Transcript
161012 en GB
211 232 44
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152
P.O. Box 67 58286 Wetter (Germany) Telephone +49 (0) 2335 92-0 Telefax +49 (0) 2335 92-7676 www.demagcranes.com Email:
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.
KBK KBK cran crane e cons constr truc ucti tion on kit, kit, proj projec ectt engi engine neer erin ing g and and comp compon onen ents ts
202 202 976 976 44 44
Redundant systems in the KBK crane construction kit
203 334 44
Operating instructions/com po ponent parts, KBK installations
206 076 44
Tab. 1
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2
1)
The documents can be ordered from the relevant Demag office.
1 1 2
1.1
.....................................................................................................................................................................4 General........................................................................................................................................................................ General ........................................................................................................................................................................4 ..........................................................................................................................................................................5
2.1
General........................................................................................................................................................................ General ........................................................................................................................................................................5
2.2
Intended use................................................................................................................................................................ use ................................................................................................................................................................5
2.3
Hazards that can be caused by the redundant systems ............................................................................................. .............................................................................................5 5 ...................................................................................................................................................6
3.1
Description ..................................................................................................................................................................6
3.2
Transport, packing, scope of delivery, storage ............................................................................................................7 ............................................................................................................7 .....................................................................................................................................................................8
4.1
Track suspensions ......................................................................................................................................................8
4.2
Crane suspensions ......................................................................................................................................................9
4.2.1 4.2.2 4.2.3 4.3
Selection table .............................................................................................................................................................9 Crane suspension on single trolley ...........................................................................................................................10 10 Crane suspension on double trolley (KBK I, KBK II, KBK III, Aluline) ....................................................................... .......................................................................12 12 Redundant system for the single trolley ....................................................................................................................12 12
4.4
Redundant system for the connecting rod .................................................................................................................13 13 ..........................................................................................................................14 14
5.1
Safety instructions when putting into service for the first time ................................................................................... ...................................................................................14 14
5.2
Inspection regulations ...............................................................................................................................................14 14 ...............................................................................................................................................15 15
6.1
General...................................................................................................................................................................... General ......................................................................................................................................................................15 15
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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 assemb assembly ly instru instruction ctions, s, ● the safety safety regula regulation tions s and and ● the safety instructions in the individual individual chapters chapters and and sections. sections.
Our KBK crane construction kit document ⇒ Tab. 1, Page 2 provides 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.
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1 1 2
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 of their development development and and manufacture, manufacture, the the redundant redundant systems systems in the the KBK kit were built according 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, conversions, modification modifications s or additions additions to the the redundant redundant systems systems in the KBK kit are prohibited prohibited unless ap‐ ap‐ proved by Demag in writing.
Redundant systems in the KBK kit are used where they are intended to prevent immediate crashes in the case of broken or loose components.
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.
A risk assessmen assessmentt has been been carried out for the redundant redundant systems. systems. The design design and execution based on on this anal‐ anal‐ ysis corresponds to state-of-the-art engineering principles. However, residual risks remain.
Assembly may only be carried out by trained trained specialist specialist personnel. personnel.
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Redundant systems prevent immediate crashes in the case of broken or loose components. 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. 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. Redundant components are subject to the same inspection and maintenance schedules as the other KBK compo‐ nents.
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Do not walk walk under the the suspended suspended load. load. Keep a sufficient safety safety distance. distance.
–
Cordon off off a large area area around around the working working zone. zone.
Transport the assemblies and parts with appropriate care.
● Check the delivery delivery to ensure it is complete and and for any transport damage damage immediately immediately on receipt. ● If any transport damage damage is visible from the outside, outside, do not accept accept the delivery or only on condition. 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 defects as soon as they they are detected, since since claims for damages damages may only be asserted asserted within the relevant claim notification periods. 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 dispose of packing material material in an environmentally environmentally friendly manner manner and in accordance accordance with local local dis‐ posal regulations. ● Contract Contract a recycling company, company, where where required. required.
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. Until they are installed, the redundant systems in the KBK kit must only be stored under the following conditions: ● Do not not store store outdo outdoors ors.. ● Store in dry and dust-free dust-free places, places, relative air humidity: humidity: max. 60%. 60%. ● Do not not expose expose to aggre aggressiv ssive e media. media. ● Protect Protect again against st direct direct sunli sunlight. ght. ● Avoid Avoid mecha mechanica nicall vibratio vibrations. ns. ● Storage Storage temp temperat erature: ure: -20 -20 to +70 +70 ℃. ● Avoid strong strong temperature temperature fluctuations fluctuations (condensation). (condensation). ● Check the general general condition of all parts of the packing packing at regular intervals. intervals. If required, refresh refresh or renew rust protection. ● If stored in damp locations, locations, the installation parts parts must be packed packed tight and protected protected against corrosion corrosion (desic‐ cant). 2 1 0 1 6 1 / 4 4 2 3 2 1 1 2
7
Fig. 1
Rope connector complete
Wire rope 6,5 8x19 + SES SZ
Weight [kg] Part no.
984 428 44
Weight [kg/m]
0,175
Part no.
583 440 44
Weight [kg]
Suspension clamp
0,5
Part no.
0,3
0,2
0,8
0,8
0,3
0,8
984 550 44
980 260 44
982 260 44
850 260 44
517 770 46 N
517 772 46 N
Tab. 2
The redundant system for the track suspension consists of: ● Rope connector connector (1) with two two rope sockets sockets (1a) and rope rope wedges wedges (1b), ● Rope Rope clamp clamps s (2), (2), ● Rope Rope (3) (3) and and ● Suspe Suspens nsion ion clam clamp p (4). (4). The rope is fitted next to the suspension fitting as a catching rope. The rope connector connects the two rope ends and acts as an additional damping element in the case of dam‐ age. The rope clamps serve as securing elements. The wire rope length must be determined in accordance with the required loop length.
Wire rope length
=
2 x length of threaded rod
+
2 x girder height
+
Flange width
+
500 mm
Tab. 3
● First fit the suspension suspension clamp clamp on the rail close to the the track suspension suspension fitting – max. max. distance 300 mm. ● Then lead one one end of the rope rope over the supporting supporting structure, whereas whereas the second second end - is lead through under the screws screws of the the suspension suspension clamp for for KBK I and and II - or, for Aluline Aluline and KBK III, is lead lead through through under under the suspension suspension clamp. clamp.
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● Push the first rope end end through the small opening opening of 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 assembly step with the second 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.
The rope clamps must not be fitted in the load-supporting area of the rope.
KBK I
KBK II
KBK I
KBK II
KBK I / II
KBK I / II
KBK III
KBK III
KBK I
KBK I
KBK II
KBK II
KBK I
KBK II
KBK III
KBK III
0,7
0,8
1,3
1,4
1,0
2,0
4,5
7,5
517 580 46 N
517 581 46 N
517 582 46 N
517 583 46 N
517 584 46 N
517 585 46 N
517 590 46 N
70
70
120
120
180
240
155
315
E
E
E
E
D
D
E
D
AL 120
AL 180
AL 120
AL 180
AL 120 / 180
AL 180 / 120
AL 120
AL 120
AL 180
AL 180
AL 120
AL 180
0,8
0,9
1,5
1,6
1,1
2,2
517 778 46 N
517 779 46 N
517 780 46 N
517 781 46 N
517 782 46 N
517 783 46 N
40
40
50
50
150
185
E
E
E
E
D
D
517 592 46 N
E = Single trolley D = Double trolley
Tab. 4
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Fig. 3
The redundant system for the crane suspension on KBK I, KBK II, Aluline single trolleys consists of: ● Catch Catching ing plate plate (1), (1), ● Suspens Suspension ion clamp clamp (2) (2) and and ● Long Long pin (3) for for single single trolle trolley. y. 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.
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.
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Fig. 4
1
Catching plate
4
Nut with plate
7
M16 screw
2
Washer 30x45x5
5
Washer 17x30x3
8
Suspension clamp
3
M16 nut
6
Washer 17x40x6
Tab. 5
The redundant system for the crane suspension on KBK III single trolleys consists of: ● Catch Catching ing plate plate and and ● Suspensi Suspension on clamp clamp with compone component nt parts. 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.
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.
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Fig. 5
1
Catching bracket
2
Suspension clamp
Tab. 6
The redundant system for the crane suspension on double trolleys consists of: ● Catch Catching ing bracke brackett and and ● 2 suspe suspensi nsion on clam clamps ps.. 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.
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.
Fig. 6 KBK II single trolley with redundant link bar (A), KBK II articulated frame (B), Aluline 180 single trolley with redundant link bar (C), Aluline 180 articulated frame (D)
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1 1 2
Redundant link bar
Trolley
Weight [kg]
0,6
1,0
1,2
2,0
Part no.
517 587 46 N
517 589 46 N
517 774 46 N
517 776 46 N
Weight [kg]
0,7
1,2
1,5
2,2
Part no.
980 610 44
982 110 44
855 050 44
855 080 44
Tab. 7
The single trolley is turned into a redundant system by creating a double trolley. This can be done by using the redundant link bar (1) or via the articulated frame (2).
Fig. 7
1
Single trolley
3
Redundant rope
2
Redundant link bar
4
Articulated frame
Tab. 8
The redundant rope (3) of the chain hoist is either lead through the redundant link bar (2) for single trolleys (1) or over the articulated frame (4) and fixed in accordance with ⇒ Fig. 2, Page 9. 9. For application in the crab frame, the chain hoist can be secured in a similar way.
In order to maintain the function of the redundant system, the following must be observed: –
During assembly, assembly, make make sure that the rope rope is not damage damaged d by contact contact with the KBK rail or the edges of sheet metal parts.
–
Check the redundant redundant rope for damage damage at regular regular intervals and replace replace it, as required. required.
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Carry out the inspection only in compliance with all safety regulations. Please also note the information in the "Operating instructions/Component parts, KBK installations" Page 2. 2.
⇒
Tab. 1,
Please also note the information in the "Operating instructions/Component parts, KBK installations" Page 2. 2.
⇒
Tab. 1,
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1 1 2
Assembly Assembly and disassemb disassembly ly are quite quite simple owing owing to the modular design of the crane construction construction kit.
Refer to the operating instructions of the installation for information on removing track sections, trolleys and cur‐ rent collector trolleys. Other parts are removed in reverse order to assembly. Waste materials left over from maintenance, repair and disassembly work must be disposed of correctly and ap‐ propriately in accordance with the relevant regulations and codes of practice.
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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 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
y n a m r e G n i d e t n i r omissions. P
