 7 Observe the relevant accident prevention regulations instructions concerning appropriate use and statutory regulations for operation and maintenance 8 Observe the r
43. ance and repair work may only be carried out by authorized instructed personnel Definition of per sonnel Page 9 in compliance with the safety regulations CAUTION Secure and fence off the working and danger zone If an elevating work platform is used for maintenance work only use appropriate attachments for the lifting of persons which ensure that work is carried out in a safe and stable position Only suitable tested and calibrated tools and accessories may be used for maintenance work Only use approved spare parts see also gt Use of spare parts Page 9 Wear protective equipment Be careful when working on open components that have sharp edges Risk of injury Keep the working area clean and tidy Store any unneeded machine or installation parts and tools in such a way that there is no risk of them falling Fit components correctly and as intended Comply with specified bolt tightening torques Incorrectly fitted components may fall and cause severe injuries Welding work may only be carried out by persons who are specially qualified DIN welding work require ments must be fulfilled The electrode holder and earth must be connected to the same assembly when welding work is carried out Otherwise serious damage may be caused to the hoist Trolleys must not be welded or drilled Customer specific regulations must be observed Loose connections Loose connections are a danger to life and limb and a risk of damage to the
44. ane with articulated Crane SUSPENSION ooonocccnccccnnononcnonnnonnnnnnnn nn cc inttr tantr cnn nn Atk rana 45 A NO 45 ASSOMDI Y ii A a A scents 46 Rigid CANES cios A A a DO 48 Crab Mame on A A a aaa 49 Trackand crane alignment siccin eein ean aien EEE E aaa ANAA EI DAUEN EENE EAEE ANATAET AN E EnaA 50 Trolleys electric travel drives cocoa O At 51 Trolleys trolley combinations seseina dotadas 51 Travel AVES ii aot ie eh Se A an eet Gu ead et a ee A ey 52 A O O Mee geal cleaver ee ett tenes 52 RF 125 trolley and DRF 200 friction wheel travel drive oo ee ceeseecenneeeeeeeeeeeneeeeeeaeeeeeeeeeeaeeeeeaeeeseneeeenaeeeeenaeeseeneees 52 Fitting an RF 100 PNsUnitcccscastecn ctneiieee hath ib 53 Fitting an RF 125 with an E22 drive isere taatia aa aa ii 57 Fitting DRF 200 sci wet ccth een A aaa ete eae ane eas 59 RF 125 manual disengaging device 24 sconce serene ew die a se ac ne ee Se 60 RE 125 travel liMitS Witches eros allas iia bl 61 Installing travel drives on KBK ergo end Cartiages oomococnncccnnnnccnnncnnnnocncnnnnnccnnno nor nnn nn 62 Link and Spacer Dar vitoria A Act deen 63 Buffers on KBK classic CrabS and Crane ocicccconiccconocininoncnnnrncn aae TE ren 65 Buffer and impact plate on A18 A22 single trolley oooonnnnnccnnnicnnnnnnnnncncnnnncccnnncnnrnccnnn nro rra rra 66 Cable power Supply MES A et eee 67 Aluline power Supply vis sie adie A ee ce a Ar 67 Fitting the trailing cable power SUpply iisniretaiii nitti
45. avel drive The tightening torque is 40 Nm Fitting RF pneumatic equipment base block UL ye 42638245_xml eps Fig 48 Item Designation Item Designation Item Designation a Washer d Torque bracket g Standard connection plate for ISO 1 valves b Travel drive e Motor h Elbow couplings c Hexagon bolt f base block Tab 35 The pneumatic equipment base block can be fitted on either side of the friction wheel travel drive e Loosen both hexagon bolts c and remove motor e together with torque bracket d 55 Remove the 13x20x2 washers a e Replace washers a with base block f Bolt motor e with torque bracket d back on The tightening torque is 40 Nm e Fit elbow couplings h Fitting the directional control valve control block 42638345_xml eps Fig 49 Item Designation Item Designation a Directional control valve c Magnet coil b 24 V DC or 230 V AC control block d Socket Tab 36 Directional control valve e Fit directional control valve a to the standard connection plate for ISO 1 valves of the pneumatic base block using the four screws M5 Use a size 4 hexagon socket key Control block e Fit control block b as shown e Fit control block b to the standard connection plate for ISO 1 valves of the pneumatic base block using the four screws M5 Use a size 4 hexagon socket key 211 259 44 110414 211 259 44 1
46. ccnnnncnnnnnnnnnonnn narrar 96 OVA Wi A dd 96 211 259 44 110414 211 259 44 110414 General 1 1 KBK modular system The KBK modular system consists of components that can be combined in the form of various parts and sub assemblies to meet a wide range of application requirements Our branch offices are pleased to advise you on use of the components and together with you can compile an installation that offers maximum benefits Our KBK Aluline crane construction kit document gt Tab 2 Page 7 and the data sheets provide information on combining individual components and assemblies cranes and runways This document and where relevant the data sheets are constituent parts of these operating instructions The ordered components are supplied individually packed or in groups The components are assembled and commissioned on site Assembly can be carried out by the customer or by our customer service 1 2 KBK documents Further documents are available for sub assemblies components in addition to these operating instructions The corresponding documents are supplied as necessary or can be ordered separately also for special designs or if additional options are ordered which differ from these operating instructions Documents Order no KBK 0 25 100 trailing cable power supply line 202 617 44 KBK crane construction kit project engineering and components 202 976
47. crane runway and to the crane girder as well as to cable trolleys The helical protective hose is always right handed and has a sag of approx 500 mm Length of protective hose travel path m x 1 3 connecting length on both sides m Quantity of cable trolleys length of travel path rounded off to full meters 1 Length of cable accumulating section quantity of cable trolleys reserve x length of cable trolley For further details see KBK Aluline crane construction kit and KBK 0 25 100 trailing cable power supply documents gt Tab 2 Page 7 Compressed air can also be supplied via a spiral hose which is support i l ed by a wire cord stretched alongside the rail section For push travel rE E cranes and trolleys the travel distance is limited to a maximum of 4 m al an The wire cord must be stretched tight between two C rails Wind the Fgm H wire cord around the web of the C rail once at each end as shown in Ir gt Fig 72 Page 71 Pa IL g 9 9A H i 42071244_xml eps Fig 72 71 72 Hose clip set 1 gt 000000 N A Y i N N A 36 41854245_xml eps Fig 73 Retaining plate d Hose clip g KBK cable trolley with
48. ct when malfunctions occur 1 Bring the installation to an immediate standstill by actuating the emergency stop without delay if malfunctions occur that result in an immediate danger of personal injury damage and or an operating hazard 2 Disconnect the installation from the power supply and secure it against reconnection 3 Inform the person responsible at the location about the malfunction 4 Have the malfunction and the cause of the malfunction identified and eliminated by authorized specialist per sonnel Conduct after a malfunction is eliminated WARNING Check for correct assembly Before reconnecting the power supply ensure that the malfunction and the cause of the malfunction have been eliminated all safety devices have been fitted properly and are in perfect working order nobody is present in the danger zone of the equipment 211 259 44 110414 211 259 44 110414 10 10 1 Disassembly disposal General information on disassembly disposal Assembly and disassembly are quite simple owing to the modular design of the crane construction kit WARNING A Before disassembly follow the safety instructions in gt Safety instructions for assembly Page 22 of these op erating instructions in particular those with reference to protecting the ends of rail sections from dropping before they are disconnected Refer to gt Assembly Page 22 of these operating instructions for information on removing com
49. de verification of their competence This person must be trained by the owner in accordance with the tasks to be performed Specialist personnel Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks such as installation setting up maintenance and fault elimination This person must be trained by the owner in accordance with the tasks to be performed Qualified electrician Qualified electricians are defined as persons who owing to their technical training knowledge and experience of electric machines as well as knowledge of the relevant valid standards codes of practice and regulations are able to assess the tasks given to them and to identify and eliminate potential hazards This person must be trained by the owner in accordance with the tasks to be performed Experienced technician Experienced technicians are defined as persons who owing to their technical training and experience have suffi cient knowledge in the field of the machine They must be familiar with the relevant national industrial safety regu lations codes of practice accident prevention regulations directives and generally accepted engineering stand ards enabling them to judge the safe operating condition of machines Assigned expert engineer in the Federal Republic of Germany according to BGV D8 Section 23 for determining the S W P An assigned expert engineer is defined as an experienced technician specifica
50. ded for lifting lowering and moving loads and may be used as stationary or traveling equipment e The installation must be designed for loads resulting from operation The maximum safe working load is the load capacity specified on the capacity plate This must not be exceeded The maximum permitted load in cludes the load and any load handling attachment e The installation may only be installed used operated maintained and removed by trained personnel when it is in perfect working order Personnel must meet the requirements according to gt Operating personnel require ments Page 14 e Intended use includes compliance with the safety instructions as well as any other instructions on assembly and disassembly commissioning function and operation maintenance and fault elimination as well as compli ance with the instructions on the machine safety devices any possible remaining hazards and protection against hazards e The installation may only be used subject to the permissible technical data gt Technical data Page 16 e The installation must be maintained regularly and appropriately by trained personnel in line with the specified deadlines and checked according to gt Maintenance schedule Page 89 Wearing parts must be replaced in good time e UVV BGV D8 and BGV D6 guidelines must be not be ignored No liability for inappropriate use The manufacturer is exempt from any liability for use other than the purpose which is
51. e Attach the on off switch to the track section with switch mounting plate 90 Arrange and connect the cables in accordance with our circuit dia grams 30 WARNING Electric shock live components En are A Contact with live components may result in danger to life mH g JC A and limb cessible position near the KBK installation and clearly marked and can be reached quickly if a dangerous situa tion occurs Cables must only be connected in accordance with De UX j mag Cranes amp Components circuit diagrams Installation Q JE j L It y work must only be carried out by skilled personnel 43489944 xml eps A M Pe A Ensure that the isolating switch is installed in an easily ac Fig 70 For further important information regarding power supply refer to our KBK Aluline crane construction kit KBK 0 25 100 trailing cable power supply DKK conductor line and DCL Pro conductor line documents gt Tab 2 Page 7 211 259 44 110414 211 259 44 110414 5 13 2 Pneumatic power supply 42640046_xml eps Fig 71 Example Single girder crane Detail X Power supply separated at transfer point gt crane bridge crane track Detail Y Power supply interface at end of crane track Supply lines are preferably laid in a protective hose and attached to special fixed points on the
52. e DRF 200 travel drive document gt Tab 2 Page 7 59 60 5 12 3 RF 125 manual disengaging device PAL Pee A Ss 43491444_xml eps Fig 54 1 2 Remove the nut bolt and washer a from the trolley Fit the manual disengaging device 211 259 44 110414 211 259 44 110414 5 12 4 RF 125 travel limit switches Aluline A12 A16 Aluline A18 A22 42741151_xml eps Fig 55 Item Designation Item Designation 141 Limit switch cpl 142 Switching vane cpl Tab 39 General Limit switch fittings are designed to be used with RF 125 travel drives on KBK systems They can be used for reliable switch over from fast to slow travel or from slow travel to the stop function Crane application When a limit switch is used with a crane long travel drive the signal from the switch must also be sent to the second travel drive Contents The limit switch cpl includes the switch the trolley fitting and the pre assembled electric cable to the drive The switching vane cpl includes two switching vanes to actuate the switch incl the fittings for attachment to the rail Assembly Attach the switching vane to the profile section usi
53. ectrically driven electrically driven Tab 28 Connect the friction wheel travel drive with e a single trolley using single trolley link 61 e a double trolley by directly attaching link bar 69c Fig 53 Page 59 of the trolley with load bar 57 e crab frame 78 by pushing link bar 69c gt Fig 53 Page 59 onto the crab frame axle together with a trolley Attach link bar 69c gt Fig 53 Page 59 to the outer holes in the spacer bar or load bar on electrically driven double girder canes 5 12 2 2 RF 125 trolley and DRF 200 friction wheel travel drive A B 42626450_xml eps Fig 43 A Aluline A12 A16 with RF 125 trolley and E11 E34 DC travel B Aluline A18 A22 with DRF 200 friction wheel travel drive drive Tab 29 For KBK Aluline A18 A22 fit an internal buffer stop 40 mm from the end of the track to protect end cap 7 gt End cap with buffer shock absorber Page 41 from collisions with RF trolleys 211 259 44 110414 211 259 44 110414 5 12 2 3 Fitting an RF 100 PN unit 245 a X x UK KBK 180 G 1 8 BSP 1 4 to Un q 42607244_xml eps Fig 44 Item Designation Item Designation Dimension Designation a Friction wheel b
54. ee yes ae A 48 O 48 Oe o_o 7 I O O lt k a See SQ sear Vy O 0 O 43489844_xml eps Fig 20 V type stiffener A Stiffener parallel or perpendicular B V type suspension fitting parallel x no spring clip or perpendicular Tab 17 Construction of lateral stiffeners as in gt Fig 19 Page 36 The threaded rods must be subjected to tensile stress only and they must therefore be arranged in pairs In order to avoid pressure forces and deformation lateral stiffener arrangements must only be provided on the outside of crane runways V type suspension fittings may also be used to replace missing suspension points in vertical suspension arrange ments In such cases the V type suspension fittings must be arranged symmetrically to the vertical suspensions Select an opening angle between 30 and 90 Fit the V type upper suspension bracket 46 dimensions as for B type upper suspension bracket to the super structure in the same way as vertical suspensions The V type upper suspension bracket is only designed for connecting one suspension rod If two or more connec tions are fitted a corresponding number of V type upper suspension brackets must be fitted next to each other The pin axis of the V type upper suspension bracket must always e be horizontal e be parallel to the pin axis of the V type hinged suspension bracket and e perpendicular to the suspension rod axis 211 2
55. eeeeeeeeeeeaeeeceaaeeeaaeeeeeaaeeeeeeaaeeceaeeeesaeeeseeaeeseeeeeeeaaeeesenaeeseeeeees 16 Transport packing scope of delivery Storage 0 ee ce ceeeteeenneeeeeeceeeeaeeeeeaeeceeeeeeesaeeeseaaeeseeeeeesaeeseeaeeeseeeeeeenaeeeeeaes 16 Operating CONGITIONS misein in devebacnesapeechegecsuvn dehbeycensidssveseaenssuebentettsheesondevsebneneedupe 17 TOCHMICAl descriptiON xotia id A cacahestdaice a ib adeseeaaeay Aaa lbs 18 General information on the technical description oo cccconnccnnncnoncconnonnnnonccn crono nar rn r nn crac 18 KBK suspension monorail suspension Crane COMPONENES cecceceeeeceeeececeeeeeeceeaeeeeeeeeeeaeeeseeaeeeseeeeeeseeeentaeeseeeeees 20 ASSOMDIV 0 iia A A ented A IA A A A E Ai SAIS 22 General assembly ANO MAIN oi tocas 22 Safety instructions TO ASS MY See el A a se ses Mie 22 Tightening tOrques icsacc Acie deiad iis iia gest activin A AA aa ac 24 Assembly checklists dineros 24 Component AESIONAtIONS wei 26 Pin retaining devices cit Aita 28 Assemblingia runway st ina 28 O O NN 28 Vertical SUSPENSION vii AA he ea eee ee ne eee eee eee eae 29 General information on the vertical SUSPENSION cece eeeceeeseeeeeeeeeeeeaeeeeeneeeeaeeeeeaeeeceeeeeesieeeeeeaeeeseeeeeeneeeeenaeeseeeeees 29 Fastening upper suspension bracket 25 with clamps 26 to I beam flange eee eeeeeeeenneeeeeeeeeneeeeenaeeeeeeeees 29 Shorteninig the SUSPENSION TOA ore cacanes iaieiiea ipada ei tae goiana deent eaea a aii 30 Ext
56. electric devices cables or insulation e Delayed operation or failure of brakes and safety devices e Missing covers or housing parts or e Damage to the supporting means or load bearing parts Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay This also applies if damage occurs to parts of machinery or equipment which makes an immediate stoppage nec essary If the KBK installation has been stopped by an emergency stop due to safety relevant defects it must be secured against being returned to operation until an experienced technician is satisfied that the cause of the hazard situa tion has been eliminated and that operation of the installation is possible without any hazard Before starting work e Wear protective equipment e Ensure that nobody is present in the danger zone of the equipment 211 259 44 110414 211 259 44 110414 7 2 2 Function checks Instructions for users where BGV D06 accident prevention regulations apply In accordance with BGV D06 the crane operator must also check operation of the emergency stop device when starting work This does not apply to slipping clutches used as an emergency stop device which do not need to be checked when starting work BGV D06 Section 30 The following main functions of the installation must be tested before work begins Component Function check Control devices Unlatch the emergency stop button on the contro
57. elevant safety regulations when repairing electric equipment 9 When removing a track section secure both track ends at a rail joint with ropes against dropping before loos ening a bolted connection 10 Reinstall safety devices as required by relevant regulations and check them for correct operation after finish ing maintenance work Maintenance work which is not possible from the ground may only be carried out from work stands or platforms The danger zone below the crane must be fenced off if there is a risk of falling objects Instructions for maintenance work in the course of operation 211 259 44 110414 211 259 44 110414 If maintenance work has to be carried out on the installation in the course of operation special safety precautions must be taken depending on the operating situation In each individual case the owner or the person assigned by him must check whether the maintenance work may be carried out in the course of operation without risk of per sonal injury and taking into account the local conditions must implement all necessary safety precautions Replace damaged or deformed spring clip fasteners and retaining elements such as split sleeves or BoClips Split pin slots must face outwards Defective bolted connections must be replaced Self locking nuts must not be replaced by other types of nut Self locking nuts must be replaced when they have been tightened and untightened five times Load bearing parts and trolleys
58. es no liability for any damage which results from the following e non compliance with the instructions e inappropriate use e untrained personnel e unauthorized conversions e technical modifications Wearing parts are not subject to liability for defects We reserve the right to incorporate technical modifications within the scope of improving the operating character istics and further development of the product Copyright These instructions are only intended to be used by people who work with or on the installation Any and all content texts drawings images and any other information are protected within the sense of copyright law and are subject to further industrial rights Any misuse is an offence No part of this documentation in whole or in part may be reproduced distributed shown in public or used in any other way without specific prior consent Infringements are an offence resulting in obligatory compensatory dam ages Further rights reserved All industrial rights reserved Use of spare parts We urgently recommend that only spare parts and accessories approved by us be used Only then can we ensure the safety and normal service life of the installation Spare parts not approved by us may cause unpredictable hazards damage malfunctions or complete failure of the installation The use of unauthorized spare parts may render null and void any claims for warranty service damages or liabili ty against the manufac
59. et 68 Load bar for special hoists a Shortened conductor bracket 69 Tractor trolley 92 Mounting bracket for terminal box complete b Pin long inserted bolt for Aluline A18 A22 trolley 93 Mounting bracket for terminal box c Link bar 94 Terminal box f Pin short 95 Mounting plate 70b Friction wheel travel drive travel drive 96 Stacker crabs a RF PN counterweight 98 End stop buffer b Dished washer pack M10 hexagon screw c Sleeve Buffer extension d Nut 100 Protective sleeve for cable e Eye bolt 101 End sleeve for protective hose f Fork carrier 102 Compressed air plastic hose 71 Link bar 103 Mounting bracket with hose clip a Link bar 120 104 Cable trolley with hose clip e RF ergo hinged block 105 Hose clip set 1 and 2 72 Hinged end piece hinged block 106 Balancer angle connection 73 Articulated spacer bar Bulkhead gland 74 Spacer bar for crane trolleys c Angle connector 75 Crane suspension eye 107 Maintenance unit a Suspension eye ball socket 108 Angle for bulkhead gland b Suspension clamp pressure clamp 110 Steel anchorage bracket 76 Spacer bar for straight track 113 RF pneumatic equipment base block 77 Raised crab frame 114 Pneumatic valve 78 Crab frame 115 Electric control e KBK ergo crab frame 117 Extending frame A1 1 79 Bracing frame 118 Extending frame B1 1 80 Crane bridge cable clamp 119 Extending frame B2 1 81 Crab frame cable clamp 121 DEL straight section 82 RF trolley cable clamp 122 DEL curved section 83 Rail end cable clamp end clamp wit
60. event of operating malfunctions for repairs and maintenance purposes if damage is detected or after finishing work the operator must carry out all prescribed safety measures or observe that they are automatically carried out Work on electric equipment may only be carried out by qualified electricians Avoid naked flames extreme heat e g welding and sparks when using cleaning agents and in the vicinity of flammable parts or parts liable to deformation e g wood plastic parts oil grease in electric equipment non compliance may result in a fire hazard harmful gases may evolve or insulation may be damaged Cooling devices such as ventilation openings may not be rendered permanently inoperative e g covered or closed Switching on Checks when starting work Before starting work the operator must be satisfied that the installation is in safe and correct operating condition Ensure that nobody is endangered by operation of the KBK installation before it is switched on or put into opera tion If the operator notices persons who may be exposed to a risk to their health or personal safety by operation of the installation he must stop operation immediately and may not resume operation until the persons are out side the danger zone If there are any defects which endanger safe and reliable operation the KBK installation must be taken out of service without delay Defects relevant to safety in this sense are for example e Damage to
61. fer stop end cap with buffer General 1 Insert the trolley combination the sliders or cable trolleys and the buffer stop into the track section 2 Install the internal buffer stop on the power supply side in accordance with the length of the accumulated sliders buffer stop design dimension An internal buffer stop can be fitted to protect the accumulated sliders or trolleys A buffer must also be fitted on the travel drive side if electric travel drives are used 3 Close the ends of the track with an end cap with buffer 4 On the power supply side attach the rail end cable clamp together with the end cap with buffer to fix the cable at the end of the rail Tools needed for the buffer stop Profile section size KBK Aluline A12 and A16 A18 and A22 Drill with drill bit dia 10 5 mm dia 8 5 mm Tools needed for end cap with buffer shock absorber Profile section size KBK Aluline A12 and A16 A18 and A22 Wrench SW 13 open or ring type SW 13 open or ring type Tab 21 Internal buffer stop 1 2 43490844 xml eps Fig 24 Profile section size KBK Aluline A12 and A16 A18 and A22 dia d mm 8 0 10 5 H mm 65 0 91 0 Tab 22 1 Mark a bore hole at the specified distance using drilling template a Drill hole through the side walls with a drill 2 Secure buffer stop c with pin d and retaining clip b 211 259 44 110414
62. ft elevating platform Material storage area fencing Tool office container 3 Preparation Services provided by the customer e g steelwork foundations Accessibility to the assembly area All material complete according to shipping list Pre assembly of suspensions trolleys and cranes Assembly of the installation in the following order Suspensions runways Cranes trolleys Power supply line electrical fittings 4 Execution Track suspension fittings Bolted connections uniformly tightened Level track Parallel crane runways l Distances between suspensions as specified Suspension fittings equally loaded no vertical play Spring clips properly fitted through suspension rods and ball head suspension rods Specified distances of joints from suspensions st No displacement between rails at joints run finger over to test and no distortion Opening angle of stiffener arrangements as specified End caps and buffers For KBK R correct assignment of phases continuous Safety distances to neighbouring works equipment Test run function check If anchor bolts are used Record of anchor bolt installation work Trolleys cranes Bolted connections uniformly tightened
63. g service handover Page 77 WARNING KBK installations may only be put into service if they have been installed assembled according to the operating 0 Safe operation of the installation is not yet ensured when it is first put into operation instructions Machines may only be put into operation by qualified personnel Check installation operation of the safety devices before commissioning Check all safety distances Check to ensure that the mains voltage and frequency match the details specified on the rating plate Check to ensure that the pressure of the compressed air supply system matches the details specified on the rating plate Ensure sufficient working clearance before starting assembly work Secure and fence off the working and danger zone Wear protective equipment Move the trolleys by hand and check that they can be moved without resistance by hand over the entire length of the track section if fitted Only trained personnel may be employed when the installation is first put into operation since e it may be necessary to render safety devices or features inoperative when adjustments or function checks are carried out e work may need to be performed in the danger zone when the installation is first put into operation CAUTION Overload incorrect specification When under load with the hoist trolley on the crane overhang cranes must not tilt on the crane suspension on the opposite side of the crane T
64. gle Do not pull free fixed or obstructed loads with the hoist Do not leave suspended loads unsupervised Do not allow the chain to pass over edges and do not use the chain as a load bearing sling Do not allow loads to drop when the chain is in a slack condition Vibration from the load being transported e g when the load is deposited on vibrating machinery must not be transmitted to the lifting equipment Do not pick the load up at full speed Avoid inching e g giving short pulses to the motor 211 259 44 110414 211 259 44 110414 7 4 Emergency stop DSC DSE 10C DSM C DRC 10 DRC DC 10 43213850_xml eps Fig 76 Position of emergency stop 13 WARNING A Unauthorized negligent or accidental switching on Danger to life and limb Check to ensure that the reason for the emergency stop has been eliminated before the machine is switched on again The emergency stop device must not be used to switch the machine off in normal operation The emergency stop switch is arranged in a clearly visible position on the control pendant see also the chain hoist operating instructions Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay This also applies in the case of damage that occurs to parts of the installation and equipment which makes it necessary to stop and secure the installation
65. h clamping 123 Stop plate plate 84 Lines and cables 125 Isolating section 85 Slider 128 Equipotential bonding 86 Cable trolleys 130 Redundant arrangement for suspension a Trolley 131 Redundant arrangement for trolley b Clamping plate 132 Redundant crane suspension feature c Clamping plate 135 RF 125 rocker d Cable bracket 137 Mechanical disengaging device e Cable strap 138 Electric disengaging device 87 Stirrup with clamping plate 141 Limit switch 88 Mains connection switch isolating switch 142 Limit switch switching vane a C rail 150 Canopy b Bolt 89 Rail attachment a Mounting bracket b Bolted bracket c Clamp section Tab 11 27 5 6 Pin retaining devices Examples BoClip 42792944 xml eps Fig 4 Either split sleeves or a BoClip pin retainer must be used as a pin retaining device i Ensure that the slots in split sleeves point outwards since otherwise they cause wear The BoClip can be fitted by hand without the need for any tools Pull the wire loop to check the BoClip is securely fitted 5 7 Assembling a runway 5 7 1 Notes CAUTION Attachment Parts may become loose is they are not secured appropriately Tighten to the specified tightening torque We recommend pre assembling KBK suspension fittings before attaching them to the steelwork The ball sockets of upper suspension brackets track suspension clamps and the joints of V type and lateral stiff eners must be well greased Use resin free ant
66. he following measures must be taken if the crane tilts Check the maximum permissible load capacity and the suspended load Compare the distances between the suspensions and the crane span dimension with the dimensions given on the project engineering drawing Compare the crane girder length and any overhangs with the dimensions given on the project engineering drawing A check may need to be carried out by a planning engineer 211 259 44 110414 211 259 44 110414 6 2 Inspection regulations WARNING A 6 3 6 4 Non compliance with operating and maintenance regulations Danger to life and limb Compliance with all inspection regulations is essential to ensure safe operation of the installation Required tests and inspections must be carried out All inspections must be arranged and documented by the owner at the specified intervals points of time Inspection in accordance with relevant national regulations e g UVV BGV D6 for cranes UVV BGV D8 for winches hoists and towing devices in Germany The owner is responsible for ensuring that power driven cranes electric travel drives are inspected by an expert engineer before they are first put into service and before they are put into service again after major modifications have been carried out This also applies to cranes that are not fitted with travel drives and which have a load capacity of more than 1000 kg Adjustment maintenance and inspection activities and
67. he latest rules and regulations and to observe new regulations during the entire service life of the installation Local indus trial safety legislation and regional regulations and codes of practice applicable at the site of operation of the in stallation must be observed outside the European Union General safety accident prevention and environmental protection regulations that apply where the installation is in operation must be observed and complied with in addition to the safety instructions contained in these operat ing instructions The owner and any personnel authorized by him are responsible for correct operation of the installation and for clearly defining responsibilities for installation operation maintenance and cleaning The operating instructions must be followed in full and without any limitations Special local conditions or applications may lead to situations which are not considered in these operating instruc tions In such cases the required safety measures must be defined and implemented by the owner Necessary measures may also relate for example to the handling of hazardous materials or tools and the provision wearing of personal protection equipment The operating instructions must if required be supplemented by the owner with instructions relating to organization of work working procedures authorized personnel supervising and reporting obligations etc For further information see gt Safety instructions for operat
68. his verified by a structural engineer 34 211 259 44 110414 211 259 44 110414 Dimensions Aluline A12 A16 390 Aluline A18 A22 410 15 Aluline A18 A22 25 Aluline A12 A16 41 Aluline A18 A22 62 Aluline A12 A16 Aluline A12 A16 75 Aluline A18 A22 120 43207147_xml eps Fig 17 Type Description B Upper suspension bracket S clamp S Cc Upper suspension bracket A and B clamp S D Upper suspension bracket S clamp S E Upper suspension bracket A and B clamp S Tab 16 Clamp section with V type suspension bracket B 43207544 eps Fig 18 A special intermediate fastening arrangement is supplied for the special fastening of V type upper suspension brackets and lateral stiffeners The specially designed part is attached by means of 4 clamps 36 5 7 4 Transverse and longitudinal lateral stiffeners V type stiffeners 43207744 eps Fig 19 Lateral stiffeners A B 26 26 T 25 3 43 lo o 43 io 40 46 49 49 j y 41 x x x
69. i friction bearing greases do not use any lubricants containing MoS All bolted connections must be tightened to the torques specified in gt Tightening torques Page 24 of these operating instructions 28 211 259 44 110414 211 259 44 110414 5 7 2 5 7 2 1 5 7 2 2 Vertical suspension General information on the vertical suspension Tools needed Profile section size KBK Aluline A12 and A16 A18 and A22 G clamp only to help assembly x X Torque wrench X X AAA SW 10 open or ring type SW 13 open or ring type 2x SW 17 open or ring type 2x SW 24 open or ring type Tab 12 Fastening upper suspension bracket 25 with clamps 26 to l beam flange 1 2 40 A h CO 25 26 43489744_xml eps Fig 5 Assembling track suspensions e Vertical suspension fittings must be aligned vertically e Maximum permissible girder gradient 1 5 The bolts must be in contact with the side of the girder flange and aligned vertically or for very narrow girders centred as close as possible to the girder flange Maximum distance 8 mm In borderline cases the spring clip may collide with the clamp screws on very narrow girder flanges In these cases we recommend the use of split sleeves as shown in gt Fig 11 Page 31 It may also be possible to insert the bolts of clamp 26 from below thus preventing the bolts from c
70. ies himself The owner must appoint a coordinator who is authorized to issue instructions before assembly work commences Despite detailed information errors cannot be excluded when the installation is assembled by the customer For this reason we recommend that this work be carried out by our trained specialists or by persons authorized by us The wiring of the KBK installation complies in all respects with current DIN VDE and accident prevention regula tions Unauthorized intervention and modifications eliminate compliance with these regulations The item numbers shown in the diagrams correspond to the those given in our KBK Aluline crane construction kit document see gt Tab 2 Page 7 This document also contains notes and diagrams that may be useful for assembly of the installation A drawing at least a good sketch must be available for assembly of each installation This drawing approval drawing with the owner s approval stamp or signature contains a diagram of the crane installation with easily legible symbols and all structural dimensions If required refer to the KBK documents for guidelines on the techni cal design The approval drawing is the basis for the test and inspection booklet to be compiled for the crane installation Modifications additions and extensions must be entered in the installation diagram assembly drawing and in the test and inspection booklet The operator of the crane installation must supply pr
71. ignation L Load LZ Operating time a Full load b Medium partial load c Small to medium partial load d Small dead load e Small to medium dead load f Heavy dead load g Very heavy dead load Tab 51 Max stress cycles per day to DIN 15018 table 14 crane operating period 10 years 250 working days per year Stress spectrum Loading group B1 B2 B3 S0 very light 80 240 800 S1 light 80 240 S2 medium 80 S3 heavy 211 259 44 110414 211 259 44 110414 8 5 Max stress cycles per day to DIN 15018 table 14 crane operating period 10 years 250 working days per year Stress spectrum Loading group so 4 12 24 An average cycle time of 3 mins 20 cycles h hook up lift cross travel long S1 5 4 12 travel lower deposit and back results in an operating period in hours per day ri of 7 S3 Tab 52 A stress cycle for the crane structure corresponds to a crane operating cycle Information on the hoist service life can be found in the corresponding operating instructions Maintenance schedule maintenance reveals that the intervals are too long they should be shortened according to the specific operating il The inspection intervals specified below apply for KBK installations in normal single shift operation If routine instructions Shorter inspection intervals are necessary for cranes used in continuous extreme operation or in multi shift operation and
72. ings sl 43206244 eps Fig 8 U bolts cast into solid ceilings Two spring clips are required for each coupling when using the coupling for threaded rod with spring clip Screw suspension rods 41 into coupling 50 and fit spring clips 43 e through the elongated hole of the coupling and e through the bore holes of the suspension rods The flat nuts which are screwed onto the end of the thread must be flush with the concrete ceiling Only upper suspension brackets A 25 can be used with this bolted connection To make it possible to align the track the U bolt should be cast in at right angles to the direction of the track M10 tightening torques 45 Nm M16 120 Nm 211 259 44 110414 211 259 44 110414 5 7 2 6 5 7 2 7 5 7 2 8 Suspension from ceiling section rails 409 AJ faa 1 a 24000 n g AAN AMRA 90 o ot ali y i y gt 41 a 43 43206344 eps Fig 9 Suspension from ceiling section rails These suspension arrangements require special building authority ap proval oscillatory load Only upper suspension bracket A 25 can be used in connection with packing plate 51 and the required special bolts supplied by the ceiling section rail manufacturer Packing plate 51 must rest against the channel section Remove concrete with a chisel if necessary Tightening torques according to manufacturer s specifications We a
73. inspection deadlines including specifications con cerning the replacement of parts assemblies prescribed in the operating instructions must be observed Please refer to the chain hoist and if necessary the trolley operating instructions for values for noise pres sure level measurement to DIN 45635 This work may only be carried out by specialist personnel Inspections before putting into service for the first time The owner is obliged to carry out the following checks before the unit is put into operation for the first time e Check continuity of the PE conductor connection e Check emergency stop device e Check direction of movement e Check operation of the brake Checks on entering service handover WARNING A Unauthorized operation Danger to life and limb if the installation is operated without previous inspection KBK installations may only be put into service if they have been checked for compliance with the corresponding accident prevention regulations By means of suitable measures carried out by the owner or on his behalf the owner must ensure that the load handling attachments and machinery ready for operation function in complete safety before they are first put into service The specified measures must allow for the static and dynamic features of the installation Since KBK installations are assembled and or installed at the place of operation this inspection must be per formed on site The following check
74. ion Page 79 Furthermore the owner must ensure that e any further working and safety instructions resulting from the risk assessment of the workplaces at the installa tion are specified in operating procedures e personnel who work with or on the installation are provided with appropriate first aid equipment Personnel must be trained in the use of the first aid equipment e the operating instructions are always kept available in the immediate vicinity of the installation for installation operating maintenance and cleaning personnel e personnel are trained in accordance with the work to be performed e the installation is only operated when in safe and proper working order e safety devices are always kept freely accessible and are checked regularly e national regulations for the use of cranes and lifting appliances are observed e any specified regular checks and inspections are carried out on time and are documented The owner is urged to develop procedures and guidelines for any malfunctions to instruct users and to affix these instructions at a suitable place where they can be easily seen 13 14 2 6 2 7 Operating personnel requirements Only authorized and trained personnel may work on the installation The personnel must have received instruction on the installation functions and any hazards that may occur Every individual given the task of working on or with the installation must have read and understood the ins
75. l panel to enable the crane switch Limit switches Check the limit switch functions by carefully approaching the switching positions This applies for the lifting motion limit switches see corresponding operating instructions and for the long and cross travel limit switches if fitted Brakes Check the run on paths of hoist unit brakes and travel drive brakes The brakes must be adjusted if the brake paths noticeably increase See the corresponding operating instructions for brake adjustment Safety equipment Check emergency limit stop and emergency stop devices Safety devices do not relieve the crane operator of his obligation to work with due care Only correct func tioning of the safety devices can guarantee the necessary level of safety in the event of a crane operator error Control unit pendant control wireless control Care must be taken to treat the control unit appropriately The crane operator selects the lifting and travel motions using the control unit Recharge the rechargeable batteries of wireless control units in good time Buffers The crane crab adjacent cranes and adjacent crabs are fitted with appropriate elastic buffers The buffers reduce the forces transmitted when the crane runs against the crane runway limit stops cross travel limit stops and or adjacent cranes adjacent crabs The crane crab buffers must not be approached in normal operation The buffers must be checked regula
76. led down for inspection The ball nut or ring nut must not be even be undone for inspection pur gt poses on any crane suspension fittings Cm These checks must also be carried out for all track suspensions 42612644_xml eps Fig 79 Electric cabling and wiring On the electric equipment collector trolleys and cable sliders must be checked for wear and the isolators terminal boxes and cables must be checked for damage If an electrical lead is damaged it must be replaced immediately Hoists units and travel drives The hoist must be checked according to the relevant operating instructions and the travel drives in accordance with the DRF 200 RF 125 friction wheel travel drive and E11 E34 DC travel drive operating instructions see documents gt Tab 2 Page 7 211 259 44 110414 211 259 44 110414 8 6 6 8 6 7 Removing trolleys and similar items from long or closed tracks be replaced tions Page 92 Fig 80 KBK Ergo The following tightening torques must be checked when maintenance work is carried out 42792744_xml eps e Install in reverse order e Pull the trolley out of the track The trolleys are fitted with travel wheels that have bearings which are lubricated for life They cannot be disassembled Replace complete trol leys if the trolley side cheeks or travel wheels are defective All pins can If this cannot be done by simply removing an end cap
77. lley Load bar 16 31 851 305 44 V type suspension bracket Crab frame suspension Double girder crane spacer bar 16 41 851 306 44 Redundant single trolley feature Aluline P A12 A16 Load bar suitable for curves 20 44 851 317 44 Buffer fitting Spacer bar 20 54 851 318 44 Crab frame 16 41 851 306 44 Single trolley link 20 44 851 317 44 130 270 tractor trolley 20 44 851 317 44 BoClip pin retaining Trolley 4 device Load bar used in V type suspension bracket 20 44 851 317 44 Single trolley link Double girder crane spacer bar Link bar 270 Link bar 130 Aluline Buffer fitting A18 A22 Spacer bar 20 54 851 318 44 Crab frame Redundant single trolley feature 220 ergo load bar 20 64 851 319 44 ergo buffer plate 20 97 851 320 44 RF 125 rocker 20 44 851 317 44 130 270 tractor trolley 20 64 851 319 44 2 Sliding shell for ball head suspension rod 25 off Aluline A12 A16 980 815 44 not for crane suspension short suspension only replace complete units Aluline A18 A22 851 394 44 Tab 55 211 259 44 110414 97 VLVOLL V 6SZ LLZ VLDOLL D 6SZ LLZ 98 99 VLVOLL V 6SZ LLZ The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found on the Demag Cranes amp Components homepage at www demagcranes com Contact and Demag worldwide
78. lly assigned by the manufacturer to determine the remaining duration of service service life of the machine S W P safe working period and to carry out a general overhaul of the machine Authorized expert engineer according to BGV D6 Section 28 in the Federal Republic of Germany In addition to the expert engineers of the Technical Supervisory and Inspection Board an authorized expert engi neer for the inspection of machines is defined as an expert engineer authorized by the Industrial Employers Mu tual Insurance Association Test and inspection booklet A test and inspection booklet filled in with all details must be available for every crane installation according to BGV D6 Section 28 in the Federal Republic of Germany The results of the regular tests and inspections must be entered into the test and inspection booklet and must be certified by the inspector Test and inspection booklet order no see gt Tab 2 Page 7 After sales service If you have any questions on our products or need technical information please contact our after sales service Please keep the serial or order number see test and inspection booklet load capacity plate on the crane for any correspondence or spare part orders Specifying this data ensures that you receive the correct information or the required spare parts Terex MHPS Corp Telephone 49 0 180 5741268 Internet http Awww demag us com 211 259 44 110414 211 259 44 110414 2 1
79. long its entire length The protective earth conductor must not be connected to mounting bolts or screws Earth junctions and connections must be protected against accidental loosening e g by using serrated lock washers to DIN 6798 It must be possible to disconnect each individual connection Protective earth conductors must not carry any current in normal operation The same number of protective earth connection points must be provided as electric power infeed and outfeed points Continuity of the PE conductor connection must be checked Mains connection switch A mains connection switch must always be provided for the main power supply line to suspension monorails and cranes The mains connection switch must be arranged to disconnect all poles of the KBK installation from the mains supply Ensure that the mains connection switch is installed in an easily accessible position near the KBK installation and clearly marked Isolating switch If two or more lifting appliances are fed from a common supply line each one should be provided with an isolating switch This makes it possible to carry out maintenance work on individual units without affecting operation of the rest of the system Power supply 23 24 5 3 CAUTION 5 4 Cold resistant PVC sheathed flat cables are used exclusively as trailing cables KBK R DEL DCL Pro and DKK AL are safety busbar lines Type of enclosure IP 23 to DIN 40050 Compressed air supply E
80. lso supply special upper suspension brackets for ceiling section rails see gt Special attachments for suspensions to technical data sheet 203 072 44 Page 33 The load bearing capacities of both ar rangements must be checked when planning the installation Fastening upper suspension bracket A with threaded rods and counterplates to solid ceilings 43206444 eps Fig 10 Upper suspension bracket fastening Floor fixture plates 43206544 eps Fig 11 Floor fixture plate arrangement The upper suspension bracket must be arranged at right angles to the direction of the track to enable the track to be adjusted The connection must be securely tightened and locked during assem bly Only then is the load bearing capacity adequate M10 tightening torques 45 Nm M16 120 Nm If floor connection plates 35 are used the connection between the up per ball head suspension rod and threaded rod is secured with a heavy duty split sleeve 37 instead of a spring clip 31 5 7 2 9 Suspension with anchor bolt connection y file 42671446_xml eps Fig 12 Anchor bolt connection 5 7 2 10 Suspension from inclined steelwork 43206644 eps Fig 13 Suspension from inclined steelwork KBK installations may be attached to concrete superstructures by an chor bolts Anchor bolts must be used that a
81. machine Metal nuts featuring a locking element self locking nuts must not be replaced by normal nuts They must be replaced when they have been connected and disconnected five times CAUTION Risk of injury Oils and lubricants may pose a health hazard Contact with these media may result in serious damage to health poisoning allergies skin irritations etc 85 86 CAUTION 8 2 8 3 Risk of injury Leaking oils and lubricants are hazards due to the increased risk of slipping Spilt oils and lubricants must be absorbed immediately by means of sawdust or oil absorbent and disposed of in an environmentally compatible way Service KBK suspension monorails and KBK suspension cranes require little maintenance under normal operating condi tions If required our trained specialists can carry out maintenance work for you either as a special order or as part as an inexpensive inspection agreement see gt After sales service Page 10 Our experts are highly experienced and are equipped with the latest overhaul and maintenance tools They carry common wearing parts with them or can obtain them quickly from local service centres Only trained personnel may carry out maintenance work on the installation Ensure that persons who carry out maintenance work on cranes are suitable and authorized Have maintenance work carried out by a Demag part ner as far as possible Basic maintenance requirements General information on m
82. n fitting and crane suspension fitting Item no Component Details to be checked Inspection intervals in months 3 6 12 1 Complete installation Overall impression general condition talk with operators m Information plates 2 Track system 89 90 Item no Component Details to be checked Inspection intervals in months 3 6 12 2 1 Suspension components Mounting damage wear Track suspensions Crane suspensions Bolted connections on support structure e g clamps Bolted connections between KBK Ergo Trolley and end carriage End carriage and stiffener plate Fit of spring clips see items 2 5 and 5 1 Depth to which suspension rods are screwed in check holes and correct fit of springs clips Fit and wear of sliding shells possibly loosen suspension clamps for inspection Short suspension arrangement without height adjustment replace the complete suspension fitting if sliding shells are worn Bolted connections on track clamping fixtures and hinge sockets Load on suspension rods vertical play Crane suspension with sliding shell fit wear lubrication of sliding shell for high load cycles or special conditions e g casting shop hot installations replace the complete crane suspension fitting if sliding shells are worn Crane suspension with pivot bearing Retaining pins on stiffeners and V type suspensions wear
83. nce work 2 Secure the mains connection switch with a padlock to prevent unauthorized or accidental reconnection to the supply 3 Only carry out maintenance work on the crane when the load has been removed 4 Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out 5 Observe the relevant accident prevention regulations instructions concerning intended use and statutory regulations for operation and maintenance 6 Observe the relevant safety regulations when repairing electric equipment 211 259 44 110414 211 259 44 110414 8 Maintenance work 8 1 Safety instructions for maintenance and repair work The following sections contain a description of maintenance work that is necessary for optimum and uninterrupted operation of the installation DANGER Live components Danger to life and limb Work on electric equipment may only be carried out by qualified specialist personnel gt Definition of person nel Page 9 in compliance with the safety regulations Switch off the electric power supply before starting work The mains connection or isolating switch must be pro tected against unauthorized or accidental restoration of the power supply by means of a padlock Compressed air powered equipment must be disconnected from the compressed air supply by means of a stop valve WARNING Inappropriate maintenance work Danger to life and limb Risk of material damage Mainten
84. nd cautious 1 The documents can be ordered from the relevant Demag office WARNING This symbol indicates a possibly hazardous situation which might result in serious injury or death Follow these instructions at all times and be particularly careful and cautious CAUTION This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage Follow these instructions at all times and be particularly careful and cautious Operating hazard for the machine e This symbol indicates information on the appropriate use of the machine e This symbol in the operating instructions indicates all warnings which if not complied with may result in mal functions or damage 1 4 Information on the operating instructions These operating instructions are designed to provide the owner and operator with useful instructions for transpor tation erection putting into service operation and maintenance of KBK suspension monorail suspension crane installations These operating instructions are an integral part of the KBK suspension monorail suspension crane installation Persons entrusted with the various types of work must know and comply with the safety regulations and the oper ating instructions The KBK suspension monorail suspension crane installation may only be operated by personnel who are fully fa miliar with the operating instructions In particular they contain the Safety section and the relevant s
85. ned on one level e Screw the threaded rod into the upper and lower ball head rod to the required depth Pay attention to the mini mum depth see gt Track and crane alignment Page 50 e Align the suspended track sections to one level see gt Track and crane alignment Page 50 211 259 44 110414 211 259 44 110414 Connecting track sections CAUTION Incorrect assembly Incorrect assembly of the rails is dangerous The track sections must be bolted together in such a way that there are no shoulders on the running sur face or on the sides of the opening at the track joints There must be no resistance when a trolley is pushed across the joint 5 7 6 2 Track section bolted joint 42611345_xml eps Fig 23 Item Designation Item Designation Item Designation Item Designation a Profile b Bolting plate c Hexagon bolt d Slot nut Tab 19 Tools needed Profile section size KBK Aluline A12 and A16 A18 and A22 Wrench SW 13 open or ring type SW 15 open or ring type Tab 20 Slide slot nuts d into profile sections a Connect the profile sections to each other by means of bolting plates b and hexagon bolts c Position bolt ing plates b so that they are centred on the joint Tighten bolts c to the correct tightening torque Aluline A12 and A16 45 Nm Aluline A18 and A22 85 Nm 39 40 5 7 7 5 7 7 1 5 7 7 2 Buf
86. ng the enclosed bolted bracket Attach the limit switch to the tractor trolley using the four M6 bolts Connect the travel drive as described in the E11 E34 DC travel drive document see KBK documents 61 5 12 5 62 Installing travel drives on KBK ergo end carriages 42638648_xml eps Fig 56 Example RF 100 PN Item Designation Item Designation Item Designation a RF trolley b KBK ergo trolley c Rigid link bar cpl d RF 100 PN travel drive Tab 40 No counterweight and no pin set are needed if rigid link bars are used e Bolt the articulated part of link bar c to the end carriage Connect rigid link bar c to the articulated section e Connect RF trolley a to RF 100 PN travel drive d and rigid link bar c using the corresponding pin Ensure that the distance washers and spacer sleeves are fitted in the correct order Slide the unit into the crane section girder Correctly adjust the counter pressure roller 211 259 44 110414 211 259 44 110414 5 12 6 Link and spacer bars Articulated spacer bar components a 63 b c 42626748_xml eps Fig 57 Articulated spacer bar components
87. normally be seen Defective parts and components and parts close to failure must be replaced Please also note gt S W P measures for achieving safe working periods Page 87 and gt Maintenance schedule Page 89 All inspections must be arranged and documented by the owner 8 4 2 S W P measures for achieving safe working periods The safety and health provisions of the EC Machinery Directive make it a legal requirement to eliminate special hazards which may be caused for example by fatigue and ageing KBK crane and monorail installations are dimensioned on the basis of the DIN 15018 Cranes DIN 4132 Crane runways and DIN 18800 Steel structures standards Cranes are designed for a limited service life as is all other machinery This is influenced by e fatigue e corrosion e accidents during operation and installation e overloads and e insufficient maintenance Therefore pay particular attention to the instructions and information in gt Maintenance work Page 85 KBK cranes are classified in lifting class H1 and loading group B3 to DIN 15018 Various operating cycle ranges result for the loading groups depending on the stress spectrum SO S3 see table 87 The following table with an explanation of the SO S3 stress spectra will help you to assess the classification of the crane installation in practical terms Stress spectra Fig 77 Item Designation Item Designation Item Des
88. nsist of the following sub assemblies Sub assembly Available components Load handling attachments See installation as required Hoist unit See Demag chain hoist rope hoist operating instructions Crab frame steelwork Crab frame Cross travel unit Crab trolleys Special load bars spacer bars Special trolleys Low headroom monorail hoist Trolley combinations Link and spacer bars Articulated spacer bar KBK spacer bar Buffers on trolleys Travel drives Tab 5 Crane bridge The crane bridge assembly can consist of the following sub assemblies Sub assembly Available components Crane main girder Crane girder straight section track elements Bolted connection busbar connection Internal buffer stop End cap with buffer Crane suspension eye KBK extending cranes Information plates Crane trolleys Crane trolleys flexible with articulated link Rigid crane trolleys KBK cranes with raised girders Travel drive for crane Trolley combinations Link and spacer bars Buffers on cranes Tab 6 211 259 44 110414 211 259 44 110414 Main group Available components Control system KBK standard electrical equipment selection table Cable arrangements and cable clamps Safety equipment Internal buffer stop End cap with buffer Spacer bar
89. nt collector trolley The current collector trolley must always be located between two trolleys or between a tractor trolley and trolley This protects it against collisions with other trolleys or buffer stops Ensure that phases L1 to L4 are connected correctly when the collector trolley is placed in the track section Assembly 1 Insert the collector trolley link between the side plates of the load trolley Place the coupling in the slot and secure it 2 Connect the load trolley and the protection trolley using the long link bar and two single trolley links Replace the trolley pin with the longer link pin and insert it in the unused link hole When used with a crab frame couple the collector trolley between the crab frame axles with a trolley Only use KBK II R5 collector trolleys in installations that have a 5 conductor busbar along the entire track 43 5 8 6 Retrofitting conductors 1 5 43496144 _xml eps Fig 30 To add DFL conductor lines at a later date the conductor straight section in the required length and 4 fixed points must be ordered for each profile section Insert the conductor line and position it against a limit stop at a distance of 1 5 mm from one end Insert two fixed points from the other end and wedge them as shown Then insert the fixed points at the other end and wedge them 5 9 External busbar 5 9 1 Use If flat cables cannot be used wi
90. ny Lodge a claim e Lodge a claim for any defects as soon as they are detected since claims for damages may only be asserted within the relevant claim notification periods Packing If no agreement has been made on the return of the packing material separate the materials according to type and size and make them available for further use or recycling Environmental protection e Always dispose of packing materials in an environmentally compatible way and according to locally applicable disposal regulations e If required utilize the services of a recycling company 211 259 44 110414 211 259 44 110414 Scope of delivery If 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 If you have any questions please contact the manufacturer a ney are installed parts of the installation and accessories must be kept closed and may only be stored un der the following conditions e Do not store outdoors e Store in dry and dust free places relative air humidity max 60 e Do not expose to aggressive media e Protect against direct sunlight e Avoid mechanical vibrations e Storage temperature 20 to 70 C if supplied with hoists or travel drives the instructions for these compo nents must also be complied with e Avoid strong temperature fluctuations c
91. olliding with spring clip 43 1 Tighten clamp fastening arrangements 26 uniformly on each side Use G clamps to hold the upper suspension brackets as necessary M10 tightening torques 45 Nm M16 120 Nm 2 Slide suspension bracket 42 from the end of the rail section into the specified position 3 Screw threaded rod 41 into ball head suspension rod 40 until spring clip 43 can be pushed through the hole in the ball head suspension rod and through the hole in the suspension rod Fasten rail section 1 to the pre assembled suspension fittings and secure suspension bracket 42 by tight ening bolts 42c in position Tightening torques M6 10 Nm M8 25 Nm 29 5 7 2 3 5 7 2 4 5 7 2 5 30 Shortening the suspension rod Aluline A12 A16 Aluline A18 A22 A o I pa Y Y O 4 For de ite at i 6 8 ry o cm z a Y 40 60 42741648_xml eps Fig 6 Item Designation Order no A Drilling jig 982 017 44 Tab 13 If standard threaded suspension rods have to be shortened for spring clips a new transverse hole must be drilled at the end of the threaded rod The drilling jig can be used for this purpose Extension of threaded rods aa SS 50 wl 43206944 eps Fig 7 Extension of threaded rods U bolts cast into solid ceil
92. ondensation e Oil all bare machine parts rust protection e Check the general condition of all parts of the packing at regular intervals If required refresh or renew rust protection e f stored in a damp location the installation parts must be packed tight and protected against corrosion desic cant 3 6 Operating conditions CAUTION Operational safety risk Safe operation is only possible under the specified conditions Contact the manufacturer if the operating condi tions differ from those specified gt After sales service Page 10 The KBK suspension monorail suspension crane installation can be operated at Ambient temperature 20 C to 50 C2 Humidity max 80 relative humidity Tab 3 For operation outdoors special measures may have to be taken to ensure safe operation e g trolleys may have to be locked against the wind Installations operated outdoors should be provided with a cover for protection against the weather or the installa tion should be kept under a canopy when it is not being used 2 Refer to the corresponding operating instructions for differing temperature ranges for drives and hoists 4 Technical description 4 1 General information on the technical description Our modular KBK crane construction kit enables you to build complete crane systems quickly and easily The ba sic elements of KBK installations are special track sections available in sizes designated Aluline A12 A
93. one at all times Keep a sufficient safety distance Never step under a suspended load Loads must not be lifted above persons Wear protective equipment WARNING A Non compliance with operating regulations industrial safety regulations Danger to life and limb if relevant regulations are disregarded KBK installations may only be operated in compliance with relevant national operating regulations e g BGV D6 for cranes in Germany If required apply a copy of the relevant operating regulations part no 214 748 44 at a suitable place where operators can read them at any time e g at the mains connection switch The KBK installation must not be put into operation or must be taken out of service immediately if any defects or irregularities are detected with reference to its operating safety and reliability or function Safety devices must not be rendered inoperative or modified contrary to their intended use Ensuring safe operation 7 80 7 2 7 2 1 Special local conditions or special applications may lead to situations which were not known when this chapter was written In this case the owner must ensure safe operation or take the installation out of service until meas ures for safe operation have been clarified and implemented in agreement with Demag or other relevant bodies In the event of a stoppage e g if defects regarding safe and reliable operation are detected in emergency situa tions in the
94. oof of the load bearing capacity of the superstructure which the crane installation is suspended from Safety instructions for assembly Incorrect assembly Danger to life and limb Incorrect installation may result in severe injury and or damage to property Therefore this work may only be carried out by authorized instructed personnel who are familiar with the principle of operation of the installation in compliance with all safety regulations Ensure sufficient working clearance before starting assembly work Secure and fence off the working and danger zone Ifan elevating work platform is used for assembly only use appropriate attachments for the lifting of per sons which ensure that work is carried out in a safe and stable position Only suitable tested and calibrated tools and accessories may be used for assembly or disassembly work Wear protective equipment Be careful when working on open components that have sharp edges Risk of injury Keep the working area clean and tidy Store any unneeded machine or installation parts and tools in such a way that there is no risk of them falling Fit components correctly and as intended Comply with specified bolt tightening torques Incorrectly fitted components may fall and cause severe injuries Structural changes compared to the original configuration can result in a reduced load capacity of the com ponents installation Welding work may onl
95. pen or ring type Wrench SW 14 open type SW 22 open type 2x SW 16 open or ring type 2x SW 24 open or ring type Tab 18 First check to establish if the suspensions are at the same level and check the height of the support superstruc ture The maximum permissible deviations are only 4 mm for Aluline A12 A16 and 12 mm for Aluline A18 A22 possible adjustment of the suspension KBK Aluline ergo suspensions are pre assembled e Insert the required number of suspensions into the rail e Lift the rail up to the steelwork e Attach the suspensions to the steelwork using clamps as described in gt Fastening upper suspension bracket 25 with clamps 26 to I beam flange Page 29 e Tighten the suspension clamps bolts by hand Tightening torque 25 Nm Loosen the counter nut on the threaded pin to adjust the height Undo the suspension clamp screws until the threaded pin can be turned Adjust the height by turning the threaded pin Re tighten the counter nuts and the suspension clamp screws fol lowing adjustment KBK Aluline ergo suspensions can be combined with short height adjustable KBK Aluline classic suspensions In KBK Aluline A12 A16 installations ensure that an upper suspension bracket type A modified with a rubber ele ment from the KBK Aluline A18 A22 range is installed Connecting track sections General remarks on connecting track sections When several track sections are suspended they must first be alig
96. peration Safety instructions for operation WARNING A Incorrect operation Risk of injury due to incorrect operation Incorrect operation may result in severe injury or damage to property The installation may only be operated by authorized and instructed personnel in compliance with all accident prevention and safety regulations National regulations for the use of cranes and lifting appliances must be observed and followed The owner must arrange for operating personnel to be trained WARNING A Danger of crushing and shearing drawing in or entanglement There is a risk of injury due to parts of the body being crushed sheared or clothing or hair becoming entangled when loads are moved lifted or lowered If the installation is suspended at a height within normal reach there is a risk of of injury between moving and stationary parts Protective devices must be provided Do not touch the supporting means Do not reach between the upper and lower entry point of the supporting means Do not reach between the load and the load handling attachment when loads are lifted There must be nobody present in the immediate danger zone when the load is set down Safety distances must be maintained The tilting moment must not be exceeded when loads are picked up and moved WARNING A Suspended load Falling parts Impact hazard Danger to life and limb if lifted loads are dropped Keep out of the danger z
97. ponents Re move parts in the opposite order to assembly Unless a return or disposal agreement has been concluded separated components must be recycled after proper removal e Scrap any remaining metallic material e Dispose of plastic elements for recycling e Separate and dispose of any other components by material type Electric scrap electronic components lubricants and other auxiliary materials are subject to special disposal regulations and may only be disposed of by certified companies National disposal regulations must be considered regarding environmentally friendly disposal Further information can be obtained from corresponding local authorities 95 96 11 11 1 11 2 Spare parts General information on spare parts Please refer to our KBK Aluline crane construction kit document gt Tab 2 Page 7 when ordering KBK compo nent and spare parts To facilitate rapid delivery kindly quote the following numbers in your order our order number for the crane delivery and e the order no of the component spare part See separate assembly instructions for component parts lists for stacker crabs monorail hoists and disengaging mechanisms Overview 1 2 ne 8 42786945_xml eps Fig 81 Item Designation dia d mm K mm Order no Tro
98. ques for 4 6 Halfen bolts e M16 60 Nm e M 20 120 Nm e M 24 200 Nm 3 2 off per suspension bracket 33 5 7 3 2 Upper suspension brackets A B and S Suspension arrangement types and use The information given applies for vertical suspensions Particular consideration must be given to the arrangement and quantity of packing plates supplied with the clamps Selection Type Profile Packing plates IPE 550 600 1 220 320 340 450 500 650 700 1000 HE A 220 320 Aluline A12 A16 340 450 HEB 500 650 700 1000 200 220 240 280 300 1000 HE M 475 500 B 550 600 N ala A U NA O N AlLW N 550 600 IPE 230 360 400 500 550 800 900 1000 HE A W N Aluline A18 A22 220 280 300 360 HE B 400 500 550 800 900 1000 220 HE M 240 280 300 1000 Aluline A12 A16 HE A 100 200 E C 100 120 Aluline A18 A22 HE A 140 200 E D Aluline A18 A22 HE A 220 260 a 280 400 Aluline A12 A16 425 550 E HE M 100 180 a2 N N gt gt N a 00 0 N BON Aluline A18 A22 HE M 100 200 a Tab 15 Verification of the load bearing capacity for the additional loads due to the clamp arrangement and the applica tion of forces to the outer edge of the flange of profile girder sections is particularly important for wide profile girder sections The customer must have t
99. quired to avoid any collision during operation Secure the connection between the upper ball head suspension rod and the threaded rod with the enclosed split sleeve see X Edge Y of the suspension bracket must be in close contact with the profile section h2 M10 tightening torques 45 Nm M16 120 150 Nm 42671344_xml eps Fig 15 Vertical suspension from U sections Special attachments for suspensions to technical data sheet 203 072 44 Upper suspension bracket H for ceiling section rails Halfen iH Fig 16 Ceiling section rails Halfen Aluline A12 A16 390 x 120 Aluline A18 A22 410 x 120 Aluline A12 A16 41 Aluline A18 A22 62 Aluline A12 A16 15 Aluline A18 A22 25 Aluline A12 A16 75 Aluline A18 A22 120 43207046_xml eps The information given applies for vertical suspensions Halfen rail Halfen bolt 3 dia d Aluline A12 A16 Aluline A18 A22 Permissible load e Permissible load e on suspension Gag on suspension Gag mm KN mm kN mm HTA 40 22 Q M 16 17 5 4 250 4 250 HTA 50 30 Q M 16 17 5 4 8 250 4 8 250 HTA 52 34 Q M20 22 7 5 280 14 300 HTA 72 48 Q M 24 26 7 5 280 14 300 Tab 14 Only use genuine Halfen bolts Clamping thickness and tightening torque must be considered Tightening tor
100. re approved for use with dynamic loads DANGER Incorrect assembly causes loads to be dropped Hazard for life and limb They must be installed by trained personnel and an instal lation report must be compiled Please refer to the KBK anchor bolt connection data sheet gt Tab 2 Page 7 Weld on a stop to prevent upper suspension bracket 46 from slipping The surface may only be inclined to the extent that the horizontal posi tion of the pin axis is maintained For installation instructions refer to gt Transverse and longitudinal lateral stiffeners V type stiffeners Page 36 5 7 2 11 Short suspension arrangement with height adjustment 26 43489644_xml eps Fig 14 Short suspension arrangement with height adjustment 32 With this arrangement screw ball headed bolt 44 into suspension rod 40 to such a depth that spring clip 43 can be pushed e through the elongated hole in the suspension rod and e through the hole in the ball headed bolt Fastening upper suspension bracket 25 with clamps 26 to l beam flanges Fig 5 Page 29 211 259 44 110414 211 259 44 110414 5 7 2 12 5 7 3 5 7 3 1 Vertical suspension from U sections Upper U type suspensions can be used on U shaped steel profile sec tions DIN 1024 in sizes U80 to U220 202 x 72 The free swing angle of the suspension fitting may be limited by the girder profile Use stiffeners as re
101. residual risks remain KBK suspension monorail suspension crane installations are industrial equipment which is designed to be operat ed with a rated voltage of up to 1000 V from low voltage mains supply networks Power feed is via power supply lines mobile cables open or enclosed power conductor systems These systems are live up to the terminals of the isolating switch During operation or when the mains connection switch is not switched off electrical compo nents inside enclosures motors switchgear cabinets terminal boxes etc carry dangerous voltages DANGER Live components Danger to life and limb Electric energy may cause very severe injuries Danger of death caused by electric current if the insulation or individual components are damaged Switch the installation off and secure it against restoration of the power supply before any maintenance cleaning or repair work is carried out Switch the power supply off before any work is carried out on the electric equipment Check to ensure that the components to be replaced are de energized _ If work has to be carried out on live parts a second person must be available to actuate the emergency stop button or mains connection switch to disconnect the power supply in an emergency Before disconnecting and connecting electrical plug and socket connections always disconnect them from the supply this does not apply to mains connections provided they do not represent
102. rly for correct operation Cracks and lasting deformation indicate poor operating characteristics Tab 50 DANGER Malfunction following assembly work Danger to life and limb if assembly work has not been carried out appropriately The control devices must be checked for correct and proper operation following work on the main power supply and before work begins If the phases are not correctly connected the switching elements and limit switches may not function as intended 7 3 Operation 7 3 1 Safety during operation WARNING Overload Danger to life and limb Higher loads than those specified on the load capacity plate must not be handled Donot exceed the maximum permissible load capacity of the crane Only use load handling attachments which are adequately dimensioned Only use load handling attachments for their intended purpose Important information for operation Observe the following during operation Take the crane installation out of service immediately if functional defects or irregularities are detected The operator is obliged to check the crane installation for any visible damage at least once per shift and to report any damage immediately Donotrender safety devices inoperative 81 82 7 3 2 7 3 3 Do not approach limit stops in normal operation e g emergency stop devices emergency limit switches emergency limit stop devices slipping clutch or emergency limit swi
103. rs for Aluline A18 A22 straight track components a Spacer bar on single trolley for double girder crane with two open ends Spacer bar on double trolley for double girder crane with two open ends Tab 44 For details see KBK Aluline crane construction kit document gt Tab 2 Page 7 Assemble by means of pin or bolted connections 211 259 44 110414 211 259 44 110414 5 12 7 Buffers on KBK classic crabs and cranes KBK buffer components a b c 45 JO 115 a E e Ol d e 70 25 LO 6 fy F Ser IKE La 42608247_xml eps Fig 61 KBK buffer components a Rubber end stop b Buffer fitting foamed plastic c RF buffer fitting foamed plastic d Buffer plate e RF buffer plate Tab 45 KBK buffer examples 42608249_xml eps Fig 62 KBK buffer examples a Buffer plate or buffer fitted to Alu b Buffer plate or buffer fitted to Alu c RF buffer fitted to RF trolley line A12 A16 single trolley link line A18 A22 single trolley link d Buffer plate or buffer fitted to Alu e Buffer plate or buffer fitted to Alu f RF buffer fitted to DRF trolley line A12 A16 double trolley link line A18 A22 load bar Tab 46
104. s connect both friction wheel travel drives with a round cable 211 259 44 110414 211 259 44 110414 Crab frame cable clamp double trolley 42610646_xml eps Fig 67 e Attach the flat cable using crab frame cable clamp 81 to the trolley to take the strain from the terminal con nections RF trolley cable clamp Aluline A12 A16 Aluline A18 A22 42610746_xml eps Fig 68 On electrically operated crabs or cranes e run the cable to the terminal box under the friction wheel travel drive via RF trolley cable clamp 82 or via the crab frame cable clamp 5 13 1 4 Fitting round cable The round cable to connect the two long travel drives lies in the upper channel of the profile section for KBK Alu line 69 70 5 13 1 5 5 13 1 6 Terminal box Aluline A12 A16 Aluline A18 A22 80 td s O 94 94 Lo qd 2 O 44 AC Eb oe Ih L 117 97 aer Y 20 O a Nel 43490044_xml eps Fig 69 A terminal box 94 part no 504 650 44 can be fitted at the end of the track using mounting bracket 92 and a bolted bracket as a transition from flat cable to round cable Isolating switch If several cranes operate with a common power supply on one track an 88 on off switch with lock 88 must be fitted on every cran
105. s must be carried out when the installation enters service e The supporting structure must be in good condition and the load capacity of the KBK installation must be checked e Safety devices must be complete and effective e Clearances and safety distances must be maintained e The emergency stop device must be checked by actuating the emergency stop e A clearance check must be carried out when the installation enters service Smooth travel over track joints Safe and reliable current collector contact The trailing cable must run smoothly 77 78 When the unit is first put into operation it must be checked to ensure that it is used as intended in all possible applications in each case with the maximum permissible load Operation of the safety devices must be checked e g by lifting an overload At the same time the behaviour of the installation must be checked when it is not used correctly Various checks of the machine must be carried out before it is handed over e Check to ensure it is suitable for operation e Acceptance inspection The test and inspection records can be compiled as soon as safe operation of the installation is ensured The test and inspection records test and inspection booklet observe relevant national regulations must be hand ed over when the installation is handed over The installation may be used as intended after it has been handed over 211 259 44 110414 211 259 44 110414 7 7 1 O
106. s of suspension clamp d together Secure suspension eye a between the two halves of suspension clamp d with knurled pin c Slide the crane suspension into profile section e and position it i Pay attention to overhangs and the crane span dimension 211 259 44 110414 211 259 44 110414 Place clamping plate b over suspension eye a and secure it with bolts f Tighten bolts f to the correct tightening torque Aluline A12 and A16 10 Nm Aluline A18 and A22 25 Nm 47 5 10 3 Rigid cranes Tools needed Profile section size KBK Aluline A12 and A16 A18 and A22 Torque wrench X X Wrench Tab 24 Frame for double girder crane SW 10 open type SW 13 open or ring type 41847245_xml eps Fig 35 Example KBK Aluline classic A12 e Slide frame a into the crane girder and position it e Lift the frame into crane trolleys b and secure with pin c and pin retainer e Align the crane taking overhangs into consideration e Tighten the bolts of pressure plates d with the correct tightening torque Aluline A12 and A16 10 Nm Aluline A18 and A22 25 Nm Rigid crane traverse for single and double girder cranes A 41847445 xml eps Fig 36 Example KBK Aluline classic A12 A Rigid single girder crane traverse Crane end carriages Pressure plate B Rigid double girder crane traverse Crane end carriage T
107. spection regulations inicia a AAA SUL A i ei Si ea ac 77 Inspections before putting into service for the first time ee eee ceeeeceeeeeeeenneeeceeaeeesaeeeesaeeeseeaeeeseeeeeenaeeeeenaeeseeneees 77 Checks on entering Service handover ccccceeecceceeeeeceaeeeeeeseeaeceeeeseeaece ees caaaaeaeeeeeedeeaeceeeeseeaeaesedsesaeaeseeseeseeeeeess 77 Opera A A A A da 79 Safety instructions for Opera oi ci 79 SWITCHING Mii stare 80 Checks When starting WOFK ccoo Ai 80 FUNCION CHECK cio A AA AA AA AA At cael 81 OPO rations aiaa e a Eaa e anita 81 Safety during operation coccion ir 81 LO ad pick iaa ta a ti n 82 MoVing the load coooiooicta o ie atea 82 Emergency SHO iii A A A A A A id 83 Taking the equipment out Of operation ocooccconncccnnnonaconcncnononcnnnno non nnrn cnn rr nano rn rre 84 Taking the equipment out of service when faults OCCUM c ooooccccnocicnoncconannncnonanan non cnn no cnn narran rn rra 84 Taking the equipment out of service at the end of the Shifb oooooonnnnnninnnnicinnnnannoncccnnonnc non nnnnorn conan rn r nn nn rnr rra rra 84 Taking the equipment out of service for maintenance and repallS oooononicinnnninioccccnnonncnonannn conc cc nan nn nr cnn nnnnn rn cnn rca 84 Maintenance Work 20 a A cda 85 Safety instructions for maintenance and repair WOFK ocoooncccnncccnnccccnnonnnnononcnnonnnnnnn cnn nnnnn nn nr rre 85 a a E E A E TIA as 86 Basic maintenance requirements cnica ec 86 Regular inSpectons
108. st be replaced when they have been tightened and untightened five times The clamping torque of a self locking nut must not be lower than the loosening torque specified by EN ISO 2320 A sufficiently secure connection can only be guaranteed by tightening to the specified tightening torque Bolted connections must not be lubricated as otherwise the specified tightening torque values will be too high Pre assembled parts e g crane suspension and short suspension must not be disassembled or modified Crane suspension fittings must not be used as swivel joints All assembly work must be completed in accordance with the operating instructions Any change or modification which prejudices safety must be reported to the nearest person responsible immedi ately Repairs may only be carried out by experienced technicians Ensure that all attachment points are freely accessible for checks and servicing or that free access can be provid ed The control device e g control pendant must be marked in such a way that the direction of movement is clear and distinct The arrow symbol on the switching elements must correspond to the direction of movement Electric safety The electrical equipment for KBK suspension monorails and cranes meet the requirements of relevant electrical VDE in Germany and accident prevention regulations in full Protective earth conductor The protective earth conductor in insulated leads and cables must be colored green and yellow a
109. tch track and limit buffers to stop move ment of the crab or crane hook assembly or bottom block against limit stops Pay attention to all regulations regarding the correct loading of chains and ropes Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing parts of the body or hair becoming entangled Load pick up Load handling devices and loads must be flexibly suspended from KBK classic trolleys Rigid connections cause uncontrolled forces to be transmitted and lead to fatigue fracture The connection between the load and the load handling attachment may be rigid in KBK Ergo installations When attaching the load ensure that loads do not fall over fall apart slip or roll off when they are picked up or deposited Transporting people is not permitted unless the lifting devices are specifically approved for transporting peo ple Do not exceed the maximum load specified on the load capacity plate Moving the load For lifting and travel motions adopt a position that provides a clear view of the danger zone or use a second person who can observe the danger zone Push travel hoists trolleys cranes may only be moved by pulling or pushing the load bottom block or load hook assembly Never pull on the control pendant Push travel loads must be guided by hand The load must never be thrown or hurled Do not handle suspended loads above persons Do not pull or drag suspended loads at an an
110. tching distance approx 25 mm for proximity switches n 6 3 Lead connections on ter Tight fit n minal strip 6 4 Fittings Tight fit of bolted connections 7 Electrical equipment on tracks 7 1 Contactor control Burnt contactor contacts n 7 2 Proximity switches Switching distance approx 15 to 25 mm 7 3 Emergency stop buttons By actuation Daily 7 4 Hoist crab spacing on 2 traveling hoists m runway 7 5 Lead connections on ter Tight fit m minal strip 8 Trailing cable power sup Condition of cable kinks n ply Wear of cable trolleys and cable sliders n compressed air hose Spacing of cable trolleys or cable sliders Cable damage n Wear of the compressed air hose Attachment and tension of the guide rope 9 Steel superstructure Bolts and bolt locking arrangements corrosion As specified by the manufacturer Tab 53 8 6 8 6 1 Maintenance work General remarks WARNING on maintenance work Performing maintenance work Danger to life and limb Loose parts may fall Use every possibility to work safely when doing inspection work Before starting any maintenance work switch off the mains connection switch and protect it against unau thorized or accidental reconnection to the power supply by locking it with a padlock Cordon off a large area around the working zone 91 92 8 6 2 8 6 3 8 6 4 8 6 5 Replace factory assembled parts crane suspension eye short suspension fitting only as complete
111. technically possible and ac ceptable according to these operating instructions In particular the manufacturer assumes no liability for damage due to inappropriate or any other prohibited use of the installation in the sense of the Intended use section No liability for structural modifications The manufacturer is not liable for any unauthorized structural modifications which have not been agreed with him This applies for example if profile sections are shortened This includes incorrect connection of the installation to 11 12 devices or equipment that do not belong to our scope of delivery or the installation or use of third party accessories equipment or sub assemblies that are not approved by the manufacturer Depending on the type and scope of the installation it may be necessary to have an inspection carried out by an expert engineer before it is to handed over to the owner The KBK suspension monorail suspension crane may only be used subject to the permissible Technical data and Operating conditions At extreme temperatures and in aggressive atmospheres or conditions differing from those specified in the Operating conditions section the owner must implement special measures after consult ing Demag 2 4 Hazards that can be caused by the installation The installation has been subjected to a risk assessment The design and execution based on this analysis corre sponds to state of the art engineering principles However
112. th Aluline A12 16 or Aluline A18 A22 track sections a compact conductor line can be attached to the Aluline section 5 9 2 DCL Pro compact conductor line 43490244 _xml eps Fig 31 Please refer to the DCL arrangement on KBK document for further information selection table and assembly instructions see gt Tab 2 Page 7 44 211 259 44 110414 211 259 44 110414 5 10 5 10 1 5 10 2 5 10 2 1 Assembling suspension cranes Preparation work Crane runways are assembled as described in gt Assembling a runway Page 28 All crane runways must be at the same height and level gt Track and crane alignment Page 50 Single girder crane with articulated crane suspension General 43490644 xml eps Fig 32 Articulated crane suspensions are only used for single girder cranes in the KBK Aluline classic system Tools needed Profile section size KBK Aluline A12 and A16 A18 and A22 Torque wrench x x Wrench SW 10 open type SW 13 open or ring type Tab 23 45 46 5 10 2 2 Assembly Type until mid 2014 1 42611744 _xml eps Fig 33 Type as of mid 2014 43491144 xml eps Fig 34 Parts can be installed by inserting them into the end of the profile section or by inserting the halves of suspension clamp d into the profile section at any point from above Place both halve
113. truc tions before any work starts Persons under the influence of drugs alcohol or medicines which affect their reactions must not work on or with the installation Age and job specific regulations relevant at the place where the installation is operated must be observed for the selection of any personnel Personnel are obliged to report to the owner without delay any changes to the installation that impair safety For independent operation crane operator or maintenance trained maintenance fitter of the KBK installation the owner may only employ persons e who are at least 18 years of age e who are mentally and physically suitable e who have been instructed in the operation and maintenance of the KBK installation and who have proven their qualification to the owner in this respect Personal protection equipment When work is carried out on or with the installation the following protective equipment is recommended to be worn according to the owner s hazard assessment e Protective clothing closely fitting working clothes low tear strength no loose sleeves no rings or any other jewelry etc e Safety shoes to protect against falling parts and against slipping e Safety helmet to be worn by everybody in the danger zone 211 259 44 110414 211 259 44 110414 2 8 2 9 Emergency stop device DSC DSE 10C DSM C DRC 10 DRC DC 10 432138
114. turer or his appointed personnel dealers and representatives Definition of personnel The manufacturer is the person who 1 manufactures the equipment under his or her own name and places it on the market for the first time 2 resells other manufacturers equipment under his or her own name whereby the reseller is not considered to be the manufacturer provided the name of the manufacturer as in 1 appears on the equipment 3 imports the equipment into the country and places it on the market for the first time or 4 exports equipment to another member state of the European Union and hands it over direct to a user in that country Owner 10 1 9 1 10 Owners employer company are defined as persons who own the machine and who use it as intended or allow it to be operated by suitable and trained persons Operating personnel operator Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper ate the machine This person must be trained by the owner in accordance with the tasks to be performed Trained person Trained persons are defined as persons who have been instructed and trained for the tasks assigned to them and on the possible hazards resulting from inappropriate conduct Personnel must be informed about the required pro tective devices protective measures relevant regulations codes of practice accident prevention regulations and operating conditions and must provi
115. under special operating conditions such as casting shops and hot applications KBK installations are normally classified in loading group B3 to DIN 15018 and DIN 4132 This means that the stress cycle range is from 2 x 10 load cycles for heavy duty to 2 x 10 load cycles for very light duty The table below is intended to assist in identifying faults liable to affect regular operation of the installation It may be used as a basis for preventive maintenance and to compile an overall service schedule This table does not contain regular inspections and checks some of which must be carried out daily Additional information can be found in the chain hoist and friction wheel travel drive instructions Within one to two months of the installation being put into operation and during regular inspections all bolted con nections of the following components must be checked and if necessary tightened or secured to compensate for the settling which always occurs in bolted connections and any reduction in initial tension e suspension fittings e track joint bolt sets and end caps e spring clip fasteners on suspension fittings e pin connections between hoist and trolley e pin connections between crane girder and track trolley e track trolley See gt Tightening torques Page 24 for bolted connection tightening torques Check and or ensure that the sliding shells are present for each ball head suspension rod ball head bolt short suspensio
116. units when they are worn These parts must not be dismantled and reassembled with new components Removing and replacing rail sections e Protect both ends of the rail against dropping e g by ropes at the track joint when a rail section is removed e Undo the bolted connection of this rail joint e Pull the joint apart The articulated suspensions make this possible without having to dismantle the suspension assemblies KBK R Pull the track sections apart until the busbar connectors protrude freely from the busbars e Push the track section to be removed to one side until the rail section ends are located next to each other KBK R Remove the busbar connectors e Undo the bolted connection of the second rail joint KBK R Pull the rail section off the busbar connectors in the direction of the track e Install in reverse order Please also note gt General remarks on connecting track sections Page 38 Crane suspension fittings with sliding shell track suspension fittings Secure the crane girder against dropping e g with a rope 43213645 eps Fig 78 Check the connection between the eye bolt and the ball socket on the crane suspension eye for correct fit wear lubrication approx 1 cm of anti friction bearing grease and defective or missing sliding shells E For crane suspension fittings on KBK Aluline the suspension clamps must be removed from the rail and the suspension eye must pul
117. ut cable brackets at equal distances over the entire length of the cable e Place the cable s on the cable straps and tighten them e Snap the cable brackets into trolley 86a To prevent collisions with the cable supports fix an internal buffer stop 6 Fig 64 Page 67 in the track section on the power supply side for crane tracks and double girder cranes in both track sections so that the crane or trolley is buffered on both sides simultaneously e See gt Internal buffer stop Page 40 Distance a end of track to hole center number of cable supports x max length of one cable support with cable s When a friction wheel travel drive is used dimension a is increased by 150 mm e Secure the flat cable on the power supply side using rail end cable clamp 83 at the end of the track girder Fitting flat cables Crane bridge cable clamp E o gt n o o0 ES 43490144_xml eps Fig 66 For push travel single or double girder cranes e fix the flat cable to the crane girder directly next to the crane suspen sion eye with crane bridge cable clamp 80 This ensures that the cable is securely held in place From this fixed point arrange the flat cable to the rail end clamp via a loop Attach to the crane long travel drive for contactor control for electric travel movement with crane switch contactor For electrically driven double girder crane
118. very KBK installation in which pneumatically operated equipment is used must be fitted with a stop valve If two or more pneumatically operated units are fed from a common connection point each one must be provided with a separate stop valve Crane switch Each crane must be provided with a crane switch so that all movements in the crane installation can be stopped from the control point The crane switch may be omitted on cranes where only the lifting equipment is electrically operated and on mono rail trolleys which have a travel motor output up to 0 5 kW KBK Ergo In contrast to KBK classic trolleys the load is always rigidly connected to KBK Ergo trolleys Due to the design specifications of KBK Ergo trolleys and KBK Ergo suspensions it is not always necessary to prevent the cranes or tracks from tilting If forces acting in the opposite direction to gravity are exerted on the trolleys KBK Ergo trolleys must always be used at the corresponding points If forces acting in the opposite direction to gravity exerted on the suspensions can be balanced by the deadweight of the rail KBK classic suspensions may also be used otherwise KBK Ergo suspensions must be selected Tightening torques M6 10 Nm KBK Aluline A12 A16 suspension clamp M8 25 Nm KBK Aluline A18 A22 suspension clamp KBK Aluline A18 A22 buffer stop KBK Aluline end cap 45 Nm KBK Aluline A12 A16 bolted connection M10 20 Nm KBK Aluline A12 A16 buffer
119. wing parts into suspension rod strainer 48 to a depth of 45 mm Aluline A12 A16 or 60 mm Aluline A18 A22 in each case the threaded rod with right hand thread on the one side and the hinged end piece with left hand thread into the other side of the suspension rod strainer The side with the left hand thread is marked with an L 4 Fit the hinged end piece of the suspension rod strainer to the V type suspension rod bracket by means of a pin secure and align it 5 After alignment turn the suspension rod strainer nut to tighten the bolted connection so that any play in the threaded rod is avoided Then secure the suspension rod strainer nut with the spring clip and lock on one side A spring clip is not required at the point marked x 6 Screw the hinged end piece onto the vertical threaded rod so that the spring clip can be pushed through the hole in the hinged end piece and through the hole in the suspension rod One spring clip is required for every connection between a hinged end piece and suspension rod Only the connection between the suspension rod strainer and suspension rod x is not provided with a spring clip 37 38 5 7 5 5 7 6 5 7 6 1 KBK Aluline ergo track suspensions Aluline A12 A16 Aluline A18 A22 43490444 xml eps Fig 22 Tools needed Profile section size KBK Aluline A12 and A16 A18 and A22 Torque wrench X X SW 10 open type SW 13 o
120. wner about any remaining hazards The owner must carry out additional measures to satisfy the safety requirements for the installation of a KBK sus pension monorail suspension crane installation supplied as partly completed machinery which is assembled with additional parts to form a machine that is ready for operation 211 259 44 110414 211 259 44 110414 1 5 1 6 1 7 1 8 Installation of a partly completed or non assembled KBK suspension monorail suspension crane installation to create machinery ready for operation must be carried out in compliance with the information provided by the man ufacturer for the KBK suspension monorail suspension crane installation The information for assembly and oper ation of the KBK suspension monorail suspension crane installation contained in these instructions must be complied with A conformity inspection in accordance with the Machinery Directive must be carried out for the assembled KBK suspension monorail suspension crane installation when it is ready for operation and a declaration of conformity must be produced Liability and warranty All information included in these instructions has been compiled on the basis of the relevant regulations state of the art engineering principles and our many years of experience These instructions must be read carefully before starting any work on and with the installation especially before it is put into service for the first time The manufacturer assum
121. y be carried out by persons who are specially qualified DIN welding work require ments must be fulfilled The electrode holder and earth must always be connected to the same assembly when welding work is carried out as otherwise serious damage may be caused to the installation Only carry out installation work when all requirements regarding the installation location are met see gt Technical data Page 16 Customer specific regulations must be observed 211 259 44 110414 211 259 44 110414 DANGER Live components Danger to life and limb Work on electric equipment may only be carried out by qualified specialist personnel gt Definition of person nel Page 9 in compliance with the safety regulations It must be possible to switch off the power supply by means of a device to disconnect the power supply e g mains connection or isolating switch with a padlock Switch off the electric power supply before starting work The mains connection or isolating switch must be pro tected against unauthorized or accidental restoration of the power supply by means of a padlock DANGER Crushing hazard Danger to life and limb Stop all moving parts and ensure that they cannot start moving while assembly work is being carried out Mechanical safety All bolted connections must be correctly tightened see also the Tightening torques section Self locking nuts must not be replaced by other types of nut Self locking nuts mu

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