Operating instructions

Demag DH 1000, DH 2000 hoist unit

100621 en GB 211 128 44 720 IS 813

 Original operating instructions
Manufacturer
Demag Cranes & Components GmbH
PO Box 67
58286 Wetter, Germany
Telephone +49 (0)2335 92-0
Fax +49 (0)2335 92-7676
www.demagcranes.com
Email: info@demagcranes.com
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DH rope hoist and important information if you ever have to contact the manufacturer or his representative.

Owner
Where in use
Size
Serial number
Main/F6 mechanical microspeed hoist motor number
Main hoist motor number
F10 mechanical microspeed unit
Microspeed hoist motor number
Microspeed hoist gearbox number
Travel drive number
Operating voltage
Control voltage
Frequency
Circuit diagram number
Contactor control
Tab. 1

Further documents are available for sub-assemblies/components in addition to these operating instructions. These possible
sub-assemblies/components are listed below. The corresponding documents are supplied as necessary or can be ordered
separately.

Documents 1) Part no. Classification

Spare parts lists
Demag hoist unit DH 1000/FG.. 217 311 44 721 IS 813
DH 2000/FG.. 217 654 44 721 IS 813
DST pendant controller 222 142 44 721 IS 951
Technical data/catalogues
Volume 1: DH and UDH hoist unit DH 600, 1000, 2000 203 702 44 714 IS 813
Volume 2: EZLDH double-rail crabs DH 600-2000 203 706 44 714 IS 813
KP-S clamp-fitted buffer 203 652 44 714 IS 888
SGDM hoist unit relay: Description of functions with circuit dia‐ 202 708 44 714 IS 952
gram
Operating, assembly, fitting instructions
Controller assembly instructions DST 206 165 44 719 IS 951
Motor assembly instructions ZBF 63 - 112 214 227 44 719 IS 919
Assembly instructions for microspeed drives FG 06, FG08, FG10 206 218 44 719 IS 911
Operating instructions for load detectors Dematik MGS/MKA-2 206 689 44 720 IS 819
Operating instructions for load detectors Dematik ZMS/FAW-1/FWL 206 880 44 720 IS 819
(206 715 44)
FB (overspeed brake)
Operating instructions with rope drum brake type 206 394 44 720 IS 823.1
HB (holding brake)
Demag log book for cranes and hoist units 206 124 44 720 IS 100
Tab. 2
211 128 44/100621

2 1) The documents can be ordered from the relevant Demag office.

 Table of contents

1 General ....................................................................................................................................................................... 7
1.1 Demag DH hoist unit ................................................................................................................................................... 7
1.2 Information on the operating instructions .................................................................................................................... 7
1.3 Symbols/signal words.................................................................................................................................................. 7
1.4 Liability and warranty................................................................................................................................................... 8
1.5 Copyright ..................................................................................................................................................................... 8
1.6 Spare parts .................................................................................................................................................................. 9
1.7 Terms/definitions ......................................................................................................................................................... 9
1.8 Log book.................................................................................................................................................................... 10
1.9 After-sales service ..................................................................................................................................................... 10
1.10 Disposal of machine parts ......................................................................................................................................... 10

2 Safety........................................................................................................................................................................ 11
2.1 General...................................................................................................................................................................... 11
2.2 Safety signs on the machines ................................................................................................................................... 11
2.2.1 Safety signs for fitting the rope socket ...................................................................................................................... 11
2.3 Intended use.............................................................................................................................................................. 11
2.4 Hazards that can be caused by the machine ............................................................................................................ 12
2.5 Responsibility of the owner ....................................................................................................................................... 13
2.6 Operating personnel requirements............................................................................................................................ 14
2.7 Personal protection equipment.................................................................................................................................. 14
2.8 Emergency-stop device ............................................................................................................................................. 15
2.9 Regular inspections................................................................................................................................................... 15
2.10 Inspection regulations ............................................................................................................................................... 15

3 Technical data ......................................................................................................................................................... 16

3.1 Explanation of size designations/type assignment ................................................................................................... 16
3.2 Selection criteria........................................................................................................................................................ 17
3.2.1 Specification of the rope hoist ................................................................................................................................... 17
3.3 Hoist motor technical data ......................................................................................................................................... 18
3.3.1 DH 1000, DH 2000 motor data .................................................................................................................................. 18
3.3.2 EUDH, EKDH travel motor data (40% CDF) ............................................................................................................ 21
3.3.3 Mounting code for ordering a mechanical microspeed unit....................................................................................... 22
3.4 Hook dimension C ..................................................................................................................................................... 23
3.4.1 DH 1000 .................................................................................................................................................................... 23
3.4.2 DH 2000 .................................................................................................................................................................... 23
3.4.3 Changes resulting from operating limit switch........................................................................................................... 23
3.4.4 EUDH 1000 standard-headroom monorail hoist ....................................................................................................... 24
3.4.5 EKDH 1000 low-headroom monorail hoist ................................................................................................................ 24
3.4.6 EZDH 1000/DRS double-rail crab ............................................................................................................................. 24
3.4.7 EZLDH 2000/DRS double-rail crab ........................................................................................................................... 25
3.4.8 Construction, application and reeving of wire ropes.................................................................................................. 25
3.5 Mounting flange positions and rope lead-offs............................................................................................................ 30
3.6 Gearbox oil filling ....................................................................................................................................................... 32
3.7 Operating conditions ................................................................................................................................................. 32
3.8 Noise emission .......................................................................................................................................................... 33
3.9 Paint finish ................................................................................................................................................................. 34
211 128 44/100621

3.10 Weight ....................................................................................................................................................................... 35

3.11 Control system .......................................................................................................................................................... 36

4 Design and function ................................................................................................................................................ 37

3
 4.1 Design ....................................................................................................................................................................... 37
4.2 Arrangement of assemblies....................................................................................................................................... 37
4.3 Drives ....................................................................................................................................................................... 38
4.3.1 Hoist drive ................................................................................................................................................................. 38
4.3.2 Travel drive................................................................................................................................................................ 38
4.3.3 Gearbox/rope reeving components ........................................................................................................................... 38
4.4 Geared limit switch .................................................................................................................................................... 38
4.5 Integrated controls..................................................................................................................................................... 39
4.6 Controller ................................................................................................................................................................... 39
4.6.1 Control element ......................................................................................................................................................... 39
4.6.2 Connecting the control cable..................................................................................................................................... 39
4.7 Types......................................................................................................................................................................... 40
4.8 Overload protection/load detector ............................................................................................................................. 40
4.9 Track girder requirements ......................................................................................................................................... 41
4.9.1 EKDH, EUDH track ................................................................................................................................................... 41
4.9.2 EKDH, EUDH trolley ................................................................................................................................................. 41
4.9.3 EZDH track girders.................................................................................................................................................... 42
4.9.4 EZDH trolley .............................................................................................................................................................. 42
4.10 Type plate (example)................................................................................................................................................. 43

5 Transport, packing, storage ................................................................................................................................... 44

5.1 Safety warnings......................................................................................................................................................... 44
5.2 Transport inspection .................................................................................................................................................. 44
5.3 Packing...................................................................................................................................................................... 44
5.4 Storage ...................................................................................................................................................................... 44

6 Installation and putting into operation for the first time...................................................................................... 45

6.1 Safety warnings......................................................................................................................................................... 45
6.2 Installing the rope hoist ............................................................................................................................................. 46
6.2.1 Checking dimensional accuracy of the EZDH track .................................................................................................. 46
6.2.1.1 Tolerance of the individual girder .............................................................................................................................. 46
6.2.1.2 Twisting ..................................................................................................................................................................... 47
6.2.1.3 Tolerance of the crab track gauge............................................................................................................................. 47
6.2.1.4 Gradient of the crab rails ........................................................................................................................................... 47
6.2.1.5 Difference in rail height.............................................................................................................................................. 48
6.2.1.6 Rail level difference ................................................................................................................................................... 48
6.2.1.7 Fitting the end stops/clamp-fitted buffers .................................................................................................................. 48
6.2.2 Installing EUDH standard-headroom monorail travelling hoists ................................................................................ 49
6.2.2.1 Assembly and adjustment ......................................................................................................................................... 49
6.2.3 Buffer installation on the runway ............................................................................................................................... 55
6.2.4 Overview of reeving arrangements ........................................................................................................................... 56
6.3 Connecting the electric equipment ............................................................................................................................ 57
6.3.1 Wiring ........................................................................................................................................................................ 57
6.3.1.1 General...................................................................................................................................................................... 57
6.3.1.2 Control cable and line voltage connection................................................................................................................. 57
6.3.1.3 Installing DST pendant controllers ............................................................................................................................ 58
6.3.1.4 Checking the direction of movement ......................................................................................................................... 60
6.4 Rope reeving ............................................................................................................................................................. 61
6.4.1 Reeving methods ...................................................................................................................................................... 61
211 128 44/100621

6.4.2 Rope reeving of the rope hoist .................................................................................................................................. 61

6.4.3 Unwind rope .............................................................................................................................................................. 62
6.4.4 Fitting the rope .......................................................................................................................................................... 63
4 6.4.5 Installing the load detector/overload protection......................................................................................................... 64
 6.4.5.1 MGS load detector .................................................................................................................................................... 64
6.4.5.2 ZMS load detector ..................................................................................................................................................... 65
6.4.6 Assembling the hook assembly for 1/1 reeving......................................................................................................... 66
6.4.7 Assembly .................................................................................................................................................................. 66
6.4.7.1 Installing the compensating sheave and load detector ............................................................................................. 66
6.4.7.2 Check suspension ..................................................................................................................................................... 77
6.4.8 Fitting DH 1000 – DH 2000 rope guides with toothing adjustment............................................................................ 79
6.5 Additional equipment................................................................................................................................................. 82
6.5.1 FG 08 – FG 10 microspeed units .............................................................................................................................. 82
6.5.1.1 Installation ................................................................................................................................................................. 82
6.5.1.2 Brake ......................................................................................................................................................................... 83
6.5.1.3 Main motor – brake adjustment ................................................................................................................................. 84
6.5.1.4 Pre-tensioning the dished washer, replacing the hollow shaft of FG 08 and FG 10 units......................................... 85
6.5.2 Demag DH hoist units and travel drive units for arduous conditions......................................................................... 86
6.6 Putting into operation for the first time....................................................................................................................... 88
6.6.1 Checks before the equipment is put into operation for the first time ......................................................................... 88
6.6.2 Inspection regulations ............................................................................................................................................... 88
6.6.3 DGS 3 and DGS 4 geared limit switches .................................................................................................................. 88
6.6.3.1 Geared limit switch function ...................................................................................................................................... 88
6.6.3.2 Set the cut-off points ................................................................................................................................................. 89
6.6.3.3 Adjusting the cut-off points ........................................................................................................................................ 90
6.6.4 Overload test at 125%............................................................................................................................................... 93
7 Operation ................................................................................................................................................................ 94
7.1 Safety warnings ......................................................................................................................................................... 94
7.2 Switching on .............................................................................................................................................................. 95
7.2.1 Checks when starting work ....................................................................................................................................... 95
7.2.2 Visual check .............................................................................................................................................................. 95
7.2.3 Check the limit switches ............................................................................................................................................ 95
7.2.4 Check strain relief elements ...................................................................................................................................... 96
7.2.5 Check operation of the brake .................................................................................................................................... 96
7.2.6 Check hook safety catch ........................................................................................................................................... 96
7.3 Controller switch assignment .................................................................................................................................... 96
7.4 Switching off ............................................................................................................................................................. 97
7.5 Stopping operation in an emergency......................................................................................................................... 97

8 Maintenance ............................................................................................................................................................ 98
8.1 Safety warnings ......................................................................................................................................................... 98
8.2 Routine inspections ................................................................................................................................................... 98
8.3 Maintenance schedule .............................................................................................................................................. 99
8.4 Wire ropes ............................................................................................................................................................... 102
8.5 Replacement criteria for the wire rope .................................................................................................................... 102
8.6 Wear limits on rope sheaves ................................................................................................................................... 103
8.7 Shortening the wire rope ......................................................................................................................................... 104
8.8 Lubricating the wire rope ......................................................................................................................................... 104
8.9 Regular inspections and monitoring measures for load hooks................................................................................ 104
8.10 KBH main hoist motor and KBA microspeed hoist motor brake.............................................................................. 105
8.10.1 Safety ...................................................................................................................................................................... 105
8.10.2 Checking for wear/axial displacement..................................................................................................................... 105
211 128 44/100621

8.10.3 Adjusting the brake on KBA motors ........................................................................................................................ 107

8.10.4 Replacing the brake lining on KBA motors.............................................................................................................. 108
8.11 Main hoist motor with mechanical microspeed unit ................................................................................................. 110
8.11.1 Adjusting the brake on KBH motors ........................................................................................................................ 110 5
 8.11.2 Checking base material of the brake linings for cracks ........................................................................................... 111
8.11.3 Replacing the brake ring on KBH motors ................................................................................................................ 111
8.11.4 Replacing the brake lining on KBH motors.............................................................................................................. 112
8.11.5 Replacing KBH motor brake springs ....................................................................................................................... 114
8.11.6 Air gap ..................................................................................................................................................................... 115
8.12 ZBF 63 – 112 travel motor brake maintenance ....................................................................................................... 117
8.12.1 Safety ...................................................................................................................................................................... 117
8.12.2 B003, B004, B020, B050 brakes ............................................................................................................................. 117
8.12.3 Checking and adjusting brake air gap s1 ................................................................................................................. 118
8.12.4 Replacing the brake disc ......................................................................................................................................... 121
8.12.4.1 Removing the fan cover .......................................................................................................................................... 121
8.12.4.2 B003 brake .............................................................................................................................................................. 122
8.12.4.3 B004, B020, B050 brakes ....................................................................................................................................... 125
8.12.5 KMF 80 travel motor brake ...................................................................................................................................... 128
8.12.5.1 Condition as supplied .............................................................................................................................................. 128
8.12.5.2 Adjusting the brake with shims................................................................................................................................ 128
8.12.5.3 Replacing the brake cup.......................................................................................................................................... 130
8.13 EZDH travel wheel wear.......................................................................................................................................... 133
8.14 Change gearbox oil ................................................................................................................................................. 134
8.14.1 Main hoist gearbox (two, three or four-stage planetary gearbox)............................................................................ 134
8.14.2 FG 08 and FG 10 microspeed units, AMK 20, AUK 30 travel drives....................................................................... 136
8.14.3 Output stage, standard and low-headroom monorail hoists.................................................................................... 138
8.14.4 Anti-friction bearing ................................................................................................................................................. 138
8.14.4.1 General information ................................................................................................................................................. 138
8.14.4.2 Motor bearings ........................................................................................................................................................ 138
8.14.5 Load-bearing bolted connections ............................................................................................................................ 139
8.15 General overhaul (GO) ........................................................................................................................................... 139

9 Malfunctions .......................................................................................................................................................... 140

9.1 Safety warnings....................................................................................................................................................... 140
9.2 Conduct when malfunctions occur .......................................................................................................................... 140
9.3 Conduct after malfunctions have been eliminated .................................................................................................. 140
9.4 Malfunctions, causes and remedy ........................................................................................................................... 141

10 Measures for achieving safe working periods ................................................................................................... 142

10.1 General.................................................................................................................................................................... 142
10.2 Calculating the actual duration of service................................................................................................................ 142
10.3 Estimating load spectrum factor kmi (by the owner) ................................................................................................. 143
10.4 Calculating the number of hours of operation (operating time) Ti by the owner ...................................................... 144
10.5 Factor depending on the type of recording f............................................................................................................ 144
10.6 Example with hook travel counter ........................................................................................................................... 145
10.7 Example with FWL load spectrum recorder ............................................................................................................ 146
Declaration of conformity ...................................................................................................................................................... 148
.................................................................................................................................................................................................. 149
Declaration of incorporation ................................................................................................................................................. 150
Index ........................................................................................................................................................................................ 151
211 128 44/100621

6
 1 General

1.1 Demag DH hoist unit

You have purchased a Demag Cranes & Components product.
This Demag rope hoist was manufactured in accordance with the relevant European standards and regulations.
The rope hoist complies with the statutory regulations of, for example, EC directive 2006/42/EC.
Demag rope hoists are of modular design. Their main assemblies include:
● Gearbox
● Hoist motor
● Integrated electric equipment
● Rope reeving components
● Controller
These operating instructions describe the Demag DH rope hoist. The following ranges are described:
● DH 1000
● DH 2000
The following data always apply for all ranges. Any differences for individual ranges are specially marked.

1.2 Information on the operating instructions

These operating instructions are designed to provide the owner with appropriate instructions for safe and correct
operation and for maintenance. These operating instructions are an integral part of the rope hoist.
Every individual given the task of transporting, installing, commissioning, operating, maintaining and repairing our
rope hoists and additional equipment must have read and understood the items listed in the following:
● the operating instructions
● the safety regulations
● the safety warnings in the individual chapters and sections.
The operating instructions must be available to operating personnel at all times in order to prevent operating er‐
rors and to ensure smooth and trouble-free operation of our products. They must be kept available in the immedi‐
ate vicinity at all times. The rope hoist may only be operated by personnel who are fully familiar with the operating
instructions.
If special designs or additional options are ordered or the latest technical modifications are incorporated, the ac‐
tual scope of supply may differ from the data and information as well as from the illustrations described here. If
you have any questions, please contact the manufacturer.
Based on Machinery Directive 2006/42/EC, the rope hoist is also designated as a machine in the sense of a
complete machine in the following. This always refers to all possible DH rope hoist types.

For a Demag rope hoist delivered ready for operation in the sense of a complete machine, we confirm conformity
with the requirements of Directive 2006/42/EC by means of the attached EC declaration of conformity.
A declaration of incorporation is enclosed for partly completed Demag rope hoists which are assembled with addi‐
tional parts to create a machine ready for operation. The declaration of incorporation refers to the scope of deliv‐
ery of the partly completed or non-assembled machinery. Before the equipment is put into operation, the user
must take additional measures to fulfil the safety requirements for the machine and issue the declaration of con‐
formity for the machine when it is ready for operation.

1.3 Symbols/signal words

Important safety information and instructions in these operating instructions are marked by corresponding sym‐
bols and signal words .
211 128 44/100621

Safety warnings and instructions must be followed. Follow these instructions with care to avoid any accidents, in‐
juries or damage.
Locally applicable accident prevention regulations and general safety regulations must also be followed.
7
 The following symbols and instructions warn against possible injuries or damage and are intended to assist you in
your work.

DANGER
This warning symbol indicates an immediate danger that can result in severe injuries or death.
– Follow these instructions at all times and be particularly careful and cautious.

WARNING
This warning symbol indicates a possibly dangerous situation that might result in severe injuries or death.
– Follow these instructions at all times and be particularly careful and cautious.

CAUTION
This warning symbol indicates a possibly dangerous situation that might result in medium to slight injuries or ma‐
terial damage.
– Follow these instructions at all times and be particularly careful and cautious.

Operating hazard for the machine.

● This symbol indicates information on appropriate use of the machine.
● Failure to follow these instructions can result in malfunctions, damage or pollution of the environment.

1.4 Liability and warranty

All information included in these operating instructions has been compiled on the basis of the relevant regulations,
state-of-the-art engineering principles and our many years of experience.
These operating instructions must be read carefully before starting any work on and with the machine, especially
before the machine is put into service for the first time. The manufacturer assumes no liability for any damage
which results from the following:
● Failure to follow the operating instructions
● Incorrect use of the machine
● Operation by insufficiently trained personnel
● Unauthorised conversions
● Any technical modifications

Wearing parts are not subject to liability for defects.

We reserve the right to incorporate technical modifications within the scope of improving the operating character‐
istics and further development of the machine.

1.5 Copyright
These operating instructions must be treated confidentially. They are only intended to be used by people who
work with or on the machine.
Any and all content, texts, drawings, images and any other information are protected within the sense of copyright
law and are subject to further industrial rights. Any misuse is an offence.
No part of this documentation, in whole or in part, may be reproduced, distributed, shown in public or used in any
other way without specific prior consent. Infringements are an offence resulting in obligatory compensatory dam‐
ages. Further rights reserved.
211 128 44/100621

All industrial rights reserved.

8
 1.6 Spare parts
Only genuine Demag spare parts may be used.

CAUTION
Incorrect or defective spare parts can cause damage, malfunctions or complete failure of the machine.
Only use genuine spare parts or parts approved by Demag.
Only genuine Demag spare parts may be used for safety-relevant wearing parts. Examples: brake, motor, ...

The use of unauthorised spare parts renders null and void any claims for warranty, service, damages or liability
against the manufacturer or his appointed personnel, dealers and representatives.

1.7 Terms/definitions
Manufacturer
The manufacturer is the person who:
1. manufactures machinery under his or her own name and places it on the market for the first time;
2. resells machinery made by other manufacturers under his or her own name, whereby the reseller is not con‐
sidered to be the manufacturer, provided the name of the manufacturer (as defined in 1.) appears on the
equipment;
3. imports machinery into Germany and places it on the market for the first time, or
4. exports machinery to another member state of the European Union and hands it over direct to a user in that
country.
Owner
Owners (employer, company) are defined as persons who own a machine and who use it as intended or allow it
to be operated by suitable and trained persons.
Operating personnel/machine operator
Operating personnel or machine operators are defined as persons entrusted by the owner of a machine with oper‐
ation of the equipment. Operating personnel must be trained by the owner in accordance with the tasks to be per‐
formed.
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 inappropriate conduct. Personnel must be informed about the required pro‐
tective devices, protective measures, relevant regulations, codes of practice, accident prevention regulations and
operating conditions and must provide verification of their competence. Trained personnel must be trained by the
owner in accordance with the tasks to be performed.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner of a machine to carry out special tasks such
as installation, setting-up, maintenance and fault elimination. Specialist personnel must be trained by the owner
before any work is carried out on or with the machine.
Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of
electric machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. Qualified electricians must
be trained by the owner in accordance with the tasks to be performed.
Experienced technician
Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐
cient knowledge in the field of machines. They must be familiar with the relevant national industrial safety regula‐
tions, codes of practice, accident prevention regulations, directives and generally accepted engineering standards
enabling them to judge the safe operating condition of machines.
211 128 44/100621

Assigned expert engineer (in the Federal Republic of Germany according to BGV D8, Section 23, for de‐
termining the S.W.P.)

9
 An assigned expert engineer is defined as an experienced technician specifically assigned by the manufacturer to
determine the remaining service life of the machine (S.W.P. = safe working period) and to carry out a general
overhaul of the machine.
Authorised expert engineer (according to BGV D6, Section 28 in the Federal Republic of Germany)
In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorised expert engi‐
neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers’ Mu‐
tual Insurance Association.
Design limit
For selection of the crane, the size is defined in accordance with the application and the customer specifications.
The design limits of the crane must not be exceeded.
Rope hoists
Rope hoists are systems used for lifting and moving loads, such as cranes, crabs and travelling hoist units, rail
systems.
Crabs and travelling hoists
A crab or travelling hoist is a moving part of a crane that is used to change the position of the lifting rope (on the
load attachment side). Depending on the type, the crab/travelling hoist carries one or several return sheaves for
the lifting rope or the crab carries the hoist unit. The crab/travelling hoist travels along a girder.

1.8 Log book

A log book filled in with all details must be available for every rope hoist. The results of the regular tests and in‐
spections must be entered in the log book and must be certified by the inspector. Log book part no.:  Tab. 2,
Page 2.

1.9 After-sales service

Our after-sales service will provide you with technical information on our machines, etc.
Please keep the serial or order number (see log book, load capacity plate on the crane) for any correspondence
or spare part orders. Specifying this data ensures that you receive the correct information or the required spare
parts.
The relevant Demag after-sales service centre is given, for example, on the back page of your rope hoist log
book.
Manufacturer’s address:
Demag Cranes & Components GmbH
PO Box 67
58286 Wetter, Germany
Telephone +49 (0)2335 92-0
Fax +49 (0)2335 92-7676
www.demagcranes.com

1.10 Disposal of machine parts

Unless a return or disposal agreement has been concluded, recycle separated components after proper removal:
● Scrap any remaining metallic material
● Dispose of plastic elements for recycling
● Separate and dispose of any other components by material type
Electric scrap, electronic components, lubricants and other auxiliary materials are subject to special disposal
regulations and may only be disposed of by certified companies.

National disposal regulations must be considered regarding environmentally friendly disposal of the machine. Fur‐
ther information can be obtained from corresponding local authorities.
211 128 44/100621

10
 2 Safety

2.1 General
The “Safety” chapter provides an overview of all important safety aspects for optimum protection of personnel as
well as safe and trouble-free operation of the machine.
At the time of its development and manufacture, the machine was built according to generally accepted engineer‐
ing standards and is considered to be safe to operate. The machine can still be a cause of danger if it is not used
correctly or as intended by suitably trained personnel.
Knowledge of the contents of the operating instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the machine safely and reliably.
Any conversions, modifications or additions to the machine are prohibited unless approved by Demag in writing.
These operating instructions describe operation with one travelling hoist; operation of several travelling hoists on
one crane girder or tandem operation of cranes are not included in these operating instructions.

2.2 Safety signs on the machines

2.2.1 Safety signs for fitting the rope socket

Any pictograms, signs or labels on the rope hoist must be obeyed and must not be removed. Pictograms, signs or
labels that are damaged or no longer legible must be replaced immediately.

Adhesive labels

43327044.eps

Fig. 1 Safety information: inserting the rope into the rope socket

Fitting the rope socket  "Installing the compensating sheave and load detector", Page 66

2.3 Intended use

The machine may only be used as intended and in compliance with the requirements for the owner and the fol‐
lowing limitations as specified in these operating instructions. Any other use may result in a danger to life and limb
and/or cause damage.
● DH rope hoists are only designed for lifting loads. The maximum safe working load is the load capacity speci‐
fied on the capacity plate. This must not be exceeded. The maximum safe working load includes the lifted load
and dead load (e.g. load handling attachments).
211 128 44/100621

● Rope hoists may only be installed, operated, maintained and removed when in perfect working order by trained
personnel in accordance with the relevant safety and accident prevention regulations. Personnel must meet
the requirements according to  "Operating personnel requirements", Page 14.
11
 ● Intended use also includes compliance with the safety instructions as well as any other instructions on assem‐
bly/disassembly, commissioning, function/operation, maintenance/fault elimination as well as compliance with
the instructions on safety devices, protection against hazards and any possible (remaining) hazards.
● The rope hoist may only be used subject to the permissible technical data,  "Technical data", Page 16. In
particular, the maximum permitted load according to these operating instructions must not be exceeded.
● The rope hoist must be maintained regularly and appropriately by trained personnel in line with the specified
deadlines and checked according to  "Maintenance schedule", Page 99. Wearing parts must be replaced in
good time in accordance with the frequency and intensity of use.
● Loads must never be pulled at an angle, pulled or dragged and fixed loads must never be pulled free.
● Transporting people with or people riding on the machine is always prohibited, this does not apply to equip‐
ment specially designed for transporting people (see intended use of lifting equipment).
● Molten masses must not be lifted or transported with Demag hoist units as standard.
● As standard, Demag hoist units are not intended or rated for tandem operation.
● UVV/BGV D8, Section 23 (2) and BGV D6, Section (1) guidelines must be not be ignored.
No liability for inappropriate use
The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐
ceptable according to these operating instructions. In particular, the manufacturer assumes no liability for damage
due to inappropriate or any other prohibited use of the machine in the sense of the "Intended use" section.
No liability for structural modifications
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of de‐
livery, or the installation or use of third-party accessories, equipment, sub-assemblies or spare parts that are not
approved by the manufacturer.
Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by an
expert engineer before it is handed over to the owner.
The machine is designed for operation indoors and at temperatures ranging from - 10° C to + 45° C. At extreme
temperatures and in aggressive atmospheres, the owner must implement special measures after consulting De‐
mag.
Use of the controller
Lifting and lowering and, if applicable, cross-travel and long-travel motions are controlled by means of the corre‐
sponding control elements on the controller. The slow speeds are intended for attaching the load, lifting it free and
depositing it. Loads can be precisely positioned at slow speeds.
Short transport times can be achieved at higher speeds. They are suitable for travelling without a load or with a
safely suspended load if no hazard can be caused by the faster motion sequences.
Inching must be avoided at fast speeds, as it causes increased wear and load sway.

2.4 Hazards that can be caused by the machine

The machine has been subjected to a risk assessment. The design and execution based on this analysis corre‐
sponds to state-of-the-art engineering principles. However, residual risks remain.
The machine operates with high electric voltage.

DANGER
Live components
Danger to life and limb.
Electric energy can cause very severe injuries. Danger of death caused by electric current if the insulation or
individual components are damaged.
– Switch the machine off and secure it against restoration of the power supply before any maintenance,
cleaning or repair work is carried out.
211 128 44/100621

– Switch the power supply off before any work is carried out on the electric equipment. Check to ensure that
the components to be replaced are de-energised.
– Do not remove any safety equipment or render it inoperative by modifications.
12
 WARNING
Crushing hazard
Body parts can be crushed when loads are lifted or lowered.
Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered.

WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
Keep out of the danger zone at all times.
– Keep a sufficient safety distance.
– Never step under suspended loads.

Certain work and practices are prohibited when using the machine as they can involve danger to life and limb and
result in lasting damage to the machine, e.g.:
● Unsafe load handling (e.g. swinging/throwing the load).
● Do not handle suspended loads above people.
● Do not pull or drag suspended loads at an angle.
● Do not pull free any fixed or obstructed loads.
● Do not exceed the maximum permitted load capacity.
● Do not leave suspended loads unsupervised.
● Do not allow load-supporting means (ropes/chains) to run over edges.
● Do not use load-supporting means (ropes/chains) as a load bearing sling.
● Do not allow loads to drop when the load-supporting means (ropes/chains) are in a slack condition.
● Do not subject the controller to inappropriate mechanical loads.
● Do not allow the control cable to wind around the rope.
● Do not allow motion of the load hook in the bottom block to be obstructed. No twisting (torsion) may be caused
in the rope.
● Do not work with twisted ropes, especially with 2/1 reeving.
● Do not tamper with or manipulate electric equipment.
● Transporting people is not permitted unless the machine is specifically approved for transporting people.
● Do not lift the load at full speed.
● Vibration from the load being transported (e.g. when the load is deposited on vibrating machinery) must not be
transmitted.
● Avoid any collisions with stationary equipment and structures; runways must be designed in such a way that
the entire travel path of the crane is always free of obstructions.

2.5 Responsibility of the owner

Information on safety at work refers to the regulations of the European Union that apply when the machine is
manufactured. The owner is obliged to ensure that the specified health and safety measures comply with the lat‐
est rules and regulations and to observe new regulations during the entire service life of the machine. Local indus‐
trial safety legislation and regional regulations and codes of practice applicable at the site of operation of the ma‐
chine must be observed outside the European Union.
General safety, accident prevention and environmental protection regulations that apply where the machine is in
operation must be observed and complied with in addition to the safety instructions contained in these operating
instructions.
211 128 44/100621

The owner and any personnel authorised by him are responsible for correct operation of the machine and for
clearly defining responsibilities for installation, operation, maintenance and cleaning. The operating instructions
must be followed in full and without any limitations.

13
 Special local conditions or applications can lead to situations which are not considered in these operating instruc‐
tions. In such cases, the required safety measures must be defined and implemented by the owner. Necessary
measures may also relate, for example, to the handling of hazardous materials or tools and the provision/wearing
of personal protective equipment. The operating instructions must, if required, be supplemented by the owner with
instructions relating to organisation of work, working procedures, authorised personnel, supervising and reporting
obligations, etc. For further information, see  "Safety warnings", Page 94.
Furthermore, the owner must ensure that
● any further working and safety instructions resulting from the hazard assessment of the machine workplaces
are specified in operating procedures.
● personnel who work with or on the machine are provided with appropriate first-aid equipment. Personnel must
be trained in the use of the first-aid equipment.
● the operating instructions are always kept available in the immediate vicinity of the machine for installation, op‐
erating, maintenance and cleaning personnel.
● personnel are trained in accordance with the work to be performed.
● the machine is only operated when in safe and proper working order.
● safety devices are always kept freely accessible and are checked regularly.
● national regulations for use of the machine are observed.
● any specified regular checks and inspections are carried out on time and are documented.
● the operating/travel area is adequately illuminated.
● suitable and tested load handling attachments are provided and used.
The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these
instructions at a suitable place where they can be easily seen.

2.6 Operating personnel requirements

Only authorised and trained specialist personnel may work on the machine. Personnel must have received in‐
struction on the machine functions and any hazards that may occur.
Every individual given the task of working on or with the machine must have read and understood the operating
instructions before any work on the machine starts.
People under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with the
machine.
Age and job-specific regulations relevant at the machine operating location must be observed for the selection of
any personnel.
Personnel are obliged to report to the owner without delay any changes to the machine that impair safety.
For independent operation (machine operator) or maintenance (trained maintenance fitter) of the machine, the
owner may only employ persons
● who are at least 18 years of age,
● who are mentally and physically suitable,
● who have been instructed in the operation and maintenance of the machine and who have proven their qualifi‐
cation to the owner in this respect.

2.7 Personal protection equipment

When work is carried out on or with the machine, the following protective equipment is recommended to be worn
according to the owner’s hazard assessment:
● Protective clothing, closely fitting working clothes (low tear strength, no loose sleeves, no rings or any other
jewellery, etc.).
● Safety shoes to protect against heavy falling parts and against slipping.
● Gloves for handling the wire rope.
211 128 44/100621

● Safety helmet to be worn by everybody in the danger zone.

14
 2.8 Emergency-stop device

WARNING
Unauthorised, negligent or accidental switching-on.
Danger to life and limb.
Check to ensure that the reason for the emergency stop
has been eliminated before the machine is switched on
again.
The emergency-stop device must not be used to switch
the machine off in normal operation.

The machine is fitted with an emergency-stop device (1) to prevent

damage and injuries. This is located on the controller. The emergency-
stop device operating function must be checked regularly.

Fig. 2

2.9 Regular inspections

The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation
and regional regulations. In Germany, this is specified by the accident prevention regulations for winches and
hoists (BGV D8) and the accident prevention regulations for cranes (BGV D6), for example. These specify that
● the machine must be inspected before it is put into operation,
● the machine must be inspected regularly,
● the elapsed share of the theoretical service life must be calculated,
● a record must be kept in a log book.
The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe
new regulations at all times.
If no comparable inspection regulations or requirements for use of the machine apply at the operating location, we
recommend compliance with the above-mentioned regulations.

2.10 Inspection regulations

Notes on inspections in accordance with:
● UVV accident prevention regulations for winches, lifting and towing devices, BGV D8
● UVV accident prevention regulations for cranes, BGV D6
● EN 14492-2 – Cranes; Power-driven winches and hoists; Part 2: Power-driven hoists
● prEN 15011 Cranes – Bridge and gantry cranes
EC Machinery Directive requirements are, therefore, also fulfilled.
211 128 44/100621

15
 3 Technical data

3.1 Explanation of size designations/type assignment

E U DH 1050 - H16 K V1 4/1 F6 1400 12.5
Max. cross-travel speed [m/min]
Track gauge [mm]
F6: Creep lifting 1:6; DH pole-changing
F10: Creep lifting 1:10; DH mechanical microspeed unit
Reeving
Lifting speed
Motor type:
K = Squirrel-cage rotor
S = Slip-ring rotor
G = DC
X = Explosion-proof motor
Hook path 16 m (for 2/1 reeving)
1000 or 2000 range
Demag rope hoist type DH
K = Low-headroom monorail hoist
U = Standard-headroom monorail hoist
Z = Double-rail crab
E = Electric travel trolley
Tab. 3

211 128 44/100621

16
 3.2 Selection criteria
3.2.1 Specification of the rope hoist
The size of the hoist is determined by the load spectrum, average operating time per working day, load capacity
and reeving.
1. What are the operating conditions?
2. What is the specified safe working load?
3. To what height must the load be lifted?
4. What is the required lifting speed?
5. Do the loads need to be lifted and lowered with great accuracy?
6. Is horizontal load travel necessary?
7. How is the hoist to be controlled?
The group is determined by the load spectrum and operating time.

Load spectrum Average operating time per working day in hours

1 Light more than
up to 2 2-4 4-8 8 - 16
16
2 Medium up to 1 1-2 2-4 4-8 8 - 16
3 Heavy up to 0,5 0,5 - 1 1-2 2-4 4-8
4 Very heavy up to 0,25 0,25 - 0,5 0,5 - 1 1-2 2-4
FEM 1Bm 1Am 2m 3m 4m
Group of mechanisms to
ISO M3 M4 M5 M6 M7
Reeving arrangement
2/2 4/2 8/2 6/1 2) 8/1 2)
1/1 2/1 4/1
Load capacity in kg Range Size
2500 5000 10000 16000 20000 - - - - 1025
3600 6300 12500 20000 25000 DH 1000 - - - 1032 -
4000 8000 16000 25000 32000 - - 1040 - -
5000 10000 20000 32000 40000 DH 1000 - 1050 - - 2050
6300 12500 25000 40000 50000 DH 2000 1063 - - 2063 -
8000 16000 32000 50000 63000 - - 2080 - -
10000 20000 40000 63000 80000 DH 2000 - 2100 - - -
12500 25000 50000 80000 100000 2125 - - - -
Tab. 4

The load spectrum (in most cases estimated) can be evaluated in accordance with the definitions (see below):
1. Light
Hoist units which are usually subject to very small loads and in exceptional cases only to maximum loads.
2. Medium
Hoist units which are usually subject to small loads but rather often to maximum loads.
3. Heavy
Hoist units which are usually subject to medium loads but frequently to maximum loads.
4. Very heavy
Hoist units which are usually subject to maximum or almost maximum loads.
211 128 44/100621

2) Only available in groups of mechanisms 1Bm, 1Am and 2m 17

 Load spectra

1. 2. 3. 4.

43241444.eps

Fig. 3

L Load d Small dead load

LZ Operating time e Small to medium dead load
a Full load f Heavy dead load
b Medium partial load g Very heavy dead load
c Small to medium partial load

Calculation example

Load capacity 10000 kg

Load spectrum “Light” from table
Lifting speed 8 m/min
Creep lifting speed 1,3 m/min
Reeving 2/1
Average hook path 4m
No. of cycles/hour 20
Working time/day 8 hours
Tab. 5

The average operating time per working day is estimated or calculated as follows:

Operating 2 x average hook path x no. of cycles/hour x working time/day

=
time/day = 60 x lifting speed

Operating 2 x 4 x 20 x 8
= 2,66 hours
time/day = 60 x 8

Tab. 6

For the medium load spectrum and an average daily operating time of 2,66 hours, the table above shows group
1Am. For a load capacity of 10 t and 2/1 rope reeving, the following table indicates hoist size DH 1050, shown in
bold  Tab. 4, Page 17.
Note on motor selection
● Check the maximum permissible number of starts per hour when selecting motors
● DH hoist unit with pole-changing motor
Main lifting speed = 80 starts per hour
Creep lifting speed = 160 starts per hour
● DH hoist unit with mechanical microspeed
Main lifting speed = 240 starts per hour
Creep lifting speed = 240 starts per hour

3.3 Hoist motor technical data

211 128 44/100621

3.3.1 DH 1000, DH 2000 motor data

The equipment is designed in accordance with the VDE regulations and the FEM design rules to meet the high
18 demands made on electric hoists. Required supply cable conductor cross-sections and fuse links.
 Main/creep lifting F6

Size No. of Group P CDF n Starts/ Rated current IN and start-up current IA for 50 Hz cos cos
poles of h
mech‐
an‐
isms
to
FEM
230 V 400 V 500 V
KBH [kW] % [rpm] IN [A] IA [A] IN [A] IA [A] IN [A] IA [A] φN φA
2 1Bm 7,1 25 2870 80 36 183 21 105 16,7 84 0,70 0,65
1Am
12 2m 1,1 15 440 160 27 35 15,7 20 12,5 16 0,40 0,50
140 B 2/12 3)
2 3m 5,7 40 2900 120 31 183 18,1 105 14,4 84 0,62 0,65
12 4m 0,85 20 460 240 27 35 15,7 20 12,5 16 0,36 0,50
2 1Bm 11,4 25 2870 80 43 248 25 143 19,8 114 0,88 0,61
1Am
12 2m 1,7 15 460 160 28 55 16,2 31 12,9 25 0,36 0,53
160 B 2/12 3)
2 3m 9,3 40 2900 120 36 248 21 14,3 16,7 114 0,86 0,61
12 4m 1,4 20 470 240 28 55 16,2 31 12,9 25 0,32 0,53
2 1Bm 17,8 25 2870 80 73 408 42 235 33 188 0,84 0,60
1Am
12 2m 2,6 15 460 160 35 64 20 37 16 30 0,36 0,48
180 B 2/12 3)
2 3m 14,2 40 2900 120 61 408 35 235 28 188 0,80 0,60
12 4m 2,1 20 475 240 33 64 19 37 15,2 30 0,31 0,48
2 1Bm 25 25 2920 80 93 595 53 342 42 274 0,84 0,50
1Am
12 2m 3,7 15 470 160 41 84 24 48 19 39 0,37 0,50
200 B 2/12 3)
2 3m 20 40 2930 120 79 595 46 342 36 274 0,81 0,50
12 4m 3 20 475 240 38 84 22 48 17,5 39 0,32 0,50
Tab. 7 Main/F6 mechanical microspeed hoist motor data

Size Mains connection delay fuse link 4) Supply lines 5) for 5% voltage drop ∆U and start-up current IA for 50 Hz
at 50 Hz
230 V 400 V 500 V 230 V (∆U 11,5 V) 400 V (∆U 20 V) 500 V (∆U 25 V)
KBH A A A mm² m mm² m mm² m
140 B 2/12 3) 80 50 50 6 3) 14 6) 2,5 3) 16 2,5 3) 23

160 B 2/12 3) 80 50 50 10 3) 18 4 3) 44 4 3) 60

180 B 2/12 3) 125 80 80 16 3) 24 6) 6 3) 21 6 3) 33

200 B 2/12 3) - 100 100 25 3) - 10 3) 31 10 3) 52

Tab. 8

Main lifting

Size Group of P CDF n Starts/h Rated current IN and start-up current IA for 50 Hz cos cos
mechanisms
FEM
230 V 400 V 500 V
KBH [kW] % [rpm] IN [A] IA [A] IN [A] IA [A] IN [A] IA [A] φN φA
1Bm
1Am 11,4 40 1420 240 53 30 24 0,72
140 B 4 2m 248 143 114 0,59
3m
9,3 60 1440 360 45 26 21 0,68
4m
1Bm
1Am 17,8 40 1440 240 76 44 35 0,78
160 B 4 2m 425 244 195 0,58
3m
14,2 60 1450 360 64 37 30 0,75
4m
211 128 44/100621

3) Only use motors with starting and braking circuitry. Voltage drop may then be 10%. See function description 202 708 44 (714 IS 952)
4) Fuse links also apply in connection with a cross-travel motor.
5) The cable lengths are calculated on the basis of an earth-loop impedance of 200 mΩ.
6) Earth-loop impedance of 100 mΩ required. 19
 Size Group of P CDF n Starts/h Rated current IN and start-up current IA for 50 Hz cos cos
mechanisms
FEM
230 V 400 V 500 V
KBH [kW] % [rpm] IN [A] IA [A] IN [A] IA [A] IN [A] IA [A] φN φA
1Bm
1Am 28,5 40 955 240 19 68 55 0,71
180 B 6 2m 496 285 228 0,46
3m
22,5 60 965 360 99 57 46 0,66
4m
1Bm
1Am 40 40 970 240 157 90 72 0,79
200 B 6 2m 760 437 350 0,60
3m
32 60 975 360 132 76 61 0,76
4m
Tab. 9 Main lifting motor data

Size Mains connection delay fuse link 7) Supply lines8) for 5% voltage drop ∆U and start-up current IA for 50 Hz
at 50 Hz
230 V 400 V 500 V 230 V (∆U 11,5 V) 400 V (∆U 20 V) 500 V (∆U 25 V)
KBH A A A mm² m mm² m mm² m
140 B 4 100 63 63 10 22 9) 4 15 4 23
160 B 4 125 80 80 25 38 9) 6 21 6 33
200 B 4 - 125 100 - - 16 32 10 52
225 B 4 - 160 125 - - 25 11 16 58
Tab. 10

Compensating the cable cross-section for large cable lengths

Inverter input voltage: 400 V, 50 Hz

Example for calculating cross-sections Q of the conductors of cables exceeding the length indicated in the table:
KBH 140 B 2/12, 400 V required length 25 m
Known cross-section x required length
Q= =
Known cable length

4 mm2 x 25 m
Q= = 6,6 mm²
15 m

Tab. 11

F10 mechanical microspeed unit

Size Group of mech‐ P CDF n Starts/h Rated current IN and start-up current IA for 50 Hz cos cos
anisms
FEM
230 V 400 V 500 V
KBA [kW] % [rpm] IN [A] IA [A] IN [A] IA [A] IN [A] IA [A] φN φA
1Bm
1Am 1,5 25 1340 240 7,9 4,6 3,6 0,73
80 B 4 2m 26 15,1 12,1 0,77
3m
1,3 40 1370 360 7,3 4,2 3,3 0,68
4m
1Bm
1Am 3,5 25 1405 240 16,5 9,5 7,6 0,72
2m 71 41 33 0,73
3m
3,0 40 1420 360 15,2 8,7 7,0 0,68
4m
100 B 4
1Bm
1Am
2m 2,3 100 425 --- 10,8 56 6,2 32 5,0 26 0,71 0,72
3m
4m
211 128 44/100621

7) Fuse links also apply in connection with a cross-travel motor.

8) The cable lengths are calculated on the basis of an earth-loop impedance of 200 mΩ.
20 9) Earth-loop impedance of 100 mΩ required.
 Size Group of mech‐ P CDF n Starts/h Rated current IN and start-up current IA for 50 Hz cos cos
anisms
FEM
230 V 400 V 500 V
KBA [kW] % [rpm] IN [A] IA [A] IN [A] IA [A] IN [A] IA [A] φN φA
1Bm
1Am 5,2 25 410 240 23 13,5 10,8 0,75
2m 106 61 49 0,68
3m
4,5 40 1425 360 21 12,1 9,7 0,70
4m
112 B 4
1Bm
1Am
2m 3,5 100 1425 --- 15,6 83 9,0 48 7,2 38 0,73 0,70
3m
4m
Tab. 12 F10 mechanical microspeed unit motor data

3.3.2 EUDH, EKDH travel motor data (40% CDF)

230 V

Size PN nN MN IN cos IA / IN MA / MN MH Jmot A MB std Weight

ZBF [kW] [rpm] [Nm] [A] φN [Nm] [kgm2] [h-1] [Nm] [kg]
0,06 675 0,85 1,15 0,59 1,40 2,20 1,7 720
63 A 8/2 B003 0,00459 1,4 10
0,25 2745 0,87 1,65 0,71 2,65 2,10 1,5 550
0,09 675 1,25 1,30 0,61 1,60 2,70 2,5 620
71 A 8/2 B003 0,00690 1,9 12,2
0,34 2785 1,15 1,75 0,73 3,50 2,60 2,5 500
0,13 6330 1,95 2,40 0,64 1,20 2,10 3,5 620
80 A 8/2 B020 0,01275 3,3 19,5
0,50 2790 1,70 2,40 0,73 4,50 2,60 4,0 500
0,20 690 2,80 2,60 0,50 1,95 2,50 6,5 580
90 B 8/2 B020 0,02169 4,4 28,2
0,80 2765 2,80 4,00 0,79 3,60 2,40 6,2 450
0,29 685 4,00 3,70 0,50 1,80 2,50 9,0 460
100 A 8/2 B050 0,03092 8,3 35,0
1,20 2760 4,20 5,60 0,82 4,00 2,50 9,5 350
0,46 705 6,20 4,30 0,49 2,50 2,40 15,0 460
112 A 8/2 B050 0,04374 11 56,4
1,90 2855 6,40 7,50 0,85 5,30 2,40 14,50 350
Tab. 13

400 V

Size PN nN MN IN cos IA / IN MA / MN MH Jmot A MB std Weight

ZBF [kW] [rpm] [Nm] [A] φN [Nm] [kgm ] 2
[h ]
-1
[Nm] [kg]
0,06 675 0,85 0,66 0,59 1,40 2,20 1,7 720
63 A 8/2 B003 0,00459 1,4 10
0,25 2745 0,87 0,95 0,71 2,65 2,10 1,5 550
0,09 675 1,25 0,76 0,61 1,60 2,70 2,5 620
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 6330 1,95 1,20 0,64 1,20 2,10 3,5 620
80 A 8/2 B020 0,01275 3,3 19,5
0,50 2790 1,70 1,40 0,73 4,50 2,60 4,0 500
0,20 690 2,80 1,50 0,50 1,95 2,50 6,5 580
90 B 8/2 B020 0,02169 4,4 28,2
0,80 2765 2,80 2,30 0,79 3,60 2,40 6,2 450
0,29 685 4,00 2,10 0,50 1,80 2,50 9,0 460
100 A 8/2 B050 0,03092 8,3 35,0
1,20 2760 4,20 3,20 0,82 4,00 2,50 9,5 350
0,46 705 6,20 2,50 0,49 2,50 2,40 15,0 460
112 A 8/2 B050 0,04374 11 56,4
1,90 2855 6,40 4,30 0,85 5,30 2,40 14,50 350
Tab. 14

500 V

Size PN nN MN IN cos IA / IN MA / MN MH Jmot A MB std Weight

211 128 44/100621

ZBF [kW] [rpm] [Nm] [A] φN [Nm] [kgm2] [h-1] [Nm] [kg]
0,06 675 0,85 0,53 0,59 1,40 2,20 1,7 720
63 A 8/2 B003 0,00459 1,4 10
0,25 2745 0,87 0,76 0,71 2,65 2,10 1,5 550

21
 Size PN nN MN IN cos IA / IN MA / MN MH Jmot A MB std Weight
ZBF [kW] [rpm] [Nm] [A] φN [Nm] [kgm2] [h-1] [Nm] [kg]
0,09 675 1,25 0,61 0,61 1,60 2,70 2,5 620
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 6330 1,95 1,10 0,64 1,20 2,10 3,5 620
80 A 8/2 B020 0,01275 3,3 19,5
0,50 2790 1,70 1,10 0,73 4,50 2,60 4,0 500
0,20 690 2,80 1,20 0,50 1,95 2,50 6,5 580
90 B 8/2 B020 0,02169 4,4 28,2
0,80 2765 2,80 1,85 0,79 3,60 2,40 6,2 450
0,29 685 4,00 1,70 0,50 1,80 2,50 9,0 460
100 A 8/2 B050 0,03092 8,3 35,0
1,20 2760 4,20 2,60 0,82 4,00 2,50 9,5 350
0,46 705 6,20 2,00 0,49 2,50 2,40 15,0 460
112 A 8/2 B050 0,04374 12 63,0
1,90 2855 6,40 3,40 0,85 5,30 2,40 14,50 350
Tab. 15

3.3.3 Mounting code for ordering a mechanical microspeed unit

Four different mounting positions A, B, C and D and three rope lead-

0 offs 1, 2 and 3 can be achieved by rotating the hoist unit about its longi‐
tudinal axis. The position of the motor terminal box can be changed,
staggered at 90°.
Position of the ventilation opening
1 3
● If the foot position is altered, it must be ensured that
the code number stamped into the gearbox casing
(gear ratio) is always at the top. Only then can it be en‐
sured that the gearbox is vented properly.
2
Indication of position of terminal boxes for main lifting and creep
Fig. 4 lifting motor (mechanical microspeed).
The position is indicated by the code numbers 0-1-2-3, ascending in an‐
ti-clockwise direction when looking at the motor end face. The position
must be indicated in accordance with the selected mounting flange po‐
sition A, B, C or D.

Terminal box position Foot position

H1 A
H0 B
H3 C
H2 D
Tab. 16

Mounting code for ordering a mechanical microspeed unit

Gearbox Basic model Main hoist motor terminal Microspeed hoist motor Transmission ratio10)
box position terminal box position
FG.. U0 H1 F1 1011)
FG.. U1 H0 F0 10 11)
FG.. U2 H1 F1 10 11)
FG.. U3 H0 F0 10 11)
Tab. 17
211 128 44/100621

10) Other transmission ratios on request

22 11) For 6-pole main hoist motor i = 15
 3.4 Hook dimension C
3.4.1 DH 1000
The hook dimensions C specified in the following apply to the upper emergency-stop cut-off point. In connection
with an operating limit switch, hook dimension C is increased with reference to the operating cut-off point.

Size Hook dimensions C with overload cut-off

1/1 4/1 4/2 A 4/1 B 4/1
with without with without with without with without with without
DH Creep lifting
1063-1032 890 935 565 605 845 865 810 830
625 670
1025 1060 1105 1160 1205 1120 1000 1020
Tab. 18

Size Hook dimensions C without overload cut-off

1/1 4/1 4/2 A 4/1 B 4/1
with without with without with without with without with without
DH Creep lifting
1063-1032 810 855 565 605 765 785 730 750
625 670
1025 980 1025 1160 1205 1040 920 940
Tab. 19

3.4.2 DH 2000

Size Hook dimensions C with overload cut-off

1/1 4/1 4/2 A 4/1 B 4/1
with without with without with without with without with without
DH Creep lifting
2125-2080 1140 1180 120 1140 1120 1140
735 780 1110 1150
2063
1260 1300 1300 1345 1365
2050 - 1030 1075
Tab. 20

Size Hook dimensions C without overload cut-off

1/1 4/1 4/2 A 4/1 B 4/1
with without with without with without with without with without
DH Creep lifting
2125-2080 1060 1100 1040 1060 1040 1060
735 780 1110 1150
2063
1180 1220 1200 1265 1285
2050 - 1030 1075
Tab. 21

3.4.3 Changes resulting from operating limit switch

If an operating limit switch is fitted for the top hook position, hook di‐
mension “C”, for 1/1, 2/1 and 4/1 rope reeving, increases as follows:

Reeving 1/1 2/1 4/1

Change in hook di‐ + 85 mm + 50 mm + 20 mm
mension
Tab. 22 Change of hook dimension

The effective hook path decreases by the values given in the following
tables ( Tab. 23, Page 23 and  Tab. 24, Page 24).
C

Reeving 1/1 2/1 4/1

Change in hook di‐ - 85 mm - 50 mm - 20 mm
mension
211 128 44/100621

Tab. 23 Operating limit switch for the top hook position

Fig. 5

23
 Reeving 1/1 2/1 4/1
Change in hook di‐ - 170 mm - 100 mm - 40 mm
mension
Tab. 24 Operating limit switch for the top and bottom hook positions

3.4.4 EUDH 1000 standard-headroom monorail hoist

Size Hook dimensions C with overload cut-off

Reeving 2/1 4/2
with creep lift‐ no creep lifting with creep lift‐ no creep lifting
ing ing
DH 1063-1032 1750 1795 1420 1460
DH 1025 1920 1965 2020 2065
Tab. 25 Hook dimension C from girder running surface

Size Hook dimensions C without overload cut-off

C

Reeving 2/1 4/2

with creep lift‐ no creep lifting with creep lift‐ no creep lifting
ing ing
DH 1063-1032 1670 1715 1420 1460
DH 1025 1840 1885 2020 2065
Tab. 26 Hook dimension C from girder running surface

Fig. 6

3.4.5 EKDH 1000 low-headroom monorail hoist

Size Hook dimensions C with overload cut-off

Reeving 2/1 4/2
Flange width b 100 - 200 305 100 - 200 305
Creep lifting with with‐ with with‐ with with‐ with with‐
out out out out
DH 1063-1032 920 960 920 960 660 680
DH 1025 1220 1225 1255 1225 1255
Tab. 27 Hook dimension C from girder running surface

Size Hook dimensions C with overload cut-off

Reeving 2/1 4/2
Flange width b 100 - 200 305 100 - 200 305
Creep lifting with with‐ with with‐ with with‐ with with‐
out out out out
Fig. 7
DH 1063-1032 840 880 840 880 660 680
DH 1025 1140 1225 1255 1225 1255
Tab. 28 Hook dimension C from girder running surface

3.4.6 EZDH 1000/DRS double-rail crab

DRS wheel block 112 125 112 125 112 125 112 125
Reeving 2/1 4/2 2/1 4/2
Size Hook dimensions C with overload cut-off
with creep lifting no creep lifting
DH 1063-1032 - 830 - 505 - 875 - 545
DH 1040-1032 835 - 530 - 900 - 570 -
DH 1025 1025 1000 1125 1100 1070 1045 1170 1145
Tab. 29
C

211 128 44/100621

43328544.eps

Fig. 8

24
 DRS wheel block 112 125 112 125 112 125 112 125
Reeving 2/1 4/2 2/1 4/2
Size Hook dimensions C without overload cut-off
with creep lifting no creep lifting
DH 1063-1032 - 750 - 505 - 795 - 545
DH 1040-1032 755 - 530 - 820 - 570 -
DH 1025 945 920 1125 1100 990 965 1170 1145
Tab. 30

DRS wheel block 125 160 200 125 160 200

Reeving 4/1
Size Hook dimensions C with overload cut-off
with creep lifting no creep lifting
DH 1063 - - 815 - - 835
DH 1050 - 770 - - 785 -
DH 1040-1032 800 - - 820 - -
DH 1025 1075 - - 1075 - -
Tab. 31

DRS wheel block 125 160 200 125 160 200

Reeving 4/1
Size Hook dimensions C without overload cut-off
with creep lifting no creep lifting
DH 1063 - - 735 - - 755
DH 1050 - 690 - - 705 -
DH 1040-1032 720 - - 740 - -
DH 1025 995 - - 995 - -
Tab. 32

3.4.7 EZLDH 2000/DRS double-rail crab

DRS wheel 200 250 200 250

block
Reeving 4/1
Size Hook dimensions C with overload cut-off
with creep lifting no creep lifting
DH 2100 - 785 - 805
DH 2080 830 - 850 -
DH 2063 990 - 990 -
Tab. 33 Hook dimensions C from girder running surface
C

DRS wheel 200 250 200 250

block
Reeving 4/1
Size Hook dimensions C without overload cut-off
with creep lifting no creep lifting
DH 2100 - 705 - 725
Fig. 9
DH 2080 750 - 770 -
DH 2063 910 - 910 -
Tab. 34 Hook dimensions C from girder running surface

3.4.8 Construction, application and reeving of wire ropes

DH 1000
Standard wire ropes
211 128 44/100621

25
 10 10 10 10
50 50 50 50
10 1050-1 10 10 10
DH size -1 1063 -1 -1 -1
63 025 63 63 63
02 02 02 02
5 5 5 5
Reeving ar‐ 2/2-212
1/1 2/1 4/1 4/2
rangement )

Group of
1A 1A 1A 1A
mecha‐ 1B 1Am-4 1B 1B 1B
m- 1Bm m- m- m-
nisms to m m m m m
4m 4m 4 4m
FEM
Wire rope m
20 20 20 20 20 20 14 14 14 14
diameter m
Number of
load-bear‐
12 12 28 12 12 12 20 28
ing wires in 126 288
6 6 8 6 6 6 8 8
the external
strand
Or Or Or Or Or Or
La La
di‐ di‐ di‐ di‐ di‐ di‐
ng Lang’s Ordina‐ ng
Lay method na na na na na na
’s lay ry lay ’s
ry ry ry ry ry ry
lay lay
lay lay lay lay lay lay
Free of
twist/rota‐ Ye Ye Ye Ye Ye
Yes No No No No
tion-resist‐ s s s s s
ant
Calculated 34
44 35 35 21 16 20 15
rope break‐ 445,9 6,3 346,35
5,9 2,2 2,2 6,4 9 1,6 9,2
ing force kN 5
Minimum
36 25 28 25 17 12 16 12
breaking 362,2 285,4
2,2 9,8 5,4 9,8 9,1 5 6,2 5
force kN
Tensile
strength of N/ 19 19 17 19 19 19 17 17
1960 1770
single m 60 60 70 60 60 60 70 70
strand m²
H1 82 82
6- 44 44
Rope – –
H2 82 82 76 90 82 82 44 82
data 4 44 44 44 44 824490 34 34 93 34
sheet
H4 76 70 82 82 44 76 70 48 90
ident.
44 44 44 44 46 44
number 0- –
44
–
44
H5 76 70
1 44 44

211 128 44/100621

26 12) See 4/2 configuration for rope spreader operation

 10 10 10 10
50 50 50 50
10 1050-1 10 10 10
DH size -1 1063 -1 -1 -1
63 025 63 63 63
02 02 02 02
5 5 5 5
D
H
10 2x
38,
63 39,6 39,6 42 22, 47,1
5
-1 6 2x
03 H1 38,
22,
2 6 5
6
D
H
– 40 40 43,2 – 47,6
10
25
D
H
10 2x
54,
63 55,3 55,3 57,7 33, 69,3
1
-1 8 2x
03 H2 54,
33,
2 4 1
8
D
H
Ro 10 – 55,7 55,7 58,8 – 69,8
pe 25
len m
gth D
s H
10 2x
86,
63 87,3 87,3 89,7 56, 114,5
1
-1 4 2x
03 H4 86,
56,
2 0 1
4
D
H
– 87,7 87,7 90,8 – 115
10
25
D
H
10 2x
10
63 109,3 109,3 111,7 72, 147,3
8,1
-1 8 2x
03 H5 10
72,
2 1 8,1
8
D
H
– 109,7 109,7 112,8 – 147,8
10
25
Tab. 35

Wire ropes with rope safety factor ≥ 5

10 10 10 10
50 50 50 50
10 1050-1 10 10 10
DH size -1 1063 -1 -1 -1
63 025 63 63 63
02 02 02 02
5 5 5 5
2/2 2/2
Reeving ar‐
1/1 1/1 2/1 2/1 4/1 4/1 -21 -21 4/2 4/2
rangement 3) 3)

Group of
1A 1A 1A 1A
mecha‐ 1B 1Am-4 1B 1B 1B
m- 1Bm m- m- m-
nisms to m m m m m
4m 4m 4m 4m
FEM
Wire rope m 20, 20,
20 20 20 20 20 14 14 14 14
diameter m 2 2
Number of
load-bear‐
12 12 20 12 28 12 20 28 12 12 20 28
ing wires in
6 6 0 6 8 6 0 8 6 6 8 8
the external
211 128 44/100621

strand

13) See 4/2 configuration for rope spreader operation 27

 10 10 10 10
50 50 50 50
10 1050-1 10 10 10
DH size -1 1063 -1 -1 -1
63 025 63 63 63
02 02 02 02
5 5 5 5
Or Or Or Or Or Or Or Or Or
La La La
di‐ di‐ di‐ di‐ di‐ di‐ di‐ di‐ di‐
ng ng ng
Lay method na na na na na na na na na
’s ’s ’s
ry ry ry ry ry ry ry ry ry
lay lay lay
lay lay lay lay lay lay lay lay lay
Free of
twist/rota‐ Ye Ye Ye Ye Ye Ye
No No No No No No
tion-resist‐ s s s s s s
ant
Calculated 34 34
44 35 58 44 35 58 21 16 20 15
rope break‐ 6,3 6,3
5,9 2,2 3,8 5,9 2,2 3,8 6,4 9 1,6 9,2
ing force kN 5 5
Minimum
36 25 49 36 28 25 49 28 17 12 16 12
breaking
2,2 9,8 0,4 2,2 5,4 9,8 0,4 5,4 9,1 5 6,2 5
force kN
Tensile
strength of N/ 19 19 22 19 17 19 22 17 19 19 17 17
single m 60 60 60 60 70 60 60 70 60 60 70 70
strand m²
H1 82 82
6- 54 44
Rope – –
H2 82 82 98 90 82 82 82 82 44 82
data 4 44 44
44 44 54 44 34 34 93 34
sheet
H4 76 70 82 82 98 90 76 70 48 90
ident.
44 44 44 44 44 44 44 46 44
number 0- –
44
–
H5 76 70
1 44 44
Rope
As for standard wire ropes
lengths m
Tab. 36

DH 2000
Standard wire ropes

210 210 210 210

2125-206 212 212 212
DH size 0-2 0-2 0-2 0-2
3 5 5 5
063 063 050 050
Reeving ar‐
1/1 2/1 4/1 2/2-214) 4/2
rangement
Group of 1A 1A 1A 1A
1B 1B 1B
mechanisms to m-3 1Bm-3m m-3 m-4 m-4
m m m
FEM m m m m
Wire rope di‐
25 25 25 20 20 20
ameter mm
Number of
load-bearing
126 208 126 208 126 126 288
wires in the ex‐
ternal strand
Or‐ Or‐
Lan di‐ Lan Lan di‐
Ordinary Ordinary
Lay method g’s nar g’s g’s nar
lay lay
lay y lay lay y
lay lay
Free of twist/
rotation-resist‐ Yes No Yes No Yes Yes No
ant
Calculated
723 640 723 445 352
rope breaking 640,8 346,35
,5 ,8 ,5 ,9 ,2
force kN
Minimum 560 563 560 362 259
563,3 285,4
breaking force kN ,2 ,3 ,2 ,2 ,8
Tensile
196 196 196 196 196
211 128 44/100621

strength of sin‐ N/m 1960 1770

0 0 0 0 0
gle strand m²

28 14) See 4/2 configuration for rope spreader operation

 210 210 210 210
2125-206 212 212 212
DH size 0-2 0-2 0-2 0-2
3 5 5 5
063 063 050 050
H18 825
Rope da‐ - 474 –
825 824 824
ta sheet H27 44 8254744 8244904
476 476 470
ident. H47 825 4 4
44 44 44
number – 476
44
DH H18 48,3 2x 43,2
212 20,
45,5
5-2 4 2x
080 44,
20,
4
DH 45,7 4
206 48,9 – 43,7
3
DH H27
2x
212
Rop 5-2 63,9 66,7 31, 65,2
4 2x
e 080 62,
m 31,
leng 7
4
ths DH 64,1
206 67,3 – 65,7
3
DH H47
2x
212
104,3 105,1 55, 113,2
5-2 2x
103 5
080 55,
,1
DH 104,6 5
206 105,7 – 113,7
3
Tab. 37

Wire ropes with rope safety factor ≥ 5

21 21 21 21
00- 21 00- 21 00- 21 00-
DH size 2125-2063
20 25 20 25 20 25 20
63 63 50 50
Reeving ar‐
1/1 2/1 4/1 2/2-215) 4/2
rangement
Group of 1A 1A 1A 1A
1Am-3 1B 1B 1B
mechanisms m- 1Bm m- m- m-
m m m m
to FEM 3m 3m 4m 4m
Wire rope di‐ m
25 25 25 20 20 20
ameter m
Number of
load-bearing
12 26 20 12 20 12 12 20 28
wires in the – –
6 0 8 6 8 6 6 0 8
external
strand
Or‐ Or‐ Or‐ Or‐ Or‐ Or‐
La La La
di‐ di‐ di‐ di‐ di‐ di‐
ng ng ng
Lay method nar – nar – nar nar nar nar
’s ’s ’s
y y y y y y
lay lay lay
lay lay lay lay lay lay
Free of twist/
Ye Ye Ye Ye
rotation-re‐ No – No – No No No
s s s s
sistant
Calculated 72 34
72 64 72 64 44 35 39
rope break‐ 7,6 – – 6,3
3,5 0,8 3,5 0,8 5,9 2,2 3,5
ing force kN 5 5
Minimum
56 61 56 56 56 36 25 34 28
breaking – –
0,2 3,4 3,3 0,2 3,3 2,2 9,8 1,7 5,4
force kN
Tensile N/
19 21 19 19 19 19 19 19 17
strength of m – –
60 60 60 60 60 60 60 60 70
single strand m²
211 128 44/100621

15) See 4/2 configuration for rope spreader operation 29

 21 21 21 21
00- 21 00- 21 00- 21 00-
DH size 2125-2063
20 25 20 25 20 25 20
63 63 50 50
H1 82 82
8- 54 54
Rope – –
H2 82 88 74 82 82 82 44 82
data 7 44 44
54 54 44 44 96 44
sheet –
H4 76 82 74 76 70 31 90
ident.
7 44 54 44 44 44 46 44
number – – –
76
44
Rope
As for standard wire ropes
lengths m
Tab. 38

3.5 Mounting flange positions and rope lead-offs

4
A C
3 4

3 1
3
1 1

2
2

2
6
2

2
2

1 1
3
3

1
3
4
B 2 D
4
2 2
1
3

3 1
1
3
1

1 3
3
1

Fig. 10 View of the hoist motor

Foot positions Item numbers

A Foot position A 1 Rope lead-off 1
211 128 44/100621

B Foot position B 2 Rope lead-off 2

C Foot position C 3 Rope lead-off 3
D Foot position D 4 Code
30
 5 Main hoist motor terminal box
6 Welded-on suspension (only for DH 2000 4/1)

DANGER
Falling hazard
The hoist unit may fall if it is incorrectly installed in foot position A.
Pay close attention to the possible bolted connections.

Four different mounting positions A, B, C and D and three rope lead-offs 1, 2 and 3 can be achieved by rotating
the hoist unit about its longitudinal axis. The position of the motor terminal box can be changed, staggered at 90°.
Position of the ventilation opening
● If the mounting flange position is altered, it must be ensured that the code number stamped into the gearbox
casing (gear ratio) is always at the top ( Fig. 10, Page 30). Only then can it be ensured that the gearbox is
vented properly.

Demag hoist unit with rope guide

Range Rope lead-off Special design

Rope lead-off
1 2 3
ɑ1 ß1 ɑ2 ß2 ɑ3 ß3
H16
H24
DH 1000 13° 8°
H40
H51 20° 25° 20° 20°
H18
DH 2000 H27 15° 0°
H47
Tab. 39

Demag hoist unit without rope guide

Range Rope lead-off Special design

Rope lead-off
1 2 3
ɑ1 ß1 ɑ2 ß2 ɑ3 ß3
H16 38°
15°
H24
DH 1000 25° 45° 66° 9°
H40 34°
3°
H51
H18
59°
DH 2000 H27 22° 33° 19° 62° 0°
H47 52°
Tab. 40
211 128 44/100621

31
 Special rope lead-offs

Rope lead-offs 4 and 5 can only be supplied on request.

4
Fig. 11

3.6 Gearbox oil filling

The quantity of oil needed in the gearbox depends on the range (DH 1000, DH 2000). Before it is delivered, the
gearbox is filled according to the order.
Under normal operating conditions, the lubricant does not have to be changed until a general overhaul is carried
out.
Under exceptional operating conditions, e.g. increased ambient temperatures, we recommend that oil change in‐
tervals be adapted to suit these operating conditions.
Oil change
The planetary gearbox must be removed. The gearbox parts and gearbox casing must be thoroughly cleaned with
commercially available cleaning agents. Then re-assemble the gearbox. Re-fill with fresh gear oil before closing
the gearbox. The required quantity and grade of oil can be seen in the table below.

Range DH 1000 DH 2000

Oil quantity [litres] 6 13
Tab. 41

At ambient temperatures of approximately -15 °C to +60 °C, use EP 220 synthetic gear oil, e.g. Klüber, SYNTHE‐
SO D 220 EP or Esso UMLAUFOEL S 220.
Part no. 472 930 44 = 2,5 litres
Part no. 472 931 44 = 1 litre

3.7 Operating conditions

Ambient temperature range -10 to +45 °C
Max. air humidity 80 %
Max. altitude/air pressure 1000 m above sea level
Tab. 42

Other operating conditions are also possible:

● Corrosive atmosphere
Please refer to the manufacturer for information on any modifications that may be necessary. For contact informa‐
tion, see  "After-sales service", Page 10.
Safe operation is only possible under the conditions specified above.
● Please contact the manufacturer for any other operating conditions.

The rope hoist can be damaged if it is operated outdoors in poor weather.

211 128 44/100621

● If it is operated outdoors, provide the rope hoist with a cover to protect it from the weather and keep travelling
hoists under shelter when they are not in use.

32
 3.8 Noise emission
Sound pressure level LpAF in relation to the load capacity and size of the rope hoist at a distance of 1 m:

Sound pressure level to DIN 45635

L
pA
[ dB(A) ]

2
90

85 1

80
3

75

70
1,6 2 2,5 3,2 4 5 6,3 8 10 12,5 16 20 25 m

DH 1000 1025 10321040 1050 1063

DH 2000 2050 2063 2080 2100 2125

Fig. 12

m Mass m x 1000 kg for 2/1 reeving

Item in diagram 1 2 3
Motor speed n = 1400 rpm n = 2800 rpm n = 900 rpm
Logarithmic regression LpA 47,69 + 8,14 * log [m/kg] [dB(A)] 42,31 + 10,92 * log [m/kg] [dB(A)] 70,27 + 2,972 * log [m/kg] [dB(A)]
Correlation coefficient r = 0.7 r = 0.7 r = 0.42
Tolerance ± 2 dB (A)
Tab. 43

The sound pressure level of a DH rope hoist can be seen in the diagram above. The specified values (emission
levels) were measured under maximum load.
The following structural influences were not considered in the measurements:
● transmission of noise via steel structures
● reflection of noise from walls, etc.
211 128 44/100621

33
 Sound pressure level measurement to DIN 45635

-3 dB(A)

-6 dB(A)

1m

2m

4m

43311444.eps

Fig. 13 Sound pressure reduction in relation to the distance from the sound source

A Measuring point
B Sound source

The sound pressure level is reduced by approx. 3 dB(A) each time the distance is doubled.

3.9 Paint finish

The machine is supplied in the following standard colours:

Hoist unit RAL 5009 azure blue

Hook assembly/bottom block RAL 1007 chrome yellow
Hook RAL 9005 jet black
Trolley RAL 5009 azure blue
Tab. 44
211 128 44/100621

34
 3.10 Weight

DH 1000, weights in kg

Reeving 1/1 2/1 4/2 Type A 4/1 Type B 4/1

Range Motor size Size
DH 1063-1025 1063-1032 1025 1063-1032 1025 1063-1032 1025 1063-1032 1025
140 665 685 700 720 765 825 890 - -
DH 1000 160 735 755 770 790 835 895 960 - -
KBH
H16 180 805 825 840 860 905 965 1030 - -
200 865 885 960 920 965 1025 1090 - -
140 755 775 790 810 855 910 985 910 985
DH 1000 160 825 845 860 880 925 980 1055 980 1055
KBH
H24 180 895 915 930 950 995 1050 1125 1050 1125
200 955 975 990 1010 1055 1110 1185 1110 1185
140 955 975 990 1010 1055 - - 1110 1185
DH 1000 160 1025 1045 1060 1080 1125 - - 1180 1255
KBH
H40 180 1095 1115 1130 1150 1195 - - 1250 1325
200 1155 1175 1190 1210 1255 - - 1310 1385
140 1075 1095 1110 1130 1075 - - 1230 1305
DH 1000 160 1145 1165 1180 1200 1245 - - 1300 1375
KBH
H51 180 1215 1235 1250 1270 1315 - - 1370 1445
200 1275 1295 1310 1330 1375 - - 1430 1505
Tab. 45

Weight of mechanical micro‐ [kg]

speed unit
FG 08 with KBA 80 55
FG 10 with KBA 90 160
FG 10 with KBA 100 186
Tab. 46

DH 2000, weights in kg

Reeving 1/1 2/1 4/2 Type A 4/1 Type B 4/1

Range Motor size Size
DH 2125-2063 2125-2080 2063-2050 2125-2063 2050 2125-2080 2063-2050 2125-2080 2063-2050
160 1155 1305 1330 1305 1375 1580 1645 - -
DH 2000 180 1235 1385 1410 1385 1455 1660 1725 - -
KBH
H18 200 1300 1450 1475 1450 1520 1725 1790 - -
225 1405 1555 1570 1555 1625 1830 1895 - -
160 1345 1495 1520 1500 1570 1800 1865 1800 1865
DH 2000 180 1425 1575 1600 1580 1650 1880 1945 1880 1945
KBH
H27 200 1490 1640 1665 1645 1715 1945 2010 1945 2010
225 1595 1745 1770 1750 1825 2050 2115 2050 2115
160 1725 1875 1900 1885 1955 - - 2150 2215
DH 2000 180 1805 1955 1980 1965 2035 - - 2230 2295
KBH
H47 200 1870 2020 2045 2030 2100 - - 2295 2360
225 1975 2120 2150 2135 2205 - - 2400 2465
Tab. 47

Weight of mechanical micro‐ [kg]

speed unit
FG 10 with KBA 90 160
FG 10 with KBA 100 186
FG 10 with KBA 112 212
Tab. 48
211 128 44/100621

35
 EZDH 1000, weight in kg

Reeving 2/1 4/2 2/1 4/2 2/1 4/2

Hook path H 16 16) H 16 H 24 H 40
DH size 1063 - 1025 1063 - 1025 1050 - 1025 1063 - 1025 1050 - 1025 1063 - 1025
1032 1032 1032 1032 1032 1032
KBH 140 980 995 14020 1065 1090 1105 1120 1165 1325 1340 1370 1395
KBH 160 1050 1065 1090 1135 160 1175 1190 1235 1395 1410 1440 1465
Motor size
KBH 180 1120 1135 1160 1205 1230 1245 1260 1305 1465 1480 1520 1535
KBH 200 1180 1195 1220 1265 1290 1305 1320 1365 1525 1540 1580 1595
Tab. 49

3.11 Control system

Direct control and contactor control systems are available for control purposes.
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 electric switchgear is installed in the electric enclosure of the hoist unit. The enclosure casing is protected to
IP 55, i.e. the switchgear is protected against harmful dust deposits and is hose-proof in all directions.
There is a risk of unacceptably high operating currents if inadequate fuse links are used.
● Do not replace fuse links by those with a rating higher than that specified in the technical data, since other‐
wise short-circuit protection will be inadequate.

211 128 44/100621

36 16) DH 1063 only possible with H16 hook path

 4 Design and function

4.1 Design

1 2 3 4 5 6 7 8 9 10 11

13 12

14

Fig. 14

1 Electric equipment cover 8 Rope drum

2 Electric components 9 Roller coupling
3 Geared limit switch 10 Motor
4 Frame 11 Main hoist motor brake
5 Journal shaft 12 Terminal box
6 Rope guide 13 Rope drum brake
7 Planetary gearbox 14 Wire rope

4.2 Arrangement of assemblies

The axial arrangement of the planetary gearbox inside the drum is one of the significant features of the design.
The 2 mounting flanges are connected by 3 longitudinal beams to form a frame. The drum with the planetary
gearbox inside it is located in the centre of the frame.
The motor and roller coupling are mounted on the foot flange at the motor end.
The complete electric equipment and geared limit switch are located beneath a cover on the opposite end.
The square shape of the foot flange enables Demag hoist units to be connected on any of the 4 sides of the
211 128 44/100621

frame.
Various mounting flange positions and rope lead-offs can be obtained by rotating the hoist unit. The planetary
gearbox must be rotated back into its original position.
37
 4.3 Drives

4.3.1 Hoist drive

The hoist drive is a Demag brake motor, which has a combined conical rotor and brake. The equipment is de‐
signed in accordance with the EN (IEC) regulations and the FEM design rules to meet the high demands made on
electric hoists. KB hoist motors feature IP 54 enclosure (IP 20 enclosure for the brake of the KB brake motor).
A creep lifting speed of 1/6 of the main lifting speed can be obtained by using a 2/12-pole motor. An FG mechani‐
cal microspeed unit can be used if other creep lifting speeds are required.
The transmission ratios available in the FG range provide a large number of possible creep lifting speeds. The
preferred transmission ratio is 1/10. Mechanical microspeed units can be installed at a later date, if required.

4.3.2 Travel drive

Demag brake motors with separately controlled brakes are used as travel drives. ZBF travel motors have IP 54
enclosure. 8/2-pole travel motors are used for the travel motion.
This provides a creep travel speed of 1/4 of the main travel speed. Only the 2-pole windings of the travel motors
are connected for a single travel speed.

4.3.3 Gearbox/rope reeving components

The torque of the motor is transmitted to the planetary gearbox by a roller coupling which is flexible both in radial
and axial directions. The 2, 3 or 4-stage planetary gearbox inside the drum houses all gear stages.
The drum, rope sheaves and rope comply with the following design rules:
● FEM 9.661
● ISO 4308-1
● prEN 13001-3.2

4.4 Geared limit switch

Motions are limited at the upper and lower limit positions by the DGS geared limit switch.
The following types are available:
● DGS 3 – Emergency limit switch for the highest and lowest hook positions, operating limit switch for the highest
hook position
● DGS 4 – Emergency limit switch/operating limit switch for the highest and lowest hook positions
The functions of all DGS contacts can be freely selected.
Every DGS unit 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 unit can be supplied with a pulse generator or this can be fitted at a later date. The pulse
wheel required for pulse generation is fitted as standard in every DGS unit.
Function description
Geared limit switch (3) is fitted inside electric equipment cover (1) of the Demag rope hoist. It is used to limit the
upper or lower hook positions of the rope hoist as standard (emergency limit switch).
It switches off the rope hoist when the top or bottom hook position is reached. The direction of movement can be
reversed. The emergency limit switch must not be approached in normal operation.
Operating limit switches are required where the end positions are approached regularly 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
211 128 44/100621

fails to operate, the emergency limit switch is actuated.

Accident prevention regulations require that the crane operator checks the emergency limit switch before starting
work. This can be done by using the 2-stage button on the controller.
38
 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 test button pressed simultaneously.
The 2-stage button must be pressed to move the hook back out of the end position (lowering).
Please refer to the relevant circuit diagram for the functions performed by the geared limit switch.

4.5 Integrated controls

Electric equipment cover (1) accommodates the control system for the required connections and powerfeeds.

4.6 Controller

4.6.1 Control element

The DST housing is made of glass fibre-reinforced polyester which is highly resistant to impacts and is resistant to
fuels, salt water, grease, oils and alkaline solutions.
The DST pendant controller features IP65 enclosure.

WARNING
Danger from acids
Strong mineral acids, e.g. hydrochloric or sulphuric acid, can corrode switch housings.
Replace such switches in good time.
Avoid contact with these substances.

Demag DST pendant controllers are used as standard and in special

applications. A test button must be installed in the controller of De‐
mag hoist units that are equipped with operating and emergency limit
switches.
1 See  206 165 44 to replace the controller and switching elements.
Demag rope hoists are generally fitted with emergency limit switches
and a 2-stage test button in the DST pendant controller. The control
2 cable is fitted according to  "Control cable and line voltage connec‐
tion", Page 57.
The pendant controller should be suspended so that the bottom edge is
approx. 1 m above floor level. Suspend the pendant controller in such a
way that the symbols (arrow symbols) match the directions of move‐
ment for the drives.

Fig. 15 Item Function

1 Emergency-stop button
2 Buttons to control the motion axes
- Test button
Tab. 50

● The two-stage test button (2) can be used to by-pass the “lifting”
operating limit switch to check the emergency limit switch.
● An additional bumper protects the housing against particularly harsh
ambient conditions.

4.6.2 Connecting the control cable

The pendant controller and the mains connection cable must be fitted by the customer in such a way that the con‐
211 128 44/100621

nectors are not subjected to any tensile or transverse forces.

The control cable of the pendant controller has strain relief cords which must be attached by the customer.

39
 4.7 Types
Four different DH hoist unit types can be supplied:
● Stationary model: DH hoist unit
● Travelling models:
- UDH standard-headroom monorail hoists (for DH 1000)
- EZLDH double-rail crabs (for DH 2000)

4.8 Overload protection/load detector

Dematik® ZMS/FGB FAW-1 electronic load detectors (standard on DH 2000; option for DH 1000) or MGS/MKA-2
mechanical load detectors (standard on DH 1000) can be used to protect Demag hoist units and supporting struc‐
tures.
A basic distinction is made between overload cut-off switches and overload protection devices (without/with creep
lifting). A summation measuring device, slack rope relay and load display can also be fitted in combination with
ZMS/FGB/FAW-1 units.

For further details, see description and instructions for load detectors 206 689 44 and  206 880 44
(206 715 44).

211 128 44/100621

40
 4.9 Track girder requirements
4.9.1 EKDH, EUDH track

43330844.eps

Fig. 16

The running surfaces must only be given a primer coat.

Minimum requirements for runways:

● Do not use profile sections for monorail hoist track which are smaller than the minimum dimensions specified in
our operating instructions, as otherwise deformation of the bottom flanges can occur. Permissible deviations in
dimension and shape of the track girder according to DIN EN 10034.
The special travel unit requirements are listed in the following chapter  "EKDH, EUDH trolley ", Page 41.
● Travel on track girders must in no way be obstructed by protruding suspension bolts, screw heads, butt straps,
clamping plates, etc.
● Track gradients should not exceed 2%.
● Limit stops must be fitted at both ends of the trolley runway.
● Track joints must be clean and smooth. Bolted joints must be outside the travel area of the travel wheels (ob‐
serve maximum web thickness).
● The running surfaces of rails and track beams must only be given a primer coat of 40 µ in the area of the
wheels and guide rollers. Travel characteristics would be impaired by a finish coat.
● Rails and track beams should be kept clean; oil, grease, ice and dirt on the running surfaces will cause travel
wheels to skid.
● In the interest of good travel characteristics, we recommend the use of the largest possible curve radii. Special
attention should be paid to the proper bending of beams for curved tracks.

4.9.2 EKDH, EUDH trolley

The trolleys are infinitely adjustable to various flange widths.
When the retaining rings and washers have been removed from the connecting rods, remove the locking bolts on
the wheel legs (on UDH also the locking bolts on the crossheads) and drive the tapered locking pin towards the
locking bolt with a punch.
The wheel legs can then be moved along the connecting rods.
Do not use the low-headroom monorail hoist to pull free, pull or drag loads on the ground. The monorail hoist
must never run against the buffer stops at full speed, as otherwise damage to the hoist unit or even accidents
may occur.
211 128 44/100621

41
 4.9.3 EZDH track girders

43311244.eps

Fig. 17

The running surfaces must only be given a primer coat.

Minimum requirements for runways:

● Do not use beams with profile sections and cross-sections that are smaller than the minimum dimensions
specified in our documents for track girders of double-rail crabs as otherwise deformation of the girders can
occur. Permissible deviations in dimension and shape of the track girder according to DIN EN 10034.
The requirements are listed by ranges in the following section  "Checking dimensional accuracy of the EZDH
track", Page 46.
- Dimensional accuracy of the tracks
- Tolerance of the individual girder, of the crab track gauge
- Difference in rail height
- Gradient of the crab rails
● Travel on track girders must in no way be obstructed by protruding suspension bolts, screw heads, butt straps,
clamping plates, etc.
● Track gradients should not exceed 2%.
● Appropriately dimensioned end stops must be fitted at both ends of the trolley runway.
● Track joints must be clean and smooth. Bolted joints must be outside the travel area of the travel wheels (ob‐
serve maximum web thickness).
● Check of the crab trolley  "Checking dimensional accuracy of the EZDH track", Page 46
● The running surfaces of rails and track beams must only be given a primer coat of 40 µ in the area of the
wheels and guide rollers. Travel characteristics would be impaired by a finish coat ( Fig. 17, Page 42).
● Rails and track beams should be kept clean; oil, grease, ice and dirt on the running surfaces will cause travel
wheels to skid.

4.9.4 EZDH trolley

The travel units have a fixed width.
Available track gauges for EZDH 1000 units are 1400 mm, 2240 mm and 2800 mm.

Before installing the travel unit on the track, it must be checked for dimensional accuracy,  "Checking dimen‐
sional accuracy of the EZDH track", Page 46.
Do not use the double-rail crab to pull free, pull or drag loads on the ground.
It must never run against the buffer stops at full speed, as otherwise damage or accidents may occur.
211 128 44/100621

42
 4.10 Type plate (example)

2 Baujahr: 20xx Fabrik-Nr.: 96751031 9

3 Gruppe: xx Tragfaehigkeit: xxxx kg 10
4 Baugroesse: xxxx x Hakenweg: xx m 11
5 Getr.i.: xx Haupthub: xx m/min 12
6 Einscherung: xx Feinhub: xx m/min 13
7 Seildurchmesser: xx mm rechn. Seilbruchkraft: xx kN 14
8 Auftrags-Nr.: 000000 - 00000000 - 00 ASN: xx

43237244.eps

Fig. 18

The type plate contains the following information 8 Order number

1 Manufacturer 9 Serial no.
2 Year of manufacture 10 Load capacity [kg]
3 Group of mechanisms to FEM/ISO 11 Hook path [m]
4 Size 12 Main lifting speed [m/min]
5 Gearbox transmission ratio i 13 Creep lifting speed [m/min]
6 Reeving 14 Calculated rope breaking force [kN]
7 Rope diameter [mm]

The type plate of the rope hoist is located on the side of the gearbox housing of the travel motor.
211 128 44/100621

43
 5 Transport, packing, storage

5.1 Safety warnings

WARNING
Risk of injury from falling parts
Danger to life and limb.
Secure components when they are transported. Do not step under suspended loads.

CAUTION
Inappropriate transport
The machine can be damaged.
Lift loads only at the marked lifting points. Only use suitable lifting equipment which has sufficient load capacity.

5.2 Transport inspection

● Check the delivery immediately on receipt to ensure that it is complete and examine it for any damage caused
in transit.
● If any transport damage is visible from the outside, only accept the delivery on condition. Note the scope of
damage in the shipping documents/delivery note of the forwarding company and lodge a claim.
● Lodge a claim for any defects that are not immediately detected as soon as they are discovered, since claims
for damages may only be asserted within the relevant claim notification periods.

5.3 Packing
If no agreement has been made on the return of the packing material, separate the materials according to type
and size and make them available for further use or recycling.
Environmental protection:
● Always dispose of packing materials in an environmentally compatible way and according to locally applicable
disposal regulations.
● If required, utilise the services of a recycling company.

5.4 Storage
Until they are installed, the machine and accessories must be kept closed and may only be stored under the fol‐
lowing conditions:
● Do not store outdoors.
● Store in dry and dust-free places, relative air humidity: max. 60%.
● Do not expose to aggressive media.
● Protect against direct sunlight.
● Avoid mechanical vibrations.
● Storage temperature: -25 °C to +55 °C.
● Avoid strong temperature fluctuations (condensation).
● Oil all bare machine parts (rust protection).
● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
protection.
● If stored in a damp location, the machine must be packed tight and protected against corrosion (desiccant).
211 128 44/100621

44
 6 Installation and putting into operation for the first time

6.1 Safety warnings

WARNING
Dangerous electric current
Danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel in compliance with the
safety regulations.
– Before starting work, switch the electric power supply off and secure it against switching on again.

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Always apply the specified tightening torques.

Special information for assembly

a) b)

43321844.eps

Fig. 19 Example of safe assembly

a) Protection for the working area

b) Example of a suitable working platform

WARNING
Risk of injury if incorrectly assembled
Incorrect installation can result in severe injuries and/or damage to property.
Therefore, this work may only be carried out by authorised, instructed personnel who are familiar with the princi‐
ple of operation of the machine in compliance with all safety regulations.
– Ensure sufficient working clearance before starting assembly work.
211 128 44/100621

– Secure and fence off the working area and danger zone ( Fig. 19, Page 45).
– If lifting platform is used for assembly, only use appropriate attachments for the lifting of persons which en‐
sure that work can be carried out in a safe and stable position ( Fig. 19, Page 45).

45
 – First check that the voltage and frequency specified on the data plates match the owner's mains power sup‐
ply.
– All clearance dimensions and safety distances (see approval drawing) must be checked before the equip‐
ment is put into operation.
– Work may need to be carried out in the danger zone when the equipment is put into operation.
– In the course of putting the unit into operation, it may be necessary to render safety devices or features
temporarily inoperative.
– Wear protective clothing.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any machine parts or fittings and tools that are not needed in
such a way that there is no risk of them falling.
– Fit components correctly and as intended. Comply with specified bolt tightening torques. Incorrectly fitted
components can fall and cause severe injuries.
– The electrode holder and earth must always be connected to the same component when welding work is
carried out as otherwise serious damage can be caused to the machine.
– Attach the rope hoist only at the intended lifting points.
– Only carry out installation work when all requirements regarding the installation location are met  "Operat‐
ing conditions", Page 32.

6.2 Installing the rope hoist

6.2.1 Checking dimensional accuracy of the EZDH track

6.2.1.1 Tolerance of the individual girder

The steel girders must be aligned properly before fitting the cross-travel units, therefore, the dimensional accuracy
of the tracks must be checked before fitting.

Lateral deviation

n s

L
2 L
2

L
L
2 L
L
2

43245944.eps

Fig. 20

n = ± 2 mm, maximum lateral deviation

s = ± 2 mm, maximum lateral rail deviation

– Measure lateral girder/rail deviation “n” or “s” by means of a cord, laser or theodolite at half of the girder
211 128 44/100621

length.

46
 6.2.1.2 Twisting

Any twist must be compensated when the connecting plates are fitted.
● Max. permissible twist "y" is 0,5mm/m.

y Calculation based on formula: ymax = 0,5 x LTr

Example for calculating permissible twist "y" for a girder length of 10 m:

● y max. = 0.5 x L Tr
● y max. = 0.5 mm/m x 10 m = 5 mm

43246144.eps

Fig. 21

6.2.1.3 Tolerance of the crab track gauge

b
L + 4 mm
a KA - +2 mm

-2 mm

43246244.eps

Fig. 22

a Track gauge: LKA ± 4 mm

b Centre of web plate

– Check track gauge over the entire travel path.

6.2.1.4 Gradient of the crab rails

a

43246344.eps

Fig. 23

a Max. gradient dimension 1 mm

– Gradient of the crab rails to be measured at points spaced 1 m apart over the entire track gauge.
211 128 44/100621

47
 6.2.1.5 Difference in rail height

43246444.eps

Fig. 24

a Max. permissible difference in height 5 mm

– To be measured at points spaced 1 m apart over the entire length of the girder.
The maximum permissible difference in rail height is 5 mm.

6.2.1.6 Rail level difference

5 mm
4 mm

43246544.eps

Fig. 25

∆H = max. 1,5 mm

– To be measured at points spaced 1 m apart over the entire length of the girder.
The maximum permissible difference in height between two measuring points arranged next to each other along
one rail is 1,5 mm.

6.2.1.7 Fitting the end stops/clamp-fitted buffers

Installation of the end stops/clamp-fitted buffers is described in detail in the separate installation instructions 
(203 652 44).
The double-rail crab must never run against the buffer stops at full speed, as otherwise damage to the hoist unit
or even accidents may occur.

The monorail hoist is counter-balanced by the thrust rocker which presses against the track from below.
211 128 44/100621

48
 6.2.2 Installing EUDH standard-headroom monorail travelling hoists

6.2.2.1 Assembly and adjustment

20 26
AMK 20 8 9 19
17 3
4 18
18 3 7 4
14

11 12 13

2 1 21 10
12
8 4 3 7 2 1
16 13
4
1 2 3 3 4
4 3
5
6
15

1 2

Fig. 26

1 Spring ring 16 Side plate

2 Washer/bush 17 Drive shaft
3 Tapered locking pin 18 Adjusting ring
4 Locking bolt 19 Torque bracket
5 Hexagon bolt 20 Locking bolts
6 Retaining nut 21 Bolt
7 Crosshead 22 Washer, see  Fig. 27, Page 50
8 Connecting rod 23 Spring element, see  Fig. 27, Page 50
9 Wheel leg, driven 24 Hexagon bolt, see  Fig. 27, Page 50
10 Wheel leg 25 Locknut, see  Fig. 27, Page 50
11 Side plate 26 Travel drive, see  Fig. 27, Page 50
12 Spring pin 27 Stud screw, see  Fig. 27, Page 50
13 Locking bolt 28 Protective cover, see  Fig. 27, Page 50
14 Wheel leg, driven 29 Pinion, see  Fig. 27, Page 50
15 Wheel leg 30 Securing strap, see  Fig. 27, Page 50
211 128 44/100621

49
 AUK 30 overview

AUK 30 25 23 23
22 22

30 28 9 19

20 24

26

17

18 27
43317844.eps

Fig. 27

9 Wheel leg, driven 24 Hexagon bolt

17 Drive shaft 25 Locknut
18 Adjusting ring 26 Trolley travel drive
19 Torque bracket 27 Stud screw
20 Locking bolts 28 Protective cover
22 Washer 30 Securing strap
23 Spring element

Installing the travel unit

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Tighten the connections to the tightening torques specified below.

Assemble the trolley as follows, image items  Fig. 26, Page 49 and  Fig. 27, Page 50:
1. Secure crosshead (7) to the Demag hoist unit with hexagon bolt (5) and set nut/retaining nut (6).
Secure the bolted connection with Loctite 033 071 44.
See table for tightening torque

Trolley size DH range Tightening torques of bolts (5)

10 1000 2/1, 4/2 670 Nm
Tab. 51

Ensure that crossheads (7) are always fitted so that the motor side marking is always in the correct position,
 Fig. 26, Page 49. This is necessary as otherwise the load centre of gravity will not be at the centre of the
beam when the trolley is adjusted.

2. Slide connecting rods (8) through crossheads (7) and wedge slightly with tapered locking pins (3).
211 128 44/100621

Do not tighten the tapered locking pin connection, as adjustment is still necessary.

50
 3. Slide wheel legs (9 + 10) onto connecting rods (8).
4. Secure side plate (11) to wheel legs (9 + 10) with split sleeve (12) and locking bolt (13).
5. Arrange washers (2) on wheel legs (9) and (10) as follows:

Wheel leg (9) Wheel leg (10)

Trolley size 10 Trolley size 10
Washer (2) - Washer (2) 5
Tab. 52

CAUTION
Tapered locking pins may only be used once.
Tapered locking pins may become loose if they are used again.
If the trolley is removed and refitted, ensure that the tapered locking pins do not engage in their previous position
(turn connecting rods (8)).
1. Install tapered locking pins as described below.
2. All tapered locking pin connections must be checked once again during assembly.
3. Locking bolt (4) must be tightened to the specified tightening torque.
Tightening torque = 200 Nm
Prior to assembly, grease tapered locking pin (3), locking bolt (4) and the threads in the wheel leg and
crosshead (7) with Molykote 321-R spray, part no. 972 398 44.

6. Then press wheel legs (9 + 10) against washers (2). Drive tapered locking pin (3) into wheel legs (9 + 10) as
far as possible with a hammer.
7. Then insert and tighten locking bolt (4) until the bolt head comes up against the wheel leg and tapered lock‐
ing pin (3) is in its end position.
Tightening torque M = 200 Nm

17

3
4

MA = 200 Nm

8
14+15

Fig. 28

Image item Designation

211 128 44/100621

3 Tapered locking pin

4 Locking bolt
8 Connecting rod

51
 14 Wheel leg
15 Wheel leg
Tab. 53

8. Slide wheel legs (14 + 15) onto connecting rods (8).

9. Secure side plate (16) to wheel legs (14 + 15) with split sleeve (12) and locking bolt (13).
10. The adjustment dimension between each pair of opposite wheel legs is determined from flange width b plus
the required lateral play. When the dimension has been determined, move wheel legs (14 + 15) to the corre‐
sponding positions and slightly wedge with tapered locking pins (3).
- for trolley size 10: adjustment dimension = b + 20 mm
- adapt the number of washers (2) during installation, see step 15.

2mm

=
=
b + ...

Fig. 29

11. Move crosshead (7) along connecting rod (8) until crosshead (7) is located at equal distances between the
wheel legs on the right and left.

CAUTION
Tapered locking pins may only be used once.
Tapered locking pins may become loose if they are used again.
If the trolley is removed and refitted, ensure that the tapered locking pins do not engage in their previous position
(turn connecting rods (8)).
1. Install tapered locking pins as described below.
2. All tapered locking pin connections must be checked once again during assembly.
3. Locking bolt (4) must be tightened to the specified tightening torque.
Tightening torque = 200 Nm
211 128 44/100621

Prior to assembly, grease tapered locking pin (3), locking bolt (4) and the threads in the wheel leg and
crosshead (7) with Molykote 321-R spray, part no. 972 398 44.

12. Drive tapered locking pins (3) into crosshead (7) and wheel legs (14 + 15) with a hammer as far as possible.
52
 13. Then insert and tighten locking bolt (4) until the bolt head comes up against the wheel leg and tapered lock‐
ing pin (3) is in its end position.
14. Tighten locking bolts (4):
Tightening torque = 200 Nm

17

3
4

MA = 200 Nm

8
14+15

Fig. 30

Image item Designation

3 Tapered locking pin
4 Locking bolt
8 Connecting rod
14 Wheel leg
15 Wheel leg
Tab. 54

15. Measure the distance between the contact surfaces of washers (2) on wheel legs (14 + 15) and the retaining
ring groove on both connecting rods (8).
16. Determine the quantity of washers  Fig. 29, Page 52.
Thickness of the washers for trolley size 10 = 4 mm
17. Fit retaining rings (1) to both connecting rods (8).
Prior to assembly, apply Esso-Pen-O-Led EP grease to the teeth of drive shaft (17).

18. Slide drive shaft (17) through wheel leg (9) and slide the two adjusting rings (18) onto drive shaft (17).
211 128 44/100621

53
 19. Insert drive shaft (17) into pinion (29) of wheel leg (14).

18
17

27
28
29

Fig. 31

Image item Designation

17 Drive shaft
18 Adjusting ring
27 Stud screw
28 Protective cover
29 Pinion
Tab. 55

20. Push adjusting ring (18) against pinion (29) of wheel leg (14) to fix drive shaft (17) in position.
21. Tighten stud screw (27) of adjusting ring (18):
Tightening torque = 36 Nm

AMK 20

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Tighten the connections to the tightening torques specified below.

1. Attach torque arm (19) to travel drive (26) with 4 locking bolts (21):
Tightening torque = 19 Nm
2. Slide travel drive (26) onto drive shaft (17).
3. Attach torque arm (19) to wheel leg (9) with 2 locking bolts (20):
Tightening torque = 65 Nm

AUK 30

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Tighten the connections to the tightening torques specified below.

1. Attach torque arm (19) to wheel leg (9) with locking bolt (20):
211 128 44/100621

Tightening torque = 65 Nm

54
 2. Slide travel drive (26) onto drive shaft (17).
3. Fix travel drive (26) to torque bracket (19) with hexagon bolt (24), spring element (23), washer (22) and lock‐
nut (25).

6.2.3 Buffer installation on the runway

b7
1

Fig. 32

1 Part no. 963 362 44

2 Buffer cpl. part no. 963 360 44

Trolley size Range b7

10 DH 1000 2/1 165 mm
Tab. 56
211 128 44/100621

55
 6.2.4 Overview of reeving arrangements

2/1 4/1 4/2

Fig. 33 2/1, 4/1 and 4/2 reeving methods

1 Rope clamp,
 "Installing the rope socket", Page 66

Check that the machine is complete and in perfect technical condition before installation.

211 128 44/100621

56
 6.3 Connecting the electric equipment

6.3.1 Wiring
6.3.1.1 General

DANGER
Live components
Danger to life and limb.
All wiring and connection work may only be carried out by an instructed and qualified electrician according to the
specifications of the electric connection diagram included in the supply.

Each machine is provided with a circuit diagram showing details of the controls.
The wiring of the Demag machine complies in all respects with current DIN VDE and accident prevention regula‐
tions. Unauthorised intervention and modifications may result in infringement of these regulations.
The switchgear is designed for extreme conditions. However, its service life depends on usage. Advise operators
that
● Inching (i.e. giving short pulses to the motor to obtain small movements) should be avoided as far as possible,
e.g. when attaching a load. It can cause excessive wear and premature failure of the switchgear.
● Corrosion on plastic (identifiable by dull, sooty or brittle surfaces) and metal components in enclosed switch‐
gear housings can be caused by too frequent inching.
● Corroded parts must be replaced in good time.
Inching operations can largely be eliminated by using a microspeed unit or two-speed travel motors.

6.3.1.2 Control cable and line voltage connection

Voltage-changing motors are wired in our works for the operating volt‐
age stated in the order of the Demag hoist unit.
The control transformer (if fitted) is also connected to the rated voltage
of the mains supply. If electronic devices are incorporated in the control
system (overload protection, time relays ...), the control voltage must be
measured when the equipment is commissioned.

CAUTION
Electric connection with incorrect voltage.
The electronic equipment may be destroyed if the
control voltage is too high.
If the measured value exceeds or drops below the voltage
specified on the machines by more than 10%, a control
transformer must be connected to terminals 11 and 12 on
the input side (see electric connection diagram).
– Before starting any connection work, use a voltmeter
to check whether the voltage and frequency specified
on the data plate match the mains supply.

The mains connection terminals are located in the lower section of the
electric enclosure. Use a screwdriver or similar to open the enclosure.
If a mounting plate is fitted, the hexagon bolts must be loosened.
The mounting plate can then be swung upwards and held in position by
the support.
211 128 44/100621

Fig. 34
Make sure that the support is in the correct holding position.

Required supply cable conductor cross-sections and fuse links,  "DH

1000, DH 2000 motor data", Page 18.
57
 Please note that in order to avoid excessive voltage drop
and to ensure that the brake is released when the motor is
switched on, the length of the supply line specified for a
given cross-section must not be exceeded.

If the supply line is longer than that indicated in the technical data ( "DH 1000, DH 2000 motor data", Page 18),
the cross-section can be calculated, see  Tab. 11, Page 20.
The wiring carried out in the factory includes a protective earth conductor which is connected to all parts of the
equipment that relevant regulations require to be included in the protective measures.

WARNING
Comply with regulations for electric connections.
Comply with any local regulations.
– The protective earth conductor marked green/yellow in the supply line must be connected to the earth ter‐
minal.
– As specified by DIN VDE 0100 Part 726, it must be possible to disconnect all poles of the hoist motor by
means of one mains connection switch.
– It must be possible to lock the mains connection switch against unauthorised or accidental interference and
it must be installed in an easily accessible place near the hoist unit.

6.3.1.3 Installing DST pendant controllers

DANGER
Incorrect assembly
Danger to life and limb if the pendant controller is incorrectly suspended and connected.
Work on electric equipment may only be carried out by qualified electricians.

– The pendant controller must be suspended approx. 1000 mm above floor level.

211 128 44/100621

58
 Assembly overview

A 340 875 44
B
M6

504 419 44
874 297 44
ca. 500 - 750 mm

A B
874 290 44

A-B 874 290 44

ca. alle 3 m

a
b

1
5-10 mm

874 299 44
ca. 500 mm

871 191 44

Fig. 35

A Standard strain relief arrangement c Clamping ring

DST 3, DST 6, DST 7, DST 9 with wire cords d Clamping ring
B Pendant controller strain relief with wire cords
approx. ± 300 mm height adjustable

Assembly notes:
● 10 - 16 mm cable diameter: do not remove any clamping rings
● 16 - 21 mm cable diameter: remove clamping ring c
211 128 44/100621

● 21 - 26 mm cable diameter: remove clamping rings c + d

59
 Pendant controller with bend protection sleeve

Strain relief by means of wire cords  Fig. 35, Page 59.

Unscrew housing screws (8) and remove housing lower section (9).
1
2 By tightening the two screws securing cap (4) to housing upper sec‐
tion (5), press protective sleeve (3) against the housing. Cut the sleeve
off as required for the relevant cable diameter (see markings on
3 sleeve).
Insert cable (1) into the protective sleeve and through clamp sec‐
tion (12) (small opening for 10–20 mm cable diameters and wide open‐
ing for 20–26 mm cable diameters) and clamp the cable by tightening
the screws.
4
Tighten hose clip (2) on protective sleeve (3). This ensures that the ca‐
12 ble entry is water-tight.
5
Carefully bunch cable conductors (11) behind cable clips (10) and con‐
11 nect them to terminals as required.
10 6
9 CAUTION
Danger resulting from incorrect connection
8 Danger to life and limb if the pendant controller is in‐
7 correctly connected.
The pendant controller must only be connected by trained
specialist personnel.
Fig. 36
Only connect the controller according to the circuit dia‐
gram.

Bolt housing lower section (9) into position when the electric connec‐
tions have been made. Ensure that sealing washers are placed below
screw heads (8).
The type designation and part number are indicated on the controller
and on the switching elements

For further details,  see DST pendant controller assembly instructions

part no. 206 165 44.

6.3.1.4 Checking the direction of movement

CAUTION
Error in assembly
Failure to carry out this check may result in severe damage or injury.

The rope hoist direction of motion depends on the phase sequence in the power supply. The load hook must
move up when you press the “Lift” switch element on the controller. If this is not the case, two of the supply cable
conductors should be swapped over to ensure that the emergency limit switches operate correctly.

Check the top and bottom hook positions and adjust accordingly,  "Set the cut-off points", Page 89.
211 128 44/100621

60
 6.4 Rope reeving

6.4.1 Reeving methods

2/1 4/1 4/2

Fig. 37 2/1, 4/1 and 4/2 reeving methods

1 Rope clamp

6.4.2 Rope reeving of the rope hoist

General
Demag DH hoist units are normally supplied with the rope separate from the bottom block.
Reeving of the ropes for Demag DH hoist units with 2/1, 4/1 and 4/2 reeving arrangements is shown in the follow‐
ing sections.
Rope routing for the various reeving arrangements is shown in the following sections.

CAUTION
Cutting hazard
Cutting hazard for fingers/hands on sharp edges of the wire rope when it is rolled out.
Always wear protective gloves when working with wire rope.

Care must be taken to keep the rope tight and not to twist it while reeving.
For single-groove rope drums, the rope is retained by a rope wedge and a rope socket anchorage that is incorpo‐
rated in the rope-retaining crosshead.

Please ensure that the load-bearing end of the rope enters the vertical part of the socket ( Fig. 39, Page 64).
The rope is properly secured if the rope wedge remains visible above the rope socket and the dead end of the
rope protrudes by approx. 10 cm when under load.
211 128 44/100621

The rope can be replaced by Demag service engineers or an authorised specialist company.

61
 The method of securing the rope end by means of this anchorage is absolutely reliable and conforms to the rele‐
vant regulations. An additional safety feature to prevent the dead end of the rope from slipping must be fitted in
accordance with ISO 4309. Fit the required rope clamp as shown in  Fig. 39, Page 64.

CAUTION
Danger if incorrectly fitted
Danger to life and limb if the rope is damaged.
The rope must not be secured with a rope clamp fitted over both rope ends. This would cause bruising and un‐
even stress in the carrying fall of the rope and thus lead to its destruction.

Check suspension of the rope socket.

Ensure that the double spring clip is correctly seated when the rope socket is fitted ( "Check suspension",
Page 77).

Check fitting of the overload protection device.

Ensure that the retaining ring clicks into the groove of the pin when the retaining ring is fitted  "Check suspen‐
sion", Page 77. It must be possible to turn the retaining ring easily after it is fitted. Grease the bearing points
with a suitable adhesive lubricant. Part no. 472 933 44.

6.4.3 Unwind rope

43297544.eps

Fig. 38

CAUTION
Cutting hazard
Cutting hazard for fingers/hands on sharp edges of the wire rope when it is rolled out.
Always wear protective gloves when working with wire rope.

DANGER
Pre-tensioned components
Danger to life and limb.
Pay attention to the following hazards when replacing wire ropes:
– Crushing hazard/cutting hazard
211 128 44/100621

– Shearing hazard
– Danger of entanglement or winding
– Hazards arising from drawing-in or entanglement
62
 Before a wire rope is reeved, the whole length of the rope should be rolled out on the ground below the rope hoist.
Any twisting of the wire rope should be strictly avoided.

6.4.4 Fitting the rope

Secure one end of the rope with the three rope clamps at the beginning of the drum, starting at the position
marked with the letter “A” on the drum (the end of the rope should protrude approximately 3 cm beyond the
clamp).
Wind approx. 5 turns of the rope tightly round the drum. To do this, switch on the hoist motor lifting motion and run
the rope through your hand, which must be protected by a thick glove or rag.
Then fit the rope guide.

 "Construction, application and reeving of wire ropes", Page 25 for construction, application and reeving of wire
ropes for the hoist unit types.

CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts can loosen or break off.
Tightening torques of rope clamp (socket head bolt to DIN 912-10.9)
– Single-groove drum:
DH 1000/2000: 121 Nm
– Double-groove drum:
DH 1000: 70 Nm
DH 2000: 121 Nm
211 128 44/100621

63
 6.4.5 Installing the load detector/overload protection
6.4.5.1 MGS load detector

Fig. 39

See  206 689 44 for installing MGS/MKA-2 and adjusting the switching point.

CAUTION
Danger resulting from incorrect assembly
Danger to life and limb.
Ensure that the components are correctly arranged and check fit of the double spring clip.

Install MGS overload protection in the crosshead and the lever as shown in the drawing.
211 128 44/100621

64
 6.4.5.2 ZMS load detector

Fig. 40

See  206 880 44 for installing ZMS/FAW-1/FWL and adjusting the switching point.

CAUTION
Danger resulting from incorrect assembly
Danger to life and limb.
Ensure that the components are correctly arranged and check fit of the double spring clip.

Install ZMS overload protection in the crosshead and the lever as shown in the drawing.
211 128 44/100621

65
 6.4.6 Assembling the hook assembly for 1/1 reeving
On 2 and 4-fall Demag hoist units (4/1 and 4/2 reeving arrangements), the rope end must be secured with a
rope socket, see  "Installing the compensating sheave and load detector", Page 66.

On single-fall Demag hoist units, the other end of the rope must be se‐
DH 1000 = 70 Nm
cured to the hook assembly by means of a rope wedge, see drawing.
DH 2000 = 110 Nm
A rope clamp must be fitted to the dead end of the rope.
1 = Rope clamp

1 2 = Rope wedge

Fig. 41

6.4.7 Assembly

6.4.7.1 Installing the compensating sheave and load detector

Installing the rope socket

Secure the rope in the rope socket with a rope wedge and rope clamp.
– Insert the load-bearing rope together with the rope wedge into the vertical part of the rope socket.
– The dead end of the rope must protrude from the rope socket by approx. 10 cm.

CAUTION
Danger if incorrectly fitted
Danger to life and limb if the rope is damaged.
The rope must not be secured with rope clamps (2) fitted over both rope ends. This would cause bruising and
uneven stress in the carrying fall of the rope and thus lead to its destruction.

– Fit the rope clamp.

CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts can loosen or break off.

Range Rope clamp tightening torque [Nm]

DH 1000 70
DH 2000 110
Tab. 57
211 128 44/100621

66
 DH 1000 rope-retaining crosshead, 2/1 reeving

MGS

2
2; 5
ZMS 2

1 10

Fig. 42

1 Pin set 100 Retaining set with spring clip

2 Link retaining set 103 MGS load detector
5 Rope socket retaining set 104 ZMS load detector
10 Rope socket set
211 128 44/100621

67
 Rope-retaining crosshead and top block 365/20: DH 1063, 1050, 1040, 1032, 4/1 reeving

2;5 5
2
1

10

MGS 25
ZMS

Fig. 43

1 Link set 25 Top block set

2 Link retaining set 29 Rope sheave set
5 Rope socket retaining set 100 Retaining set with spring clip
10 Rope socket set 103 MGS load detector
16 Pin set/retaining set 104 ZMS load detector
211 128 44/100621

68
 DH 1032, 1025 rope-retaining crosshead and top block, 4/1 reeving

2;5 5
2
1

10

MGS 25
ZMS

Fig. 44

1 Link set 25 Top block set

2 Link retaining set 29 Rope sheave set
5 Rope socket retaining set 100 Retaining set with spring clip
10 Rope socket set 103 MGS load detector
16 Pin set/retaining set 104 ZMS load detector
211 128 44/100621

69
 DH 1063, 1050, 1040, 1032 - H40, H51 rope-retaining crosshead and top block, 4/1 reeving, type B

MGS

ZMS

Fig. 45

1 Link set 20 Rope sheave set

2 Link retaining set 100 Retaining set with spring clip
5 Rope socket retaining set 103 MGS load detector
10 Rope socket set 104 ZMS load detector
16 Top block retaining set
211 128 44/100621

70
 DH 1032, 1025, - H40, H51 rope-retaining crosshead and top block, 4/1 reeving, type B

MGS

ZMS

Fig. 46

1 Link set 20 Rope sheave set

2 Link retaining set 24 Compensating washer set
5 Rope socket retaining set 100 Retaining set with spring clip
10 Rope socket set 103 MGS load detector
16 Top block retaining set 104 ZMS load detector
211 128 44/100621

71
 DH 2125, 2100, 2080, 2063 rope-retaining crosshead and top block, 2/1 reeving

Fig. 47

2 2000 2-4/1 rope-retaining crosshead 100 Pin connection set with spring clip
6 Pin connection set with spring clip 104 ZMS load detector
10 DH 2000 rope socket set

211 128 44/100621

72
 DH 2080 2063 H18 - H27 rope-retaining crosshead and top block, 4/1 reeving

24

13

13

13
13

13

17

Fig. 48

2 2000 2-4/1 rope-retaining crosshead 22 DH 2000 bearing lower section

6 Pin connection set with spring clip 24 M20 x 190 HV bolt set (2 off)
10 DH 2000 rope socket set 100 Pin connection set with spring clip
13 Top block complete 104 ZMS load detector
17 Rope sheave
211 128 44/100621

73
 DH 2125, 2100, 2080, H27 - H47 rope-retaining crosshead and top block 440/25, 4/1 reeving, type B

13

13

13

13

13

16

Fig. 49

2 Rope-retaining crosshead components 22 DH 2000 bearing lower section

6 Pin connection set with spring clip 24 M20 x 190 HV bolt set (2 off)
10 DH 2000 rope socket set 100 Pin connection set with spring clip
13 Top block complete 104 ZMS load detector
17 Rope sheave
211 128 44/100621

74
 DH 2080, 2063, H27 - H47 rope-retaining crosshead and top block 560/25, 4/1 reeving, type B

13

13

13

13

13

16

Fig. 50

2 Rope-retaining crosshead components 22 DH 2000 bearing lower section

6 Pin connection set with spring clip 24 M20 x 190 HV bolt set (2 off)
10 DH 2000 rope socket set 100 Pin connection set with spring clip
13 Top block complete 104 ZMS load detector
17 Rope sheave
211 128 44/100621

75
 280/20 compensating sheave, DH 2000, 4/2 reeving

11

Fig. 51

1 280/20 compensating sheave, H18, H27, H47 9 DH 2000 bearing lower section
2 Retaining ring 11 Bolt set
3 Pin 12 Compensating sheave, H16, H24, H42
4 Shim 13 Retaining plate
5 Grooved ball bearing 14 Hexagon socket bolts
6 Retaining ring 15 ZMS load detector
7 Rope sheave 16 MGS load detector
211 128 44/100621

76
 6.4.7.2 Check suspension

4 5

8
4
12 3

Fig. 52 DH 1000 2/1 example

1 Head pin 5 Pin

2 Double spring clip 6 Retaining plate
3 Supporting washers 7 Retaining ring
4 Grease bearing points 8 Retaining ring
211 128 44/100621

77
 4 5

1 mm
6

8
4

12 3

Fig. 53 DH 2000 example

1 Head pin 5 Pin

2 Double spring clip 6 Retaining plate
3 Supporting washers 7 Retaining ring
4 Grease bearing points 8 Retaining ring

Ensure that the double spring clip is correctly seated when the rope socket is fitted,  Fig. 52, Page 77 or
 Fig. 53, Page 78.
Ensure that the retaining ring clicks into the groove of the pin when the retaining ring is fitted.
It must be possible to turn the retaining ring easily after it is fitted.
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)
211 128 44/100621

78
 6.4.8 Fitting DH 1000 – DH 2000 rope guides with toothing adjustment

Overview
Disassemble the rope guide before installing it:
1. Segment with rope guide rollers
2. Segment
3. Hexagon bolt
4. Hexagon nut with flange
5. Side section
6. Socket head bolt
7. Locknut
– Fit segment with rope guide rollers (1) with the rollers pointing towards the wire rope on the drum. Then fit
segment (2) to the drum.

1 3 2
6 7

5 4

11 22
6 7 3

Fig. 54 Fig. 55

– Push hexagon bolt (3) into moulded hexagon recess of segment (2).
– Fit segment with rope guide rollers (1) to hexagon bolt (3) and secure with hexagon nut (4).
– When fitting, ensure that toothed segments (1+2) are properly engaged.
– Slide the rope guide sideways until it rests next to the wire rope in the empty groove on the drum. The rope
guide rollers lie over the wire rope. Now rotate the rope guide upwards.
211 128 44/100621

79
 – Push hexagon bolt (3) into moulded hexagon recess of segment (2). Fit segment with rope guide rollers (1)
to hexagon bolt (3) and secure with hexagon nut (4).

3 4
2 3 4

Fig. 56 Fig. 57

Both ends of segments (1+2) are provided with teeth. The clearance of the rope guide on the drum can be ad‐
justed by means of these teeth. When fitting, ensure that toothed segments (1+2) are properly engaged.

– Both bolted connections should be adjusted evenly.

It must be possible to move the fitted rope guide on the drum by hand.
Tighten the bolts.
Tightening torque = 10 Nm

Fig. 58

Ensure the same distance s is maintained on both sides when they are installed.

– Grease longitudinal beam (part no.: 011 057 44): 850 g

– Place side section (5) with its guide slot on the longitudinal beam at the bottom of the frame.
– Rotate the rope guide downwards until the bore holes in the segment with rope guide rollers (1) coincide with
the bore holes in side section (5).
– Insert the two socket head bolts (6) and secure using locknut (7).
211 128 44/100621

Tightening torque = 10 Nm

80
 – Lift the rope guide rollers with a screwdriver to press them against the rope.
– Remove the split pin.

7 1 5 6

Fig. 60
Fig. 59

Performing a function test

– Switch the hoist lifting motion on and raise the hook to its top position, while watching the rope guide and
reeving of the rope.
If any twisting occurs during lifting the motion, the bottom block must be set down and the wedge removed
from the anchorage fitted in the crosshead so that the rope can be untwisted and wedged in again.
– Then switch the hoist lowering motion on until the rope guides reaches its lowest limit position and ensure
that the first turns of the rope are wound tight on 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.
– Adjust geared limit switch,  "DGS 3 and DGS 4 geared limit switches", Page 88.
Correct adjustment of the two limit switch emergency cut-off points is important, as otherwise the hoist unit could
be damaged and accidents may occur. The limit switch needs to be readjusted when the wire rope length is
changed, e.g. when its end is pulled further through the rope wedge anchorage in the crosshead.

– The load on the rope 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 to allow
the rope to slowly stretch and settle.
Re-tighten the bolted connections after running in.
● Since new wire ropes stretch, the rope clamp securing screws on the drum need to be retightened after short
periods of operation.
211 128 44/100621

81
 6.5 Additional equipment

6.5.1 FG 08 – FG 10 microspeed units

6.5.1.1 Installation

f i b

c
e
7 g 11 h

6 12
1
4 A
3

A 8 9 10 2 5 13 14

Fig. 61

1 Inspection window 9 Retaining ring

2 Tensioning nut 10 Brake shaft
3 Tensioning screw 11 Adjusting key
4 Plug 12 DIN 6325 cylindrical pins
5 Bolt FG 08 = 8 m 6 x 24
6 Brake disc FG 10 = 10 m 6 x 32
7 Brake ring 13 Stud screw
8 Tensioning screw 14 Hexagon socket nut

Range a b c d e f g h i Part no.

FG 08 130 20 40 26 8 H7 16 12 17 20 717 398 44
FG 10 140 25 60 36 12 H7 19 17 17 20 717 498 44
Tab. 58 Adjusting tool dimensions

A microspeed unit can be installed on Demag hoist units at a later date. Conversion is done as follows:
– Unscrew the four hexagon socket screws (5) or hexagon socket nuts (14) holding the brake cover and re‐
move the cover.
– Screw the four stay bolts into the end cap (FG 08).
– Fit microspeed hoist gearbox with microspeed hoist motor to main hoist motor.

CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts can loosen or break off.
Check tightening torques of bolted connections
211 128 44/100621

– Evenly tighten the four hexagon socket nuts (14) or socket head bolts (5, only for FG 08 with 140 KBH main
hoist motor and FG 10).

82
 Size Base Tightening torque of the bolts in Nm
materia Main motor KBA microspeed motor
l
Motor Microspeed cov‐ Motor/micro‐ Gearbox Bearing Motor/ Intermediate flange/motor
size er/gearbox speed cover housing cover/ gearbox 71 80 90 100 112
ZBH housing gearbox housing
housing
Bolt
Verbus DIN 912 Nut DIN 912 Verbus Ripp
Ripp
AL - - - - - - 75 18 - - - -
112
GG 65 - - 25 69 65 - - - - - -
AL - - - - - - 75 - 45 - - -
FG 08 125
GG 65 - - 25 69 65 - - - - - -
AL - - - - - - 75 - 45 - - -
140
GG 65 - 50 - 69 65 - - - - - -
160 70 - - 30 - -
FG 10 GG 200 270 - 120 - 120 270 65 - - - 65 -
225 295 - - - - 65
Tab. 59

– Determine the path of displacement in inspection window (1). If the path of displacement is too small or too
great, see Main hoist motor – Adjusting the brake, section 5.11.2.

6.5.1.2 Brake
The microspeed drive is supplied with the brake of the brake motor adjusted for the minimum rotor displacement
path Iv min. As the brake lining wears down, the path of rotor displacement increases from Iv min to Iv max.

The brake must be adjusted as soon as Iv max is reached.

KBH size Path of displacement [mm]

lv min lv max
100, 112 1,8 3,5
125, 140 2 4
160, 180, 200, 225 2,3 4,5
Tab. 60 Axial shaft displacement

It is imperative to ensure, by regular maintenance, that the brake is adjusted before the maximum rotor displace‐
ment is reached.
● To enable adjustment of the main hoist motor brake, an adjusting key must first be made ( Fig. 61,
Page 82).
● The adjusting key can also be ordered under the following part numbers:
FG 08 - 717 398 44
FG 10 - 717 498 44
211 128 44/100621

83
 6.5.1.3 Main motor – brake adjustment
– Determine the path of displacement in inspection window (1).
– Remove plug (4).
– Remove bolts (3).
– Adjustment can be made with the adjusting key.
– Set the minimum path of displacement by turning adjusting nut (2) clockwise, see  Tab. 60, Page 83.
One revolution of the adjusting nut corresponds to a displacement of the brake cup of 2 mm on FG 08 and
FG 10 units.

CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts can loosen or break off.

– Bolt brake shaft (10) and adjusting nut (2) together with bolts (3).
Tightening torques for bolt (3):
FG 08 = 25 Nm
FG 10 = 120 Nm

211 128 44/100621

84
 6.5.1.4 Pre-tensioning the dished washer, replacing the hollow shaft of FG 08 and FG 10 units

2
3

4
t2

t1

Fig. 62

1 Surface A 4 Cover
2 Thrust ring 5 Dished washers
3 Seal

When fitted, dished washer (1) must be pre-tensioned by 0,5 mm.

Compensating tolerances:
– Use a depth gauge to measure dimension t1 on the microspeed hoist gearbox.
– Use a depth gauge to measure dimension t2 on the cover with seal in position: t1 - t2 = t
Compensate dimension t by fitting a suitable number of shims on surface A.

Pre-tensioning the dished washer:

– The number of shims required based on dimension t plus 2 x 0,1 mm and 1 x 0,3 mm results in the amount
of pre-tension.
– The dished washer is pre-tensioned by 0,5 mm when cover (2) is fitted.

Shims

Range Part no. Dimensions

341 439 99 90 x 100 x 0,1
FG 08
211 128 44/100621

341 509 99 90 x 110 x 0,3

341 531 99 120 x 150 x 0,1
FG 10
341 538 99 120 x 150 x 0,3
Tab. 61

85
 6.5.2 Demag DH hoist units and travel drive units for arduous conditions

1
3

Fig. 63

Conversion to IP 55
Demag hoist units can be converted to IP 55. The following steps/changes are required:
● Use Loctite 510 (part no. 033 075 44) to seal the stator centring collars between the stator and the brake end
cap and between the stator and the drive end cap.
● Check tight fit of the seal between the drive end cap and the terminal box base, and of the seal between the
terminal box base and the terminal box cover.
● Replace existing brake cover (1) with weatherproof type.
211 128 44/100621

● For ZBF travel motors, the brake must be retrofitted with a friction plate (4) and a sealing strip (5).

86
 ● Stamp IP 55 and all other relevant data on a blank rating plate and replace the existing rating plate with this
plate.
● Seal air gap (3) between the frame and the gearbox housing with silicon.
211 128 44/100621

87
 6.6 Putting into operation for the first time
6.6.1 Checks before the equipment is put into operation for the first time
The owner is obliged to carry out the following checks before putting the unit into operation for the first time,
 "Regular inspections", Page 15.

Activity See section Check

Check oil level in the rope hoist gearbox  "Gearbox oil filling", Page 32 x
Check rope securing devices and rope guide - x
Check electric switchgear and wiring  "Wiring", Page 57 x
Check operation of the limit switch  "Switching on", Page 95 x
Check strain relief elements, cable & pendant controller housing for damage  "Check strain relief elements", Page 96 x
Check operation of the brake  "Check operation of the brake", Page 96 x
Check operation of overload protection device - x
Check lubrication of rope - x
Check hook and hook safety catch -
Check with an overload of 125%  "Overload test at 125%", Page 93 x
Tab. 62

6.6.2 Inspection regulations

Inspection before the equipment is put into service 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, Section 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 BGV D8 mainly consists of a visual inspection and a function check. It is de‐
signed to ensure that the equipment is in a safe condition and that any defects and damage, e.g. caused by inap‐
propriate handling during transport, are identified and repaired.
In addition, regulations specific to cranes must also be taken into consideration during acceptance and other in‐
spections in accordance with relevant accident prevention regulations for cranes (BGV D6).

6.6.3 DGS 3 and DGS 4 geared limit switches

6.6.3.1 Geared limit switch function

The DGS geared limit switch is fitted in the electric equipment enclosure of the DH hoist unit.
It switches off the hoist motor when the top or bottom hook position is 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 regularly 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 is actuated.
Accident prevention regulations require that the crane operator checks the emergency limit switch before starting
work. This can be done using the test button in the control unit.
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 test button pressed simultaneously.

The test button must be pressed to move the hook back out of the end position (lowering).
Please refer to the relevant circuit diagram for the functions performed by the geared limit switch.
Switching elements S1 – S3 in the DGS 3 and S1 – S4 in the DGS 4 can be used for the following switching
arrangements:
211 128 44/100621

88
 Switching element con‐ Designation DGS 3 DGS 4
tacts 2 NC
(11 - 12 and 21 - 22)
S1 Emergency limit switch for top hook position x x
S2 “Main lifting” limit switch (only for hoist units with 2 speeds) x x
Operating limit switch for highest hook position, limit switch for
incorrect phase sequence
S3 Emergency limit switch for bottom hook position - x
S4 Operating limit switch for bottom hook position - x
Part number: 875 200 44 875 201 44
Tab. 63

6.6.3.2 Set the cut-off points

The emergency limit switches must be properly adjusted to ensure accidents are prevented and to avoid damag‐
ing the hoist unit. The emergency limit switches are adjusted before leaving the factory to avoid complete unwind‐
ing of the rope, only.
Following installation of the hoist unit, they must be readjusted and checked for the particular operating condi‐
tions.
If you want to set the maximum possible lifting height for your specific operating conditions, the following must be
observed:
● The emergency limit switch for the top hook position must be set so that when it switches off the lifting motion,
the minimum distance between the top edge of the bottom block and the bottom edge of the hoist unit frame is
maintained (see table below).

Function DGS limit switch cut-off point for the top hook position Dimension F [mm]  Fig. 64,
Page 89
for reeving
1/1 2/1 4/1
Emergency limit switch A Simultaneous cut-off of main and creep lifting motions
Switching element S1 105 70 50
B Successive cut-off of main and creep lifting motions
Switching element S2 main lifting motion 105 70 50
Switching element S1 creep lifting motion 30 30 25
Operating limit C Simultaneous cut-off of main and creep lifting motions
switches Switching element S2 190 120 70
DGS with protection D An additional DGS switching element is required as protection against in‐
against incorrect pha‐ correct phase sequence so that the lowering contactor is de-energised in
ses the highest hook position. Protection against incorrect phase sequence is
not possible with successive cut-off of the main and creep lifting motions
(cut-off points as in table 2, line B).
Emergency limit switch S1 190 120 70
Protection against incorrect phase sequence S2 105 20 50
Tab. 64

The emergency limit switch for the bottom hook position must be set so
that the load hook does not touch the floor.
F

Adjustment of the cut-off points is described in the Adjusting instruc‐

tions ( "Adjusting the cut-off points", Page 90).

Function DGS limit switch cut-off point for the bot‐ Dimension X [mm]
tom hook position  Fig. 64, Page 89
for reeving
1/1 2/1 4/1
Emergency A Simultaneous cut-off of main and creep lifting
limit switch motions
Switching element S3 150 70 50
Operating C Simultaneous cut-off of main and creep lifting
X

limit switches motions

211 128 44/100621

Switching element S4 190 120 70

Tab. 65
Fig. 64

89
 6.6.3.3 Adjusting the cut-off points

Adjusting S1 emergency limit switch for top hook position

9 8 7

Fig. 65

1 Contact maker 6 Retaining screw B

2 Cam shaft A 7 Cam shaft B
3 Adjusting screws A1 – A4 8 Hook travel counter
4 Retaining screw A 9 Plunger
5 Adjusting screws B1 – B4 X  Fig. 66, Page 91

The following tools are needed to adjust the limit switch:

● Two 1 x 4 mm and 1 x 6 mm screwdrivers.
– Raise the load hook to the level of dimension F = approx. 200 mm  Fig. 64, Page 89.
– Gradually adjust the cut-off point so that when the lifting motion has been switched off, dimension F is not
smaller than the values shown in the table ( Tab. 64, Page 89).
Allow for run-on.
– Note direction of rotation of cam shaft A. (Important for later adjustment.)
– Loosen retaining screws A (4,  Fig. 65, Page 90) and B (6,  Fig. 65, Page 90) by approx. 2 turns.
211 128 44/100621

90
 – Turn adjusting screw 1B (5,  Fig. 65, Page 90) until adjusting marker (1,  Fig. 66, Page 91) is aligned
with white marker (2,  Fig. 66, Page 91) on the cam wheel.

1 2

Fig. 66

– Turn adjusting screw 1A until plunger (3) no longer protrudes from the bottom of switching element (4).
– Then turn adjusting screw 1A in the direction of rotation of cam shaft A until plunger (3) and adjusting marker
(5) are level.
– In this position, the normally closed contacts of switching element S1 are open.

3 4

Fig. 67

S2 main lifting motion limit switch

211 128 44/100621

Adjust as for S1, except with adjusting screws 2A-2B.

Different dimensions need to be set depending on the function,  Tab. 64, Page 89.

91
 S2 as emergency limit switch,  Tab. 64, Page 89, line A:
● If dimension F is set to a value which is greater than that shown in line A, 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,  Tab. 64, Page 89, line C
● For cut-off point, see line C. According to German regulations, a test button is required in the control unit
( "Geared limit switch function", Page 88).
● Adjust as for S1, except with adjusting screws 2A-2B.

S2 limit switch for incorrect phase sequence,  Tab. 64, Page 89, line D
● For cut-off points, see line D.
● Adjust as for S1, except with adjusting screws 2A-2B.

S3 emergency limit switch for bottom hook position

S3 emergency limit switch for bottom hook position,  Tab. 65, Page 89, line A.
● For cut-off points, see line A.
● Adjust as for S1, except with adjusting screws 3A-3B.
● Opposite direction of rotation for adjustment to that for S1.

S4 operating limit switch for bottom hook position

S4 operating limit switch for bottom hook position,  Tab. 65, Page 89, line B.
● For cut-off points, see line B.
● Adjust as for S1, except with adjusting screws 4A-4B.
● Pay attention to the direction of rotation for adjustment.
The adjustment range of the DGS unit covers a maximum of 142 revolutions of the drum.

Following adjustment

When adjustment has been completed, ensure that central retaining screw A (4,  Fig. 65, Page 90) and B (6,
 Fig. 65, Page 90) of cam shaft B (6) and cam shaft A (3) is tightened to a torque of ≥ 2 Nm.
Approach the limit positions (cut-off points) several times to check the limit switch functions are operating correct‐
ly.
Ensure that the correct number of safety turns is wound on the drum when the geared limit switch is re-
adjusted.

Range Safety windings

Reeving
1/1, 2/1, 4/1 2/2, 4/2
DH 1000 4 4,5
DH 2000 4,5 4
Tab. 66
211 128 44/100621

92
 6.6.4 Overload test at 125%

The switch setting for the overload test is located under the equipment
cover.

789
● After DIP switch 6 has been switched from OFF to ON, the overload
protection device is de-activated for 15 minutes and limited to 146%
456

AB
CDE so that the crane acceptance test can be carried out at 125%.
23

● After 15 minutes or every time the hoist unit is switched off and on
F0 1

(start-up of the control system) or after switch 6 is reset to OFF, the

789 overload protection device (110%) becomes active again.
456

AB

All DIP switches are set to OFF by default.

CDE
23

F0 1

789
456

AB
CDE
23

F0 1

1
8
7
6
5
4
3
2
ON

43239544.eps

Fig. 68
211 128 44/100621

93
 7 Operation

7.1 Safety warnings

WARNING
Incorrect operation
Incorrect operation can result in severe injuries and/or damage to property.
The machine may only be operated by authorised and trained personnel in compliance with all accident-preven‐
tion and safety regulations.
– National regulations for the use of cranes and lifting appliances must be observed and followed.

WARNING
Danger if duty to exercise care is neglected
Danger to life and limb if the machine is operated with little care.
Requirements for operating the machine include:
– All installation/assembly work has been carried out according to the operating instructions.
– The rope must be adequately lubricated.
– The rope must be in good condition. Operation with defective or damaged ropes results in a high risk of
accidents with personal injuries and is therefore prohibited. Risk of damage to the machine.
– Any changes or modifications which prejudice safety must be reported to the nearest person responsible
immediately.
– Defects may only be eliminated by experienced technicians.

WARNING
Falling loads
Any person remaining in this danger zone may suffer serious injury or death.
Only use suitable and tested load handling attachments.
– Observe the operating instructions for the load handling attachment.
– Do not exceed the maximum permissible load capacity of the load handling attachment.
– Do not transport loads above people when using load handling attachments that retain the load by means
of magnet, friction or suction forces without an additional load securing device.

Before starting work:

● Put on protective clothing.
● Ensure that nobody is present in the danger zone of the machine.
● Check operation of the brakes, emergency limit stop devices and emergency-stop devices.
During operation:
● Do not approach emergency limit stop devices (e.g. emergency limit switch) in normal operation.
● Do not render safety devices inoperative.
● Adopt a position that ensures a clear view of the danger zone for lifting and travel motions.
● Never touch the ropes while the machine is in operation.

WARNING
Damaged components/malfunctions on the machine
Danger to life and limb.
If obvious defects or malfunctions occur, stop the machine without delay and secure it against switching on
again.
211 128 44/100621

94
 CAUTION
Danger due to premature wear/corrosion
Corrosion on plastic (identifiable by dull, sooty or brittle surfaces) and metal components in enclosed switchgear
housings can be caused by too frequent inching. Corroded parts must be replaced in good time.

Advise operators to avoid inching (i.e. giving short pulses to the motor to obtain small movements) as far as pos‐
sible, e.g. when attaching a load. It can cause excessive wear and premature failure of the switchgear.

7.2 Switching on

7.2.1 Checks when starting work

The operator is obliged to carry out the following checks before starting work ( "Regular inspections", Page 15):

Activity Section Check

Visual check  "Visual check", Page 95 x
Check operation of the limit switch  "Check the limit switches", Page 95 x
Check strain relief elements, cable & pendant controller  "Check strain relief elements", Page 96 x
housing for damage
Check operation of the brake  "Check operation of the brake", Page 96 x
Check hook and hook safety catch  "Check hook safety catch", Page 96 x
Check rope for damage and broken wires  "Replacement criteria for the wire rope", Page 102 x
Tab. 67

7.2.2 Visual check

– Check the machine to ensure it is complete. Do not operate the machine if parts have been removed (cov‐
ers, limit stop buffers, ...).
– Check the machine for any visible external damage.

7.2.3 Check the limit switches

- By-pass the operating limit switch by pressing the test button .

- Approach the emergency limit switch using motion axis control buttons
( "Controller switch assignment", Page 96).

- Simultaneously actuate the test button and the motion axis control
buttons to back away from the emergency limit switch.

Fig. 69
211 128 44/100621

95
 7.2.4 Check strain relief elements
– Carry out a visual inspection of the strain relief elements:
The strain relief cords must be firmly attached. No forces must act on the connector when the pendant con‐
troller is moved.

7.2.5 Check operation of the brake

– Raise the load hook and lower it again. The load hook must only run on a short distance when the button is
released.
The load hook must stay at the same height (i.e. it must not lower without a button being actuated) when a
load is attached to it.
Significant run-on or lowering when in the idle position indicates that the brake is worn.
– Drive the travelling hoist to the right/left. Braking of the travelling hoist must be clearly noticeable when the
button is released.
It must not be possible to move the travelling hoist by pulling the ropes to the side.
Significant run-on or the possibility of moving it when in the idle position indicates that the brake is worn.
– Brake linings must be inspected once a year, ⇒ also assembly instructions 214 228 44.

WARNING
Only operate the machine if it is in safe operating condition.
If inspection reveals that a brake slips, the brake must be adjusted or repaired. Do not operate the machine if the
brake slips.

7.2.6 Check hook safety catch

Check the hook safety catch  "Regular inspections and monitoring measures for load hooks", Page 104.

7.3 Controller switch assignment

The motion directions of the crane/load hook are clearly identified with
fixed symbols regardless of the controller type. Example for DST 6:

Lift load

Lower load

Long travel forwards

Long travel backwards

Fig. 70
211 128 44/100621

96
 7.4 Switching off
- When work has been completed, position the unloaded bottom block
outside the travel area.
- Press emergency-stop button (1). Turn the emergency-stop button to
unlock it.
- Switch off the power supply at the mains connection or isolating
switch.

Fig. 71

7.5 Stopping operation in an emergency

Press emergency-stop button (1).
It then locks automatically.

WARNING
Causes of malfunctions must be eliminated.
The emergency-stop device must only be reset after the
hazard and its cause have been eliminated.

To unlock the actuated emergency-stop button, turn the pushbutton in

the direction of the arrow and release.

Fig. 72
211 128 44/100621

97
 8 Maintenance

8.1 Safety warnings

The following sections contain a description of maintenance work that is necessary for optimum and uninterrupted
operation of the machine.

WARNING
Risk of injury.
Incorrect maintenance work can result in severe injuries and/or damage to property.
Maintenance work may only be carried out by authorised and trained specialist personnel in compliance with all
safety regulations.

DANGER
Live components
Electric current can cause danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel in compliance with the
safety regulations.

Always:
1. Wear personal protection equipment.
2. Fence off the working area.
3. Before starting work, switch off the machine and secure it against switching on again.
4. Switch off the power supply at the mains connection or isolating switch. Check that the system is de-ener‐
gised.
5. Ensure that there is sufficient freedom of movement.
6. Parts of the body can be crushed when working on the machine. Secure the machine/machine parts against
unintended movement and work with the utmost care and caution.
7. Keep the working area clean and tidy. Loose parts or tools left lying around can cause accidents.
8. Reinstall safety devices as required by relevant regulations and check them for correct operation after finish‐
ing maintenance work.
9. Only use genuine Demag spare parts.

CAUTION
Lubricants/oils
Risk of injury resulting from contact with the body/skin. Oils and lubricants are a health hazard.
Contact with these media can result in serious damage to health (poisoning, allergies, skin irritation, etc.)
– Pay attention to the manufacturer’s safety data sheets and instructions.

CAUTION
Risk of injury. Risk of slipping.
Leaking oils and lubricants are hazards due to the increased risk of slipping.
Spilt oils and lubricants must be absorbed immediately by means of sawdust or oil absorbent and disposed of in
an environmentally compatible way.
211 128 44/100621

8.2 Routine inspections

Hoists and cranes must be inspected by an experienced technician at least once a year. Regular inspections
mainly consist of visual inspections and function checks which should include a check to determine the condition
98
 of components and equipment regarding damage, wear, corrosion or other alterations and a check to determine
the integrity and efficiency of safety devices.
It may be necessary to remove parts in order to inspect wearing parts.
Load-bearing media and suspensions must be inspected along their entire length, including those parts which
cannot normally be seen. A function and brake test with a load (test load that is close to the maximum permissible
load capacity) must be carried out.
Updating the log book
● The owner must arrange for all inspections to be carried out and documented in the hoist or crane log book.

8.3 Maintenance schedule

The specified inspection and maintenance intervals refer to normal operating conditions. If routine maintenance
reveals that the maintenance intervals are too long, they must be shortened according to the specific operating
conditions.

Check before putting into operation, before starting work and during operation

Activity See section Before the unit Before starting Every 6 Once per year
is first put into work months
operation
Check coupling halves of main hoist motor
KD 17) Every 4 - 5 years
for tight fit
Check roller spiders for signs of wear and re‐
KD 17) Every 4 - 5 years
place them
Check rope securing devices and rope guide  "Reeving methods",
X X X
Page 61
Check electric switchgear and wiring  "Connecting the elec‐
X X
tric equipment", Page 57
Check operation of the limit switch  "Check the limit
X X X
switches", Page 95
Check strain relief elements, cable and pend‐  "Check strain relief el‐
X X X
ant controller housing for damage ements", Page 96
Check operation of the brake  "Check operation of
the brake", Page 96 KD X X X
17)

Check operation of overload protection de‐

KD 17) X X
vice
Check condition of the brake lining KD 17) X
Check brake ring or base material of the  "Checking base ma‐
brake linings of the KBH main hoist motor for terial of the brake linings
Every 4 - 5 years
cracks for cracks", Page 111,
KD
Replace brake ring of the KBH main hoist  "Replacing the brake
motor ring on KBH motors", Every 10 years
Page 111, KD
Check lubrication of rope  "Lubricating the wire
X X
rope", Page 104
Check hook and hook safety catch  "Regular inspections
and monitoring meas‐
X X X
ures for load hooks",
Page 104
Check rope for damage and broken wires  "Replacement criteria
for the wire rope", X X
Page 102
Tab. 68
211 128 44/100621

17) The inspection may only be carried out by Demag Customer Service or by authorised specialist personnel. 99
 Checks during operation

Activity See section Before the unit Before starting Every 6 Once per year
is work months
first put into
operation
Check adhesive lubricant in bearing points of
top blocks, crossheads, compensating  "Rope reeving of the
X
sheaves and pins of the rope socket, re- rope hoist", Page 61
grease as required
Check suspension of the rope socket
Check play of setbolt/pin in counter bore hole  "Rope reeving of the
X
of retaining plate rope hoist", Page 61
Check spring clip for correct fit
Check brake displacement, adjust as re‐  "KBH main hoist mo‐
quired tor and KBA microspeed
hoist motor brake",
Page 105 X X
 "Main hoist motor with
mechanical microspeed
unit", Page 110
Check all connections (bolts, weld seams,
KD 18) X
etc.)
Check rope securing devices and play of  "Rope reeving of the
X
rope guide on drum rope hoist", Page 61
Check rope for damage and broken wires  "Replacement criteria
for the wire rope", X X
Page 102
Lubricate rope  "Lubricating the wire
X
rope", Page 104
Check load hooks for cracks, deformation  "Regular inspections
and wear and monitoring meas‐
X
ures for load hooks",
Page 104
Check hook safety catch for deformation  "Regular inspections
and monitoring meas‐
X
ures for load hooks",
Page 104
Check wear of the travel wheels, EZDH  "EZDH travel wheel
X
wear", Page 133
Check hook bearing for wear - X
Check bottom block and hook assembly - X
Check bottom block KD 18) X
Check securing elements (clips, bolts, etc.) 18)
KD X
for tight fit and corrosion
Check and apply or supplement corrosion
KD 18) X
protection, as required
Check creep lifting motor coupling  "Adjusting the brake
on KBA motors", X
Page 107
Change oil in main hoist gearbox Every 8 - 10 years
Change gearbox oil: F10 mechanical micro‐
Every 4 - 5 years
speed unit – cross-travel gearbox
Check plastic components of the limit switch
KD 18) X
for corrosion
Check electric enclosure seals KD 18) X
Check condition of all buffers KD 18) X
Check power supply lines (main and crab
power supply). For current collectors: check
KD 18) X
sliding contacts and travel rollers for wear
and sliding contacts for contact pressure
Replace grease filling in the protective covers  "FG 08 and FG 10 mi‐ Every 4 years
of the last stage of the gearbox of monorail crospeed units, AMK 20,
hoist trolley size 10 AUK 30 travel drives",
Page 136
Tab. 69
211 128 44/100621

100 18) The inspection may only be carried out by Demag Customer Service or by authorised specialist personnel.
 WARNING
Danger due to incomplete maintenance.
Danger to life and limb since safe operation of the machine is not ensured.
– Carry out all specified maintenance work appropriately and in time.
– Please contact Demag Customer Service for any work that you cannot carry out yourself.
– Make sure that the entries in the crane installation log book are complete.

General overhaul (GO)

The general overhaul should coincide with the annual inspection On reaching the theoretical duration of service
Fit rope hoist-specific Demag GO set X
Tab. 70
211 128 44/100621

101
 8.4 Wire ropes
List of wire ropes used,  "Construction, application and reeving of wire ropes", Page 25.

8.5 Replacement criteria for the wire rope

The following information on the assessment and maintenance of wire ropes has been compiled on the basis of
German, European and international standards as well as relevant trade literature and is to be regarded only as
the most significant information that is not intended to be complete, but to help the owner of a Demag rope hoist
to become familiar with “Replacement criteria for wire ropes”. Furthermore, all national standards, regulations or
any legislation of other countries must be fulfilled and considered together with the above information or they take
priority, as applicable.
Assessment of the replacement criteria for wire ropes requires many years of experience and expert
knowledge. An assessment may only be carried out by a Demag service engineer or by a corresponding
specialist.
A visual check must always be carried out over the entire length of the rope, including points which cannot nor‐
mally be seen, critical points must be inspected with particular care and attention.

CAUTION
Risk of injury
Risk of injury due to possibly broken wires.
Always wear protective gloves when checking wire ropes.

To discover broken wires more easily, the load must be removed from the unit and the wire rope bent manually
along its entire working length. Run the rope through your hand, which must be protected by a thick glove. The
bending radius should be approximately the same as the rope sheave radius.
A wire rope must be discarded when its condition is no longer considered to be safe for continued operation:
● If there are any structural changes, such as swelling, loosening.
The installation must be stopped immediately if this type of damage occurs.
● When the number of visible broken load-carrying wires in the external strands at the worst spot has reached
the following figures, counted over a reference length of rope of 6 times or 30 times the rope diameter, which‐
ever gives the worst result  Tab. 71, Page 103.
Critical points, for example, include:
1. Rope zones subject to the highest number of alternating bending cycles and in particular to alternating de‐
flection. This also applies to rope zones on compensating sheaves which are subject to a very high number
of reversed bending cycles due to rope swing or uneven winding on rope drums. These rope sections show
increased abrasion and a higher number of broken wires.
2. The zones in which loads are picked up, i.e. rope zones which are on a rope sheave at a preferred load pick-
up point or rope zones which are wound onto or off a rope drum.
3. Rope anchorages that subject the wire rope to a load in addition to normal tensile load. Vibrations in the tran‐
sition area and moisture penetrating into the rope anchorage result in corrosion and broken wires.
4. Rope zones on rope drums. The load pick-up point on the rope drum is subject to increased wear (abrasion,
broken wires and/or structural changes).
5. Rope zones exposed to aggressive media, general weather conditions or high temperatures. Observe the
manufacturer’s specifications for the wire rope and the lubricant to be used.
The rope can be replaced by Demag service engineers or an authorised specialist company.
211 128 44/100621

102
 Number n of load-bearing Number of visible broken wires for discarding
wires in the external Group of mechanisms to FEM/ISO
strands
1Em, 1Dm, 1Cm, 1Bm, 1Am 2m, 3m, 4m, 5m
Ordinary lay Lang’s lay Ordinary lay Lang’s lay
over a length of over a length of over a length of over a length of
6x Ø 30x Ø 6x Ø 30x Ø 6x Ø 30x Ø 6x Ø 30x Ø
up to 50 2 4 1 2 4 8 2 4
51 to 75 3 6 2 3 6 12 3 6
76 bis 100 4 8 2 4 8 16 4 8
101 to 120 5 10 2 5 10 19 5 10
121 to 140 6 11 3 6 11 22 6 11
141 to 160 6 13 3 6 13 26 6 13
161 bis 180 7 14 4 7 14 29 7 14
181 to 200 8 16 4 8 16 32 8 16
201 to 220 9 18 4 9 18 35 9 18
221 to 240 10 19 5 10 19 38 10 19
241 to 260 10 21 5 10 21 42 10 21
261 bis 280 11 22 6 11 22 45 11 22
281 to 300 12 24 6 12 24 48 12 24
more than 300 0,04 x n 0,08 x n 0,02 x n 0,04 x n 0,08 x n 0,16 x n 0,04 x n 0,08 x n
Tab. 71

8.6 Wear limits on rope sheaves

43240444.eps

Fig. 73

Part no. Groove root dia. Rope dia. Min. flange plate thickness Max. depth of strand impres‐
[mm] [mm] tmin sions
[mm]
828 390 44 225 4,6
14 0,7
829 682 44 280 6,3
829 672 44 365 14 8,4 0,7
829 446 44 450 20,4 1,0
7,7
829 675 44 16 0,8
365
829 678 44 20 7,0 1,0
829 454 44 25 1,3
440 9,1
211 128 44/100621

829 425 44 28 1,4

829 442 44 450 20 7,7 1,0

103
 Part no. Groove root dia. Rope dia. Min. flange plate thickness Max. depth of strand impres‐
[mm] [mm] tmin sions
[mm]
829 435 44 28 1,4
829 457 44 560 25 9,1 1,3
555 046 46 20 1,0
Tab. 72

The cross-section of the rope groove must not be less than the specified minimum dimension tmin at any position.
Negative impressions in the rope groove root must not exceed the specified maximum dimension.

8.7 Shortening the wire rope

If, in exceptional cases, it is necessary to shorten the wire rope, this must be done in compliance with engineering
standards.

8.8 Lubricating the wire rope

All lubrication points of the Demag hoist unit are adequately greased.
Grease the rope with a suitable lubricant and preservative, e.g. Cedracon. Ensure that the agent reaches the inte‐
rior of the rope structure, part no. 665 019 44.
When hoist units are operated outdoors and in applications with a corrosive atmosphere, we recommend that
the wire rope be additionally greased from the outside (part no. 011 057 44, 850 g).

Grease the bearing points of the top block, crosshead, compensating sheave, the pin of the rope socket and the
guide rod of the rope guide with a suitable adhesive lubricant, part no. 472 933 44.

8.9 Regular inspections and monitoring measures for load hooks

If a check or inspection reveals that these components are worn beyond the dimensions shown in  Fig. 74,
Page 104 and the table, or if deformations and cracks can be seen in these parts, the affected parts must be
replaced at once with genuine spare parts.

Load hook inspection

Range DH 1000 DH 2000

Reeving 2/1 4/1 2/1, 4/2 4/1
a2 Group of mechanisms 2m/M 5... 2m/M5 ... 1Am/M4 ... 4m/M7
a to FEM/ISO 4m/M7 4m/M7 3m/M6
Hook size 1 1,6 2,5 4 5
a Hook opening 34 40 41 49 55
a1 50 56 63 71 80
a2 Nominal dimension 40 45 50 56 63
a1 19)

a2 Maximum dimen‐ 44 49,5 55 61,6 69,3

sion
h2

h2 Nominal dimen‐ 40 48 58 67 75
sion20)
43240044.eps
h2 Minimum dimen‐ 38 45,6 55,1 63,6 71,2
Fig. 74 sion
Tab. 73

Check the hook safety catch for correct operation and for any damage.
211 128 44/100621

19) Permissible difference: +10%

104 20) Permissible difference: -5%
 8.10 KBH main hoist motor and KBA microspeed hoist motor brake

8.10.1 Safety

WARNING
Operating safety risk
Danger to life and limb if the brakes are not correctly maintained.
The following work may only be carried out by specialist personnel.
Follow the safety instructions in the maintenance section and general safety warnings  "Safety", Page 11.

8.10.2 Checking for wear/axial displacement

Demag hoist units or hoist units with a mechanical microspeed unit are supplied with the brake of the Demag mo‐
tor adjusted for the minimum rotor displacement path lv min.
The brakes of KBH 140/160/180/200 B 2/12 pole-changing hoist motors are rated for electric braking. They can,
therefore, only be used together with an SGDM-1 brake application relay.

As the brake lining wears down, the path of rotor displacement increases from Iv min to Iv max (see table 12). The
brake must be adjusted as soon as Iv max is reached.

Axial shaft displacement for KBH and KBA motors

Size Path of displacement [mm]
lv min lv max
71, 80, 90 1,5 3
100, 112 1,8 3,5
125, 140 2 4
160, 180, 200, 225 2,3 4,5
Tab. 74

It is imperative to ensure, by regular maintenance, that the brake is adjusted before the maximum rotor
displacement is reached.
If the braking action starts to decrease on Demag hoist units fitted with microspeed units, the microspeed and
main hoist motor brakes must first be checked to see if they need to be adjusted.
The path of rotor displacement between the running and braking positions can be measured on the brake side
when the louvers have been removed. This measurement must be taken both when the motor is running and
when it is at standstill.
211 128 44/100621

105
 Measurement of the path of displacement for the main hoist motor of the mechanical microspeed unit:

f i b

c
e
7 g 11 h

6 12
1
4 A
3

A 8 9 10 2 5 13 14

Fig. 75

1 Inspection window 9 Retaining ring

2 Tensioning nut 10 Brake shaft
3 Tensioning screw 11 Adjusting key
4 Plug 12 DIN 6325 cylindrical pins
5 Hexagon socket bolts FG 08 = 8 m 6 x 24
6 Brake disc FG 10 = 10 m 6 x 32
7 Brake ring 13 Stud screw
8 Tensioning screw 14 Hexagon socket nut

– Determine the path of displacement in inspection window (1).

It is imperative to ensure, by regular maintenance, that the brake is adjusted before the maximum rotor displace‐
ment is reached.
● To enable adjustment of the main hoist motor brake, an adjusting key must first be made ( Fig. 75,
Page 106).
● The adjusting key can also be ordered under the following part numbers:

Range a b c d e f g h i Part no.

FG 08 130 20 40 26 8 H7 16 12 17 20 717 398 44
FG 10 140 25 60 36 12 H7 19 17 17 20 717 498 44
Tab. 75 Adjusting tool dimensions

Adjustment can be repeated several times.

It is advisable to keep a spare brake ring or a spare brake lining in stock.
211 128 44/100621

106
 8.10.3 Adjusting the brake on KBA motors

12 3 4 6
5

Fig. 76

1 Brake disc
2 Brake cover
3 Brake ring
4 Tensioning nut
5 Bolts
6 Louver
7 Retaining ring

– Measure the path of rotor displacement Iv.

– Remove end plate with louvers (6) and four screws (5).
– Insert two bolts (5) into the threaded holes of adjusting nut (4) and tighten until brake disc (1) is separated
from adjusting nut (4).
– Turn adjusting nut (4) anticlockwise until path of displacement Iv min has been reached, see  Tab. 74,
Page 105.

CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts can loosen or break off.
– M5 = 6 Nm
– M6 = 11 Nm
– M8 = 25 Nm
– M10 = 50 Nm
– M12 = 86 Nm

– Replace and tighten bolts (5).

211 128 44/100621

– Refit end plate with louvers (6).

107
 8.10.4 Replacing the brake lining on KBA motors

12 3 4 6
5

Fig. 77

1 Brake disc
2 Brake cover
3 Brake ring
4 Tensioning nut
5 Bolts
6 Louver
7 Retaining ring

– Remove end plate with louvers (6) and brake cover (2).
– Remove retaining ring (7). Remove screws (5), then separate brake disc (1) ( "Adjusting the brake on KBA
motors", Page 107).
– Remove adjusting nut (4) and pull off brake disc (1).
– Remove worn brake ring (3) from brake disc (1).
– After moistening the rubber ring with water (never with oil), press the new brake ring onto brake disc (1).
Push brake ring (3) in all the way round by tapping with a rubber hammer until it is flush. Make sure that the
brake ring is not deformed. It is best fitted with a special pressure plate.
For increased requirements, it is advisable to replace the complete brake disc or to re-turn the brake ring after
fitting, e.g.:
● high brake loads
● high braking accuracy
● short run-in periods of the brake
Size Permissible cone angle
71 - 200 21°
225 20°
Tab. 76
211 128 44/100621

– Install brake disc (1) and adjust path of displacement Iv min ( Tab. 74, Page 105).

108
 CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts can loosen or break off.
– M5 = 6 Nm
– M6 = 11 Nm
– M8 = 25 Nm
– M10 = 50 Nm
– M12 = 86 Nm

– Replace and tighten bolts (5).

– Screw on brake cover (2) and end plate with louvers (6).
211 128 44/100621

109
 8.11 Main hoist motor with mechanical microspeed unit
8.11.1 Adjusting the brake on KBH motors

f i b

c
e
7 g 11 h

6 12
1
4 A
3

A 8 9 10 2 5 13 14

Fig. 78

1 Inspection window 9 Retaining ring

2 Tensioning nut 10 Brake shaft
3 Tensioning screw 11 Adjusting key
4 Plug 12 DIN 6325 cylindrical pins
5 Hexagon socket bolts FG 08 = 8 m 6 x 24
6 Brake disc FG 10 = 10 m 6 x 32
7 Brake ring 13 Stud screw
8 Tensioning screw 14 Hexagon socket nut

– Determine the path of displacement in inspection window (1).

– Remove plug (4) and screws (3).
– Adjust using the adjusting key.
● Making the adjusting key, see  Fig. 78, Page 110.
● The adjusting key can also be ordered under the following part numbers:

Range a b c d e f g h i Part no.

FG 08 130 20 40 26 8 H7 16 12 17 20 717 398 44
FG 10 140 25 60 36 12 H7 19 17 17 20 717 498 44
Tab. 77 Adjusting tool dimensions

– Set the minimum path of displacement Iv by turning adjusting nut (2) clockwise as shown in the table.
One revolution of the adjusting nut corresponds to a displacement of the brake cup of 2 mm on FG 08 and
FG 10 units.
Axial shaft displacement for KBH and KBA motors
Size Path of displacement in mm
lv min lv max
71, 80, 90 1,5 3
211 128 44/100621

100, 112 1,8 3,5

125, 140 2 4
160, 180, 200, 225 2,3 4,5
Tab. 78
110
 CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts can loosen or break off. Tightening torque for bolt item 3:
– FG 08 = 25 Nm
– FG 10 = 120 Nm

– Bolt brake shaft (10) and adjusting nut (2) together with bolts (3).
The microspeed hoist motor coupling must be checked every time the brake is adjusted.

8.11.2 Checking base material of the brake linings for cracks

Cracks can develop in the base material of the brake linings when the brake ring ages.
– Remove the cover of the brake. The brake does not need to be disassembled any further.
– Visually check the rubberized base material on the brake ring installed on the brake disc for defects, such as
cracks (on both side surfaces of the base material as well as on the surfaces between the brake linings).
– Replace the brake ring if the base material shows any cracks or other defects.

8.11.3 Replacing the brake ring on KBH motors

– Remove the four hexagon socket nuts (14),  Fig. 78, Page 110, or socket head bolts (5) and remove the
microspeed hoist gearbox and creep lifting motor.
– Remove retaining ring (9).
– Unscrew tensioning screws (8) from adjusting nut (2).
– Insert two tensioning screws (8) into the threaded holes of the adjusting nut and tighten until brake disc (6) is
separated from adjusting nut (2).
– Unscrew adjusting nut (2) and remove brake disc (6) from the motor shaft.
– Remove worn brake ring (7) from brake disc (6).
– Check the rubberized base material on the new brake ring of the brake linings for defects, such as cracks.
– Make a note of the production date stamped on the new brake ring and set the maintenance intervals ac‐
cording to this production date (and not according to the date when it is installed).
– After moistening the rubber ring with water (never with oil), press the new brake ring onto brake disc (6).
Use a rubber hammer to tap the brake ring around its entire circumference until it sits flush. Make sure that
the brake ring is not deformed. It is best fitted with a special pressure plate.
For increased requirements, it is advisable to replace the complete brake disc or to re-turn the brake ring after
fitting, e.g.:
● high brake loads
● high braking accuracy
● short run-in periods of the brake
– Refit brake disc (6) to the shaft and turn adjusting nut (2) up to the shaft collar.
Then unscrew adjusting nut (2) by 1,5 turns.
– Bolt brake disc (6) and adjusting nut (2) together with tensioning screws (8).
KBH main hoist motor Tightening torque
211 128 44/100621

100, 112 11 Nm
125, 140 25 Nm

111
 KBH main hoist motor Tightening torque
160 50 Nm
200, 225 86 Nm
Tab. 79

– Fit retaining ring (9) to the shaft end.

– Fit microspeed hoist gearbox with microspeed hoist motor to the main hoist motor.
Evenly tighten the four hexagon socket nuts (14) or socket head bolts (5) to the tightening torques given be‐
low.
Size KBH motor size Bolt
DIN 912 Nut
140 50 -
FG 08
160 70 -
200 120 -
FG 10
225 295 -
Tab. 80

– To obtain the full braking torque more quickly, switch the motor on and off repeatedly to wear in the brake
lining.

8.11.4 Replacing the brake lining on KBH motors

f i b
d

c
e

7 g 11 h

6 12
1
4 A
3

A 8 9 10 2 5 13 14

Fig. 79

1 Inspection window 9 Retaining ring

2 Tensioning nut 10 Brake shaft
3 Tensioning screw 11 Adjusting key
4 Plug 12 DIN 6325 cylindrical pins
5 Hexagon socket bolts FG 08 = 8 m 6 x 24
6 Brake disc FG 10 = 10 m 6 x 32
7 Brake ring 13 Stud screw
8 Tensioning screw 14 Hexagon socket nut

– Remove the four hexagon socket nuts (14) or socket head bolts (5) and remove the microspeed hoist gear‐
box and microspeed hoist motor.
211 128 44/100621

– Remove retaining ring (9). Remove bolts (8) from the adjusting nuts.
– Insert two bolts (8) into the threaded holes of the adjusting nut and tighten until the brake disc is separated
from the adjusting nut.
112
 – Unscrew the adjusting nut and pull brake disc (6) off the motor shaft.
– Remove worn brake ring (7) from brake disc (6).
– After moistening the rubber ring with water (never with oil), press new brake ring (3) onto brake disc (1).
– Push brake ring (3) in all the way round using a press or by tapping with a rubber hammer until brake ring (3)
is flush. Make sure that the brake ring is not deformed. It is best fitted with a special pressure plate.
For increased requirements, it is advisable to replace the complete brake disc or to re-turn the brake ring after
fitting, e.g.:
● high brake loads
● high braking accuracy
● short run-in periods of the brake
– Refit brake disc (6) to the shaft, and turn the adjusting nut up to the shaft collar.
Then unscrew the adjusting nut by 1,5 turns.

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Ensure that the specified tightening torques are applied.

– Bolt brake disc (6) and adjusting nut together with screws (8).
Tightening torque:

KBH main hoist motor Tightening torque

100, 112 11 Nm
125, 140 25 Nm
160 50 Nm
200, 225 86 Nm
Tab. 81 Tightening torques for tensioning screws (8)

– Fit retaining ring (9) to the shaft end.

– Fit microspeed hoist gearbox with microspeed hoist motor to the main hoist motor.
Evenly tighten the four hexagon socket nuts (14) or socket head bolts (5) to the tightening torques given be‐
low.

Size KBH motor size Bolt

DIN 912 Nut
140 50 -
FG 08
160 70 -
200 120 -
FG 10
225 295 -
Tab. 82 Tightening torques for hexagon socket nuts (5) or bolt (5)

– To obtain the full braking torque more quickly, switch the motor on and off repeatedly to wear in the brake
lining.
211 128 44/100621

113
 8.11.5 Replacing KBH motor brake springs

1 2 3 11

12

4 5 6 7 9 10

Fig. 80

1 End cap 7 Stator

2 Thrust ring 8 Thrust bearing
3 Brake spring 9 End cap
4 Spring ring 10 Brake disc
5 Dished washer pack 11 Brake cover
6 Reduction rings

– Remove motor end cap (1).

– Compress brake spring (3) by pressing on thrust ring (2).
– Remove spring ring (4) from the shaft and carefully release the brake spring.
– Remove thrust ring (2) and dished washer pack (5).
– Replace brake spring (3) and, if necessary, also adapter rings (6).
– Compress brake spring (3) with dished washer pack (5) and thrust ring (2). Refit spring ring (4). It must be
ensured that spring ring (4) snaps into the corresponding groove on the shaft.
– Refit motor end cap (1).
211 128 44/100621

114
 8.11.6 Air gap

1 2 3 11

12

4 5 6 7 9 10

Fig. 81

1 End cap 7 Stator

2 Thrust ring 8 Thrust bearing
3 Brake spring 9 End cap
4 Spring ring 10 Brake disc
5 Dished washer pack 11 Brake cover
6 Reduction rings

Check and, if necessary, adjust the air gap between the rotor and stator after each regular motor overhaul and
also after replacement of the motor end cap, stator and rotor or the dished washer pack, the tolerances of which
influence the air gap dimension.
If the air gap is too great, motor performance is reduced and the motor temperature rises excessively. If the air
gap is too small, the rotor grazes against the stator, resulting in destruction of the motor.

Motor Size 71 80 90 100 112 Motor Size 125 140 160 180 200 225
Range Air gap δ Range Air gap δ
KBH, KBA δmin 21) [mm] 0,25 0,25 0,30 0,30 0,35 KBH, KBA δmin 21) [mm] 0,35 0,40 0,45 0,50 0,50 0,55
δmax [mm] 0,30 0,30 0,35 0,35 0,45 δmax [mm] 0,45 0,50 0,55 0,60 0,60 0,65
Feeler gauge Feeler gauge
Size Size
0,25x3x250 x x 0,35x5x300 x
0,30x3x250 x x x x 0,40x5x300 x x
0,35x3x300 x x x x x 0,45x5x300 x x x
0,40x3x300 x x x x x 0,50x5x300 x x x x x x
0,45x3x300 x x x 0,55x5x350 x x x x x x
0,50x3x300 x x x 0,60x5x350 x x x x x x
0,55x3x300 x x x 0,65x5x350 x x x x
- 0,70x5x350 x x x
Feeler gauge 100...84 150 150 151 151 152 100...84 153 154 155 156 156 156
set
Tab. 83
211 128 44/100621

21) When fitting a new dished washer pack, increase nominal setting of air gap δ
min by 0,05 mm as the dished washer pack will settle after a few
switching operations. 115
 Follow the instructions on removing/installing the coupling in document 206 218 44 on installing the coupling.

– Remove coupling half from motor shaft.

– Remove brake cover (11), brake disc (10) and end cap (9).
– Place the motor on a suitable base as shown.

12

2
8

Fig. 82

– Remove rotor (12).

– Remove spring ring (4), thrust ring (2), dished washer pack (5) and brake spring (3) and, if necessary, adapt‐
er washers (6) from rotor shaft (12).
– In the following order, fit dished washer pack (5), thrust ring (2) and spring ring (4) onto rotor shaft (12).
The thrust ring is supplied in a variety of thicknesses to compensate for manufacturing tolerances. First se‐
lect a thrust ring of medium thickness.
– Fit thrust ring (2) with 45° bevel facing towards spring ring (4).
– Insert rotor (12), fitted as above, into stator (7) and lower carefully until thrust ring (2) is in contact with thrust
bearing (8).
– Insert three feeler gauges of the correct air gap dimension at 120° from each other into the air gap between
the stator and rotor core for their entire length.
The air gap is correctly adjusted when all three feeler gauges can be moved up and down with little effort.
Fit a thinner thrust ring if the air gap is too wide, or a thicker one if it is too narrow instead of the first one on rotor
shaft (12) and check the air gap once more.

– Remove rotor (12).

– Remove spring ring (4), thrust ring (2) and dished washer pack (5).
– Then fit brake spring (3) and, if required, adapter washers (6) and the removed parts onto rotor shaft (12).
It must be ensured that spring ring (4) snaps into the relevant groove on the shaft.

– When released, brake spring (3) pushes thrust ring (2) against spring ring (4).
211 128 44/100621

– Refit end cap (9).

– Fit brake disc (10) and brake cover (11), see  "Adjusting the brake on KBH motors", Page 110.

116
 8.12 ZBF 63 – 112 travel motor brake maintenance
8.12.1 Safety

WARNING
Operating safety risk
Danger to life and limb if the brakes are not correctly maintained.
The following work may only be carried out by specialist personnel.
Follow the safety instructions in the maintenance section and general safety warnings  "Safety", Page 11.

8.12.2 B003, B004, B020, B050 brakes

Apart from brake wear, the brake is virtually maintenance-free. The brake lining is designed in such a way that
worn surface particles are only given off as minimal abrasion. This built-in regeneration of the brake lining surface
ensures that the braking characteristics remain constant.
It is advisable to check air gap s1 at certain intervals.

To ensure the brake releases reliably, air gap s1 must be adjusted, as required.

Brake air gap

● s1min = 0,30 mm
● s1max = 1,2 mm

The brake disc can be freely turned when the brake is released (power applied to brake coil). It is only possible to
give guide values for braking work until the brake needs to be adjusted as these values depend on the given op‐
erating conditions.

Brake size B003 B004 B020 B050

Brake work until readjustment WN in Ws 200 × 106 200 × 106 300 × 106 500 × 106
Tab. 84

When the brake has been adjusted several times, the remaining thickness bmin of the brake disc must be checked.

B004, B020, B050 brake

The collared pins have a clearly visible mark which makes it easy to identify the minimum dimension ( "Check‐
ing and adjusting brake air gap s1", Page 118).

B003 brake
The brake can be adjusted twice. After it has been adjusted for the 2nd time, check the remaining thickness bmin
of the brake disc at regular intervals. This brake can only be checked visually.

B003, B004, B020, B050 brake

The brake disc must be replaced when the remaining thickness is too small or wear differs considerably between
the two linings. A wearing part set is available for replacement. In addition to the brake disc and the required small
parts, the set also includes the assembly instructions.
An overhaul set is available for general overhauls.

ZBF motors
Brake size Overhaul set Wearing part set
63/71 80 90B 100 112A
B003 260 960 84 260 962 84
B004 260 964 84 260 965 84
211 128 44/100621

B020 260 973 84 260 974 84 260 975 84

B050 260 978 84 260 979 84 260 980 84
Tab. 85

117
 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.

8.12.3 Checking and adjusting brake air gap s1

Removing the fan cover

1. 2.

3. 4.

Fig. 83

1. Unscrew the four retaining bolts.

2. Remove the fan cover.
3. Remove the retaining ring.
4. Remove the fan.
211 128 44/100621

118
 Checking the remaining thickness of the brake disc

B003 B004, B020, B050

bn

2
3

12

bmin

2
3
4

Fig. 84

2 Armature plate 12 Covering tape

3 Brake disc bn = Condition when new
4 Collared pin bmin = Remaining thickness

B003 brake
Brake type B003 can only be checked visually.
– To check the brake visually, push covering tape (12) to the side with a screwdriver.
B004, B020, B050
– If the edge of armature plate (2) has reached mark (x) on collared pin (4), brake disc (3) must be replaced.
Replacing the brake disc  "Replacing the brake disc", Page 121.
Brake size B004 B020 B050
Remaining thickness bmin [mm] 5 6 7
Tab. 86

– If the remaining thickness of the brake disc is within the specified tolerances, check brake air gap s1
( "Checking/adjusting the brake air gap", Page 120).
211 128 44/100621

119
 Checking/adjusting the brake air gap

B003 B004, B020, B050

9 11 3 14 6 9 11 3 7 6

s1 s1

10

Fig. 85

3 Brake disc 9 Magnet assembly

6 End cap 11 Feeler gauge
7 Retaining plate for covering tape 14 Friction plate
- only for IP55 s1 Brake air gap

Brake air gap

● s1min = 0,30 mm
● s1max = 1,2 mm

Brake size B003 B004 B020 B050

Adjusting angle α1 120° 120° 120° 90°
Tab. 87

– Tighten magnet assembly (9) with the three hexagon nuts (10) uniformly until the air gap is zero.
– Then loosen the three hexagon nuts (10) by adjusting angle α1.
– Check air gap s1 using a feeler gauge at three points around the circumference.
If the measured value is within the specified range, the motor can be re-assembled. If this is not the case, adjust
again as required.
211 128 44/100621

120
 Fitting the fan cover

1. 2.

43320044.eps

Fig. 86

1. Fit the fan on the shaft and secure it with the retaining ring.

CAUTION
Danger if incorrectly fitted
Danger to life and limb.
Ensure the retaining ring correctly clicks into the slot on the shaft when assembly is complete.
- It must be possible to move the retaining ring in the slot.

2. Fit the fan cover.

CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts can loosen or break off.
- ZBF 63 - 100 motor tightening torque = 4 Nm
- ZBF 112 motor tightening torque = 6 Nm

8.12.4 Replacing the brake disc

8.12.4.1 Removing the fan cover

To remove the fan cover, see  "Removing the fan cover", Page 118
211 128 44/100621

121
 8.12.4.2 B003 brake

1. 2. + 3.
11

10 15 9 12 1 2 3 4 5 13 6

43320144.eps

Fig. 87

1 Stop plate 10 Hexagon nut

2 Armature plate 11 Terminal box cover
3 Brake disc 12 Covering tape
4 Stud screws 13 Sleeve
5 Distance springs 14 Friction plate
6 End cap 15 Washers
9 Magnet assembly

1. Remove terminal box cover (11). Undo hexagon nut (10) and remove washers (15), magnet assembly (9)
and covering tape (12).
2. Remove stop plate (1), armature plate (2), distance springs (5) and brake disc (3).
Check stud screws (4), sleeve (13) and braking surfaces for wear.

WARNING
Risk of brake failure.
Worn or damaged components can cause the brake to fail and are a safety risk.
“Damaged” should be understood to mean any deformation of stop plate (1), however small it may be.
- Replace worn or damaged parts with genuine spare parts.

Replace stud screws and end cap (6), if necessary.

Collared pin/stud screw (4) tightening torques

Brake size B003 B004 B020 B050
Tightening torque [Nm] 3 3 4 9
Tab. 88

3. Remove end cap (6). Remove sleeve (13) and friction plate (14).
Unscrew the three defective stud screws (4).
Fit new stud screws (4). Friction plate (14) is provided with mark “I”.
End cap (6) is also provided with a mark.
211 128 44/100621

The mark on friction plate (14) must be aligned with the mark on end cap (6) when friction plate (14) is fitted.
Push sleeve (13) onto stud screws (4). Fit new end cap (6).

122
 Fitting B003 brakes

1. 2.
X 11

1 2 3 4 5 13 6 10 15 9 8 12 4 5 6
43320244.eps

Fig. 88

1 Stop plate 10 Hexagon nut

2 Armature plate 11 Terminal box cover
3 Brake disc 12 Covering tape
4 Stud screws 13 Sleeve
5 Distance springs 14 Friction plate
6 End cap 15 Washers
8 Brake spring X Spring arrangement  Fig. 89, Page 124
9 Magnet assembly

1. Fit brake disc (3).

The recess on the outer diameter and the bore hole on stop plate (1) must be aligned with the mark on end
cap (6) when armature plate (2) is fitted.
The machined surface of armature plate (2) is the opposite surface of the brake disc.
Follow installation instructions below:
● Ensure that stop plate (1) has no deformation and is in contact with armature plate (2) across its entire sur‐
face.
● Ensure that stop plate (1) is not jammed between stud screw (4), sleeve (13) and armature plate (2).

2. Push distance springs (5) onto stud screws (4).

Place brake springs (8) into magnet assembly (9).
Insert covering tape (12) into the groove of end cap (6).
Push magnet assembly (9) and discs (15) over stud screws (4) and secure with hexagon nut (10).
Ensure that covering tape (12) engages the groove of magnet assembly (9) when magnet assembly (9) is
fitted. The tighten magnet assembly (9) with the three hexagon nuts (10) uniformly until the air gap is zero.
Then loosen the three hexagon nuts (10) by adjusting angle α1 = 120°.
Check air gap s1 using a feeler gauge at three points around the circumference. If the measured value is
within the specified range, the motor can be re-assembled. Checking/adjusting the brake air gap  "Check‐
ing/adjusting the brake air gap", Page 120.
Pull the connecting cable of magnet assembly (9) back into the terminal box. Fit terminal box cover (11).

Motor Brake torque Quantity of brake springs Spring arrangement Part no.
211 128 44/100621

[Nm] Red Blue See diagram

ZBF 63 A 8/2 B003 1,4 - 3  Fig. 89, Page 124 260 027 84
ZBF 71 A 8/2 B003 1,9 3 -  Fig. 89, Page 124 260 011 84
Tab. 89 Arrangement of brake springs
123
 Spring arrangement

ZBF 63 A ZBF 71 A

3 bl 3 rt
43326844.eps

Fig. 89

Fitting the fan cover

Fit fan and fan cover,  "Fitting the fan cover", Page 121.

211 128 44/100621

124
 8.12.4.3 B004, B020, B050 brakes

1. 2.

11

10 9 1 2 3 4 5 7 6

3.

4 7 6
43320344.eps

Fig. 90

1 Stop plate 6 End cap

2 Armature plate 7 Retaining plate
3 Brake disc 9 Magnet assembly
4 Collared pin 10 Hexagon nut
5 Distance springs 11 Terminal box cover

1. Remove terminal box cover (11).

Unscrew hexagon nut (10) and remove magnet assembly (9).
2. Remove stop plate (1), armature plate (2), distance springs (5) and brake disc (3).
Check collared pins (4) and braking surfaces for wear.

WARNING
Risk of brake failure.
Worn or damaged components can cause the brake to fail and are a safety risk.
“Damaged” should be understood to mean any deformation of stop plate (1), however small it may be.
- Replace worn or damaged parts with genuine spare parts.

Replace collared pin/end cap, if necessary.

211 128 44/100621

125
 Collared pin/stud screw (4) tightening torques
Brake size B003 B004 B020 B050
Tightening torque [Nm] 3 3 4 9
Tab. 90

3. Remove end cap (6).

Unscrew the three defective collared pins (4).
Fit new collared pins (4). Fit new end cap (6).
Retaining plate (7) is only fitted on units with IP55 enclosure.
● Fit retaining plate (7) with collared pins (4).

Fitting B004, B020, B050 brakes

1. 2.
X 11
1 20 21
8

1 2 3 4 5 7 6 10 9 8 4 5
43320444.eps

Fig. 91

1 Stop plate 7 Retaining plate

2 Armature plate 9 Magnet assembly
3 Brake disc 10 Hexagon nut
4 Collared pin 11 Terminal box cover
5 Distance springs x Spring arrangement,  Fig. 92, Page 127
6 End cap

1. Fit brake disc (3).

Mark “I” and the bore hole on stop plate (1) must be aligned with the mark on end cap (6) when armature
plate (2) is fitted.
Follow installation instructions below:
● Ensure that stop plate (1) has no deformation and is in contact with armature plate (2) across its entire sur‐
face.
● Ensure that stop plate (1) does not jam between collared pin (4) and armature plate (2).

2. Push distance springs (5) onto collared pins (4).

Place brake springs (8) into magnet assembly (9). Push magnet assembly (9) over collared pins (4) and se‐
cure with hexagon nut (10).
The tighten magnet assembly (9) with the three hexagon nuts (10) uniformly until the air gap is zero. Then
loosen the three hexagon nuts (10) by adjusting angle α1 = 120°.
211 128 44/100621

Check air gap s1 using a feeler gauge at three points around the circumference. If the measured value is
within the specified range, the motor can be re-assembled.

126
 Checking/adjusting the brake air gap  "Checking/adjusting the brake air gap", Page 120.
Pull the connecting cable of magnet assembly (9) back into the terminal box. Fit terminal box cover (11).
Motor Brake torque Quantity of brake springs Spring arrangement Part no.
[Nm] Red Blue See diagram
ZBF 63 A 8/2 B004 1,3 3 - 260 211 84
ZBF 71 A 8/2 B004 1,8 - 6 260 127 84
ZBF 80 A 8/2 B020 3,3 3 - 260 211 84
 Fig. 92, Page 127
ZBF 90 B 8/2 B020 4,4 4 - 260 211 84
ZBF 100 A 8/2 B050 8,3 3 - 260 311 84
ZBF 112 A 8/2 B050 11 4 - 260 311 84
Tab. 91 Arrangement of brake springs

Spring arrangement

ZBF 63 A
ZBF 90 A
ZBF 80 A ZBF 71A
ZBF 112 A
ZBF 100 A

3 rt 4 rt 6 bl

43326944.eps

Fig. 92

Fitting the fan cover

Fit fan and fan cover,  "Fitting the fan cover", Page 121.
211 128 44/100621

127
 8.12.5 KMF 80 travel motor brake
8.12.5.1 Condition as supplied
The Demag motor is supplied with the brake adjusted for the minimum displacement of approx. 1,5 - 2,0 mm for
size 80 motors.
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 maximum of 3,0 mm for size 80 motors.
For brake adjustment, the load must be removed from the hoist unit. Adjustment can be repeated several times.
It is imperative to ensure, by regular maintenance, that the brake is adjusted before the maximum rotor displace‐
ment is reached.
● It is advisable to have a spare brake cup in stock.

Number of shims

Motor Qty Segment thickness

KMF 80 2x5 0,8 mm
Tab. 92

8.12.5.2 Adjusting the brake with shims

Safety

WARNING
Risk of brake failure.
Incorrect work on the brake represents a high safety risk.
This work may only be carried out by specialist personnel.
– Observe relevant safety regulations and codes of practice and the section on safety instructions.
– It is imperative that the brake displacement is measured at regular intervals. The brake must be adjusted
when the path of displacement has reached the maximum displacement value.

211 128 44/100621

128
 Adjusting the brake

1. 2. 3.

4. 5. 6.

7. 8.

43320544.eps

Fig. 93

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Ensure that the specified tightening torques are applied.

1. Measure brake displacement.

Path of displacement should be = 1,5 - 2,0 mm
Brakes must be adjusted if their displacement is outside the tolerance.
2. Unscrew the fan cover retaining bolts and remove the fan cover.
3. Unscrew the end cap retaining bolts.
4. Loosen the end cap.
5. Remove shims to adjust the brake displacement.
Ensure the same number of shims is fitted on both sides.
6. Bolt the end cap on.
Tightening torque for KMF 80 motor = 10,5 Nm
7. Measure brake displacement.
KMF 80 motor: displacement of approx. 1,5 - 2 mm
211 128 44/100621

8. Fit the fan housing.

Tightening torque = 3 Nm
129
 8.12.5.3 Replacing the brake cup

Safety

WARNING
Risk of brake failure.
Incorrect work on the brake represents a high safety risk.
This work may only be carried out by specialist personnel.
– Observe relevant safety regulations and codes of practice and the section on safety instructions.

Replacing the brake cup

1. 2. 3.

4. 5. 6.

7.

43320644.eps

Fig. 94

1. Unscrew the fan cover retaining bolts and remove the fan cover.
2. Unscrew the end cap retaining bolts.
3. Loosen the end cap.
4. Remove fan with end cap.
5. Lock the brake cup using a screwdriver and remove the bolts.
6. Loosen the brake cup with light blows (hammer and pin).
7. Remove the brake cup.
211 128 44/100621

130
 Assembly

1. 2. 3.
2

3 3 1

4. 5. 6.

7.

43320744.eps

Fig. 95

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Ensure that the specified tightening torques are applied.

1. Fit the brake cup and tighten the bolts.

Secure the brake cup in place using a screwdriver, tightening torque = 10,5 Nm.
After fitting the brake cup, fit the new shims supplied with it.
Ensure the same number of shims is fitted on both sides.
2. Ensure that the components are installed correctly:
Item 1: Guide for brake release stirrup.
Item 2: Splines to assist in assembly.
Item 3: Ensure that the fan clips are correctly seated in the bearing bush.
3. Install the brake release stirrup as shown.
4. Fit the end cap.
211 128 44/100621

5. Press fan cap onto brake release stirrup.

131
 6. Align the marks on the fan and fan cap.
7. Tighten the end cap retaining bolts:
KMF 80 motor tightening torque = 10,5 Nm

Checking brake displacement

1. 2.

43320844.eps

Fig. 96

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Ensure that the specified tightening torques are applied.

1. Measure brake displacement.

KMF 80 motor: displacement of approx. 1,5 - 2 mm
2. Fit the fan housing and tighten the bolts:
Tightening torque = 3 Nm

211 128 44/100621

132
 8.13 EZDH travel wheel wear

DRS 160, 200 DRS 250, 315

s s

d1
43311644.eps

Fig. 97

➨ Wear indicators

The wear indicator on the flange facilitates preventive inspections of the installation.
The travel wheel must already be replaced even if only one segment of the wear indicator is open, as shown in
the lower part of the diagram.

Tread wear
Travel wheels must be replaced when the following limit values are reached:

Travel wheel rated diameter Remaining minimum flange Minimum travel wheel diameter Maximum difference in travel
width d1 wheel diameters for coupled
s wheels
[mm] Dimensions in [mm]
112 5,0 105,4 0,1
125 6,0 118,4 0,1
160 7,0 153,4 0,15
200 8,4 193,0 0,15
211 128 44/100621

250 9,5 242,0 0,20

Tab. 93

133
 The new wheel blocks have to aligned horizontally when wheel blocks are replaced.

8.14 Change gearbox oil

8.14.1 Main hoist gearbox (two, three or four-stage planetary gearbox)

Under normal operating conditions, the lubricant does not have to be changed until a general overhaul is carried
out.
Under exceptional operating conditions, e.g. increased ambient temperatures, we recommend that oil change in‐
tervals be adapted to suit these operating conditions.

CAUTION
Follow the assembly instructions:
Danger resulting from incorrect assembly.
Follow the installation instructions below:
– For brake adjustment, the load must be removed from the Demag hoist unit.
– When a complete motor is fitted, the surface between the motor and gearbox flange (1) must be sealed
with Loctite 573.
Part no. 033 068 44

DH 1000 = 115 Nm
DH 2000 = 300 Nm

DH 1000/2000 = 75 Nm

Fig. 98

– Tighten to the specified tightening torques, see drawing.

211 128 44/100621

134
 Oil change

1 2 3 4

Fig. 99

Components DH 1000 = 121 Nm

1 Breather DH 2000 = 295 Nm
2 Sealing surfaces 6 Tightening torque for motor bolts:
3 Code DH 1000 = 115 Nm
4 Sealing surface between motor and gearbox DH 2000 = 300 Nm
sealed with Loctite 573. 7 Tightening torque for gearbox bolts:
Part no.: 033 068 44 DH 1000 = 75 Nm
Tightening torques DH 2000 = 75 Nm
5 Gearbox cover tightening torques:

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Ensure that the specified tightening torques are applied.

Notes for assembly:

● After the oil has been changed on units that have cast-iron gearbox housings, seal the sealing surfaces be‐
tween the gearbox cover, internally toothed wheel rim and gearbox housing with Loctite 573.
● Ensure that the code number (gear ratio) on the gearbox housing and the air vent screw are located as
shown above when the gearbox cover is fitted.

– Remove the planetary gearbox.

– Thoroughly clean the gearbox parts and gearbox casing with commercially available cleaning agents.
– Then re-assemble gearbox.
– Re-fill with fresh gear oil before closing the gearbox.
Required quantity and grade of oil  "Gearbox oil filling", Page 32.
211 128 44/100621

135
 Grease chamber and roller bearing

DH 1000, DH 2000
Fill grease chamber and roller bearing with STABURAGS NBU 12 K.

Range Grease quantity

DH 1000 140 gr.
DH 2000 210 gr.
Tab. 94 Quantities of grease for DH 1000, DH 2000

Part no. 472 933 44, 100 g tube

Fig. 100

Gearbox tightening torques

A B C

1 2 1 2 3 1 2 3 4

Fig. 101

A 2-stage gearbox B 3-stage gearbox

C 4-stage gearbox

CAUTION
Loose connections
Loose connections are a danger to life and limb.
Ensure that the specified tightening torques are applied.

Gearbox type: 2-stage 3-stage 4-stage

Item in the diagram 1 2 1 2 3 1 2 3 4
DH 1000 121 Nm 70 Nm 121 Nm 70 Nm 36 Nm - - - -
Range
DH 2000 - - 295 Nm 120 Nm 70 Nm 295 Nm 120 Nm 70 Nm 36 Nm
Tab. 95 Bolt tightening torque

8.14.2 FG 08 and FG 10 microspeed units, AMK 20, AUK 30 travel drives

Oil lubrication
211 128 44/100621

Under normal operating conditions, the lubricant should be changed after 10000 hours of service. Under excep‐
tional operating conditions, e.g. increased ambient temperatures, we recommend that oil change intervals be
adapted to suit these operating conditions.
136
 Oil change
Drain the old oil at operating temperature. To do this, first remove the air vent screw at the top of the gearbox and
then the oil drain screw at the bottom, and the oil will run out.
For the first oil change we recommend that the gearbox be flushed with oil of the same type as that used before
for lubrication.

The flushing oil should have a viscosity of 46 – 68 mm2/s at 40 °C. The quantity of flushing oil used should be
approximately twice that specified for lubrication. Run the gearbox for a few minutes at no load and then drain the
flushing oil. Repeat this operation several times, also in alternate directions of rotation, to ensure that all remains
of the old lubricant are drained from the gearbox together with the flushing oil.
Refer to the gearbox data plate for the required quantity of oil.

Oil grades

Gear oil with a viscosity of 220 mm2/s at +40 °C with mild high-pressure additives should be used for ambient
temperatures of approx. -10 °C to +50 °C, e.g.
● BP ENERGOL GR-XP 220
● Esso Spartan EP 220
● SHELL Omala Oil 220
● Mobilgear 630
● Aral Degol BG 220
At higher or lower ambient temperatures, a type of oil used must be selected to match the specific temperature
conditions.

Oil filling quantities/venting of travel drives and mechanical microspeed unit

A) Travel drive for EUDH monorail hoist, required oil quantity:

A ● AMK 20 = 0,50 litre
● AUK 30 = 0,90 litre
● See arrow for vent
B) Travel drive for EZLDH double-rail crab, required oil quantity:
● AMK 20 = 0,50 litre
B ● AUK 30 = 0,90 litre
● See arrow for vent

Fig. 102
211 128 44/100621

137
 Basic model U0, oil quantity:
● FG 08 = 2 litres
● FG 10 = 5 litres
● See arrow for vent
U0 Basic model U1, oil quantity:
● FG 08 = 1,5 litres
● FG 10 = 4 litres
● See arrow for vent
U1
Basic model U2, oil quantity:
● FG 08 = 2 litres
● FG 10 = 5 litres
U2 ● See arrow for vent
Basic model U3, oil quantities:
● FG 08 = 1,5 litres
● FG 10 = 4 litres
● See arrow for vent
U3

Fig. 103

8.14.3 Output stage, standard and low-headroom monorail hoists

On monorail hoist trolleys, one pair of opposing travel wheels is driven.

The output stage is covered by a split plastic casing filled with grease.
The two-piece plastic casing is held together by a strap. Be careful not
to tighten this strap excessively during assembly.

Trolley size 10
Grease quantity in g 210
Part no. 472 915 44 (400 g)
Tab. 96

Fig. 104

8.14.4 Anti-friction bearing

8.14.4.1 General information

Anti-friction bearings which do not form an integral part of gearboxes and rope sheaves, i.e. motor-end drum
bearings and travel wheel bearings, are provided with a quantity of grease that is sufficient under normal operat‐
ing conditions. These bearings must be replaced when the general overhaul is carried out. Special operating con‐
ditions may require replacement at an earlier date.
To do this, the bearings must be disassembled and thoroughly cleaned with a commercially available detergent;
then refill approx. 2/3 of the space inside the bearing with fresh anti-friction bearing grease.
211 128 44/100621

8.14.4.2 Motor bearings

Demag brake motors normally have 2 cylindrical roller bearings and 1 ball thrust bearing. The rollers run directly
on the hardened shaft. The grease in the bearings should generally be replaced every 4 years unless exceptional
138
 operating conditions make it necessary to replace it at an earlier date. To do this, the bearings must be disassem‐
bled and thoroughly cleaned with a commercially available detergent; then refill approx. 2/3 of the space inside
the bearing with fresh anti-friction bearing grease.

8.14.5 Load-bearing bolted connections

All load-bearing bolted connections are hardened and tempered and are secured by means of split pins or lock
washers. The bolted connections should be checked for tight fit at the intervals indicated in the maintenance
schedule and retightened if necessary. Replacement screws and bolts must be of the same quality and secured in
the same way (with lock washers or split pins).
Maintenance tasks to be carried out are the checks indicated in the maintenance schedule. Any dirt accumulating
on the controller housing over long periods of use can be removed using a household liquid detergent.

8.15 General overhaul (GO)

The owner is obliged to carry out a general overhaul when the theoretical duration of service is reached ( "Reg‐
ular inspections", Page 15).

WARNING
Operating safety at risk
Specified general overhaul intervals must be strictly complied with.

When 90% of the theoretical duration of service has elapsed – after 8 to 10 years if the hoist is correctly classified
– the owner must arrange for a GO general overhaul to be carried out. A GO general overhaul must be carried out
by the end of the theoretical duration of service.
During the general overhaul, the following parts must be replaced in addition to the checks and work specified in
the inspection and maintenance schedule:
● Gear wheels of the gearbox
● Gearbox bearings
● Motor
● Rope drum
● Gear oil
● Connecting elements
● Switchgear in the control system
The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not
listed separately.
Therefore, the provisions of the relevant UVV accident prevention regulations and BGV D8 are satisfied.
The equipment may continue to be used when an expert engineer has entered the conditions for continued opera‐
tion in the log book. Completion of the general overhaul must be confirmed in the log book and a further period of
utilisation in accordance with FEM 9.755 must be entered.
The general overhaul may be carried out by Demag expert engineers or an authorised specialist company.
● The general overhaul carried out by the manufacturer or a specialist company authorised by him satisfies the
requirement to be met for continued operation of the machine.
211 128 44/100621

139
 9 Malfunctions

9.1 Safety warnings

WARNING
Risk of injury.
Incorrect elimination of malfunctions can result in severe injuries and/or damage to property.
Malfunctions may only be eliminated by authorised and trained specialist personnel in compliance with all safety
regulations.

DANGER
Live components
Electric current can cause danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel in compliance with the
safety regulations.

9.2 Conduct when malfunctions occur

Always:
1. Bring the machine to an immediate standstill by actuating the emergency stop without delay if malfunctions
occur that result in an immediate danger of injuries, damage and/or an operating safety hazard.
2. Disconnect the machine from the power supply and secure the machine against re-connection.
3. Inform the person responsible at the operating location about the malfunction.
4. Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per‐
sonnel.

9.3 Conduct after malfunctions have been eliminated

WARNING
Putting into operation again
Danger to life and limb.
Before switching on again, check that:
– Malfunction and cause of malfunction have been eliminated.
– All safety devices have been fitted properly and are in perfect condition and working order.
– Nobody is present in the danger zone of the machine.
211 128 44/100621

140
 9.4 Malfunctions, causes and remedy
Fault Cause Remedy
Rope hoist and long travel not functioning System switched off Check whether unit is switched on
Emergency stop actuated Release emergency stop
Operating voltage missing Check voltage
Control voltage missing Check voltage
Circuit breaker has tripped Check cables
Rope hoist does not lift or lower, long and cross Phases swapped Swap phase sequence of powerfeed, inform
travel functioning Service
Brake release signal missing22) Inform Service
Phase missing Check voltage
Rope hoist only lifts or lowers at low lifting speed Incorrect geared limit switch setting Set according to operating instructions
Rope hoist only lowers Overload lifted Remove overload
Rope hoist only lowers, long and cross travel pos‐ Thermal contact of hoist motor active22) Allow hoist motor to cool down
sible
Lifting motion does not reach "top" or "bottom" po‐ Incorrect geared limit switch setting Set according to the operating instructions
sition, but lifts and lowers
Cross travel not functioning Cross-travel circuit breaker has tripped Check cables
Thermal contact of cross-travel motor ac‐ Allow cross-travel motor to cool down
tive22)
Brake of cross-travel motor does not release Brake or control defective,
Inform Service
Tab. 97
211 128 44/100621

22) Optional 141

 10 Measures for achieving safe working periods

10.1 General
The safety and health provisions of EC directive 2006/42/EC make it a legal requirement to eliminate special haz‐
ards which may be caused, for example, by fatigue and ageing.
This requirement is also reflected in the third supplement to German accident prevention regulations BGV D8 of
1.4.1996. This requirement obliges the owner of serial hoist units to determine the actual duration of service of the
hoist unit on the basis of the operating hours, load spectra and 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 op‐
eration. Premature failure cannot, however, be ruled out.
The following items have been taken from FEM rule 9.755 with reference to Demag DH hoist units:
1. The actual duration of service determined on the basis of operating time and load must be documented at
least once per year.
2. The operating time Ti (number of operating hours) can be estimated or read on the hook travel counter of the
DGS geared limit switch ( "DGS 3 and DGS 4 geared limit switches", Page 88).
3. 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 re‐
cording factor f = 1,1.
5. The actual duration of service S is calculated as: S = kmi · Ti · 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 dura‐
tion 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
component parts close to failure and the replacement of all such components and parts.
● Following a general overhaul, the machinery is in a condition similar to that of the same machinery in new con‐
dition 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 (conver‐
ted into full load hours):

Group of mecha‐ 1Bm 1Am 2m 3m 4m

nisms
Full load hours [h] 400 800 1600 3200 6300
Tab. 98

The actual duration of service is considerably increased if the hoist unit is only operated with partial loads. 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.

10.2 Calculating the actual duration of service

The actual duration of service S for a Demag DH hoist unit can be calculated using the following method:
● S = kmi · Ti · f
● kmi: Load spectrum factor
● Ti: Number of operating hours
211 128 44/100621

● f: Factor depending on the method of recording

When powered hoist units are used, the owner must determine and record the used share of the theoretical dura‐
tion of service for the hoist, see BGV D8 ( "Regular inspections", Page 15).

142
 A general overhaul must be arranged to be carried out when 90% of the service life has elapsed (when 10% is
shown on the display).

Safe working period (S.W.P.)

The theoretical duration of service (to ISO 4301/FEM 9.755) in connection with the actual mode of operation
( "Selection criteria", Page 17) results in the S.W.P. (safe working period).

10.3 Estimating load spectrum factor kmi (by the owner)

Fig. 105

L Load
t Time

To simplify estimation, each type of load can be grouped together into km load spectrum 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 considered.
The operating time for each type of load is divided up within the inspection interval (e.g. 1 year) in terms of per‐
centage. The following bar diagram shows the km load spectrum modules for the load conditions 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 spectrum factor kmi can be obtained by adding together the individual km load spectrum modules.
211 128 44/100621

143
 10.4 Calculating the number of hours of operation (operating time) Ti by the owner
Every Demag DH hoist unit has a hook travel counter (1) fitted in the
DGS geared limit switch as standard.
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 follow‐
4

ing equation.
1
3

H*Z
Ti [h] =
1000
0000000 Tab. 99

3 Factor Z for 1/1, 2/1, 4/1, 6/1, 8/1 reeving:

4
2

1 Reeving DH
1/1 2/1 4/1 6/1 8/1 1000 2000
Lifting speed [m/min] Factor Z
1 8,0 4,0 2,0 1,3 1,0 1,97 2,48
10,0 5,0 2,5 1,6 1,2 1,58 1,98
11,2 5,6 2,8 1,9 1,4 1,41 1,77
Fig. 106 12,5 6,3 3,1 2,0 1,5 1,26 1,58
14,2 7,1 3,6 2,4 1,8 1,11 1,39
16,0 8,0 4,0 2,6 2,0 0,98 1,24
18,0 9,0 4,5 3,0 2,3 0,87 1,1
20,0 10,0 5,0 3,3 2,5 0,79 0,99
22,4 11,2 5,6 3,7 2,8 0,7 0,88
25,0 12,5 6,3 4,1 3,1 0,63 0,79
28,0 14,0 7,0 4,6 3,5 0,56 0,7
32,0 16,0 8,0 5,3 4,0 0,49 0,62
36,0 18,0 9,0 6,0 4,5 0,43 0,55
50,0 25,0 12,5 - - 0,31 0,39
Tab. 100

The number of hours of operation (operating time) Ti takes into account

all lifting and lowering motions during an inspection interval. Long and
cross-travel times are not taken into consideration.

10.5 Factor depending on the type of recording f

f = 1,1 For calculating the operating hours using an operating time counter. The S.W.P. can be calculated by
means of the number of operating hours Ti, the estimated load spectrum factor kmi and the factor depending on
the type of recording f.
211 128 44/100621

144
 10.6 Example with hook travel counter

Fig. 107

L= Load
t= Time

DH 1050 H16 KV2 2/1, group of mechanisms 1Am with 8 m/min lifting speed
In the calculated operating time, the specified hoist unit has transported the following loads per inspection interval:
Adding the load spectrum modules km together results in load spectrum factor:
kmi = 0,119

Read out the hook travel counter:

Date Hoist unit counter

26.03.2008 0 000 001
31.03.2009 0 393 366
Calculated H value 393 365
Tab. 101

Factor Z = 0,68,  Tab. 100, Page 144

H*Z
Ti = [h]
1000

393 365 * 0,68

Ti = = 267,5 hours
1000
Tab. 102

Therefore, the actual duration of service amounts to:

S = kmi × Ti × f = 0,119 × 267,5 × 1,1 = 35,0 [h]

For classification in FEM group of mechanisms 1Am (see DH data plate) with a theoretical duration of service of
800 hours, the hoist has a theoretical remaining duration of service of 765 hours. Enter these values in your log
book or crane log book. This entry may appear as follows:

Date Load spectrum Actual dura‐

Operat‐ Theoretical du‐ Remaining
Loading [%] / km - Factor factor (sum of tion of serv‐
ing hours ration of service use
km factors) ice
From To Ti value with‐ D [h] Group of
full 3/4 1/2 1/4 kmi f S [h] D - S [h]
[h] out mech.
0000001 0393366 393365 5 10 20 15 50
211 128 44/100621

3.1.-- 30.12.-- 267,5 0,05 0,042 0,025 0,0023 - 0,119 1,1 35 800 / 1Am 765

Tab. 103
145
 10.7 Example with FWL load spectrum recorder

LK
180 360 540 720 900 1080 1260 1440 x 1000

DR

100
90
80
70
60
50
40
30
20
10
0

1Bm 0 50 100 150 200 250 300 350 400

1Am 0 100 200 300 400 500 600 700 800
2m 0 200 400 600 800 1000 1200 1400 1600
3m 0 400 800 1200 1600 2000 2400 2800 3200
4m 0 800 1600 2400 3200 4000 4800 5600 6300

FEM S in [h] D in [h]

Fig. 108 Approximate calculation of duration of service S using a diagram

LK Load spectrum (counter reading) S Duration of service

DR Remaining use D Theoretical use

Assess the safe working period SWP with a FWL load spectrum recorder.
For hoists fitted with a load spectrum recorder, the counter reading can be used direct to estimate the remaining
duration of service.
The theoretical duration of service expires when the counter reading reaches 1,440,000.

Example,  Fig. 108, Page 146

● DH 1050 H16 KV2 2/1 1Am
● Counter reading: 140.355
The actual duration of service S amounts to approx. 75 hours. With the same type of service, a duration of service
of approx. 90% remains.
Exact calculation of duration of service S:

D * LK
211 128 44/100621

S=
1.440.000

146
 800 * 140.355
S= = 77,9 h
1.440.000
Tab. 104

Enter the duration of service figure in your log book or crane log book.
211 128 44/100621

147
 Original Ident. number / Language
EC conformity declaration for a machine 19964844 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
1217 1/ 2

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

declare that the product

Demag DH rope hoist

Serial no.: XXX-XXX-XXX
ready for service - as a series product or manufactured to order - after completion of
assembly/being put into service including function check and load test prior to being
put into service to be confirmed on page 2 complies with all relevant requirements of

EC Machinery Directive 2006/42/EC.

The safety objectives of Low Voltage Directive 2014/35/EU are achieved.

The product additionally complies with the following relevant directives/provisions:
EU EMC Directive 2014/30/EU

e
pl Applied harmonised standards and/or C standard drafts, in particular:

EN 14492-2 Cranes - Power driven winches and hoists -

Part 2: Power driven hoists
EN 60204-32 Safety of machinery - Electrical
equipment of machines - Part 32:
Requirements for hoisting machines
EN 61000-6-2 Electro-magnetic compatibility (EMC), Part 6-2:
am

Generic standards - Immunity for

industrial environments
EN 61000-6-4 Electro-magnetic compatibility (EMC), Part 6-4:
Generic standards - Emission for
industrial environments

Authorised representative for technical documentation:

Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany
S

Düsseldorf, 11.06.2021

ppa. Thomas Wiesmann i.V. Oliver Moll

Head of Plant Wetter Hoist Platform

Industrial Equipment
U04281

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
EC conformity declaration for a machine 19964844 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
1217 2/ 2

Demag DH rope hoist

Serial no.: XXX-XXX-XXX

-----------------------------------------------------------------------------------------------------------

For assembly / first putting into service including function check

...................................., date ................................................

Company that carries out the work: ................................................

Function in the company: ................................................

Name: ................................................

Signature: ................................................

e
pl ------------------------------------------------------------------------------------------------------------

For the load test in the scope of the acceptance test

...................................., date ................................................

Company that carries out the work: ................................................

am

Function in the company: ................................................

Name: ................................................

Signature: ................................................
S

Industrial Equipment
U04281

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
Declaration for fitting partly completed machinery 19964744 / EN
according to Machinery Directive 2006/42/EC, Annex IIB Issue Page
0919 1/ 1

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

declare that the product

Demag DH rope hoist

Serial no.: XXX-XXX-XXX
supplied as partly completed machinery is intended to be incorporated into machinery and its
initial bringing into service is prohibited until the machinery* into which this partly completed
machinery is to be incorporated has been declared in conformity with all relevant provisions of

EC Machinery Directive 2006/42/EC.

(* insofar as this machinery is subject to the scope of application)

Basic requirements of the EC Machinery Directive, insofar as they are relevant for the scope of
delivery, are met by application of the following harmonised standards or C standard drafts:

e
EN 14492-2 Cranes - Power driven winches and hoists -
Part 2: Power driven hoists
EN 60204-32 Safety of machinery - Electrical
equipment of machines - Part 32:
pl EN 61000-6-2
Requirements for hoisting machines
Electro-magnetic compatibility (EMC), Part 6-2:
Generic standards - Immunity for
industrial environments
EN 61000-6-4 Electro-magnetic compatibility (EMC), Part 6-4:
am

Generic standards - Emission for

industrial environments

The safety objectives of Low Voltage Directive 2014/35/ЕU are achieved

The product additionally complies with the following relevant directives/provisions:
EU EMC Directive 2014/30/EU

The special technical documentation according to Annex VII Part B of Directive 2006/42/EC has
been compiled and will be made available to authorised national authorities by the designated
S

authorised representative in response to a justified request.

Authorised representative for technical documentation
Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany

Düsseldorf, 11.06.2021

ppa. Thomas Wiesmann i.V. Oliver Moll

Head of Plant Wetter Hoist Platform

Industrial Equipment
U04281

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
UK Declaration of Conformity of the Machinery 19943244 / EN
acc. to Supply of Machinery (Safety) Regulations 2008, Issue Page
Annex II, sub. A 0721 1/ 2

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

declare that the product

Demag DH rope hoist

Serial no.: XXX-XXX-XXX
ready for service - as a series product or manufactured to order - after completion of
assembly/being put into service including function check and load test prior to being
put into service to be confirmed on page 2 complies with all relevant requirements of

Supply of Machinery (Safety) Regulations 2008 No. 1597.

The safety objectives of Electrical Equipment (Safety) Regulations 2016 No. 1101 are achieved.

e
The product additionally complies with the following relevant statutory instruments/provisions:
pl Electromagnetic Compatibility Regulations 2016 No. 1091

Applied designated standards and/or C standard drafts, in particular

- regarding 2008 No. 1597:
EN 14492-2:2006+A1:2009
- regarding 2016 No. 1091:
EN 61000-6-2:2005
EN 61000-6-4:2007+A1:2011
am

- regarding 2016 No. 1101:

EN 60204-32:2008

Person authorised to compile the technical file:

Paul Bartlett, Beaumont Road, Banbury, OX16 1QZ, United Kingdom

Düsseldorf, 27.08.2021
S

ppa. Thomas Wiesmann i.V. Oliver Moll

Senior Director Director
Supply CTO Wetter Hoist Platforms

Industrial Equipment
U04281

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
UK Declaration of Conformity of the Machinery 19943244 / EN
acc. to Supply of Machinery (Safety) Regulations 2008, Issue Page
Annex II, sub. A 0721 2/ 2

Demag DH rope hoist

Serial no.: XXX-XXX-XXX

-----------------------------------------------------------------------------------------------------------

For assembly / first putting into service including function check

...................................., date ................................................

Company that carries out the work: ................................................

Function in the company: ................................................

Name: ................................................

Signature: ................................................

e
pl ------------------------------------------------------------------------------------------------------------

For the load test in the scope of the acceptance test

...................................., date ................................................

Company that carries out the work: ................................................

am

Function in the company: ................................................

Name: ................................................

Signature: ................................................
S

Industrial Equipment
U04281

Subject to change. No liability for errors or omissions

 Original UK Declaration of Incorporation Ident. number / Language
of partly completed Machinery 19943144 / EN
acc. to Supply of Machinery (Safety) Regulations 2008, Issue Page
Annex II, sub. B 0721 1/ 1

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

declare that the product

Demag DH rope hoist

Serial no.: XXX-XXX-XXX
supplied as partly completed machinery is intended to be incorporated into machinery and its
initial bringing into service is prohibited until the machinery* into which this partly completed
machinery is to be incorporated has been declared in conformity with all relevant provisions of

Supply of Machinery (Safety) Regulations 2008 No. 1597.

(* insofar as this machinery is subject to the scope of application)

Basic requirements of the Supply of Machinery (Safety) Regulations, insofar as they are relevant

e
for the scope of delivery, are met by application of the following designated standards or C
standard drafts
- regarding 2008 No. 1597:
EN 14492-2:2006+A1:2009
pl - regarding 2016 No. 1091:
EN 61000-6-2:2005
EN 61000-6-4:2007+A1:2011
- regarding 2016 No. 1101:
EN 60204-32:2008
am

The safety objectives of Electrical Equipment (Safety) Regulations 2016 No. 1101 are achieved.

The product additionally complies with the following relevant statutory instruments/provisions:
Electromagnetic Compatibility Regulations 2016 No. 1091

The special technical documentation according to Annex VII, sub. B of Supply of Machinery
(Safety) Regulations 2008 No. 1597 has been compiled and will be made available to authorised
national authorities by the designated authorised person in response to a justified request.
S

Person authorised to compile the technical file:

Paul Bartlett, Beaumont Road, Banbury, OX16 1QZ, United Kingdom

Düsseldorf, 27.08.2021

ppa. Thomas Wiesmann i.V. Oliver Moll

Senior Director Director
Supply CTO Wetter Hoist Platforms

Industrial Equipment
U04281

Subject to change. No liability for errors or omissions

 Index

A
After-sales service address 10
Assigned expert engineer 10

D
Design 37
Design limit 10
Drives 38

E
Experienced technician 9
Expert engineer 10

G
Geared limit switch 88
GO (General overhaul) 139

M
Machine operator 9
Maintenance 98
Manufacturer 9
Manufacturer’s address 2
Model code 16

O
Operating personnel 9
Operation 94
Owner 9

P
Planetary gearbox 38

Q
Qualified electrician 9

R
Roller coupling 38

S
Signal words 7
Size designations 16
Specialist personnel 9
Switching off 97
Symbols 7
S.W.P. 143

T
211 128 44/100621

Trained person 9
Travelling hoist 10

151
The current addresses of our sales offices, subsidiaries and agencies worldwide can be
found on the homepage
www.demagcranes.com

Demag Cranes & Components GmbH

PO Box 67 · 58286 Wetter (Germany)
Phone +49 (0)2335 92-0
Printed in Germany

Fax +49 (0)2335 92-7676

www.demagcranes.com

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany) Subject to change. Not liable for errors or omissions.