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 info@njdotti.com

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.