Operating instructions

Demag DH 160, DH 200 hoist units

41152944.eps

0501 EN / PDF 180602 214 391 44 720 IS 813

 Manufacturer Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone (+ 2335) 92-0, Telefax (+ 2335) 92 7676
www.demagcranes.de

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/F4 creep hoist motor number

Main hoist/F6 creep hoist motor number

Main hoist motor number

Travel drive unit number

Operating voltage

Control voltage

Frequency

Wiring diagram number

Contactor control

Accompanying documents
Component parts list for Demag hoist unit DH 160 222 567 44 721 IS 813
DH 200 222 706 44 721 IS 813
Assembly instructions for DSE control pendant 214 214 44 720 IS 951
Technical data for DSE control pendant 203 119 44 714 IS 951
Assembly instructions for DST control pendant 206 166 44 720 IS 951
Component parts list for control pendant DST 222 143 44 721 IS 951
Demag crane inspection booklet 206 092 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 (206 649 44) 206 880 44 720 IS 819
Operating instructions for rope drum brake
21439101.p65/180602

Type FB (overspeed brake) 206 394 44 720 IS 823.1

Technical data
DH, UDH and KDH hoist units DH 160-2000 203 341 44 714 IS 813
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 Contents

0 Foreword 5
0.1 Copyright 5
0.2 After-sales service 5
0.3 Guarantee 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 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 Designation 14
2.2 Explanation of size designation 14
2.3 Selection criteria 15
2.4 Hoist motor data 16
2.5 EKDH/EUDH travel motor data 17
2.6 Hook dimension C 19
2.6.1 DH hoist units 19
2.6.2 UDH standard-headroom monorail hoist, 2/1 and 4/1 reeving 19
2.6.3 KDH low-headroom monorail hoist, 2/1, 4/1 and 4/2 reeving 20
2.7 Mounting flange positions and rope lead-offs 21
2.8 Indication of the position of the terminal boxes for the main hoist motor 22
3 General 23
3.1 Inspection regulations 23
3.2 Hoist units operating outdoors 23
3.3 Packing and storage 23
3.4 Paint finish 23
3.5 Operating conditions 23
3.6 Sound pressure level measurement according to DIN 45635 24
4 Description 25
4.1 Design 25
4.2 Motor 25
4.3 Gearbox/rope reeving components 25
4.4 Arrangement of the major assemblies 26
4.5 Geared limit switches 26
4.6 Control pendant 26
4.7 Models 26
4.8 Load detectors for Demag DH hoist units 26
4.9 Runways 27
4.10 Trolleys 27
5 Assembly 28
5.1 Electrical equipment 28
5.2 Connection to the electrical supply 28
5.3 Checking the direction of movement 29
5.4 Control 29
5.5 DSE, DST control pendants 29
5.6 Assembly instructions for DSE control pendant 30
5.7 Assembly instructions for DST control pendant 32
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5.8 Fitting the wire rope 34

5.8.1 Construction, application and reeving of wire ropes 34
5.8.2 Rope reeving methods for the Demag DH hoist unit 36
5.8.3 MGS/MKA and ZMS/FAW-1 load detectors 38
5.8.4 Lubrication 39
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 5.8.5 Fitting the rope socket 39
5.8.6 Fitting the rope guide with bolted connection 40
5.9 Assembly and adjustment of EKDH low-headroom monorail trolley
Trolley size 3,2 EKDH 168 – 165
Trolley size 5 – EKDH 212 – 208
4/1 reeving 42
5.9.1 Assembly of the trolley – trolley size 3,2 – 5 43
5.9.2 Assembly/disassembly of the return sheave, 4/1 reeving 44
5.9.3 Assembly/disassembly of the travel drive 45
5.10 Assembly and adjustment of EKDH low-headroom monorail trolley
Trolley size 3,2 EKDH 168 – 165 – EKDH 212 – 208
2/1 reeving 46
5.10.1 Assembly/disassembly of the rope retaining crosshead, 2/1 reeving 47
5.11 Assembly and adjustment of EKDH low-headroom monorail trolley
Trolley size 3,2 – EKDH 168 – 165 ( H19 ) – EKDH 212 – 208 ( H16 )
4/2 reeving 48
5.11.1 Assembly/disassembly of the compensating sheave, 4/2 reeving 49
5.12 Assembly and adjustment of EUDH standard-headroom monorail trolley
Trolley size 3,2 – EUDH 168 – 165, 2/1 and 4/1 reeving
Trolley size 3,2 – EUDH 212 – 208, 2/1 reeving 50
5.13 Assembly and adjustment of EUDH standard-headroom monorail trolley
Trolley size 5 – EUDH 212 – 208, 4/1 reeving 56
6 Putting the Demag DH hoist unit into service 60
6.1 DGS 3 and DGS 4 geared limit switches 60
6.1.1 Determining the cut-out point for the geared limit switch 60
6.2 Setting instructions for DGS 3 and DGS 4 geared limit switches 61
6.2.1 S1 emergency limit switch for top hook position 62
6.2.2 S2 main lifting motion limit switch 62
6.2.3 S3 emergency limit switch for bottom hook position 63
6.2.4 S4 operating limit switch for bottom hook position 63
6.3 Inspection when putting the hoist into operation 64
6.4 Safety instructions 64
6.5 Starting operation 64
6.6 KMH 90 –112 motors 64
7 Taking the Demag hoist unit out of service 65
7.1 Emergency-stop button 65
7.2 Taking the hoist out of service at the end of the shift 65
7.3 Taking the hoist out of service for maintenance purposes 65
8 Inspections/maintenance/general overhaul GO 66
8.1 Inspection before starting work and during operation 66
8.2 Inspection and maintenance schedule 66
8.3 General overhaul GO 66
8.4 Wire rope 68
8.5 KMH 90–112 hoist motor brake, KMF 80 travel motor 70
8.5.1 Adjusting the brake with shims 70
8.5.2 Replacing the brake cup 71
8.5.3 Replacing the fan 73
8.6 ZBF 71 – 80 travel motor brake 75
8.6.1 B003, B004, B020 brakes 75
8.6.2 Checking and adjusting the brake air gap s1 76
8.6.3 Replacing the brake disc 78
8.7 Travel motor brake 13/6 PKF 81
8.7.1 Adjusting the brake with shims 81
8.7.2 Fitting new brake lining to travel motor 81
8.7.3 Gluing on brake linings 82
8.8 Gearbox 82
8.8.1 EKDH travel drive/trolley 83
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8.8.2 EUDH travel drive/trolley 83

8.9 Antifriction bearings 83
8.9.1 Motor bearings 83
8.10 Load-bearing bolted connections 83
8.11 Control pendants 83
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 9 Measures for achieving safe working periods 84
9.1 Calculating the actual duration of service S 84
9.1.1 Estimating the load spectrum factor kmi (by the owner) 85
9.1.2 Calculating the number of hours of operation
(operating time) Ti (by the owner) 85
9.1.3 Factor depending on type of recording f 85
9.1.4 Example with hook travel counter 86
9.2 Example with FWL load spectrum recorder 87

0 Foreword

You have purchased a Demag product. This hoist unit was manufactured in accord-
ance with German and European standards and regulations, e.g. EC Machinery
Directive 98/37/EC, and state-of-the-art engineering principles.
Demag electric hoist units are of modular design.
The main assemblies include:
• the gearbox
• the hoist motor
• the integrated electrics
• the rope reeving components
• 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 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.

0.2 After-sales service Our after-sales service will provide you with all technical information on Demag
products 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.
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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.
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 0.3 Guarantee 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.
Guarantee claims must be made by quoting the order number immediately on
detecting the defect.
The guarantee is cancelled, for example, in the event of:
• inappropriate use,
• faulty devices or equipment connected or attached to the hoist unit which are not
part of our scope of supplies and services,
• incorrect or inappropriate application of the cables and wiring which are not part
of our scope of supplies and services,
• incorrect or inappropriate connection of the cables and wiring 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 the guarantee.

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.
Therefore, no claims can be derived from the information, illustrations and descrip-
tions contained in these operating instructions.
We assume no liability for damage and malfunctions caused as a result of operating
errors, noncompliance with these operating instructions or inappropriate repairs.
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 used.
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 and exempt Demag from any liability for damages resulting therefrom.
With the exclusion of any further claims, Demag is liable for any faults or omissions on
our part within the scope of the warranty obligations entered into in the original con-
tract. Claims for damages are excluded, irrespective of the legal reason from which
such claims are derived.
Translations are done to the best of our knowledge. We are unable to accept liability
for translation errors, irrespective of whether the text is translated by us or on our
behalf. The original text is definitive alone.
The descriptions and illustrations contained in this documentation do not necessarily
correspond to the scope of delivery or any subsequent spare part delivery. The
drawings and illustrations are not to scale.
Only documentation belonging to the actual order is valid.
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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
special 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, protective
measures, relevant regulations, codes of practice, accident prevention regulations
and operating conditions and who have proven their qualifications.

Experienced technician
Experienced technicians are defined as persons, who, owing to their technical training
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) 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 Association.

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 = 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.

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 industrial equipment designed to be used with a rated voltage of up to
690 V for alternating current.
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.
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 Serious personal injury or damage to property may occur 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.:
• Unsafe load handling (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 transport-
ing persons, is not permitted.
• Do not tamper with or manipulate electrical equipment.

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.
Any failure to comply with the safety instructions stated in these operating instruc-
tions can result in death or personal injury.
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 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/wear-
ing 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 instruct-
ed. 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 partic-
ular 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 em-
ploy 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 theoretical
training, instruction also includes sufficient practical operating experience as well
as acquiring the ability to identify defects which are a hazard to safe operation),
• who can be expected to carry out the work assigned to them reliably.
The owner must assign operating and maintenance personnel to their relevant task
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 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 regula-
tions.
• 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.

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
load detectors.
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 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 ventila-
tion 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, maintenance and inspection activities and inspection deadlines including
specifications concerning replacement of parts/assemblies prescribed in the operat-
ing 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.
• Ensure that 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.
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 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, mainte-
nance and repair work is to be carried out on parts of hoist units, these must – if
prescribed by regulations – be isolated. 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).
21439101.p65/180602

13
 2 Technical data

2.1 Designation

Electrical equipment cover Frame Rope drum Motor

Enclosure for electrical components
and geared limit switch

Return sheave with

MGS load detector

4/1 bottom block

41152944.eps

2.2 Explanation of size designation

EK DH 168 H12 K V1 4/1 F4 300 12,5
Trolley travel in m/min

Flange width of the girder in mm

F 4 – creep lifting 1:4, (pole-changing)

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

Single-groove drum

Four-fall reeving

Hoist speed code

Motor type: K = squirrel-cage

Hook path 12 m (for 2/1 reeving)

Rope pull on the drum 8 kN

Size 168

Range 160
21439102.p65/180602

Demag hoist unit type DH

U = Standard-headroom monorail hoist

K = Low-headroom monorail hoist

E = Electric travel carriage

14
 2.3 Selection criteria The size of the hoist is determined by the load spectrum, average operating time per
working day, SWL and reeving.
The load spectrum (in most cases estimated) can be evaluated in accordance with
the following definitions:
1. What are the operating conditions?
2. What is the specified SWL?
3. To what height must the load be lifted?
1 Light 4. What is the required lifting speed?
Hoist units which are usually subject to very small
loads and in exceptional cases only to maximum 5. Do the loads need to be lifted and lowered with high precision?
loads. 6. Is horizontal load travel required?
7. How is control to be effected?
Small partial load
Small dead load The group is determined from the operating time and load spectrum.
SWL

Operating time Load spectrum Average operating time per day in hours

1 Light 2-4 4-8 8-16

2 Medium
Þ
Hoist units which are usually subject to small loads
but rather often to maximum loads. 2 Medium 1-2 2-4 4-8

3 Heavy 0,5-1 1-2 2-4

Heavy partial load
Medium partial load
Medium dead load 4 Very heavy 0,25-0,5 0,5-1 1-2
SWL

Group of mechanisms to FEM 1Am 2m 3m

Operating time
Rope reeving arrangement Range Size
3 Heavy
Hoist units which are usually subject to medium 2/2 4/2
loads but frequently to maximum loads. 1/1 2/1 4/1

SWL in kg

Heavy partial load

500 1000 2000 165

630 1250 2500 166 -

SWL

Operating time
800 1600
Þ 3200 DH160 168 208 -
4 Very heavy
1000 2000 4000 - 210 -
Hoist units which are usually subject to maximum
or almost maximum loads.
1250 2500 5000 DH 200 212 - -
Very heavy dead load

Check the frequency of starts per hour when selecting motors for DH hoist units
(see page 16).
DH hoist unit with pole-changing motor
SWL

Operating time Main lifting speed = 80 starts/h

Creep lifting speed = 160 starts/h

Example (see line) Þ

SWL 1600 kg
Load spectrum “Light” from table
Lifting speed 7,1 m/min
Creep lifting speed 1,8 m/min
Rope reeving 2/1
Average hook path 4m
No. of cycles/hour 20
Working time/day 8 hours

The average operating time per working day is estimated or calculated as follows:
2 x av. hook path x no. of cycles/h x working time/day 2 x 4 x 20 x 8
21439102.p65/180602

Op. time/day = = = 3 hours

60 x lifting speed 60 x 7,1

For the light load spectrum and an average daily operating time of 3 hours the table
shows FEM group 1 Am. For an SWL of 1600 kg and 2/1 rope reeving, the table
indicates a hoist size DH 168.
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 F4 Required supply cable conductor cross sections and fuse links
Size No. Groups of P % CDF n Starts/h Rated current IN and starting current IA for 50 Hz cos cos
of mechanisms
poles to F E M 230 V 400 V 500 V jN jA
K MH kW rpm IN (A) IA (A) IN (A) IA (A) IN (A) IA (A)

2 1,7 40 2800 120 6,9 31 4 18,1 3,2 14,4 0,9 0,82

90 B 2/8
8 1 Am 0,42 20 640 240 4 7,8 2,3 4,5 1,8 3,6 0,6 0,75

2 2 m, 3 m 2,5 40 2720 120 10,7 45 6,2 26 4,9 21 0,86 0,79

100 B 2/8
8 0,62 20 620 240 5,3 10,7 3 6,2 2,4 4,9 0,65 0,72

2 4 25 2770 80 17,4 83 10 48 8 38 0,82 0,68

112 B 2/8 1 Am, 2 m
8 0,97 15 670 160 10,7 21 6,2 12,4 4,9 9,9 0,5 0,68

Size Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop D U and starting current I A for 50 Hz 2)
230 V 400 V 500 V 230 V (DU 11,5 V) 400 V (DU 20 V) 500 V (DU 25 V)

KMH A A A mm² m mm² m mm² m

90 B 2/8 16 10 10 1,5 20 1,5 60 1,5 119

100 B 2/8 16 16 10 2,5 26 1,5 47 1,5 75

112 B 2/8 35 20 16 2,5 16 1,5 30 1,5 47

Main/creep lifting F6
Size No. Groups of P % CDF n Starts/h Rated current IN and starting current IA for 50 Hz cos cos
of mechanisms
poles to FEM 230 V 400 V 500 V jN jA
KMH kW rpm IN (A) IA (A) IN (A) IA (A) IN (A) IA (A)

2 1 Am, 2 m, 4 25 2770 80 17,3 83 10 48 8 38 0,82 0,68

112 B 2/12
12 3m 0,57 15 370 160 9,3 14,7 5,3 8,5 4,3 6,8 0,47 0,57

Size Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop D U and starting current I A for 50 Hz 2)
230 V 400 V 500 V 230 V (DU 11,5 V) 400 V (DU 20 V) 500 V (DU 25 V)

KMH A A A mm² m mm² m mm² m

112 B 2/12 35 20 16 2,5 16 1,5 30 1,5 47

Main lifting
Size Groups of P % CDF n Starts/h Rated current IN and starting current IA for 50 Hz cos cos
mechanisms
to F E M 230 V 400 V 500 V jN jA
K MH kW rpm IN(A) IA (A) IN(A) IA (A) IN(A) IA (A)

100 B 2 1 Am, 2 m 3 40 2810 240 13,2 69 7,6 40 6,1 32 0,8 0,78

Size Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop D U and starting current I A for 50 Hz 2)
230 V 400 V 500 V 230 V (DU 11,5 V) 400 V (DU 20 V) 500 V (DU 25 V)

KMH A A A mm² m mm² m mm² m

100 B 2 35 20 20 2,5 15 1,5 28 1,5 48

21439102.p65/180602

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

2) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 m W.

16
 2.5 Travel motor data

EKDH travel motor (40 % CDF)

PN nN MN IN cos j N IA / I N MA /MN MH Jmot A MB stat Weight
Size 230 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
ZBF 71 A 4 B003 0,18 1350 1,25 1,00 0,69 3,20 2,70 2,8 0,00690 700 1,9 12,2
ZBF 80 A 4 B020 0,25 1320 1,80 1,60 0,73 2,70 2,60 4,0 0,01275 650 3,3 19,5

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

Size 400 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
ZBF 71 A 4 B003 0,18 1350 1,25 0,60 0,69 3,20 2,70 2,8 0,00690 700 1,9 12,2
ZBF 80 A 4 B020 0,25 1320 1,80 0,90 0,73 2,70 2,60 4,0 0,01275 650 3,3 19,5

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

Size 500 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
ZBF 71 A 4 B003 0,18 1350 1,25 0,48 0,69 3,20 2,70 2,8 0,00690 700 1,9 12,2
ZBF 80 A 4 B020 0,25 1320 1,80 0,72 0,73 2,70 2,60 4,0 0,01275 650 3,3 19,5

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

Size 230 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
0,09 650 1,30 1,40 0,65 1,50 1,95 2,4 620
ZBF 71 A 8/4 B003 0,00690 1,9 12,2
0,18 1370 1,25 1,25 0,63 2,65 2,20 2,5 400

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

Size 400 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
0,09 650 1,30 0,80 0,65 1,50 1,95 2,4 620
ZBF 71 A 8/4 B003 0,00690 1,9 12,2
0,18 1370 1,25 0,72 0,63 2,65 2,20 2,5 400

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

Size 500 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
0,09 650 1,30 0,64 0,65 1,50 1,95 2,4 620
ZBF 71 A 8/4 B003 0,00690 1,9 12,2
0,18 1370 1,25 0,58 0,63 2,65 2,20 2,5 400

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

Size 230 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
0,09 675 1,25 1,3 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 1,7 0,73 3,50 2,60 2,5 500
0,13 630 1,95 2,1 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 2,4 0,73 4,50 2,60 4,0 500

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

Size 400 V
21439102.p65/180602

kW rpm Nm A Nm kgm2 h-1 Nm Kg

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 17
 EKDH travel motor (40 % CDF)
PN nN MN IN cos j N IA / IN MA /MN MH Jmot A MB stat Weight
Size 500 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
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

EKDH 200 travel motor for trolley size 5, 4/1 reeving (15/40 % CDF)
PN nN MN IN cos j N IA / IN MA /MN MH Jmot A MB stat Weight
Size 230 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
0,06 415 1,40 2,60 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

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

Size 400 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
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

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

Size 500 V
kW rpm Nm A Nm kgm2 h-1 Nm Kg
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 160 travel motor for trolley size 3,2, 2/1, 4/2 and 4/1 reeving
EUDH 200 travel motor for trolley size 3,2, 2/1 and 4/2 reeving
Size No. of P % CDF n Rated current IN and starting current IA for 50 Hz cos cos
poles
230 V 400V 500 V jN jA
kW rpm I N (A) I A (A) I N (A) I A (A) I N (A) I A (A)

13/6 PKF 2 2 0,3 40 2840 1,5 8,8 0,85 5 0,68 4 0,78 0,8

13/6 PKF 4 4 0,2 40 1320 1,1 3 0,62 1,7 0,49 1,4 0,86 0,88

13/6 PKF 8 8 0,1 40 710 1,6 3,7 0,95 2,1 0,68 1,5 0,50 0,72

8 0,07 40 680 1,3 2,6 0,74 1,5 0,53 1,1 0,57 0,86
13/6 PKF 8/2
2 0,27 40 2900 1,8 8,6 1,1 5,0 0,76 3,6 0,71 0,86

12 0,05 20 450 2,2 2,8 1,3 1,6 0,91 1,2 0,66 0,82
13/6 PKF 12/4
4 0,17 40 1440 1,8 6,2 1,1 3,6 0,76 2,8 0,55 0,86

EUDH 200 travel motor for trolley size 5, 4/1 reeving

Size P % CDF n Rated current IN and starting current IA for 50 Hz cos cos

230 V 400 V 500 V j j

N A
kW rpm I N (A) I A (A) I N (A) I A (A) I N (A) I A (A)
K M F 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 sections of the conductors of cables exceeding the
length indicated in the table:
21439102.p65/180602

KMH 110 B 2/8, 230 V required length 40 m

Known cross section ⋅ required length 2,5⋅ 40

= = 4 mm²
Known length of cable 26
18
 2.6 Hook dimension C 2.6.1 DH 160/DH 200 hoist unit
Size Hook dimension C with and without overload cut-out

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

with without with without with without with without

Microspeed unit

DH 168-165 350 390 320 340

450 490 370 410
DH 212-208 420 460 410 430

When an operating limit switch is fitted for the highest hook position, the hook
dimension C is increased for 1/1, 2/1 and 4/1 rope reevings as follows:
C

Table 1
1/1 2/1 4/1
85 mm 50 mm 20 mm
41200944.eps

The useful hook path is reduced by the values given in tables 2/3.

Operating limit switch for the highest hook position

Table 2
1/1 2/1 4/1
-85 mm -50 mm -20 mm

Operating limit switch for the highest and lowest hook position
Table 3
1/1 2/1 4/1
-170 mm -100 mm -40 mm

2.6.2 UDH standard-headroom Hook dimension C from girder running surface

monorail hoist
Size Hook dimension C with and without overload cut-out

2/1 4/1

with microspeed unit w/o microspeed unit with microspeed unit w/o microspeed unit

DH 168-165 815 835

945 985
DH 212-208 940 960

Hook dimension C with and without overload cut-out

Size 4/2

with microspeed unit w/o microspeed unit

DH 168-165 H 19
C

865 905
DH 212-208 H 16
21439102.p65/180602

41648044.eps
19
 2.6.3 KDH standard-headroom
monorail hoist KDH 160/200

C
41200844.eps

Hook dimension C from girder running surface, trolley size 3,2

KDH 160 low-headroom monorail hoist, 2/1 reeving

Flange width b 82-105 106-110 120-140 150 160-180 200 220 240 260 280 300 400

Size microspeed unit Hook dimension C with and without overload cut-out

without 530 525 520 515 510 520 590

DH 168-165
with 470 485 480 475 470 480 550

KDH 160 low-headroom monorail hoist, 4/2 reeving

Flange width b 82 - 200 220 240 260 280 300 400

Size microspeed unit Hook dimension C with and without overload cut-out

without 430 445 460 480 505 530 660

DH 168-165 H 19
with 390 405 420 440 465 490 620

KDH 160 low-headroom monorail hoist, 4/1 reeving

Flange width b 82-105 106-110 120-140 150 160-180 200 220 240 260 280 300 400
microspeed
Size Hook dimension C with and without overload cut-out
unit
without 360 370 380 390 400 510
DH 168-165
with 340 350 360 370 380 490

Hook dimension C from girder running surface, trolley size 3,2

KDH 200 low-headroom monorail hoist, 2/1 reeving

Flange width 82-105 106-110 120-140 150 160-180 200 220 240 260 280 300 400

Size microspeed unit Hook dimension C with and without overload cut-out

without 535 520 530 550 560 580 650

DH 212-208
with 495 480 490 510 520 540 610

KDH 200 low-headroom monorail hoist, 4/2 reeving

Flange width 82-200 220 240 260 280 300 400

Size microspeed unit Hook dimension C with and without overload cut-out

without 430 445 460 480 505 530 660

DH 212-208 H 16
with 390 405 420 440 465 490 620

Hook dimension C from girder running surface, trolley size 5

KDH 200 low-headroom monorail hoist, 4/1 reeving
21439102.p65/180602

Flange width 105-300 400

Size microspeed unit Hook dimension C with and without overload cut-out

without 420 510

DH 212-208
with 400 490
20
 2.7 Mounting flange positions and rope lead-offs

Mounting flange position A Mounting flange position C

Code number Code number

3 1
3
Pay attention to DH 160
1 1
3 and DH 200 mounting
positions.

2
Terminal box
Main hoist motor 2

2
2
2

2
3

1 1 3
1 3
41148344.eps 41148544.eps

Mounting flange position Mounting flange position D

Code number Code number

2
2

1
2

1
3
3

3
3
1

1
1

2
Looking at main hoist motor end face 2

2 41148644.eps
Fig. 1 41148444.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

Range Rope lead-off Special design
Rope lead-off
1 2 3
a1 b1 a2 b2 a3 b3

DH 160/DH 200 20° 28° 20° 18° 20° 12°

Demag hoist unit without rope guide

Range Rope lead-off

1 2 3
a1 b1 a2 b2 a3 b3
21439102.p65/180602

DH 160/DH 200 20° 50° 25° 15° 60° 10°

21
 2.8 Indication of the The position is indicated by the code numbers 0-1-2-3, ascending in anticlockwise
direction when looking at the motor end face.
position of the terminal
The required position must be indicated in accordance with the selected mounting
boxes for the main flange position A, B, C or D.
hoist motor
Standard
Mounting flange
Terminal box location
position
0 H1 A

H0 B

H3 C

H2 D
1 3

40134144.eps

21439102.p65/180602

22
 3 General

3.1 Inspection regulations Notes on inspections in accordance with

Relevant accident prevention regulations for winches,
hoists and towing devices (BGV D8, up until now VBG 8)
Relevant accident prevention regulations for cranes (BGV D6, up until now VBG 9)
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 winch-
es, 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 condition and
that any defects and damage, e.g. caused by inappropriate 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 hoist 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.
The owner must arrange for all inspections to be carried out.

3.2 Hoist units 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
operating considerable length of time.
outdoors

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%
21439102.p65/180602

• air pressure up to 1000 m above sea level

Other operating conditions are also possible.
Please refer to the manufacturer for information on any modifications that may be
necessary. See page 2 for the address. 23
 3.6 Sound pressure level The sound pressure level of a hoist unit can be seen in the following table.
measurement accord-
ing to DIN 45635

L pA
[ dB(A) ]

80

75 Motor speed n = 2800 rpm

Logarithmic Regression
Logarithmische regression
: :

m
__
L = 42,31 + 10,92 log
pA kg [dB(A)]

Correlation coefficient r = 0,7

Tolerance
Toleranz = = ± 2 dB (A)

Mass
70 m
Massse
1 1,25 1,6 2 2,5 3 4 5 [ 1000 kg ]
in 2/1
DH 160 165 166 168 - -
DH 200 - - 208 210 212

41146444.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
21439102.p65/180602

Sound pressure level reduction in

1m
relation to the distance from the sound
2m source

4m

24 41120044.eps
 4 Description

4.1 Design

Electrical equipment cover

Enclosure for electrical Frame Rope drum Motor
components and geared limit
switch

Return sheave
with MGS load detector

4/1 bottom block

41152944.eps

The Demag DH160/DH 200 hoist unit is manufactured in three sizes according to the
FEM groups.

4.2 Motor The hoist motor is the proven sliding rotor brake motor with a newly developed rotor
shaft connection, torsionally resistant, axially free, fail-safe coupling and conical brake
with asbestos-free brake lining (type of enclosure IP 55). It is designed in accordance
with British standards, the DIN VDE regulations and the design rules of the FEM, to
meet the high demands made on electric hoists.
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 can be 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 1/4 or 1/6 of the main lifting speed can be obtained by using
the 2/8 and 2/12-pole motor.

4.3 Gearbox/rope reeving The torque of the motor is transmitted to the planetary gearbox directly by the splined
motor shaft.
components
The 3-stage planetary gearbox inside the drum houses all gear stages. The drum,
21439102.p65/180602

rope sheaves and rope comply with the FEM design rules.

25
 4.4 Arrangement of the The 2 mounting flanges are connected by 3 longitudinal beams to form a frame.
major assemblies The drum with planetary gearbox inside it is located in the centre of the frame.
The motor is 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 pendant Mechanical interlocking of the switching elements prevents movement in opposite
directions being switched on simultaneously. The shock and impact-resistant housing
of high quality thermoplastic of the DSK and DSE and the glass fibre reinforced
DST housing are resistant to fuels, salt water, fats, oils and alcaline solutions.
Type of enclosure IP 55 (65) for DSK and 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

4.8 Load detectors for The electronic Dematik ZMS/FGB FAW-1 (optional) or the mechanical MGS/MKA
load detectors (standard) are used to protect hoist units and supporting structures
Demag DH hoist units 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.
21439102.p65/180602

26
 4.9 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.

Grey running surfaces with prime coat only.

Fig. 2 41651944.eps

4.10 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 42 – 56.
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.
21439102.p65/180602

27
 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 VDE and acci-
dent 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.
Corroded 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 41422344.eps Fig. 5 41422444.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 protec-
tion, time relays ...), the control voltage must be measured when the equipment 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) and remove
cover.
If a mounting plate is fitted, the retaining springs at the upper edge of the electrical
enclosure must be pushed upwards (see fig. 4). The mounting plate can then be
swung downwards (see fig. 5).
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
prevent the conical rotor of the motor from sliding into running position when the
21439103.p65/180602

motor is switched on.

28
 The cross section can be calculated according to the example given in section 2.4,
if the supply line is longer than that indicated in section 2.5.
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
disconnect 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 Demag DSK multi-button pendant control switches are used to control the hoist unit.
Travelling hoist units are controlled using Demag DSE control pendants.
For direct control and in special cases, Demag DST control pendants are used.
Multi-button pendant switches for Demag hoist units fitted with a heavy duty and an
emergency limit switch will be fitted with a check button, if required. For replace-
ment of control pendants and their switching elements, refer to the instructions in
sections 5.6 and 5.7.
The multi-button 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 respective movement.

DSE DST
21439103.p65/1806020

40989546.eps 41233544.eps 29
 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

Fig. 8 42506344.eps

Fig. 7 41775244.eps

Connecting the strain relief

340 875 44
M6

504 419 44

Centring
web
Strip strain relief wire cords
in the clamping area

41775445eps

42337644.eps

1) To ensure strain relief of the control cable, the control cable must be approx. 100 mm longer than the
21439103.p65/180602

required strain relief cords.

For further information, see DSE control pendant assembly instructions, ident. no. 214 214 44

Fig. 6 40989544.eps
30
 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. 1) 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.
21439103.p65/1806020

Pay attention to the protruding emergency-stop button.

42324844.eps 42330744.eps 42325844.eps 42324944.eps 31
 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

21439103.p65/180602

32 Fig. 10 41116044.eps
 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. 206 166 44
21439103.p65/1806020

33
 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

Range Drum
single groove double groove
DH 160/DH 200 14 Nm 14 Nm

5.8.1 Construction, application and reeving of wire ropes

Range DH 160

Reeving 1/1 2/1 4/1 2/2-2 3) 4/2

Group of mechanisms to FEM 1 Am 1 Am 1 Am 1 Am 1 Am

Wire rope dia. mm 7 7,5 7,5 5,5 5,5

see fig. 1 2 2 3 4

Theoretical breaking force of rope approx. kN 49 49 49 29,6 24

Minimum breaking force kN 40 41 41 24 19,5

Tensile strength of individual wire N/mm² 1960 1960 1960 2260 1770

Rope length m FDH 168 - 165 H 12 29,1 29,5 30,3 - -

FDH 168 - 165 H 19 43,1 43,5 44,3 2 x 24,3 47,9

KDH 168 - 165 H 12 - 29,4 30,1 - -

KDH 168 - 165 H 19 - 43,4 44,1 2 x 24,2 47,7

Part no. 82246044 82148044 58109144 58109044

16 x 7 = 112 wires 8 x 19 = 152 wires 9 x 6 = 54 wires 6 x 19 = 114 wires

+ 1 steel core / RH + 1 steel core / LH + 1 steel core / zZ + 1 Fibre core / RH
21439103.p65/180602

Fig. 1 40126644.eps Fig. 2 40109544.eps Fig. 3 40133844.eps Fig. 4 40140944.eps

RH = right hand ordinary lay rope

LH = left hand ordinary lay rope
34 zZ = right hand Lang’s lay rope
 Range DH 200
Reeving 1/1 1/1 2/1 4/1 2/2-2 3) 4/2
Group of mechanisms to FEM 1 Bm 1 Am 1 Bm 1 Bm 1 Bm 1 Bm
Wire rope dia. mm 9 9 9 9 6,5 6,5
see fig. 1 3 2 2) 2 2) 1 2 1)
Theoretical breaking force of rope approx. kN 80,2 60,5 76,6 40,6 31,9
Minimum breaking force kN 62,5 47,2 63 31,2 25
Tensile strength of individual wire N/mm² 1960 1770 1960 1960 1770
H 10 23,3 23,3 23,9 25,3 - -
Rope length m DH 212 -208
H 16 35,2 35,2 35,8 37,2 2 x 22 46,2
Part no. 82147044 58448544 82149144 82146044 58344044

16 x 7 = 112 wires 8 x 19 = 152 wires 18 x 7 = 126 wires

+ 1 steel core / RH + 1 steel core / 1), 2) + 1 steel core / RH

Fig. 1 40126644.eps Fig. 2 40109544.eps Fig. 3 40139344.eps

1) RH = right hand ordinary lay rope

2) LH = left hand ordinary lay rope
3) For spreader operation, see 4/2 version.
21439103.p65/1806020

35
 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. 12, 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. 12. 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.
4/1 reeving
Due to the very compact design of the bottom block, a certain inclination of the rope
sheave axle occurs in unloaded condition. The resulting inclined running of the wire
rope is tolerable since in this loading condition the service life of the rope is not im-
paired.

FDH hoist unit and UDH standard-headroom monorail trolley, 2/1, 4/1 and 4/2 rope reeving

2/1 4/1 4/2

Tigthening torque = 6 Nm

Fig. 12 41150044.eps Fig. 13 41149944.eps Fig. 14 41149844.eps

21439103.p65/180602

36
 KDH low-headroom monorail trolley, 2/1, 4/1 and 4/2 rope reeving

2/1 4/1 4/2

Fig. 15 41153144.eps Fig. 16 41153244.eps Fig. 17 41161244.eps

21439103.p65/1806020

37
 5.8.3 MGS/MKA and ZMS/FAW-1
load detectors

2/1 reeving

41152644.eps

MGS/MKA load detectors

See description and instructions
206 689 44 for fitting MGS/MKA and
ZMS/FAW-1 load detectors adjusting the switching point.
See description and instructions
206 880 44 for fitting ZMS/FAW-1 and
adjusting the switching point.

When fitting the load detec-

tor, it must be ensured that
the double spring clip clicks
into place (see section 5.8.5).

41160944.eps 41160844.eps

4/1 reeving

MGS/MKA load detector

When fitting the load detector,

it must be ensured that the
retaining ring clicks into place
21439103.p65/180602

(see section 5.8.5).

41152944.eps
38
 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 atmos-
phere, we recommend additionally greasing the rope from the outside with e.g.
DG 67B (part no. 011 058 44) 850 g.
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. 011 057 44. (60 g).
Grease pivot bearings of the top block, crosshead, compensating sheave with Renolit
S2. Part no. 460 000 44 (400 g).

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).

Head pin
Double spring clip
Shims

Pin

40984344.eps
1 mm

40979244.eps Retaining plate

Retaining ring

Pin

Shims

Grease bearing points

21439103.p65/1806020

40984444.eps 40984544.eps

Fig. 18 39
 5.8.6 Fitting the rope guide with bolted connection

6 7 1 3 2

5
4

6 7 3 1
42031444.eps 41147544.eps
Before it is fitted to the drum, the rope guide must be
taken to pieces. Fit segment with rope guide rollers (1) with the rollers pointing
(1) Segment with rope guide rollers towards the wire rope on the drum.
(2) Segment Then fit segment (2) to the drum.
(3) Hexagon screw
(4) Hexagon nut with flange
(5) Side section
(6) Socket head screw
(7) Lock nut

2 3 3
4

3
1

4
3
1

41478244.eps
41478344.eps
Connect segments (1 + 2) with hexagon screw (3) and Slide the rope guide sideways until it rests in the empty
secure with hexagon nut (4). groove next to the rope on the drum so that the rope guide
rollers lie over the rope.
Now rotate the rope guide upwards.
Tightening torque 8 Nm Connect segments (1 + 2) with hexagon screw (3) and se-
cure with hexagon nut (4).
21439103.p65/180602

Tightening torque 8 Nm

It must be possible to move the fitted rope guide by hand on

the drum.
40
 7 1 5 6

41478444.eps 41111844.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. them with a screwdriver.
Rotate the rope guide downwards until the bore holes in The split pin can then be removed.
the segment with guide rollers (1) coincide with the bore
holes in section (5).
Insert the two socket head screws (6) and tighten to a

tightening torque of 8 Nm.

On single-fall hoist units the other rope end is secured to the hook fittings by means
Rope clamp
of a rope wedge and an additional clamp fitted to the dead end of the rope (fig. 19).
Tightening torque = 6 Nm
On 2 and 4-fall hoist units the rope end is secured as described in section 5.8.2.
Then switch on the hoist for lifting and raise the hook to its top position. During this
operation, the rope guide and the reeving of the rope should be watched. If twisting
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. 19 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.
21439103.p65/1806020

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.

41
 5.9 Assembly and adjustment of EKDH low-headroom monorail hoist trolleys
Trolley size 3,2 – EKDH 168 – 165
Trolley size 5 – EKDH 212 – 208
4/1 reeving

Assembly of rope retaining

crosshead for 4/1 reeving

Return sheave assembly

see section 5.9.2

Travel drive assembly

see section 5.9.3 41155244.eps

View
3

10 3
2
4

5
11

4 1

Fig. 20 41152544.eps

When assembling, all threaded pin connections must be rechecked. Threaded pin
connection (5) must be tightened with the specified torque of 200 Nm.

Further assembly/disassembly
See 5.9.1 for assembling the trolley
See 5.9.2 Assembly/disassembly of the return sheave, 4/1 reeving.
See 5.9.3 for assembling the travel drive.
21439104.p65/180602

42
 5.9.1 Assembly of the trolley
Trolley size 3,2 – 5

6
7 8

Drive split sleeve (6) into wheel legs (1+2). Fix wheel legs (1+2) to the sides of the Demag hoist Slide both connecting rods (4) into the holes of
unit frame. Fix with washer (7) and hexagon bolt (8). trolley wheel legs (1+2) until connecting rods (4)
Tightening torque = 86 Nm meet with resistance.
41154844.eps 41155044.eps 41154944.eps

4
5 b+1

Fix connecting rod (4) with threaded pin (5). Adjust trolley to existing flange width as follows:
Threaded pin must fit in groove of connecting rod Slide side cheek (3) onto connecting rod (4). Setting dimension between both opposing guide
(see fig.) Tightening torque = 200 Nm rollers is flange width b + 1mm.
41152844.eps 41151044.eps 41151244.eps

b+1

3 9
5

11
10

Setting dimension between the two guide rollers Fix side cheek (3) on connecting rod (4) with the Then place spacer tubes (9) onto connecting
Flange width b + 1mm threaded pins (5). rods (4) as required. Enough space must remain to
Tightening torque = 200 Nm fit washer (10) and retaining clip (11).
41210844.eps 41151144.eps 41155144.eps
21439104.p65/180602

43
 5.9.2 Assembly/disassembly of the
Assembly
return sheave, 4/1 reeving

Insert return sheave from below. Fit pin.

41151944.eps 41151544.eps

Fit pivot bearings to pin. Ensure correct fit of pivot bearings. Push return sheave into position in trolley side
Before fitting pivot bearings, grease pin with See fig. 20, page 42 for view for fitting pivot cheek. Move to end position.
Renolit S2. bearings.
41151744.eps 41162144.eps 41152344.eps

Disassembly

Lift pivot bearings using two screwdrivers.

41152344.eps 41152144.eps
21439104.p65/180602

Remove pivot bearings. Remove pin. Remove return sheave downwards.

41151744.eps 41151544.eps 41154644.eps
44
 5.9.3 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 Fit tension bolt (5) and washer (6) from above.

6 See illustration for further assembly.
(7) Washer
(8) Spring
7 (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:
8 To reach the contact pressure of drive wheel 2, tension
locknut (4) as follows:
4
4 Hoist unit Reeving Flange width
L

up to 150 up to 300 up to 400

DH 160 2/1 u. 4/2 Dim. L + 5 Dim. L + 8 Dim. L + 9
Dimension L + .. DH 200 2/1 u. 4/2 Dim. L + 8 Dim. L + 12 Dim. L + 13
DH 160 4/1 Dim. L + 10 Dim. L + 13 Dim. L + 14 Drive wheel 2
DH 200 4/1 Dim. L + 7 Dim. L + 9 Dim. L + 10
41153644.eps 41152444.eps

Disassembly 5
2 3

Remove tension bolt (5) with all parts. Remove plug (3) and retaining ring (2).
41155844.eps 41155744.eps

100
The travel drive pin can be removed as 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
21439104.p65/180602

2 Spanner SW17
See illustration for disassembly.

Washer
Grooved ball bearing Remove travel drive.
41153444.eps 41210744.eps 45
 5.10 Assembly and adjustment of EKDH low-headroom monorail trolley
Trolley size 3,2 – EKDH 168 – 165 – EKDH 212 – 208
2/1 reeving

Travel drive assembly

See section 5.9.3 Assembly of rope retaining crosshead
See section 5.10.1

View 3

1110 9
2
4

4 1

Fig. 21 41155544.eps

When assembling, all threaded pin connections must be rechecked. Threaded pin
connection (5) must be tightened with the specified torque of 200 Nm.

Further assembly/disassembly
See 5.9.1 for assembling the trolley
See 5.9.3 for assembling the travel drive.
See 5.10.1 for assembling the rope retaining crosshead
21439104.p65/180602

46
 5.10.1 Assembly/disassembly of the Assembly 13 washers
rope retaining crosshead, 7 washers
2/1 reeving

Insert rope retaining crosshead from below. Fit pin and washers.

41156144.eps 41156544.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. 21, page 46 for view for fitting pivot bear- side cheek, move to end position.
Renolit S2. ings
41156044.eps 41162244.eps 41156344.eps

Disassembly

Lift pivot bearings using two screwdrivers.

41156344.eps 411562044.eps
21439104.p65/180602

Remove pivot bearings. Remove pin and washers. Remove rope retaining crosshead downwards.

41156044.eps 41156544.eps 41156444.eps 47

 5.11 Assembly and adjustment of EKDH low headroom monorail trolley
Trolley size 3,2 – EKDH 168 – 165 (H19) – EKDH 212 – 208 (H16)
4/2 reeving

Travel drive assembly Assembly of compensating sheave

See section 5.9.3 See section 5.11.1

View

11
10 9
2
4

4 1

Fig. 22 41622244.eps

When assembling, all threaded pin connections must be rechecked. Threaded pin
connection (5) must be tightened with the specified torque of 200 Nm.

Further assembly/disassembly
See 5.9.1 for assembling the trolley.
See 5.9.3 for assembling the travel drive.
See 5.11.1 for assembling the compensating sheave.
21439104.p65/180602

48
 5.11.1 Assembly/disassembly of the Assembly
compensating sheave,
4/2 reeving

Fit pin.
Insert compensating sheave from below.
41152044.eps 41151644.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. 22, page 48 for view for fitting pivot side cheek.
Renolit S2. bearings.
41151844.eps 41162044.eps 41155344.eps

Disassembly

Lift pivot bearings using two screwdrivers.

41155344.eps 41152244.eps
21439104.p65/180602

Remove pivot bearings. Remove pin. Remove compensating sheave downwards.

41151844.eps 41151644.eps 41154744.eps 49
 5.12 Assembly and adjustment of EUDH standard-headroom monorail trolley
Trolley size 3,2 – EUDH 168 – 165, 2/1 and 4/1 reeving
Trolley size 3,2 – EUDH 212 – 208, 2/1 reeving

RUDH EUDH
Tightening torque 42 Nm

2 4 5 6

Tightening torque 160 Nm

1

2mm
Grease enclosure
3

The trolley crossbar (1) of the must

be held at this point with a
wrench. (SW 40).

Fig. 23 41268844.eps 41800044.eps

Assembling the trolley Insert trolley crossbar (1) into side cheek (2) (see fig. 23). Then adjust the trolley ac-
cording to the girder flange width of the track by arranging the distance washers as
specified under assembling trolleys (see pages 51 – 55).
The locknut (3) must be tightened to the specified tightening torque (see fig. 23).
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 DG 67B, part no. 011 058 44 – see fig. 23. 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.

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 can be screwed onto the trolley crossbar for pre-assembly without being
pre-tensioned.
For final assembly, only unscrew the locknut until the trolley can be placed on the
girder.
Then tighten the locknut with the specified tightening torque (see fig. 23).
21439104.p65/180602

50
 Adjustment of RU/EUDH trolleys, 2/1 reeving
Trolley A Trolley B

l
l

41299544.eps 41299644.eps

View for the position of

the distance washers
Trolleys A and B

41446044.eps

Flange width b mm 82 90 98 106 113 119 125 131 137 143

Max. flange
t mm 22 / without anti-tip pin 28 mm
thickness
Trolley
Trolley crossbar I mm A = 283 / B = 235
Position of distance washers (4 mm distance washers)
Required number of distance washers
inside - 1 2 2 3 4 5 5 6 7
Side cheek, left
outside 9 8 8 6 5 4 3 3 2 1
A
Side cheek, right inside 4 5 6 5 6 6 7 8 9 9

outside 8 7 6 5 4 4 3 2 1 1

inside 2 3 4 5 6 7 8 8 9 10
Side cheek, left
B outside 16 14 12 10 8 7 5 4 2 1

Side cheek, right inside 4 5 6 7 8 8 9 10 11 11

Trolley crossbar

Pins 839 553 44

A Tubes 839 575 44 839 550 44

Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 113 44

21439104.p65/180602

Trolley crossbar

Pins 839 077 44

B
Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 114 44 51

 Trolley A Trolley B

l
l

41299544.eps 41299644.eps

View for the position of

the distance washers
Trolleys A and B

41446044.eps

Adjustment of RU/EUDH trolleys, 2/1 reeving

Flange width b mm 144 149 155 163 170 178 185 200 201 210 220 240 260 280 300
Max. flange
t mm 22 / without anti-tip pin 28 mm
thickness
Trolley
Trolley crossbar I mm A = 340 / B = 292 A = 440 / B = 392
Position of distance washers (4 mm distance washers)
Required number of distance washers
inside 7 8 8 9 2 3 4 6 6 7 8 4 6 9 11
Side cheek, left
outside 8 7 7 6 5 4 3 1 14 12 11 9 6 4 1
A
Side cheek, right inside 9 10 11 12 5 6 6 8 8 10 11 6 9 11 14

outside 8 7 6 5 4 3 3 1 13 12 11 8 6 4 1

inside 10 11 11 12 13 14 15 17 17 18 19 22 24 25 29
Side cheek, left
B outside 15 13 12 10 8 6 4 1 25 23 21 16 11 6 1

Side cheek, right inside 11 12 13 14 15 16 17 18 19 20 21 23 26 30 31

Trolley crossbar

Pins 839 554 44 839 555 44

A Tubes 839 550 44 839 551 44 839 552 44

Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 113 44

Trolley crossbar

Pins 839 081 44 839 085 44

B
21439104.p65/180602

Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 114 44

52
 Adjustment of RU/EUDH 168 – 165 – H 12 trolleys, 4/1 reeving
Flange width b mm 82 90 98 106 113 119 125 131 137 143

Max. flange thickness t mm 22 / without anti-tip pin 28 mm

Trolley
Trolley crossbar I mm A = 283 / B = 235
Position of distance washers (4 mm distance washers)
Required number of distance washers
inside - 1 2 3 4 5 6 6 7 8
Side cheek, left
outside 9 8 7 6 5 4 3 3 2 1
A
Side cheek, right inside 1 2 3 4 5 5 6 7 8 8

outside 8 7 6 5 4 4 3 2 1 1

inside 4 4 5 6 7 8 9 9 10 11
Side cheek, left
B outside 16 14 12 10 8 7 5 4 2 1

Side cheek, right inside 3 4 5 6 7 7 8 9 10 10

Trolley crossbar

Pins 839 553 44

A Tubes 893 550 44

Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 113 44

Trolley crossbar

Pins 839 077 44

B
Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 114 44

Flange width b mm 144 149 155 163 170 178 185 200 201 210 220 240 260 280 300

Max. flange thickness t mm 22 / without anti-tip pin 28 mm

Trolley
Trolley crossbar I mm A = 340 / B = 292 A = 440 / B = 392
Position of distance washers (4 mm distance washers)
Required number of distance washers
inside - 1 1 2 3 4 5 7 - 1 2 5 7 10 12
Side cheek, left
outside 8 8 7 6 5 4 3 1 14 12 11 9 6 4 1
A
Side cheek, right inside - - 2 3 4 5 5 7 - 2 3 5 8 10 13

outside 8 7 6 5 4 3 3 1 13 12 11 8 6 3 1

inside 11 12 12 13 14 15 16 18 18 19 20 23 25 28 30
Side cheek, left
B outside 15 13 12 10 8 6 4 1 25 23 21 16 11 6 1

Side cheek, right inside 10 11 12 13 14 15 16 17 18 19 20 22 25 27 30

Trolley crossbar

Pins 839 554 44 839 555 44

A Tubes 839 551 44 839 552 44

Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 113 44

Trolley crossbar

Pins 839 081 44 839 085 44

B
Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 114 44

21439104.p65/180602

53
 Adjustment of RU/EUDH 168 – 165 – H 19 trolleys, 4/1 reeving

Trolley A Trolley B

l
l

41299544.eps 41299644.eps

View for the position of

the distance washers
Trolleys A and B

41446044.eps

Flange width b mm 82 90 98 106 113 119 125 131 137 143

Max. flange thickness t mm 22 / without anti-tip pin 28 mm

Trolley
Trolley crossbar I mm A = 283 / B = 235
Position of distance washers (4 mm distance washers)
Required number of distance washers
inside 1 3 5 7 8 9 10 10 11 12
Side cheek, left
outside 9 8 7 6 5 4 3 3 2 1
A
Side cheek, right inside - - - - 1 1 2 3 4 4

outside 8 7 6 5 4 4 3 2 1 1

inside 4 6 8 10 11 12 13 13 14 15
Side cheek, left
B outside 16 14 12 10 8 7 5 4 2 1

Side cheek, right inside 2 2 2 2 3 3 4 5 6 6

Trolley crossbar

Pins 839 553 44

A Tubes 893 550 44

Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 113 44

Trolley crossbar

Pins 839 077 44

B
Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 114 44

21439104.p65/180602

54
 Flange width b mm 144 149 155 163 170 178 185 200 201 210 220 240 260 280 300

Max. flange thickness t mm 22 / without anti-tip pin 28 mm

Trolley
Trolley crossbar I mm A = 340 / B = 292 A = 440 / B = 392
Position of distance washers (4 mm distance washers)
Required number of distance washers
inside - 1 3 5 7 8 9 11 - 3 5 9 11 14 16
Side cheek, left
outside 8 8 7 6 5 4 3 1 14 12 11 9 6 4 1
A
Side cheek, right inside - - - - - 1 1 3 - - - 1 4 6 9

outside 8 7 6 5 4 3 3 1 13 12 11 8 6 3 1

inside 11 12 14 16 18 19 20 22 18 21 23 27 29 32 34
Side cheek, left
B outside 15 13 12 10 8 6 4 1 25 23 21 16 11 6 1

Side cheek, right inside 10 11 10 10 10 11 12 13 18 17 17 18 21 23 26

Trolley crossbar

Pins 839 554 44 839 555 44

A Tubes 839 551 44 839 552 44

Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 113 44

Trolley crossbar

Pins 839 081 44 839 085 44

B
Nuts/washers 334 687 99 / 502 220 44

Trolley, cpl. 840 114 44

21439104.p65/180602

55
 5.13 Assembly and adjustment of EUDH standard-headroom monorail trolley
Trolley size 5 – EUDH 212 – 208, 4/1 reeving

RUDH EUDH

Tightening torque 42 Nm

2 4 5 6

Tightening torque 160 Nm

2mm

Grease enclosure

8 6 3 1 3

Fig. 24 41268844.eps 42229144.eps

Assembling the EUDH trolley Insert trolley crossbar (1) into side cheek (2) (see fig. 24 ). Then adjust the trolley ac-
cording to the girder flange width of the track by arranging the distance washers as
specified in the tables on pages 57 – 59.
Castle nut (3) must be tightened to the specified tightening torque (see fig. 24) and
secured with a split pin.
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 DG 67B, part no. 011 058 44 – see fig. 24. 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. 24 ). Then adjust the trolley ac-
cording to the girder flange width of the track by arranging the distance washers as
specified in the tables on pages 55 – 56.
Locknut (8) must be tightened to the specified tightening torque (see fig. 24).

Removing/fitting the If the locknut (8) is completely removed from the crossbar, a new locknut (8)
trolley crossbar locknut acc. to DIN 985 must be used.
The locknut (8) can be screwed onto the trolley crossbar for pre-assembly without
being pre-tensioned.
21439104.p65/180602

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. 24).

56
 Adjustment of RU/EUDH 212 – 208 – H 10 trolleys, 4/1 reeving
Trolley A – RUDH Trolley B – EUDH

l l

42229044.eps
41299544.eps

View for the position of

the distance washers
Trolleys A and B

41945744.eps

Flange width b mm 106 113 119 125 131 137 143

Trolley Max. flange thickness t mm 22 / without anti-tip pin 28 mm

Position of distance washers (4 mm distance washers)
Required number of distance washers
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

Side cheek, right inside 4 5 5 6 7 8 8

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

Side cheek, right inside 1 2 3 3 4 5 6

outside 10 9 8 8 7 6 5

Trolley crossbar, cpl. 839 556 44

A
Trolley, cpl. 840 113 44

Trolley crossbar
21439104.p65/180602

Pins 839 574 44

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

Trolley, cpl. 839 794 44

57
 Adjustment of RU/EUDH 212 – 208 – H 10 trolleys, 4/1 reeving
Flange width b mm 144 149 155 163 170 178 185 200 201 210 220 240 260 280 300

Max. flange thickness t mm 22 / without anti-tip pin 28 mm

Trolley
Position of distance washers (4 mm distance washers)
Required number of distance washers
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

Side cheek, right inside - 1 2 3 4 5 5 7 - 2 3 5 8 10 13

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 -

Side cheek, right inside 6 7 7 8 9 10 11 13 13 14 16 18 21 23 26

outside 5 4 4 3 2 1 - 12 12 11 10 7 5 2 -

Trolley crossbar, cpl. 839 557 44 839 558 44

A
Trolley, cpl. 840 113 44

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

Trolley, cpl. 839 794 44

Adjustment of RU/EUDH 212 – 208 – H 16 trolleys, 4/1 reeving

Trolley A – RUDH Trolley B – EUDH

l l

42229044.eps
41299544.eps

View for the position of

21439104.p65/180602

the distance washers

Trolleys A and B

41945744.eps
58
 Flange width b mm 106 113 119 125 131 137 143

Trolley Max. flange thickness t mm 22 / without anti-tip pin 28 mm

Position of distance washers (4 mm distance washers)
Required number of distance washers
Trolley crossbar I mm 283

inside 4 6 8 9 10 11 12
Side cheek, left
A outside 6 5 4 3 3 2 1

Side cheek, right inside 3 3 2 3 73 4 4

outside 5 4 4 3 2 1 1

Trolley crossbar I mm 380

inside 2 4 5 7 8 9 9
Side cheek, left
B outside 10 9 9 7 7 6 6

Side cheek, right inside - - - - - 1 2

outside 10 9 8 8 7 6 5

Trolley crossbar, cpl. 839 556 44

A
Trolley, cpl. 840 113 44

Trolley crossbar

Pins 839 574 44

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

Trolley, cpl. 839 794 44

Flange width b mm 144 149 155 163 170 178 185 200 201 210 220 240 260 280 300

Max. flange thickness t mm 22 / without anti-tip pin 28 mm

Trolley
Position of distance washers (4 mm distance washers)
Required number of distance washers
Trolley crossbar I mm 340 440

inside - 1 3 5 7 8 9 11 - 3 5 9 7 14 16
Side cheek, left
A outside 8 8 7 6 5 4 3 1 14 12 11 9 6 4 1

Side cheek, right inside - - - - - 1 1 3 - 2 3 1 4 6 9

outside 8 7 6 5 4 3 3 1 13 12 11 8 6 3 1

Trolley crossbar I mm 380 494

inside 6 7 9 11 13 14 15 17 13 16 18 22 24 27 29
Side cheek, left
B outside 5 5 4 3 2 1 - 13 13 12 10 8 5 3 -

Side cheek, right inside 6 6 5 5 5 6 17 9 13 12 13 14 17 19 22

outside 5 4 4 3 2 1 - 12 12 11 10 7 5 2 -

Trolley crossbar, cpl. 839 557 44 839 558 44

A
Trolley, cpl. 840 113 44

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

Trolley, cpl. 839 794 44

21439104.p65/180602

59
 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.
Actuate check button for leaving the end position (lowering).
The functions carried out by the geared limit switch can be seen in the wiring diagram
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 lifiting" limit 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 bottom 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 4).
DGS limit switch cut-out points for the top hook position (fig. 25)
Dimension F (mm)
Table 4
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 C Simultaneous cut-out of main and creep lifting motions
limit switch
S2 switching element 190 120 70
D An additional DGS switching element is required as protection against incorrect phase sequence so that
D G S w i th the lowering contactor is deenergized in the top hook position. With successive cut-out of the main and
protection creep lifting motions (cut-out points acc. to table 2, line B), protection against incorrect phase sequence
21439105.p65/180602

against is not possible.

incorrect 120
phases S1 emergency limit switch 190 70
S2 protection against incorrect phase sequence 105 70 50

60
 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. 25)
F

Table 5
Dimension X (mm)
with rope reeving
1/1 2/1 4/1

A Simultaneous cut-out of main and creep lifting

Emergency
limit switch
X

S3 switching element 150 70 50

B Simultaneous cut-out of main and creep lifting

Operating
Fig. 25 40133744.eps limit switch
S4 switching element 190 120 70

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. 27 3
B1 – B4

Retaining screw B

Plunger Hook travel Cam shaft B

counter
Fig. 26 5 6

4
Fig. 28

Fig. 29 41110144.eps 41110044.eps

The following tools are required for setting the limit switch:
21439105.p65/180602

Two 1 x 4 mm and 1 x 6 mm screwdrivers.

61
 X
Contact maker

Cam shaft A

Setting screws
A1 – A4

Retaining screw A
42525945.eps
Setting screws Fig. 27 3
B1 – B4

Retaining screw B

Plunger Hook travel Cam shaft B

counter
Fig. 26 5 6

4
Fig. 28

Fig. 29 41110144.eps 41110044.eps

6.2.1 S1 emergency limit switch Raise the load hook to the level of dimension F = approx. 200 mm (fig. 25). Set cut-
for 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 4.
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. 27 and 28).
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. 29).
In this position, the normally closed contacts of switching element S1 are open.

6.2.2 S2 main lifting motion limit Setting 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
table 4, the switching point of S2 may only be max. 1 drum revolution ahead of
switching 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 4, line C.
21439105.p65/180602

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.
62 For cut-out points see table 4, line D.
 6.2.3 S3 emergency limit Setting is for S1, except with adjusting screws 3A-3B.
switch for bottom hook For cut-out points see table 5, line A.
position
Direction of rotation for setting opposite to that for S1.

6.2.4 S4 operating limit switch for Setting is as for S1, except with adjusting screws 4A-4B.
bottom hook position For cut-out points see table 5, 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 A and
B of cam shaft A and B is tightened to a torque of ³ 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 160 3,5 4,5
DH 200 4 4,5
21439105.p65/180602

63
 6.3 Inspection when When putting the hoist into operation for the first time, the inspections in accordance
with section 8.3, table 6 must be carried out.
putting 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 results in a high risk of accident for per-
sons and the rope hoist 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

6.6 KMH 90–112 motors The surfaces marked on the motor shaft (see fig. 30) are preserved with Rustban
391. The involute spline is coated with lubricating varnish 321.
The preservative and the lubricating varnish must not be removed when dismantling
the motor. When maintenance is carried out, the surfaces marked below must be
checked and a new coat must be applied, if, required.

Coated with lubricating varnish 321

Part no. 972 398 44
60

Apply thin coat of Rustban 391

Part no. 660 002 44

Fig. 30 42049644.eps

The red paste which can be seen in the area of the braking surface is used for preser-
vation until putting into operation and running in the braking surface of the motor.
This preservative must not be removed, however, it is not necessary to apply it again
during maintenance.
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64
 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.
It then locks automatically.
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
Emergency-stop
been eliminated.
button

7.2 Taking the hoist out of service at the end of the shift
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-
41233544.eps
served for operation and maintenance.
Tests and inspections required must be carried out, see section 1 Safety instructions
and the notes contained in the maintenance schedule, page 67, table 6.
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65
 8 Inspections/maintenance/general overhaul GO

8.1 Inspection before The operator must carry out inspections in accordance with table 6 before starting
work. Hoist units must be taken out of service immediately or not put into operation if
starting work and any defects relating to operating safety and reliability are detected.
during 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 The specified inspection and maintenance intervals (table 6) apply to normal hoist unit
service conditions.
maintenance 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.

8.3 General overhaul GO The theoretical duration of service D (hours at full load h) depends on the Group of
Mechanisms classification of the hoist unit (see section 9, table 8).
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 overhaul
GO to be carried out. A general overhaul must be carried out on reaching the theoreti-
cal 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 6).
• 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 com-
pany fulfills the condition for continued operation of the hoist unit. Thus the relevant
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 general
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.
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66
 Table 6
Inspection and maintenance schedule
See Before putting When Every 6 Once per
Check when putting into operation, starting operation and during time section into operation starting months year
of 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 X

Check lubrication of rope 5.8.4 X X

Check hook and hook safety catch X X X

Check during time of 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 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

Check long and cross travel units, in particular condition of flanges/guide rollers and seals of the
X
anti-friction bearings and trolley approach dimensions
Check plastic parts of limit switch for corrosion 6.1 X

Check electrical enclosure seals X

Check condition of all buffers 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
8.8.1
Regularly check lubrication of the geared travel roller of the monorail hoist trolley X
8.8.2
Check bearing points of rotor for corrosion, apply new preservative 6.6 every 5 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 determination of the actual duration of service S reveals that the
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theoretical duration of service D is reached earlier than after 8 to 10 years, the

current maintenance should be adapted to the actual operating conditions and the
maintenance intervals should be shortened.
For repairs, only use genuine Demag parts (see component parts list).
67
 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 7),
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 7)) when the following numbers of broken
wires are visible
Wire rope Group of mechanisms
1 Bm, 1 Am 2 m, 3 m 1 Bm, 1 Am 2 m, 3 m
to DIN 15020/FEM
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
Wire rope
Part no. construction Number of Length of Number of Length of Number of Length of Number of Length of
as in fig. mm broken wires rope mm broken wires rope mm broken wires rope mm broken wires rope mm
822 460 44 1 7 5 42 10 42 10 210 19 210

821 480 44 2 7,5 5 45 10 45 10 225 19 225

581 091 44 3 5,5 3 33 6 33 6 165 12 165

581 090 44 4 5,5 3 33 8 33 6 165 12 165

583 440 44 2 6,5 3 39 6 39 6 195 12 195

584 485 44 3 9 4 54 8 54 8 270 16 270

821 470 44 1 9 5 54 - - 10 270 - -

821 491 44 2 9 5 54 10 54 10 270 19 270

821 460 44 1 6,5 5 39 10 39 10 195 19 195

Rope construction – section 5.8.1

Fitting a new wire rope and rope guide – sections 5.8 and 5.8.6.

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68
21439105.p65/180602

69
 8.5 KMH 90 – 100 – 112 Hoist units are supplied with the brake of the Demag motor adjusted for the minimum
rotor displacement path of approx.
hoist motor brake,
1,5 – 2,0 mm motors 80, 90
KMF 80 travel motor
1,8 – 2,3 mm motors 100, 112.
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 motors 80, 90 and 3,5 mm for motors 100, 112.

It is therefore imperative to ensure, by regular maintenance, that the brake is adjusted

before the maximum rotor displacement is reached.
During adjustment, the hoist unit must be in unloaded condition.
Adjustment can be repeated serveral times.
It is advisable to have a spare brake cup set in stock.

Number of shims Segment

Motor Quantity
thickness
80 2x5 0,8 mm
90 2x6 0,8 mm
100 2x9 1 mm
112 2 x 10 1 mm

8.5.1 Adjusting the brake This work may only be carried out by specialist personnel.
with shims Observe relevant safety regulations and section 1 “Safety recommendations“.
It is imperative that the rotor displacement is measured at regular intervals. The brake
must be adjusted when the path of displacement has reached the maximum dis-
placement value.

Measure rotor displacement.

Measure KMH 100 – 112
hoist motor in braking and
running positions.

41062044.eps 41062144.eps
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Remove shims to adjust the rotor

displacement.
Ensure same number of shims are
Loosen brake end cap fitted on both sides.
41062344.eps 41062444.eps 41062544.eps
70
 Tightening torque Measure rotor displacement.
KMH 90, KMF 80 motors Tightening torque = 5 Nm
KMH 90 – 100 mot. = 10,5 Nm
Check rotor displacement
KMH 112 mot. = 25 Nm
(approx. 1,5 – 2 mm)
KMF 80 mot. = 10,5 Nm
41062244.eps 41062644.eps 41062144.eps

Measure rotor displacement.

Measure KMH 100 – 112 motor in braking and
running positions.
Check rotor displacement
(approx. 1,8 – 2,3 mm)

41062044.eps

8.5.2 Replacing the brake cup This work may only be carried out by specialist personnel.
Observe relevant safety regulations and section 1 “Safety recommendations”.
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Loosen brake end cap.

41062144.eps 41062344.eps 41062444.eps

71
 Remove fan with brake end cap. Lock brake cup using a screwdriver and
remove bolts.

41062744.eps 41063244.eps 41063144.eps

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 tighten bolts

with a tightening torque of 25 Nm.

Remove brake cup.

41062844.eps 41062944.eps

3 3 1

1 Guide for brake release stirrup.

2 Splines to assist in assembly.
1 Brake release stirrup. Fit brake end cap.
3 Ensure that fan clips are correctly seated
in bearing bush.
41054844.eps 41054944.eps 41063044.eps
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Tightening torque
Press fan cap onto brake release stirrup. Match marks on fan and fan cap. KMH 90 – 100 mot. = 10,5 Nm
KMH 112 mot. = 25 Nm
KMF 80 mot. = 10,5 Nm
41055144.eps 41067344.eps 41062244.eps
72
 Measure rotor displacement. Measure rotor displacement.
KMH 90, KMF 80 motors
Measure KMH 100 – 112 motor in braking
Check rotor displacement
Tightening torque = 5 Nm and running positions.
(approx. 1,5 – 2 mm)
Check rotor displacement
(approx. 1,8 – 2,3 mm)
41062644.eps 41062144.eps 41062044.eps

8.5.3 Replacing the fan This work may only be carried out by specialist personnel.
Observe relevant safety regulations and section 1 “Safety recommendations”.

41062144.eps 41062344.eps
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Loosen brake end cap. Remove fan with brake end cap. Press fan clips in direction of arrows and remove
fan.

41062444.eps 41062744.eps 41055744.eps

73
 Fit fan to brake end cap.

41055244.eps 41055344.eps 41055444.eps

3 3 1

1 Guide for brake release stirrup. Fit brake end cap.

2 Splines to assist in assembly. Before fitting end cap, ensure same
1 Brake release stirrup
3 Ensure that fan clips are correctly seated number of shims are fitted on both
in bearing bush. sides.
41054844.eps 41054944.eps 41063044.eps

Tightening torque
KMH 90 – 100 mot. = 10,5 Nm
Press fan cap onto brake release stirrup. Match marks on fan and fan cap. KMH 112 mot. = 25 Nm
KMF 80 mot. = 10,5 Nm
41055144.eps 41067344.eps 41062244.eps
21439106.p65/180602

Measure rotor displacement. Measure rotor displacement.

KMH 90, KMF 80 motors Measure KMH 100 – 112 motor in braking
Check rotor displacement and running positions.
(approx. 1,5 – 2 mm) Tightening torque = 5 Nm
Check rotor displacement
(approx. 1,8 – 2,3 mm)
41062644.eps 41062144.eps 41062044.eps
74
 8.6 ZBF 71– 80 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 brakes Apart from wear, the brake is virtually maintenance-free. The organic/mineral brake
lining is designed in such a way that worn surface particles are only given off as mini-
mal 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 certain 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

Braking work until readjustment WN in Ws 200 × 106 300 × 106

When the brake has been adjusted several times, the remaining thickness bmin of the
brake disk must be checked.
B004, B020 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 brakes
The brake 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 replacement. 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
71 80

B 003 260 960 84 – 260 962 84

B 004 260 963 84 – 260 965 84

B 020 – 260 973 84 260 975 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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75
 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

Remaining thickness
5 6
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 brakes
check brake air gap s1
(see checking/adjusting the brake air gap on page 77).
Status when new

B003 brake

The B003 brake can only be checked visually.

Remaining thickness bmin

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For a visual check, push covering tape (12) to the side

using a screwdriver.

76 41777744.eps 42028944.eps
 Checking/adjusting the brake air gap

Brake air gap s1min = 0,30mm – s1max= 1,2 mm

Tighten magnet assembly (9) with the three hexagon screws (10) uniformly until
the air gap is zero.
Loosen the three hexagon screws (10) by angle a1.

Brake size B003 B004 B020

Adjusting angle a 1 120° 120° 120°

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 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

21439106.p65/180602

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 71 – 80 mot. = 4 Nm

41432144.eps 41431945.eps 77
 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 Mannesmann Dematic authorised

workshop.

Undo the four screws and remove the fan cover. Remove the retaining ring and fan.

41431944.eps 41432144.eps 41432244.eps

B003 brake B004, B020 brakes

Remove terminal box cover (11). Remove terminal box cover (11).
Undo hexagon screw (10) and pull off washers (15), magnet Undo hexagon screw (10) and pull off magnet assembly (9).
assembly (9) and covering tape (12).

42508644.eps 42022544.eps

B003 brake B004, B020 brakes

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 of end shield (6) for
wear. wear.
21439106.p65/180602

Replace worn or damaged parts.

Damages means any deformation of stop plate (1),
however small it may be.

42508344.eps 42288144.eps
78
 Disassembly/assembly of the B003 brake Disassembly/assembly of the B004, B020 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 collared pins (4). Fit new collared pins (4).
Fit new collared pins (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

Tightening torque of collared pins/grub screws

Brake size B003 B004 B020
Tightening torque 3 Nm 3 Nm 4 Nm

Fitting the brake Fitting the brake

B003 brakes B004, B020 brakes

Recess on armature disk (2) Bore hole on stop plate (1)

Mark “I” on friction disk (14)

Mark “I” on armature disk (2)
Mark on end shield (6)
Mark on end shield (6)
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.
21439106.p65/180602

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 79
 B003 brakes B004, B020 brakes

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 with nut (10).
hexagon screw (10). Then tighten the magnet assembly (9) with the three hexagon nuts (10)
When fitting magnet assembly (9) ensure that covering tape (12) engages the uniformly until the air gap is zero. Loosen the three hexagon nuts (10) by
groove of magnet assembly (9). angle a1 = 120°.
Then tighten the 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.
angle a1 = 120°. If the measured result is within the specified range, the motor can be re-
Check air gap s1 using a feeler gauge at three points around the circumfer- assembled.
ence. For checking/adjusting the brake air gap, see page 77.
If the measured result is within the specified range, the motor can be re- Pull the connecting cable of magnet assembly (9) back into the terminal box.
assembled. Fit terminal box cover (11).
For checking/adjusting the brake air gap, see page 77.
Arrangement of brake springs (8)
Pull the connecting cable of magnet assembly (9) back into the terminal box.
Fit terminal box cover (11). Brake Number of Spring Part no.
Motor
torque springs arrangement
Arrangement of brake springs (8)
Nm see item
Brake Number of Spring Part no.
Motor
torque brake springs arrangement ZBF 71 A 8/2 B004 1,8 6 blue 5) 260 111 84
Nm red see item
ZBF 80 A 8/2 B020 3,3 3 red 3) 260 211 84
ZBF 71 A 8/2 B003 1,9 3 2) 260 011 84

2) 3) 5)

3 rt 3 rt 6 bl

42508046.eps 42508049.eps
21439106.p65/180602

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 71 – 80 motors = 4 Nm

80 41432144.eps 41431945.eps
 8.7 Travel motor Demag travel drives are supplied with the brake adjusted for the minimum rotor dis-
placement of approx. 1 – 1,5 mm.
brake 13/6 PKF As the brake lining wears down, the path of rotor displacement increases.
It is therefore imperative to ensure, by regular maintenance, that the brake is adjusted
before the maximum rotor displacement is reached.
Adjustment can be repeated several times.
It is advisable to have a spare brake lining or a complete brake end cap available.

8.7.1 Adjusting the brake with shims Measure the path of rotor displacement:
This is done by measuring the distance between the motor shaft end and the brake
end cap, first with the brake engaged (fig. 31) and then with the brake released
(fig. 32). If the path of displacement is approx. 3 mm, the brake must be adjusted.

Fig. 31 41058044.eps Fig. 32 40208844.eps

Loosen the four nuts (2) and remove brake end cap (1).
Remove the necessary number of shims (3) in order to obtain a path of displacement
of 1 – 1,5 mm (shim thickness 0,8 mm); it is absolutely essential that the number of
shims at the top is the same as at the bottom.
Screw on brake end cap (1) evenly with the four hexagon socket nuts (2) (for tighten-
ing torque see fig. 33). Any paint or dirt must be removed from the centering faces.
Check path of rotor displacement (should be 1 – 1,5 mm).

8.7.2 Fitting new brake lining Loosen the four hexagon socket nuts (2) and remove brake end cap (1) with its worn
to travel motor lining.
Remove old brake lining from brake end cap.
Tightening torque 6 Nm
Glue new brake lining into brake end cap (see section 8.7.3).
3 2 1
21439106.p65/180602

Fig. 33 41141544.eps

81
 8.7.3 Gluing on brake linings A two-component glue is supplied with every replacement brake lining. The lining
must be held in position by a clamping device.
Remove end cap (brake end shield) (1), heat to 100 – 150° C and remove worn brake
6 lining. (To do this, put the end cap on a heating plate and pour some water into re-
cess “X” of the end cap. The required temperature has been reached when the water
3 boils. Remove the remains of the old lining with a screwdriver or similar tool).
2 Surfaces to be glued together must be free from grease, oil, paint, rust, dirt and mois-
ture. They should be emery-papered and wiped with acetone or any other good sol-
1 vent.
x x
Squeeze adhesive out of the two tubes supplied and mix the two components
thoroughly in a ratio of 1:1. Apply a thin layer to both surfaces with a brush or paint
scraper.
5 Locate annular brake lining (2) in its proper position and apply pressure by fitting
pressure disk (3), bolt (4), washer (5) and nut (6) as illustrated in fig. 34.
4 Allow the glue to solidify under pressure for 20 hours at room temperature.
Fig. 34 40208744.eps Remove the gluing jig (components 3 to 6).
Fit adjusting shims and end cap (see section 8.7.1).

8.8 Gearbox Main hoist gearbox (three stage planetary gearbox)

Under normal operating conditions, the oil does not have to be changed until the
general overhaul is carried out.
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 gearbox
is closed, fill it with the new oil. Required oil quantity 0.6 litres.
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

Code number

Sealing surfaces Motor/gearbox bolts

Tightening torque = 75 Nm
Vent screw

Tightening torque = 14 Nm

Fig. 35 41146844.eps 41148844.eps

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 Delo-ML 5328 bonding agent (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.
21439106.p65/180602

When fitting the gearbox cover, ensure that the code number (gear ratio) on the gear-
box casing and the air vent screw are situated as shown in fig. 35.

82
 Drum bearing

Grease chamber and roller bearing half-filled with STABURAGS NBU 123 K,
part no. 472 933 44, (70 g tube).

41148944.eps

Gearbox tightening torques

15 Nm 15 Nm

15 Nm
41147744.eps

8.8.1 EKDH travel drive/trolley The travel drive teeth under the cover are lubricated with grease (approx. 100 g
Renolit S2). Part no. 460 000 44 (200 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.

8.8.2 EUDH travel drive/trolley The gearbox is lubricated with grease (approx. 60 g DG 67 B).
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 have 2 grooved ball bearings. 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. These bolts and screws should be checked for a
connections tight fit at the intervals indicated in the maintenance schedule and retightened if nec-
essary. Replacement screws and bolts must be of the same quality and secured in
21439106.p65/180602

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. 83
 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 1.04.1996. 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 can-
not, however, be ruled out.

The following items have been taken from FEM rule 9.755 with reference to the
DH electric rope hoist:

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 read on the hook
travel counter of the DGS geared limit switch
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 compo-
nents 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 8
1Am 2m 3m
[h] 800 1600 3200

The actual duration of service is considerably increased if the hoist unit is only
operated with partial load. For a hoist unit operated on average with half load, for
example, this results in an 8-fold increase in the actual duration of service.

9.1 Calculating the actual For the Demag DH hoist unit the actual duration of service S can be calculated using
the method below.
duration of service S
21439107.p65/180602

S = kmi x Ti x f
kmi : Load spectrum factor
Ti : Number of operating hours
84 f : Factor depending on the type of recording
 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
0,05
0,10
0,021
0,042
Full load 0,0062
3/4-load 0,0125
0,0008 km-values
1/2-load 0,0016
1/4-load Dead load
No load Time
5 10 5 10 5 10 5 10 40
[%]
100

The load spectrum factor kmi can be obtained by adding together the individual km 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. 122).
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 9
Factor Z for 1/1, 2/1, 4/1reeving
4

Rope reeving DH
1
3

1/1 2/1 4/1 160/200

2

Hoist speed
Factor Z H·Z
[ m/min ] Ti [h] =
0000000 1000
18,0 9,0 4,5 0,43
3 22,4 11,2 5,6 0,35
4
2

1 28,0 14,0 7,0 0,28

Hook travel counter

Fig. 36 41209644.eps

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.
21439107.p65/180602

9.1.3 Factor depending on type of f = 1,1 for calculating the operating hours using an elapsed time indicator
recording f
By means of the number of operating hours Ti calculated, the estimated load spec-
trum factor kmi and the factor depending on type of recording f, the S.W.P. can be
calculated.
85
 9.1.4 Example with hook travel DH168 H12 KV2 2/1 Group of mechanisms 1Am with 9 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 km together results in the load spectrum factor
kmi = 0,1194

On the hook travel counter for the period

from 26 April 1995 to 1 April 1996 the following H value was calculated:
0 000 001 0 393 366 => 393 365
Factor Z to table 9 => = 0,43

393365 x 0,43
Ti [h] = = 169,15 [h]
1000

Thus, the actual duration of service amounts to:

S = kmi x Ti x f = 0,1194 x169,15 x1,1 = 22,2 (h)

For classification in FEM group of mechanisms 1Am (see DH data plate) with a
theoretical duration of service of 800 hours (see table 10) the hoist has a theoretical
remaining duration of service of 777,9 hours.

Enter these values in your test and inspection booklet or crane installation test and
inspection booklet.
This entry may appear as follows:
Table 10
Actual Remaining
Operating Load factor Theoretical duration of
Date Load [ % ] / km factor duration of duration of
hours (sum of km factors) service
service service
D [h]/group of
from until Ti value [ h] full 3/4 1/2 1/4 none km f S[h] D - S [h]
mechanisms
0000001 0393366 393365 5 10 20 15 50

3.1.-- 30.12.-- 169,15 0,05 0,042 0,025 0,0023 - 0,119 1,1 22,1 800 / 1Am 777,9
21439107.p65/180602

86
 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 (LSR), 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: DH168 H12 KV2 2/1 1Am
Counter reading: 140,355
Approximate calculation of duration of service S using a diagram

LSR counter
Remaining reading
duration of 180 360 540 720 900 1080 1260 1440 x 1000
service in [%]

100
90
80
70
60
50
40
30
20
10
0

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
Theor.
Group of duration
mecha- Duration of service S in [hours] of service
nisms D [hours]
42030444.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

The calculation shows: S= D x LK

1.440.000
800 x 140 355
S= = 78 h
1.440.000

D= Theoretical duration of service

LK = Load spectrum (counter reading)
S= Duration of service

Enter these values in your test and inspection booklet or crane installation test and
inspection booklet.
21439107.p65/180602

87
 Printed in Germany DZS/0601/3T / PDF 180602

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.