kbk classic and kbk ergo crane construction kit classic and kbk ergo crane construction kit overhead...

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KBK Classic and KBK Ergo Crane Construction KitOverhead transport, exact positioning, ergonomic handling

Distributed by Ergonomic PartnersEmail: [email protected]: www.ergonomicpartners.comPH: 314-884-8884 | FAX: 800-570-5584

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KBK classic suspension monorails can bebuilt to almost any design: from simple,manually controlled straight sections tocomplex, semi or fully automated closed-circuit monorail systems.

Suspension monorails from the KBK classic crane construction kit are theoptimum solution for linear, overheadhandling.

Outstanding versatilityA wide range of components makes itpossible to adapt the route precisely tomeet the structural requirements of yourworkshop. At the same time, the systemensures that all specific product andworkplace requirements of your produc-tion facility are met.

Transfer between suspension monorailsand single-girder suspension cranes isalso possible using latching devices.

Ideal equipment carriersThe special profiles of the KBK craneconstruction kit are particularly suitablefor applications such as tracks for loadbalancers fitted with testing devices andelectric and pneumatic tools, etc. andpower supply lines for cranes and othermobile equipment.

Cable trolleys can also be used for suspending hoses for transporting fluidsor gases.

Suspension monorailsIdeal for linear handling

Profile selection: max. distances between supports, headroom dimensions

KBKTrack

Profile Capacity 175 lb 275 lb 550 lb 1100 lb 2200 lb 3530 lb 4400 lb100 Maximum 9.8 ft. 7.9 ft.

I Hanger 16.4 ft. 13.5 ft. 8.2 ft.II-L Spacing 23.0 ft. 19.0 ft. 11.5 ft.II (ft.) 26.2 ft. 17.7 ft. 10.5 ft.III 26.2 ft. 18.7 ft. 13.5 ft. 11.2 ft.

Monorail Hanger Spacing

32058 31051 37387-1

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Single-girder suspension cranesFavourable dimensions, low deadweight

Single-girder suspension cranes fromthe KBK crane construction kit are usedfor fast and safe area-serving overheadhandling and exact positioning of awide variety of goods.

Flexible ball and socket connectionsbetween the crane girder and end carriages enable single-girder cranes tooperate on tracks that are not parallel.

The benefits of KBK classic single-girdersuspension cranes include latchingdevices that allow direct transfer of thehoist trolley between the crane and asuspension monorail.

Easy and cost-effective KBK classic single-girder suspensioncranes can be simply suspended from the building roof or superstructure.Additional supports for the crane runwayare not necessary. Even partial areas of a workshop may be easily fitted withsuspension cranes at low cost.

Profile selection: Max. distances between supports,crane spans, girder lengths

Smooth and reliable handlingThanks to their low deadweight andfree-running trolleys, the cranes allowheavy and awkward components to be moved quickly and easily by hand.

Crane span lkr

Girder length lHT

Crane span lkr

Girder length lHT

Crane span lkr

Girder length lHT

Crane span lkr

Girder length lHT

Crane span lkr

Girder length lHT

9.4 ft. 8.5 ft.

9.8 ft. 9.8 ft.

15.3 ft. 15.1 ft. 9.0 ft.

19.7 ft. 16.4 ft. 9.8 ft.

23.0 ft. 20.0 ft. 12.1 ft.

26.2 ft. 23.0 ft. 13.1 ft.

24.4 ft. 19.4 ft. 11.5 ft.

26.2 ft. 23.0 ft. 13.1 ft.

27.6 ft. 20.7 ft. 14.1 ft. 11.8 ft.

29.5 ft. 23.0 ft. 16.4 ft. 13.1 ft.

175 lb 275 lb 550 lb 1100 lb 2200 lb 3530 lb 4400 lb

100

l

ll-L

ll

lll

KBK section

Load capacity

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Double-girder suspension cranesLarge lifting heights, spans and high load capacities

Double-girder suspension cranes from the KBK classic crane construction kit feature a low deadweight and favourablestructural dimensions. In addition, thependulating suspension largely absorbsthe horizontal forces caused by starting,braking and stopping. Double-girder suspension cranes can even be installed in buildings of light steelconstruction.

Cranes operating on several runwaysprovide larger spans to cover extensivestorage and production areas.

Large lifting heightsArrangement of the hoist unit betweenthe two crane girders provides KBK classic double-girder cranes with agreater useful lifting height.

Large spansKBK classic double-girder cranes can alsooperate on several runways, thus providing large spans to cover extensivestorage and production areas.

Power supply cable trolleys travel in theKBK runway or crane girder sections. The control pendant can also travel inde-pendently of the hoist when fitted to aseparate travel rail.

Profile selection: Max. distances between supports,crane spans, girder lengths

The cranes can be easily moved by hand.However, electric friction wheel traveldrives from the KBK crane constructionkit are recommended for spans greaterthan 6 m and load capacities exceeding500 kg.

Crane span lkr

Girder length lHT

Crane span lkr

Girder length lHT

Crane span lkr

Girder length lHT

Crane span lkr

Girder length lHT

Crane span lkr

Girder length lHT

100

l

ll-L

ll

lll

175 lb 275 lb 550 lb 1100 lb 2200 lb 3530 lb 4400 lb 7000 lb

14.4 ft. 12.5 ft.

16.4 ft. 16.4 ft.

20.3 ft. 16.4 ft. 10.2 ft.

29.5 ft. 19.7 ft. 13.1 ft.

24.9 ft. 21.3 ft. 14.1 ft.

32.8 ft. 23.0 ft. 16.4 ft.

28.9 ft. 20.0 ft. 15.1 ft. 11.8 ft.

36.1 ft. 23.0 ft. 16.4 ft. 13.1 ft.

29.9 ft. 24.3 ft. 20.7 ft. 13.8 ft.

45.9 ft. 29.5 ft. 23.0 ft. 16.4 ft.

KBK section

Load capacity

With the KBK ergo modular system,double-girder suspension cranes can alsobe designed as manipulator cranes. Theycan be designed to meet the exact needsof the relevant loads, processes and production conditions. They make it possible to- Move workpieces and subassemblies

into the most favourable positions forthe relevant process,

- Serve workplaces, machinery andinstallations from any direction,

- perform operations outside the suspension area, thus increasing theoperating range.

Innovative and ready to meet tomorrow’s needsBased on KBK-I, KBK-II-L or KBK-II rails,manipulator cranes are built using selected KBK ergo components to meet

Manipulator cranesOptimum ergonomic load handling

the operating requirements. They featurethe ability to accommodate kick-upforces. In addition, they offer outstand-ing positioning accuracy, together with a high working speed. In this way, handling operations can be optimised inline with ergonomic requirements formaximum efficiency.

Fast upgradeIf you already have double-girder suspen-sion cranes from the KBK classic craneconstruction kit, they can be easily andquickly extended with KBK ergo compo-nents to become manipulator cranes.

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Overhung and extending cranesLarge overhang – constant or variable

If you also want to move loads beyondthe limits of the crane suspension – wecan make this possible with KBK.

Overhung cranesKBK-ergo overhung cranes are fittedwith crane girders that extend up to 2.5 m beyond the width of the cranerunway. This enables you to reach bays

added at a later date, for example. Oryou can handle loads below ducts, radiant heaters, pipes or similar obstaclesbetween the wall and roof which resultin the crane runway having to be positioned at a distance to the wall.

Extending cranesKBK classic and KBK ergo extendingcranes feature additional girders that arearranged between or beneath the cranegirders. Depending on the design, theycan be extended to one or both sidesbeyond the crane runway width. Thesecranes can also be used for lifting andpositioning loads in almost inaccessibleareas, e.g. between pillars and columns.

Depending on the required extensionlength, extending cranes may be com-pleted with KBK classic or also with KBKergo elements.

Max. permissible overhang dimensionsdepending on profile and extension type,also dependent on the load.

Max. permissible overhang dimensionsaccording to profile and crane type; alsodependent on the load.

KBK I KBK II-L KBK II

NA 4.9 ft. 5.9 ft.

5.2 ft. 7.5 ft. 8.2 ft.

KBK II-L KBK II

A1/1 4.9 ft. 5.9 ft.

B2/1 4.9 ft. 6.6 ft.

B2/2 7.5 ft. 8.2 ft.

Maximum Extending Length (ft)

Maximum Overhang (ft)

Single-girder crane

Double-girder crane

24820

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Stacker cranes, portal cranesSpecialised handling equipment for warehouse and factory

Stacker cranesStacker cranes from the KBK classic crane construction kit consist mainly of aKBK classic double-girder suspensioncrane and a special stacker trolley. Theyare used wherever unit loads, containersor pallets weighing up to 500 kg have to be transported, sorted and stored.They make it possible to complete alltasks in one work cycle without the need for ladders, order picking trolleys or similar equipment.

The lifting carriage can be fitted withforks, prongs, gripper tongs or otherload handling attachments in accordancewith the specific load handling require-ments. The mast with its trolley is easilymoved by hand and can rotate through360˚.

Portal cranesPortal cranes from the KBK classic craneconstruction kit with a load capacity up to 1,000 kg can be used wherever asuspension crane is not cost-effective

or cannot be installed. They run on solideven surfaces and can be manoeuvredeasily in all directions, making them idealfor repair and assembly work.

A particular advantage in many applica-tions is that KBK classic portal cranes canbe easily dismantled, transported andquickly re-erected elsewhere. The cranegirder span can also be adjusted.

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Track switchesOf compact, enclosed design, trackswitches are branching or convergingcomponents in the material flow.Options allow manual, electric or pneu-matic switching for semi- or fullyautomatic control.

SuspensionsTo prevent bending stresses and tominimise horizontal forces in thesuperstructure, KBK track sections aresuspended so as to allow pendulation.Plastic shells in the upper and lower balljoints reduce maintenance, surge loadingand noise to a minimum. The trackheight can be easily and precisely adjust-ed by means of the threaded suspensionrods that connect the ball joint heads.

Drop sectionsDrop sections are mainly used in closed-circuit tracks for picking up and depositingloads at predetermined positions.This eliminates the need for hoist units.

When lowered in the drop section, thetrolley is mechanically locked in place.Mechanical locks in the track stop othertrolleys on either side of the drop section.

KBK classic crane construction kit components

Profile sectionsThe basic elements are special cold-rolled track sections available in sixsizes:

KBK 100 Load capacity up to 125 kgKBK I Load capacity up to 500 kgKBK II-L Load capacity up to 1,000 kgKBK II Load capacity up to 2,000 kgKBK II-R Load capacity up to 2,000 kg,

with 5-pole power supply arranged inside

KBK II-T strengthened section forsingle and double-girdercranes

KBK III Load capacity up to 3,200 kg

For each size, all standardised compo-nents and assemblies, such as straightand curved track sections, track switches, turntables, drop sections, etc., have the same uniform jointdimensions. Self-centering plug-in, bolted connections allow them to beeasily assembled in any combination. Different profile section sizes can beused for single and double-girder suspension crane runways and girders.

All components are either galvanised orfinished with a coat of synthetic resin-based paint or powder-coated.

Straight and curved sectionsStraight and curved sections are madeof special cold-rolled profiles which feature high rigidity and stability for alow deadweight. The profile sectionsfor loads up to 2,000 kg are hollowtrack sections with protected inside-running surfaces. The KBK III profile of outside-running section design is available for loads up to 3,200 kg. KBK II and KBK III profile sections can also be supplied with integratedconductor lines.

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Push travel trolleysFitted with bearing-mounted plasticwheels, push travel trolleys are easy tomove. The maintenance-free, low-wearing wheels absorb vibration and aresilent-running.

TurntablesTurntables make it possible to changedirection in a minimum of space.Integrated mechanical locking devicesprevent trolleys from leaving or enteringthe turntable section during the slewingoperation. Turntables can be manuallyor electrically operated.

Latching devicesLatching devices make it possible toconnect single-girder suspension cranesand suspension monorails so that thehoist trolley can transfer between them.When disengaged, the crane travelspast the end of the monorail withoutmechanical contact.

19196

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Power supplyPower supply is preferably by means of flat festoon cables which are simple andinexpensive. With more than two craneson a runway or more than two travellinghoists on a suspension monorail and in the case of track systems with switches,turntables, latching devices or drop sec-tions, power supply is via conductor lines:for KBK II-R track sections with 5 inter-nalconductors, for KBK III track sections withup to 8 individual conductor lines.

KBK II-R power supplies are designed to UL specifications and protected against accidental contact in accordancewith relevant regulations.

Friction wheel travel drivesLarge friction wheels fitted with high fric-tional rubber tires ensure that the driveforces are transmitted efficiently. Dishedwashers provide constant pressure between the driving wheel and runningsurface of the KBK track sections. Frictionwheel travel drives are quiet-running.

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KBK ergo crane construction kit components

Demag Cranes & Components hasextended the crane construction kit toinclude additional applications with KBKergo components.

SuspensionsFitted with integrated damping elements,KBK ergo suspensions absorb energy from various directions, thus preventingunnecessary loads being transmitted to the roof or supporting structure.

End carriagesEnd carriages provide improved rigidityand increased positioning accuracy.Firmly connected to the crane trolleys,they precisely transfer all forces reliably to the crane or trolley runways.

bearings. A horizontal wheel provideslateral guidance in the runway.

KBK-II ergo trolleys of aluminium alloyfeature articulated axles, adjustablecounter-pressure rollers and a pair ofguide rollers.

End capsSpecial shock absorbers are required on KBK ergo cranes if the limit positions arefrequently approached in normal opera-tion. Shock absorbers integrated in theend caps dissipate the energy transmittedby the loads to all components and assem-blies as well as the support superstructure.

Crab frameThe specially developed crab frame is arugged, high load bearing system formounting specially equipped hoists andmanipulators.

TrolleysThe KBK ergo crane construction kitincludes trolleys in two sizes.

KBK-I ergo trolleys are made of steel andfeature axles mounted in articulated

They can be used to build cranes thathave to accommodate kick-up forces.This may be the case for overhung,extending and manipulator cranes.

They reliably accommodate the additional kick-up and lateral forcesexerted by offset loads. The floating axle arrangement ensuresuniform distribution of forces to all fourtravel wheels.

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Chain Hoists and Balancers

DK Chain Hoists for loads of 5000 to11000 lbs. are available in many speeds, lifting heights, and equipment combina-tions. DK Chain Hoists feature twospeed stages, slip clutch, 360 starts perhour and 60% duty factor. Variablespeed hoist units are provided with anintegrated inverter and a specially devel-oped analog control pendant with whichthe lifting and lowering speed can beinfinitely varied by varying the pressureon the buttons. This allows exceptionalcontrol of fragile or precise lifting appli-cations. The hoist is also available in amanulift model.

DCM Manulift units operate on thesame principle as DC Chain Hoists.Connected via a helical cable, they fea-ture a control unit with an integratedquick-change connector for load han-dling modules. The control unit with its“spade handle” can also be used to guide the load.

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DKHC High Cycle Chain Hoists The Demag DKHC features a 100% duty2-speed Demag Conical Rotor BrakeMotor, engineered for high cycling andexcessive starts/stops. This design is crucial in areas of production where zerodowntime and constant workflow is amust. In addition, the Demag DKHCboasts a specially designed fan cooledmotor and insulation thickness thatallows the operator to have practicallylimitless lifting and lowering capabilitywithout overheating.

Demag DBS Air Blancers allow loadsup to 250 lb to be safely and ergonomically handled. Productivity isincreased and the risk of muscle andback injuries are greatly reduced. Thedesign is excellent, allowing for highcycling capability, low operating costsand unparalleled safety. Demag DBS AirBalancers are available in two sizes, DBS55 (110 lb) and DBS 110 (250lb). Eachsize is available with the following control options to match your specificmaterial handling requirement.

• Up/Down (Pendant)• Single Load, Zero G Control• Dual Load, Zero G Control• Handforce Control

DC Chain HoistsThe DC Chain Hoists is designed for per-formance, safety, reliability, and main-tainability. This hoist is standard 2 speedand is available in a wide range ofcapacities up to 4400 lbs. The hoist israted for 1900 full load operating hoursand 360 starts and stops/per hour. Theintegrated electronics monitor and con-trol the regenerative braking and slipclutch. An LED display provides mainte-nance and trouble shooting data. Thefield adjustable pushbutton allows forsimple height adjustments up to 10 ft.The maintenance panel provides easyaccess to the chain guide and standardquick disconnect for power and push-button. The delivery on most models is48 hours or less.

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Demag DKHC Chain Hoists900 389 49

Demag DKM Manulifts229 115 49

Demag KBK Alu Enclosed Track900 239 49

Demag DK Variable SpeedChain Hoists930 242 49

Demag Air Balancer D-BPHandle your loads safe and easy, with precision

38539


Demag DBS Air Balancers900 371 49

Demag KBK Ergo900 236 49

Demag KBK Jib Cranes930 074 49

Demag KBK FreestandingWorkstations900 239 49

Demag KBK Jib Cranes


Demag DK Chain Hoist229 115 49


Demag KBK Alu Enclosed TrackConstruction KitThe aluminum overhead crane system – low dead weight – ergonomic design

38540


Distributed by Ergonomic PartnersEmail: [email protected]: www.ergonomicpartners.comPH: 314-884-8884 | FAX: 800-570-5584

0505 EN/US 930 072 49 701 IS 152

Sales and Service Centers in North America

MissouriDistributed by Ergonomic PartnersEmail: [email protected]: www.ergonomicpartners.comPH: 314-884-8884 | FAX: 800-570-5584

Other Demag component product literature

Nobody has more waysNobody has more waysNobody has more waysto move more.to move more.to move more. Nobody has more waysNobody has more waysNobody has more ways

to move more.to move more.to move more.Nobody has more waysNobody has more waysNobody has more waysto move more.to move more.to move more.





kbk classic and kbk ergo crane construction kit classic and kbk ergo crane construction kit overhead...

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