Assembly instructionsRedundant systems in the KBK crane construction kit 161012 en GB 211 232 44 719 IS 152 Original assembly instructions Manufacturer Demag Cranes & Components GmbH P.O. Box 67 58286 Wetter (Germany) Telephone +49 (0) 2335 92-0 Telefax +49 (0) 2335 92-7676 www.demagcranes.com Email:
[email protected] Further documents are available for sub-assemblies/components in addition to these assembly instructions. If required, the corresponding documents are supplied or can be ordered separately, even if special designs or additional options differing from these assembly instructions are ordered. Documents1) Technical data/catalogues Operating instructions – Assembly – Adjustment – Dimensions Tab. 1 KBK crane construction kit, project engineering and components Redundant systems in the KBK crane construction kit Operating instructions/component parts, KBK installations Ident. no. 202 976 44 203 334 44 206 076 44 2 1) The documents can be ordered from the relevant Demag office. 211 232 44/161012 Table of contents 1 1.1 2 2.1 2.2 2.3 3 3.1 3.2 4 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.4 5 5.1 5.2 6 6.1 Foreword ..................................................................................................................................................................... 4 General........................................................................................................................................................................ 4 Safety .......................................................................................................................................................................... 5 General........................................................................................................................................................................ 5 Intended use................................................................................................................................................................ 5 Hazards that can be caused by the redundant systems ............................................................................................. 5 Technical description................................................................................................................................................... 6 Description .................................................................................................................................................................. 6 Transport, packing, scope of delivery, storage............................................................................................................ 7 Assembly ..................................................................................................................................................................... 8 Track suspensions ...................................................................................................................................................... 8 Crane suspensions...................................................................................................................................................... 9 Selection table ............................................................................................................................................................. 9 Crane suspension on single trolley ........................................................................................................................... 10 Crane suspension on double trolley (KBK I, KBK II, KBK III, Aluline) ....................................................................... 12 Redundant system for the single trolley .................................................................................................................... 12 Redundant system for the connecting rod................................................................................................................. 13 Putting into service for the first time .......................................................................................................................... 14 Safety instructions when putting into service for the first time................................................................................... 14 Inspection regulations ............................................................................................................................................... 14 Disassembly, disposal ............................................................................................................................................... 15 General...................................................................................................................................................................... 15 211 232 44/161012 3 1 Foreword 1.1 General The redundant systems in the KBK crane construction kit are supplied as component parts, partly packed in bags. Before beginning assembly, check that the delivery is complete using the enclosed shipping papers. These as‐ sembly instructions are intended to provide the user with instructions for safe and appropriate assembly. Every individual given the task of transporting, installing, commissioning, maintaining and repairing the redundant systems must have read and understood ● the assembly instructions, ● the safety regulations and ● the safety instructions in the individual chapters and sections. The operating instructions of the installation must be available to the owner / operator at all times in order to prevent operating errors and to ensure smooth and trouble-free operation of our products. Our KBK crane construction kit document ⇒ Tab. 1, Page 2 provides information on combining individual compo‐ nents and assemblies to create cranes and runways. In particular it includes the technical description of the KBK systems. The document is a supplement to these assembly instructions. 4 211 232 44/161012 2 Safety 2.1 General The "Safety" chapter provides an overview of all important safety aspects for safe and trouble-free assembly of the redundant systems in the KBK crane construction kit. At the time of their development and manufacture, the redundant systems in the KBK kit were built according to generally accepted engineering standards and are considered to be safe to operate. However, the redundant sys‐ tems in the KBK kit may still be a cause of danger if they are not fitted correctly or as intended by suitably trained personnel. Knowledge of the contents of the assembly instructions is one of the requirements necessary to protect personnel from hazards and to avoid malfunctions and, therefore, to fit the redundant systems in the KBK kit. Any conversions, modifications or additions to the redundant systems in the KBK kit are prohibited unless ap‐ proved by Demag in writing. 2.2 Intended use Redundant systems in the KBK kit are used where they are intended to prevent immediate crashes in the case of broken or loose components. Please also note the information in the operating instructions of the installation. No liability for structural modifications The manufacturer is not liable for any unauthorised structural modifications which have not been agreed in ad‐ vance. This also includes incorrect connection of the installation to attached or connected equipment which is not part of our scope of supplies and services. 2.3 Hazards that can be caused by the redundant systems A risk assessment has been carried out for the redundant systems. The design and execution based on this anal‐ ysis corresponds to state-of-the-art engineering principles. However, residual risks remain. WARNING Crushing hazard, shearing hazard Adjustment work may be necessary when the redundant systems in the KBK kit are assembled; parts of the body may be crushed or sheared. Assembly may only be carried out by trained specialist personnel. 211 232 44/161012 5 3 Technical description 3.1 Description Redundant systems Redundant systems prevent immediate crashes in the case of broken or loose components. Quasi-redundant systems The majority of KBK subassemblies are already redundant owing to the assembly structure. Other components perform additional load bearing functions in the case of an accident, partially at overload, how‐ ever, without a crash. In principle multiple bolted connections can be considered to be redundant, since in the case of broken or loos‐ ened bolts the emergency properties of the other bolts are applied. In the KBK system safety nuts are used which provide a high degree of safety against loosening. Mode of operation If a redundant system is triggered (failure of a component), the installation does not necessarily have to be opera‐ tional by using the redundant components. It suffices that the accident is noticed and no crash or injury occurs. Inspection and maintenance Redundant components are subject to the same inspection and maintenance schedules as the other KBK compo‐ nents. 6 211 232 44/161012 3.2 Transport, packing, scope of delivery, storage Safety instructions WARNING Falling parts Risk of injury from falling parts during transport, loading and unloading operations. – – WARNING Damage caused during transport The redundant systems in the KBK kit may be damaged or destroyed by inappropriate transport. Transport the assemblies and parts with appropriate care. Transport inspection ● Check the delivery to ensure it is complete and for any transport damage immediately on receipt. ● If any transport damage is visible from the outside, do not accept the delivery or only on condition. Note the scope of damage in the shipping documents/delivery note of the forwarding company. Lodge a claim. ● Lodge a claim for any defects as soon as they are detected, since claims for damages may only be asserted within the relevant claim notification periods. Packing If no agreement has been made on the return of the packing material, separate the material according to type and size and make it available for further use or recycling. Environmental protection: ● Always dispose of packing material in an environmentally friendly manner and in accordance with local dis‐ posal regulations. ● Contract a recycling company, where required. Scope of 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. Storage Until they are installed, the redundant systems in the KBK kit must only be stored under the following conditions: ● Do not store outdoors. ● Store in dry and dust-free places, relative air humidity: max. 60%. ● Do not expose to aggressive media. ● Protect against direct sunlight. ● Avoid mechanical vibrations. ● Storage temperature: -20 to +70 ℃. ● Avoid strong temperature fluctuations (condensation). ● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust protection. ● If stored in damp locations, the installation parts must be packed tight and protected against corrosion (desic‐ cant). 211 232 44/161012 Do not walk under the suspended load. Keep a sufficient safety distance. Cordon off a large area around the working zone. 7 4 Assembly 4.1 Track suspensions Fig. 1 Designation Weight [kg] Part no. Weight [kg/m] Part no. Weight [kg] Part no. 0,3 984 550 44 0,2 980 260 44 0,8 982 260 44 KBK 100 KBK I KBK II 0,5 984 428 44 0,175 583 440 44 0,8 850 260 44 0,3 517 770 46 N 0,8 517 772 46 N KBK III AL 120 AL 180 Max. SWL 1700 kg Rope connector complete Wire rope 6,5 8x19 + SES SZ Suspension clamp Tab. 2 The redundant system for the track suspension consists of: ● Rope connector (1) with two rope sockets (1a) and rope wedges (1b), ● Rope clamps (2), ● Rope (3) and ● Suspension clamp (4). The rope is fitted next to the suspension fitting as a catching rope. The rope connector connects the two rope ends and acts as an additional damping element in the case of dam‐ age. The rope clamps serve as securing elements. The wire rope length must be determined in accordance with the required loop length. Wire rope length Tab. 3 = 2 x length of threaded rod + 2 x girder height + Flange width + 500 mm ● First fit the suspension clamp on the rail close to the track suspension fitting – max. distance 300 mm. ● Then lead one end of the rope over the supporting structure, whereas the second end - is lead through under the screws of the suspension clamp for KBK I and II - or, for Aluline and KBK III, is lead through under the suspension clamp. 8 211 232 44/161012 ● Push the first rope end through the small opening of the rope socket, place it around the rope wedge and push it through the large open‐ ing of the same rope socket. Now press the rope wedge with the rope placed around it into the rope socket. The free end must protrude from the rope socket by at least 50 mm. ● Carry out the same assembly step with the second rope end on the other side of the rope socket. Fig. 2 For adjusting the length, make sure that the rope is loose enough to avoid any restriction of the movement of flexi‐ ble suspensions and that it is lead close enough to reach a max. falling height of 50 mm. Finally fit the rope clamps on the free ends of the rope. The distance to the rope socket is 20 mm. Tightening torque 3 – 5 Nm. CAUTION Danger of falling by inappropriate assembly The rope clamps must not be fitted in the load-supporting area of the rope. 4.2 4.2.1 Crane runway Crane Weight [kg] Part no. Crane suspensions Selection table KBK I KBK I 0,7 517 580 46 N 70 E AL 120 AL 120 0,8 517 778 46 N 40 E KBK II KBK I 0,8 517 581 46 N 70 E AL 180 AL 120 0,9 517 779 46 N 40 E KBK I KBK II 1,3 517 582 46 N 120 E AL 120 AL 180 1,5 517 780 46 N 50 E KBK II KBK II 1,4 517 583 46 N 120 E AL 180 AL 180 1,6 517 781 46 N 50 E KBK I / II KBK I 1,0 517 584 46 N 180 D AL 120 / 180 AL 120 1,1 517 782 46 N 150 D KBK I / II KBK II 2,0 517 585 46 N 240 D AL 180 / 120 AL 180 2,2 517 783 46 N 185 D E = Single trolley D = Double trolley KBK III KBK III 4,5 517 590 46 N 155 E KBK III KBK III 7,5 517 592 46 N 315 D Overhang Umin [mm] Trolley Crane runway Crane Weight [kg] Part no. Overhang Umin [mm] Trolley Tab. 4 211 232 44/161012 9 4.2.2 Crane suspension on single trolley KBK I, KBK II, Aluline Fig. 3 The redundant system for the crane suspension on KBK I, KBK II, Aluline single trolleys consists of: ● Catching plate (1), ● Suspension clamp (2) and ● Long pin (3) for single trolley. The standard trolley pin is not needed. For Aluline, first slide the catching plate into the crane girder in such a way that after assembly it is located within the crane track. Fit the crane suspension fittings to the crane girder in accordance with the operating instructions. Slide the trolley through the opening of the catching plate (1) and fit the long pin (3) in the trolley. The two roll pins serve as pin securing elements. Then fix the free end of the catching plate with the suspension clamp (2) on the crane girder between the crane runways in such a way that the catching plate surrounds the single trolley and the pin without making contact. CAUTION Wear by inappropriate assembly In order to ensure functioning of the redundant system, check after assembly whether free movement of the crane bridge, the crane suspension fitting and the trolley is ensured. 10 211 232 44/161012 KBK III Fig. 4 Item 1 2 3 Tab. 5 Designation Catching plate Washer 30x45x5 M16 nut Item 4 5 6 Designation Nut with plate Washer 17x30x3 Washer 17x40x6 Item 7 8 Designation M16 screw Suspension clamp The redundant system for the crane suspension on KBK III single trolleys consists of: ● Catching plate and ● Suspension clamp with component parts. First fix the M16 screw (7) in the suspension clamp (8) with a tightening torque of 120 Nm. Observe the sequence of the washers (5 + 6). In the second step, pre-assemble the suspension clamp with catching plate (1) without tightening in accordance with the drawing and then slide it into the crane girder in such a way that it is positioned within the crane track. Then fit the crane suspension fitting in accordance with the operating instructions. Connect the trolley with the two installed assemblies by means of the connecting rod. Make sure that the crane suspension fitting is suspended centrally in the trolley, while you push the catching plate (1) with washer (2) through one of the two smaller outer openings of the trolley. The suspension clamp of the redundant system can then be aligned on the crane girder and be tightened with the M8 screws, tightening torque 25 Nm. Finally fix the nut with plate (4) and the nut (3) on the screw threading and counter-lock the nuts. The plate should not contact the catching plate. CAUTION Wear by inappropriate assembly In order to ensure functioning of the redundant system, check after assembly whether free movement of the crane bridge, the crane suspension fitting and the trolley is ensured. 211 232 44/161012 11 4.2.3 Crane suspension on double trolley (KBK I, KBK II, KBK III, Aluline) Fig. 5 Item 1 Tab. 6 Designation Catching bracket Item 2 Designation Suspension clamp The redundant system for the crane suspension on double trolleys consists of: ● Catching bracket and ● 2 suspension clamps. Before sliding the trolley into the crane runway, first suspend the crane suspension fitting in the double trolley and then fix it on the crane girder. In the case of Aluline, make sure that the catching bracket (1) is also pushed into the profile section. Carry out assembly in accordance with the operating instructions. Then fix the catching bracket on the crane girder in such a way that the centre of the catching bracket is posi‐ tioned above the centre of the double trolley without making contact. Tightening torques of the suspension clamps in accordance with the operating instructions. Finally move the trolley into the crane runway. CAUTION Wear by inappropriate assembly In order to ensure functioning of the redundant system, check after assembly whether free movement of the crane bridge, the crane suspension fitting and the trolley is ensured. 4.3 Redundant system for the single trolley 12 211 232 44/161012 Fig. 6 KBK II single trolley with redundant link bar (A), KBK II articulated frame (B), Aluline 180 single trolley with redundant link bar (C), Aluline 180 articulated frame (D) Designation Redundant link bar Trolley Tab. 7 Weight [kg] Part no. Weight [kg] Part no. KBK I 0,6 517 587 46 N 0,7 980 610 44 KBK II 1,0 517 589 46 N 1,2 982 110 44 AL 120 1,2 517 774 46 N 1,5 855 050 44 AL 180 2,0 517 776 46 N 2,2 855 080 44 The single trolley is turned into a redundant system by creating a double trolley. This can be done by using the redundant link bar (1) or via the articulated frame (2). 4.4 Redundant system for the connecting rod Fig. 7 Item 1 2 Tab. 8 Designation Single trolley Redundant link bar Item 3 4 Designation Redundant rope Articulated frame The redundant rope (3) of the chain hoist is either lead through the redundant link bar (2) for single trolleys (1) or over the articulated frame (4) and fixed in accordance with ⇒ Fig. 2, Page 9. For application in the crab frame, the chain hoist can be secured in a similar way. CAUTION Wear of the redundant rope results in loss of the additional safety function. In order to maintain the function of the redundant system, the following must be observed: – – During assembly, make sure that the rope is not damaged by contact with the KBK rail or the edges of sheet metal parts. Check the redundant rope for damage at regular intervals and replace it, as required. 211 232 44/161012 13 5 Putting into service for the first time 5.1 Safety instructions when putting into service for the first time WARNING Unauthorised operation Danger to life and limb if KBK installations are operated without previous inspection. Carry out the inspection only in compliance with all safety regulations. Please also note the information in the "Operating instructions/Component parts, KBK installations" ⇒ Tab. 1, Page 2. 5.2 Inspection regulations Please also note the information in the "Operating instructions/Component parts, KBK installations" ⇒ Tab. 1, Page 2. 14 211 232 44/161012 6 Disassembly, disposal 6.1 General Assembly and disassembly are quite simple owing to the modular design of the crane construction kit. WARNING Before disassembly, follow the safety instructions in the operating instructions of the installation, in particular those with reference to protecting the ends of rail sections to be disconnected from dropping. Refer to the operating instructions of the installation for information on removing track sections, trolleys and cur‐ rent collector trolleys. Other parts are removed in reverse order to assembly. Waste materials left over from maintenance, repair and disassembly work must be disposed of correctly and ap‐ propriately in accordance with the relevant regulations and codes of practice. 211 232 44/161012 15 The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found on the Demag Cranes & Components homepage at www.demagcranes.com/Contact Demag Cranes & Components GmbH PO Box 67 · 58286 Wetter, Germany Phone +49 (0 )2335 92-0 Fax +49 (0 )2335 92-7676 www.demagcranes.com Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany) Subject to change. Not liable for errors or omissions. Printed in Germany