Project Overview
This project supplies a batch of cranes for the KD bus assembly plant located in Venezuela. As a key Chinese-invested local CKD manufacturing base, the factory focuses on bus component assembly, body welding, vehicle finishing, tooling handling and parts storage. With multi-station simultaneous production, the workshop requires high stability, unified performance, batch delivery capability and strong on-site adaptability for lifting equipment.
Considering Venezuela's tropical high-temperature and high-humidity climate, local 480V/60Hz power grid, container shipping limitations and insufficient local installation experience, we customized and delivered a batch of cranes to support daily handling operations of the KD production line.
Customer Pain Points
1. Multiple parallel KD assembly production lines require coordinated operation of several cranes, demanding consistent equipment quality, punctual batch delivery and unified commissioning.
2. The factory steel structure and runway beam civil works were completed in advance, so crane wheel load, span and installation dimensions must fully match the existing building without major reconstruction.
3. Venezuela's tropical humid and dusty climate easily causes moisture damage and dust accumulation on ordinary electrical parts, requiring high dustproof, waterproof and anti-corrosion performance.
4. The local industrial power standard is 480V 60Hz, which requires full electrical system adaptation.
5. The 22.5 m integral main girder is too long for container‑based transportation.
6. Local professional technicians for crane installation and commissioning are in short supply, requiring us to provide full‑process on‑site technical guidance.
Customized Solution
In view of KD plant's process flow, lifting requirements, and on-site factory conditions and Venezuela's local environment, a batch of lifting equipment: single‑girder overhead cranes, single‑girder underslung cranes, single‑girder semi‑gantry cranes and electric hoists were supplied for this project.
● The working class of the equipment is adapted to frequent lifting operations in the workshop, complying with FEM 2M / ISO M5 classification to meet repeated start‑stop lifting requirements for body assemblies, vehicle frames and large tooling dies.
● The entire electrical system was modified to match the local 480V/60Hz three‑phase industrial power supply, preventing equipment failures caused by mismatched voltage and frequency.
● The complete machine electrical system features IP55 high‑protection rating. Key electrical components are additionally treated for moisture and dust resistance to suit the hot‑humid tropical operating conditions in South America.
● Dual‑control modes including wireless remote control and floor‑mounted push‑button operation are supported for multi‑person collaborative working scenarios.
● The 22.5m integral main beam is transported by bulk carrier.
● A full set of assembly drawings, electrical schematic diagrams, operation manuals and load test standards are provided.
● Our technical team will be dispatched to give on‑site guidance for local Venezuelan teams through installation, wiring, commissioning and load acceptance tests.
Project Implementation
● In the early stage, we accurately matched the factory's civil drawings and runway beam parameters, calculating wheel load, span and lifting height to ensure full compatibility with the existing plant structure.
● During production, every crane completed pre-assembly, no-load testing and precision calibration to guarantee unified batch quality. All equipment was modularly disassembled and provided with anti-rust packaging.
● After arrival, our technical team provided full on-site guidance for track leveling, girder assembly, end beam alignment, electrical connection and system commissioning.
● All cranes passed static and dynamic load tests at 1.25 and 1.1 times the rated load, respectively, in accordance with international standards and were officially put into operation for KD bus assembly.
Project Achievements
● Multiple cranes deliver stable support for the KD assembly line, significantly boosting handling efficiency for components, bus bodies and tooling, while ensuring reliable operation across multiple production lines.
● Custom-engineered 480V/60Hz electrical adaptation together with a high-protection rating design delivers optimal performance under South American tropical operating conditions, cutting failure rates and maintenance costs.
● The delivery model featuring on‑site installation guidance offsets local installation‑skill gaps in Venezuela. It enables Chinese‑funded overseas factories to complete rapid equipment deployment and production launch, and provides a proven, replicable lifting solution for comparable CKD auto‑plant hoisting‑support projects in South America.
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