Light-duty lifting systems are classified as special equipment; the quality of their installation directly determines operational stability, safety factors, and service life. Strict adherence to national standards—such as GB 6067.1-2010 and GB/T 3811-2008—is mandatory. Standardized processes for installation, commissioning, and acceptance must be followed to eliminate installation deviations, structural hazards, and electrical faults, thereby ensuring the equipment enters service in full compliance with regulations. While installation details vary slightly depending on the specific type of light-duty lifting equipment, the overall construction workflow, commissioning standards, and acceptance requirements remain consistent; this article outlines the universal standardized system for construction and acceptance.
Pre-installation preparation and foundation construction are critical preliminary steps; a specialized construction plan must be formulated based on the equipment model and load parameters. For fixed-track or pillar-mounted light-duty lifting equipment, foundation load-bearing capacity must be calculated in advance, and a concrete foundation of appropriate strength poured. For equipment with a capacity exceeding 2 tons, the concrete strength must be at least C30. The spacing, depth, and flatness of embedded anchor bolts must strictly conform to equipment drawings, and the foundation requires a minimum curing period of seven days to prevent future settlement or tilting. For KBK flexible track systems and wall-mounted light-duty equipment, the load-bearing capacity of the mounting substrate must be verified beforehand; walls and steel beams serving as mounting bases must meet the equipment's load-bearing requirements, and installation on lightweight structures or substandard substrates is strictly prohibited. Mobile light-duty equipment does not require a civil engineering foundation; however, the operating surface must be level, hardened, and possess uniform load-bearing capacity, free from protrusions, depressions, oil stains, or debris. Additionally, prior to construction, the completeness of accessories, material compliance, and the integrity of components must be verified to prevent the use of substandard parts.
The installation of the main assembly follows a standardized sequence: securing the mounting base, assembling the structure, and finally connecting the mechanical and electrical systems. First, the load-bearing base is secured, and the verticality and horizontality of pillars, brackets, and track bases are calibrated. Verticality deviation for pillars must be ≤1/1000, and track horizontality deviation ≤2 mm/m, ensuring uniform load distribution and preventing off-center loading. Next, the metal structure is assembled by joining components such as the main girder, cantilevers, and supports. High-strength connecting bolts are tightened diagonally and evenly to prevent loosening or loose connections; structural flatness and stability are verified upon completion of assembly. Finally, mechanical drive components and electrical systems are installed—including the electric hoist, traveling mechanism, and slewing mechanism—and motors, control lines, and power cables are connected. Insulation testing and grounding procedures are performed, with grounding resistance strictly controlled to within 4Ω to eliminate hazards such as electrical leakage or short circuits.
Commissioning of the entire unit comprises three core stages: no-load testing, incremental load testing, and safety function testing; all test items must be fully documented and archived. No-load testing involves operating the equipment without a load to verify all movements—lifting, traveling, and slewing—while checking for operational smoothness, abnormal noises or sticking, braking sensitivity, and start-stop response times to ensure the mechanical drive functions correctly. Load testing proceeds in stages at 50%, 75%, and 100% of the rated load, with each stage lasting at least 30 minutes to observe structural deformation, stress conditions, and drive performance; successful completion requires no permanent deformation, abnormal vibration, slippage, or sticking during full-load operation. For 10-ton models, an additional overload test at 1.25 times the rated load is required to verify the equipment's ultimate load-bearing stability.
Safety testing and final acceptance constitute the final stage before the equipment enters service. Key checks focus on the sensitivity and reliability of safety devices—such as overload protection, upper and lower travel limits, emergency stops, anti-fall brakes, and anti-hook-dislodgement mechanisms—ensuring timely triggering, rapid power cutoff, and effective locking. Once all tests pass, acceptance inspections covering appearance, structure, performance, and safety are conducted in accordance with special equipment standards. Documentation—including installation drawings, commissioning records, material reports, and certificates of conformity—is compiled, and equipment usage registration is completed. The equipment may only be put into industrial operation after passing acceptance; use of unaccepted or failed equipment is strictly prohibited.
