KBK II-H crane construction kit Classic system

KBK II-H crane construction kit Classic system Supplement to technical document 202 976 44 42794844.eps 120711 enen 203 733 44 714 IS 152

Manufacturer Demag Cranes & Components GmbH PO Box 67 58286 Wetter, Germany Telephone +49 (0) 2335 92-0 Telefax +49 (0) 2335 927676 www.demagcranes.com Contents 1 KBK crane construction kit, general 4 1.1 General 4 1.2 Design principles 4 2 KBK classic planning and project drafting 5 2.1 Profi le load capacities according to the diagram 5 2.2 Determining load G AB on one suspension fitting 5 2.3 System dimensions and system limits 6 2.4 Structural dimensions for monorail tracks and cranes 7 2.5 Reading off from the selection table 8 3 Basic components for monorail track, crane runway, crane girder 11 3.1 Crane and track elements 11 3.1.1 Straight sections 11 3.1.2 Coupling tube 11 3.2 Joint bolt set 11 3.3 Internal buffer stop 12 3.4 End cap with buffer 12 3.5 KBK II-H-R components 13 3.6 Maintenance section 14 3.7 Information plates 15 4 Assemblies for monorail tracks 16 4.1 General 16 4.2 Trolley latch 16 5 Track suspension 17 5.1 Vertical suspension on I-beams 17 5.1.1 Suspension with suspension rod 17 5.1.2 Short suspension arrangement with height adjustment 18 5.1.3 Short suspension arrangement without height adjustment 19 5.2 V-type suspension fi tting, stiffener 19 5.2.1 V-type hinged suspension bracket 19 6 Trolleys and trolley combinations 20 6.1 Crane traverses with rigid crane girder connection 20 6.1.1 Crane traverse carriage, rigid (standard height) 20 6.1.2 Crane traverse carriage, rigid, raised 21 7 Crab 22 7.1 Crab frame 22 7.2 Raised crab frame 22 8 Parts for building cranes 23 8.1 Crane suspension eye 23 8.2 Bracing frame 23 9 Travel drives for crabs and cranes 24 9.1 RF 125 friction wheel travel drive 24 9.1.1 RF 125 rocker, KBK II-L, II, II-H 24 9.2 Disengaging devices 24 9.2.1 RF 125 manually actuated disengaging devices 24 9.2.2 RF 125 electrically actuated disengaging devices 25 9.2.3 Angle bracket for housing 25 9.3 Travel limit switches 26 2

Contents 10 Trolleys for travel drives 27 11 Link and spacer bars 28 11.1 Hinged block 28 12 Buffers and end stops 29 12.1 KBK II-H buffer 29 13 Fittings 30 13.1 Rail attachment 30 13.1.1 Mounting bracket 30 13.2 Canopy 30 14 Power supply to crabs and cranes 31 14.1 Electrical power supply 31 14.1.1 Trailing cable components and fi ttings 31 14.1.2 Mounting brackets for switches and terminal boxes 32 14.2 Pneumatic power supply 33 14.2.1 Components 33 15 KBK standard electrical equipment 34 15.1 Cable input sets 34 3

1 KBK crane construction kit, general General 1.1 General This document is a supplement to technical document 202 976 44 and must be used together with it. The new KBK II-H profile section is an addition to the existing KBK profi le section system. The proven components from the KBK II profile section range are mainly used. This document describes the new or modified components for KBK II-H. i The following main components from the KBK II crane construction kit cannot be used in combination with KBK II-H and are still being revised: - Latching devices - Extending frames - RF 100 - All ergo components Furthermore, a KBK III crane runway can currently only be combined with a KBK II-H crane girder by using a traverse for KBK III double-girder crane (item 66). For this reason, this combination is currently not included in any of the selection tables and a separate enquiry must be sent. The following KBK II assemblies can be used with the adaptor unit: - Curved parts - Track switches - Turntables If you are not sure about how to use the new profi le section range, please contact your Demag partner. For the same trolley load capacity as KBK II, the KBK II-H profi le makes it possible to achieve signifi cantly larger span dimensions for cranes and runways. This profi le section may also be combined with different profi le sizes for cranes and runways, refer to Section 2.3 Possible combinations of sections for crane and crane runway. KBK II-H is also available with the proven internal conductor rails as KBK II-H-R. The joint between profi le sections for monorails or crane runways can be located at virtually any position (for further information, see Distance of joint from suspension fi tting ). KBK II-H replaces the KBK II-T profi le section. 1.2 Design principles Weight 23,7 kg/m + 1,3 kg Moment of inertia 1647 cm 4 Neutral axis approx. profi le centre Material S355 4 KBK II KBK II-H 42797244.eps

2 KBK classic planning and project drafting 2.1 Profile load capacities according to the diagram Diagram for crane and track selection Diagram: Spacing between supports, crane spans (Curve applies if hoists are used with lifting speeds up to 16 m/min.) l w /l Kr [m] Planning Max. length of straight sections Important: - - - Limit curve for maximum length of straight sections; pay attention to the distance between supports and distances of joints (see section 2.2 and 2.3). Lifted load coeffi cient ψ, dead weight coeffi cient ϕ to DIN 15018 and oscillation coeffi cient ϕ to DIN 4132 for crane group H1, B3 as well as the dead weight of each loaded girder are already considered in the calculation diagrams. K = Load on the profi le section l w = Distance between supports l Kr = Crane span dimension K [kg] 42797445.jpg 2.2 Determining load G AB on one suspension fitting The maximum permissible load G AB on a suspension fitting for KBK II-H amounts to: - M16: 1700 kg - M20: 2600 kg. 5

2.3 System dimensions and system limits Overhang u KBK II-H Shortest possible overhang [mm] u min 60 Project engineering values for overhang [mm] u 300 Planning Permissible distance st of joint from suspension fitting KBK II-H Minimum distance [mm] st min 45 1) Maximum permissible distance [mm] st max any for tracks 0,25 x span dimension l Kr for cranes 1) The track suspension clamp must be fully located on one of the two connected profi le sections. The special load capacity of the rail joint is only guaranteed on original quality profiles. Crane girder lengths l HT Crane girders measuring up to 8 m in length should be made of one profi le section. The specifi ed minimum distance of the joint from the suspension fi tting must be maintained for multiple-section girders. Crane girder length in m KBK II-H l Ht l Kr l G1 l G2 l G3 9 4,50-5,50 3 6 5,50-8,85 2 7 10 5,50-6,70 3 7-6,70-9,85 2 8 11 6,50-8,00 3 8 8,00-10,50 2 7 2 12 7,50-9,00 3 6 3 9,00-10,50 2 8 2 13 8,50-10,50 3 7 3 14 9,50-10,50 3 8 3 Possible combinations of sections for crane and crane runway Track Crane KBK 100 KBK I KBK II-L KBK II KBK II-H KBK III KBK 100 KBK I X (X) (X) (X) - 6 X = recommended (X) = possible, not recommended - = not possible KBK II-L X X KBK II (X) X X KBK II-H KBK III - - (X) - (X) X

2.4 Structural dimensions for monorail tracks and cranes Suspension monorail Single-girder crane Planning 42797345.eps Dimension h 2 [mm] (suspension from I-beam superstructures with upper suspension bracket) Short suspension fi tting Length of suspension rod for spring clip without height adjustment with spring clip 100 300 600 1000 3000 KBK II-H 75 105 185 385 685 1085 3085 Dimension h 3 for cranes [mm] KBK crane runway II II-H KBK crane girder II-H I II-L II II-H III Trolleys single 508 433 492 522 555 588 double 523 448 507 537 570 603 Crab trolleys Dimension h [mm] (to top edge of pin) KBK II-H single 19 double 34 Crab frame II -206 Crab frame II, DC -196 7

2.5 Reading off from the selection table l w data apply to one crane on the crane runway. Crane girder overhangs are always the same on both sides of the crane. Deflection limits: Crane, runways: 1/350, Frequency 2,8 Hz l HT = Crane girder length l Kr = Crane span dimension l w = Distance between suspensions Suspension loads on request All dimensions in m Planning Project engineering data for crane installations must be selected from the adjacent table for KBK single and double-girder cranes. In individual cases, exact static analysis calculations may lead to different results for I Kr and I w. You can confi gure your system online at www.demag-designer.de. Where there are several cranes on the same runway, the end carriages of single-girder cranes must always be designed as double or quadruple trolleys. Distances between suspensions l w must then be calculated separately. Intermediate lengths for crane girders are possible. Data calculated on the basis of cranes of standard design for standard components and without special attachments. Check suspension loads. Cranes according to DIN 15018, tracks according to DIN 4132: H1, B3 (H2, B3 on request). Crane girder profile, crane girder length KBK II-H KBK II-H Load capacity: 125 kg, hoist weight: 35 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 1,50-1,85 6,95 9,00 10,50 1,50-1,85 6,65 9,00 10,50 3 2,10-2,85 6,60 9,00 10,50 1,50-2,85 5,70 7,85 10,50 4 2,60-3,85 6,30 8,75 10,50 2,00-3,85 5,35 7,40 10,50 5 3,00-4,85 6,05 8,35 10,50 2,50-4,85 5,15 7,10 10,50 6 3,40-5,85 5,80 8,05 10,50 3,00-5,85 4,95 6,85 10,50 7 3,70-6,85 5,60 7,80 10,50 3,50-6,85 4,80 6,60 10,45 8 4,00-7,85 5,45 7,55 10,50 4,00-7,85 4,65 6,40 10,15 9 4,50-8,85 5,35 7) 7,40 7) 10,50 7) 4,50-8,85 4,50 6,20 9,80 10 5,50-9,85 5,35 7) 7,40 7) 10,50 7) 5,50-9,85 4,45 6,15 9,70 11 6,50-10,50 5,35 7) 7,40 7) 10,50 7) 6,50-10,50 4,40 6,10 9,60 12 7,50-10,50 5,30 7) 7,35 7) 10,50 7) 7,50-10,50 4,35 6,00 9,40 13 8,50-10,50 5,25 1) 7,25 1) 10,50 1) 8,50-10,50 4,25 5,90 9,25 14 9,50-10,50 5,20 1) 7,15 1) 10,50 1) 9,50-10,50 4,20 5,80 9,10 Load capacity: 250 kg, hoist weight: 35 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 1,60-1,85 5,45 7,60 10,50 1,50-1,85 5,50 7,60 10,50 3 2,35-2,85 5,30 7,35 10,50 1,50-2,85 4,70 6,50 10,20 4 3,00-3,85 5,15 7,15 10,50 2,00-3,85 4,45 6,15 9,70 5 3,60-4,85 5,00 6,95 10,50 2,50-4,85 4,30 5,95 9,35 6 4,15-5,85 4,90 6,75 10,50 3,00-5,85 4,20 5,75 9,10 7 4,60-6,85 4,75 6,60 10,40 3,50-6,85 4,10 5,65 8,85 8 5,05-7,85 4,65 6,45 10,15 4,00-7,85 4,00 5,50 8,65 9 5,45-8,85 4,50 7) 6,25 7) 9,90 7) 4,50-8,85 3,85 5,35 8,45 10 5,90-9,85 4,40 7) 6,15 7) 9,75 7) 5,50-9,85 3,85 5,35 8,45 11 7,45-10,50 4,50 7) 6,25 7) 9,90 7) 6,50-10,50 3,80 5,35 8,40 12 8,80-10,50 4,55 1) 6,25 1) 9,90 1) 7,50-10,50 3,75 5,30 8,30 13 10,10-10,50 4,55 1) 6,25 1) 9,90 1) 8,50-10,50 3,70 5,25 8,25 14 - - - - 9,50-10,50 3,60 5,15 8,15 8 1) Two end carriages on each side of the crane 2) Double trolley unit 3) Quadruple trolley end carriages on each side of crane 7) Two end carriages on each side of the crane with l Kr 8 m 8) Quadruple trolleys on the crane, M20 suspension on the track

Crane girder profile, crane girder length KBK II-H KBK II-H KBK II-H Load capacity: 500 kg, hoist weight: 60 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 1,70-1,85 3,90 1) 5,60 1) 8,85 1) 1,50-1,85 4,25 5,85 9,25 3 2,55-2,85 3,80 1) 5,50 1) 8,70 1) 1,65-2,85 3,55 5,10 8,05 4 3,35-3,85 3,70 1) 5,40 1) 8,55 1) 2,35-3,85 3,40 4,95 7,80 5 4,10-4,85 3,60 1) 5,30 1) 8,40 1) 2,95-4,85 3,25 4,80 7,60 6 4,80-5,85 3,50 1) 5,25 1) 8,30 1) 3,55-5,85 3,10 4,60 7,40 7 5,50-6,85 3,40 1) 5,15 1) 8,15 1) 4,05-6,85 3,00 4,45 7,25 8 6,10-7,85 3,30 1) 5,05 1) 8,05 1) 4,50-7,85 2,90 4,25 7,05 9 6,70-8,85 3,20 1) 4,90 1) 7,90 1) 4,95-8,85 2,75 4,10 6,90 10 7,95-9,25 3,25 1) 4,95 1) 7,95 1) 5,50-9,85 2,70 4,00 6,80 11 9,15-9,30 3,25 1) 5,00 1) 8,00 1) 6,50-10,50 2,75 4,05 6,85 12 - - - - 7,50-10,50 2,70 4,05 6,85 13 - - - - 8,50-10,50 2,70 4,00 6,80 14 - - - - 9,80-10,50 2,70 4,00 6,80 Load capacity: 630 kg, hoist weight: 65 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 1,50-1,85 2) 3,25 1) 5,00 1) 8,00 1) 1,50-1,85 3,85 5,35 8,45 3 2,40-2,85 2) 3,20 1) 4,85 1) 7,90 1) 1,75-2,85 3,10 4,60 7,40 4 3,20-3,85 2) 3,10 1) 4,75 1) 7,75 1) 2,45-3,85 3,00 4,40 7,20 5 4,00-4,85 2) 3,05 1) 4,65 1) 7,65 1) 3,15-4,85 2,85 4,25 7,05 6 4,80-5,85 2) 2,95 1) 4,55 1) 7,55 1) 3,75-5,85 2,75 4,05 6,80 7 5,50-6,85 2) 2,90 1) 4,45 1) 7,45 1) 4,30-6,85 2,65 3,90 6,70 8 6,20-7,85 2) 2,85 1) 4,35 1) 7,40 1) 4,85-7,85 2,55 3,75 6,55 9 6,85-8,30 2) 2,75 1) 4,25 1) 7,30 1) 5,30-8,85 2,45 3,65 6,40 10 7,85-8,30 2) 2,75 1) 4,25 1) 7,25 1) 5,90-9,85 2,40 3,55 6,30 11 - - - - 6,65-10,50 2,40 3,50 6,25 12 - - - - 7,85-10,50 2,40 3,55 6,35 13 - - - - 9,10-10,50 2,45 3,55 6,35 14 - - - - 10,35-10,50 2,45 3,55 6,35 Load capacity: 800 kg, hoist weight: 65 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 1,50-1,85 2) 2,75 1) 4,15 1) 7,20 1) 1,50-1,85 3,30 4,85 7,65 3 2,40-2,85 2) 2,65 1) 4,10 1) 7,15 1) 1,80-2,85 2,70 3,95 6,75 4 3,30-3,85 2) 2,60 1) 4,00 1) 7,05 1) 2,55-3,85 2,60 3,85 6,65 5 4,10-4,85 2) 2,55 1) 3,95 1) 6,95 1) 3,25-4,85 2,50 3,70 6,50 6 4,90-5,85 2) 2,50 1) 3,85 1) 6,90 1) 3,95-5,85 2,40 3,55 6,35 7 5,70-6,85 2) 2,45 1) 3,80 1) 6,80 1) 4,55-6,85 2,35 3) 3,45 3) 6,20 3) 8 6,40-7,40 2) 2,40 1) 3,70 1) 6,75 1) 5,15-7,85 2,30 3) 3,35 3) 6,10 3) 9 7,15-7,45 2) 2,40 1) 3,65 1) 6,70 1) 5,70-8,85 2,25 3) 3,25 3) 6,00 3) 10 - - - - 6,20-9,85 2,05 3) 3,20 3) 5,90 3) 11 - - - - 7,10-10,00 2,05 3) 3,20 3) 5,90 3) 12 - - - - 8,40-10,05 2,20 3) 3,20 3) 5,95 3) 13 - - - - 9,60-10,05 2,20 3) 3,20 3) 5,95 3) Planning 1) Two end carriages on each side of the crane 2) Double trolley unit 3) Quadruple trolley end carriages on each side of crane 7) Two end carriages on each side of the crane with l Kr 8 m 8) Quadruple trolleys on the crane, M20 suspension on the track 9

Planning Crane girder profile, crane girder length KBK II-H KBK II-H KBK II-H KBK II-H Load capacity: 1000 kg, hoist weight: 120 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 1,55-1,85 2) 2,20 1) 3,35 1) 6,35 1) 1,50-1,85 2,65 3,95 6,70 3 2,45-2,85 2) 2,80 3) 3,90 3) 6,35 3) 1,85-2,85 2,25 3) 3,25 3) 6,00 3) 4 3,35-3,85 2) 2,75 3) 3,85 3) 6,30 3) 2,65-3,85 2,05 3) 3,20 3) 5,90 3) 5 4,20-4,85 2) 2,75 3) 3,80 3) 6,25 3) 3,40-4,85 1,50 3) 3,10 3) 5,80 3) 6 5,05-5,85 2) 2,70 3) 3,75 3) 6,20 3) 4,15-5,85 1,25 3) 3,05 3) 5,75 3) 7 5,85-6,50 2) 2,65 3) 3,70 3) 6,15 3) 4,85-6,85 1,10 3) 2,95 3) 5,65 3) 8 - - - - 5,50-7,85 0,95 3) 2,90 3) 5,55 3) 9 - - - - 6,10-8,85 0,85 3) 2,80 3) 5,50 3) 10 - - - - 6,70-9,10 0,80 3) 2,60 3) 5,40 3) 11 - - - - 7,75-9,10 0,80 3) 2,80 3) 5,45 3) 12 - - - - 8,95-9,10 0,85 3) 2,80 3) 5,45 3) Load capacity: 1250 kg, hoist weight: 120 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 - - - - 1,50-1,85 2,35 3) 3,40 3) 6,05 8) 3 - - - - 1,95-2,85 1,00 3) 2,95 3) 5,50 8) 4 - - - - 2,80-3,85 0,95 3) 2,85 3) 5,45 8) 5 - - - - 3,60-4,85 0,90 3) 2,25 3) 5,40 8) 6 - - - - 4,35-5,85 0,85 3) 1,80 3) 5,30 8) 7 - - - - 5,10-6,85 0,80 3) 1,50 3) 5,25 8) 8 - - - - 5,80-7,85 0,75 3) 1,30 3) 5,20 8) 9 - - - - 6,45-8,25 0,75 3) 1,15 3) 5,10 8) 10 - - - - 7,10-8,25 0,70 3) 1,05 3) 5,05 8) Load capacity: 1600 kg, hoist weight: 120 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 - - - - 1,50-1,85 0,95 3) 2,90 3) 5,45 8) 3 - - - - 2,00-2,85 0,70 3) 1,00 3) 5,00 8) 4 - - - - 2,85-3,85 0,65 3) 0,95 3) 4,95 8) 5 - - - - 3,70-4,85 0,65 3) 0,90 3) 4,90 8) 6 - - - - 4,50-5,85 0,65 3) 0,85 3) 4,85 8) 7 - - - - 5,25-6,85 0,30 3) 0,70 3) 4,80 8) 8 - - - - 6,00-7,40 0,30 3) 0,80 3) 4,75 8) 9 - - - - 6,70-7,40 0,30 3) 0,75 3) 4,70 8) Load capacity: 2000 kg, hoist weight: 120 kg Single-girder crane Double-girder crane l HT l Kr lw l Kr lw min max KBK II-L KBK II KBK II-H min max KBK II-L KBK II KBK II-H 2 - - - - 1,50-1,85 0,65 3) 0,95 3) 5,00 8) 3 - - - - 2,00-2,85 0,30 3) 0,70 3) 4,55 8) 4 - - - - 2,90-3,85 0,30 3) 0,65 3) 4,55 8) 5 - - - - 3,90-4,85 0,30 3) 0,65 3) 4,50 8) 6 - - - - 4,95-5,85 0,30 3) 0,65 3) 4,50 8) 7 - - - - 6,05-6,70 0,30 3) 0,65 3) 4,50 8) 10 1) Two end carriages on each side of the crane 2) Double trolley unit 3) Quadruple trolley end carriages on each side of crane 7) Two end carriages on each side of the crane with l Kr 8 m 8) Quadruple trolleys on the crane, M20 suspension on the track

3 Basic components for monorail track, crane runway, crane girder 3.1 Crane and track elements 3.1.1 Straight sections (Item 1) KBK II-H KBK II-H-R 42794944.eps Item Designation Length l G KBK II-H KBK II-H-R [mm] 1000 Weight [kg] 25,00 26,22 Part no. 858 201 44 858 951 44 2000 Weight [kg] 48,70 51,14 Part no. 858 202 44 858 952 44 3000 Weight [kg] 72,40 76,06 Part no. 858 203 44 858 953 44 1 Straight section 4000 Weight [kg] 96,10 100,97 Part no. 858 204 44 858 954 44 5000 Weight [kg] 119,80 125,89 Part no. 858 205 44 858 955 44 6000 Weight [kg] 143,50 150,80 Part no. 858 206 44 858 956 44 7000 Weight [kg] 167,20 175,68 Part no. 858 207 44 858 957 44 8000 Weight [kg] 190,90 200,58 Part no. 858 208 44 858 958 44 Basic components 3.1.2 Coupling tube 1a Coupling tube, 16 off Weight [kg] 2,58 Part no. 858 890 44 The full load capacity of the rail joint is no longer guaranteed for small coupling pipes that have subsequently been welded on. 3.2 Joint bolt set Joint bolt set (item 2) Conductor connection (item 3) Bolted connection 2 Bolted connection 3 Conductor connection Weight [kg] 1,42 Part no. 858 258 44 Weight [kg] 0,07 - Part no. 873 649 44 Joint bolt set 858 258 44 will also be used for KBK III. The previous KBK III joint bolt set (850 258 44) will no longer be supplied. 11

Adaptor unit KBK II / II-H (Item 2a) Basic components 43408444.eps 2a Adaptor unit KBK II / II-H Weight [kg] 24,80 26,02 Part no. 858 220 44 858 970 44 The adaptor unit enables the connection of KBK II-H- with KBK II profi les. A suspension fi tting must be provided on the KBK II side in the vicinity of the joint. The permissible distance of the joint from the suspension fi tting must be maintained. 3.3 Internal buffer stop (Item 6) 42795144.eps Weight [kg] 0,28 6 Internal buffer stop Part no. 858 120 44 This buffer stop can also be used for KBK II-L, KBK II and Aluline 180 profile sections. 3.4 End cap with buffer (Item 7) 12 42795244.eps 7 End cap with buffer Weight [kg] 1,74 1,77 Part no. 858 126 44 858 920 44

3.5 KBK II-H-R components Power feed end cap with buffer (Item 8) 42795345.eps Item Designation KBK II-H-R 8 Power feed end cap with buffer Weight [kg] 2,00 Part no. 858 926 44 Power feed end cap comprises an end face M20 bolted connection. Partial sections with a diameter of 20,5 mm or. 25,5 mm should be provided. Basic components Centre powerfeed section (Item 9) 43408544.eps Item Designation KBK II-H-R 9 Centre powerfeed section Weight [kg] 29,60 Part no. 858 615 44 DFL bracket (Item 210) Item Designation KBK II-H-R 210 DFL bracket for KBK II-H-R (20 units + 5 screws) Weight [kg] 0,15 Part no. 858 912 44 The set is designed for retrofi tting KBK II-H profi les with a busbar line. Determining the number of brackets for each straight section: Length of straight sections [m] / 0,7 + 1 The DFL busbar line must be ordered separately. 13

3.6 Maintenance section (Item 11) 43408644.eps Basic components Item Designation KBK II-H-R 11 KBK II-H-R maintenance section Weight [kg] 28,00 Part no. 858 665 44 14

3.7 Information plates Capacity plate (item 15) 43408744.eps Item Designation Load capacity KBK 100 / KBK I / Aluline 120 h = 40 mm, w = 285 mm 15 Capacity plate Special capacity plate KBK II-L / KBK II / KBK II-H / KBK III h = 60 mm, w = 420 / 440 mm [kg] Part no. Part no. 50 980 861 44-80 980 862 44-100 980 863 44-125 980 864 44-160 980 865 44-200 980 866 44-250 980 867 44 851 491 44 315 980 868 44-400 980 869 44-500 980 870 44 851 492 44 630-851 493 44 800-851 494 44 1000-851 495 44 1250-851 496 44 1600-851 497 44 2000-851 498 44 2500-851 499 44 10-500 715 540 46-100 - 3200-715 560 46 Basic components These part numbers replace the previous numbers for the KBK capacity plates. The manufacturer s plate (trilingual: German, English and French) showing the manufacturer, year of construction, KBK type, the serial number and CE confi rmation must be fitted to each crane bridge or electric monorail hoist. The manufacturer's plate on the hoist is sufficient for monorail push travel trolleys. Capacity plates must be fi tted to both sides of all crane bridges. Such plates must be fi tted to monorail tracks at suitable distances and in such a manner that operators can see the permissible load capacity from any operating position. The load capacity stated on the hoist and on the crane or suspension monorail must be identical. Design: Self-adhesive foil 15

4 Assemblies for monorail tracks 4.1 General The KBK II-H can be combined with the track switch and KBK II turntable assemblies via the adaptor unit. 4.2 Trolley latch (Item 155) 42769645.eps 155 Trolley latch Weight [kg] 7,30 Part no. 715 345 46 156 Pin for the trolley latch Weight [kg] 0,30 Part no. 851 417 44 Assemblies An extended trolley pin is part of the lock device. More pins must be ordered for additional trolley. 16

5 Track suspension 5.1 Vertical suspension on I-beams 5.1.1 Suspension with suspension rod (Item 30) 42795445.eps Item Designation Suspension rod [mm] Upper suspension bracket Type KBK II-H KBK II-H-R 30 Complete suspension with M16 suspension rod Max. load on suspension 1700 kg 100 300 600 1000 A B A B A B A B Weight [kg] 4,05 Part no. 858 147 44 Weight [kg] 4,90 Part no. 858 149 44 Weight [kg] 4,36 Part no. 858 148 44 Weight [kg] 5,21 Part no. 858 151 44 Weight [kg] 4,69 Part no. 715 320 46 Weight [kg] 5,22 Part no. 715 322 46 Weight [kg] 5,29 Part no. 715 321 46 Weight [kg] 6,14 Part no. 715 323 46 Suspension fitting 100 Weight [kg] 14,38 Part no. 858 264 44 Complete suspension with M20 suspension rod Max. load on suspension 2600 kg 300 600 B Weight [kg] 14,79 Part no. 715 721 46 Weight [kg] 15,42 Part no. 715 723 46 1000 Weight [kg] 16,25 Part no. 715 725 46 17

Suspension fitting in component parts 42795745.eps 25 M20 suspension plate: 40 M20 ball rod 42 M16 suspension clamp Max. load on suspension 1700 kg M20 suspension clamp Max. load on suspension 2600 kg Weight [kg] 11,50 Part no. 858 304 44 Weight [kg] 0,27 Part no. 858 343 44 Weight [kg] 0,72 Part no. 858 260 44 Weight [kg] 0,67 Part no. 858 280 44 Suspension fitting Part number 858 343 44 replaces previous number 850 343 44, which cannot be used with KBK II-H. 5.1.2 Short suspension arrangement with height adjustment (Item 31) 42795544.eps 18 Item Designation Upper suspension bracket 31 Complete suspension fi tting Short suspension arrangement with M16 height adjustment Type A B KBK II-H KBK II-H-R Max. load on suspension 1700 kg Weight [kg] 3,81 Part no. 858 145 44 Weight [kg] 4,72 Part no. 858 146 44

5.1.3 Short suspension arrangement without height adjustment (Item 45) 42795644.eps Item Designation Upper suspension bracket 45 Short suspension arrangement without M16 height adjustment Type A B KBK II-H KBK II-H-R Max. load on suspension 1700 kg Weight [kg] 2,07 Part no. 858 370 44 Weight [kg] 2,95 Part no. 858 371 44 The clamps (26) must be ordered separately. 5.2 V-type suspension fitting, stiffener 5.2.1 V-type hinged suspension bracket (Item 47) V-type suspension fi tting Lateral stiffener Suspension fitting 43408945.eps 47 V-type hinged suspension bracket v [mm] = h1 (suspension rod length) + 100 ± 7 Weight [kg] 2,45 Part no. 858 080 44 19

6 Trolleys and trolley combinations 6.1 Crane traverses with rigid crane girder connection 6.1.1 Crane traverse carriage, rigid (standard height) (Item 62) 43409044.eps Trolleys Item Designation e KT Trolley type 1) K max Crane girder [mm] [kg] KBK II KBK II-H 62 Single-girder crane traverses, rigid (Track KBK II-L, II, II-H) Double-girder crane traverses, rigid (Track KBK II-L, II, II-H) l Ka = 550mm Double-girder crane traverses, rigid (Track KBK II-L, II, II-H) l Ka = 650mm 1000 E 1200 E 1600 E 2000 E 1000 D 1200 D 1600 D 1150 1300 2000 D 1170 1200 E 1600 E 2000 E 1140 1200 D 2340 1600 D 2250 2000 D 1620 1300 D 1600 D 2350 2000 D 1740 Weight [kg] 32,00 Part no. 715 324 46 715 374 46 Weight [kg] 35,40 Part no. 715 327 46 715 377 46 Weight [kg] 42,30 Part no. 715 327 46 715 377 46 Weight [kg] 49,20 Part no. 715 327 46 715 377 46 Weight [kg] 31,70 Part no. 715 326 46 715 376 46 Weight [kg] 35,10 Part no. 715 329 46 715 379 46 Weight [kg] 42,00 Part no. 715 329 46 715 379 46 Weight [kg] 48,90 Part no. 715 329 46 715 379 46 Weight [kg] 43,20 Part no. 715 330 46 715 380 46 Weight [kg] 50,20 Part no. 715 330 46 715 380 46 Weight [kg] 57,00 Part no. 715 330 46 715 380 46 Weight [kg] 42,90 Part no. 715 332 46 715 382 46 Weight [kg] 49,80 Part no. 715 332 46 715 382 46 Weight [kg] 56,70 Part no. 715 332 46 715 382 46 Weight [kg] 44,60 Part no. 715 333 46 715 383 46 Weight [kg] 49,80 Part no. 715 333 46 715 383 46 Weight [kg] 56,70 Part no. 715 333 46 715 383 46 20 1) E = Single trolley Two trolleys on each side of the crane D = Double trolley Four trolleys on each side of the crane The trolleys must be ordered separately. Maximum crane girder length: KBK II = 6 m KBK II-H = 8 m

6.1.2 Crane traverse carriage, rigid, raised (Item 67) 43409144.eps Load capacity [kg] Single-girder crane 1) KBK II-L KBK II KBK II-H Double-girder crane Single-girder crane 1) Double-girder crane Single-girder crane Double-girder crane l HT [m] l Kr [m] l HT [m] l Kr [m] l HT [m] l Kr [m] l HT [m] l Kr [m] l HT [m] l Kr [m] l HT [m] l Kr [m] l HT [m] l Kr [m] l HT [m] l Kr [m] 160 5,00 5,255 6,00 6,255 6,00 6,255 7,00 7,255 8,00 8,255 8,00 8,255 8,00 8,255 8,00 8,255 200 5,00 5,255 6,00 6,255 6,00 6,255 7,00 7,255 8,00 8,255 8,00 8,255 8,00 8,255 8,00 8,255 250 5,00 5,255 6,00 6,255 6,00 6,255 7,00 7,255 8,00 8,255 8,00 8,255 8,00 8,255 8,00 8,255 315 4,00 4,255 6,00 6,255 6,00 6,255 7,00 7,255 8,00 8,255 8,00 8,255 8,00 8,255 8,00 8,255 400 3,50 3,755 6,00 6,255 6,00 6,255 7,00 7,255 8,00 8,255 8,00 8,255 8,00 8,255 8,00 8,255 500 3,00 3,255 5,50 5,755 5,50 5,755 7,00 7,255 8,00 8,255 8,00 8,255 8,00 8,255 8,00 8,255 630 2,50 2,755 5,00 5,255 4,30 4,555 7,00 7,255 8,00 8,255 8,00 8,255 8,00 8,255 8,00 8,255 800 2,00 2,255 4,20 4,455 3,30 3,555 6,50 6,755 7,00 7,255 8,00 8,255 8,00 8,255 8,00 8,255 1000 3,80 4,055 5,50 5,755 5,60 5,855 6,00 6,255 8,00 8,255 8,00 8,255 1250 7,50 7,755 1600 6,60 6,855 2000 6,00 6,255 e KT [mm] 1000 1000 1000 1000 1000 1000 1000 1200 l Ka [mm] 550 550 550 550 650 Weight [kg] 31,00 36,00 31,90 37,10 34,08 39,90 39,50 47,10 Part no. 715 336 46 715 340 46 715 338 46 715 342 46 3) 715 386 46 715 388 46 715 390 46 715 392 46 Trolley 2) E E E E E E D D Trolleys The trolleys must be ordered separately. 1) only for push travel 2) E = Single trolley Two trolleys on each side of the crane D = Double trolley Four trolleys on each side of the crane 3) Alternative for trolley type D : 715 344 46 21

7 Crab 7.1 Crab frame (Item 78) 42795844.eps 78 KBK II-L crab frame KBK II crab frame Weight [kg] 18,20 Part no. 858 110 44 Weight [kg] 19,30 Part no. 858 310 44 These part numbers replace previous numbers 855 110 44 and 984 310 44, respectively, which cannot be used with KBK II-H. 7.2 Raised crab frame (Item 77) Double-rail crab 22 Crab frame Execution Max. load for alternative Dimension Dimension H Dimension Weight 1) HB DC 1/2 DC 5 DC 10 1/1 DC 10 2/1 B1 [kg] Hoist unit [mm] [mm] [mm] [mm] [mm] [mm] [kg] KBK II-H Black 1200 Red 2100 1) if the unit cannot be raised to the maximum position Part no. DC 1/2 DC 5/10 336 28 80 169 400 26,7 517 910 46 DC 5 DC 10 388 28 117-28,7 517 920 46 DC 10-477 - 28 30,9 517 930 46 DC 5 DC 10 388-28 117 209-44,3 517 940 46 DC 10 1/1 DC 10 2/1 477 28 120 47,9 517 950 46 - DC 10 2/1-546 - 51 50,7 517 960 46 From April 2011, the raised crab frames can also be implemented in KBK II-H crane girders. 43409344.eps

8 Parts for building cranes 8.1 Crane suspension eye (Item 75) Crane components 42795944.eps Max. load on suspension 1400 kg 75 Crane suspension eye Weight [kg] 1,00 Part no. 858 555 44 8.2 Bracing frame (Item 79) 42795944.eps Weight [kg] 11,10 79 Bracing frame Part no. 858 435 44 23

9 Travel drives for crabs and cranes 9.1 RF 125 friction wheel travel drive 9.1.1 RF 125 rocker, KBK II-L, II, II-H (Item 135) 1 Travel drives 2 3 1 Tractor trolley 2 RF 125 rocker 3 E 22 travel drive 42673546.eps Weight [kg] 4,40 135 RF 125 rocker Part no. 858 245 44 This part number replaces previous part number 851 245 44, which cannot be used with KBK II-H. 9.2 Disengaging devices 9.2.1 RF 125 manually actuated disengaging devices (Item 137) 42740847.eps 24 137 RF125 manual disengaging device Weight [kg] 1,10 Part no. 858 340 44 This part number replaces previous part number 851 340 44, which cannot be used with KBK II-H.

9.2.2 RF 125 electrically actuated disengaging devices (Item 138) 42740947.eps Travel drives Weight [kg] 9,30 138 RF125 electric disengaging device Part no. 858 350 44 This part number replaces previous part number 851 350 44, which cannot be used with KBK II-H. 9.2.3 Angle bracket for housing (Item 92) 42741046.eps 92 Angle bracket Weight [kg] 0,54 Part no. 858 357 44 This part number replaces previous part number 851 357 44, which cannot be used with KBK II-H. 25

9.3 Travel limit switches RF 125 limit switch fitting (Items 141, 142) Travel drives 42796144.eps 141 Limit switch, cpl. Weight [kg] 0,85 Part no. 858 351 44 142 Switching vane, cpl. Weight [kg] 0,66 Part no. 858 352 44 Part number 858 351 44 replaces previous number 851 351 44, which cannot be used with KBK II-H. 26

10 Trolleys for travel drives Tractor trolley (Item 69) Trolley 130 with RF 125 Trolley 270 with DRF 200 42796244.eps 69 130 tractor trolley Weight [kg] 3,95 Part no. 858 480 44 270 tractor trolley Weight [kg] 4,30 Part no. 858 490 44 RF trolleys These part numbers replace previous numbers 982 480 44 and 982 490 44, respectively, which cannot be used with KBK II-H. 27

11 Link and spacer bars 11.1 Hinged block (Item 72) RF hinged block KBK II-L, II 42626749.eps Weight [kg] 0,61 72 RF hinged block Part no. 858 399 44 This part number replaces previous part number 982 399 44, which cannot be used with KBK II-H. Link bars 28

12 Buffers and end stops 12.1 KBK II-H buffer (Item 98) 42796344.eps Weight [kg] 0,45 98 RF foamed-plastic buffer fitting Part no. 858 375 44 This part number replaces previous part number 982 375 44, which cannot be used with KBK II-H. 42796444.eps Weight [kg] 0,16 98 RF buffer plate Part no. 858 374 44 This part number replaces previous part number 982 374 44, which cannot be used with KBK II-H. Buffer 29

13 Fittings 13.1 Rail attachment 13.1.1 Mounting bracket (Item 89) 42796544.eps Weight [kg] 1,00 89 Mounting bracket Part no. 858 365 44 13.2 Canopy (Item 150) Fittings 42767245.eps Item Designation Chain hoists KBK II-H KBK II-H-R Weight [kg] 19,90 DK 1-5, DC 1-5 Part no. 715 347 46 150 Canopy Weight [kg] 22,20 DK 10, DC 10 Part no. 715 348 46 30

14 Power supply to crabs and cranes 14.1 Electrical power supply 14.1.1 Trailing cable components and fittings Rail end cable clamp (item 83) 42796644.eps Weight [kg] 0,21 83 Rail end cable clamp Part no. 858 114 44 Crane bridge cable clamp (Item 80) 42796744.eps Weight [kg] 0,83 80 Crane bridge cable clamp Part no. 858 680 44 RF trolley cable clamp (Item 82) Power supply 42627944.eps 82 RF trolley cable clamp Weight [kg] 0,26 Part no. 858 578 44 This part number replaces previous part number 982 578 44, which cannot be used with KBK II-H. 31

14.1.2 Mounting brackets for switches and terminal boxes Mounting bracket for terminal box (Item 92) 42796844.eps Weight [kg] 0,57 92 Terminal box mounting bracket Part no. 858 695 44 Bracket for isolator switch (Item 90) 42796944.eps Power supply Weight [kg] 1,64 90 Bracket for isolator switch Part no. 858 224 44 32

14.2 Pneumatic power supply 14.2.1 Components Mounting bracket with hose clip (Item 103) 1 22,5 interval 2 Hose clip set 2 3 Retaining plate 1 2 3 42797044.eps Weight [kg] 0,33 103 Mounting bracket with hose clip Part no. 858 115 44 This part number replaces previous part number 855 146 44, which cannot be used with KBK II-H. KBK II-H anchorage bracket (Item 110) 1 2 3 4 1 Screw set 2 Anchorage plate 3 22,5 interval 4 Hose clip set 2 42797144.eps Weight [kg] 0,80 110 KBK II-H anchorage bracket Part no. 858 693 44 Power supply 33

15 KBK standard electrical equipment Standard elec. equip. 15.1 Cable input sets (Items 190, 191) 190 Flat cable set 4 x 1,5 mm 2 Weight [kg] 0,11 Part no. 873 989 44 4 x 2,5 mm 2 Weight [kg] 0,15 Part no. 873 990 44 13 x 1,5 mm 2 Weight [kg] 0,10 Part no. 873 991 44 191 Round cable set 5 x 1,5 mm 2 Weight [kg] 0,11 Part no. 873 992 44 The cable sets comprise the relevant small parts required for the installation of KBK systems using series components. The assignment of the sets for the relevant application is specifi ed below. The cable set includes: 873 989 44: 2 x self-sealing grommets for M20 fl at cable, M20 locknut, M25-M20 reducer, M20 locknut, M20 bolted connection 873 990 44: 2 x self-sealing grommets for M25 fl at cable, 2 x M20 locknuts, 2 x M20-M25 extensions, M20 bolted connection 873 991 44: 2 x self-sealing grommets for M25 fl at cable 873 992 44: 2 x M25 locknuts, 2 x M20 locknuts, 1 x M25-M20 reducer, 2 x M25 bolted connections, 2 x M20 bolted connections Assignment of the cable set: Power supply on the monorails or crane runways: - 4 x 1,5mm 2 trailing cables: 1 x 873 989 44 for each power supply point - 4 x 2,5mm 2 trailing cables: 1 x 873 990 44 for each power supply point - Conductor line: no cable set required Power supply to the crane (refer to following table): Lifting Electrical movement Cross travel Long travel Isolator switch on crane Power supply to the crane (for each crane): Trailing cable Cross section 1,5 mm 2 Cross section 2,5 mm 2 Conductor line 4 x 1,5 mm 2 13 x 1,5 mm 2 4 x 2,5 mm 2 4 x 2,5 mm 2 + 8 x 1,5 mm 2 O O O 1 x 873 992 44 1 x 873 989 44 1 x 873 990 44 O O O O O 1 x 873 992 44 1 x 873 989 44 1 x 873 990 44 O O 2 x 873 992 44 1 x 873 991 44 1 x 873 989 44 O O O 3 x 873 992 44 1 x 873 991 44 1 x 873 992 44 1 x 873 990 44 1 x 873 992 44 O O O 2 x 873 992 44 1 x 873 991 44 1 x 873 989 44 O O O O 3 x 873 992 44 1 x 873 991 44 1 x 873 992 44 1 x 873 990 44 1 x 873 992 44 34

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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 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