Operating Instructions: Demag DH 300, 400, 500, 600, 1000, 2000 Hoist Units

Operating instructions
Demag DH 300, 400, 500, 600, 1000, 2000 hoist units
41123944.eps
090903 EN 214 286 44 720 IS 813

Manufacturer Demag Cranes & Components GmbH
P.O. Box 67 · D-58286 Wetter
Telephone (+49/2335) 92-0 · Telefax (+49/2335) 927676
www.demagcranes.com
Please fill in the following table before first putting the hoist unit into service.
This provides you with a definitive documentation of your Demag hoist unit and im-
portant information if you ever have to contact the manufacturer or his
representative.
Owner
Where in use
Model
Serial number
Main hoist/F6 creep hoist motor number
Main hoist motor number
F10 microspeed unit
Creep hoist motor number
Creep hoist gearbox number
Travel drive unit number
Operating voltage
Control voltage
Frequency
Wiring diagram number
Contactor control
Accompanying documents
Component parts lists for Demag hoist units DH 300/FG.. 222 302 44 721 IS 813
DH 400/FG.. 222 726 44 721 IS 813
DH 500/FG.. 222 307 44 721 IS 813
DH 600/FG.. 222 731 44 721 IS 813
DH 1000/FG.. 222 312 44 721 IS 813
DH 2000/FG.. 222 655 44 721 IS 813
Assembly instructions for DSE control pendants 214 214 44 720 IS 951
Technical data for DSE control pendants 203 119 44 714 IS 951
Assembly instructions for DST control pendants 206 165 44 720 IS 951
Component parts lists for control pendants DST 222 142 44 721 IS 951
Test and inspection booklet for Demag crane installations 206 124 44 720 IS 100
Operating instructions for ZBF 63 - 132 motors 214 228 44 720 IS 919
Operating instructions for Dematik MGS/MKA-2 load detectors 206 689 44 720 IS 819
Operating instructions for Dematik ZMS/FAW-1/FWL load detectors (206 715 44) 206 880 44 720 IS 819
SGDM hoist unit relay
Function description with wiring diagram 202 708 44 714 IS 952
Operating instructions for DH drum brake
Type FB (overspeed brake)
HB (holding brake) 206 394 44 720 IS 823.1
21428601.p65/090903
Technical data
DH, UDH and KDH hoist units DH 300-2000 203 341 44 714 IS 813
2 EZDH/EZLDH double-rail crabs DH 300-2000 203 346 44 714 IS 813

Contents
0 Foreword 5
0.1 Copyright 5
0.2 After-sales service 5
0.3 Liability for defects 6
0.4 Limitations of liability 6
0.5 Definitions 7
1 Safety instructions 8
1.1 Symbols 8
1.2 Appropriate use 8
1.3 Prohibited practices 9
1.4 General safety information 9
1.5 Selection and qualification of operating and maintenance personnel 10
1.6 Safety instructions for installation and disassembly 11
1.7 Safety instructions when first putting the hoist into service
after completing installation 11
1.8 Safety instructions for operation 11
1.9 Safety instructions for maintenance 12
2 Technical data 14
2.1 Design 14
2.2 Explanation of size designation 14
2.3 Selection criteria 15
2.4 Hoist motor data 16
2.5 EUDH, EKDH, EZDH, EZLDH travel motor data 18
2.5.1 Mounting code for ordering a mechanical microspeed unit 20
2.6 Setting hook dimension C 20
2.6.1 DH 300, DH 400, DH 500, DH 600, DH 1000, DH 2000 hoist units 21
2.6.2 KDH low-headroom monorail hoist 22
2.6.3 UDH standard-headroom monorail hoist 24
2.6.4 EZDH/DRS double-rail crabs 25
2.6.5 EZLDH/DRS double-rail crabs 26
2.7 Mounting flange positions and rope lead-offs 28
3 General 30
3.1 Inspection regulations 30
3.2 Hoist units operating outdoors 30
3.3 Packing and storage 30
3.4 Paint finish 30
3.5 Operating conditions 30
3.6 Sound pressure level measurement according to DIN 45635 31
4 Description 32
4.1 Design 32
4.2 Motor 32
4.3 Gearbox/rope reeving components 32
4.4 Arrangement of the major assemblies 33
4.5 Geared limit switches 33
4.6 Control pendant 33
4.7 Models 33
4.8 Load detectors for Demag DH hoist units 33
4.9 Runways 34
4.10 Trolleys 34
4.11 Trolley size 5 for DH 300/400, 2/1 and 4/2 rope reeving 35
4.11.1 Runways 35
4.11.2 Trolleys 35
5 Assembly 36
5.1 Electrical equipment 36
5.2 Connection to the electrical supply 36
5.3 Checking the direction of movement 37
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5.4 Control 37
5.5 DSE, DST control pendants 37
5.6 Assembly instructions for DSE control pendant 38
5.7 Assembly instructions for DST control pendant 40
3
5.8 Fitting the wire rope 42
5.8.1 Construction, application and reeving of wire ropes 42
5.8.2 Rope reeving methods for the Demag DH hoist unit 46
5.8.3 MGS/MKA-2 and ZMS/FAW-1 load detectors 48
5.8.4 Lubrication 49
5.8.5 Fitting the rope socket 49
5.8.6 Fitting the rope guide DH 300 – 2000 with toothing adjustment 50
5.9 Assembly and adjustment of EUDH standard-headroom monorail trolleys 52
5.9.1 Assembly of the trolley 52
5.9.2 Adjusting the trolley 54
5.9.3 Changing the travel drive from AMK 10 to AUK 30 – EUDH 56
5.9.4 Changing the travel drive from AUK 30 to AMK 20 – EUDH 57
5.10 Assembly and adjustment of EUDH standard-headroom monorail trolley
Trolley size 5 – EUDH 300/400, 2/1 rope reeving 58
5.11 Assembly and adjustment of EKDH low-headroom monorail trolley
Trolley size 5 – EKDH 300/400, 2/1 and 4/2 rope reeving 62
5.11.1 Assembly of the trolley size 5 63
5.11.2 Assembly/disassembly of the travel drive 64
Trolley size 5 – EKDH 300/400, 2/1 rope reeving 66
5.12.1 Assembly/disassembly of the rope retaining crosshead, 2/1 rope reeving 67
Trolley size 5 – EKDH 300/400 hoist unit (H20) 4/2 rope reeving 68
5.13.1 Assembly/disassembly of the compensating sheave, 4/2 rope reeving 69
5.14 Assembly and adjustment of EKDH low-headroom monorail trolley 70
5.14.1 Assembly of the trolley 71
5.14.2 Adjusting the trolley for size 6 when combined with Demag DH 300/400
4/1 – DH 500/600 2/1 hoist unit and trolley size 10 when combined with
Demag DH 500/600 4/1 hoist unit 74
5.14.3 Adjusting trolley size 10 when combined with Demag DH 1000 2/1
hoist unit 75
5.14.4 Changing the travel drive from AMK 10 to AUK 30 – EKDH 76
5.14.5 Changing the travel drive from AUK 30 to AMK 20 – EKDH 78
5.15 Counterweight box filling for EKDH trolleys 80
5.15.1 Dimensions for attaching end stops to runways 81
5.16 FG 06 – FG 08 – FG 10 microspeed units 82
5.16.1 Brake 82
5.16.2 Main hoist motor 82
5.16.3 Changing the hollow shaft of the FG 08 and FG 10 84
5.17 Demag DH hoist units and travel drive units for arduous conditions 85
6 Putting the Demag DH hoist unit into service 86
6.1 DGS 3 and DGS 4 geared limit switches 86
6.1.1 Determining the cut-out point for the geared limit switch 86
6.2 Setting instructions for DGS 3 and DGS 4 geared limit switches 87
6.2.1 S1 emergency limit switch for top hook position 87
6.2.2 S2 main lifting motion limit switch 88
6.2.3 S3 emergency limit switch for bottom hook position 88
6.2.4 S4 operating limit switch for bottom hook position 88
6.3 Inspection when putting the hoist into operation 89
6.4 Safety instructions 89
6.5 Starting operation 89
7 Taking the Demag hoist unit out of service 89
7.1 Emergency-stop button 89
7.2 Taking the hoist out of service at the end of the shift 89
7.3 Taking the hoist out of service for maintenance purposes 89
8 Inspections/maintenance/general overhaul GO 90
8.1 Inspection before starting work and during operation 90
8.2 Inspection and maintenance schedule 90
8.3 General overhaul GO 90
8.4 Wire rope 92
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8.5 KBH main hoist motor and KBA microspeed motor brake 94
8.5.1 Adjusting the brake 95
8.5.2 Fitting a new brake lining 95
8.5.3 Adjusting the brake 96
8.5.4 Fitting a new brake lining 96
8.5.5 Fitting new KBH brake springs 98
8.5.6 Air gap 98
8.6 ZBF 63 – 112 travel motor brake 101
8.6.1 B003, B004, B020, B050 brakes 101
8.6.2 Checking and adjusting the brake air gap s1 102
8.6.3 Replacing the brake disk 104
8.7 KMF 80 travel motor brake 107
8.8 Gearbox 110
8.8.1 Main hoist gearbox (two, three or four-stage planetary gearbox) 110
8.8.2 FG 06, 08 and 10 mechanical microspeed units, AMK 10, AMK 20,
AUK 30, AUK 40, AUK 50 travel drives 112
8.8.3 Output stage, standard and low-headroom monorail hoists 112
8.8.4 EKDH 300/400 2/1 and 4/2, travel drive/trolley size 5 113
8.8.5 EUDH 300/400 2/1 and 4/2, travel drive/trolley size 5 113
8.9 Antifriction bearings 113
8.9.1 Motor bearings 113
8.10 Load-bearing bolted connections 113
8.11 Control pendants 113
9 Measures for achieving safe working periods 114
9.1 Calculating the actual duration of service S 114
9.1.1 Estimating the load spectrum factor kmi (by the owner) 115
9.1.2 Calculating the number of hours of operation (operating time) Ti
by the owner 115
9.1.3 Factor depending on type of recording f 116
9.1.4 Example with hook travel counter 116
9.2 Example with FWL load spectrum recorder 117
You have purchased a Demag product.

0 Foreword This hoist unit was manufactured in accordance with European standards and
regulations.
The hoist unit complies with legal requirements, e.g. EC Machinery Directive
98/37/EC.
The main assemblies include:
• the gearbox
• the hoist motor
• the integrated electrics
• the rope drive mechanism
• the control pendant
These operating instructions are designed to provide the operator with appropriate
instructions for safe and correct operation and to facilitate maintenance.
Every individual given the task of transporting, installing, commissioning, operating,
maintaining and repairing our hoist units and additional equipment must have read
and understood
• the operating instructions
• the safety regulations and
• safety instructions in the individual chapters and sections.
The operating instructions must be available to the operating personnel at all times in
order to prevent operating errors and to ensure smooth and trouble-free operation of
our products.
0.1 Copyright These operating instructions must be treated confidentially. They should only be used
by authorized personnel. They may only be entrusted or made available to third
parties with the prior written consent of Demag. All documents are protected within
21428601.p65/090903
the sense of copyright law.

No part of this documentation may be reproduced, utilized or transmitted without
specific prior consent. Infringements are an offence resulting in obligatory compensa-
tory damages.
All industrial rights reserved. 5
0.2 After-sales service Our after-sales service will provide you with all technical information on Demag prod-
ucts and their systematic application.
Should you have any questions regarding our products, please refer to one of our
after-sales service stations, the relevant representative or to our main office.
Kindly quote the serial or order number (see test and inspection booklet, hoist unit
data plate) in any correspondence or for spare part orders.
Specifying this data ensures that you receive the correct information or the required
spare parts.
The relevant after-sales service station of Demag is specified for example on the back
page of the test and inspection booklet.
0.3 Liability for defects These operating instructions must be read carefully before installing and putting hoist
units into operation.
We assume no liability for damage and malfunctions resulting from failure to comply
with the operating instructions.
Any liability claims for defects must be made by quoting the order number immedi-
ately on detecting the defect.
Liability claims for defects are void in the event of:
• inappropriate use,
• faulty devices or equipment connected or attached to the product which are not
part of our scope of supplies and services,
• use of non-genuine spare parts and accessories,
• refurbishment or modification of the hoist unit unless approved in writing by
Demag.
Wearing parts are not subject to liability for defects.
0.4 Limitations of liability All technical information, data and instructions for operation contained in these oper-
ating instructions were up-to-date on going to print and are compiled on the basis of
our experience and to the best of our knowledge.
We reserve the right to incorporate technical modifications within the scope of further
development of the hoist units which are the subject of these operating instructions.
The information, illustrations and descriptions contained in these operating instruc-
tions are therefore only intended for information purposes.
The descriptions and illustrations contained in this documentation do not necessarily
correspond to the scope of delivery or any subsequent spare part delivery, either; the
drawings and illustrations are not to scale.
Only documentation belonging to the actual order is valid.
We assume no liability for defects, damage and malfunctions caused as a result of
operating errors, noncompliance with these operating instructions or omitted and/or
inappropriate repairs and maintenance.
We expressly point out that only Demag spare parts and accessories approved by us
may be used. Accordingly, this also applies to other manufacturers’ parts supplied by
us.
For safety reasons, the fitting and use of spare parts or accessories which have not
been approved and unauthorized modification and conversion of the hoist unit are
not permitted; we assume no liability for defects or damages resulting therefrom.
With the exclusion of any further claims, our liability for defects and liability obligations
for any defects pertaining to the products supplied or faults in the documentation
delivered or any negligence on our part are exclusively based on the stipulations of
the original contract. Any further claims, in particular any and all claims for damages,
are excluded with the exception of legal claims in accordance with product liability
legislation.
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0.5 Definitions Owner
Owners (employer, company) are defined as persons who own hoist units and who
use them appropriately or allow them to be operated by suitable and instructed
persons.
Operating personnel
Operating personnel are defined as persons entrusted by the owner of the hoist unit
with operation and/or transportation of the equipment.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner to carry out spe-
cial tasks such as installation, setting-up, maintenance and fault elimination.
Qualified electrician
Qualified electricians are defined as persons, who, owing to their technical training,
knowledge and experience of electrical installations as well as knowledge of the
relevant standards, are able to assess the tasks given to them and identify and
eliminate potential hazards.
Trained person
Trained persons are defined as persons who have been instructed and trained for
the tasks assigned to them and on the possible hazards resulting from incorrect
handling and who have been informed about the required protective devices, protec-
tive measures, relevant regulations, codes of practice, accident prevention regula-
tions and operating conditions and who have proven their qualifications.
Experienced technician
Experienced technicians are defined as persons, who, owing to their technical train-
ing and experience, have sufficient knowledge of hoist units and are familiar with the
relevant national industrial safety regulations, codes of practice, accident prevention
regulations, directives and generally accepted engineering standards enabling them
to judge the safe operating condition of hoist units.
Assigned expert engineer (in the Federal Republic of Germany according to

BGV D8* § 23 (VBG 8), for determining the S.W.P.)
An assigned expert engineer is defined as an experienced technician specifically
assigned by the manufacturer to determine the remaining duration of service
(service life) and to carry out general overhauls of serial hoists (S.W.P. = safe working
period).
Authorized expert engineer (according to BGV D6 § 28 (VBG 9))

In addition to the expert engineers of the Technical Supervisory and Inspection
Board, an authorized expert engineer for the inspection of hoist units is defined as an
expert engineer authorized by the Industrial Employers’ Mutual Insurance Associa-
tion.
Hoist units
Hoist units are systems used for lifting and moving loads, such as cranes, crabs and
travelling hoist units, S/R-machines, rail systems.
* BGV D/VBG = German Industrial Employers’ Mutual Insurance Association responsible for the prevention
of accidents
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1 Safety instructions
1.1 Symbols The following symbols and instructions warn against possible personal injuries or
damage to property and are intended to assist you in your work.
Safety at work symbol

This symbol appears in the operating instructions next to all instructions relating to
safety at work wherever a potential danger to life and limb exists.
Follow these instructions at all times and be particularly careful and cautious.
Pass on safety instructions to all persons entrusted with working on the hoist unit
including track and power supply.
In addition to the safety instructions, observe all general safety regulations and
factory accident prevention regulations at all times.
Warning against electrical hazards

Contact with live parts can result in immediate death. Protective covers (e.g. covers
and enclosures of electrical equipment) marked with this sign may only be opened by
qualified electricians. Before opening, all relevant operating, control, feed or other
voltages must be disconnected.
Warning against suspended load

Any person remaining in this danger zone may suffer serious injury or death.
Never transport loads above persons when using load handling attachments which
retain the load by means of magnet, friction or suction forces without an additional
load securing device. In each case the special safety and operating instructions
contained in the operating instructions for the load handling attachment in question
must be complied with.
Operating hazard for the installation

This symbol in the operating instructions indicates all warnings which, if not complied
with, may result in malfunctions or damage to the hoist unit or the load.
1.2 Appropriate use Electric hoist units are only intended for lifting and moving loads and may be used as
stationary or travelling units.
Electric hoist units may only be operated when in perfect working order by trained
personnel in accordance with the relevant safety and accident prevention regulations.
This also includes compliance with operating and maintenance conditions specified
in the operating instructions.
Hoist units are designed to be used with a rated voltage of up to 690 V.
Power feed is via power supply lines (mobile cables, open or enclosed power con-
ductor systems, cable drums). These systems are live up to the terminals of the
isolating switch (mains connection switch, isolating switch).
The relevant isolating switch must be switched off and secured when performing
maintenance/repair work. During operation or when the main switch is not switched
off, electrical components inside enclosures, motors, switchgear cabinets, load
handling attachments, terminal boxes, etc., carry dangerous voltages. This voltage
may cause fatal injuries.
Design limit The theoretical duration of service (to FEM 9.755) in conjunction with the
actual mode of operation (see 2.3 Selection criteria) determines the safe
working period (S.W.P.).
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Non-compliance may result in serious personal injury or damage to property in the
event of:
• unauthorized removal of covers,
• inappropriate use of the hoist unit,
• incorrect operation,
• insufficient maintenance,
• exceeding the maximum permitted load
(The rated load capacity/S.W.L. is the maximum permitted load. Pay attention to
the sum of the load to be lifted and the load handling attachment.),
• working on live parts.
Advise operators to avoid inching as far as possible. It might cause excessive wear
and premature failure of the hoist unit. Inching means giving short pulses to the mo-
tor to obtain small movements, e.g. when lifting loads or moving the travelling hoist
unit or the crane.
1.3 Prohibited practices Certain work and practices are prohibited when using the hoist unit as they may
involve danger to life and limb and result in lasting damage to the hoist unit, e.g.:
• Do not handle loads in an unsafe way (e.g. swinging the load).
• Do not handle suspended loads above persons.
• Do not pull or drag suspended loads at an angle.
• Do not pull free fixed or obstructed loads with the hoist unit.
• Do not exceed the maximum permitted load and permitted load dimensions.
• Do not leave suspended loads unsupervised.
• Do not allow the rope to run over edges.
• Do not use the rope as a load bearing sling.
• Always move the hoist unit with push travel trolley by pulling on the load, bottom
block or load hook assembly – never pull on the control pendant.
• Do not allow loads to drop when the rope is in a slack condition.
• Do not subject the control pendant to inappropriate mechanical loads.
• Transporting persons, unless lifting devices are specifically approved for trans-
porting persons, is not permitted.
• Do not tamper with or manipulate electrical equipment.
• Do not lift the load when the rope is in a slack condition.
• Do not lift at full speed.
1.4 General safety Persons under the influence of drugs, alcohol or medicines which affect reactions
must not install, operate, put into service, maintain, repair or disassemble hoist units.
information Any conversions and modifications to the installation require the written consent of
Demag.
Work on electrical equipment of hoist units may only be carried out by qualified
electricians in accordance with electrical regulations. In the event of malfunctions,
hoist unit operation must be stopped, the hoist switched off and the relevant main
switches locked immediately. Defects must be rectified immediately.
National accident prevention regulations and codes of practice and general safety
regulations must be observed when operating our products. Important information
and instructions are marked by corresponding symbols.
Follow these instructions and/or safety regulations in order to avoid accidents and
damage. The operating instructions must be kept available at the place where the
hoist unit is in use at all times. They include significant aspects and appropriate
excerpts from the relevant guidelines, standards and regulations. The owner must
instruct his personnel appropriately.
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Any failure to comply with the safety instructions stated in these operating instruc-
tions can result in death or personal injury.
9
Observe general statutory and other obligatory regulations relating to accident pre-
vention and environmental protection and basic health and safety requirements in
addition to those included in these operating instructions. Such requirements may
also relate, for example, to the handling of hazardous materials or the provision/
wearing of personal protection equipment. Comply with these regulations and
general accident prevention regulations relevant for the place at which the hoist unit
is used and follow the instructions therein when working with the hoist unit. The hoist
unit may still constitute a danger to life and limb if it is not installed, operated,
maintained or used appropriately by personnel which have not been trained or
specially instructed. The operating instructions must, if required, be supplemented by
the owner with instructions and information (e.g. factory regulations) relating to
organization of work, working procedures, operating personnel, etc. Supervising and
reporting obligations as well as special operating conditions must also be taken into
consideration.
Personnel assigned to working with the hoist unit must have read and understood
the operating instructions and, in particular, the chapter on safety information.
All activities relating to hoist units which are not described in these operating instruc-
tions may only be carried out by specialist personnel specifically trained for the par-
ticular hoist unit.
The owner must ensure that personnel work in a safety and hazard-conscious
manner in compliance with the operating instructions.
The owner must ensure that the hoist unit is only operated when in proper working
order and that all relevant safety requirements and regulations are complied with.
Hoist units must be taken out of service immediately if functional defects or irregulari-
ties are detected. In the event of a stoppage (e.g. if defects regarding safe and
reliable operation are detected, in emergency situations, in the event of operating
malfunctions, for repairs and maintenance purposes, if damage is detected or after
finishing work), the operator/experienced technician must carry out all prescribed
safety measures.
Personal protective clothing must be worn as necessary or as required by regula-
tions.
Personnel must not wear loose clothing, jewellery including rings or long hair loose.
Injury may occur, for example, by being caught or drawn into the mechanism.
All safety and hazard information and recommendations on the hoist unit, e.g. at
access points and mains connection switches must be maintained in complete and
legible condition.
Inching (i.e. giving short pulses to the motor) must always be avoided.
Emergency limit stop devices (e.g. slipping clutch or emergency limit switch) must
not be approached in normal operation.
Modifications, additions to and conversions of the hoist unit which may impair safety
in any way must not be carried out without the written consent of Demag. This also
applies to the subsequent installation of safety devices as well as for performing
welds on load bearing parts. Safety devices must not be rendered inoperative.
Only genuine Demag spare parts and accessories may be used.
Observe prescribed deadlines or those specified in the operating instructions for
routine checks/inspections.
1.5 Selection and qualifi- For independent operation or maintenance of the hoist unit, the owner may only
employ persons
cation of operating
• who are at least 18 years of age,
personnel
• who are mentally and physically suitable,
• who have been instructed in the operation or maintenance of the hoist unit and
have proven their qualification to the owner in this respect (in addition to theoreti-
cal training, instruction also includes sufficient practical operating experience as
well as acquiring the ability to identify defects which are a hazard to safe opera-
tion),
• who can be expected to carry out the work assigned to them reliably.
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The owner must assign operating and maintenance personnel to their relevant task
10
1.6 Safety instructions • Installation and disassembly work may only be performed by experienced techni-
cians.
for installation and • Installation and disassembly work must be coordinated by the person carrying out
disassembly the work and the owner within the scope of their responsibility.
• The working and danger zone must be made safe.
• The installation must be isolated in accordance with the relevant electrical
regulations.
• Customer-specific regulations must be observed.
• Only appropriate, tested and calibrated tools and equipment may be used.
• The electrode holder and earth must be connected to the same assembly when
welding work is carried out. If the current flow is returned via protective conduc-
tors, screening elements or anti-friction bearings, serious damage may be caused
to these or other components.
• Demag hoist units must be slung at the contact points provided for this purpose.
1.7 Safety instructions • The working area or danger zone must be made safe.
when first putting the • First check that the voltage and frequency specified on the data plates match the
owner’s mains power supply.
hoist into service after
• All clearance dimensions and safety distances (see approval drawing) must be
completing installation checked before putting the hoist into service.
• When putting the hoist unit into service, it may be necessary to perform work in
the danger zone.
• In the course of putting the hoist unit into service, it may be necessary to tempo-
rarily render safety devices or features inoperative.
• It must be ensured that only trained personnel are employed for putting the hoist
unit into service.
1.8 Safety instructions for The operator must check the function of the brakes and emergency limit stop and
emergency stop devices before starting work.
operation All instructions and measures described in the operating instructions with regard to
safe operation and items concerning general safety and accident prevention which
have to be observed before, during and after putting into service must be strictly
complied with. Any failure to comply can lead to accidents resulting in fatalities.
Hoist units must be taken out of service immediately or not put into operation if any
defects relating to operating safety and reliability are detected.
Safety devices must not be rendered inoperative or modified in contradiction to their
intended use.
Only operate hoist units when all protective devices and safety-relevant equipment,
e.g. movable protective devices and emergency-stop devices, are fitted and fully
functioning.
Anybody who identifies an immediate danger of personal injury must actuate the
emergency-stop button without delay. This also applies in the case of damage
occurring to parts of the installation and equipment which makes immediate stop-
page necessary. After an “emergency-stop”, the operator must not switch on and
restart the hoist unit until an experienced technician is satisfied that the cause which
led to actuation of this function has been rectified and that continued operation of the
installation constitutes no further hazard.
Hoist units must be switched off immediately in the event of the following faults:
• In the event of damage to electrical devices and cables as well as parts of the
insulation.
• In the event of brake and safety device failure.
• If the lifting motion is switched off during lifting of the load, this may indicate trig-
gering of the overload protection device. In this case, the lifting motion must be
interrupted and a lifted load must be immediately deposited.
For a description of the load measuring function, see enclosed documentation on
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load detectors.
11
Before switching on/putting into operation of the hoist unit it must be ensured that
nobody is endangered by operation of the hoist.
If the operator notices persons who may be exposed to a risk to health or personal
safety by operation of the hoist unit, he must suspend operation immediately and
may not resume operation again until the persons are outside the danger zone.
Before putting the hoist unit into operation, the operator must be satisfied that the
installation is in safe and correct operating condition.
Work on hoist units may only be carried out when instructions to this effect have
been issued, when operation and function of the hoist unit have been explained and
when the working and danger zone has been made safe. Cooling devices, such as
ventilation openings, may not be rendered permanently inoperative (e.g. covered or
closed).
Special local conditions or special applications can lead to situations which were not
known when this chapter was written. In such cases, special safety measures must
be implemented by the owner.
1.9 Safety instructions for Maintenance measures are defined as regular maintenance, inspection and repair
work.
maintenance Mechanical and electrical repairs and maintenance work may only be carried out by
appropriately trained personnel (experienced technicians).
Adjustment and maintenance activities and inspection intervals including specifica-
tions concerning replacement of parts/assemblies prescribed in the operating
instructions must be observed.
Ensure that all electrical components are de-energized before commencing work on
electrical installations and devices.
When all work on the hoist unit has been completed, operation of the hoist unit must
not resume until the owner has given approval to this effect.
Unauthorized persons must be prohibited from carrying out work on machinery or
parts of the hoist unit.
Before starting all repair and maintenance work, the hoist unit must be switched off,
taken out of operation and secured (switches must be locked) against accidental or
unauthorized putting into operation (restarting).
It must be ensured that
• the hoist unit is switched off and checked that it is de-energized and, in special
cases, isolated,
• moving parts are stationary and stopped,
• moving parts cannot start moving while maintenance work is being performed,
• the power supply cannot be accidentally restored as long as the hoist unit has
been taken out of service for maintenance and repair purposes.
• operating and auxiliary materials as well as spare parts are disposed of in a safe
and environmentally sound way.
Instructions for repair work in the course of operation

The danger zone must be marked off with red/white safety ropes or safety tape and
indicated with warning signs. In each individual case, the owner or the person speci-
fied by him must check whether the relevant work may be carried out in the course
of operation without risk of personal injury owing to the particular local conditions.
To avoid injury, only use calibrated and appropriate tools and auxiliary materials for
maintenance, inspection and repair purposes. If there is a risk of objects falling, the
danger zone must be made safe.
Maintain a sufficient safety distance to moving or rotating parts to prevent clothing,
parts of the body or hair becoming entangled.
Avoid naked flames, extreme heat and sparks in the vicinity of cleaning agents and
flammable parts or parts liable to deformation (e.g. wood, plastic parts, oil, grease)
as well as in electrical installations – noncompliance may result in fire hazard. Harmful
gases may evolve or insulation may be damaged.
21428601.p65/090903
12
Additional instructions for repair work on electrical equipment
Only use genuine fuse links with specified amperage and tripping characteristics.
Defective fuse links must not be repaired or bridged and must only be replaced by
fuse links of the same type. Switch off the hoist unit immediately in the event of elec-
trical power supply malfunctions.
Work on the electronic and electrical components or equipment may only be carried
out by qualified electricians. If inspection, maintenance and repair work is to be car-
ried out on parts of hoist units, these must – if prescribed by regulations – be isolat-
ed. First verify the safe isolation of the parts from the supply before commencing
work. The electrical equipment of the hoist unit must be inspected and checked at
regular intervals. Defects, such as loose connections, damaged cables and worn
contactors must be rectified immediately.
Since it is possible that after a longer period of operation the switching points of
relays (time, frequency, monitoring relays) change due to ageing of the components,
the relay switching points in circuits relevant to safety must be checked at regular
intervals.
Electrical equipment must be replaced as a preventive measure on reaching the limit
of its theoretical duration of service (service life).
If work has to be carried out on live parts, a second person must be available in
order to actuate the emergency-stop button or mains connection switch/isolating
switch for voltage disconnection in an emergency. The second person must be
familiar with resuscitation measures.
Only use insulated tools.
Before disconnecting and connecting electrical plug-and-socket connections,
always disconnect them from the supply (this does not apply to mains connections,
provided they do not represent a dangerous contact voltage in the sense of the
safety regulations).
21428601.p65/090903
13
2 Technical data
2.1 Design
24625-1.tif
1 Electrical equipment cover 6 Rope guide 11 Main lifting motor brake

2 Electrical components 7 Planetary gearbox 12 Terminal box
3 Geared limit switch 8 Rope drum 13 Rope drum brake
4 Frame 9 Roller coupling 14 Wire rope
5 Connecting shaft 10 Motor
2.2 Explanation of size designation

EU DH 5 2 5 H12 K V1 - 4 / 1 F6 300 12,5
Trolley travel in m/min
Flange width of the girder in mm
F 6 – creep lifting 1:6, DH (pole-changing)
F 10 – creep lifting 1:10, DH (microspeed unit)
Single-groove drum
Four-fall reeving
Lifting speed
Motor type: K = squirrel-cage

S = slip-ring rotor
G = DC
X = explosion-proof
Hook path 12 m (for 2/1 reeving)
Rope pull on the drum 25 kN
Size 525
Range 500
21428602.p65/090903
Demag hoist unit type DH
U = Standard-headroom monorail hoist

K = Low-headroom monorail hoist
Z = Double-rail crab
E = Electric travel trolley

14 R = Push travel trolley
2.3 Selection criteria
The size of the hoist is determined by the load 1. What are the operating conditions? 5. Do the loads need to be lifted and lowered with
spectrum, average operating time per working day, 2. What is the specified SWL? high precision?
SWL and reeving. 3. To what height must be load be lifted? 6. Is horizontal load travel required?
4. What is the required lifting speed? 7. How is control to be effected?
The load spectrum (in most cases estimated) can be

evaluated in accordance with the following defini- The group is determined from the operating time and load spectrum.
tions:
Load spectrum Average operating time per day in hours
1 Light
Hoist units which are usually subject to very small 1 light up to 2 2-4 4-8 8-16 above
loads and in exceptional cases only to maximum ⇒ 16
loads. 2 medium up to 1 1-2 2-4 4-8 8-16
3 heavy up to 0,5 0,5-1 1-2 2-4 4-8
Small partial load 4 very heavy up to 0,25 0,25-0,5 0,5-1 1- 2 2-4

Small dead load
SWL
Group of mechanisms to FEM 1 Bm 1 Am 2m 3m 4m

Operating time
2 Medium Rope reeving arrangement Range Size
Hoist units which are usually subject to small loads
but rather often to maximum loads. 2/2 4/2 8/2
1/1 2/1 4/1 6/1 1) 8/1 1)
SWL in kg
Heavy partial load
Medium partial load 800 1600 3200 - - - - - - - 308
Medium dead load
SWL
1000 2000 4000 - - - - - - 310 410

Operating time 1250 2500 5000 - - - - - 312 412 512
3 Heavy 1600 3200 6300 - - - - 316 416 516 616

Hoist units which are usually subject to medium loads
but frequently to maximum loads. 2000 4000 8000 12500 16000 DH 300 320 420 520 620 -
2500 5000 10000 16000 20000 DH 400 425 525 625 - 1025
⇒
Heavy dead load 3200 6300 12500 20000 25000 DH 500 532 632 - 1032 -
4000 8000 16000 25000 32000 DH 600 640 - 1040 - -

SWL
Operating time 5000 10000 20000 32000 40000 - - 1050 - - 2050
4 Very heavy 6300 12500 25000 40000 50000 DH 1000 1063 - - 2063 -
Hoist units which are usually subject to maximum 8000 16000 32000 50000 63000 - - - 2080 - -
or almost maximum loads.
10000 20000 40000 63000 80000 - - 2100 - - -
Very heavy dead load
12500 25000 50000 80000 100000 DH 2000 2125 - - - -
(see line ⇒
SWL
Example )
Operating time SWL 5000 kg
Load spectrum “Light” from table
1) Only available in groups of mechanisms Lifting speed 8 m/min
1 Bm, 1 Am and 2 m.
Creep lifting speed 1,3 m/min
Rope reeving 2/1
Average hook path 4m
No. of cycles/hour 20
Check the frequency of starts per hour when select- Working time/day 8 hours
ing motors for DH hoist units (see pages 16 to 18).
The average operating time per working day is estimated or calculated as follows:
DH hoist unit with pole-changing motor
Operating
2 x average hook path x no. of cycles/h x working time/
Main lifting speed = 80 starts/h time/day = =
day 60 x lifting speed
Creep lifting speed = 160 starts/h
DH hoist unit with microspeed unit 2 x 4 x 20 x 8

21428602.p65/090903
= 2,66 hours
60 x 8
Main lifting speed = 240 starts/h
Creep lifting speed = 240 starts/h
For the light load spectrum and an average daily operating time of 2,66 hours the
table shows FEM group 1 Am. For an SWL of 5000 kg and 2/1 rope reeving, the
table indicates a hoist size DH 525. 15
2.4 Hoist motor data Design in accordance with the VDE regulations and the design rules of the FEM, to
meet the high demands made on electric hoists.
Main/creep lifting F6 Required supply cable conductor cross sections and fuse links
Size No. Groups of P % CDF n Starts/h Rated current I N and starting current I A for 50 Hz cos cos
of mecha-
poles nisms to 230 V 400 V 500 V ϕN ϕA
FEM
KBH kW rpm I N (A) I A (A) I N (A) I A (A) I N (A) I A (A)
2 1 Bm 3,6 25 2740 80 14,9 83 8,6 48 6,8 38 0,84 0,69
12 1 Am, 2 m 0,51 15 410 160 8,9 14 5,1 8,1 4,1 6,5 0,47 0,57
112 B 2/12
2 2,9 40 2800 120 12,4 83 7,1 48 5,7 38 0,80 0,69
3 m, 4 m
12 0,43 20 420 240 8,9 14 5,1 8,1 4,1 6,5 0,45 0,57
2 1 Bm 4,6 25 2870 80 22 124 12,5 71 10 57 0,74 0,67
12 1 Am, 2 m 0,68 15 430 160 14,2 21 8,2 12,4 6,5 9,9 0,41 0,51
125 B 2/12
2 3,6 40 2890 120 20 124 11,6 71 9,3 57 0,68 0,67
3 m, 4 m
12 0,53 20 450 240 14 21 8,1 12,4 6,5 9,9 0,38 0,51
2 1 Bm 7,1 25 2870 80 36 183 21 105 16,7 84 0,70 0,65
12 1 Am, 2 m 1,1 15 440 160 27 35 15,7 20 12,5 16 0,40 0,50

140 B 2/12
1) 2 5,7 40 2900 120 31 183 18,1 105 14,4 84 0,62 0,65
3 m, 4 m
12 0,85 20 460 240 27 35 15,7 20 12,5 16 0,36 0,50
2 1 Bm 11,4 25 2870 80 43 248 25 143 19,8 114 0,88 0,61
12 1 Am, 2 m 1,7 15 460 160 28 55 16,2 31 12,9 25 0,36 0,53

160 B 2/12
1) 2 9,3 40 2900 120 36 248 21 143 16,7 114 0,86 0,61
3 m, 4 m
12 1,4 20 470 240 28 55 16,2 31 12,9 25 0,32 0,53
2 1 Bm 17,8 25 2870 80 73 408 42 235 33 188 0,84 0,60
12 1 Am, 2 m 2,6 15 4 60 160 35 64 20 37 16 30 0,36 0,48

180 B 2/12
1) 2 14,2 40 2900 120 61 408 35 235 28 188 0,80 0,60
3 m, 4 m
12 2,1 20 475 240 33 64 19 37 15,2 30 0,31 0,48
2 1 Bm 25 25 2920 80 93 595 53 342 43 274 0,84 0,50
12 1 Am, 2 m 3,7 15 470 160 41 84 24 48 19 39 0,37 0,50

200 B 2/12
1) 2 20 40 2930 120 79 595 46 342 36 274 0,81 0,50
3 m, 4 m
12 3 20 475 240 38 84 22 48 17,5 39 0,32 0,50
Size Mains connection delay fuse for 50 Hz 2) Supply lines for 5% voltage drop ∆U and starting current IA for 50 Hz 4)
230 V 400 V 500 V 230 V (∆U 11,5 V) 400 V (∆U 20 V) 500 V (∆U 25 V)
KBH A A A mm ² m mm ² m mm ² m
112 B 2/12 25 20 20 2,5 16 1,5 29 1,5 46
125 B 2/12 50 25 25 4 18 1,5 20 1,5 32
140 B 2/12 6 14 2,5 2,5

80 50 50 16 23
1) 1) 3) 1) 1)
160 B 2/12 10 4 4
80 50 50 18 44 60
1) 1) 1) 1)
180 B 2/12 16 24 6 6
125 80 80 21 33
1) 1) 3) 1) 1)
200 B 2/12 25 10 10
- 100 100 - 31 52
1) 1) 1) 1)
1) Only use motors with starting and braking circuitry. Voltage drop may then be 10%.
(See function description 202 708 44 (714 IS 952))
21428602.p65/090903
2) Fuse links also apply in conjunction with a cross-travel motor.

3) Earth-loop impedance of 100 mΩ required.
4) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.
16
Main lifting
Size Groups of P % CDF n Starts/h Rated current I N and starting current I A for 50 Hz cos co s
ϕA ϕN
mecha-
230 V 400 V 500 V
nisms to
KBH FEM kW rpm I N (A) I A (A) I N (A) I A (A) I N (A) I A (A)
1 Bm
3,6 40 1400 240 18,2 71 10,5 41 8,4 33 0,72
1 Am, 2 m
100 B 4 0,73
3 m, 4 m 2,3 60 1430 360 15,7 71 9 41 7,2 33 0,62
1 Bm
4,6 40 1420 240 23 106 13,3 61 10,6 49 0,68
1 Am, 2 m
1 12 B 4 0,68
3 m, 4 m 3,6 60 1440 360 21 106 12,4 61 9,9 49 0,66
1 Bm
7,1 40 1410 240 33 135 19 78 15,2 62 0,78
1 Am, 2 m
125 B 4 0,65
3 m, 4 m 5,7 60 1420 360 30 135 17,1 78 13,7 62 0,76
1 Bm
11,4 40 1420 240 53 248 30 143 24 114 0,72
1 Am, 2 m
140 B 4 0,59
3 m, 4 m 9,3 60 1440 360 45 248 26 143 21 114 0,68
1 Bm
17,8 40 1440 240 76 425 44 244 35 195 0,78
1 Am, 2 m
160 B 4 0,58
3 m, 4 m 14,2 60 1450 360 64 425 37 244 30 195 0,75
1 Bm
28,5 40 955 240 119 496 68 285 55 228 0,71
1 Am, 2 m
200 B 6 0,46
3 m, 4 m 22,5 60 965 360 99 496 57 285 46 228 0,66
1 Bm
40 40 970 240 157 760 90 437 72 350 0,79
1 Am, 2 m
225 B 6 0,60
3 m, 4 m 32 60 975 360 132 760 76 437 61 350 0,76
Size Mains connection delay fuse for 50 Hz 2) Supply lines for 5% voltage drop ∆U and starting current IA for 50 Hz 4)
230 V 400 V 500 V 230 V (∆U 11,5 V) 400 V (∆U 20 V) 500 V (∆U 25 V)
KBH A A A mm ² m mm ² m mm ² m
100 B 4 35 20 20 2,5 18 1,5 32 1,5 50
112 B 4 50 25 25 4 18 1,5 23 1,5 36
125 B 4 63 35 35 6 16 2,5 32 1,5 20
22
140 B 4 100 63 63 10 4 15 4 23
2)
38
160 B 4 125 80 80 25 6 21 6 33
2)
200 B 6 - 125 100 - - 16 32 10 52
225 B 6 - 16 0 125 - - 25 11 16 58
1) Fuse links also apply in conjunction with a creep lifting or cross-travel motor.
2) Earth-loop impedance of 100 mΩ required.
21428602.p65/090903
3) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.
17
F10 microspeed unit
Size Groups of P % CDF n Starts/h Rated current I N and starting current I A for 50 Hz cos cos
mechanisms
to FEM 230 V 400 V 500 V ϕN ϕA
KBA kW rpm I N (A) I A (A) I N (A) I A (A) I N (A) I A (A)
1 Bm
0,83 25 1310 240 4,6 13,7 2,7 7,9 2,1 6,3 0,75
1 Am, 2 m
71 B 4 0,77
3 m, 4 m 0,72 40 1340 360 4,3 13,7 2,5 7,9 2,0 6,3 0,70
1 Bm
1,5 25 1340 240 7,9 26 4,6 15,1 3,6 12,1 0,73
1 Am, 2 m
80 B 4 0,77
3 m, 4 m 1,3 40 1370 360 7,3 26 4,2 15,1 3,3 12,1 0,68
1 Bm
2,3 25 1365 240 11,4 41 6,6 24 5,2 19 0,74
1 Am, 2 m
90 B 4 0,71
3 m, 4 m 2,0 40 1390 360 10,2 41 5,9 24 4,7 19 0,70
1 Bm
3,5 25 1405 240 16,5 71 9,5 41 7,6 33 0,72
1 Am, 2 m
100 B 4 0,73
3 m, 4 m 3,0 40 1420 360 15,2 71 8,7 41 7,0 33 0,68
1 Bm
5,2 25 1410 240 23 106 13,5 61 10,8 49 0,75
1 Am, 2 m
112 B 4 0,68
3 m, 4 m 4,5 40 1425 360 21 106 12,1 61 9,7 49 0,70
2.5 EUDH, EKDH, EZDH, EZLDH travel motor data (40% CDF)
PN nN MN IN cos ϕ N IA / IN MA /MN MH Jmot A MB stat Weight
Size 230 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
0,06 675 0,85 1,15 0,59 1,40 2,20 1,7 720
ZBF 63 A 8/2 B003 0,00459 1,4 10
0,25 2745 0,87 1,65 0,71 2,65 2,10 1,5 550
0,09 675 1,25 1,30 0,61 1,60 2,70 2,5 620
ZBF 71 A 8/2 B003 0,00690 1,9 12,2
0,34 2785 1,15 1,75 0,73 3,50 2,60 2,5 500
0,13 630 1,95 2,10 0,64 1,20 2,10 3,5 620
ZBF 80 A 8/2 B020 0,01275 3,3 19,5
0,50 2790 1,70 2,40 0,73 4,50 2,60 4,0 500
0,20 690 2,80 2,60 0,50 1,95 2,50 6,5 580
ZBF 90 B 8/2 B020 0,02169 4,4 28,2
0,80 2765 2,80 4,00 0,79 3,60 2,40 6,2 450
0,29 685 4,00 3,70 0,50 1,80 2,50 9,0 460
ZBF 100 A 8/2 B050 0,03092 8,3 35
1,20 2760 4,20 5,60 0,82 4,00 2,50 9,5 350
0,46 705 6,20 4,40 0,49 2,50 2,40 15 460
ZBF 112 A 8/2 B050 0,04374 11 56,4
1,90 2855 6,40 7,50 0,85 5,30 2,40 14,5 350
PN nN MN IN cos ϕ N IA / IN MA /MN MH Jmot A MB stat Weight

Size 400 V
0,06 675 0,85 0,66 0,59 1,40 2,20 1,7 720
ZBF 63 A 8/2 B003 0,00459 1,4 10
0,25 2745 0,87 0,95 0,71 2,65 2,10 1,5 550
0,09 675 1,25 0,76 0,61 1,60 2,70 2,5 620
ZBF 71 A 8/2 B003 0,00690 1,9 12,2
0,34 2785 1,15 1,00 0,73 3,50 2,60 2,5 500
0,13 630 1,95 1,20 0,64 1,20 2,10 3,5 620
ZBF 80 A 8/2 B020 0,01275 3,3 19,5
0,50 2790 1,70 1,40 0,73 4,50 2,60 4,0 500
0,20 690 2,80 1,50 0,50 1,95 2,50 6,5 580
ZBF 90 B 8/2 B020 0,02169 4,4 28,2
21428602.p65/090903
0,80 2765 2,80 2,30 0,79 3,60 2,40 6,2 450

0,29 685 4,00 2,10 0,50 1,80 2,50 9,0 460
ZBF 100 A 8/2 B050 0,03092 8,3 35
1,20 2760 4,20 3,20 0,82 4,00 2,50 9,5 350
0,46 705 6,20 2,50 0,49 2,50 2,40 15 460
ZBF 112 A 8/2 B050 0,04374 11 56,4
1,90 2855 6,40 4,30 0,85 5,30 2,40 14,5 350
18
EUDH, EKDH travel motor (40 % CDF)
PN nN MN IN cos ϕ N I A / IN MA /MN MH Jmot A MB stat Weight
Size 500 V
0,06 675 0,85 0,53 0,59 1,40 2,20 1,7 720
ZBF 63 A 8/2 B003 0,00459 1,4 10
0,25 2745 0,87 0,76 0,71 2,65 2,10 1,5 550
0,09 675 1,25 0,61 0,61 1,60 2,70 2,5 620
ZBF 71 A 8/2 B003 0,00690 1,9 12,2
0,34 2785 1,15 0,80 0,73 3,50 2,60 2,5 500
0,13 630 1,95 0,96 0,64 1,20 2,10 3,5 620
ZBF 80 A 8/2 B020 0,01275 3,3 19,5
0,50 2790 1,70 1,10 0,73 4,50 2,60 4,0 500
0,20 690 2,80 1,20 0,50 1,95 2,50 6,5 580
ZBF 90 B 8/2 B020 0,02169 4,4 28,2
0,80 2765 2,80 1,85 0,79 3,60 2,40 6,2 450
0,29 685 4,00 1,70 0,50 1,80 2,50 9,0 460
ZBF 100 A 8/2 B050 0,03092 8,3 35
1,20 2760 4,20 2,60 0,82 4,00 2,50 9,5 350
0,46 705 6,20 2,00 0,49 2,50 2,40 15 460
ZBF 112 A 8/2 B050 0,04374 11 56,4
1,90 2855 6,40 3,50 0,85 5,30 2,40 14,5 350
EKDH 300/400 travel motor for trolley size 5, 2/1 and 4/2 rope reeving (15/40 % CDF)
PN nN MN IN cos ϕ N IA / I N MA /MN MH Jmot A MB stat Weight
Size 230 V
0,06 415 1,40 2,70 0,71 1,00 2,40 3,0 620
ZBF 80 A 12/4 B020 0,01275 3,3 19,5
0,25 1380 1,75 1,70 0,64 2,80 2,10 3,6 380

Size 400 V
0,06 415 1,40 1,50 0,71 1,00 2,40 3,0 620
ZBF 80 A 12/4 B020 0,01275 3,3 19,5
0,25 1380 1,75 0,97 0,64 2,80 2,10 3,6 380

Size 500 V
0,06 415 1,40 1,20 0,71 1,00 2,40 3,0 620
ZBF 80 A 12/4 B020 0,01275 3,3 19,5
0,25 1380 1,75 0,78 0,64 2,80 2,10 3,6 380
EUDH 300/400 travel motor for trolley size 5, 2/1 and 4/2 rope reeving
Size P % CDF n Rated current IN and starting current IA for 50 Hz cos co s
230 V 400 V 500 V ϕ ϕ

N A
kW rp m I N (A) I A (A) I N (A) I A (A) I N (A) I A (A)
KMF 80 A 4 0,32 40 1350 1,7 5,5 0,95 3,1 0,76 2,5 0,74 0,82
2,0 3,3 1,1 1,9 0,91 1,5 0,71 0,84
KMF 80 A 8/2 0,13/0,5 40 630/2710
2,5 9,9 1,4 5,7 1,1 4,6 0,88 0,84
Example for calculating the cross KBH 112 B 2/12, 230 V required length 25 m
sections of the conductors of cables
exceeding the length indicated in the Known cross section x required length 2,5 x 25
= = 4 mm2
table: Known length of cable 16
21428602.p65/090903
19
2.5.1 Mounting code for ordering a mechanical microspeed unit
Indication of the position of the terminal boxes for the main hoist motor and creep
hoist motor (microspeed unit).
The position is indicated by the code numbers 0–1–2–3, ascending in anticlockwise
0 direction when looking at the motor end face.
The required position must be indicated in accordance with the selected mounting
flange position A, B, C or D.
1 3 Standard
Mounting flange
Terminal box location
position
H1 A
2 H0 B
H3 C
1) Other gear ratios on application
40134144.eps
H2 D
2) For 6-pole main hoist motor i = 15
Main hoist motor Microspeed motor

Gearbox Basic form Gear ratio 1)
terminal box location terminal box location
FG.. - U0 - H1 - F1 / 10 2)
FG.. - U1 - H0 - F0 / 10 2)
FG.. - U2 - H1 - F1 / 10 2)
FG.. - U3 - H0 - F0 / 10 2)
2.6 Setting hook dimension C
When an operating limit switch is fitted for the highest hook position the hook dimen-
sion C is increased for 1/1, 2/1 and 4/1 rope reevings as follows:
Table 1
1/1 2/1 4/1
85 mm 50 mm 20 mm
The useful hook path is reduced by the values given in table 2/3.
C
Operating limit switch for highest hook position
Table 2
1/1 2/1 4/1
40257744.eps - 85 mm - 50 mm - 20 mm
Operating limit switch for highest and lowest hook position
Table 3
1/1 2/1 4/1
- 170 mm - 100 mm - 40 mm
21428602.p65/090903
20
2.6.1 DH 300, DH 400, DH 500, DH 600, DH 1000, DH 2000 hoist units
Size Hook dimension C with overload cut-off Hook dimension C without overload cut-off
1/1 2/1 4/2 A 4/1 1/1 2/1 4/2 A 4/1
with w/o with w/o with w/o with w/o with w/o with w/ o with w/o with w/o
Creep lifting Creep lifting
DH 320-310 605 650 545 565 545 590 485 505

410 455 520 565 410 455 520 565
DH 308 700 740 615 640 680 555
1/1 2/1 4/2 A 4/1 1/1 2/1 4/2 A 4/1
with w/o with w/o with w/o with w/o with w/o with w/ o with w/o with w/o
DH 425 - -
605 650 545 565 545 590 485 505
DH 420-412 520 565 520 565
410 455 410 455
DH 410 700 740 615 640 680 555
1/1 2/1 4/2 A 4/1 B 4/1 1/1 2/1 4/2 A 4/1 B 4/1
w it h w/o with w/o with w/o with w/o with w/o with w/o with w/o with w/o with w/o with w/o
DH 532-516 750 455 500 630 650 630 650 680 455 500 560 580 560 580
555 600 555 600
DH 512 925 570 610 850 850 855 570 610 780 780
1/1 2/1 4/2 A 4/1 B 4/1 1/1 2/1 4/2 A 4/1 B 4/1
w it h w/o with w/o with w/ o with w/o with w/o with w/o with w/o with w/o with w/o with w/o
DH 640 - -
750 455 500 630 650 630 650 680 455 500 560 580 560 580
DH 632-620
555 600 555 600
DH 616 925 570 610 850 850 855 570 610 780 780
1/1 2/1 4/2 A 4/1 B 4/1 1/1 2/1 4/2 A 4/1 B 4/ 1
w it h w/o with w/o with w/o with w/o with w/o with w/o with w/o with w/o with w/o with w/o
DH 1063-1032 890 935 565 605 845 865 810 830 810 855 565 605 765 785 730 750
625 670 625 670
DH 1025 1060 1105 1160 1205 1120 1000 1020 980 1025 1160 1205 1040 920 940
1/1 2/1 4/2 A 4/1 B 4/1 1/1 2/1 4/2 A 4/1 B 4/1
con with w/o with w/o with w/o with w/o with w/o with w/o with w/o with w/o with w/o with
DH 2125-2080 1140 1180 1120 1140 1120 1140 1060 1100 1040 1060 1040 1060
735 780 1110 1150 735 780 1110 1150
DH 2063
1260 1300 1300 1345 1365 1180 1220 1200 1265 1285
DH 2050 - 1030 1075 - 1030 1075
21428602.p65/090903
21
2.6.2 KDH low-headroom monorail
KDH 300/400 2/1 and 4/2 KDH
hoist
C
C
Hook dimension C from girder running surface
42030044.eps 40257944.eps
KDH 300/400 low-headroom monorail hoist, 2/1 rope reeving

Flange width b 106-160 180 200 106-160 180 200
Creep
lifting
w/o 790 730
DH 425
with 750 690
DH 320-310 w/o 750 690

DH 420-412 with 710 650
DH 308 w/o 840 830 780 770

DH 410 with 800 790 740 730

Size 106-180 200
Creep lifting w/o Hook dimension C with and without overload cut-off
DH 320-310 with 690 720

DH 425-412 w/ o 650 680
DH 308 with 630 660

DH 410 mit 590 640

Flange width b 201-220 240-260 280 300 400 201-220 240-260 280 300 400
Creep
lifting
w/o 790 800 880 730 740 820
DH 425
with 750 760 880 690 700 820
DH 320-310 w/o 750 770 800 880 69 0 710 740 820

DH 420-412 with 710 730 760 880 650 670 700 820
DH 308 w/o 830 820 810 800 880 770 760 750 740 820
DH 410 with 790 780 770 760 880 730 720 710 700 820

Flange width b 201 220 240 260 280 300 400
Creep
Size Hook dimension C with and without overload cut-off
lifting
DH 320-310 w/o 720 740 770 790

780 810 940
21428602.p65/090903
DH 425-412 with 680 700 730 750
DH 308 w/ o 660 680 710 730

720 750 880
DH 410 with 620 640 670 690
22
Rope reeving 4/1
Flange width b 100-200 305 100-200 305

Creep
lifting
DH 320-310 w/o
600 665 540 605
DH 425-412 with
DH 308 w/o
780 720
DH 410 with
Rope reeving 2/1 4/2 2/1 4/2
Flange width b 100-200 305 100-200 305 100-200 305 100-200 305
Creep
lifting
DH 532-516 w/ o 770 700

530 600 550 620
DH 640-620 with 730 660
DH 512 w/ o 650 670

945 875
DH 616 with 610 630
Rope reeving 4/1
Flange width b 110-305 110-305

Creep
lifting
DH 532-516 w/o 680 610

DH 640-620 with 660 590
w/o
H 12 1010 940
DH 512 with
DH 616 w/o
H 20 910 840
with
Rope reeving 2/1 4/2 2/1 4/2
Flange width b 100-200 305 100-200 305 100-200 305 100-200 305
Creep
lifting
w/ o 960 880
DH 1063-1032 660 680 660 680
with 920 840
w/ o 1255 1255
DH 1025 1220 1140
with 1225 1225
21428602.p65/090903
23
2.6.3 UDH standard-headroom UDH 300/400 2/1 and 4/2 UDH 300/400 4/1
monorail hoist
UDH 500/600 2/1, 4/2 and 4/1
UDH 1000 2/1
C
Hook dimension C from
girder running surface
42240944.eps 40257844.eps
2/1 4/2 2/1 4/2
with creep lifting w/o creep lifting with creep lifting w/o creep lifting with creep lifting w/o creep lifting with creep lifting w/o creep lifting
DH 320-310
1175 1220 1115 1160
DH 425-412
1090 1135 1090 1135
DH 308
1290 1310 1210 1250
DH 410
4/1 4/1
with creep lifting w/o creep lifting with creep lifting w/o creep lifting
DH 320-310
1140 1160 1080 1100
DH 425-416
DH 308
1210 1150
DH 410
2/1 4/2 2/1 4/2
DH 532-516
1390 1095 1140 1320 1095 1140
DH 640-620
DH 512
1565 1210 1250 1495 1210 1250
DH 616
4/1 4/1
DH 532-516
1305 1325 1235 1255
DH 640-620
DH 512
1525 1455
DH 616
2/1 4/2 2/1 4/2
21428602.p65/090903
DH 1063-1032 1750 1795 1420 1460 1670 1715 1420 1460
DH 1025 1920 1965 2020 2065 1840 1885 2020 2065
24
2.6.4 EZDH/DRS double-rail crabs EZDH/DRS
C
40258044.eps
DRS wheel block 112
Rope reeving 2/1 4/2 2/1 4/2 2/1 4/2 2/1 4/2
DH 320-310
575 620 515 560
DH 425-412
490 595 490 535
DH 308
670 710 610 650
DH410
DRS wheel block 112 DRS wheel block 125
Rope reeving 4/1 Rope reeving 4/1

Hook dimension C with Hook dimension C without Hook dimension C with Hook dimension C without
Size Size
overload cut-off overload cut-off overload cut-off overload cut-off
with creep w/o creep with creep w/o creep with creep w/o creep with creep w/o creep
lifting lifting lifting lifting lifting lifting lifting lifting
DH 320-310 DH 320-310
515 535 455 475 490 510 430 450
DH 420-412 DH 425-412
DH 308
575 515 DH410 560 500
DH410
DRS wheel block 112 125 112 125 112 125 112 125 112 125 112 125 112 125 112 125
Rope reeving 2/1 4/2 2/1 4/2 2/1 4/2 2/1 4/2
DH 532-516
715 - 420 - 715 - 465 - 645 - 420 - 645 - 465 -
DH 640-616
DH 532-520
- 690 - 395 - 690 - 440 - 620 - 395 - 620 - 440
DH 640-620
DH 512
890 - 535 - 890 - 575 - 820 - 535 - 820 - 575 -
DH 616
DRS wheel block 112 125 112 125 112 125 112 125
Rope reeving 4/1 4/1
DH 520-516
590 - 610 - 52 0 - 540 -
DH 620
21428602.p65/090903
DH 512
815 - 815 - 745 - 745 -
DH 616
DH 532-516
- 570 - 590 - 500 - 520
DH 640-620
DH 512
- 790 - 790 - 720 - 720
DH 616 25
2.6.4 EZDH/DRS double-rail crabs EZDH/DRS
C
40258044.eps
DRS wheel block 112 125 112 125 112 125 112 125 112 125 112 125 112 125 112 125
Rope reeving 2/1 4/2 2/1 4/2 2/1 4/2 2/1 4/2
DH 1063-1032 - 830 - 505 - 875 - 545 - 750 - 505 - 795 - 545
DH 1040-1032 835 - 530 - 900 - 570 - 755 - 530 - 820 - 570 -
DH 1025 1025 1000 1125 1100 1070 1045 1170 1225 945 920 1125 1100 990 965 1170 1145
DRS wheel block 125 160 200 125 160 200 125 160 200 125 160 200
Rope reeving 4/ 1 4/1
DH 1063 - - 815 - - 835 - - 735 - - 755
DH 1050 - 770 - - 785 - - 690 - - 705 -
DH 1040-1032 800 - - 820 - - 720 - - 740 - -
DH 1025 1075 - - 1075 - - 995 - - 995 - -
2.6.5 EZLDH/DRS double-rail crabs EZLDH/DRS

C
40258144.eps
DRS wheel block 112
21428602.p65/090903
DH 320-310
435 480 375 420
DH 425-412
DH 308
530 570 470 510
26 DH410
DRS wheel
DRS wheel block 112 125
block
Rope reeving 4/1 Rope reeving 4/1
Size Size
with w/o with w/o with w/o with w/o
creep lifting creep lifting creep lifting creep lifting creep lifting creep lifting creep lifting creep lifting
DH 320-310 DH 320-310
375 395 315 335 355 375 295 315
DH 420-412 DH 425-412
DH 308
445 385 DH 410 425 3 65
DH 410
DRS wheel
DRS wheel block 112 125 112 125 112 125 112 125 125
block
Rope reeving 2/1 2/1 Rope reeving 4/1
Size Size
with w/o with w/o with w/o with w/o
creep lifting creep lifting creep lifting creep lifting creep lifting creep lifting creep lifting creep lifting
DH 532-516
580 - 580 - 510 - 510 - DH 640 440 460 370 390
DH 632-620
DH 532-516 DH 532-516
- 565 - 565 - 495 - 495 445 465 375 395
DH 640-620 DH 632-620
DH 512 DH 512
755 - 755 - 685 - 685 - 665 595
DH 616 DH 616
DRS wheel block 125 125 160 200 125 125 160 200 125 125 160 200 125 125 160 200
Rope reeving 2/1 4/ 1 2/1 4/1 2/1 4/1 2/1 4/1
DH 1063-1032 695 - - - 740 - - - 615 - - - 660 - - -
DH 1063 - - - 560 - - - 580 - - - 480 - - - 500
DH 1050 - - 605 - - - 625 - - - 525 - - - 545 -
DH 1040-1032 - 650 - - - 670 - - - 570 - - - 590 - -
DH 1025 865 925 - - 910 925 - - 785 845 - - 830 845 -
DRS wheel block 200 250 200 250 200 250 200 250
DH 2100 - 785 - 805 - 705 - 725
DH 2080 830 - 850 - 750 - 77 0 -
DH 2063 990 - 990 - 910 - 91 0 -

21428602.p65/090903
27
2.7 Mounting flange positions and rope lead-offs
Code number
Mounting flange Mounting flange position C
Code number
position A
Pay attention to mounting positions
3
3 provided on DH 2000
3 1
1 1
Terminal box
2
Main hoist motor Welded-on suspension only for
DH 300 – DH 400 and DH 500 – DH 2000 4/1 2
2
2
2
2
1 1
3
1 3
3
41443144.eps 41443344.eps
Mounting flange Mounting flange position D
position B Code number Code number
2 2
1
1
1
3
3
3
3
Remove suspension of
1
DH 300 – DH 400 at
1 2
this point (if necessary).
1
Looking at main hoist motor end face 2

Fig. 1 41443244.eps 41443444.eps
Four different mounting positions A, B, C and D and three rope lead-offs 1, 2 and 3
can be obtained by rotating the hoist unit about its longitudinal axis (see fig. 1).
The position of the motor terminal box can be changed, staggered at 90°.
If the mounting flange position is altered, it must be ensured that the code number
stamped into the gearbox casing (gear ratio) always points upwards (see fig. 1).
Only then do we guarantee that the gearbox is vented properly.
Demag hoist unit with rope guide Demag hoist unit without rope guide
Range Rope lead-off Special design Range Rope lead-off
Rope lead-off 1 2 3
1 2 3 α1 β1 α2 β2 α3 β3
α1 β1 α2 β2 α3 β3 DH 300 H 12
22° 57° 34° 16° 66° 11°
DH 300/400 DH 400 H 20
23° 11° 21° 9°
DH 500/600 23° 10° 21° 8° DH 500 H 12

20° 25° 50° 12°
DH 1000 DH 600 H 20
20° 13° 20° 8°
24° 35° 71° 9°
DH 2000 20° 15° 20° 0° H 40
DH 500 35° 2°
H 52
Special rope lead-offs 4 and 5 H 16 38°
(on application) 15°
H 24
DH 1000 25° 45° 66° 9°
H 40 34°
3°
H 51
H 18
59°
DH 2000 H 27 22° 33° 19° 62° 0°
21428602.p65/090903
5 H 47 52°
4
41111144.eps
28
21428602.p65/090903
29
3 General
3.1 Inspection regulations Notes on inspections in accordance with

Relevant accident prevention regulations for winches,
hoists and towing devices BGV D8 (VBG 8)
Relevant accident prevention regulations for cranes BGV D6 (VBG 9)
The EC machinery directive requirements are therefore also complied with.

Inspection when putting the hoist into operation for the first time
If hoist units are used as cranes, an inspection must be carried out by an expert
engineer in accordance with relevant accident prevention regulations BGV D6 § 25
for cranes.
Hoist units used in accordance with relevant accident prevention regulations for
winches, hoists and towing devices BGV D8 must be inspected by an experienced
technician.
The inspection in accordance with relevant accident prevention regulations for
winches, hoists and towing devices BGV D8 mainly consists of a visual inspection
and a function check. It is designed to ensure that the equipment is in a safe condi-
tion and that any defects and damage, e.g. caused by improper handling during
transport, are identified and repaired.
In addition, regulations specific to cranes must also be taken into consideration
during acceptance and other inspections in accordance with relevant accident
prevention regulations for cranes BGV D6.
Routine inspections
Hoists and cranes must be inspected by an experienced technician at least once a
year. Routine inspections mainly consist of a visual inspection and a function check
which should include a check to determine the condition of components and equip-
ment regarding damage, wear, corrosion or other alterations and a check to deter-
mine the integrity and efficiency of safety devices and brakes. It may be necessary to
dismantle the unit in order to inspect wearing parts.
Load carrying means must be inspected along their entire length, including those
parts which cannot normally be seen. A function and brake test with load (test load
close to the max. permissible load capacity) must be carried out.
The owner must arrange for all inspections to be carried out and documented in the
test and inspection booklet of the hoist unit.
3.2 Hoist units oper- Hoist units operating outdoors should be provided with a cover for protection against
the weather. Travelling hoists should be kept under shelter if they are not used for a
ating outdoors considerable length of time.
3.3 Packing and storage The hoist unit and accessories such as rope, hook with fittings, bottom block and
control pendant as well as the trolley are shipped in cardboard packaging or on
pallets.
Store the hoist unit and accessories in a dry place.
3.4 Paint finish The hoist unit is supplied in the following standard colours:
Hoist unit RAL 5009 Azure blue
Bottom block/hook with fittings RAL 1007 Chrome yellow
Hook RAL 9005 Jet black
Trolley RAL 5009 Azure blue
3.5 Operating conditions The hoist unit can be operated at:

• – 10° to + 40° C
• air humidity up to 80%
• air pressure up to 1000 m above sea level
21428603.p65/090903
Other operating conditions are also possible.

• Aggressive environment
Please refer to the manufacturer for information on any modifications that may be
necessary. See page 2 for the address.
30
3.6 Sound pressure level The sound pressure level of a hoist unit can be seen in the following table.
measurement according
to DIN 45635
L pA
Motor speed n = 2800 rpm
[ dB(A) ]
Logarithmic regression:
m
__
L = 42,31 + 10,92 log
pA kg [dB(A)]
90
Correlation coefficient r = 0,7
Tolerance = ± 2 dB (A)
m
__
L = 47,69 + 8,14 log
pA kg [dB(A)]
85
80

75
m
__
L = 70,27 + 2,97 log
pA kg [dB(A)]

Mass
70 m
1,6 2 2,5 3,2 4 5 6,3 8 10 12,5 16 20 25 [1000 kg]
for 2/1
DH 300 308 310 312 316 320

DH 400 410 412 416 420 425
DH 500 516 520 525 532
DH 600 616 620 625 632 640
DH 1000 1025 1032 1040 1050 1063
DH 2000 2063 2080 2100 2125 42035044.eps
Sound pressure level LpA in relation to the load capacity and size of the hoist
unit at a distance of 1 m
The specified values (emission values) were measured under maximum load.
Structural influences such as:
• transmission of noise via steel structures
• reflection of noise from walls, etc.
were not allowed for in the above measurements.
The sound pressure level is reduced by approx. 3 dB(A) each time the distance is
doubled.
Measuring point
-3 dB(A)
-6 dB(A)
Sound source
21428603.p65/090903
Sound pressure level

1m reduction in relation to the
distance from the sound
2m source
4m
41120044.eps
31
4 Description
4.1 Design
24625-1.tif
1 Electrical equipment cover 6 Rope guide 11 Main lifting motor brake

2 Electrical components 7 Planetary gearbox 12 Terminal box
3 Geared limit switch 8 Rope drum 13 Rope drum brake
4 Frame 9 Roller coupling 14 Wire rope
5 Connecting shaft 10 Motor
Six ranges of Demag DH hoist units are manufactured in five sizes corresponding to
the DIN/FEM groups.
4.2 Motor The Demag brake motor used as hoist drive is a combination of electric motor and
brake which operates on the sliding rotor principle. It is designed in accordance with
the EN (IEC) regulations and the design rules of the FEM, to meet the high demands
made on electric hoists. KB hoist motors feature IP 54 enclosure (IP 20 enclosure for
the brake of the KB brake motor).
Demag brake motors with separately controlled brakes are used as travel drives.
Type of enclosure of the ZBF travel motors is IP 54.
A creep travel speed of 1/4 of the main travel speed is obtained by using a 8/2-pole
motor. Only the 2-pole winding of the travel motors is connected for a single travel
speed.
A creep lifting speed of 1/6 of the main lifting speed can be obtained by using a
2/12-pole motor.
A mechanical microspeed unit of the FG range can be used where other creep lifting
speeds are required.
The transmission ratios available in the FG range produce a large number of creep
lifting speed possibilities. The preferred transmission ratio is 1/10.
Mechanical creep speed units may be fitted at a later stage, if required.
21428603.p65/090903
4.3 Gearbox/rope reeving The torque of the motor is transmitted to the planetary gearbox by a roller coupling
which is flexible in both radial an axial directions.
components
The 2, 3 or 4-stage planetary gearbox inside the drum houses all gear stages.
The drum, rope sheaves and rope comply with the FEM 9.666 design rules.
32
4.4 Arrangement of the The axial arrangement of the planetary gearbox inside the drum is one of the signifi-
cant features of the design.
major assemblies The 2 mounting flanges are connected by 3 longitudinal beams to form a frame.
The drum with planetary gearbox inside it is located in the centre of the frame.
The motor and roller coupling are mounted on the hoist flange.
The electrical equipment and geared limit switch are located in a box on the opposite
flange.
The DH hoist unit can be mounted on any of the 4 sides of the frame.
Various mounting flange positions and rope lead-offs can be obtained by rotating the
hoist unit.
If this is done, the planetary gearbox must be rotated to ensure that the oil does not
leak from the gearbox breather, which must be in the upper vertical position.
4.5 Geared limit switches Limitation of motion at the upper and lower end positions is effected by the
DGS geared limit switch.
The following types are available:
DGS 3 – Emergency limit switch for highest and lowest hook position
Operating limit switch for highest hook position
DGS 4 – Emergency limit switch/operating limit switch
for highest and lowest hook position
The function of all DGS contacts can be freely selected. Every DGS is fitted with a
mechanical counter as standard. The difference between the various counter levels
can be used to determine the operating period of each device.
Pulse generator
If required, the DGS can be supplied with a pulse generator or this can be fitted at a
later date. The toothed wheel required for pulse generation is fitted as standard in
every DGS.
4.6 Control pendants The shock and impact-resistant housing of high quality thermoplastic of the DSE and
the glass fibre reinforced DST housing are resistant to fuels, salt water, fats, oils and
alcaline solutions.
Type of enclosure IP 65 for DST/DSE.
Strong mineral (e.g. hydrochloric or sulphuric) acids may corrode pendant switch
casings. Replace such pendant switches in due time.
4.7 Models Stationary model

DH hoist unit
Travelling models
UDH standard-headroom monorail hoists
KDH low-headroom monorail hoists
EZDH/EZLDH double-rail crabs
4.8 Load detectors for The electronic Dematik ZMS/FGB FAW-1 (standard on DH 2000; optional for
DH 300 – DH 1000) or the mechanical MGS/MKA-2 (standard on DH 300 –
Demag DH hoist units DH 1000) load detectors are used to protect hoist units and supporting structures
against excessive stresses. A basic distinction is made between overload cut-off
switches and overload protective devices (without/with creep lifting).
In combination with ZMS/FGB/FAW-1 load detectors, a summation measuring de-
vice, slack rope relay and digital load indicator can be fitted. For further details, see
description and instructions for load detectors 206 689 44 and 206 880 44
(206 715 44).
21428603.p65/090903
33
4.9 Runways The profile sections of beams selected for a monorail hoist track must be designed to
take into account all imposed stresses including normal and transverse bending.
Track curve radii must not be less than those specified by us, but should always be
made as large as possible in order to facilitate smooth hoist travel. Special attention
should be paid to the proper bending of beams for curved tracks. Gradients should
not exceed 2%.
Hoist travel on track beams must in no way be obstructed by protruding suspension
bolts, screw heads, butt straps, clamping plates, etc.
End stops must be fitted at both ends of the runway.
The running surfaces of rails or track beams must not be painted as this would impair
hoist travel. Rails and track beams should be kept clean; oil, grease, ice and dirt on
the running surfaces will cause travel wheels to skid.
4.10 Trolleys The trolleys are infinitely variable within the range for adjustment to different flange
widths.
When the retaining rings and washers have been removed from the connecting rods,
remove the locking screws on the wheel legs (on UDH also the locking screws on the
crossheads) and drive the tapered locking pins with a punch towards the locking
screws.
The wheel legs can then be moved along the connecting rods.
For further details see assembly and adjustment of the trolley on pages 52 – 79.
The travelling hoist unit must never be used for snatching or pulling loads or for
dragging them along the ground. The speed of the trolley should always be reduced
before the buffer stops are reached, otherwise damage or accidents may occur.
KDH low-headroom monorail hoists are supplied with an attached counterweight
box.
In order to reduce transport costs, the box is dispatched empty.
Before the trolley is put into service the counterweight box must be filled with scrap.
The quantity is determined by the width of the flange and type of trolley drive.
Balance the KDH monorail hoist exactly. Refer to assembly section 5.15 for the
counterweight.
21428603.p65/090903
34
4.11 Trolley size 5 for DH 300/400, 2/1 and 4/2 rope reeving
4.11.1 Runways The minimum profile sections of beams for a monorail hoist track specified in our
brochures must be adhered to since otherwise deformations of the bottom flanges
might occur. Gradients should not exceed 2%.
Hoist travel on track beams must in no way be obstructed by protruding suspension
bolts, screw heads, butt straps, clamping plates, etc.
End stops must be fitted at both ends of the runway.
The running surfaces of rails or track beams must only be painted in the area of the
wheels with a prime coat of 40 µ. Travel characteristics would be impaired by a top
coat (see fig. 2).
Rails and track beams should be kept clean; oil, grease, ice and dirt on the running
surfaces will cause travel wheels to skid.
Hatched running surfaces with prime coat only.

Fig. 2 41651944.eps
4.11.2 Trolleys The trolleys are infinitely variable within the range for adjustment to different flange
widths.
When the retaining rings and bushes have been removed from the connecting rods,
release the threaded pin in the trolley side cheek.
The trolley side cheek can then be moved along the connecting rods.
For further details see assembly and adjustment of the trolley on pages 58 – 69.
The travelling hoist unit must never be used for snatching or pulling loads or for drag-
ging them along the ground. The speed of the trolley should always be reduced be-
fore the buffer stops are reached; otherwise damage or accidents may occur.
The low-headroom monorail hoist is counterbalanced by drive wheel 2 of the drive
carrier which presses against the track from below.
21428603.p65/090903
35
5 Assembly
5.1 Electrical equipment Work on electrical equipment may only be carried out by qualified electricians or
trained personnel, see also section 1 Safety instructions.
Each Demag hoist unit is provided with a wiring diagram showing details of the con-
trols.
The wiring of Demag hoist units complies in all respects with current DIN VDE and
accident prevention regulations. Unauthorized intervention and modifications may
result in infringement of these regulations.
The switchgear is designed for extreme conditions. However, its life depends on
usage.
Advise operators to avoid inching (i.e. giving short pulses to the motor to obtain small
movements) as far as possible, e.g. when lifting loads, to prevent excessive contact
burning and thus premature destruction of the switchgear.
Corrosion on plastic (identifiable by dull, sooty or brittle surfaces) and metal compo-
nents in enclosed switchgear housings can be caused by too frequent inching. Cor-
roded parts must be replaced accordingly. Creep speed hoisting and two speed
travel assist in limiting inching operations.
5.2 Connection to the

electrical supply
Fig. 3 41110244.eps Fig. 4 42330944.eps Fig. 5 41110444.eps
First check that the voltage and frequency specified on the data plate match your
mains supply.
Voltage changing motors are wired in our works for the voltage stated in the order.
The control transformer (if fitted) is also connected to the nominal voltage of the
mains supply. If electronic devices are incorporated in the control system (overload
protection, time relays ...), the control voltage must be measured when the equip-
ment is commissioned. If the measured value exceeds the voltage specified on the
devices by more than 10 %, the control transformer must be connected on the
primary side to terminals 11 and 12.
The equipment can be damaged if the voltage is too high!
The terminals for mains connection are located on the rear wall of the electrical
enclosure. Use a screwdriver or similar to open the enclosure (see fig. 3). If a mount-
ing plate is fitted, the hexagon screws must be removed (see fig. 4). The mounting
plate can then be swung upwards and held in position by the support (see fig. 5).
Make sure that the support is in the correct holding position.
The required supply cable conductor cross sections and fuse links can be seen in
section 2.4. Please note that the length of the supply line specified for a given cross
section must not be exceeded in order to avoid excessive voltage drop, which might
21428604.p65/090903
prevent the conical rotor of the motor from sliding into running position when the
motor is switched on.
36
The cross section can be calculated according to the example given in section 2.4/
2.5, if the supply line is longer than that indicated in section 2.4.
The wiring carried out in a works includes an earth lead which is connected to all
parts of the equipment which relevant regulations require to be included in the pro-
tective measures.
The protective conductor marked green/yellow in the supply line must be connected
to the earth terminal.
Relevant regulations DIN VDE 0100 part 726 require that it must be possible to dis-
connect all poles of the hoist motor by means of a mains switch. The mains switch
must be lockable against unauthorized or accidental interference and mounted in an
easily accessible place near to the hoist unit.
5.3 Checking the direction The direction of the hoist unit’s movement is dependent on the sequence of phases
in the power supply. When the controls for “lifting” are actuated, the load hook must
of movement move upwards. If this is not the case, two leads from the supply should be changed
over to ensure proper functioning of the emergency limit switches.
Check the top and bottom hook positions and adjust properly.
Failure to do this may result in serious damage or injury.
5.4 Control Direct control and contactor control systems are available for hoist units.
For standard controls, switchgear specially developed for Demag hoist units is used.
It features a high degree of operating safety and low space requirements with a long
service life. The electrical switchgear is installed in the electrical enclosure of the hoist
unit. The enclosure casing is protected to IP 55, i.e. it is protected against harmful
dust deposits and is hose-proof in all directions.
Do not replace fuse links by those with a rating higher than that indicated in section
2.4, since otherwise short circuit protection will be inadequate.
5.5 DSE, DST control The hoist units/trolleys are controlled by means of DSE control pendants.
pendants For direct control and in special cases, Demag DST control pendants are used.
Control pendants for Demag hoist units fitted with an operating and an emergency
limit switch must be fitted with a check button. For replacement of control pen-
dants and their switching elements, refer to the instructions in sections 5.6 and 5.7.
The control pendants should be suspended so that the bottom edge is approx. 1 m
above floor level.
The arrow symbols on the buttons must indicate the correct direction of the respec-
tive movement.
DSE DST
21428604.p65/090903
40989546.eps 41233544.eps 37
5.6 Assembly instructions for DSE control pendant
Electrical installation work must only be carried out by qualified electricians, see also
section 1 “Safety instructions”.
Control pendant suspension height approx. 1000 mm above floor level.
Separating the strain relief wire cords

Correct Incorrect Incorrect
42506344.eps
Fig. 7 41775244.eps Fig. 8
Connecting the strain relief
340 875 44
M6
504 419 44
Centring web
Strip strain relief wire cords
in the clamping area
41775445.eps
42337644.eps
1) To ensure strain relief of the control cable, the control cable must be approx. 100 mm longer than the required
21428604.p65/090903
strain relief cords.
For further information, see DSE control pendant assembly instructions, ident. no. 214 214 44
Fig. 6 40989544.eps
38
5.6.1 Connecting the control cable To connect the control cable with vulcanised strain relief wire cords, proceed as
with vulcanised strain relief follows:
wire cords to the DSE control • Undo the four recessed head screws (1) and remove rear part (2) of the housing.
pendant
• Remove housing cap (3).
• Cut off protective sleeve (4) as required for the relevant control cable diameter.
• Push protective sleeve (4) onto control cable (5). Use lubricant (e.g. washing-up
liquid).
• Separate vulcanised strain relief wire cords (6) from control cable (5) (fig. 8).
3
• Push tube clip (8) up to strain relief wire cords (6) and control cable (5).
1
• Undo the two recessed head screws (13) of pressure sleeve (7).
• Push pressure sleeve (7) onto control cable (5) (fig. 6).
• Slide control cable (5) through washer (9) and sealing ring (10).
The sealing washers and the sealing rings are assigned to the corresponding
control cable diameter in accordance with table 1.
2 • Strip insulation from the end of the control cable (fig. 7). Pay attention to the
mounting dimensions.
• Pull conductors into front part (11) of the housing.
• Slide washer (10), sealing ring (9) and pressure sleeve (7) down to the front
part (11) of the housing.
Fig. 9 40989944.eps • Tighten the two recessed head screws (13).
• Strip insulation of strain relief wire cords (6) (fig. 6).
• Shorten strain relief wire cords (6) (fig. 6) and insert on the side into the groove of
pressure sleeve (7).
• Fix strain relief wire cords with tube clip (8) (fig. 6).
• Connect conductors in accordance with wiring diagram and assignment diagram
in rear part (2) of the housing.
• Open the cage clamp terminals with a 3,5 mm wide screwdriver or an offset
screwdriver as shown in fig. 9 (part no. 772 798 44).
• Push protective sleeve (4) onto pressure sleeve (7). The protective sleeve is flush
with the pressure sleeve flange.
• Fit housing cap (3).
• Screw rear part (2) of the housing back onto front part (11) of the housing.
• Finally fit bumper (12) (see section 5.6.2).
Table 1
Control cable outside Pressure sleeve with seal Control cable outside Pressure sleeve with seal
diameter diameter
Item 9 Item 9
2 x 772 576 44 1 x 772 574 44
Sealing washer 9 Sealing washer
9
10-15 10 15-20 10
10,5 - 14,5 15 - 20
Item 10 9 Item 10
1 x 772 575 44 1 x 772 546 44
Sealing ring 10-15 42029544.eps Sealing ring 15-20 41800144.eps
5.6.2 Fitting the rubber bumper Fit the bumper at room temperature.
We recommend that a lubricant (e.g. washing-up liquid) be used for further assembly.
21428604.p65/090903
Pay attention to the protruding emergency-stop button.

42324844.eps 42330744.eps 42325844.eps 42324944.eps
39
5.7 Assembly instructions
for DST control
Electrical installation work must only be carried out by a qualified electrician, see also
pendant section 1 Safety instructions.
Control pendant suspension height approx. 1000 mm above floor level.
Standard design DST3, DST6, Control pendant strain relief with

DST7, DST9 strain relief with wire cords approx. ± 300 mm height
wire cords adjustable
34087544
approx. 500 – 750 mm
M6
50441944
87429744
87429744
Cable clamp A B
87429044 A+B 87429044
approx. every 3 m
a
b
Wire cord
40221844.eps
approx. 500 mm
5 – 10 mm
87429944
87119144
Cable diameter (mm)

10 – 16 all clamping rings fitted
16 – 21 clamping ring (a) removed
21 – 26 clamping rings (a + b) removed
DST3
approx. 1000 mm above floor level

21428604.p65/090903
Fig. 10 41116044.eps
40
Control pendant with sleeve protecting against kinking 18
2 Strain relief by wire cords; see fig. 10
19
Loosen the four or six housing screws 8. Remove lower part 7 of the housing. By
tightening the two screws securing cap 12 to upper part 13 of the housing, press
18
sleeve protecting against kinking 18 against the housing. Cut off sleeve protecting
against kinking 18 as required for the relevant cable diameter (see markings on
sleeve). Pass cable 2 through sleeve 18 and clamp 4 (small opening for cables of
10 – 20 mm diameter and wide opening for cables of 20 – 26 mm diameter) and
clamp the cable by tightening the screws. Tighten clip 19 on sleeve 18. This ensures
that the cable inlet is watertight. Carefully bunch conductors 5 behind clip 6 and
12 connect them to terminals as required.
4
13 Connect only in compliance with the wiring diagram.
6 14
Fit lower part 7 of the housing by tightening the screws provided. Ensure that sealing
washers are placed below screw heads 8. This ensures that the cable inlet is water-
tight.
7
The type designation and part number are indicated on the control pendant and on
8
the switching elements
41059544.eps
For further information, see DST control pendant assembly instructions,

ident. no. 206 165 44
21428604.p65/090903
41
5.8 Fitting the wire rope Before a rope is reeved, the whole length of the rope should be rolled out on the
ground as shown in fig. 11. Any twisting of the rope should be strictly avoided.
Secure one rope end by means of the 3 clamps provided on the drum; commence
this operation at the spot marked “A” on the drum (clamping must begin approx.
3 cm from the end of the rope).
Incorrect! Correct!
Fig. 11 41116144.eps
Wind the rope tightly approx. 5 turns round the drum. To do this, switch on the hoist
motor for lifting, holding the rope taut. Wear thick gloves or use rags to protect the
hands.
Then fit the rope guide (see section 5.8.6).
For construction, application and reeving of wire ropes for the hoist unit ranges, see
section 5.8.1.
Tightening torques of rope clamp
socket head screws to DIN 912-10.9
Drum
Range
single groove double groove
DH 300/400 36 Nm 15 Nm
DH 500/600 70 Nm 36 Nm
5.8.1 Construction, application and DH 1000 121 Nm 70 Nm
reeving of wire ropes DH 2000 121 Nm 121 Nm
DH range 320 316-308 320-308 316-308 320-308

Type of reeving 1/1 1/1 2/1 4/1 2/2-2 4) 4/ 2
Group of mechanisms to FEM 1 Bm 1 Am - 4m 1 Bm - 4m 1 Am - 4m 1 Bm - 4 m
Wire rope dia. mm 11 11 11 11 7 7, 5
see fig. 7 3 2 3) 2 3) 1 2 2)
approx.
Calculated rope breaking force 139,5 109 107,5 49,9 48,6
kN
Minimum breaking force kN 108,8 78,5 80,7 37,8 41
Tensile strength of single strand N/mm² 1960 1960 1960 1960
Rope length m DH 325 - 312 27,5 28,2 29,6 34
H 12 27,4 2 x 16,6
DH 310 - 308 - 28,4 30,3 34,5
DH 325 - 312 43,6 44,4 45,9 56,8
H 20 43,6 2 x 28
DH 310 - 308 - 44,6 46,5 57,3
Part no. 82247544 82247044 82249044 82246044 58169044
DH range 420 416-410 425-410 416-410 425-410

Type of reeving 1/1 1/1 2/1 4/1 2/2-2 4) 4/2
Group of mechanisms to FEM 1 Am 2m-4m 1 Bm - 4 m 2m-4m 1 Bm - 4 m
Wire rope dia. mm 11 11 11 11 7 7,5
see fig. 7 3 8 8 1 10
approx.
Calculated rope breaking force 139,5 109 140,5 49,9 59
kN
Minimum breaking force kN 108,8 78,5 113,6 37,8 48
Tensile strength of single strand N/mm² 1960 1960 1960 2100
Rope length m DH 425 - 412 27,5 28,2 29,6 34
H 12 27,4 2 x 16,6
DH 410 - 28,4 30,3 34,5
21428604.p65/090903
DH 425 - 412 43,6 44,4 45,9 56,8

H 20 43,6 2 x 28
DH 410 - 44,6 46,5 57,3
Part no. 82247544 82247044 82249244 82246044 58119044
4) See 4/2 configuration for rope spreader operation
42
DH range 532 525 - 512 532 - 512 532 - 512 532 - 512
Type of reeving 1/1 1/1 2/1 4/1 2/2-2 4) 4/2
Group of mechanisms to FEM 1 Bm 1 Am - 4 m 1 Bm - 4 m 1 Bm - 4 m 1 Bm - 4 m
Wire rope dia. mm 14 14 14 14 11 11
see fig. 7 3 4 4 3 2 3)
approx.
Calculated rope breaking force 224,9 169 159 109 107,5
kN
Minimum breaking force kN 175,4 125 125 79 80,7
Tensile strength of single strand N/mm² 1960 1960 1770 1960 1960
Rope length m DH 532 - 520 27,4 28,3 30 29,2
H 12 27,4 2 x 13,8
DH 516 - 512 - 28,5 30,7 29,5
DH 532 - 520 43,4 44,3 46 49,1
H 20 43,4 2 x 23,2
DH 516 - 512 - 44,6 46,7 49,4
Part no. 82347544 82347044 82349044 82247044 82249044
DH 532 - 520 83,4 84,3 86 99,1
H 40 83,4 2 x 48,2
DH 516 - 512 - 84,6 86,7 99,4
DH 532 - 520 107,4 108,3 110 129,1
H 52 107,4 2 x 63,2
DH 516 - 512 - 108,6 110,7 129,4
Part no. 82347544 82347044 82347044 1) 82349044 82247044 82249044
DH range 632 625 - 616 640 - 616 640 632 - 616 640 - 616
Type of reeving 1/1 1/1 2/1 4/1 2/2-2 4) 2/2-2 4) 4/2
Group of mechanisms to FEM 1 Am 2m-4m 1 Bm - 4 m 1 Bm 1 Am - 4 m 1 Bm - 4 m
Wire rope dia. mm 14 14 14 14 11 11 11
see fig. 7 3 11 11 7 3 2 2)
approx.
Calculated rope breaking force 224,9 169 216,5 140 109 107,5
kN
Minimum breaking force kN 175,4 125 189,5 107 78,5 80,7
Tensile strength of single strand N/mm² 1960 1960 1960 1960 1960 1960
Rope length m DH 640 - 620 27,4 28,3 30 2 x 13,8 29,2
H 12 27,4 2 x 13,8
DH 616 - 28,5 30,7 - 29,5
DH 640 - 620 43,4 44,3 46 2 x 23,2 49,1
H 20 43,4 2 x 23,2
DH 616 - 44,6 46,7 - 49,4
Part no. 82347544 82347044 82349244 82247544 82247044 82249044
16 x 7 = 112 wires 8 x 19 = 152 wires 18 x 7 = 126 wires 8 x 36 = 288 wires

+ 1 steel core / RH + 1 steel core / 2), 3) + 1 steel core / RH + 1 steel core / LH
Fig. 1 40126644.eps Fig. 2 40109544.eps Fig. 3 40139344.eps Fig. 4 40110044.eps
18 x 7 = 126 wires 8 x 19 = 152 wires 5 x 19 + 5 x 7 = 130 wires 9 x 19 = 171 wires

+ 1 steel core / RH + 1 steel core / LH + 1 steel core / RH + 1 steel core / LH
21428604.p65/090903
Fig. 7 82447544.eps Fig. 8 41179744.eps Fig. 10 58119044.eps Fig. 11 82349244.eps

1) For rope construction and technical data of rope, 2) RH = right hand ordinary lay rope 3) LH = left hand ordinary lay rope
see 1/1 reeving 43
DH range 1063 1050 - 1025 1063 - 1025 1063 1050 - 1025 1063 - 1025
Type of reeving 1/1 1/1 2/1 4/1 2/2-2 4) 2/2-2 4) 4/2
Group of mechanisms to FEM 1 Bm 1 Am - 4 m 1 Bm - 4 m 1 Bm 1 Am - 4 m 1 Bm - 4 m
Wire rope dia. mm 20 20 20 20 14 14 14
see fig. 7 5 4 4 7 3 4
approx.
Calculated rope breaking force 460,7 350 343,7 224,9 169 159
kN
Minimum breaking force kN 360,1 259 285 175,4 125 125
Tensile strength of single strand N/mm² 1960 1960 1770 1960 1960 1770
Rope length m DH 1063 - 1040 38,5 39,6 42 2 x 22,6 47,1
H 16 38,5 2 x 22,6
DH 1032 - 1025 - 40 43,2 - 47,6
DH 1063 - 1040 54,1 55,3 57,7 2 x 33,8 69,3
H 24 54,1 2 x 33,8
DH 1032 - 1025 - 55,7 58,8 - 69,8
Part no. 82447544 82447044 82449044 82347544 82347044 82349044
DH 1063 - 1040 86,1 87,3 89,7 2 x 56,4 114,5
H 40 86,1 2 x 56,4
DH 1032 - 1025 - 87,7 90,8 - 115
DH 1063 - 1040 108,1 109,3 111,7 2 x 72,8 147,3
H 51 108,1 2 x 72,8
DH 1032 - 1025 - 109,7 112,8 - 147,8
Part no. 82447544 82447044 82447044 1) 82449044 82347544 82347044 82349044
DH range 2100 - 2063 2125 - 2063

Type of reeving 1/1 2/1 4/1
Group of mechanisms to FEM 1 Am - 3 m 1 Bm - 3 m
Wire rope dia. mm 25 25 25
see fig. 7 9 9
approx.
Calculated rope breaking force 723,5 640,9
kN
Minimum breaking force kN 560,2 558,6
Tensile strength of single strand N/mm² 1960 1960
Rope length m DH 2125 - 2100 44,4 45,5 48,3
H 18
DH 2080 - 2063 - 45,7 48,9
DH 2125 - 2100 62,7 63,9 66,7
H 27
DH 2080 - 2063 - 64,1 67,3
Part no. 82548744 82548644
DH 2125 - 2100 104,3 105,1
H 47 103,1
DH 2080 - 2063 104,6 105,7
Part no. 82548744 82548744 1) 82548644
DH range 2125 2100 - 2050 2125 - 2050

Type of reeving 2/2-2 4) 2/2-2 4) 4/2
Group of mechanisms to FEM 1 Bm 1 Am - 4 m 1 Bm - 4 m
Wire rope dia. mm 20 20 20
see fig. 7 5 4
approx.
Calculated rope breaking force 460,7 350 343,7
kN
Minimum breaking force kN 360,1 259 285
Tensile strength of single strand N/mm² 1960 1960 1770
Rope length m DH 2125 - 2080 2 x 20,4 43,2
H 18 2 x 20,4
DH 2063 - 2050 43,7
DH 2125 - 2080 2 x 31,4 65,2
H 27 2 x 31,4
DH 2063 - 2050 65,7
Part no. 82447544 82447044 82449044
DH 2125 - 2080 2 x 55,5 113,2
H 47 2 x55,5
DH 2063 - 2050 113,7
Part no. 82447544 82447044 82449044
21428604.p65/090903
1) For rope construction and technical data of rope see 1/1 reeving
44
18 x 7 = 126 wires 8 x 36 = 288 wires
+ 1 steel core / RH + 1 steel core / LH
Fig. 3 40139344.eps Fig. 4 40110044.eps
36 x 7 = 252 wires 18 x 7 = 126 wires

+ 1 steel core / RH + 1 steel core / RH
Fig. 5 40109944.eps Fig. 7 82447544.eps
10 x 26 = 260 wires
+ 1 steel core / LH
RH = right hand ordinary lay rope

LH = left hand ordinary lay rope
Fig. 9 82549244.eps
21428604.p65/090903
45
5.8.2 Rope reeving methods for the The DH hoist unit is normally supplied with the rope separate from the bottom block.
Demag DH hoist unit For single-fall operation, the hook with fittings is attached to the rope.
Rope reeving arrangements 2/1, 4/1 and 4/2 on the DH hoist unit can be seen in the
following figs. 12 – 17.
Care must be taken to keep the rope tight and not to twist it during reeving.
The rope is retained by means of a wedge and an anchorage which is incorporated
into a special crossmember.
The rope end is properly secured if the carrying fall is introduced along the vertical
side of the anchorage, as in fig. 13, so that under load the wedge remains visible
above the anchorage and the dead end protrudes downwards by approx. 10 cm.
Refer to section 5.8 for replacement of wire ropes.
The method of securing the rope end by means of this anchorage is absolutely relia-
ble and conforms to the relevant regulations. As an additional safety feature to pre-
vent the dead end from slipping, a clip is fitted as shown in fig. 13. Additional clips
must not be used since these would cause bruising and uneven stress in the carrying
fall of the rope and thus lead to its destruction.
Single-fall ropes 1/1
The clip above the hook fittings, on the dead end of single fall ropes, prevents the
wedge from slipping out when the hook is set down.
DH hoist unit and UDH standard-headroom monorail hoist, rope reeving 2/1, 4/1 and 4/2
2/1 4/1 4/2
Tightening torque
DH 300/400 = 33 Nm
DH 500/600 = 33 Nm
DH 1000 = 70 Nm
DH 2000 = 110 Nm
21428604.p65/090903

46
KDH low-headroom monorail hoist, rope reeving 2/1, 4/1 and 4/2
2/1 4/1 4/2
Tightening torque
DH 300/400 = 33 Nm
DH 500/600 = 33 Nm
DH 1000 = 70 Nm
DH 2000 = 110 Nm

21428604.p65/090903
47
5.8.3 MGS/MKA-2 load detector, DH 300 – DH 1000
ZMS/FAW-1 load detector, DH 300 – DH 2000
See description and instructions 206 689 44 for

fitting MGS/MKA-2 and adjusting the switching
point.
Ensure the double spring clip is correctly 41121444.eps
seated in the grooves of both setpins when

fitting the load detector (see section 5.8.5).
21428604.p65/090903
See description and instructions 206 880 44 for

fitting ZMS/FAW-1 and adjusting the switching
point.
41121344.eps
48
5.8.4 Lubrication All lubrication points of Demag hoist units are adequately greased. The gearbox is
filled with oil.
Grease the rope with a gear oil, e. g. C-LP 220.
Ensure that the oil reaches the interior of the rope construction.
When hoist units are operated outdoors and in applications with corrosive
atmosphere, we recommend additionally greasing the rope from the outside
(part no. 011 057 44) 850 g.
Fitting the rope guide: for greasing longitudinal beams, see section 5.8.6.
Grease the bearing points of the top block, crosshead, compensating sheave and
the pin of the rope anchorage with a suitable adhesive lubricant (see fig. 18).
Part no. 472 933 44.
5.8.5 Fitting the rope socket Check suspension of rope socket.

When fitting the rope socket, it must be ensured that the double spring clip engages
the groove in the setbolt/pin (see fig. 18).
When fitting the retaining ring, it must be ensured that it engages the groove in the
setbolt/pin (see fig. 18). After fitting, check whether the retaining ring can be easily
turned.
Grease the bearing points with a suitable adhesive lubricant.
Checks during maintenance work
Check play of the setbolt/pin in the counter bore hole of the retaining plate (max.
widening in retaining plate 1 mm, see fig. 18).
Pin
Head pin Grease bearing points
Double spring clip

Shims
1 mm
Retaining plate
Retaining ring
Pin
40979244.eps
Grease bearing points
Pin Shims
41181044.eps
1 mm
Retaining plate
Shims
Retaining ring
Double spring clip
21428604.p65/090903
Pin
Head pin

Shim
Fig. 18 41181144.eps
49
5.8.6 Fitting the rope guide DH 300 – 2000 with toothing adjustment
1 3 2
6 7
Toothing
5
4
1 2
6 7 3
Fig. 19 41477944.eps 41478144.eps
Before it is fitted to the drum, the rope guide must be Fit segment with rope guide rollers (1) with the rollers pointing
taken to pieces. towards the wire rope on the drum.
(1) Segment with rope guide rollers Then fit segment (2) to the drum.
(2) Segment
(3) Hexagon screw
(4) Hexagon nut with flange
(5) Side section
(6) Socket head screw
(7) Lock nut
2 3 3
4
41497844.eps
Ensure same distance

to both sides
3
1
1 4
3
Fig. 20 41478244.eps Fig. 21 41478344.eps
Push hexagon screw (3) into moulded hexagon recess of seg- Push hexagon screw (3) into moulded hexagon recess of seg-
ment (2). Fit segment (2) with rope guide rollers (1) to hexagon ment (2). Fit segment (2) with rope guide rollers (1) to hexagon
screw (3) and secure with hexagon nut (4). When fitting, ensure screw (3) and secure with hexagon nut (4).
that toothed segments (1 + 2) are properly engaged. Adjust as
illustrated in figs. 20 + 21. Tightening torque 10 Nm
Both ends of segments (1 + 2) are provided with toothing, see

Tightening torque 10 Nm fig. 19. The clearance of the rope guide on the drum can be
adjusted by means of this toothing. When fitting, ensure that
toothed segments (1 + 2) are properly engaged. Adjust as
21428604.p65/090903
Fig. 21
illustrated in figs. 20 + 21.
Slide the rope guide sideways until it rests in the empty
groove next to the rope on the drum so that the rope It must be possible to move the fitted rope guide by hand on
guide rollers lie over the rope. the drum.
50 Now rotate the rope guide upwards.
7 1 5 6
Apply grease here

41478444.eps 41495144.eps
Place side section (5) with its guide slot on the longitudinal In order to press the rope guide rollers against the rope, lift
beam at the bottom of the frame (grease longitudinal them with a screwdriver.
beams in advance (part no. 011 057 44) 850 g. The split pin can then be removed.
Rotate the rope guide downwards until the bore holes in
the segment with guide rollers (1) coincide with the bore
holes inside section (5).
Insert the two socket head screws (6) and secure using
lock nut (7).
Tightening torque 10 Nm
Rope clamp On single-fall hoist units the other rope end is secured to the hook fittings by means
Tightening torque
of a rope wedge and an additional clamp fitted to the dead end of the rope (fig. 22).
On 2 and 4-fall hoist units the rope end is secured as described in section 5.8.2.
DH 300/400 = 33 Nm
DH 500/600 = 33 Nm Then switch on the hoist for lifting and raise the hook to its top position. During this
DH 1000 = 70 Nm operation, the rope guide and the reeving of the rope should be watched. If twisting
DH 2000 = 110 Nm occurs during hoisting, the bottom pulley block must be set down and the wedge
removed from the anchorage fitted in the crosshead so that the rope can be untwist-
ed and wedged in again.
Then switch on the hoist for lowering until the load hook reaches its bottom position
and ensure that the first turns of rope fit closely to the drum. If necessary, the three
rope clamps can be unscrewed from the drum and retightened securely after the
rope has been pulled to fit snugly in the grooves.
Then reset the geared limit switch as described under section 6.1 in the Putting the
hoist unit into service chapter.
Rope wedge
Correct adjustment of the two limit switch emergency cut-out points is

important (see section 6.2), as otherwise the hoist unit could be damaged
and accidents may occur.
Resetting the limit switch is necessary each time the rope length has been altered,
e.g. after pulling its end further through the rope wedge anchorage in the crosshead.
Fig. 22 40110544.eps The load on new ropes should be small at first and gradually increased before the
safe working load is lifted. During this period the loads should be raised and lowered
from one hook end position to the other, in order to allow the rope to slowly stretch
and settle.
21428604.p65/090903
Owing to the stretching of new ropes, it is necessary to retighten the rope clamp
securing screws on the drum after short periods of lifting duty.
51
5.9 Assembly and adjustment of EUDH standard-headroom monorail hoist trolleys
AMK 10/20
25 23 23
AUK 30 22 22
2 3 9 19
20 24
26
17
4
Fig. 23 41911744.eps 41909644.eps
Tapered locking pin connection!

If the trolley is removed and refitted, turn the connecting rods (8) to ensure that the
tapered locking pins do not engage in their previous position.
Then assemble using the tapered locking pins as described.
When assembling, all tapered locking pin connections must be rechecked. The lock-
ing screws (4) must be tightened with the specified torque of 200 Nm.
Prior to assembly, grease locking screws (4), tapered locking pins (3) and the
threads in the wheel legs and crossheads (7) with Molykote 321-R spray, part
no. 972 398 44.
5.9.1 Assembly of the trolley The trolley is assembled as follows:
Fixing crossheads (7) to the Demag hoist unit: apply Loctite 033 071 44 to hexagon
bolts (5) and set nuts (6) and tighten to the prescribed torque (see table).
Trolley size DH range Tightening torque of screws (5)

21428605.p65/090903
300/400 4/1 310 Nm

6
500/600 2/1, 4/2 390 Nm
500/600 4/1 620 Nm
10
1000 2/1, 4/2 670 Nm
52
Make sure that crossheads (7) are always fitted so that the “Motorseite”
Prior to assembly, grease tapered
locking pin (3), locking screw (4) and
(motor side) label is in the position as indicated in fig. 23.
thread in the wheel leg and cross- This is necessary as otherwise the centre of gravity of the load will not be at
head (7) with Molykote 321-R spray, the centre of the beam when the trolley is adjusted.
part no. 972 398 44
17 Slide connecting rods (8) through crossheads (7) and wedge slightly with tapered
locking pins (3).
Place wheel legs (9 + 10) on connecting rods (8).
Fix side plate (11) to wheel legs (9 + 10) with split sleeves (12) and locking
screws (13).
The washers (2) are arranged on the wheel legs (9) and (10) as follows:
Wheel leg (9) Wheel leg (10)

Trolley size 6 10 Trolley size 6 10
41825644.eps Washer (2) 1 - Washer (2) 5 5
Tapered locking pin (3)
Locking screw (4)

Then press wheel legs (9 + 10) against washers (2). Drive tapered locking pins (3) into
MA = 200 Nm wheel legs (9 + 10) as far as possible with a hammer. Then insert and tighten locking
screws (4) until the screw heads come up against the wheel legs and tapered locking
pins (3) are in their final positions (see fig. 24).
Locking screws (4) must be tightened to a torque of 200 Nm.
Connecting rod Slide wheel legs (14 + 15) onto connecting rods (8).
Wheel leg or crosshead Fix side plate (16) to wheel legs (14 + 15) with split sleeves (12) and locking
Fig. 24 40133044.eps screws (13).
Adjusting ring (18)
Prior to assembly, apply Esso-Pen-O-Led EP grease to the teeth of the
Drive shaft drive shaft (17).
Then slide drive shaft (17) through wheel leg (9) and slide the two adjusting rings (18)
onto drive shaft (17).
Push drive shaft (17) into the pinion of wheel leg (14) (see fig. 25).
In order to fix drive shaft (17) in position, push adjusting ring (18) against the pinion of
Grub screw wheel leg (14) and tighten the grub screw of adjusting ring (18) to a torque of 36 Nm.
Protective cover For the remainder of assembly and adjustment see section Adjusting the trolley.
Pinion
Fig. 25 40133144.eps AMK 10/AMK 20
Fix torque arm (19) on travel drive (26) with the 4 locking screws (21). (Tightening
torque 19 Nm).
Slide travel drive (26) onto drive shaft (17) and attach torque arm (19) to wheel leg (9)
using the two locking screws (20) (see fig. 23).
(Tightening torque 65 Nm).
AUK 30
Fix torque arm (19) to wheel leg (9) with locking screw (20). (Tightening torque
65 Nm).
Slide travel drive (26) onto drive shaft (17).
Fix travel drive (26) to torque bracket (19) with hexagon bolt (24), spring element (23),
washer (22) and lock nut (25).
21428605.p65/090903
53
5.9.2 Adjusting the trolley
AMK 10/20
25 23 23
AUK 30 22 22
2 3 9 19
20 24
26
17
4
41911744.eps 41909644.eps
Tapered locking pin connection!

If the trolley is removed and refitted, turn connecting rods (8) to ensure that the ta-
pered locking pins do not engage in their previous position.
Then assemble using the tapered locking pins, as described.
Prior to assembly, grease tapered locking pins (3), locking screws (4) and the
threads in the wheel legs and crossheads (7) with Molykote 321-R spray,
part no. 972 398 44.
The trolley is infinitely variable within the range for adjustment to various flange
widths b.
If the trolley has to be readjusted, first remove retaining rings (1) and washers (2) from
supporting wheel legs (14 + 15).
Loosen tapered locking pins (3) after removing locking screws (4) from wheel legs
(14 + 15) and crossheads (7).
Loosen adjusting ring (18) on drive shaft (17) at wheel leg (9) and slide it to the centre
of the shaft.
Crossheads (7) and wheel legs (14 + 15) can now be moved along connecting
rods (8).
21428605.p65/090903
The setting dimension between each pair of opposite wheel legs is calculated from
flange width b + ... mm (fig. 27).
When the dimension has been calculated, move wheel legs (14 + 15) to the corres-
ponding positions and slightly wedge with tapered locking pins (3).
54
locking pins (3), locking screws (4)
and the threads in the wheel legs with
Molykote 321-R spray,
part no. 972 398 44.
b
17
2mm
41825644.eps = Adapt quantity

Tapered locking pin (3) on assembly
=
Locking screw (4) b + ...
MA = 200 Nm Trolley size 6 = b + 6 mm

Trolley size 10 = b + 20 mm
Fig. 27 41909744.eps Fig. 28 40133244.eps
Connecting rod
Wheel leg or crosshead
Fig. 26 40133044.eps
Now move crossheads (7) along connecting rods (8) until crossheads (7) are at the
centre between the wheel legs to the right and left of them.
Drive tapered locking pins (3) into crossheads (7) and wheel legs (14 + 15) with a
hammer as far as possible. Then insert and tighten locking screws (4) until the screw
heads come up against the crossheads and wheel legs, thus bringing tapered lock-
ing pins (3) into their final positions (see fig. 26).
Now measure on connecting rods (8) the distance between the contact surfaces of
washers (2) at wheel legs (14 + 15) and the grooves for retaining rings (1). This is
done to determine the number of washers required (see fig. 28).
Thickness of the washers:
Trolley sizes 6 = 10 mm
Trolley size 10 = 4 mm
Fit retaining rings (1) to both connecting rods (8).
In order to secure drive shaft (17), push adjusting ring (18) against the pinion of wheel
leg (9).
Then tighten the grub screw of adjusting ring (18) to a torque of 36 Nm.
21428605.p65/090903
55
5.9.3 Changing the travel drive from AMK 10 to AUK 30 – EUDH
Adjusting ring (4)
1 3 4 4 2 9 19 20 26 AMK 10
2 3
Drive shaft (17)
17
Grub screw 21
Protective cover (3) with securing strap (2)
Pinion shaft with bearing (7) Motor

40133144.eps Motorseite
seite
AUK 30 25 23 23
22 22
2 3 9 19
20 24
26 41910544.eps
17
4
Fig. 29 41911744.eps 41911744.eps
When replacing AMK 10 travel drives with AUK 30, attention must be paid to the
following:
Splined shaft W 25 = AMK 10 W 30 = AUK 30
Disassembly
1) Loosen locking screw (20) and pull travel drive (26) from drive shaft (17).
2) Remove securing strap (2) and plastic casing (3).
3) Remove pinion shaft with bearing (7) from wheel legs (1 + 9).
Assembly
4) Fit the two new pinion shafts with bearing (7).
5) Refit plastic casing (3) with grease filling.
(For grease quantity, see section 8.8.3).
6) When fitting securing strap (2), be careful not to tighten securing strap (2) ex-
cessively.
7) Prior to assembly, apply Esso-Pen-0-Led EP grease to the splines of drive
shaft (17).
8) Slide drive shaft (17) through wheel leg (9) and pinion shaft with bearing (7) and
place adjusting rings (4) on drive shaft (17). Push drive shaft (17) into pinion
shaft with bearing (7) of wheel leg (1) (see fig. 29).
9) In order to fix drive shaft (17) in position, push adjusting rings (4) right and left
against pinion shaft with bearing (7). Tighten the grub screw of adjusting ring (4)
with a torque of 36 Nm.
10) Fit new torque bracket (19) and tighten locking screw (20) with a tightening
21428605.p65/090903
torque of 65 Nm.
11) Slide travel drive (26) onto drive shaft (17) and fix to torque bracket (19).
56
5.9.4 Changing the travel drive from AUK 30 to AMK 20 – EUDH
Adjusting ring (4) 25 23 23 26

1 23 4 17 4 239 19 24 22 22 AUK 30
Drive shaft (17)
Grub screw
Motor
Pinion shaft with bearing (7) seite
40133144.eps
AMK 20
Fig. 30 41923144.eps 41910444.eps
When replacing AUK 30 travel drives with AMK 20, attention must be paid to the
following:
Splined shaft W 30 = AUK 30/AMK 20
Disassembly
Assembly
2) Fix torque arm (19) on travel drive (26) with the 4 socket head screws (21).
shaft (17).
4) Slide travel drive (26) onto drive shaft (17). Then attach torque bracket (19) to
wheel leg (9) using the two locking screws (20) (see fig. 30).
21428605.p65/090903
57
5.10 Assembly and adjustment of EUDH standard-headroom monorail trolley
Trolley size 5 – EUDH 300/400, 2/1 rope reeving
RUDH EUDH
2 4 5 6
2mm
Grease enclosure
8 6 3 1 3
Fig. 31 41268844.eps 42229144.eps
Assembling the EUDH trolley Insert trolley crossbar (1) into side cheek (2) (see fig. 31). Then adjust the trolley
according to the girder flange width of the track by arranging the distance washers
as specified under assembling trolleys (see pages 59 – 60).
The locknut (3) must be tightened to the specified tightening torque (see fig. 31).
Since girder flange width tolerances are relatively high, the gap between the travel
wheel flange and the girder flange must be checked on both sides to ensure that the
play does not exceed 2 mm.
Fitting the travel drive Knock the split sleeve into the hole in the side cheek (2). Then fill the travel drive with
grease – approx. 60 g, part no. 011 058 44 – see fig. 31. Screw travel drive (6) to
side cheek (2) with screw (5).
Fit the travel drive in such a way that the play between the teeth of the drive pinion
and the two travel wheels is the same.
Assembling the RUDH trolley Insert trolley crossbar (6) into side cheek (7) (see fig. 31). Then adjust the trolley
according to the girder flange width of the track by arranging the distance washers
(see pages 59 – 60).
The locknut (8) must be tightened to the specified tightening torque (see fig. 31).
Removing/fitting the If the locknut is completely removed from the crossbar, a new locknut acc. to
trolley crossbar locknut DIN 985 must be used.
The locknut (8) can be screwed onto the trolley crossbar for pre-assembly without
being pre-tensioned.
21428605.p65/090903
For final assembly, only unscrew the locknut (8) until the trolley can be placed on the
girder.
Then tighten the locknut (8) with the specified tightening torque (see fig. 31).
58
Adjustment of RU/EUDH trolleys, 2/1 rope reeving
Trolley A – RUDH Trolley B – EUDH
l l
42229044.eps
41299544.eps
View of the position of the

distance washers
Trolleys A and B
41945744.eps
Flange width b mm 106 113 119 125 131 137 143

Trol- Max. flange
t mm 22 / without anti-tip pin 28 mm
ley thickness
Position of distance washers (4 mm distance washers)
Required number of distance washers for straight and curved sections
Trolley crossbar I mm 283
inside 3 4 5 6 6 7 8
Side cheek, left
A outside 6 5 4 3 3 2 1
inside 4 5 5 6 7 8 8
Side cheek, right
outside 5 4 4 3 2 1 1
Trolley crossbar I mm 380
inside 1 2 2 4 4 5 5
Side cheek, left
B outside 10 9 9 7 7 6 6
inside 1 2 3 3 4 5 6
Side cheek, right
outside 10 9 8 8 7 6 5
Trolley crossbar, cpl. 839 556 44

A
Trolley cpl. 840 113 44
Trolley crossbar
21428605.p65/090903
Pins 839 574 44

B
Castle nut/split pin/washers 335 738 99 / 342 105 99 / 502 220 44 / 340 028 99
59
Adjustment of RU/EUDH trolleys, 2/1 rope reeving
Trolley A – RUDH Trolley B – EUDH
l l
42229044.eps
41299544.eps
View of the position of the

distance washers
Trolleys A and B
41945744.eps
Flange width b mm 144 149 155 163 170 178 185 200 201 210 220 240 260 280 300
Max. flange
Trol- t mm 22 / without anti-tip pin 28 mm
thickness
ley
Position of distance washers (4 mm distance washers)
Required number of distance washers for straight and curved sections
Trolley crossbar I mm 340 440
inside - - 1 2 3 4 5 7 - 1 2 5 7 10 12
Side cheek, left
A outside 8 8 7 6 5 4 3 1 14 12 11 9 6 4 1
inside - 11 2 3 4 5 5 7 - 2 3 5 8 10 13
Side cheek, right
outside 8 7 6 5 4 3 3 1 13 12 11 8 6 3 1
Trolley crossbar I mm 380 494
inside 6 6 7 8 9 10 11 13 13 14 15 18 20 23 25
Side cheek, left
B outside 5 5 4 3 2 1 - 13 13 12 10 8 5 3 -
inside 6 7 7 8 9 10 11 13 13 14 16 18 21 23 26
Side cheek, right
outside 5 4 4 3 2 1 - 12 12 11 10 7 5 2 -
Trolley crossbar,
839 557 44 839 558 44
A cpl.
21428605.p65/090903
Trolley crossbar
Pins 839 573 44 839 574 44

B
Castle nut/split pin/washers 335 738 99 / 342 105 99 / 502 220 44 / 340 028 99

60
21428605.p65/090903
61
Trolley size 5 – EKDH 300/400
2/1 and 4/2 rope reeving
A counter weight is only required for flange widths 106 – 200 mm

2/1 rope reeving Assembly with counterweight
2 13 14
Assembly of rope retaining

crosshead see section 5.12.1 2 13 14 3
14
View 16 14 5
3 15
2 5
42031544.eps
13 15
9 2 8
4
5
14
5
Travel drive assembly

4 1
see section 5.11.2
6 10
11
41916644.eps
4/2 rope reeving Assembly with counterweight

2 13 14
Return sheave assembly 2 13

14 3
see section 5.13.1
14
View
5
3 16 14
15
2 5 42031644.eps
13 15
9 2 8
4
14
5

see section 5.11.2 4 1
6 10
11
21428606.p65/090903
41916744.eps
When assembling, all threaded pin connections must be rechecked. Threaded pin
connection (5) must be tightened with the specified torque of 200 Nm.
62
5.11.1 Assembly of the trolley size 5
9 Fix wheel legs (1+2) to the sides of the Demag hoist

unit frame.
8 Upper bore hole:
6
Push hexagon bolt (8) through bore hole and fix with
lock nut (9) (tightening torque = 215 Nm).
Upper bore hole:
Fix with washer (10) and hexagon bolt (11).
Tightening torque = 86 Nm
11 10
Drive split sleeves (6) into lower bore holes of wheel
legs (1+2).
41917544.eps 41917644.eps
4
5
4
3
Slide both connecting rods (4) into the holes of trolley

Fix connecting rod (4) with threaded pin (5). Slide side cheek (3) onto connecting rod (4).
wheel legs (1+2) until connecting rods (4) meet with
Threaded pin must fit in groove of connecting rod
resistance.
(see fig.) Tightening torque = 200 Nm
41917744.eps 41917844.eps 41917944.eps
Calculation of trolley adjustment for existing flange

width:
Setting dimension between both opposite guide
rollers is b + 1 mm.
3
b+1
5
b+1
Fix side cheek (3) on connecting rod (4) with the

threaded pins (5).
41918044.eps 41923244.eps 41918144.eps
Fitting the counter weight
Then place spacer tubes (15) and washers (14) onto

connecting rods (4) as required. Enough space must remain
to fit washer (13) and retaining clip (12).
15
15
21428606.p65/090903
Fitting the counter weight 12

12 Then place spacer tubes (15), washers (14) and 13 14 16
13 14 counter weight (16) onto connecting rods (4) as
required. Enough space must remain to fit the
3 washers (14), washer (13) and retaining clip (12).
41918244.eps 42031744.eps
63
5.11.2 Assembly/disassembly
of the travel drive Assembly 1 2 3
Fit travel drive into trolley side cheek from below. Fit pin.
Fit bush (1), retaining ring (2) and plug (3).
41155644.eps 41153544.eps
5 5 6
4
4
L
Dimension L + .. Drive wheel 2
41153644.eps 41152444.eps
Fit tension bolt (5) and washer (6) from above.

See illustration for further assembly.
(7) Washer
(8) Spring
(4) Fit locknut.
Compress spring (8) with locknut (4) until travel wheel and drive wheel are in contact with the runway girder.
Then measure dimension L:
To reach the contact pressure of drive wheel 2, tension locknut (4) as follows:
Hoist unit Rope reeving max. flange thickness mm

106 150 200 250 300 400
DH 300
2/1 and 4/2 L + 11 L + 12 L + 13 L+7 L+8 L+9
DH 400
21428606.p65/090903
64
Disassembly 5
2 3
Remove tension bolt (5) with all parts. Remove plug (3) and retaining ring (2).
41155844.eps 41155744.eps
The travel drive pin can be removed as

100 follows:
Tools
1 Tube 60 x 4,5 x 100
1 Hexagon bolt M10 x 150, DIN 933
1 Hexagon nut M10
1 Washer 10,5 x 70 x 20
1 Grooved ball bearing 51103
2 Spanner SW17
See illustration for disassembly.
Washer
Grooved ball bearing
41153444.eps
Remove travel drive.

41210744.eps
21428606.p65/090903
65
Trolley size 5 – EKDH 300/400
2/1 rope reeving
Assembly of rope retaining

crosshead see section 5.12.1
View
3
2
13 15
9 2 8
4
5
14
5

4 1
see section 5.11.2
6 10
11
Fig. 32 41916644.eps
connection (5) must be tightened with the specified torque of 200 Nm..
Further assembly/disassembly
5.11.1 Assembly/disassembly of the trolley
5.11.2 Assembly/disassembly of the travel drive
5.13.1 Assembly/disassembly of the return sheave, 4/1 reeving
21428606.p65/090903
66
5.12.1 Assembly/disassembly of the Assembly 1 washer
rope retaining crosshead,
2/1 rope reeving 1 washer
Insert rope retaining crosshead from below. Fit pin and washers.
41918344.eps 41918444.eps
Fit pivot bearings to pin. Ensure correct fit of pivot bearings. Push rope retaining crosshead into position in trolley
Before fitting pivot bearings, grease pin with See fig. 32, page 66 for view for fitting pivot bearings side cheek, move to end position.
Renolit S2 (part no. 460 000 44).
41918544.eps 41918644.eps 41918744.eps
Disassembly
Lift pivot bearings using two screwdrivers.
41918744.eps 41918844.eps
1 washer
1 washer
21428606.p65/090903
Remove pivot bearings. Remove pin and washers. Remove rope retaining crosshead downwards.
41918544.eps 41918444.eps 41918944.eps

67
Trolley size 5 – EKDH 300/400 (H 20)
4/2 rope reeving
Assembly of compensating sheave

See section 5.13.1
View
3
2
13 15
9 2 8
4
14
5

See section 5.11.2 4 1
6 10
11
Fig. 33 41916744.eps
connection (5) must be tightened with the specified torque of 200 Nm.
Further assembly/disassembly
5.11.1 Assembly/disassembly of the trolley
5.11.2 Assembly/disassembly of the travel drive
5.13.1 Assembly/disassembly of the compensating sheave
21428606.p65/090903
68
5.13.1 Assembly/disassembly of the Assembly 1 washer
compensating sheave,
4/2 rope reeving 1 washer
Insert compensating sheave from below. Fit pins and washers.

41919044.eps 41919144.eps
Fit pivot bearings to pin. Ensure correct fit of pivot bearings. Push compensating sheave into position in trolley
Before fitting pivot bearings, grease pin with See fig. 33, page 68 for view for fitting pivot bearings. side cheek.
Renolit S2.
41919244.eps 41162044.eps 41919344.eps
Disassembly
Lift pivot bearings using two screwdrivers.
41919344.eps 41919444.eps
1 washer
1 washer
21428606.p65/090903
Remove pivot bearings. Remove pins and washers. Remove compensating sheave downwards.
41919244.eps 41919144.eps 41919544.eps

69
2 3 4 6
1 5 2 3 4 6 5 Table 4
Trolley DH range Split sleeves Hexagon screw Tightening
size torque of
screws
(Nm)
7 8 9 (4) (9) (2) (7) (2) (7) (15)
7 89
300/400 4/1 - 16 x 18 M 16 x 50 M 12 x 45 215 86
6 280
500/600 2/1, 4/2 21 x 24 21 x 16 M 16 x 60 M 16 x 45 215 215
40133444.eps 500/600 4/1 - 21 x 28 M 20 x 65 M 16 x 60 500 215
10 530
1000 2/1, 4/2 25 x 28 25 x 28 M 20 x 75 M 20 x 75 410 410
AMK 10/20
4/1 rope reeving
41909844.eps
Trolley size 10
41458344.eps
AUK 30
Fig. 34 41911844.eps
Tapered locking pin connection

If the trolley is removed and refitted, turn connecting rods (10) to ensure that the

21428606.p65/090903
threads in the wheel legs with Molykote 321-R spray, part no. 972 398 44.
70
5.14.1 Assembly of the trolley The trolley is assembled as follows:
Fix trolley wheel legs (1 + 6) to the Demag hoist unit as described below.
Tap split sleeves (4) into the top holes and split sleeves (9) into the bottom holes of
trolley wheel legs (1 + 6) (see fig. 34, table 4).
Insert the ends of the split sleeves protruding from wheel legs (1 + 6) into the holes
on the side of the hoist unit frame.
Place washers (3) onto hexagon screws (2) (table 4) and push screws through split
sleeves (4) in the top holes of the wheel legs.
Then screw on lock nuts (5) and tighten to the prescribed torque (see table 4).
Place washers (8) onto hexagon screws (7) and insert screws into the bottom holes
of the wheel legs and tighten to the torques specified in table 4.
Slide connecting rods (10) into the holes at the bottom of trolley wheel legs (1 + 6).
Then slide wheel legs (11 + 12) onto connecting rods (10).
On trolley sizes 6 and 10 (size 10 only when combined with DH 500/600 4/1 hoist
unit), fit retaining rings (16).
Tap split sleeves (14) through the 4 holes of connecting plate (13) into trolley wheel
legs (11 + 12).
Bolt connecting plate (13) and wheel legs (11 + 12) together with locking
screws (15) (see table 4 for tightening torques).
Prior to assembly, grease tapered locking On trolley sizes 6 and 10 (size 10 only when combined with DH 500/600 4/1 hoist
pins (17), locking screws (18) and threads unit), push wheel legs (11 + 12) up against retaining rings (16).
in wheel legs with Molykote 321-R spray,
part no. 972 398 44. On trolley size 10, when combined with DH 1000 2/1 hoist unit, fit retaining rings (36)
17 to rods (10). Pull rods (10) until retaining rings (36) come up against wheel legs
(1 + 6).
Drive tapered locking pins (17) with a hammer as far as possible into wheel legs
(11 + 12) or, for trolley size 10 combined with DH 1000 2/1 hoist unit into wheel legs
(1 + 6).
Then insert and tighten locking screws (18) until the screw heads come up against
the wheel legs and tapered locking pins (17) are in their final positions (see fig. 35).
Tighten locking screws (18) to a torque of 200 Nm.

41825644.eps
Tapered locking pin (17) Prior to assembly, apply Esso-Pen-O-Led EP grease to the teeth of drive shaft (22).
Locking screw (18)
Then slide drive shaft (22) through wheel leg (12) and fit the two adjusting rings (21)
MA = 200 Nm
onto drive shaft (22).
Slide drive shaft (22) into the pinion of wheel leg (6) until it meets resistance. Then pull
drive shaft (22) back by 1 mm (fig. 36).
Connecting rod To fix drive shaft (22) in position, push adjusting ring (21) against the pinion of wheel
leg (6).

Tighten the grub screw of adjusting ring (21) to a torque of 36 Nm.
Fig. 35 40133044.eps
1 Drive shaft
Adjusting ring For further assembly and adjustment see Adjusting the trolley for trolley sizes 6
and 10 (size 10 when combined with Demag DH 500/600 4/1 hoist unit) or trolley
size 10 with Demag DH 1000 2/1 hoist unit.
21428606.p65/090903
Grub screw
Wheel leg Protective cover
Mounting bolt of Pinion with bearing
hoist unit
Fig. 36 40133344.eps
71
Assembly: AMK 10/AMK 20
Prior to assembly, grease tapered locking
pins (17), locking screws (18) and threads Fix torque arm (35) on travel drive (23) with the 4 locking screws (37). (Tightening
in wheel legs with Molykote 321-R spray, torque 19 Nm).
part no. 972 398 44.
17 Slide travel drive (23) onto drive shaft (22) and attach torque arm (35) to
wheel leg (12) using the two locking screws (36) (see fig. 34).
To secure travel drive (23), fit retaining ring (28) to drive shaft (22).
Assembly: AUK 30
Slide travel drive (23) onto drive shaft (22).
Fix travel drive (23) to connecting plate (13) with hexagon bolt (24), washer (25),
41825644.eps spring element (26) and lock nut (27).
Tapered locking pin (17) To secure travel drive (23), fit retaining ring (28) to drive shaft (22).
Locking screw (18)
Depending on the rope reeving arrangement of the hoist, insert either the rope retain-
MA = 200 Nm
ing crosshead (for 2/1), the return sheave (for 4/1) or the compensating sheave
(for 4/2) into connecting plate (13), then fix in position with sleeve (29) and retaining
ring (30).
Connecting rod
For 4/1 reeving, attach the rope retaining crosshead to the hoist unit frame (see
fig. 34).
Fit retaining rings (31) on connecting rods (10).
Wheel leg or crosshead Slide counterweight box (32) onto rods (10) and fix with retaining rings (33).
Fig. 35 40133044.eps See section 5.15 for counterweight.
1 Drive shaft
Adjusting ring
Grub screw
Wheel leg Protective cover
Mounting bolt Pinion with bearing
of hoist unit
Fig. 36 40133344.eps
21428606.p65/090903
72
2 3 4 6
1 5 2 3 4 6 5 Table 4
size torque of
screws
(Nm)
7 8 9 (4) (9) (2) (7 ) (2) (7) (15)
7 89
300/400 4/1 - 16 x 18 M 16 x 50 M 12 x 45 215 86
6 280
500/600 2/1, 4/2 21 x 24 21 x 16 M 16 x 60 M 16 x 45 215 215
40133444.eps 500/600 4/1 - 21 x 28 M 20 x 65 M 16 x 60 500 215
10 530
1000 2/1, 4/2 25 x 28 25 x 28 M 20 x 75 M 20 x 75 410 410
AMK 10/20
4/1 rope reeving
41909844.eps
Trolley size 10
41458344.eps
AUK 30
Fig. 34 41911844.eps

When assembling, all tapered locking pin connections must be rechecked. The
21428606.p65/090903
locking screws (18) must be tightened with the specified torque of 200 Nm.
73
5.14.2 Adjusting the trolley for size 6 when combined with Demag DH 300/400 4/1 – DH 500/600 2/1, 4/2 hoist unit and
trolley size 10 when combined with Demag DH 500/600 4/1 hoist unit
2 3 4 6
1 5 2 3 4 6 5 Table 4
size torque of
screws
(Nm)
7 8 9 (4) (9) (2) (7) (2) (7) (15)
7 89
300/400 4/1 - 16 x 18 M 16 x 50 M 12 x 45 215 86
6 280
500/600 2/1, 4/2 21 x 24 21 x 16 M 16 x 60 M 16 x 45 215 215
40133444.eps 500/600 4/1 - 21 x 28 M 20 x 65 M 16 x 60 500 215
10 530
1000 2/1, 4/2 25 x 28 25 x 28 M 20 x 75 M 20 x 75 410 410
AMK 10/20
4/1 rope reeving
41909844.eps
Trolley size 10
41458344.eps
AUK 30
41911844.eps

When assembling, all tapered locking pin connections must be rechecked. The
21428606.p65/090903
locking screws (18) must be tightened with the specified torque of 200 Nm.
74
The trolleys are infinitely variable within the range for adjustment to various flange
locking pins (17), locking screws (18)
widths b.
and the threads in the wheel legs with If the trolley is to be readjusted, first remove retaining rings (19) and washers (20).
Molykote 321-R spray, part no.
972 398 44. Loosen tapered locking pins (17) after removing locking screws (18) from wheel legs
17 (1 + 6).
Loosen adjusting ring (21) on drive shaft (22) at wheel leg (12) and slide it to the
centre of the shaft.
Wheel legs (1 + 6) can now be moved along connecting rods (10). The setting
dimension between each pair of opposite wheel legs is calculated from flange width
b + .... mm (fig. 38).
When the dimension has been calculated, move wheel legs (1 + 6) to their corre-
sponding positions.
Drive tapered locking pins (17) into wheel legs (1 + 6) with a hammer as far as possi-
41825644.eps
ble. Then insert and tighten locking screws (18) until the screw heads come up
Tapered locking pin (17)
against the wheel legs, thus bringing tapered locking pins (17) into their final
Locking screw (18) positions (see fig. 37).
MA = 200 Nm Locking screws (18) must be tightened to a torque of 200 Nm.
Now measure on connecting rods (10) the distance between the contact surfaces of
washers (20) at wheel legs (1 + 6) and the grooves for retaining rings (19). This is
Connecting rod done to determine the number of washers required (see fig. 39).
Thickness of the washers: trolley sizes 6 and 10 = 4 mm
Fit retaining rings (19) to both rods (10).
In order to secure drive shaft (22), push adjusting ring (21) against the pinion of
wheel leg (12).
Fig. 37 40133044.eps
Then tighten the grub screw of adjusting ring (21) to a torque of 36 Nm.
b See section 5.15 for counterweights.
5.14.3 Adjusting trolley size 10 when combined with Demag DH 1000 2/1 hoist
2mm
unit
If the trolley is readjusted, first remove retaining rings (33), counterweight box (32),
retaining rings (31 + 35) and washers (34) from rods (10).
Turn tapered locking pins (17) after removing locking screws (18) from wheel legs
b + ... (11 + 12).
Trolley size 6 = b + 6 mm Loosen adjusting ring (21) on drive shaft (22) at wheel leg (12) and slide it to the cen-
Trolley size 10 = b + 20 mm tre of the shaft.
Fig. 38 41910244.eps
Wheel legs (11 + 12) can now be moved along connecting rods (10). The setting
Trolley sizes 6 and 10 when combined with dimension between each pair of opposite wheel legs is calculated from flange width
Demag DH 500/600 4/1 hoist unit b + ... mm (fig. 38).
When the dimension has been calculated, move wheel legs (11 + 12) to their corre-
sponding positions.
Drive tapered locking pins (17) into wheel legs (11 + 12) with a hammer as far as
possible.
Then insert and tighten locking screws (18) until the screw heads come up against
the wheel legs, thus bringing tapered locking pins (17) into their final positions
Adapt quantity
(see fig. 37).
on assembly
Fig. 39 41909944.eps
Trolley size 10 when combined with

Demag DH 1000 2/1 hoist unit Now measure on rods (10) the distance between the contact surfaces of wash-
ers (34) at wheel legs (11 + 12) and the grooves for retaining rings (31 + 35). This is
done to determine the numbers of washers required (see fig. 40).
Thickness of washers = 4 mm
Fit retaining rings (35 + 31) to rods (10).
Slide counterweight box (32) onto rods (10) and secure with retaining rings (33). See
section 5.15 for counterweights.
21428606.p65/090903
In order to secure drive shaft (22), push adjusting ring (21) against the pinion of wheel
leg (12).
Adapt quantity
on assembly Then tighten the grub screw of adjusting ring (21) to a torque of 36 Nm.
Fig. 40 41910044.eps 75
5.14.4 Changing the travel drive from AMK 10 to AUK 30 – EKDH
AMK 10
Adjusting ring (4)

1
41910344.eps
Drive shaft (22)
Grub screw
Wheel leg (1)

Mounting bolt Pinion shaft with bearing (5)

of hoist unit
40133344.eps
AUK 30
Fig. 41 41911844.eps
21428606.p65/090903
76
When replacing AMK 10 travel drives with AUK 30, attention must be paid to the
following:
Splined shaft W 25 = AMK 10 W 30 = AUK 30
Disassembly
2) Remove securing strap (2) and plastic casing (3).
3) Remove pinion shaft with bearing (5) from wheel legs (6 + 12).
4) Remove connecting plate (13).
Assembly
5) Fit the two new pinion shafts with bearing (5).
6) Tap split sleeves (14) through the four bore holes of connecting plate (13) into
wheel legs (11 + 12). Bolt connecting plate (13) to wheel legs (11 + 12) using
locking screw (15). (See table for tightening torque).
Trolley size Locking screw (15)

6 280 Nm
10 530 Nm
7) Refit plastic casing (3) with grease filling.

(For grease quantity, see section 8.8.3).
8) When fitting securing strap (2), be careful no to tighten securing strap (2) exces-
sively.
shaft (22).
10) Slide drive shaft (22) through wheel leg (12) and pinion shaft with bearing (5) and
place adjusting rings (4) on drive shaft (22). Slide drive shaft (22) into pinion shaft
with bearing (5) of wheel leg (6) until drive shaft (22) meets resistance. Then re-
tract drive shaft (22) by 1 mm (see fig. 41).
11) In order to fix drive shaft (22) in position, push adjusting rings (4) right and left
against pinion shaft with bearing (5). Tighten the grub screw of adjusting ring (4)
with a torque of 36 Nm.
12) Slide travel drive (23) onto drive shaft (22).
13) Fix travel drive (23) to connecting plate (13) with hexagon bolt (24), washer (25),
spring element (26) and lock nut (27).
21428606.p65/090903
77
5.14.5 Changing the travel drive from AUK 30 to AMK 20 – EKDH
AUK 30 26
25
27
13 26
25
24
15
11 14 13
23
4 4 5 12 22 23
6
41910144.eps
Adjusting ring (4)

1
Drive shaft (22)
AMK 20
Grub screw
Wheel leg (1)

Mounting bolt Pinion shaft with bearing (5)

of hoist unit
40133344.eps
41911944.eps
21428606.p65/090903
78
When replacing AUK 30 travel drives with AMK 20, attention must be paid to the
following:
Splined shaft W 30 = AUK 30/AMK 20
Disassembly
1) Loosen connecting elements (24 – 27) and pull travel drive (23) from drive
shaft (22).
2) Remove connecting plate (13).
Assembly
3) Tap split sleeves (14) through the four bore holes of connecting plate (13) into
wheel legs (11 + 12). Bolt connecting plate (13) to wheel legs (11 + 12) using
locking screw (15). (See table for tightening torque).
Trolley size Locking screw (15)

6 280 Nm
10 530 Nm

shaft (22).
5) Fix torque arm (35) on travel drive (23) with the 4 socket head screws (37).
6) Slide travel drive (23) onto drive shaft (22).
Then attach torque arm (35) to wheel leg (12) using the two locking screws (36)
21428606.p65/090903
79
5.15 Counterweight box KDH low-headroom monorail hoists are supplied with an attached counterweight box
with lid.
filling for EKDH trolleys
In order to reduce transport costs, the box is dispatched empty. The counterweight
box must be filled with scrap when the trolley is assembled.
The quantity of scrap required is determined by the width of the flange and type of
trolley drive.
Please balance the KDH monorail hoist exactly. The counterweight is shown in the
following table.
Recommended EKDH counterweight box filling
Flange width Counterweight box filling

Trolley size Range Reeving Motor size
b [mm] approx. [kg]
100 45
KBH 100
305 15
100 55
KBH 112
DH 300 H 12 305 20
DH 400 H 12 100 60
KBH 125
305 25
100 80
KBH 140
305 40
4/1
100 60
KBH 100
305 25
100 70
KBH 112
DH 300 H 20 305 30
DH 400 H 20 100 75
KBH 125
305 35
100 95
KBH 140
305 50
6
100 85
KBH 112
305 40
100 95
KBH 125
DH 500 H 12 305 50
DH 600 H 12 100 110
KBH 140
305 60
100 140
KBH 160
305 85
2/1, 4/2
100 105
KBH 112
305 55
100 115
KBH 125
DH 500 H 20 305 65
DH 600 H 20 100 130
KBH 140
305 75
KBH 160 100 155
305 95
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80
Flange width Counterweight box filling
Trolley size Range Reeving Motor size
b [mm] approx. [kg]
100 80
KBH 112
305 30
100 90
KBH 125
DH 500 H 12 305 40
DH 600 H 12 100 100
KBH 140
305 50
100 130
KBH 160
305 75
10 4/1
100 95
KBH 112
305 45
100 105
KBH 125
DH 500 H 20 305 55
DH 600 H 20 100 115
KBH 140
305 65
100 150
KBH 160
305 90
110 260
KBH 140
305 200
110 300
KBH 160
305 240
DH 1000 H 16
110 330
KBH 180
305 260
110 360
KBH 200
305 290
110 305
KBH 140
305 240
110 330
KBH 160
305 260
10 DH 1000 H 24 2/1, 4/2
110 370
KBH 180
305 300
110 400
KBH 200
305 335
110 400
KBH 140
305 335
110 450
KBH 160
305 370
DH 1000 H 40
110 470
KBH 180
305 390
110 500
KBH 200
305 420
When a standard type U0 or U2 microspeed unit is fitted the counterweight box filling should be increased by
50 % of the weight of the unit, and by 80 % of the weight of the unit for the standard type U1.
5.15.1 Dimensions for attaching
end stops to runways End stops must be attached to both ends of the travelling hoist runway.
UDH Trolley size Range b7 KDH Trolley size Range b7

DH 300/400 4/1 DH 300/400 4/1
6 143 6 170,5
DH 500/600 2/1 DH 500/600 2/1
DH 500/600 4/1 DH 500/600 4/1
10 165 10 200
DH 1000 2/1 DH 1000 2/1
Buffer cpl. Buffer cpl.

Part no. 96336044 Part no. 96336044
21428606.p65/090903
b7
Part no. 96336244 Part no. 96336244

Fig. 102 41904044.eps 41903944.eps
81
5.16 FG 06 – FG 08 – FG 10 A microspeed unit can be retrofitted to Demag hoist units.
microspeed units Conversion is done as follows:
Unscrew the four hexagon socket screws holding the brake cover and remove the
cover.
Screw the four stay bolts into the end cap (FG 06, FG 08).
Fit creep speed gearbox with creep speed motor to main hoist motor. Tighten the
four hexagon socket nuts (5) or (only in the case of FG 08 with main hoist motor
140 KBH and FG 10) socket head screws (5) uniformly to the specified torque (see
table 7).
Determine the path of displacement in inspection window (1).
If the path of displacement is too small or too great, see Main hoist motor – Adjusting
the brake, section 5.16.2.
5.16.1 Brake The creep hoist motor is supplied with the brake adjusted for the minimum rotor
displacement path lv min.
As the brake lining wears down, the path of rotor displacement increases from Iv min
to Iv max (see table 5). The brake must be adjusted as soon as Iv max is reached.
Table 5
Axial displacement of the shaft
Motor size Displacement path in mm
lv min lv max
100, 112 1,8 3,5
125, 140 2 4
160, 200, 225 2,3 4,5
It is therefore imperative to ensure, by regular maintenance, that the brake is adjust-

ed before the maximum rotor displacement is reached.
In order to be able to adjust the main hoist motor brake, an adjusting key must first
be made (see fig. 42 and table 6).
The adjusting key can also be ordered under the following part numbers:
FG 06 – 717 298 44
FG 08 – 717 398 44
FG 10 – 717 498 44
5.16.2 Main hoist motor Adjusting the brake

Determine the path of displacement in inspection window (1).
Remove plug (4).
Remove screws (3).
Adjustment can be made with the adjusting key (see fig. 42).
Set the minimum path of displacement as indicated in table 5 by turning adjusting
nut (2) clockwise. One revolution of the adjusting nut corresponds to a displacement
of the brake cup on the FG 06 of 1,5 mm, on the FG 08 and FG 10 of 2 mm.
Bolt brake shaft (10) and adjusting nut (2) together with screws (3).
Tightening torques for screws (3):
FG 06 = 6 Nm
FG 08 = 25 Nm
21428606.p65/090903
FG 10 = 120 Nm
82
1 Inspection window
2 Adjusting nut
Table 6
3 Adjusting screw Size a b c d e f g h i Part no.
4 Plug
5 Nut FG 06 120 12 25 18 5 H7 24 8 17 20 717 298 44
6 Brake disk FG 08 130 20 40 26 8 H7 16 12 17 20
7 Brake lining
8 Adjusting screw FG 10 140 25 60 36 12 H7 19 17 17 20 717 498 44
9 Retaining ring
10 Brake shaft
Adjusting key
a
7
f i b
6
4
1
3
c
e
g h
8 9 10 2 Cylindrical pins DIN 6325

FG 06 = 5 m 6 x 18
FG 08 = 8 m 6 x 24
5 FG 10 = 10 m 6 x 32
Fig. 42 41116344.eps 41118244.eps
Table 7
Size Base material Screw tightening torques in Nm
Main motor Microspeed motor
Motor Microspeed cover/ Motor/ Gearbox Bearing cover/ Motor/
size gearbox casing microspeed cover casing gearbox casing gearbox intermediate flange/motor
casing
71 80 90 100 112
Screw
Verbus DIN 912 Nut DIN 912 Verbus Ripp
Ripp
AI - - - - 12 45 45 18 - - - -
FG 06 100
GG - 35 - 10 - - - - - - - -
AI - - - - - - 75 18 - - - -
112
GG 65 - - 25 69 65 - - - - - -
AI - - - - - - 75 - 45 - - -
FG 08 125
GG 65 - - 25 69 65 - - - - - -
AI - - - - - - 75 - 45 - - -
140
GG 65 - 50 - 69 65 - - - - - -
160 270 - 70 - 120 270 65 - - 30 - -
FG 10 GG 200 270 - 120 - 120 270 65 - - - 65 -
225 270 - 295 - 120 270 65 - - - - 65
21428606.p65/090903
83
5.16.3 Changing the hollow shaft of
the FG 08 and FG 10
Surface A
Cover
Seal
2
t2
t1
Fig. 43 40188344.eps
When fitted, the dished spring washer (1) must be loaded with an initial stress of
0,5 mm.
Compensating tolerances (see fig. 43).
Use a depth gauge to measure dimension t1 on the microspeed unit. Use a depth
gauge to measure dimension t2 on the cover with seal in position.
t1 – t2 = t
Compensate dimension t by fitting a suitable number of washers on surface A.
Loading the dished washer with initial stress
The number of washers required based on dimensions t plus 2 x 0,1 mm and

1 x 0,3 mm results in the amount of initial stress.
The dished washer is loaded with an initial stress of 0,5 mm when cover (2) is fitted.
Washers
Size Part no. Dimensions
341 439 99 90 x 100 x 0,1

FG 08
341 509 99 90 x 110 x 0,3
341 531 99 120 x 150 x 0,1
21428606.p65/090903
FG 10
341 538 99 120 x 150 x 0,3
84
5.17 Demag DH hoist units and travel drive units for arduous conditions
DH 300, DH 400, DH 500, DH 600, DH 1000, DH 2000
5 24625-2.tif
AMK 10, AMK 20, AUK 30, AUK 40, AUK 50
42032744.eps
Converting to IP 55:
Using Loctite 510 (part no. 033 075 44), seal stator centering collars between stator
and brake end cap and between stator and drive end cap.
Check tight fit of the seal between drive end cap and base of terminal box, and of
the seal between base of terminal box and its cover.
Replace existing brake cover (1) by weatherproof type.
For ZBF travel motors, the brake must be retrofitted with a friction plate (4) and a
sealing strip (5).
Stamp IP 55 and all other relevant data on a blank rating plate and fit this plate in-
21428606.p65/090903
stead of the existing rating plate.

Seal the air gap (3) between the frame and the gearbox casing with silicon.
85
6 Putting the Demag DH hoist unit into service
6.1 DGS 3 and DGS 4 The DGS geared limit switch is fitted in the electrical equipment enclosure of the
DH hoist unit. It switches off the hoist motor when the top or bottom hook position is
geared limit switches reached. The direction of movement can be reversed. The emergency limit switch
must not be actuated during normal operation.
Operating limit switches are required where the end positions are approached regu-
larly during normal operation.
In such cases, the switches must be adjusted so that the operating limit switch is
actuated first and then, i.e. if this fails to operate, the emergency limit switch.
If required by accident prevention regulations, a facility for the crane operator to
check the emergency limit switch before starting work will be provided. This is then
possible using the check button in the controls. The operating limit switch can be
by-passed by pressing this button. In order to approach the emergency limit switch,
the hoist unit must be switched on and the check button pressed simultaneously.
The check button must also be pressed in order to move the hook back out of
the end position (lowering).
The functions carried out by the geared limit switch can be seen in the wiring dia-
gram provided.
Switching elements S1 – S3 in the DGS 3 and S1 – S4 in the DGS 4 can be used for
the following switching possibilities:
Switching element contacts DGS 3 (part no. 875 200 44) DGS 4 (part no. 875 201 44)
2 NC (11 - 12 and 21 - 22)
S1 Emergency limit switch for top hook position

"Main lifting" switch
(only for hoist units with 2 speeds)
S2
Operating limit switch for top hook position
Limit switch for incorrect phase sequence
S3 Emergency limit switch for bottom hook position
S4 Operating limit switch for top hook position
6.1.1 Determining the cut-out point The emergency limit switches must be properly adjusted to ensure prevention of
for the geared limit switch accidents and to avoid damaging the hoist unit. The emergency limit switches are
adjusted before leaving the factory to avoid complete unwinding of the rope, only.
Following installation of the hoist unit, they must be readjusted and checked for the
particular operating conditions.
If you wish to set the greatest possible lifting height for your specific operating con-
ditions, it is essential to observe the following:
The emergency limit switch for the top hook position must be set so that when it
switches off the lifting movement, the minimum distance between the top edge of
the bottom block and the bottom edge of the hoist unit frame is maintained (see
table 8).
DGS limit switch cut-out points for the top hook position (fig. 44)
Dimension F (mm)
Table 8
with rope reeving
1/1 2/1 4/1
A Simultaneous cut-out of main and creep lifting motions
S1 switching element 105 70 50

Emergency limit
switch B Successive cut-out of main and creep lifting motions
S2 main lifting motion switching element 105 70 50

S1 creep lifting motion switching element 30 30 25
Operating limit C Simultaneous cut-out of main and creep lifting motions
switch

21428607.p65/090903
DGS with An additional DGS switching element is required as protection against incorrect phase sequence so that the
D
protection lowering contactor is deenergized in the top hook position. With successive cut-out of the main and creep
against lifting motions (cut-out points acc. to table 2, line B), protection against incorrect phase sequence is not
incorrect possible.
phases
S1 emergency limit switch 190 120 70
S2 protection against incorrect phase sequence 105 70 50
86
The emergency limit switch for the bottom hook position must be set so that the load
hook does not touch the floor.
Setting the cut-out points is described in the setting instructions (section 6.2.1).
DGS limit switch cut-out point for the bottom hook position (fig. 44)
F
Dimension X (mm)
Table 9
with rope reeving
1/1 2/1 4/1
A Simultaneous cut-out of main and creep lifting motions
Emergency
limit switch

X
B Simultaneous cut-out of main and creep lifting motions

Operating limit
switch
Fig. 44 40133744.eps
6.2 Setting instructions for DGS 3 and DGS 4 geared limit switches
X
Contact maker
Cam shaft A
Setting screws
A1 - A4
Retaining screw A
42525945.eps
Setting screws Fig. 46 3
B1 - B4
Retaining screw B
Plunger Hook travel Cam shaft B

counter
Fig. 45 5 6
4
Fig. 47
Fig. 48 41110144.eps 41110044.eps
The following tools are required for setting the limit switch:
21428607.p65/090903
Two 1 x 4 mm and 1 x 6 mm screwdrivers.
87
X
Contact maker
Cam shaft A
Setting screws
A1 - A4
Retaining screw A
42525945.eps
Setting screws Fig. 46 3
B1 - B4
Retaining screw B
Plunger Hook travel Cam shaft B

counter
Fig. 45 5 6
4
Fig. 47
Fig. 48 41110144.eps 41110044.eps
6.2.1 S1 emergency limit switch for Raise the load hook to the level of dimension F = approx. 200 mm (fig. 44). Set cut-
top hook position out point gradually so that, after the lifting movement has been switched off, dimen-
sion F is not smaller than the values shown in table 8.
Allow for run-on!
Note direction of rotation of shaft A! (Important for later adjustment!)

Loosen fastening screws 2 by approx. 2 turns.
Turn adjusting screw 1B until adjusting marker 3 is aligned with white marker 4 on
the cam wheel (figs. 46 and 47).
Turn adjusting screw 1A until plunger 5 no longer protrudes from the bottom of
switching element 6, i.e. the plunger is in its lowest position.
Then turn screw 1A in the direction of rotation of shaft A until plunger 5 and adjusting
markers 7 are level (see fig. 48).
In this position, the normally closed contacts of switching element S1 are open.
6.2.2 S2 main lifting motion limit

Fitting is the same as for S1, except with adjusting screws 2A–2B.
switch
If dimension F is set to a value which is greater than that shown under line A in ta-
ble 8, the switching point of S2 may only be max. 1 drum revolution ahead of switch-
ing point S1.
S2 operating limit switch for top hook position
Setting is the same as for S1, except with adjusting screws 2A–2B.
For cut-out point see table 8, line C.
21428607.p65/090903
When required, a check button is provided in the control unit (see section 6.1).
S2 limit switch for incorrect phase sequence
Setting is as for S1, except with adjusting screws 2A–2B.
88 For cut-out points see table 8, line D.
6.2.3 S3 emergency limit Setting is for S1, except with adjusting screws 3A–3B.
switch for bottom For cut-out points see table 9, line A.
hook position Direction of rotation for setting opposite to that for S1!
6.2.4 S4 operating limit switch for Fitting is as for S1, except with adjusting screws 4A–4B.
bottom hook position For cut-out points see table 9, line B.
Pay attention to the direction of rotation for setting.
The adjustment range of the DGS covers max. 142 revolutions.
When setting has been completed, make sure that the centre fastening screw (2)
of supporting cam shaft (B) and switching cam shaft (A) is tightened to a torque
of ≥ 2 Nm.
Operate the hoist/lower motions several times to check the limit switch functions are
operating correctly.
When resetting the geared limit switch, ensure the correct number of safety turns on
the drum.
Safety turns
Range Rope reeving

1/1, 2/1, 4/1 2/2, 4/2
DH 300/400 3,5 4,5
3
DH 500/600 3,5
(DH 600 = 3,5)
DH 1000 4 4,5
DH 2000 4,5 4
21428607.p65/090903
89
6.3 Inspection when putting When putting the hoist into operation for the first time, the inspections in accordance
with section 8.3, table 10 must be carried out.
the hoist into operation
6.4 Safety instructions All fitting and assembly work must be completed in accordance with the operating
instructions and the hoist rope must be greased.
Operation with defective or damaged ropes result in a high risk of accident for per-
sons and the hoist unit and is therefore prohibited.
Any change or modification which prejudices safety must be reported to the nearest
person responsible immediately. Unauthorized repairs are not permitted.
6.5 Starting operation See section 8.1
7 Taking the Demag hoist unit out of service
7.1 Emergency-stop button

Every hoist unit is fitted with an emergency-stop device with which all motions can be
stopped in the event of a hazard.
The emergency-stop button is arranged on the control pendant.
To actuate the emergency-stop button, press the button until it reaches the end stop.
Emergency-stop It then locks automatically.
button
To unlock the actuated emergency-stop button, turn the push button in the direction
of the arrows and release.
The emergency-stop device must only be reset after the hazard and its cause have
been eliminated.
7.2 Taking the hoist out of service at the end of the shift
41233544.eps
When the work has been completed, raise the hook assembly or bottom block out-
side the travel area. Switch off the power supply at the mains connection or isolating
switch.
7.3 Taking the hoist out of service for maintenance purposes

Maintenance work on the Demag hoist unit must not commence before the load has
been removed and the mains switch/isolator switched off.
The relevant accident prevention regulations and statutory regulations must be ob-
served for operation and maintenance.
Tests and inspections required must be carried out.
Note:
See section 1 Safety instructions and the notes contained in the maintenance
21428607.p65/090903
schedule, page 92, table 10.
90
8 Inspections/maintenance/general overhaul GO
8.1 Inspection before start- The operator must carry out inspections in accordance with table 10 before starting
work. Hoist units must be taken out of service immediately or not put into operation
ing work and during if any defects relating to operating safety and reliability are detected.
operation Such defects are e.g.:
• brake and safety device failure
• damage to the rope
• unusual noise in the gearbox, etc.
8.2 Inspection and mainte- The specified inspection an maintenance schedule (table 10) apply to normal hoist
unit service conditions.
nance schedule
If routine maintenance reveals that the intervals are too long or too short, they should
be adapted to the specific operating conditions.
For repairs, only use genuine Demag parts (see component parts list).
The use of spare parts not approved by Demag renders any liability and guarantee
claims void.
The theoretical duration of service D (hours at full load h) depends on the Group of
8.3 General overhaul GO Mechanisms classification of the hoist unit (see section 9, table 16).
Upon expiration of 90 % of the theoretical duration of service – if the hoist units are
correctly classified after 8 to 10 years – the owner must arrange for a general over-
haul GO to be carried out. A general overhaul must be carried out on reaching the
theoretical duration of service at the latest.
During the general overhaul the following parts must be replaced in addition to the
checks and work specified in the inspection and maintenance schedule (see
table 10).
• Gearing
• Gearbox bearings
• Motor shaft
• Motor bearings
• Connection elements
• Gear oil
The small parts (screws, washers ...) to be replaced during maintenance and assem-
bly work are not listed separately.
The general overhaul carried out by the manufacturer or an authorized specialist
company fulfils the condition for continued operation of the hoist unit. Thus the rele-
vant accident prevention regulations and the BGV D8 (VBG 8) are complied with.
Further utilization is approved when an expert engineer has entered the conditions
for further utilization into the test and inspection booklet. The completion of the gen-
eral overhaul must be confirmed in the test and inspection booklet and a further
period of utilization in accordance with FEM 9.755 must be entered.
The general overhaul may be carried out by expert engineers of Demag or an
authorized specialist company.
21428607.p65/090903
91
Table 10
Inspection and maintenance schedule
Before putting When Every 6 Once per
Check when putting into operation for the first time, at the beginning See section
into operation starting months year
of each shift and during operation operation
Check rope securing devices and rope guide 5.8.6 X X
Check electrical switchgear and wiring 5.1 X X
Check operation of emergency limit switch 6.1 X X X
Check strain relieving elements, control cables and control pendant housing for damage X X X
Check operation of the brake 8.5/8.6 X X X
Check operation of the load detector X X
Check lubrication of rope 5.8.4 X X
Check hook and hook safety catch X X X
Check during operation

Check adhesive grease in bearings of return sheaves, crossheads, compensating sheaves and
5.8.4 X
pins of rope anchorage and re-grease, as required
Check suspension of rope anchorage
Check play of the setbolt/pin in the counter bore hole of the retaining plate
5.8.5 X
Check double spring clip for correct fit
Check retaining ring for correct fitting in the groove of the setbolt/pin
Check path of rotor displacement and adjust as necessary 8.5/8.6 X
Check all bolted connections, nuts, welds, etc. X
Check rope securing devices and play of rope guide on drum 5.8.6 X
Examine wire rope for damage and broken wires 8.4 X X
Oil rope 5.8.4 X
Examine load hooks for cracks, cold deformation and wear X
Check hook safety catch for deformation X
Check hook bearing for wear X
Check bottom block and hook fittings X
Check securing elements (clips, bolts, etc.) for tight fit and corrosion X
Check and apply or supplement corrosion protection, as required X
Change oil in main hoist gearbox every 8-10 years
Change oil in following gearboxes: F10 mechanical microspeed unit - cross travel unit gearbox every 4-5 years
Check coupling of the creep speed hoist motor 8.5.3 X
Check plastic parts of limit switch for corrosion 5.1/6.1 X
Check electrical enclosure seals X
Check condition of all end stops X

Check current supply lines (main and cross current supply).
On busbar lines: check insulators, busbars, connections and expansion joints
X
On current collectors: check sliding contacts and travel wheels for wear and sliding contacts for
contact pressure
Lubrication of the geared trolley travel wheels must be checked regularly (DH 300/400, 2/1 and 8.7.4
X
4/2 reeving) 8.7.5
Change grease in the protective caps of the last stage of the gearbox of monorail hoist trolleys 8.7.3 every 4 years
General overhaul
The general overhaul should coincide with the annual inspection On reaching the theoretical duration of service
Fit hoist unit specific Demag GO set 8.3 X
The small parts (screws, washers ...) to be replaced during maintenance and assembly work are not listed separately. The tasks
specified in the inspection and maintenance schedule must be carried out during a GO.
The specified maintenance intervals apply to normal hoist unit service conditions.
If the annual calculation of the actual duration of service S indicates that the theoreti-
cal duration of service D will be reached before a period of 8 – 10 years, regular main-
21428607.p65/090903
tenance work must be adapted to the operating conditions and maintenance must be
carried out at shorter intervals.
For repairs, only use genuine Demag parts (see component parts list).
92
8.4 Wire rope For safety reasons, the wire ropes must be discarded when the number of visible
broken wires at the worst spot has reached the following figures (see table 11),
counted over a reference length of rope of 6 times or 30 times the rope diameter,
whichever gives the worst result.
A wire rope must be discarded immediately if a strand is broken, if it is found to suffer

from swelling, bruising, kinks, permanent bends or corrosion, or if it is badly worn or
damaged.
In order to discover broken strands more easily, the load must be removed from the
hoist and the rope bent manually along its entire working length, the bending radius
being approximately that of the rope sheaves.
Wire ropes for Demag hoist units can be supplied ex stock direct from our stores or
through our distributors.
Wire ropes must be replaced (according to DIN 15020, sheet 2, page 3 (table 11)) when the following numbers of broken
wires are visible
Wire rope Group of mechanisms
1 Bm, 1 Am 2 m, 3 m, 4 m 1 Bm, 1 Am 2 m, 3 m, 4 m
to F E M
Rope dia. Number of broken wires over length of rope Number of broken wires over length of rope
6 x rope diameter 30 x rope diameter
Part no. Wire rope Number of Rope length Number of Rope length Number of Rope length Number of Rope length
construction broken broken broken broken
as in fig. mm
wires mm wires mm wires mm wires mm
822 460 44 1 7 5 42 10 42 10 210 19 210
581 690 44 2 7,5 5 45 10 45 10 225 19 225
581 190 44 10 7,5 6 45 11 45 11 225 22 225
822 490 44 2 11 5 66 10 66 10 330 19 330
822 470 44 3 11 4 66 8 66 8 330 16 330
822 475 44 7 11 6 66 11 66 11 330 22 330
822 492 44 8 11 5 66 10 66 10 330 19 330
823 490 44 4 14 12 84 24 84 24 420 48 420
823 470 44 3 14 4 84 8 84 8 420 16 420
823 475 44 7 14 6 84 11 84 11 420 22 420
823 492 44 11 14 6 84 11 84 11 420 22 420
824 490 44 4 20 12 120 24 120 24 600 48 600
824 475 44 7 20 6 120 - - 11 600 - -
824 470 44 5 20 6 120 11 120 11 600 22 600
825 487 44 7 25 6 150 11 150 11 750 22 750
825 486 44 9 25 10 150 21 150 21 750 42 750
Rope construction – section 5.8.1

Fitting a new wire rope and rope guide – section 5.8 and 5.8.6.
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93
8.5 KBH main hoist motor Demag hoist units, hoist units with mechanical creep lifting and the travel drive units
for monorail hoists and double-rail crabs are supplied with the brake adjusted for the
and KBA microspeed minimum rotor displacement path lv min.
motor brake The brakes of KBH 140/160/180/200 B 2/12 pole-changing hoist motors are rated
for electrical braking. They can, therefore, only be used in conjunction with an
SGDM-1 brake relay.
As the brake lining wears down, the path of rotor displacement increases from lv min
to lv max (see table 12). The brake must be adjusted as soon as lv max is reached.
Table 12
Axial shaft displacement for KBH, KBF and KBA motors
Motor size Path of displacement in mm
lv min lv max
71, 80, 90 1,5 3
100, 112 1,8 3,5
125, 140 2 4
160, 180, 200, 225 2,3 4,5
It is imperative to ensure, by regular maintenance, that the brake is adjusted before

the maximum rotor displacement is reached.
Should the braking action on Demag hoist units fitted with microspeed units diminish,
it must first be checked whether the creep or main motor brake requires adjustment.
The rotor displacement path between running and braking positions can be meas-
ured on the brake side once the louvers have been removed. This measurement
must be taken both when the motor is running and when it is at standstill.
Main hoist motor with mechanical microspeed unit
Measure the path of rotor displacement at the inspection window (see page 96,
fig. 49).
In order to be able to adjust the main hoist motor brake, an adjusting key must first
be made (see page 96, fig. 49 and table 13).
This adjusting key can also be ordered under the following part numbers:
FG 06 = 717 298 44/FG 08 = 717 398 44/FG 10 = 717 498 44.
Adjustment can be repeated several times.
It is advisable to have a spare brake lining in stock.
For brake adjustment the load must be removed from the Demag hoist unit.
When a complete motor is fitted, the surface between the motor and gearbox flange
must be sealed with Loctite 573, part no. 033 068 44.
Sealing surface
Motor mounting
tightening torque
DH 300 = 75 Nm
DH 400 = 75 Nm
DH 500 = 115 Nm
DH 600 = 115 Nm
DH 1000 = 115 Nm
DH 2000 = 300 Nm
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41109644.eps
94
KBH main hoist motor and KBA microspeed motor brake
8.5.1 Adjusting the brake Measure the path of rotor displacement lv.
Remove end plate with louvers (6) and four screws (5).
Insert two screws (5) into the tapped holes of adjusting nut (4) and tighten until brake
disk (1) is separated from adjusting nut (4).
Turn adjusting nut (4) anticlockwise until displacement path lv min as shown in ta-
ble 12 has been reached.
Replace and tighten the four screws (5) (see Tightening torques of screws (5)).
Refit end plate with louvers (6).
12 3 4 6
5
Tightening torques of
screws (5)
7
Screw size Tightening torque
M5 6 Nm
M6 11 Nm
M8 25 Nm
M 10 50 Nm
41109544.eps M 12 86 Nm
8.5.2 Fitting a new brake lining Remove end plate with louvers (6) and brake cover (2).
Remove retaining ring (7).
Remove screws (5), then separate brake disk (1) (see previous section).
Remove adjusting nut (4) and pull off brake disk (1).
Remove worn brake lining (3) from brake disk (1).
After moistening the rubber ring with water (never with oil), press the new brake lining
onto the brake disk (1). Push brake lining (3) in all the way round by tapping with a
rubber hammer until it is flush. Make sure that the brake lining is not deformed. It is
best fitted with a special pressure plate.
For special requirements such as
• high brake loads,
• high braking accuracy,
• short run-in periods of the brake
it is advisable to replace the brake disk completely or to re-turn the brake lining after
fitting. The cone angle is
Size 71 - 200 21°
Size 225 20°
Refit brake disk (1) and adjust to a displacement path lv min (see table 12, page 94).
Fit and tighten screws (5) (see Tightening torques of screws (5)).
Screw on brake cover (2) and end plate with louvers (6).
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95
Main hoist motor with mechanical microspeed unit
8.5.3 Adjusting the brake Determine the path of displacement in inspection window (1).
Remove plug (4) and screws (3).
Adjustment can be made with the adjusting key (see fig. 49).
Set the minimum path of displacement as indicated in table 12 by turning adjusting
nut (2) clockwise. One revolution of the adjusting nut corresponds to a displacement
of the brake cup on the FG 06 of 1,5 mm, on the FG 08 and FG 10 of 2 mm.
Bolt brake shaft (10) and adjusting nut (2) together with screws (3).
Tightening torques for screws (3)
FG O6 = 6 Nm/FG 08 = 25 Nm/FG 10 = 120 Nm
The microspeed motor coupling must be checked every time the brake is
adjusted.
Table 13
Size a b c d e f g h i Part no.
FG 06 120 12 25 18 5 H7 24 8 17 20 717 298 44
FG 08 130 20 40 26 8 H7 16 12 17 20
FG 10 140 25 60 36 12 H7 19 17 17 20 717 498 44
Adjusting key
7 a
f i b
6
4
1
3
d
c
e
g h
8 9 10 2
Cylindrical pins DIN 6325
FG 06 = 5 m 6 x 18
5 FG 08 = 8 m 6 x 24
Fig. 49 41116344.eps FG 10 = 10 m 6 x 32 41118244.eps
8.5.4 Fitting a new brake lining Remove the four nuts (5) or socket head screws (5) and remove creep hoist gearbox
with creep hoist motor. Remove retaining ring (9). Remove screws (8) from adjusting
nut (see fig. 49).
Insert 2 screws (8) into the tapped holes of the adjusting nut and tighten until the
brake disk is separated from the adjusting nut.
Unscrew the adjusting nut and pull brake disk (6) off the motor shaft.
Remove worn brake lining (7) from brake disk (6).
After moistening the rubber ring with water (never with oil), press new brake lining (3)
onto brake disk (1). Push brake lining (3) in all the way round using a press or by
tapping with a rubber hammer until it is flush. Make sure that the brake lining is not
deformed. It is best fitted with a special pressure plate.
See section 8.5.3 for special requirements.
Refit brake disk (6) to the shaft, and turn the adjusting nut up to the shaft collar. Then
unscrew the nut by 1,5 turns.
Bolt brake disk (6) and adjusting nut together with screws (8) (for tightening torques
see page 97, table 15).
Fit retaining ring (9) to the shaft end.
Fit creep hoist gearbox with creep hoist motor to the main hoist motor. Tighten the
4 hexagon socket nuts (5) or socket head screws (5) uniformly to the specified torque
21428608.p65/090903
(see page 97, table 14).

In order to obtain full braking torque more rapidly, switch motor on and off repeated-
ly, thus wearing in the brake lining.
96
Table 14
Tightening torques for hexagon socket nuts (5) or
screws (5)
Screw
Size Motor size
DIN 912 Nut
FG 06 100 - 10
112 - 25
FG 08 125 - 25
140 50 -
160 70 -
7
FG 10 200 120 -
6 225 295 -
4
1
3 Table 15
Tightening torques for tensioning screws (8)
Main hoist motor Tightening torque
KBH 100, 112 11 Nm
8 9 10 2
KBH 125, 140 25 Nm
KBH 160 50 Nm
5 KBH 200, 225 86 Nm
41116344.eps
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97
8.5.5 Fitting new KBH brake springs Remove motor end cap (1)
Compress brake spring (3) by pressing on thrust ring (2), thus revealing spring
ring (4).
Remove spring ring (4) from the shaft and carefully release the brake spring.
Remove thrust ring (2) and dished washer pack (5).
Replace brake spring (3) and, if necessary, also adapter rings (6).
Compress brake spring (3) with dished washer pack (5) and thrust ring (2). Refit
spring ring (4).
It must be ensured that spring ring (4) snaps into the corresponding groove on the
shaft.
Refit motor end cap (1).
1 2 3 11 12
12
2 8
45 6 7 9 10
Fig. 50 40132844.eps 40266544.eps
8.5.6 Air gap Check and, if necessary, adjust the air gap between the rotor and stator after each
regular motor overhaul and also after replacement of the motor end cap, stator and
rotor or the dished washer pack, the tolerances of which influence the air gap dimen-
sion.
If the air gap is too great, motor performance is reduced and the motor temperature
rises excessively. If the air gap is too small, the rotor grazes against the stator, result-
ing in destruction of the motor.
Remove coupling half from motor shaft.
Remove brake cover (11), brake disk (10) and end cap (9).
Place motor on suitable base as in fig. 50.
Remove rotor (12).
Remove spring ring (4), thrust ring (2), dished washer pack (5) and brake spring (3)
and, if necessary, adapter washers (6) from rotor shaft (12).
In the following order, fit dished washer pack (5), thrust ring (2) and spring ring (4)
onto rotor shaft (12). The thrust ring is supplied in a variety of thicknesses to com-
pensate for manufacturing tolerances. First select the thrust ring of a medium
thickness. Fit thrust ring (2) with 45° bevel facing towards spring ring (4).
Insert rotor (12), fitted as above, into stator (7) and lower carefully until thrust ring (2)
butts against thrust bearing (8).
Insert three feeler gauges of the correct air gap dimension at 120° from each other
into the air gap between stator and rotor core for their entire length. The air gap is
correct when all three feeler gauges can be moved up and down with little effort.
21428608.p65/090903
98
If the air gap is too wide fit a thinner thrust ring, or if too narrow a thicker thrust ring
instead of the first one onto rotor shaft (12) and check the air gap once more.
Take rotor (1) out again and remove spring ring (4), thrust ring (2) and dished washer
pack (5). Then fit brake spring (3) and, if required, adapter washers (6) and the re-
moved parts onto rotor shaft (12).
It must be ensured that spring ring (4) snaps into the corresponding groove on the
shaft. When released, brake spring (3) pushes thrust ring (2) against spring ring (4).
Refit end cap (9).
Fit brake disk (10) and brake cover (11) as in section 8.5.1.
Motor Size 71 80 90 100 112 Motor Size 125 140 160 180 200 225
Range Air gap δ Range Air gap δ
δmin 1) mm 0,25 0,25 0,30 0,30 0,35 δmin 1) mm 0,35 0,40 0,45 0,50 0,50 0,55
KBH, KBA KBH, KBA
δmax mm 0,30 0,30 0,35 0,35 0,45 δmax mm 0,45 0,50 0,55 0,60 0,60 0,65
Feeler gauge Feeler gauge
Size Size
0,25x3x250 x x 0,35x5x300 x
0,30x3x250 x x x x 0,40x5x300 x x
0,35x3x300 x x x x x 0,45x5x300 x x x
0,40x3x300 x x x x x 0,50x5x300 x x x x x x
0,45x3x300 x x x 0,55x5x350 x x x x x x
0,50x3x300 x x x 0,60x5x350 x x x x x x
0,55x3x300 x x x 0,65x5x350 x x x x
0,70x5x350 x x x
Set of feeler
100...84 150 150 151 151 152 100...84 153 154 155 156 156 156
gauges
1) When fitting a new dished washer pack, increase nominal setting of air gap δmin by 0,05 mm as the dished
washer pack will settle after a few switching operations.
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99
100
21428609.p65/090903
8.6 ZBF 63–112 travel The following work may only be carried out by qualified personnel.
Observe relevant safety regulations and codes of practise and the instructions con-
motor brake tained in the “Safety instructions” section.
8.6.1 B003, B004, B020, B050 Apart from wear, the brake is virtually maintenance-free.
brakes The brake lining is designed in such a way that worn surface particles are only given
off as minimal abrasion. This built-in regeneration of the brake lining surface ensures
constant braking characteristics. It is advisable to check the brake air gap s1 at cer-
tain intervals and to adjust it as necessary to ensure the brake releases reliably.
Brake air gap s1min = 0,30 mm – s1max = 1,2 mm
When the brake is released (power applied to brake coil), the brake disk can be freely
turned.
It is only possible to give guide values for brake operation until adjustment as they
depend on the given operating conditions.
Brake size B003 B004 B020 B050
Brake work until readjustment WN in Ws 200 ⋅ 106 200 ⋅ 106 300 ⋅ 106 500 ⋅ 106
When the brake has been adjusted several times, the remaining thickness bmin of the
brake disk must be checked.
B004, B020, B050 brakes
The guide pins feature an easily visible marking which clearly indicates the minimum
dimension (see section 8.6.2).
B003 brake
The brake can be adjusted twice. After the second adjustment, check remaining
thickness b min of the brake disk at regular intervals.
This brake can only be checked visually.
B003, B004, B020. B050 brakes
The brake disk must be replaced when the remaining thickness is too small or wear
differs considerably between the two linings. A wear part set is available for replace-
ment. In addition to the brake disk and the required small parts, the set also includes
the assembly instructions.
For a general overhaul, an overhaul set is available.
ZBF motors
Overhaul set
Brake size Wear part set
63/71 80 90B 100 112A
B 003 260 960 84 – – – – 260 962 84
B 004 260 964 84 – – – – 260 965 84
B 020 – 260 973 84 260 974 84 – – 260 975 84
B 050 – – – 260 978 84 260 979 84 260 980 84
The air gap must be adjusted when the max. permissible value s1 has been reached,
(however, immediately if the brake no longer releases).
If the brake is not adjusted, it will no longer release after further wear. If the
motor then operates against the applied brake, the brake and motor may be
damaged.
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101
8.6.2 Checking and adjusting the
brake air gap s1
Undo the four screws and remove the fan cover.
41431944.eps 41432044.eps
Remove the retaining ring and fan.

41432144.eps 41432244.eps
Checking the remaining thickness of the brake disk

Brake size B004 B020 B050
Remaining thickness
5 6 7
b min
1) If armature disk edge (2) has reached the mark (x) on guide pin (4), brake disk (3)
must be replaced.
For replacing the brake disk, see section 8.6.3.
2) If the remaining thickness of the brake disk is within the specified tolerances, B004, B020, B050 brakes
check brake air gap s1
(see checking/adjusting the brake air gap on page 103).
Status when new
B003 brake
The B003 brake can only be checked visually.
Remaining thickness bmin

21428609.p65/090903
For a visual check, push covering tape (12) to the side

using a screwdriver.
41777744.eps 42028944.eps
102
Checking/adjusting the brake air gap
Brake air gap s1min = 0,30 mm – s1max= 1,2 mm
Tighten magnet assembly (9) with the three hexagon nuts (10) uniformly until the air
gap is zero.
Loosen the three hexagon nuts (10) by angle α1.
Adjusting angle α 1 120° 120° 120° 90°
Check air gap s1 using a feeler gauge at three points around the
circumference. If the measured result is within the specified range,
the motor can be re-assembled.
If this is not the case, adjust again as required.
B003 brake B004, B020, B050 brakes
Magnet assembly (9) Magnet assembly (9)
Feeler gauge Feeler gauge
Brake disk (3) Brake disk (3)
Friction plate (14) Retaining plate for sealing tape (7) – only for IP55
End cap (6) End cap (6)
Stop plate (1) Stop plate (1)
Armature disk (2) Armature disk (2)
41777344.eps 42288844.eps 42029144.eps

21428609.p65/090903
Fit the fan and secure it with the retaining ring. Fit the fan cover
Tightening torque
Ensure the retaining ring clicks correctly into place. ZBF 63 – 100 motors = 4 Nm
ZBF 112 motor = 6 Nm
41432144.eps 41431945.eps
103
8.6.3 Replacing the brake disk The following work may only be carried out by qualified personnel.
Observe relevant safety regulations and codes of practise and the instructions con-
tained in the “Safety instructions” section.
Damaged brakes may only be repaired by a Demag authorised workshop.
Undo the four screws and remove the fan cover. Remove the retaining ring and fan.
41431944.eps 41432144.eps 41432244.eps
Remove terminal box cover (11). Remove terminal box cover (11).
Undo hexagon nut (10) and pull off washers (15), magnet assem- Undo hexagon nut (10) and pull off magnet assembly (9).
bly (9) and covering tape (12).
42508644.eps 42022544.eps
Remove stop plate (1), armature disk (2), distance springs (5) Remove stop plate (1), armature disk (2), distance springs (5) and
and brake disk (3). brake disk (3).
Check grub screws (4), sleeve (13) and braking surfaces for Check collared pins (4) and braking surface for wear.
wear.
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Replace worn or damaged parts only by genuine spare

parts.
Damage means any deformation of stop plate (1), however
small it may be.
42508344.eps 42288144.eps
104
Disassembly/assembly of the B003 brake Disassembly/assembly of the B004, B020, B050 brakes
Grub screws/end shield (6) – if required collared pins/end shield (6) – if required
Remove end shield (6). Remove end shield (6).
Remove sleeve (13) and friction disk (14). Unscrew the three defective collared pins (4).
Unscrew the three defective grub screws (4). Fit new collared pins (4).
Fit new grub screws (4). Refit new end shield (6).
Friction disk (14) is provided with mark “I”.
End shield (6) is also provided with a mark. Retaining plate (7) is only fitted for
When fitting friction disk (14) ensure that the mark of friction type of enclosure IP55.
disk (14) is aligned with the mark of end shield (6). Fit retaining plate (7) with collared
Slide sleeve (13) onto grub screws (4). pins (4).
Refit new end shield (6).
Mark “I” on friction disk (14)
Mark on end shield (6)
42508444.eps 42287944.eps
Tightenting torque of collared pins/grub screw

Tightening torque 3 Nm 3 Nm 4 Nm 9 Nm
Fitting the brake Fitting the brake
B003 brakes B004, B020, B050 brakes
Recess on armature disk (2) Bore hole on stop plate (1)
Mark “I” on friction disk (14)

Mark “I” on armature disk (2)
Bore hole on
stop plate (1)
Fit brake disk (3).

The recess on the outer diameter and the bore hole on stop plate (1) Fit brake disk (3).
must be aligned with the mark on end shield (6) when fitting armature Mark “I” and the bore hole on stop plate (1) must be aligned with the
disk (2).
mark on end shield (6) when fitting armature disk (2).
The machined surface of armature disk (2) is the opposite surface of
the brake disk.
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Ensure that stop plate (1) is not deformed and lies absolutely Ensure that stop plate (1) is not deformed and lies absolutely
flat on armature disk (2). flat on armature disk (2).
Ensure that stop plate (1) does not jam between screw (4), Ensure that stop plate (1) does not jam between collared
sleeve (13) and armature disk (2). pin (4) and armature disk (2).
42508344.eps 42288144.eps
105
Brake spring (8)
Brake spring (8)
42508244.eps 42022444.eps
Push distance spring (5) onto grub screws (4). Push distance spring (5) onto collared pins (4).
Place brake springs (8) into magnet assembly (9). Place brake springs (8) into magnet assembly (9).
Insert covering tape (12) into the groove of end shield (6). Push magnet assembly (9) over collared pins (4) and secure with hexagon
Push magnet assembly (9) and disks (15) over grub screws (4) and secure nut (10).
with hexagon nut (10). Then tighten magnet assembly (9) with the three hexagon nuts (10) uniformly
When fitting magnet assembly (9) ensure that covering tape (12) engages until the air gap is zero. Loosen the three hexagon nuts (10) by angle α1 =
the groove of magnet assembly (9). 120°.
Then tighten magnet assembly (9) with the three hexagon nuts (10) Check air gap s1 using a feeler gauge at three points around the circumfer-
uniformly until the air gap is zero. Loosen the three hexagon nuts (10) by ence. If the measured result is within the specified range, the motor can be
angle α1 = 120°. re-assembled.
Check air gap s1 using a feeler gauge at three points around the circum- For checking/adjusting the brake air gap, see page 103.
ference. If the measured result is within the specified range, the motor can Pull the connecting cable of magnet assembly (9) back into the terminal box.
be re-assembled. Fit terminal box cover (11).
For checking/adjusting the brake air gap, see page 103.
Pull the connecting cable of magnet assembly (9) back into the terminal Arrangement of brake springs (8)
box. Brake Number of Spring Part no.
Motor
Fit terminal box cover (11). torque brake springs arrangement
see item
Nm red blue
Arrangement of brake springs (8) ZBF 63 A 8/2 B004 1,3 3 - 3) 260 211 84
Brake Number of Spring Part no. ZBF 71 A 8/2 B004 1,8 - 6 5) 260 127 84
Motor
torque brake springs arrangement ZBF 80 A 8/2 B020 3,3 3 - 3) 260 211 84
Nm red blue see item ZBF 90 B 8/2 B020 4,4 4 - 4) 260 211 84
ZBF 63 A 8/2 B003 1,4 - 3 1) 260 027 84 ZBF 100 A 8/2 B050 8,3 3 - 3) 260 311 84
ZBF 71 A 8/2 B003 1,9 3 - 2) 260 011 84 ZBF 112 A 8/2 B050 11 4 - 4) 260 311 84
1) 2) 3) 4) 5)
3 bl 33 rt
rd 3 rd
rt rd
4 rt 6 bl
42508044.eps 42508048.eps
21428609.p65/090903
Fit the fan and secure it with the retaining ring. Fit the fan cover
Tightening torque
Ensure the retaining ring clicks correctly into place. ZBF 63 – 100 motors = 4 Nm
ZBF 112 motor = 6 Nm
41432144.eps 41431945.eps
106
8.7 KMF 80 travel motor Hoist units and travel drives are supplied with the brake of the Demag motor
adjusted for the minimum brake displacement path of approx.
brake 1,5-2,0 mm mot. 80.
As the brake lining wears down, the path of rotor displacement increases.
The brake must be adjusted before the path of displacement has reached a maxi-
mum of 3,0 mm for 80 motors
It is therefore imperative to ensure, by regular maintenance, that the brake is
adjusted before the maximum brake displacement is reached.
For brake adjustment the load must be removed from the hoist unit.
Adjustment can be repeated several times.
It is advisable to have a spare brake cup in stock.
Number of shims Motor Qty Shim thickness
80 2x5 0,8 mm
8.7.1 Adjusting the brake This work may only be carried out by specialist personnel.
with shims Observe all relevant safety regulations and Section 1 safety recommendations!
It is imperative that the brake displacement is measured at regular intervals.
The brake must be adjusted when the path of displacement has reached the maxi-
mum displacement value.
Measure the path of rotor

displacement
41062044.eps 41062144.eps
21428609.p65/090903
Remove shims to adjust the brake

displacement!
Ensure same number of shims are
Loosen brake shield fitted on both sides!
41062344.eps 41062444.eps 41062544.eps

107
Tightening torque Measure the path of rotor displacement.
Motor KMF 80
Mot. KMF 80 = 10,5 Nm Tightening torque = 3 Nm
Check rotor displacement
(approx. 1,5 – 2 mm displacement).
41062244.eps 41062644.eps 41062144.eps
8.7.2 Replacing the This work may only be carried out by authorised personnel.
brake cup Observe all relevant safety regulations and Section 1 safety recommendations.
Loosen brake shield
41062144.eps 41062344.eps 41062444.eps
Remove fan with brake shield. Lock brake cup using a screwdriver and
remove bolts.
41062744.eps 41063244.eps 41063144.eps

21428609.p65/090903
108
After fitting the brake cup, fit the new shims supplied
with it.
Ensure same number of shims are fitted on

both sides!
Lock brake cup using a screwdriver and remove bolts

with a tightening torque
of 10,5 Nm.
Remove fan with brake shield.
41062844.eps 41062944.eps
3 3 1
1 Guide for brake release stirrup.

2 Splines to assist in assembly.
3 Ensure that fan clips are correctly seated in 1 Brake release stirrup. Fit brake shield.
bearing bush
41054844.eps 41054944.eps 41063044.eps
Tightening torque
Mot. KMF 80 = 10,5 Nm
Press fan cap onto brake release stirrup. Match marks on fan and fan cap!
41055144.eps 41067344.eps 41062244.eps

21428609.p65/090903
Measure the path of rotor displacement.

Motor KMF 80
Check rotor displacement
(approx. 1,5 – 2 mm displacement).
41062644.eps 41062144.eps
109
8.8 Gearbox
8.8.1 Main hoist gearbox (two, three Under normal operating conditions, the oil does not have to be changed until the
or four-stage planetary general overhaul is carried out.
gearbox) Under exceptional operating conditions, e.g. increased ambient temperatures, we
recommend that oil changes be adapted to suit these conditions.
Oil change
Remove the planetary gearbox. Thoroughly clean the gears and gearbox casing with
commercially available detergents. Then reassemble the gearbox. Before the gear-
box is closed, fill it with the new oil. The oil grades and quantities can be seen from
the following table.
Main hoist gearbox DH 300/400 DH 500/600 DH 1000 DH 2000

Oil quantity in litres 1,35 2 6 13
For ambient temperatures of approx. -15 °C to +60 °C use EP 220 synthetic gear oil,
e.g. Klüber, SYNTHESO D 220 EP or Esso UMLAUFOEL S 220.
Part no. 472 930 44 = 2,5 litres – part no. 472 931 44 = 1 litre
Vent screw Sealing surface

Tightening torques for
Code number Surface between motor and gear-
Sealing surfaces motor securing bolts
box sealed with Loctite 573.
DH 300 = 75 Nm
Part no. 033 068 44 DH 400 = 75 Nm
DH 500 = 115 Nm
DH 600 = 115 Nm
DH 1000 = 115 Nm
DH 2000 = 300 Nm
Tightening torques for

Tightening torque gearbox securing bolts
DH 300 = 36 Nm DH 300 = 37 Nm
DH 400 = 36 Nm DH 400 = 37 Nm
DH 500 = 70 Nm DH 500 = 25 Nm
DH 600 = 70 Nm DH 600 = 30 Nm
DH 1000 = 121 Nm DH 1000 = 75 Nm
DH 2000 = 295 Nm DH 2000 = 75 Nm
Fig. 51 40132444.eps 41109644.eps
DH 300 – DH 2000 gearbox casing of cast iron

After the oil has been changed, seal the surfaces between gearbox cover, internally
toothed wheel rim and gearbox casing with Loctite 573.
DH 300/400 gearbox casing of aluminium

After the oil has been changed, seal the surfaces between gearbox cover, internally
toothed wheel rim and gearbox casing with the activator Delo-Quick 5003 (part no.
662 007 44) and the adhesive Delo-ML 5328 (part no. 000 379 44). The contact
surfaces must be free of oils and greases in order to ensure good adhesion. Use
Delothen NK 1 (part no. 000 528 44) to clean the surfaces. Do not touch the bonding
surfaces when they have been cleaned.
DH 300 – DH 2000
When fitting the gearbox cover, ensure that the code number (gear ratio) on the
gearbox casing and the air vent screw are situated as shown in fig. 51.
214286010.p65/090903
110
DH 300 – DH 600 DH 1000, DH 2000 Grease chamber and roller bearing half-filled with
STABURAGS NBU 123 K, part no. 472 933 44, (100 g tube).
Range Grease quantity

DH 300/400 70 gr.
DH 500/600 70 gr.
DH 1000 140 gr.
DH 2000 210 gr.
41114144.eps 41116044.eps
Gearbox tightening torque
2-stage 3-stage 4-stage

1 2 1 2 3 1 2 3 4
40777244.eps 40777344.eps 40777444.eps
Gearbox
2-stage 3-stage 4-stage
Range
Tightening torques of bolts in Nm
1 2 1 2 3 1 2 3 4
DH 300/400 36 15 36 15 15
DH 500/600 70 36 70 36 15
DH 1000 121 70 121 70 36
DH 2000 - - 295 120 70 295 120 70 36
21428610.p65/090903
111
8.8.2 FG 06, 08 and 10 mechanical Oil lubrication
microspeed units, AMK 10, Under normal operating conditions, the oil should be changed after 10,000 hours of
AMK 20, AUK 30, AUK 40, service. Under exceptional conditions, e.g. increased ambient temperatures, we
AUK 50 travel drives recommend that oil changes be adapted to suit these conditions.
Oil change
Drain the old oil at operating temperature. To do this, first remove the air vent screw
at the top of the gearbox and then the plug at the bottom, and the oil will run out. For
the first oil change we recommend that the gearbox be flushed with oil of the same
type as that used before for lubrication.
The flushing oil should have a viscosity of 46-68 mm²/s at 40 °C. The quantity of
flushing oil should be approx. twice that specified for lubrication. Switch the motor on
and allow the gears to run without load for several minutes before draining the flush-
ing oil. Repeat this operation several times, also in alternate directions of rotation, to
ensure that all remains of the old lubricant are drained together with the flushing oil.
The quantity of oil required is indicated on the gearbox data plate.
Oil grades
For ambient temperatures of approx. -10° C to +50° C, a gear oil of 220 mm²/s at
40° C with mild high-pressure additives should be used, e.g. BP ENERGOL
GR-XP 220, Esso Spartan EP 220, SHELL Omala oil 220, Mobilgear 630 or Aral
Degol BG 220. At higher or lower ambient temperatures, the type of oil used should
be adapted to the specific conditions.
Fit the air vent screw at the highest possible position on the gearbox
Travel drive for EU/EKDH monorail Travel drive for EZDH/EZLDH double- Mechanical microspeed unit for DH hoist
carriage rail carriage
Oil quantity
Basic model
in litres
FG 06 = 1
U0 FG 08 = 2
FG 10 = 5
FG 06 = 0,6
U1 FG 08 = 1,5
FG 10 = 4
Oil Oil FG 06 = 1
AMK 10 = 0,35 l AMK 10 = 0,35 l
AMK 20 = 0,50 l U2 FG 08 = 2
AMK 20 = 0,50 l
AUK 30 = 0,90 l AUK 30 = 0,90 l FG 10 = 5
AUK 40 = 1,50 l
AUK 50 = 2,20 l FG 06 = 0,6
U3 FG 08 = 1,5
FG 10 = 4
401329U0-U3.eps
41124044.eps 41124144.eps
8.8.3 Output stage, standard and low-headroom monorail hoists

On monorail hoist trolleys, one pair of opposing travel wheels is driven. The output
stage is covered by a split plastic casing filled with grease, which is held together by
means of a securing strap. Be careful not to tighten this strap excessively during
assembly.
Trolley size 6 10
Grease quantity in g 180 210

214286010.p65/090903
Part no. 472 915 44 400 g
40110844.eps
112
8.8.4 EKDH 300/400 2/1 and 4/2 The travel drive teeth under the cover are lubricated with grease (approx. 100 g
Travel drive/trolley size 5 Renolit S2). Part no. 460 000 44 (400 g).
The same grease must be regularly applied to the toothed travel wheel.
This lubrication is sufficient for approx. 2 years under normal operating conditions.
8.8.5 EUDH 300/400 2/1 and 4/2 The gearbox is lubricated with grease (approx. 60 g).
Travel drive/trolley size 5 Under normal conditions this grease suffices for approx. 2 years after which the
gears need relubricating. The geared travel wheels must be lubricated regularly
with the same grease.
Part no. 011 058 44, 60 gr.
8.9 Antifriction bearings Antifriction bearings which do not form an integral part of gearboxes and rope
sheaves, i.e. motor bearings, motor-end drum bearings and travel wheel bearings,
are provided with a quantity of grease sufficient under normal service conditions.
The grease should be changed when carrying out the general overhaul unless special
circumstances require an earlier change.
To do this, the bearings must be disassembled and thoroughly cleaned with a com-
mercially available detergent; then refill approx. 2/3 of the space inside the bearing
with fresh antifriction bearing grease.
8.9.1 Motor bearings Demag brake motors normally have 2 cylindrical roller bearings and 1 ball thrust
bearing. The rollers run directly on the hardened shaft. The grease in the bearings
should generally be replaced every 4 years unless exceptional operating conditions
require an earlier change.
To do this, the bearings must be disassembled and thoroughly cleaned with a com-
mercially available detergent; then refill approx. 2/3 of the space inside the bearing
with fresh antifriction bearing grease.
8.10 Load-bearing bolted All load-bearing screws and bolts are hardened and tempered and are secured by
means of split pins or lock washers.
connections These bolts and screws should be checked for a tight fit at the intervals indicated in
the maintenance schedule and retightened if necessary. Replacement screws and
bolts must be of the same quality and secured in the same way (with lock washers
or split pins).
8.11 Control pendants Maintenance tasks to be carried out are the checks indicated in the maintenance
schedule. Any dirt accumulating on switch casings over long periods of use can be
removed using a household liquid detergent.
21428610.p65/090903
113
9 Measures for achieving safe working periods
The safety and health provisions of EC directive 98/37/EC make it a legal

requirement to eliminate special hazards which may be caused by, for example,
fatigue and ageing.
This requirement is also reflected in the 3rd supplement to German accident preven-
tion regulations BGV D8 (VBG 8) of 1.4.1996. This requirement obliges the owner of
serial hoist units to determine the actual duration of service of the hoist unit on the
basis of the operating hours, load spectra and/or recording factors. This is based on
FEM 9.755/06.1993 “Measures for achieving safe working periods for powered serial
hoist units (S.W.P.)”.
The objective of this rule is to determine measures for achieving safe working periods
(S.W.P.) over the entire duration of service, although, according to the state-of-the-
art, hoist units are designed for specific periods of operation. Premature failure
cannot, however, be ruled out.
The following items have been taken from FEM rule 9.755 with reference to the
DH hoist unit:
1. The actual duration of service determined on the basis of operating time and load
must be documented at least once per year.
2. The operating time Ti (number of operating hours) can be estimated or read on the
hook travel counter of the DGS geared limit switch (see section 6.1).
3. The load kmi (load spectrum factor) must be estimated.
4. The value determined for operating time Ti using a hook travel counter must be
multiplied by the type of recording factor f = 1,1.
5. The actual duration of service S is calculated as: S = kmi x Ti x f
6. A general overhaul must be carried out when the theoretical duration of service is
reached.
7. All checks and inspections and the general overhaul must be arranged by the
owner of the hoist unit.
8. The measures listed under items 1 – 5 are not required if the duration of service is
determined using a load spectrum recorder (optional). The general overhaul does
not have to be carried out until the theoretical duration of service has been
reached.
A general overhaul is defined as:
An inspection of the machinery with the purpose of finding all defective components
and/or components and parts close to failure and the replacement of all such com-
ponents and parts. Following a general overhaul, the machinery is in a condition
similar to that of the same machinery in new condition as far as the principle of
operation and performance values are concerned.
For DH hoists classified according to FEM 9.511, the following theoretical durations
of service D [h] apply (converted into full load hours):
Table 16
1Bm 1Am 2m 3m 4m
(h) 400 800 1600 3200 6300
The actual duration of service is considerably increased if the hoist unit is only oper-
ated with partial load. For a hoist unit operated on average with half load, for exam-
ple, this results in an 8-fold increase in the actual duration of service.
9.1 Calculating the actual The S.W.P. for the DH hoist unit can be calculated based on the following method:
duration of service S S = kmi x Ti x f
kmi : Load spectrum factor
21428611.p65/090903
Ti : Number of operating hours

f : Factor depending on the type of recording
114
9.1.1 Estimating the load spectrum To simplify estimation, each type of load can be grouped together into km load spec-
factor kmi (by the owner) trum modules. The types of load are simplified and quoted as 1/4, 1/2, 3/4 load and
full load.
Dead loads are added to the loads. Loads up to 20% of the rated load capacity are
not taken into consideration.
The operating time for each type of load is divided up within the inspection interval
(e.g. 1 year) in terms of percentage.
The following bar diagram shows the km load spectrum modules for the load condi-
tions from no load up to full load in time increments of 5 and 10%. Larger shares of
the time period must be correspondingly added together.
Load
0,0062
0,0125
0,0008
0,0016
0,021
0,042
0,05
0,10
km values
Full load
3/4-load Dead load
1/2-load
1/4-load Time
5 10 5 10 5 10 5 10 40
No load [%]
100
42651344.eps
The load spectrum factor kmi can be obtained by adding together the km individual
load spectrum modules.
9.1.2 Calculating the number of Every DH hoist has a hook travel counter fitted in the DGS geared limit switch as
hours of operation (operating standard (see fig. 52).
time) Ti by the owner The number of hours of operation (operating time) Ti can be calculated by applying
the H value read from the hook travel counter to the following equation.
Table 17
Factor Z for 1/1, 2/1, 4/1, 6/1, 8/1 reeving
Rope reeving DH DH DH DH
1/1 2/1 4/1 6/1 8/1 300/400 500/600 1000 2000

4
Hoist speed
1
Factor Z
3
[ m/min ]
2
8,0 4,0 2,0 1,3 1,0 1,15 1,37 1,97 2,48
10,0 5,0 2,5 1,6 1,2 0,92 1,1 1,58 1,98

0000000
11,2 5,6 2,8 1,9 1,4 0,82 0,98 1,41 1,77
3
12,5 6,3 3,1 2,0 1,5 0,74 0,88 1,26 1,58
4
2
1 14,2 7,1 3,6 2,4 1,8 0,65 0,77 1,11 1,39
16,0 8,0 4,0 2,6 2,0 0,57 0,68 0,98 1,24
18,0 9,0 4,5 3,0 2,3 0,51 0,61 0,87 1,1
20,0 10,0 5,0 3,3 2,5 0,46 0,55 0,79 0,99

Hook travel counter
22,4 11,2 5,6 3,7 2,8 0,41 0,49 0,7 0,88
Fig. 52 41209644.eps 25,0 12,5 6,3 4,1 3,1 0,37 0,44 0,63 0,79
28,0 14,0 7,0 4,6 3,5 0,33 0,39 0,56 0,7
32,0 16,0 8,0 5,3 4,0 0,28 0,34 0,49 0,62
36,0 18,0 9,0 6,0 4,5 0,25 0,3 0,43 0,55
Ti [h] = H · Z 50,0 25,0 12,5 - - 0,18 0,22 0,31 0,39

1000
21428611.p65/090903
The number of hours of operation (operating time) Ti takes into account all lifting and
lowering movements during an inspection interval.
Long and cross-travel times are not taken into consideration. 115
9.1.3 Factor depending on type of f = 1,1 for calculating the operating hours using an
recording f elapsed time indicator
By means of the number of operating hours Ti, the estimated load spectrum factor
kmi and the factor depending on the type of recording f, the S.W.P. can be calculated.
9.1.4 Example with hook travel DH525 H20 KV2 2/1 Group of mechanisms 1Am with 8 m/min hoist speed
counter In the calculated operating time, the specified hoist unit has transported the following
loads per inspection interval:
0,05
0,042
km values
5 % of time with full load 0,025
10% of time with ¾ load
0,0024
20% of time with ½ load
15% of time with ¼ load
50% of time without load
5 10 20 15 50 Time
100 [%]
Adding the load spectrum modules together results in the load spectrum factor
kmi = 0,119
On the hook travel counter for the period
from 23 March 1999 to 1 April 2000 the following H value was calculated:
0 000 001 0 393 366 => 393 365
factor Z to table 17 => 0,68
393365 x 0,68
Ti [h] = = 267,5 [h]
1000
Thus, the actual duration of service amounts to:
S = kmi x Ti x f = 0,119 x 267,5 x 1,1 = 35,0 (hours)
For classification in FEM group of mechanisms 1Am (see DH data plate) with a
theoretical duration of service of 800 hours (see table 18) the hoist has a theoretical
remaining duration of service of 765 hours.
Enter these values in your test and inspection booklet or crane installation test and
inspection booklet.
Table 18
Load factor Actual Remaining
Operating Theoretical duration of
Date Load [ % ] / km factor (sum of duration of duration of
hours service
km factors) service service
D [ h ] / group of
from to Ti value [ h] full 3/4 1/2 1/4 none kmi f S[h] D - S [h]
mechanisms
21428611.p65/090903
0000001 0393366 393365 5 10 20 15 50
3.1.-- 30.12.-- 267,5 0,05 0,042 0,025 0,0023 - 0,119 1,1 35 800 / 1Am 765
116
9.2 Example with FWL load Assessing the safe working period with the FWL load spectrum recorder
spectrum recorder For hoists fitted with a load spectrum recorder, the counter reading can be used
directly to estimate the remaining duration of service.
The theoretical duration of service expires when the counter reading reaches
1,440,000.
Example: DH525 H20 KV2 2/1 1Am
Counter reading: 140,355
Approximate calculation of duration of service S using a diagram
LSR counter reading

Remaining 180 360 540 720 900 1080 1260 1440 x 1000
duration
of service
in [%]
100
90
80
70
60
50
40
30
20
10
0
1Bm 0 50 100 150 200 250 300 350 400

1Am 0 100 200 300 400 500 600 700 800
2m 0 200 400 600 800 1000 1200 1400 1600
3m 0 400 800 1200 1600 2000 2400 2800 3200
4m 0 800 1600 2400 3200 4000 4800 5600 6300
Theoretical
Group of
duration
mecha-
Duration of service S of service
nisms
in [hours] D [hours]
41116444.eps
The actual duration of service S amounts to approx. 75 hours. With the same type of
service, a duration of service of approx. 90% remains.
Exact calculation of duration of service S
D x LK
The calculation shows: S=
1.440.000
800 x 140.355
S= = 77,9 h
1.440.000
D = Theoretical duration of service
21428611.p65/090903
LS = Load spectrum (counter reading)

S = Duration of service
Enter these values in your test and inspection booklet or crane installation test and
inspection booklet. 117
118
21428611.p65/090903
21428611.p65/090903
119
Printed in Germany DZE/130106/2T
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.

Operating Instructions: Demag DH 300, 400, 500, 600, 1000, 2000 Hoist Units

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Operating Instructions: Demag DH 300, 400, 500, 600, 1000, 2000 Hoist Units

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Operating instructions

Demag DH 300, 400, 500, 600, 1000, 2000 hoist units

090903 EN 214 286 44 720 IS 813

2 EZDH/EZLDH double-rail crabs DH 300-2000 203 346 44 714 IS 813

You have purchased a Demag product.

the sense of copyright law.

Assigned expert engineer (in the Federal Republic of Germany according to

Authorized expert engineer (according to BGV D6 § 28 (VBG 9))

Safety at work symbol

Warning against electrical hazards

Warning against suspended load

Operating hazard for the installation

Instructions for repair work in the course of operation

1 Electrical equipment cover 6 Rope guide 11 Main lifting motor brake

2.2 Explanation of size designation

Trolley travel in m/min

Flange width of the girder in mm

F 6 – creep lifting 1:6, DH (pole-changing)

F 10 – creep lifting 1:10, DH (microspeed unit)

Motor type: K = squirrel-cage

Hook path 12 m (for 2/1 reeving)

Rope pull on the drum 25 kN

Demag hoist unit type DH

U = Standard-headroom monorail hoist

E = Electric travel trolley

The load spectrum (in most cases estimated) can be

3 heavy up to 0,5 0,5-1 1-2 2-4 4-8

Small partial load 4 very heavy up to 0,25 0,25-0,5 0,5-1 1- 2 2-4

Group of mechanisms to FEM 1 Bm 1 Am 2m 3m 4m

1000 2000 4000 - - - - - - 310 410

3 Heavy 1600 3200 6300 - - - - 316 416 516 616

4000 8000 16000 25000 32000 DH 600 640 - 1040 - -

Operating time 5000 10000 20000 32000 40000 - - 1050 - - 2050

DH hoist unit with microspeed unit 2 x 4 x 20 x 8

2 1 Bm 3,6 25 2740 80 14,9 83 8,6 48 6,8 38 0,84 0,69

2 1 Bm 4,6 25 2870 80 22 124 12,5 71 10 57 0,74 0,67

2 1 Bm 7,1 25 2870 80 36 183 21 105 16,7 84 0,70 0,65

12 1 Am, 2 m 1,1 15 440 160 27 35 15,7 20 12,5 16 0,40 0,50

2 1 Bm 11,4 25 2870 80 43 248 25 143 19,8 114 0,88 0,61

12 1 Am, 2 m 1,7 15 460 160 28 55 16,2 31 12,9 25 0,36 0,53

2 1 Bm 17,8 25 2870 80 73 408 42 235 33 188 0,84 0,60

12 1 Am, 2 m 2,6 15 4 60 160 35 64 20 37 16 30 0,36 0,48

2 1 Bm 25 25 2920 80 93 595 53 342 43 274 0,84 0,50

12 1 Am, 2 m 3,7 15 470 160 41 84 24 48 19 39 0,37 0,50

112 B 2/12 25 20 20 2,5 16 1,5 29 1,5 46

125 B 2/12 50 25 25 4 18 1,5 20 1,5 32

140 B 2/12 6 14 2,5 2,5

2) Fuse links also apply in conjunction with a cross-travel motor.

100 B 4 35 20 20 2,5 18 1,5 32 1,5 50

112 B 4 50 25 25 4 18 1,5 23 1,5 36

125 B 4 63 35 35 6 16 2,5 32 1,5 20

200 B 6 - 125 100 - - 16 32 10 52

PN nN MN IN cos ϕ N IA / IN MA /MN MH Jmot A MB stat Weight

0,80 2765 2,80 2,30 0,79 3,60 2,40 6,2 450

PN nN MN IN cos ϕ N I A / IN MA /MN MH Jmot A MB stat Weight

PN nN MN IN cos ϕ N I A / IN MA /MN MH Jmot A MB stat Weight

230 V 400 V 500 V ϕ ϕ

Main hoist motor Microspeed motor

2.6 Setting hook dimension C

Operating limit switch for highest hook position

Operating limit switch for highest and lowest hook position

1/1 2/1 4/2 A 4/1 1/1 2/1 4/2 A 4/1

Creep lifting Creep lifting