Assembly instructions

Low-headroom monorail hoist with Demag DC chain hoist

KDC 5 - 10 / KLDC 5 - 10
These assembly instructions must always be used together with our DC operating instructions

270315 en GB 211 017 44 719 IS 817

 Original assembly instructions
Manufacturer
Terex MHPS GmbH
Forststraße 16
40597 Düsseldorf, Germany
www.demagcranes.com
mhps-info@terex.com
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative.

Owner

Where in use

Size

Serial number

Year of manufacture

Operating voltage

Control voltage

Frequency

Wiring diagram number

Tab. 1

The metric system is used in this document and all figures are shown with a comma as the decimal separator.

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 Table of contents

1 General........................................................................................................................................................................ 4
1.1 Information on the assembly instructions .................................................................................................................... 4
1.2 DC documents............................................................................................................................................................. 4

2 Safety .......................................................................................................................................................................... 5
2.1 General........................................................................................................................................................................ 5
2.2 Project engineering for the installation ........................................................................................................................ 5
2.3 Regular inspections..................................................................................................................................................... 5

3 Technical data ............................................................................................................................................................. 6

3.1 General information on technical data......................................................................................................................... 6
3.2 Design overview .......................................................................................................................................................... 6
3.3 Scope of delivery......................................................................................................................................................... 6
3.4 Trolleys and drives ...................................................................................................................................................... 7
3.5 Hook dimensions C/dimensions .................................................................................................................................. 8

4 Assembly ................................................................................................................................................................... 12
4.1 EKDC 5 and 10 with EU11 DC - EU34 DC ............................................................................................................... 12
4.2 Auxiliary trolley type RU 3/2 ...................................................................................................................................... 14
4.3 Thrust rocker (optional) ............................................................................................................................................. 15

5 Maintenance/repair.................................................................................................................................................... 16
5.1 Safety information for maintenance/repair ................................................................................................................ 16
5.2 Inspection and maintenance schedule ...................................................................................................................... 16
5.3 Low-headroom monorail hoist tightening torques ..................................................................................................... 16
5.4 Maintenance work ..................................................................................................................................................... 17
5.4.1 Replacing the chain set ............................................................................................................................................. 17
6 Accessories ............................................................................................................................................................... 19
6.1 Assemblies ................................................................................................................................................................ 19
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 1 General

1.1 Information on the assembly instructions

These instructions inform the manufacturer of an installation with low-headroom monorail hoists about:
● basic technical information,
● some typical risks,
● the installation of low-headroom monorial hoists.
For operation of the installation, the manufacturer of the installation must provide additional operating instructions
as the result of a hazard analysis, as required, and inform the owner about any remaining hazards.
The instructions contained in this document may be used as the basis for the hazard analysis and operating in‐
structions which must be compiled by the manufacturer of the installation in compliance with the Machinery Direc‐
tive.
If the low-headroom monorail hoist is operated with a Demag chain hoist, the corresponding chain hoist assembly
and operating instructions must be complied with. In particular, the safety instructions must be observed and fol‐
lowed.

1.2 DC documents
Further documents are available for sub-assemblies/components in addition to these assembly instructions. If re‐
quired, the corresponding documents are supplied or can be ordered separately, even if special designs or addi‐
tional options differing from these assembly instructions are ordered.

Documents 1) Order no.

Demag DC-Pro 1 - 25 chain hoist
203 525 44
Demag DCS-Pro 1 - 10 chain hoist
Demag DC-Com chain hoist 203 571 44
Technical data/catalogues U11-U34/DC/DCM/DK trolley 203 569 44
DC electric accessories 203 656 44
Clamp-fitted buffer 203 313 44
KBK crane construction kit, project engineering and components 202 976 44
DC-Pro 1 - 15 chain hoist 214 741 44
DC-Com chain hoist 214 802 44
Operating instructions/component
DCS-Pro chain hoist 214 827 44
parts
DC-ProCC/DC/FC 1-15 chain hoist 211 191 44
KBK installations 206 076 44
E11-E34 DC travel drive (I) 214 810 44
E11-E34 DC travel drive (II) (circuit diagrams) 211 229 44
KDDC/UDDC articulated trolley 211 159 44
DRC-DC radio control system 214 689 44
DRC-DC quick-step instructions 211 045 44
DC geared limit switches 211 011 44
DC protective sleeve 211 227 44
PGS parallel grippers 214 095 44
Assembly – Adjustment – Dimen‐
DC Polu box 211 249 44
sions
Friction force checking device 206 973 44
DC PWM/3ST signal converter 211 094 44
DCS analogue/PWM signal converter 214 951 44
DSC-EX control pendant 214 832 44
DSE10-C control pendant 214 998 44
DC tandem box 211 108 44
VG11-34 EU11-34 dual-output gearbox 211 122 44
DSC strain relief device 211 092 44
DC test and inspection booklet 214 745 44
Test and inspection booklet
Certificates 235 309 44
Tab. 2
211 017 44/270315

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

 2 Safety

2.1 General

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
This documentation contains additional information for operating the low-headroom monorail hoist. It must be
used together with our operating instructions. Please pay particular attention to the safety instructions in the op‐
erating instructions.

2.2 Project engineering for the installation

WARNING
Suspended load. Falling parts.
Danger to life and limb from falling parts.
The track ends must be closed appropriately to prevent the low-headroom monorail hoist from falling.

WARNING
Crushing hazard
There is a risk of injury due to parts of the body being crushed/sheared or clothing or hair becoming entangled.
Protective devices must be provided if the low-headroom monorail hoist is fitted at a suspension height within
normal reach.

In order to ensure the safe operation of the chain hoist, attention must be paid to the following:
● Chain hoists of the DCS-Pro range must only be operated if a protective earth conductor is connected. If the
protective earth conductor connection is damaged or interrupted, the chain hoist must be disconnected from
the power supply without delay.
● Fault-free operation of the DCS-Pro unit with a current-operated e.l.c.b. (earth-leakage circuit-breaker) is en‐
sured with a tripping current ≥ 30 mA if residual-current-operated circuit breakers (type B to EN 50178, e.g.
Siemens 5SZ3 ... G00) are used.

2.3 Regular inspections

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
Required tests and inspections must be carried out.
In the course of the annual inspection, the low-headroom monorail hoist must be checked for:
– deformation or cracks,
– chipping or wear of the travel wheels,
– completeness of all parts,
– correct flange width adjustment.
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 3 Technical data

3.1 General information on technical data

For further information, refer to the DC chain hoist operating instructions and technical data  Tab. 2, Page 4.

3.2 Design overview

Fig. 1 Two-fall illustration

Item Designation Item Designation Item Designation

1 Load trolley 5 Crab frame 9 Dual-output gearbox
2 Auxiliary trolley 6 Bottom block 10 Buffer
3 Hoist motor 7 Guide plate
4 Return sprocket 8 Chain anchorage for 2/1 reeving
Tab. 3

3.3 Scope of delivery

The delivery comprises the following parts:
● DC chain hoist, see chain hoist operating instructions  Tab. 2, Page 4,
● crab frame,
● optional driven trolleys  Tab. 2, Page 4,
211 017 44/270315

● control pendant (standard cable length H4, H5, H8),

● Connecting cables to the travel drive, see also "Assembly instructions for travel drive"  Tab. 2, Page 4.

6 The connecting cables between the chain hoist and the travel drive are of plug-in design.
 The chain hoist is supplied fitted in the crab frame. The trolleys have to be fitted when RK/EK units are put into
service.

3.4 Trolleys and drives

U11 - U34 and E11 - E34
Load capacity Chain hoist size Flange width Max. flange thick‐ Load trolley Auxiliary trol‐ Travel drive Dual-output
ness 2) 3) ley 3) gearbox
[kg] KDC [mm] [mm]
58 - 200 U11 - 200 - -
non-driven
201 - 310 U11 - 310 - -
≤ 1000 5 22 RU 3/2
58 - 200 U11 - 200
driven E11 VG11 - 34
201 - 310 U11 - 310
58 - 200 U11 - 200 U11 - 200 - -
non-driven
201 - 310 U11 - 310 U11 - 310 - -
≤ 1000 16
58 - 200 U11 - 200 U11 - 200
driven E11 VG11 - 34
201 - 310 U11 - 310 U11 - 310
10
74 - 200 U22 - 200 U11 - 200 - -
non-driven
201 - 310 U34 - 310 U11 - 310 - -
≤ 2000 22
74 - 200 U22 - 200 U11 - 200 E22
driven VG11 - 34
201 - 310 U34 - 310 U11 - 310 E34
Tab. 4

For further information on these subjects, see our documents  Tab. 2, Page 4
● U11 - U34 trolley,
● E11 - E34 DC travel drive,
● VG11 - 34 dual-output gearbox for EU11 - 34.

RU / EU 11 DK and RU / EU 22 DK
Load capacity Chain hoist size Flange width Max. flange thick‐ Load trolley Auxiliary trolley Travel drive
ness
[kg] KDC-ProDC [mm] [mm]
non-driven -
≤ 1000 5 78 - 300 16 4) RU 11 DK RU 3/2
driven 13/* PKF
non-driven -
≤ 2000 10 82 - 300 22 5) RU 22 DK RU 11
driven 13/* PKF
Tab. 5
211 017 44/270315

2) Optional trolley-drive combination EU/RU22 or EU/RU34 as load trolley and RU22 or RU34 as auxiliary trolley with up to 30 mm flange thick‐
ness.
3) U11 trolley with steel travel rollers on request
4) 27 mm without anti-run-off device
5) 28 mm without anti-run-off device 7
 3.5 Hook dimensions C/dimensions

KDC 5

Fig. 2

Chain hoist size Reeving  Fig. 2, Page 8 C [mm] C1 [mm]

H5 H8 H25
1/1 A 300 446 476 540
KDC 5
2/1 B 386 540 540 -
Tab. 6
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 KDC 10

Fig. 3

Chain hoist size Reeving  Fig. 3, Page 9 Trolley C [mm] C1 [mm] F [mm] H [mm] P [mm]
H5 H8 H20
1/1 A U11 353 539 628 614 110 533 60
KDC 10
2/1 B U22 / U34 432 638 624 - 128 543 70
Tab. 7
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 KLDC with extended distance between hooks (for big bag applications)

Fig. 4

Chain hoist size Reeving Trolley C [mm] C1 [mm] Total length of grid pitch Rs [mm]
H5 H8 H20 250 500 750 1000 1250 1500
1/1 324 446 476 540
KLDC 5 (A) U11 + RU 3/2 845 1095 1345 1595 1845 2095
2/1 412 540 540 -
1/1 U11 368 539 628 614
KLDC 10 (B) 1060 1310 1560 1810 2060 2310
2/1 U22 / U34 440 638 624 -
Tab. 8

For further information, see "KBK crane construction kit, project drafting and components", "Demag DC-Pro 1 - 25
chain hoist technical data" and "Demag DC-Com chain hoist technical data" documents  Tab. 2, Page 4.
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 KDC with KBK II

Fig. 5 Short type with single trolley (a), not for driven trolleys. Straight travel with single trolley (not shown). Straight travel with articulated frame
(B). Curve travel with single trolley (C). Curve travel with articulated frame (D).

Load capacity Chain hoist size Reeving C dimension from lower edge of KBK section L1 L2 L3 L4
(A) (B) (C) (D)
[kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
≤ 500 1/1 285 366 - 366 -
KDC5 73 369 684 104
2/1 in preparation
≤ 1000
1/1 361 453 - 453 -
KDC10 79 308 625 231
≤ 2000 2/1 - - 536 - 536
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Tab. 9

For further information, see "KBK crane construction kit, project drafting and components", "Demag DC-Pro 1 - 25
chain hoist technical data" and "Demag DC-Com chain hoist technical data" documents  Tab. 2, Page 4.

11
 4 Assembly

4.1 EKDC 5 and 10 with EU11 DC - EU34 DC

Fig. 6

Item Designation Item Designation

1 Load trolley side cheek Position of the crossbar:
2 Adjusting ring A - U11 load trolley, U11 auxiliary trolley, 1/1 reeving, (standard)
3 Travel drive
4 (3x plate only for (A)) B - U22 load trolley, U11 auxiliary trolley, 2/1 reeving, (standard)
5 Crossbar
6 Dual-output gearbox C - U22 load trolley, U22 auxiliary trolley, (large flange thickness)
7 Auxiliary trolley side cheek
Tab. 10

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
The regulations and data in the operating instructions of the chain hoist must be observed.
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 Chain hoist Trolley size Flange width [mm]
size
KDC 58 66 74 82 90 100-200 201-310
U11 - 200 4 SW 6 SW 10 SW AR -
Load trolley
U11 - 310 - AR
5
RU 3/2 - 200
Auxiliary trolley  "Auxiliary trolley type RU 3/2", Page 14
RU 3/2 - 310
U11 - 200 2 SW 6 SW 8 SW AR -
U11 - 310 - AR
Load trolley
U22 - 200 - 4 SW 6 SW 10 SW AR -
U34 - 310 - AR
10
U11 - 200 8 SW AR -
U11 - 310 - AR
Auxiliary trolley
U22 - 200 - 8 SW 12 SW AR
U34 - 310 - AR

* SW Number of 2,5 mm-thick supporting washers

AR Adjusting rings
K No adjusting rings or supporting washers
Tab. 11

1. Depending on the flange thickness (see  Tab. 11, Page 13), supporting washers or adjusting rings (2) are
required to centre the chain hoist on crossbars (5). These are placed onto the trolley crossbars.
2. Lubricate crossbars (5) with bearing grease before fitting the side cheeks. It must be possible to turn cross‐
bars (5) easily in the bore holes.
3. Fit side cheeks (1+7) onto crossbars (5) and adjust to the approximate flange width so that they are posi‐
tioned symmetrically with the retaining arrangement.

CAUTION
Premature wear of the chain guide and chain.
Danger of falling load.
If the crossbars are on different levels, this may result in premature wear of the chain drive.
Check that the crossbar is correctly positioned (see  Fig. 6, Page 12, item A, B or C).
For a low-headroom monorail hoist that has an EU11 DC as the load and auxiliary trolley, 3 plates must be fitted
in the crab frame.

4. Align adjusting rings (2) with the side cheeks.

5. Tighten the grub screws on one side cheek by hand.
6. Place the monorail hoist on the girder and adjust the play of the guide rollers on the girder flanges. Adjust‐
ment should be done at the widest point on girders that have an uneven width. The total play should be
≤ 1 mm. Low play has a positive effect on the service life of the travel and guide rollers. Tighten the grub
screws of adjusting rings (2) by hand only.
7. Move the monorail hoist forwards and backwards along the entire girder. The monorail hoist must not jam at
any point.
8. Tighten the grub screws of adjusting rings (2) to the specified tightening torque (U11 = 18 Nm, U22 - U34 =
36 Nm). Final tightening must be carried out no later than 30 minutes after first tightening the grub screws,
as they are provided with a micro-encapsulated screw retaining arrangement which hardens after tightening
and secures the grub screws against loosening. If the grub screws of the adjusting rings are loosened after
60 minutes or at any later time, they must be replaced with new ones.
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 4.2 Auxiliary trolley type RU 3/2

Fig. 7

A Flange width 78 - 202 mm B Flange width 203 - 306 mm L Flange width + 42 mm

Tab. 12

Flange width [mm] 58 66 78 82 90 98 106 114 122 130 138 146 154 162 170 178
Crossbar, part no.: 718 840 45
 Fig. 7, Page 14 Item (A)
1 Washers 0 2 4 6 8 10 4 6 8 10 4 6 8 10 4 6
Inside
2 Sleeve 16 0 0 0 0 0 0 2 2 2 2 4 4 4 4 6 6
1 Washers 10 8 6 4 2 0 6 4 2 0 6 4 2 0 6 4
Outside
2 Sleeve 16 6 6 6 6 6 6 4 4 4 4 2 2 2 2 0 0

Flange width [mm] 186 194 202 210 218 226 234 242 250 258 266 274 282 290 298 306
Crossbar, part no.: 718 840 45 748 425 46
 Fig. 7, Page 14 Item (A) (B)
1 Washers 8 10 0 2 4 6 8 10 12 14 0 2 4 6 8 10
Inside 2 16 6 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Sleeve
3 32 0 0 4 4 4 4 4 4 4 4 6 6 6 6 6 6
1 Washers 2 0 14 12 10 8 6 4 2 0 14 12 10 8 6 4
Outside 2 16 0 0 4 4 4 4 4 4 4 4 4 4 4 4 4 4
Sleeve
3 32 0 0 2 2 2 2 2 2 2 2 0 0 0 0 0 0
Tab. 13

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
If the locknut is completely removed from the crossbar, a new locknut to DIN 980 must be used.

– The locknut can be screwed onto the trolley crossbar for pre-assembly without being pre-tensioned.
– For final assembly, only unscrew the locknut until the trolley can be placed on the girder.
– Then tighten the locknut with the specified tightening torque of 170 Nm.
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 4.3 Thrust rocker (optional)

Fig. 8

From 05/2009 the thrust rocker is no longer required for electrically driven monorail hoists and is replaced by a
dual-output gearbox for two-wheel drive.

Item Designation
1 Pin
2 Contact plate

Flange thickness 7 to 15,5 mm, as delivered Flange thickness 15,6 to 28 mm, conversion required
A Pin (1) mounted in the upper bore hole C Pin (1) mounted in the lower bore hole
B View from below: D View from below:
Contact plate (2) mounted with bore hole on the left-hand Contact plate (2) mounted with bore hole on the right-hand
side side
Tab. 14

1. For flange thicknesses between 15,6 and 28 mm, install pin (1) in the lower bore hole.
2. Install contact plates (2) with the bore hole on the right-hand side (see "D"  Fig. 8, Page 15).
3. Tighten the bolt until there is no more play.
4. Now tighten the bolt by five more turns.
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 5 Maintenance/repair

5.1 Safety information for maintenance/repair

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
The regulations and data contained in the chain hoist operating instructions must be observed and complied
with.

5.2 Inspection and maintenance schedule

Activity Section Before first put‐ Before starting During the an‐
ting into opera‐ work nual inspection
tion
Check the bearings of the return sprockets for smooth operation (also
X
in the bottom block)
Check the bearings of the return sprockets for wear (also in the bottom
X
block)
Check the return sprockets X
Relubricate the bearings of the return sprockets (more frequently if
X
used particularly intensively)
Chain guide in the trolley frame X
Bolted connections on the trolley frame  "Low-head‐
room monorail
hoist tightening X
torques",
Page 16
Adjust thrust rocker X
Tab. 15

For further information on maintenance work, please refer to the DC-Pro, DCS-Pro, DC-Com operating instruc‐
tions  Tab. 2, Page 4.

5.3 Low-headroom monorail hoist tightening torques

Designation Tightening torques [Nm]
RU 3/2 170
Locknut on the crossbar EU 11 DK 120
EU 22 DK 160
Grub screw in adjusting U11 18
ring U22 - U34 36

Strength class M5 M6 M8 M10 M12 M16 M20 M24 M27 M30

Bolted connections on
8.8 4,9 8,5 20,5 41 71 170 350 600 880 1190
the trolley frame µ 0,1
10.6 7,3 12,5 30 60 104 250 490 850 1250 1700
Tab. 16
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 5.4 Maintenance work
5.4.1 Replacing the chain set
For the installation steps described below, please also refer to the corresponding operating instructions of your
Demag chain hoist  Tab. 2, Page 4:
● Open the service cover and remove the chain collector box (see "Removing the chain collector box").
● Remove the old chain set, but do not pull the old chain out of the crab frame (see "Replacing the chain set").
Remove the chain guide from the old chain.
● Install the new chain set on the output shaft (see "Replacing the chain set").

Fitting the chain in the crab frame

Fig. 9

Before pulling the chain into the crab frame, check the return sprockets and their bearings for wear and replace
them, if required.
1. Connect the new chain to the old chain.
2. Use the old chain to pull the new chain through the crab frame.
3. Check the position and alignment of the new chain along its entire length.

DANGER
Danger of broken chain and falling load
An incorrectly installed chain may result in a broken chain and falling loads.
When the chain is installed, ensure that it is introduced in the same position and with the same alignment.
The chain must operate without any twist.

1/1 reeving

Item Designation
1 Spacer tube
2 Chain entry plate
3 Switch for limit switch
Tab. 17

Replace the hook assembly (see "Replacing the hook assembly, 1/1
reeving", chain hoist operating instructions).
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Fig. 10 17
 2/1 reeving

Fig. 11

Item Designation Item Designation

M8x55 hexagon socket screw
1 5 M8 locknut
Tightening torque 23 Nm
2 Stop plate 6 Chain entry plate
3 Chain anchorage 7 Leaf spring for limit-switch cut-off
M6x12 hexagon socket screw
4 8 Switch for limit switch
Tightening torque 10,5 Nm
Tab. 18

● Use the old chain to pull the new chain through the bottom bock or replace the bottom block as described in
the chain hoist operating instructions.
● Install the chain anchorage, see  Fig. 11, Page 18. If necessary, shorten the end of the chain by one link to
ensure the new chain is in the correct position. Chain links facing the same direction must be arranged oppo‐
site each other without being twisted.

Further assembly for 1/1 and 2/1 reeving:

● Fit the limit stop (see "Fitting the limit stop").
● Grease the chain (see "Lubricating the hoist chain").
● Fit the chain collector box to the chain hoist.
● Close the service cover.
Carry out a test run at partial load after the chain hoist has been fully re-assembled. Ensure that the chain runs
smoothly during the test run.
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 6 Accessories

6.1 Assemblies

Fig. 12

Item Description Size Order no.

KDC crab frame, completely assembled, consisting of: KDC 5 718 801 45
1
crab frame, 2x chain return arrangement, limit switch KDC 10 715 801 45
RU3/2 trolley for KDC 5, consisting of: RU 3/2 - 200 718 806 45
2
trolley, crossbar RU 3/2 - 310 718 807 45
2/1 chain anchorage, consisting of:
3 chain anchorage, DK5 bottom block, switch-off springs, leaf spring for limit KDC 5 718 802 45
switch
4 2/1 chain anchorage without bottom block, leaf spring for limit switch KDC 10 715 802 45
Return sprocket assembly, consisting of: KDC 5 718 808 45
1 return sprocket, 1 pin, 1 retaining ring, 1 supporting washer, 2 thrust wash‐
5
ers, 2 needle-roller assemblies KDC 10 715 808 45
(2x chain return arrangements are already included in KDC)
1500 mm 720 070 45
6 DC 1 - 10 control cable set for E11 - E34 monorail hoist
3000 mm 720 142 45
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1500 mm 720 072 45

7 DC 1 - 10 power supply cable set for E11 - E34 monorail hoist
3000 mm 720 144 45
KDC limit switch cut-off 1500 mm 718 382 45
8
KLDC limit switch cut-off 3500 mm 718 377 45
Tab. 19 19
The current addresses of our sales offices, subsidiaries and agencies worldwide can be
found on the Terex MHPS GmbH homepage at
www.demagcranes.com/Contact

Terex MHPS GmbH

PO Box 67 · 58286 Wetter (Germany)
Phone +49 (0 )2335 92-0
Fax +49 (0 )2335 92-7676
Printed in Germany

www.demagcranes.com

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