KBK Light Crane(classic single girder bridge)
Operating instructions/component assembly
Nanjing dotii Lifting Equipment Co., ltd
6-102,54 Jiangjiawei,Nanjing,PRC
Fax 025-58820470,Tel025-66153201
E-mail [email protected]
1. Foreword
The KBK crane construction kit is supplied in sub-assemblies and as component
parts, partly packed in bags. Before beginning assembly, check that the delivery is
complete using the enclosed shipping list. This operating instructions provide
the user with information and recommendations for safe and appropriate operation
and facilitate simple maintenance.
The operating instructions should be available to the owner/operator at all times
in order to prevent operating errors and to ensure smooth and trouble-free
operation.
This instruction is tailor-made for the order from YS Korea due to the complete
explanation of the KBK system must consume reader much time, and may arouse
many hesitation.
Meanwhile, some kits have been pre-assembled on the profiles before shipment because
the goods will be received at Korea, the explanation will not be easy enough.
Electronic version of Operating instructions, and drawings
(YS-1308-LC-LO-001, YS-1308-LC-LO-002, YS-1310-LC-LO-001)
Shipping list( General Shipping List & Individual Shipping List)
Assembly list<Assembly list of each unit>.
have transmitted By E-mail to you.
All documents will help assembly.
2. Safety instructions
2.1 Intended use KBK installations are only intended for lifting and moving loads and may be used
both as stationary or travelling units. The maximum safe working load is the load
capacity specified on the capacity plate. This must not be exceeded. The maximum
safe working load includes the lifted load and dead load (e.g. load handling attachments).
KBK installations are designed for operation indoors and for temperatures ranging
from – 20° to + 450° C. At extreme temperatures and in aggressive atmospheres,
the owner must implement special measures after consulting manufacture。
2.2 Prohibited practices
• Transporting persons is not permitted
• Do not handle suspended loads above persons.
• Do not pull or drag suspended loads at an angle.
• Do not pull free fixed or obstructed loads with the chain hoist.
• Vibration from the load being transported (e.g. when the load is deposited on
vibrating machinery) must not be transmitted to the crane installation.
• Do not exceed the maximum load specified on the load capacity plate.
• Do not leave suspended loads unsupervised.
• Do not allow the load supporting means (chains and ropes) to pass over edges.
• Do not use the load supporting means (chains and ropes) as a load bearing sling.
• Always move the chain hoist with push travel carriage by pulling on the load,
bottom block or load hook assembly. Never pull on the control pendant.
• Do not allow loads to drop when the load supporting means (e.g. chain) is in a
slack condition.
• Avoid load sway.
• The load must never be thrown.
NJ dotti is not liable for any damage resulting from prohibited
practices. The risk is borne by the user alone.
3. Tightening torques for KBK installations
For reference M 6: 10 Nm KBK I track suspension clamp
M 8: 25 Nm KBKII track suspension clamp
KBK I joint bolt set
M 10: 45 Nm KBK I suspension fitting
M 16: 120 – 150 Nm KBK II suspension fitting
4. Assembling
Complete KBK system
This instruction is for use of such personals that are assembling KBK system with
sufficient Knowledge and experience since the location is oversea. To fulfill the task of a
complete KBK system crane like the picture above, we should progressively accomplish
the following work.
4.1 Preparing job
*Beafore assembling, you should read the drawings given along
shipment
(YS-1308-LC-LO-001, YS-1308-LC-LO-002, YS-1310-LC-LO-001)
*Check with General Shipping List & Individual Shipping List which have
transmitted
By E-mail to you.
4.2 Prepare and accomplish steel work before KBK assembly. Every
steel frame is for use of specified KBK system, we can select components
according to the <Assembly list of each unit>.
4.3 Rail installation. Refer drawings
of YS-13…to find designed distangce
between each 2 hanger.
Individual hanger will be assembled as show picture.
It is unnecessary to screw tighten because the tightening will do while alignment.
4-4. Bridge suspension
To assemble rail and bridge, refer the pic.
6m of the girder span is 5500mm.
Two group of the Double Trolley and the Girder Hanger
can form a span.
4-5. Rail connection
Basic length of KBK Profile is 6m, 9m or 12m means the
rail must be connected by two pieces of KBK Profiles
Refer the pic. to jiont 2 ends.
The connections are 3 of Screw with nuts. M12-140
4-6. Install Chain Hoist under bridge
The course is very alike “4. Bridge suspension”
1). Position the hoist in such a way that the opening for the supply cable on the hoist
points along the track.
2). Position the suspension eye of the chain hoist or other appliance between the side
cheeks of the trolley, load bar or load traverse.
3). Insert the pin and secure with split sleeves.
To adjust the suspension eye and electrical installation and to commission the hoist,
refer to the chain hoist operating instructions.
4-7. Track and crane alignment
Refer the bellow table
Actually,a check must be carried out to ensure that the crane and crab trolleys can be
moved without resistance by hand over the entire length of the track section.
You can tighten all screw upon the checke is found acceptable now.
4-8. Cable trolley and cable clip
Cable trolley
*Cable trolley is used for fixing cable along KBK profile, each 1500mm between 2 trolleys
*Cable clip is used for fixing cable at the end of the girder and rail.
4-9. Trolley stops
The trolley stop is used to prevent collision between Double trolley and Cable trolley
Trolley stop
When double trolley moves close the end of profile, the trolley stop prevents
cable trolley crashed by double trolley since the height of the top edge of cable trolley
is lower than the bottom edge of Trolley stop.
Fasten the trolley stop to the top of the section on the power supply side
according to the length of the accumulated cable trolleys.
For instance, a 6m length of girder, we use 6.2m of cable and 4 of cable trolley.
You may fasten the trolley stop at power supply side about 65x4=260mm.
4-10. Protecting ring
The ring is used for Security
To prevent the girder fallen injuring operator.
2 holes need drill inside of the span of girder, the wire-rope need lock fasten.
4-11. Assembling Festoon cable arrangement
Mains on/off switch/isolator and any fuse and adaptor inserts as necessary, owner should
prepare before assembly, and fix it on the wall or column.
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 or cable trolleys are fitted.
2). 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.( usually, the space between two supports is 1500mm)
Cable trolleys may cause jamming in curve sections. In this case, the maximum
distance between the cable trolleys should be equal to the curve radius.
3). Tighten the bolts/nuts on the cable sliders/cable trolleys so that flat cable
does not slip through the cable supports.
4). Place the cable supports in the profile section.
4-12. The load capacity plates, Maker’s plate, Warning Signs etc. should be attached
to each crane.
5. Commissioning
KBK installations may only be put into operation when they have been
assembled in accordance with the relevant accident prevention regulations
and inspected by an expert engineer
Before the installation is first put into operation:
• the working area must be secured
• the mains voltage and frequency must be checked to match those specified on
the rating plate
• all safety distances have to be checked
• a check must be carried out to ensure that the crane and crab trolleys can be
moved without resistance by hand over the entire length of the track section.
6. Putting into operation, be sure
• the working area must be secured
• the mains voltage and frequency must be checked to match those specified on
the rating plate
• all safety distances have to be checked
• a check must be carried out to ensure that the crane and crab trolleys can be
moved without resistance by hand over the entire length of the track section.