Operating instructions/component parts

Demag pillar and wall-mounted slewing jib cranes

031218 en GB 211 277 44 720 IS 132

 Original operating instructions
Manufacturer
Demag Cranes & Components GmbH
Forststraße 16
40597 Düsseldorf, Germany
www.demagcranes.com
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 slewing jib crane and important information if you ever have to contact the manufacturer or his representative.

Owner

Where in use

Crane type

Year of manufacture

Load capacity

Crane outreach

Crane serial number

Chain hoist model code

Chain hoist serial number

Drawing number

Operating voltage

Control voltage

Frequency

Circuit diagram number

Contactor control/direct control

Supplier

Assembled by

Signature Date
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........................................................................................................................................................................ 6
1.1 Demag pillar and wall-mounted slewing jib cranes ..................................................................................................... 6
1.2 Documents on Demag pillar or wall-mounted slewing jib cranes ................................................................................ 6
1.3 Symbols/signal words.................................................................................................................................................. 6
1.4 Information on the operating instructions .................................................................................................................... 7
1.5 Liability and warranty................................................................................................................................................... 7
1.6 Copyright ..................................................................................................................................................................... 8
1.7 Use of spare parts ....................................................................................................................................................... 8
1.8 Definition of personnel................................................................................................................................................. 8
1.9 Test and inspection booklet......................................................................................................................................... 9
1.10 After-sales service ....................................................................................................................................................... 9

2 Safety ........................................................................................................................................................................ 10
2.1 General...................................................................................................................................................................... 10
2.2 Safety signs on the equipment .................................................................................................................................. 10
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 ............................................................................................................................................. 14
2.9 Regular inspections................................................................................................................................................... 15

3 Types......................................................................................................................................................................... 16
3.1 Design overview ........................................................................................................................................................ 16
3.2 Model code ................................................................................................................................................................ 17
3.3 Pillar-mounted slewing crane with two jibs................................................................................................................ 17
3.4 Trolley travel drive ..................................................................................................................................................... 17
3.5 Power supply............................................................................................................................................................. 17
3.6 Noise emission/sound pressure level ........................................................................................................................ 18
3.7 Transport, packing and storage................................................................................................................................. 18
3.7.1 Safety instructions ..................................................................................................................................................... 18
3.7.2 Scope of delivery....................................................................................................................................................... 18
3.7.3 Transport inspection.................................................................................................................................................. 18
3.7.4 Packing...................................................................................................................................................................... 18
3.7.5 Storage ..................................................................................................................................................................... 19
3.8 Surface protection and paint finish ............................................................................................................................ 19
3.9 Operating conditions ................................................................................................................................................. 19

4 Description of the sub-assemblies ............................................................................................................................ 20

4.1 Pillar-mounted slewing jibs........................................................................................................................................ 20
4.1.1 Pillars......................................................................................................................................................................... 20
4.1.2 Anchor bolt set and template..................................................................................................................................... 22
4.1.3 Anchorage ................................................................................................................................................................. 22
4.2 Wall-mounted slewing jibs......................................................................................................................................... 23
4.2.1 Brackets .................................................................................................................................................................... 23
4.2.2 Bracket clamping arrangements................................................................................................................................ 25
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4.3 Jib .............................................................................................................................................................................. 27

4.3.1 Jib with KBK Aluline profile section, fitted with brace ................................................................................................ 27
4.3.2 Jib with KBK steel profile section, fitted with brace ................................................................................................... 28
4.3.3 Jib with I-beam section, fitted with brace................................................................................................................... 29
3
 4.3.4 Jib with I-beam section, low-headroom design ......................................................................................................... 30
4.4 Components .............................................................................................................................................................. 31
4.4.1 Bearing ...................................................................................................................................................................... 31
4.4.1.1 Bearing with KBK 100 jib (LA = 350) ......................................................................................................................... 31
4.4.1.2 Support bearing for all other sizes............................................................................................................................. 31
4.5 Trolleys ...................................................................................................................................................................... 32
4.5.1 KBK trolley................................................................................................................................................................. 32
4.5.2 Articulated frame ....................................................................................................................................................... 33
4.5.3 Trolley on I-beam section .......................................................................................................................................... 34
4.6 Slewing jib cranes with electric slewing mechanisms ............................................................................................... 34
4.7 Electric equipment..................................................................................................................................................... 35

5 Assembly................................................................................................................................................................... 36
5.1 General...................................................................................................................................................................... 36
5.2 Safety instructions for assembly................................................................................................................................ 36
5.3 Tightening torques..................................................................................................................................................... 38
5.4 Installation procedure ................................................................................................................................................ 38
5.5 Mounting and anchoring............................................................................................................................................ 39
5.6 Installing the pillar...................................................................................................................................................... 40
5.6.1 Securing the pillar...................................................................................................................................................... 40
5.6.1.1 Foundations with cast-in anchors.............................................................................................................................. 40
5.6.1.2 Anchorage with anchors and intermediate plate ....................................................................................................... 41
5.6.2 Erecting the pillar....................................................................................................................................................... 42
5.7 Fitting the bracket ...................................................................................................................................................... 43
5.7.1 General information on fitting the bracket ................................................................................................................. 43
5.7.2 Securing the bracket ................................................................................................................................................. 44
5.7.3 Securing the bracket with clamping arrangement ..................................................................................................... 45
5.8 Assembling the jib ..................................................................................................................................................... 46
5.8.1 KBK 100 jib................................................................................................................................................................ 46
5.8.2 KBK I, II, I-beam section, aluminium profile section jib ............................................................................................. 48
5.9 Electric slewing mechanism ...................................................................................................................................... 50
5.10 Electric cabling and wiring ......................................................................................................................................... 53
5.10.1 Circuit diagram .......................................................................................................................................................... 53
5.10.2 Pillar-mounted slewing jib crane................................................................................................................................ 54
5.10.3 Wall-mounted slewing jib........................................................................................................................................... 55
5.11 Pin retainer on the KBK trolley .................................................................................................................................. 56
5.12 Suspending the hoist ................................................................................................................................................. 56
5.13 Maker’s plate and load capacity plate ....................................................................................................................... 57

6 Options ...................................................................................................................................................................... 58
6.1 Slewing limiter and jib locking device ........................................................................................................................ 58
6.1.1 General information on slewing limiter and jib locking device ................................................................................... 58
6.1.2 Slewing limiter for pillar-mounted slewing jib cranes, fitted with brace...................................................................... 58
6.1.3 Slewing limiter for low-headroom pillar-mounted slewing jib cranes ......................................................................... 59
6.1.4 Slewing limiter for low-headroom wall-mounted slewing jibs, fitted with brace ......................................................... 60
6.1.5 Slewing limiter for two jibs ......................................................................................................................................... 61
6.1.6 Jib retaining mechanism for KBK steel profile sections............................................................................................. 62
6.2 Hoist trolley locking device on the KBK jib ................................................................................................................ 64
6.3 Canopy on the KBK jib .............................................................................................................................................. 65
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7 Putting into service for the first time .......................................................................................................................... 66

7.1 Safety instructions when putting into service for the first time................................................................................... 66
4 7.2 Inspection regulations ............................................................................................................................................... 66
 7.3 Inspections before putting into service for the first time ............................................................................................ 67
7.4 Checks on entering service, handover ...................................................................................................................... 67

8 Operation................................................................................................................................................................... 68
8.1 Safety instructions for operation................................................................................................................................ 68
8.2 Switching on .............................................................................................................................................................. 69
8.2.1 Checks when starting work ....................................................................................................................................... 69
8.2.2 Function checks ........................................................................................................................................................ 69
8.3 Operation................................................................................................................................................................... 70
8.3.1 Safety during operation ............................................................................................................................................. 70
8.3.2 Load pick-up.............................................................................................................................................................. 70
8.3.3 Moving the load ......................................................................................................................................................... 70
8.4 Possible adjustments ................................................................................................................................................ 71
8.5 Emergency stop ........................................................................................................................................................ 71
8.6 Taking the equipment out of operation...................................................................................................................... 72
8.6.1 Taking the equipment out of service when faults occur ............................................................................................ 72
8.6.2 Taking the equipment out of service at the end of the shift....................................................................................... 72
8.6.3 Taking the equipment out of service for maintenance and repairs............................................................................ 72
9 Maintenance work ..................................................................................................................................................... 73
9.1 Safety instructions for maintenance and repair work ................................................................................................ 73
9.2 Basic maintenance requirements .............................................................................................................................. 74
9.3 Regular inspections................................................................................................................................................... 75
9.3.1 Required tests and inspections ................................................................................................................................. 75
9.3.2 S.W.P. measures for achieving safe working periods ............................................................................................... 76
9.4 Maintenance schedule .............................................................................................................................................. 77
9.5 Maintenance work ..................................................................................................................................................... 78
9.5.1 Lubrication of pivot pins............................................................................................................................................. 78
10 Malfunctions/warnings ............................................................................................................................................... 79
10.1 Safety instructions for malfunctions/warnings ........................................................................................................... 79

11 Disassembly/disposal ................................................................................................................................................ 80
11.1 General...................................................................................................................................................................... 80
Index........................................................................................................................................................................................... 81
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 1 General

1.1 Demag pillar and wall-mounted slewing jib cranes

Demag pillar and wall-mounted slewing jibs are of modular design and are supplied pre-assembled and packed in
sub-assemblies.
This Demag slewing jib crane was manufactured to European standards and regulations in accordance with state-
of-the-art engineering principles. The EC Machinery Directive requirements are satisfied.
The main sub-assemblies of Demag pillar and wall-mounted slewing jib cranes include:
● pillar or wall bracket,
● jib (KBK Aluline profile section, KBK steel profile section or I-beam section) with mechanical accessories,
● electric accessories,
● DC, DCM, DCS, D-SH, DS hoist.
The basic elements of KBK jibs are special track sections which can be used in sizes KBK 100, KBK I, KBK II,
A12, A16, A18 and A22.
All KBK components are produced in series as standardised assemblies.
Refer to the "Slewing jib crane technical data" document for the planning and selection of slewing jib cranes, see
 Tab. 2, Page 6.

1.2 Documents on Demag pillar or wall-mounted slewing jib cranes

Further documents are available for sub-assemblies/components in addition to these operating instructions. The
corresponding documents are supplied as necessary or can be ordered separately – also for special designs or if
additional options are ordered which differ from these operating instructions.

Documents 1)
Brochure Order no. Operating instructions/component parts Order no.

KBK pillar and wall-mounted slewing jib cranes 208 755 44 KBK installations 206 077 44
Technical data/catalogues Order no. KBK Aluline 211 259 44
Slewing jib crane 211 277 44
General KBK system 202 977 44 Explosion protection for KBK installations 214 783 44
KBK Aluline 203 813 44 DC-Pro/Com 1-15 chain hoist 211 273 44
Slewing jib crane 203 814 44 DCS-Pro chain hoist 214 828 44
KBK anchor bolt connection 203 277 44 DC-ProDC/CC/FC 1-15 chain hoist 211 193 44
KBK cranes and tracks in explosion hazard areas 203 372 44 PGS parallel grippers 214 096 44
Demag DC-Pro/DC-Com chain hoist 203 526 44 Assembly – Adjustment – Dimensions Order no.
U11-U34/DC/DCM/DK trolley 203 569 44
Test and inspection booklet Order no. DRF 200 travel drive 214 396 44
E11-E34 DC travel drive (I) 214 810 44
DC chain hoist 214 745 44 Installation report on anchor bolts for KBK installations 214 563 44
KBK system On request DC geared limit switches 211 012 44
Friction force checking device 206 973 44
DC protective sleeve 211 227 44
DSC strain relief device 211 092 44
Tab. 2

1.3 Symbols/signal words

Important safety information and instructions are marked by corresponding symbols and signal words in these in‐
structions.
Safety warnings and instructions must be followed. Exercise particular caution to ensure that accidents, injuries
and damage are avoided in such cases.
Any locally applicable accident prevention regulations and general safety regulations must also be followed.
The following symbols and instructions warn against possible injuries or damage and are intended to assist you in
your work.
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6 1) The documents can be ordered from the relevant Demag office.

 DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.

WARNING
This symbol indicates a possibly hazardous situation which might result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.

CAUTION
This symbol indicates a possibly hazardous situation which might result in medium to light injury or 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.
● This symbol in the operating instructions indicates all warnings which, if not complied with, can result in mal‐
functions or damage.

1.4 Information on the operating instructions

These operating instructions are an integral part of the machine. They describe the safe and correct use of the
machine.
These operating instructions are designed to provide the owner and operator with useful instructions for transport‐
ing, installing, commissioning, operating and maintaining our Demag pillar and wall-mounted slewing jib cranes.
Persons entrusted with the various types of work must know and comply with the safety regulations and the oper‐
ating instructions.
The machine may only be operated by personnel who are fully familiar with the operating instructions. In particu‐
lar, they contain the "Safety" section and the relevant safety instructions in the working sections of these operat‐
ing instructions. The operating instructions must be available to operating personnel at all times in order to pre‐
vent operating errors and to ensure smooth and trouble-free operation of our products. They must be kept in the
immediate vicinity.

1.5 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 Demag pillar or
wall-mounted slewing jib crane, especially before it is put into service for the first time. The manufacturer as‐
sumes no liability for any damage which results from the following:
● failure to comply with the operating instructions,
● inappropriate use,
● untrained personnel,
● unauthorised conversions,
● 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 product.
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 1.6 Copyright
These operating instructions are only intended to be used by people who work with or on the Demag pillar or wall-
mounted slewing jib crane.
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.
All industrial rights reserved.

1.7 Use of spare parts

We urgently recommend that only spare parts and accessories approved by us be used. Only then can we ensure
the safety and normal service life of the installation.
Spare parts not approved by us may cause unpredictable hazards, damage, malfunctions or complete failure of
the Demag pillar or wall-mounted slewing jib crane.
The use of unauthorised spare parts may render null and void any claims for warranty, service, damages or liabili‐
ty against the manufacturer or his appointed personnel, dealers and representatives.

1.8 Definition of personnel

The manufacturer is the person who:
1. manufactures the equipment under his or her own name and places it on the market for the first time;
2. resells other manufacturers' equipment under his or her own name, whereby the reseller is not considered to
be the manufacturer provided the name of the manufacturer (as in 1.) appears on the equipment;
3. imports the equipment into the country and places it on the market for the first time or
4. exports equipment 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 the machine and who use it as intended or allow it
to be operated by suitable and trained persons.
Operating personnel/operator
Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper‐
ate the machine. This person must be trained by the owner in accordance with the tasks to be performed.
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. This person 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 the machine to carry out special tasks,
such as installation, setting-up, maintenance and fault elimination. This person must be trained by the owner in
accordance with the tasks to be performed.
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. This person 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‐
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cient knowledge in the field of the machine. They must be familiar with the relevant national industrial safety regu‐
lations, codes of practice, accident prevention regulations, directives and generally accepted engineering stand‐
ards enabling them to judge the safe operating condition of machines.

8
 Assigned expert engineer (where the rules and regulations of the German Social Accident Insurance (DGUV) ap‐
ply in the Federal Republic of Germany)
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 (where the rules and regulations of the German Social Accident Insurance (DGUV)
apply 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.

1.9 Test and inspection booklet

A test and inspection booklet filled in with all details must be available for the Demag pillar or wall-mounted slew‐
ing jib crane (according to the rules and regulations of the German Social Accident Insurance (DGUV) in the Fed‐
eral Republic of Germany). The results of the regular tests and inspections must be entered into the test and in‐
spection booklet and must be certified by the inspector. Test and inspection booklet order no.:  Tab. 2, Page 6.

1.10 After-sales service

If you have any questions on our products or need technical information, please contact our after-sales service.
Please keep the serial or order number (see test and inspection booklet, 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 current addresses of our sales offices in Germany and our subsidiaries and agencies worldwide can be found
on our homepage at www.demagcranes.com
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 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.
When it is placed on the market, the machine is built according to generally accepted engineering standards and
is considered to be safe to operate. It may 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 the manufacturer in
writing.
If the Demag pillar or wall-mounted slewing jib crane is operated with a Demag chain hoist, the corresponding
chain hoist assembly and operating instructions (see  Tab. 2, Page 6) must be observed. In particular, the safe‐
ty instructions must be observed and followed.

2.2 Safety signs on the equipment

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

Fig. 1

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 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 to the machine and/or load.
● Demag pillar and wall-mounted slewing jib cranes are only designed for lifting, lowering and moving loads.
● The support structure must be designed for loads resulting from operation of the crane. The maximum safe
working load is the load capacity specified on the capacity plate. This must not be exceeded. The maximum
permitted load capacity includes the load and any load handling attachment.
● The machine may only be installed, used, operated, maintained and removed by trained personnel when it is in
perfect working order. Personnel must meet the requirements according to  "Operating personnel require‐
ments", Page 14.
● Intended use includes compliance with the safety instructions as well as any other instructions on assembly
and disassembly, commissioning, function and operation, maintenance and fault elimination as well as compli‐
ance with the instructions on the machine safety devices, any possible remaining hazards and protection
against hazards.
● The machine may only be used subject to the permissible technical data,  "Types", Page 16.
● The machine must be maintained regularly and appropriately by trained personnel in line with the specified
deadlines and checked according to  "Maintenance schedule", Page 77. Wearing parts must be replaced in
good time.
● National occupational safety and health regulations must be observed and followed.
No liability for inappropriate use
The manufacturer is exempt form 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 or sub-assemblies 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.
Demag pillar and wall-mounted slewing jib cranes are designed for operation at temperatures from - 20 °C to
+ 70 °C. Note that the plastic travel wheels of the trolleys only have their full load-bearing capacity at tempera‐
tures ranging from - 10° C to + 40° C, see "General KBK system technical data"  Tab. 2, Page 6. The hoists
may be subject to other operating conditions, see corresponding operating instructions  Tab. 2, Page 6. At ex‐
treme temperatures and in aggressive atmospheres or conditions differing from those specified in the "Operating
conditions" section, the owner must implement special measures after consulting the manufacturer.
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 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 may 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.
– 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.

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 Demag pillar or wall-mounted slewing jib crane is installed within
arm’s reach.

WARNING
Crushing hazard
Parts of the body can be crushed when loads are lifted, lowered or moved.
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 a suspended load.

Certain work and practices are prohibited when using the machine as they may involve danger to life and limb
and result in lasting damage to the machine. Observe the safety instructions in the sections:
●  "Assembly", Page 36
●  "Putting into service for the first time", Page 66
●  "Operation", Page 68
●  "Maintenance work", Page 73
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 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.
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.
Special local conditions or applications may 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 protection 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 instructions for operation", Page 68.
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 the use of cranes and lifting appliances are observed.
● any specified regular checks and inspections are carried out on time and are documented.
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.
The owner is obliged to ensure that
● the rules and regulations of the German Social Accident Insurance (DGUV) are applied in the Federal Repub‐
lic of Germany.
● national occupational safety and health regulations are observed and followed.

Extract from the transfer list of the rules and regulations of German Social Accident Insurance (DGUV)
Previous no. New no. Title
BGV D6 DGUV Regulation 52 Cranes
BGV D8 DGUV Regulation 54 Winches, lifting and towing devices
BGG/GUV-G 905 DGUV Policy 309-001 Inspection of cranes
Tab. 3
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 2.6 Operating personnel requirements
Only authorised and trained personnel may work on the machine. The personnel must have received instruction
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.
Persons 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 place where the machine is operated 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 Demag pillar or
wall-mounted slewing jib crane, 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 Demag pillar and wall-mounted slewing jib
cranes and who have proven their qualification to the owner in this respect.

2.7 Personal protection equipment

When work is carried out on or with the installation, 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 falling parts and against slipping;
● Safety helmet to be worn by everybody in the danger zone.

2.8 Emergency-stop device

If the Demag pillar or wall-mounted slewing jib crane is operated with a
Demag chain hoist, the machine is equipped with an emergency-stop
device (1) to prevent damage and injuries. This is located on the control
pendant. The emergency-stop device operating function must be
checked regularly.

Fig. 2 Position of emergency stop (1)

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14
 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. This is regulated by the rules and regulations of the German Social Accident Insurance
(DGUV) in the Federal Republic of Germany, 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 test and inspection booklet.
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 apply at the place where the machine is operated, we
recommend compliance with the above-mentioned regulations.
211 277 44/031218

15
 3 Types

3.1 Design overview

Fig. 3

Item Designation Item Designation

A Pillar-mounted slewing jib crane (SSK) B Wall-mounted slewing jib crane (WSK)
1 Jib with buffer 5 Load capacity plate (2 off)
2 Bracket or pillar, complete 6 Manufacturer’s plate
3 Pivot bearing 7 Trolley
4 Electric equipment and cable carriers 8 Hoist unit
Tab. 4

General
Demag pillar or wall-mounted slewing jib cranes are rated to DIN 15018, lifting class H1, loading group B3.
Smooth-running trolleys and special bearings on the jibs facilitate very low travel and slewing forces.
Further pillar-mounted slewing jib crane sub-assemblies
● Anchor bolt set,
● Heavy-duty anchors with intermediate plate to document "KBK anchor bolt connection" see  Tab. 2, Page 6.

Electric power supply can be provided:

● from below - opening in the base plate of the pillar;
● at the side - opening at the base of the pillar;
● from above - bore hole in the upper cover plate of the pillar.
211 277 44/031218

16
 3.2 Model code
JC- P- 270- I- LH- M- 2000- 4000
Outreach [mm]
Load capacity [kg]
M Manual slewing
E Electric slewing
Slewing arm design
LH low-headroom
BR supported by brace
Slewing arm profile section
I I-beam section
KBK KBK steel profile section (e.g. KBK I, KBK II)
Al KBK aluminium profile section (e.g. A12, A16, A18, A22)
Slewing range
P Pillar-mounted slewing jib crane
W Wall-mounted slewing jib
JC product range
Tab. 5 Example for model code

Not all features of the model code can be combined.

3.3 Pillar-mounted slewing crane with two jibs

Fig. 4 Combinations, working areas: jibs opposite each other (1), jibs next to each other (2)

Pillar-mounted slewing jib cranes with two jibs provide better use of the working area while little space is required
for the crane itself. They are constructed in the same way as pillar-mounted slewing jib cranes. Only manual slew‐
ing is possible.
The pillar, supporting elements and hole pattern of the base plate are the same.

3.4 Trolley travel drive

Trolleys fitted in aluminium profile section, KBK II track section or I-beam section jibs can also be fitted with a
travel drive.

For further information, refer to the travel drive operating instructions and our "General KBK system technical da‐
ta" and "KBK Aluline technical data" documents  Tab. 2, Page 6, which contain further details on fittings, electric
equipment and controls.

Refer to our "KBK installation operating instructions" document  Tab. 2, Page 6 for information and recommen‐
dations on assembly.

3.5 Power supply

211 277 44/031218

Information on alternative power supply systems, such as KBK II-R, can be found in our "General KBK system
technical data" and "KBK Aluline technical data" documents and in the "KBK installation operating instructions"
and "KBK Aluline operating instructions"  Tab. 2, Page 6. 17
 3.6 Noise emission/sound pressure level
If the Demag pillar or wall-mounted slewing jib crane is operated with a Demag chain hoist, refer to the corre‐
sponding chain hoist operating instructions (see  Tab. 2, Page 6) for the values.
The following structural influences were not considered in the measurements:
● transmission of noise via steel structures,
● reflection of noise from walls, etc.

3.7 Transport, packing and storage

3.7.1 Safety instructions

WARNING
Falling parts
Risk of injury from falling parts during transport, loading and unloading operations.
– Do not step under suspended loads. Keep a sufficient safety distance.
– Cordon off a large area around the working zone.

WARNING
Damage caused in transit
The Demag pillar or wall-mounted slewing jib crane may be damaged or destroyed by inappropriate transport.
Attach lifting and handling equipment only at the correspondingly marked points.

3.7.2 Scope of delivery

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.

3.7.3 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, do not accept the delivery or only on condition. Note the
scope of damage in the shipping documents/delivery note of the forwarding company. Lodge a claim.
● Lodge a claim for any defects as soon as they are detected, since claims for damages may only be asserted
within the relevant claim notification periods.

3.7.4 Packing
Demag pillar and wall-mounted slewing jib cranes and their accessories are supplied packed partly in wooden
and cardboard packing and in bags.
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.
211 277 44/031218

18
 3.7.5 Storage
Until they are installed, the equipment and accessories must be kept closed and may only be stored under the
following 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: -20 to +70 °C, if supplied with hoists or travel drives, the instructions for these compo‐
nents must also be complied with.
● 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 equipment must be packed tight and protected against corrosion (use desic‐
cant).

3.8 Surface protection and paint finish

As standard, Demag pillar or wall-mounted slewing jib cranes are supplied with Category C2-M corrosion protec‐
tion to DIN EN ISO 12944 in the following colours:

Finish
Pillar, bracket RAL 1007 Daffodil yellow
I-beam section, KBK steel profile sec‐
Jib RAL 1007 Daffodil yellow
tion
Jib KBK Aluline profile section RAL 9005, or aluminium Jet black, or anodized
Tab. 6

Other colours are also possible.

3.9 Operating conditions

CAUTION
Operational safety risk
Safe operation is only possible under the specified operating conditions. Contact the manufacturer if the operat‐
ing conditions differ from those specified  "After-sales service", Page 9

Ambient temperature: -20 °C to +70 °C (steel)

-20 °C to +50 °C (aluminium)
Humidity: Max. 80% relative humidity
Tab. 7

Refer to the corresponding operating instructions for differing temperature ranges for drives and hoists.
KBK trolleys have reduced load capacities under extreme temperature conditions.
Special operating conditions may be agreed with the manufacturer in individual cases.
Demag pillar and wall-mounted slewing jib cranes operating outdoors should be provided with a cover for protec‐
tion against the weather. Mobile components should be kept under a canopy when not in use.
211 277 44/031218

19
 4 Description of the sub-assemblies

4.1 Pillar-mounted slewing jibs

4.1.1 Pillars

Fig. 5
211 277 44/031218

20
 Pillar type Distance be‐ Slewing h G S1 Δ C P dia. y1 y2 ø dV Weight Pillar
tween support dK Part no.
bearings LA
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg]
3015 87,10 984 565 44
1 (140) 350 155 20 13 140 260 - 200 - 19
3265 94,00 984 735 44
3000 68,00 668 102 44
3500 77,20 668 104 44
2 (205) 500 4000 228 15 12 205 275 268 103 248 16 86,30 668 106 44
4500 95,40 668 108 44
5000 104,50 668 110 44
3000 90,00 668 202 44
Manual 3500 101,00 668 204 44
3 (258) 500 4000 274 15 12 258 340 330 126 305 20 112,50 668 206 44
4500 124,00 668 208 44
5000 135,50 668 210 44
3500 154,50 669 102 44
4000 172,00 669 104 44
4 (296) 750 4500 323 15 17 296 380 373 143 345 20 189,50 669 106 44
5000 207,00 669 108 44
5500 224,50 669 110 44
3500 204,00 669 202 44
4000 226,00 669 204 44
Manual 4500 386 248,00 669 206 44
5000 270,00 669 208 44
5500 293,00 669 210 44
5 (372) 750 20 17 372 475 468 179 432 25
3500 208,00 669 241 44
4000 230,00 669 242 44
Electric 4500 436 252,00 669 243 44
5000 276,00 669 244 44
5500 296,00 669 245 44
4000 347,00 670 102 44
4500 380,00 670 104 44
Manual 5000 445 412,00 670 106 44
5500 443,00 670 108 44
6000 475,00 670 110 44
6 (435) 1000 20 20 435 555 548 210 506 29
4000 349,00 670 141 44
4500 381,00 670 142 44
Electric 5000 465 413,00 670 143 44
5500 445,00 670 144 44
6000 477,00 670 145 44
4000 432,00 670 202 44
4500 470,00 670 204 44
Manual 5000 507,00 670 206 44
5500 545,00 670 208 44
6000 583,00 670 210 44
7 (515) 1000 510 25 20 515 660 648 248 599 35
4000 437,00 670 241 44
4500 474,00 670 242 44
Electric 5000 512,00 670 243 44
5500 550,00 670 244 44
6000 588,00 670 245 44
Tab. 8

The base plates and the upper cover plates have an opening for the electric cable.
Type 1 (140) pillars have bore holes to accommodate the jib with a sliding bearing (plastic) and through pin. The
bearing components belong to the jib.
211 277 44/031218

All other pillars are equipped with pivot pins and sliding bearings. In this case, the bearing parts are packed sepa‐
rately.

21
 4.1.2 Anchor bolt set and template

Fig. 6

General remarks on anchor bolt set and template

The anchor arrangement for pillars consists of anchor rods, nuts and a template. Profile angle sections are addi‐
tionally included for pillar size 1 (140).
The details for foundations given in this document must be checked by the customer taking into consideration the
local conditions.
The foundation must be prepared by a building company that specialises in this work.
The bolted connections and the base of the crane must always remain accessible for checks and inspections. Un‐
dergrout the crane base flange of size 1 (140) pillars after completion of erection.

As delivered

Pillar type Foundation depth a ST e Anchor bolt Anchor bolt set

Ft Weight Part no.
[mm] [mm] [mm] [mm] [kg]
1 (140) 560 35 600 M16 12,33 984 771 44
2 (205) 800 400 40 450 M12 5,00 668 171 44
3 (258) 450 45 550 M16 10,00 668 271 44
4 (296) 450 45 590 M16 11,00 669 171 44
900
5 (372) 550 55 700 M20 17,00 669 271 44
6 (435) 600 60 810 M24 26,00 670 171 44
1100
7 (515) 700 75 970 M30 47,00 670 271 44
Tab. 9

4.1.3 Anchorage

The unit is anchored to the floor by means of intermediate plates and

special chemical anchor bolts that are approved for dynamic loads.
For further information, see "KBK anchor bolt connection" document
 Tab. 2, Page 6.

Pillar type ⃞ Lb Min. concrete thickness

[mm] [mm]
1 (140) 340
2 (205) 390
3 (258) 450
4 (296) 530 200
5 (372) 830
211 277 44/031218

6 (435) 1170
7 (515) 1475
Tab. 10
Fig. 7
22
 4.2 Wall-mounted slewing jibs
4.2.1 Brackets
W-350-M brackets have bore holes to accommodate the jib with a sliding bearing (plastic) and through pin. The
bearing components belong to the jib.
All other wall brackets are equipped with pivot pins and sliding bearings. In this case, the bearing parts are
packed separately.

From 11/2018

Fig. 8

Bracket type Distance between support Slewing Anchor bolt t e Weight Part no.
bearings
[mm] [mm] [mm] [kg]
W-350-M 350 10 170 9,49 984 730 44
M16
W-500-M 500 Manual 12 170 13,14 668 600 44
W-750-M 210 30,00 669 600 44
750 15
W-750-E Electric 340 42,00 669 650 44
M24
W-1000-M Manual 255 63,95 670 600 44
1000 20
W-1000-E Electric 365 93,24 670 650 44
Tab. 11
211 277 44/031218

23
 Until 10/2018

Fig. 9

Bracket type Distance between support Slewing Anchor bolt t e Weight Part no.
bearings
[mm] [mm] [mm] [kg]
W-350-M 350 M16 10 160 16,10 851 061 44
W-500-M 500 Manual M14 15 170 15,00 668 030 44
W-750-M 210 30,00 669 030 44
750 M20 15
W-750-E Electric 340 40,00 669 085 44
W-1000-M Manual 255 50,00 670 030 44
1000 M30 20
W-1000-E Electric 365 79,00 670 085 44
Tab. 12
211 277 44/031218

24
 4.2.2 Bracket clamping arrangements

From 11/2018

Fig. 10

Bracket type Clamping ar‐ Width x Depth u v z Threaded rod Tightening torque Weight Part no.
rangement y
size from to max.
[mm] [mm] [mm] [mm] [mm] [mm] [Nm] [kg]
S 200 330 807 50 420 75 16,81 668 610 44
W-350
M 200 460 807 50 550 75 M16 170 18,81 668 615 44
W-500
L 460 650 787 60 740 85 25,50 668 620 44
S 280 400 750 60 530 100 54,33 669 610 44
W-750 M 280 550 710 80 680 130 81,09 669 615 44
L 550 750 670 100 880 140 110,56 669 620 44
M24 725
S 280 400 750 60 530 245 108,84 670 610 44
W-1000 M 280 550 710 80 680 275 162,35 670 615 44
L 550 750 670 100 880 285 221,30 670 620 44
Tab. 13

Clamping arrangements for W-1000 each include 2x one clamping arrangement for W-750
211 277 44/031218

25
 Until 10/2018

Fig. 11

Bracket type Clamping ar‐ Width x Depth u v z Threaded rod Tightening torque Weight Part no.
rangement y
size from to max.
[mm] [mm] [mm] [mm] [mm] [mm] [Nm] [kg]
S 200 330 850 50 400 75 21 668 040 44
W-500 M 200 460 850 50 530 75 M14 67 26 668 045 44
L 460 650 830 60 720 85 40 668 050 44
S 250 400 810 60 490 90 36 669 040 44
W-750 M 250 550 770 80 640 120 M20 200 60 669 045 44
L 550 750 770 80 840 120 74 669 050 44
S 300 400 750 80 532 135 75 670 040 44
W-1000 M 400 550 710 100 682 145 M30 685 96 670 045 44
L 550 750 670 120 882 155 132 670 050 44
Tab. 14

211 277 44/031218

26
 4.3 Jib
4.3.1 Jib with KBK Aluline profile section, fitted with brace

Fig. 12

Distance between sup‐ Slewing Outreach l 2) Load capacity Jib profile section LES Weight Jib
port bearings LA
[mm] [m] [kg] [mm] [kg] Part no.
2 400 1503 25,00 668 432 44
500 3 160 A12 2717 34,21 668 433 44
4 80 3721 42,80 668 434 44
2 500 1444 34,24 669 432 44
3 500 2685 45,03 669 433 44
750 4 315 A16 3698 55,18 669 434 44
5 160 4101 63,46 669 435 44
6 125 5007 77,26 669 436 44
2 1000 1477 55,00 669 462 44
3 800 2505 73,50 669 463 44
4 500 3517 96,20 669 464 44
750 A18
5 315 4422 114,90 669 465 44
6 200 5427 134,60 669 466 44
Manual
7 160 5958 149,80 669 467 44
3 1000 2453 82,60 670 433 44
4 800 3481 105,30 670 434 44
1000 5 400 A18 4396 124,10 670 435 44
6 315 5406 143,80 670 436 44
7 200 5940 159,00 670 437 44
4 1000 3489 112,10 670 464 44
5 800 4402 132,40 670 465 44
5 3) 1000 4402 158,20 670 485 44
1000 6 500 A22 5411 153,80 670 466 44
6 3) 630 5411 179,60 670 486 44
7 315 5944 170,80 670 467 44
7 3) 400 5944 209,00 670 487 44
Tab. 15
211 277 44/031218

2) Outreach rated dimension +/- 10 mm

3) Jib with 2 struts 27
 4.3.2 Jib with KBK steel profile section, fitted with brace

Fig. 13

Distance between sup‐ Slewing Outreach l 4) Load capacity Jib profile section LES Weight Jib
port bearings LA
[mm] [m] [kg] [mm] [kg] Part no.
2 1775 19,0 984 562 44
350 80 KBK 100
3 2785 25,0 984 563 44
2 315 1640 24,4 668 302 44
3 250 2740 34,7 668 303 44
500 KBK I
4 125 3590 44,1 668 304 44
5 80 4740 54,6 668 305 44
2 1650 55,0 669 302 44
1000
3 2500 79,9 669 303 44
4 500 3200 97,0 669 304 44
750 Manual KBK II
5 315 4200 119,4 669 305 44
6 250 5200 141,8 669 306 44
7 160 5900 162,4 669 307 44
4 1000 3510 108,8 670 304 44
5 800 4310 132,4 670 305 44
5 1000 4660 159,8 670 308 44
1000 KBK II
6 630 5410 153,1 670 306 44
6 1000 5660 191,6 670 309 44
7 400 5910 181,0 670 307 44
Tab. 16

211 277 44/031218

28 4) Outreach rated dimension +/- 10 mm

 4.3.3 Jib with I-beam section, fitted with brace

Fig. 14

Distance between sup‐ Slewing Outreach l 5) Load capacity Jib profile section LES Weight Jib
port bearings LA
[mm] [m] [kg] [mm] [kg] Part no.
4 250 IPE 160 3265 92,0 669 348 44
4 500 IPE 200 3280 119,0 669 359 44
5 250 IPE 160 4175 111,0 669 347 44
5 500 IPE 200 4190 145,0 669 358 44
Manual 6 125 IPE 160 5080 130,0 669 346 44
6 250 IPE 200 5090 170,0 669 357 44
750 7 125 IPE 160 5980 150,0 669 345 44
7 250 IPE 200 5995 196,0 669 356 44
8 125 IPE 200 6045 221,0 669 355 44
4 IPE 200 3285 132,0 669 377 44
500
5 IPE 200 4190 158,0 669 376 44
Electric
6 IPE 200 5095 183,0 669 375 44
250
7 HEA 160 5985 270,0 669 326 44
4 1000 IPE 200 3240 150,0 670 349 44
4 2000 IPE 240 3250 183,0 670 360 44
5 1000 IPE 200 4155 181,0 670 348 44
5 2000 IPE 240 4165 222,0 670 359 44
6 500 IPE 200 5065 212,0 670 347 44
6 1000 IPE 240 5070 262,0 670 357 44
Manual
6 1600 IPE 240 5070 262,0 670 358 44
7 500 IPE 200 5975 243,0 670 346 44
7 1000 IPE 240 5970 301,0 670 356 44
8 250 IPE 200 6025 273,0 670 345 44
8 500 IPE 240 6030 339,0 670 355 44
8 HEA 160 7025 380,0 670 322 44
1000 1000
4 IPE 200 3250 158,0 670 377 44
4 2000 IPE 240 3260 192,0 670 380 44
5 1000 IPE 200 4165 190,0 670 376 44
5 2000 IPE 240 4170 230,0 670 379 44
6 500 IPE 200 5070 220,0 670 375 44
6 1000 IPE 240 5075 270,0 670 378 44
Electric
6 1600 HEA 160 4710 300,0 670 327 44
7 500 HEA 160 5720 337,0 670 328 44
7 1000 HEA 160 5720 337,0 670 329 44
8 250 HEA 160 6025 383,0 670 330 44
8 500 HEA 160 7030 383,0 670 381 44
8 1000 HEA 160 7030 383,0 670 382 44
Tab. 17
211 277 44/031218

5) Outreach rated dimension +/- 10 mm 29

 4.3.4 Jib with I-beam section, low-headroom design

Fig. 15

Distance between support Slewing Outreach l 6) Load capacity Jib profile section Weight Jib
bearings LA
[mm] [m] [kg] [kg] Part no.
2 125 IPE 160 48,0 668 348 44
2 250 IPE 200 66,0 668 352 44
3 125 IPE 160 64,0 668 347 44
3 250 IPE 200 88,0 668 351 44
500 Manual
4 63 IPE 160 80,0 668 346 44
4 125 IPE 200 110,0 668 350 44
5 63 IPE 160 96,0 668 345 44
5 125 IPE 200 132,0 668 349 44
2 500 IPE 240 104,0 669 354 44
2 1000 IPE 300 142,0 669 364 44
3 500 IPE 240 135,0 669 353 44
3 1000 IPE 300 184,0 669 363 44
Manual 4 250 IPE 240 165,0 669 352 44
4 500 IPE 300 226,0 669 362 44
750 5 250 IPE 240 196,0 669 351 44
5 500 IPE 300 268,0 669 361 44
6 250 IPE 300 310,0 669 360 44
2 IPE 300 154,0 669 381 44
1000
3 IPE 300 196,0 669 380 44
Electric
4 IPE 300 238,0 669 379 44
500
5 IPE 300 280,0 669 378 44

211 277 44/031218

30 6) Outreach rated dimension +/- 10 mm

 Distance between support Slewing Outreach l 6) Load capacity Jib profile section Weight Jib
bearings LA
[mm] [m] [kg] [kg] Part no.
2 IPE 360 217,0 670 354 44
2000
3 IPE 360 274,0 670 353 44
4 1000 IPE 360 331,0 670 352 44
4 2000 IPE 400 348,0 670 361 44
5 1000 IPE 360 388,0 670 351 44
5 2000 IPE 450 485,0 670 364 44
Manual 6 250 IPE 300 358,0 670 335 44
6 500 IPE 360 432,0 670 337 44
6 1000 IPE 400 480,0 670 362 44
6 1600 IPE 450 560,0 670 365 44
7 250 IPE 360 505,0 670 350 44
1000 7 500 IPE 400 546,0 670 363 44
7 1000 IPE 450 638,0 670 366 44
2 IPE 360 227,0 670 386 44
2000
3 IPE 360 285,0 670 385 44
4 1000 IPE 360 342,0 670 384 44
4 2000 IPE 400 365,0 670 390 44
5 1000 IPE 360 400,0 670 383 44
Electric
5 2000 IPE 450 488,0 670 392 44
6 500 IPE 360 460,0 670 387 44
6 1000 IPE 360 460,0 670 388 44
6 1600 IPE 450 565,0 670 391 44
7 500 IPE 400 565,0 670 389 44
Tab. 18

4.4 Components

4.4.1 Bearing

4.4.1.1 Bearing with KBK 100 jib (LA = 350)

The bearing with KBK 100 jib consists of a supporting through pin and sliding bearings. It is included in the scope
of delivery for the jib.

4.4.1.2 Support bearing for all other sizes

Distance between support bearings LA Slewing Weight Part no.

[mm] [kg]
500 1,23 668 000 44
Manual
3,16 669 000 44
750
Electric 2,98 669 246 44
Manual 5,89 670 000 44
1000
Electric 5,18 670 246 44
Tab. 19
211 277 44/031218

6) Outreach rated dimension +/- 10 mm 31

 4.5 Trolleys
4.5.1 KBK trolley

Fig. 16

Trolley Max. load Weight Part no.

[kg] approx. [kg]
KBK 100 for DC 1, DCM 1, DKM, DKUN 1 100 0,70 984 530 44
KBK I for DC 2, DCM 2, DKM, DKUN 1-2 300 0,75 980 610 44
KBK II-L, II for DC 5, DCM 5, DKM, DKUN 1-5 600 1,90 982 110 44
A12/A16 for DC 2, DCM 2, DKM, DKUN 1-2 300 1,20 855 250 44
A18/A22 for DC 5, DCM 5, DKM, DKUN 1-5 800 2,47 855 280 44
Tab. 20

The load handling attachment and load must be flexibly suspended.

Trolleys are fitted with 4 plastic travel wheels mounted on permanently lubricated anti-friction bearings. KBK II
trolleys and Aluline trolleys have two additional horizontal guide rollers. The trolley side cheek protrudes beyond
the travel wheels in the direction of travel to protect them.

Traction resistance of a loaded trolley in % of the attached load

Trolley KBK 100, KBK I, KBK II A12/A16/A18/A22
Start-up resistance 1-1,5 % <1%
With constant displacement approx. < 0,5 % < 0,4 %
Tab. 21

Temperature range: – 20° to + 70° C. The load must be reduced under extreme temperature conditions:

Continuous temperature in °C - 20 - 15 -10 to +40 50 60 70

% of load 50 80 100 90 75 50
Tab. 22

Pins with BoClip pin retainers can be ordered individually.

211 277 44/031218

Trolley KBK 100, KBK I, A12/A16 KBK II, A18/A22

Pin with pin retainer 851 305 44 851 317 44
Tab. 23
32
 4.5.2 Articulated frame

Fig. 17

Articulated frame Max. load Weight Part no.

[kg] approx. [kg]
for DC 2, DCM 2, DKM, DKUN 1-2 1,00 980 305 44
KBK 100 200
Double trolley, completed 2,40 On request
for DC 5, DCM 5, DKM, DKUN 1-5 1,00 980 305 44
KBK I 400
Double trolley, completed 2,50 980 322 44
for DC 10, DCM 10, DKM, DKUN 1-10 1,88 982 305 44
KBK II 1200
Double trolley, completed 5,68 851 132 44
for DC 5, DCM 5, DKM, DKUN 1-5 1,00 980 305 44
A12/A16 600
Double trolley, completed 3,40 855 422 44
for DC 10, DCM 10, DKM, DKUN 1-10 2,00 982 305 44
A18/A22 1200
Double trolley, completed 6,95 855 622 44
Tab. 24

A double trolley is created by joining two trolleys with an articulated frame. Holes drilled in the ends of KBK II and
A18/A22 articulated frames are provided for fitting spacer bars and link bars (items 69 and 71, see "General KBK
system" and "KBK Aluline" documents  Tab. 2, Page 6), they are not designed for connecting loads.
Pins with BoClip pin retainers can be ordered individually.

Trolley KBK 100, KBK I, A12/A16 KBK II, A18/A22

Pin with pin retainer 851 305 44 851 317 44
Tab. 25
211 277 44/031218

33
 4.5.3 Trolley on I-beam section

Fig. 18

For information on trolleys on I-beam sections, see "U11-U34/DC/DCM/DK trolley technical data" document
 Tab. 2, Page 6 (included in the scope of delivery for the trolley).

4.6 Slewing jib cranes with electric slewing mechanisms

Designation Distance between support bear‐ Part no.
ings [mm]
Slewing drive, complete 750 669 255 44
(geared motor, frequency inverter with
enclosure, geared limit switch) 1000 670 255 44

Electric enclosure for DC 772 401 45

Electric enclosure for DCS 772 402 45
Enclosure mounting plate 669 265 44
Tab. 26

Slewing jib cranes with electric slewing mechanisms are supplied with
special jibs. They cannot be fitted to standard jibs at a later date.
A gear ring welded to the lower end of the pivot axis transmits the turn‐
ing motion of the geared motor to the jib.
The cranes have a single-speed slewing motion. The frequency inverter
is used for gentle acceleration and to specify the slewing speed de‐
pending on the outreach (default slewing speed [rpm] = 0,6-1). The first
stage of the slewing range is switched off by the geared limit switch.
Fig. 19 The motor is a conical-rotor brake motor. This means that no brake
control is needed.
The supply cable from the isolating switch and the trailing cable to the travelling hoist are connected in the electric
equipment enclosure.
211 277 44/031218

34
 4.7 Electric equipment
Designation SSK WSK
Part no. Part no.
Basic electric equipment 668 940 44 668 941 44
Tab. 27

The following component parts are included:

Designation Quantity
SSK WSK
Load isolating switch 1 1
Self-tapping screws for isolating switch 4 –
Wire end sleeve 10 10
Twist-type cable entry gland for flat cable 1 1
Twist-type cable entry gland for round cable 1 1
Pillar earthing accessories 1 –
Jib earthing accessories 1 –
Tab. 28

The flat cable to the hoist unit and required cable carriers are selected according to the jib length.
The supply cable with connecting elements from the switch to the mains connection are not included in the scope
of supply.

Designation Jib profile section Weight Part no.

KBK 100/KBK I/A12/A16 0,03 kg 980 759 44
Cable sliders for flat cable max. 4 x 2,5
KBK II/A18/A22 0,04 kg 851 690 44
IPE 160 - 330, HE-A 160 0,57 kg 668 930 44
Narrow cable trolley for flat cable max. 4 x 2,5
IPE 360 - 600 0,9 kg 668 931 44
IPE 160 - 330, HE-A 160 0,8 kg 668 932 44
Wide cable trolley
IPE 360 - 600 1,13 kg 668 933 44
4 x 1,5 0,22 kg/m 471 352 44
Flat cable with PE
13 x 1,5 0,55 kg/m 895 171 44
Round cable 4 x 1,5 0,24 kg/m 471 954 44
Tab. 29
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35
 5 Assembly

5.1 General
These operating instructions enable the owner to install or replace the Demag pillar or wall-mounted slewing jib
crane. The owner must appoint a coordinator who is authorised to issue instructions before assembly work com‐
mences.
Despite detailed information, errors cannot be excluded when the installation is assembled by the customer. For
this reason, we recommend that this work be carried out by our trained specialists or by persons authorised by
us.

The wiring of Demag pillar and wall-mounted slewing jib cranes complies in all respects with current DIN VDE and
accident prevention regulations.
Unauthorised intervention and modifications eliminate compliance with these regulations.

DANGER
Live components
Danger to life and limb.
It must be possible to switch off the power supply by means of a device to disconnect the power supply (e.g.
mains connection or isolating switch with a padlock).

If the Demag pillar or wall-mounted slewing jib crane is operated with a Demag chain hoist, the corresponding
chain hoist assembly and operating instructions (see  Tab. 2, Page 6) must be observed. In particular, the
safety instructions must be observed and followed.

5.2 Safety instructions for assembly

DANGER
Incorrect assembly
Danger to life and limb.
Incorrect installation can result in severe injury and/or damage to property. Therefore, this work may only be car‐
ried out by authorised, instructed personnel who are familiar with the principle of operation of the machine in
compliance with all safety regulations.
– Ensure sufficient working clearance before starting assembly work.
– Secure and fence off the working and danger zone.
– If an elevating work platform is used for assembly, only use appropriate attachments for the lifting of per‐
sons which ensure that work is carried out in a safe and stable position.
– Only suitable, tested and calibrated tools and accessories may be used for assembly or disassembly work.
– Wear protective equipment.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any unneeded machine parts or fittings and tools 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 may fall and cause severe injuries.
– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐
ments must be fulfilled. The electrode holder and earth must be connected to the same assembly when
welding work is carried out. Otherwise serious damage may be caused to the hoist.
– Customer-specific regulations must be observed.
211 277 44/031218

36
 DANGER
Live components
Danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐
nel", Page 8) in compliance with the safety regulations.
Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐
tected against unauthorised or accidental restoration of the power supply by means of a padlock.

Mechanical safety
All bolted connections must be correctly tightened.
Self-locking nuts must not be replaced by other types of nut. Self-locking nuts must be replaced when they have
been tightened and untightened five times. The clamping torque of a self-locking nut must not be lower than the
loosening torque specified by EN ISO 2320.
A sufficiently secure connection can only be guaranteed by tightening to the specified tightening torque.
Bolted connections must not be lubricated as otherwise the specified tightening torque values will be too high.
Check to ensure that pin connections are correctly fitted.
All assembly work must be completed in accordance with the operating instructions.
Any change or modification which prejudices safety must be reported to the nearest person responsible immedi‐
ately. Repairs may only be carried out by experienced technicians.
Ensure that all attachment points are freely accessible for checks and inspection work or that free access can be
provided.
The control device (e.g. control pendant) must be marked in such a way that the direction of movement is clear
and distinct. The arrow symbol on the control elements must correspond to the direction of movement.
Electric safety
The operating instructions are generally binding for the use of Demag pillar and wall-mounted slewing jib cranes.
Protective earth conductor
The protective earth conductor in insulated leads and cables must be coloured green and yellow along its entire
length.
The protective earth conductor must not be connected to retaining bolts or screws.
Protective earth junctions and connections must be protected against accidental loosening (e.g. by using serrated
lock washers to DIN 6798). It must be possible to disconnect each individual connection.
Protective earth conductors must not carry any current in normal operation.
The same number of protective earth conductor connection points must be provided as electric power infeed and
outfeed points.
Continuity of the PE conductor connection must be checked.
Mains connection switch
A mains connection switch must always be provided for the main power supply line to the machine. The mains
connection switch must be arranged to disconnect all poles of the Demag pillar or wall-mounted slewing jib crane
from the mains supply.
Ensure that the mains connection switch is installed in an easily accessible position in the vicinity of your machine
and that it is clearly marked.
Isolating switch
If two or more lifting appliances are fed from a common main power supply, each one should be provided with an
isolating switch. This enables you to carry out maintenance work on individual hoist units after turning off the iso‐
lating switch, without affecting operation of the rest of the system.
Power supply line
The power supply line/cable to be used depends on the motor size and cable length.
211 277 44/031218

37
 5.3 Tightening torques
Tightening torques for Demag pillar or wall-mounted slewing jib cranes
Thread size Tightening tor‐ Component See section
que
[Nm]
End cap with buffer - KBK 100  "KBK 100 jib", Page 46
M6 10  "KBK I, II, I-beam section, aluminium profile section jib",
Bolt for pivot pin
Page 48
Bolt on supporting pin - KBK100  "KBK 100 jib", Page 46
 "KBK I, II, I-beam section, aluminium profile section jib",
End cap with buffer - KBK I
Page 48
Trolley locking device bolted brackets  "Hoist trolley locking device on the KBK jib", Page 64
25 Canopy bolted brackets  "Canopy on the KBK jib", Page 65
M8
 "KBK I, II, I-beam section, aluminium profile section jib",
Bolt for pivot pin
Page 48
Slewing motion locking device mounting brackets  "Hoist trolley locking device on the KBK jib", Page 64
End cap and cable slider plate See KBK Aluline operating instructions  Tab. 2, Page 6
42 VB.RIPP bolt on supporting pin - KBK100  "KBK 100 jib", Page 46
45 Bolt for pivot pin
 "KBK I, II, I-beam section, aluminium profile section jib",
M10 Locking bolt on aluminium profile section connection to sup‐
85 Page 48
porting tube and to strut
 "KBK I, II, I-beam section, aluminium profile section jib",
80 End cap with buffer - KBK II
Page 48
Pillar 2 (205) mounting arrangement with foundation anchor
45  "Erecting the pillar", Page 42
M12 bolts
80 Slewing motion locking device latch  "Hoist trolley locking device on the KBK jib", Page 64
Locking bolt on aluminium profile section connection to sup‐  "KBK I, II, I-beam section, aluminium profile section jib",
130
porting tube and to strut Page 48
M14 67 W-500 wall bracket mounting arrangement (until 10/2018)  "Securing the bracket", Page 44
70 W-350 wall bracket mounting arrangement (until 10/2018)  "Securing the bracket", Page 44
Pillar 1 (140) mounting arrangement with foundation anchor
bolts
105  "Erecting the pillar", Page 42
M16 Pillar 3 (258)/4 (296) mounting arrangement with foundation
anchor bolts
W-350 and W-500 wall bracket mounting arrangement (from  "Securing the bracket", Page 44
170
11/2018)
Pillar 5 (372) mounting arrangement with foundation anchor
 "Erecting the pillar", Page 42
M20 200 bolts
W-750 wall bracket mounting arrangement (until 10/2018)  "Securing the bracket", Page 44
Pillar 6 (435) mounting arrangement with foundation anchor
350  "Erecting the pillar", Page 42
bolts
M24
W-750 and W-1000 wall bracket mounting arrangement (from
725  "Securing the bracket", Page 44
11/2018)
Pillar 7 (515) mounting arrangement with foundation anchor
 "Erecting the pillar", Page 42
M30 685 bolts
W-1000 wall bracket mounting arrangement (until 10/2018)  "Securing the bracket", Page 44
Tab. 30

CAUTION
Loose connections
Loose connections are a danger to life and limb and a risk of damage to the machine.
Metal nuts featuring a locking element (self-locking nuts) must not be replaced by normal nuts.

5.4 Installation procedure

1. Unpack and dispose of the packing material in an environmentally compatible way  "Transport, packing
211 277 44/031218

and storage", Page 18.

2. Check the delivery is complete  "Transport inspection", Page 18.
3. Install the pillar or the bracket  "Installing the pillar", Page 40.
38
 4. Install the jib  "Assembling the jib", Page 46.
5. Install the electric slewing mechanism  "Electric slewing mechanism", Page 50.
6. Install the electric equipment  "Electric cabling and wiring", Page 53.
7. Install the hoist unit, see chain hoist operating instructions  Tab. 2, Page 6.
8. Carry out checks before putting the unit into operation for the first time  "Inspections before putting into
service for the first time", Page 67.
9. The equipment is ready for operation  "Operation", Page 68.

5.5 Mounting and anchoring

Fig. 20

WARNING
Under-dimensioned building structures
Danger to life and limb.
Ensure that the support superstructure has sufficient load-bearing capacity.
– Appropriate local conditions must be provided at the place where Demag pillar or wall-mounted slewing jib
cranes are installed. Buildings and parts of buildings such as workshop floors, intermediate floors, founda‐
tions, walls and roof supports must have the required load-bearing capacity and be able to accommodate
the specified anchor bolt tensile and shear forces.

Depending on the jib position, the anchor arrangement of wall-mounted slewing jibs is subject to
● tensile forces when the jib is positioned at right angles to the wall,
● shear forces when the jib is positioned parallel to the wall.
The anchor bolts of pillar-mounted slewing cranes are subjected to different loads depending on the position of
the jib and load. The specified loads are calculated on the basis of the maximum load and load position taking
account of deadweight. Oscillation coefficients are not included.
The forces are dynamic and pulsating. They fluctuate according to the position of the load. If in doubt, have the
anchorage arrangement and/or the supporting superstructure designed and approved by a structural engineer.
211 277 44/031218

39
 5.6 Installing the pillar

5.6.1 Securing the pillar

5.6.1.1 Foundations with cast-in anchors

WARNING
Under-dimensioned building structures
Danger to life and limb if the cast-in anchors are not adequately dimensioned.
– This solution must be checked by a structural engineer before installation. At the same time, the local
ground conditions and the pressure to which the ground may be subjected must be taken into account.

The foundation size recommended in our data sheets or the drawing is based on foundations located on a clear
foundation level. If the foundations are to be incorporated into an existing reinforced concrete floor, this has the
advantage of more favourable dimensions.
Proceed as follows for foundation mounting arrangement as specified by the manufacturer:

Pillar 1 (140)

Cast in the anchor bolts combined with profile section angles using a
template (see  "Anchor bolt set and template", Page 22). A gap of 40
– 60 mm must be left between the base plate and the concrete so that
the pillar can be aligned following installation.
A cable duct must be provided for the four-core supply cable, which
emerges under the centre of the base plate. The base plate also has an
opening to allow the supply cable to pass through to the mains connec‐
tion switch on the pillar.
Remove the template after the foundation has been cast.
Fill the gap with concrete or grouting when the pillar has been aligned.
Fig. 21

Pillar 2 (205) to pillar 7 (515)

Fig. 22

The template also serves as a ground plate for the pillar and must be installed at the same level as the top edge
of the foundations.
1. Screw the narrow nuts onto the anchor rods, pay attention to the projecting thread;
2. Insert the anchor rods into the template and secure them with the side nuts;
3. Place this assembly into the foundations;
If required, provide a cable duct in the foundations for the electric supply cable;
The top edge of the template should be flush with the top edge of the foundations;
211 277 44/031218

Align the template with a spirit level.

40
 Pillar 2 (205) 3 (258) 4 (296) 5 (372) 6 (435) 7 (515)
Thread M12 M16 M16 M20 M24 M30
Projection ST [mm] 40 45 45 55 60 75
Tab. 31

5.6.1.2 Anchorage with anchors and intermediate plate

Fig. 23

Item Designation Item Designation Item Designation

Upat UMV multicone dynamic anchor
1 2 Pillar bolted 3 Anchor bolt plate
bolt
Tab. 32

WARNING
Under-dimensioned building structures
Danger to life and limb if the anchors used are not adequately dimensioned.
– The use of positive anchors must be agreed with a structural engineer and they must be installed in accord‐
ance with relevant building regulations. A record of the installation work must be kept.

Slewing jib crane anchors are subject to dynamic and pulsating forces.
We supply an intermediate plate with anchors and bolts for fitting the pillar to the intermediate plate for any type of
pillar. The intermediate plate is necessary as positive anchors require greater distances between the axes with
correspondingly lower tensile forces.
Attach the intermediate plate to the concrete floor as specified by the manufacturer of the anchor bolts.
Remember that a record of the installation work must be compiled.
If the power supply is to be introduced into the pillar from below, this must be considered before the intermediate
plate is attached.
For information on procedures, project engineering and installation, see "KBK anchor bolt connection" document
 Tab. 2, Page 6.
211 277 44/031218

41
 5.6.2 Erecting the pillar

Power supply from the foundations and erecting the pillar

Fig. 24

● Lay the supply cable so that it protrudes from the foundation.

● Lay the power supply cable:
- from the foundations into the pillar from below
- from the side into the base of the pillar or
- from above into the top of the pillar.
● Lay the supply cable out through the opening for the switch. Secure the supply cable so that it cannot slip
back.
● Place the pillar upright and set it on the foundation.

Aligning the pillar

● The pillar must be aligned vertically so that the jib does not tend to
swing automatically to a particular position. Align the pillar:
Size 1 (140) by adjusting the nuts;
Size 2 (205) to 7 (515), as required, by placing filler plates between
the pillar base and template.
Check the vertical alignment with a spirit level or plumb bob on the
supporting pin or jib pivot pin.
Shims can be placed under the entire base of the pillar to align the
pillar.
The pillar cannot be aligned with reference to the pillar
shaft. The shaft is not parallel to the supporting pin/jib piv‐
ot pin.

● Bolt the pillar firmly to the foundation. Ensure that the nuts are tight‐
ened securely and uniformly.
● Size 1(140) Fill the gap between the base plate and concrete with an
expanding plastic mortar (or a non-shrink mortar). The gap must be
completely filled with mortar.

Fig. 25

WARNING
Incorrect attachment of fittings
Danger to life and limb if the required tightening torques are not complied with.
211 277 44/031218

For tightening torques for bolt grades supplied by us, refer to the table below  Tab. 33, Page 43.
Please refer to the corresponding tightening torques for other bolt grades. Anchor bolts must be installed as
specified by their manufacturer.
42
 Pillar 1 (140) 2 (205) 3 (258)/4 (296) 5 (372) 6 (435) 7 (515)
Thread M16 M12 M16 M20 M24 M30
Tightening torque [Nm] 105 45 105 200 350 680
Tab. 33

5.7 Fitting the bracket

5.7.1 General information on fitting the bracket

Fig. 26 Brackets from 11/2018

Bracket type Dimensions (from 11/2018) Dimensions (until 10/2018)

d n [mm] u [mm] d n [mm] u [mm]
W-350-M M16 150 444 M16 250 500
W-500-M M16 150 594 M14 150 594
W-750-M/W-750-E M24 210 880 M20 190 870
W-1000-M/W-1000-E M24 210 1140/1430 M30 220 1160
Tab. 34

WARNING
Under-dimensioned building structures
Danger to life and limb if the load-bearing capacity of the support superstructure is not ensured.
Before the bracket is fitted, the pillar or wall to which the wall-mounted slewing jib crane is to be attached must
be checked by a structural engineer. The pillar or wall must be sufficiently dimensioned to withstand the tensile
forces and loads that occur.

Depending on the jib position, the anchor bolts are subject to

● tensile stress when the jib is positioned at right angles to the wall,
● shear stress when the jib is positioned parallel to the wall.
The contact surfaces must be thoroughly cleaned before installation, since brackets and clamping arrangements
are held pre-tensioning and the friction connection.
If the required friction connection cannot be achieved due to a lack of friction, keep plates or dowel pins must be
installed to ensure that retaining brackets do not move. If the bolts are not adequately pre-tensioned, the bracket
can move slightly out of vertical and so adversely affect the slewing motion of the jib. Additional protection against
slipping can be fitted below the bracket or clamping arrangement, if required. Depending on the existing structure
211 277 44/031218

of the building (steel, reinforced concrete or brick), the bracket can be secured by means of a channel section
with anchor rods or anchor bolts embedded in concrete. Minimum grade 5.6 until 10/2018, minimum grade 8.8
from 11/2018.

43
 5.7.2 Securing the bracket

● Ensure that the bracket is absolutely vertical so that the jib does not
tend to swing automatically to a particular position.
Check the vertical alignment with a spirit level or plumb bob on the
supporting pin or jib pivot pin.
The bracket cannot be aligned with reference to the con‐
necting strut of the bracket plates. For production rea‐
sons, the connecting strut is not parallel with the jib sup‐
porting pin/jib pivot pin.

● Firmly bolt the bracket to the pillar or wall. Ensure that the nuts are
tightened securely and uniformly.
● Align the bracket and secure the nuts using the locknuts.

Fig. 27

WARNING
Incorrect attachment of fittings
Danger to life and limb if the required tightening torques are not complied with.
For tightening torques, refer to the table below  Tab. 35, Page 44.
Please refer to the corresponding tightening torques for other bolt grades. Anchor bolts must be installed as
specified by their manufacturer.

Bracket type From 11/2018 Until 10/2018

Thread Tightening torque [Nm] Thread Tightening torque [Nm]
W-350-M M16 170 M16 70
W-500-M M16 170 M14 67
W-750-M/W-750-E M24 725 M20 200
W-1000-M/W-1000-E M24 725 M30 685
Tab. 35
211 277 44/031218

44
 5.7.3 Securing the bracket with clamping arrangement

Fig. 28

Item Designation Item Designation Item Designation

1 Threaded rod 4 U-profile section 7 Locknut
2 Nut 5 Tab washer
3 Square sleeve 6 Nut
Tab. 36

● First install the upper clamping arrangement at the required height on the pillar;
- Place tab washer (5) with the recess facing the clamping arrangement onto the threaded rod at the front and
rear and tighten nuts (6) by hand;
- Slide square sleeves (3) located on threaded rods (1) with their round collars between U-profile sections (4)
and tighten nuts (2) by hand;
● Attach the front part of the lower clamping arrangement to the bracket;
● Attach this assembly to the upper clamping arrangement by hand and align the bracket;
● Then install the lower clamping arrangement to the pillar in the same way as the upper one;
● Knock square sleeves (3) at all positions until they are in close contact with the pillar;
● Check the alignment again and, if necessary, correct it and move the square sleeves back into contact with the
pillar;
● Tighten front nuts (6) and secure them with locknuts (7);
● Tighten rear nuts (6) to the specified tightening torque and secure them with locknuts (7);
● Fix the square sleeves into position with nuts (2);
● Attach the bracket to the clamping arrangement with the correct tightening torque.

WARNING
Incorrect attachment of fittings
Danger to life and limb if the required tightening torques are not complied with.
For tightening torques, refer to the table below  Tab. 37, Page 46.
211 277 44/031218

45
 Bracket type From 11/2018 Until 10/2018
Thread Tightening torque [Nm] Thread Tightening torque [Nm]
W-350-M M16 170 - -
W-500-M M16 170 M14 67
W-750-M/W-750-E M24 725 M20 200
W-1000-M/W-1000-E M24 725 M30 685
Tab. 37

5.8 Assembling the jib

5.8.1 KBK 100 jib

Fig. 29

Item Designation Tightening torque Item Designation Tightening torque

1 Bolt on supporting pin M8 = 42 Nm 11 Buffer bolt
2 Locknut 12 Cable carrier
3 Supporting pin 13 Internal buffer stop
4 Bearing bush halves 14 Flat cable
5 Upper bracket plate 15 Manufacturer’s plate
6 Lower bracket plate 16 Capacity plate
7 Supporting tube 17 Pin with pin retainer
8 Supporting ring 18 Trolley
211 277 44/031218

9 Side buffer 19 End cap with buffer KBK 100 = M6 = 10 Nm

Bolted connection (pre-assem‐
10 Nut for internal buffer stop 20 25 Nm
bled)
Tab. 38

46
 Grease with solid additives such as molybdenum sulphide must not be used.

1. Remove bolt (1) and nut (2) from supporting pin (3). The bearing bushes must be greased. Use non-ageing
lithium soap greases for lubrication.
2. Position the jib between upper bracket plate (5) and lower bracket plate (6).
Ensure that an additional supporting ring (8) is fitted between bearing bush (4) and lower bracket plate (6).
3. Lightly lubricate supporting pin (3).
Insert the supporting pin with the keep plate into the bore hole from above until the keep plate is lying on top
of upper bracket plate (5). If space is limited, this can also be done in the same way from below.
4. To stop the supporting pin from turning, secure the keep plate of the supporting pin to upper bracket plate (5)
with bolt (1) and locknut (2).
5. Bore holes for mounting the two side buffers (9) and internal buffer (13) must be drilled close to the pivot axis
on the jib. If the jib arm can knock against a wall, adjacent pillar, machine etc., we recommend that the side
buffers be fitted in this area.
6. Install an internal buffer stop (13) in the track section on the power-supply side to protect the cable carriers.
Drill a 7 mm diameter hole through the top of the section.
The minimum dimension from the "supporting tube to the bore hole centre" is:
Number of cable carriers x length of a cable carrier + 170 mm.
7. After the cable carriers (12) and trolley or double-trolley (18) (see also  "Jib with KBK steel profile section,
fitted with brace", Page 28) have been inserted into the jib arm, close off the end of the track with end cap
with buffer (19) and firmly screw the cap into place.
Tighten the bolts with the specified tightening torque for KBK jibs.
Retighten all bolted connections 1 – 2 months after putting into service to compensate for settling.
211 277 44/031218

47
 5.8.2 KBK I, II, I-beam section, aluminium profile section jib

Fig. 30

Item Designation Item Designation Item Designation

1 Friction washer (plastic) 9 Side buffer nut 17 End cap with buffer
2 Thrust washer (steel) 10 Side buffer bolt 18 Upper bracket plate
3 Upper pivot pin 11 Internal buffer stop for KBK profile section 19 Lower bracket plate
Internal buffer stop bolt for KBK profile Internal buffer stop for I-beam or alumini‐
4 Lower pivot pin 12 20
section um profile section
Internal buffer stop nut for KBK profile
5 Bolt (6 off, shorter) 13 21 Cable trolley
211 277 44/031218

section
6 Spring 14 Cable carrier 22 Trolley
7 Bolt for spring (3 off, longer) 15 Double trolley 23 Cable slider plate
8 Side buffer 16 Pin with pin retainer 24 T-head bolt
48 Tab. 39
 Grease with solid additives such as molybdenum sulphide must not be used.

1. First position friction washer (plastic) (1) followed by thrust washer (steel) (2) on the upper and lower contact
surfaces of the pivot arrangement. Check to ensure that the parts are correctly positioned when the pivot
pins are installed.
2. Position the jib between upper bracket plate (18) and lower bracket plate (19) and ensure that the bore holes
of the pivot arrangement and the bracket are concentric with each other.
3. Lightly grease pivot pins (3 + 4). Insert (3 + 4) into the relevant bore holes from above and below. Ensure
that pivot pin (4) is positioned with the three bore holes on the underside of bracket (19).
4. To stop pivot pins (3 + 4) from turning, secure the pivot pins to upper bracket plate (18) and lower bracket
plate (19) with shorter bolts (5).
Three blind holes and three through holes alternate around upper bracket plate (18). Shorter bolts (5) must
be inserted into the blind holes. Tighten bolts (5) to the specified tightening torque (see  "Tightening tor‐
ques", Page 38).
The bearings of electric slewing jibs that have a bearing distance of 1000 mm are provided lubricating nip‐
ples. They must be initially lubricated and then regularly lubricated every 3 months (see  "Lubrication of
pivot pins", Page 78).
5. Insert springs (6) and longer bolts (7) into the remaining through holes on upper pivot pin (3). The pressure
needed to move the jib can be adjusted by turning bolts (7) against thrust washer (2) and friction washer (1).
6. Bore holes for mounting the two side buffers (8) must be drilled close to the pivot axis on the steel profile
section jib.
Press side buffers (8) into the upper slot of the aluminium profile section close to the pivot axis on aluminium
jibs in size A12/A16.
Install side buffers (8) in the upper slot of the aluminium profile section close to the pivot axis on aluminium
jibs in size A18/A22. To do this, turn the slot nut into the slot and secure the round rubber buffer with the M8
hexagon socket bolt with a tightening torque of 20 Nm.
If the jib arm can knock against a wall, adjacent pillar, machine etc., we recommend that the side buffers be
fitted in this area.
7. Install a rail buffer (11) in the track section to protect cable carriers (14) or cable trolleys (21).
● Holes must be drilled through the top of the profile section and an internal buffer stop (11) must be installed in
jibs that have a steel profile section.
- KBK I: two 9,5 mm dia. holes, 32 mm apart across the track axis.
The minimum dimension from the "supporting tube to the bore hole centre" is:
Number of cable carriers x length of a cable carrier + 180 mm.
KBK II: two 9,5 mm dia. holes, 50 mm apart across the track axis.
The minimum dimension from the "supporting tube to the bore hole centre" is:
Number of cable carriers x length of a cable carrier + 235 mm.
● Plates are welded to I-beam section jibs to accommodate buffer stops (20).
● Cable slider plate (23) is fitted at a distance of 300 mm (min. distance 200 mm) from the supporting tube with
T-head bolts (24) in the lower slot of the aluminium profile section on jibs that have an aluminium profile sec‐
tion.
- A bore hole must be drilled through the side wall of aluminium jibs to attach the buffer and internal buf‐
fer (11) must be installed.
The minimum distance from the "cable slider plate to bore hole centre" is:
Number of cable carriers x length of a cable carrier.
- Insert rubber element (11c) into the jib and secure it with pin (11a). Secure the pin with retaining clip (11b).
8. For KBK jibs, insert cable carriers (14) and trolley or double trolley (15) (see also  "Jib with I-beam section,
211 277 44/031218

fitted with brace", Page 29), close off the end of the track with end cap with buffer (17) and firmly screw the
cap into place. Tighten the bolts with the specified tightening torque for KBK jibs.
For I-beam section jibs, position and adjust cable trolleys (21) and trolleys (22) on the track.
Retighten all bolted connections 1 – 2 months after putting into service to compensate for settling. 49
 5.9 Electric slewing mechanism

Fig. 31
211 277 44/031218

50
 Item Designation Item Designation
1 Pinion 6 2 short bolts
2 Geared motor 7 Geared limit switch
3 Toothed wheel 8 Geared limit switch bolts
4 2 long bolts 9 Frequency inverter
5 Locknut 10 Electric enclosure
Tab. 40

The cranes have a single-speed slewing motion. The frequency inverter is used to specify the slewing speed de‐
pending on the outreach (default setting). The first stage of the slewing motion is switched off by the geared limit
switch.
The motor is a conical-rotor brake motor. This means that no brake control is needed.

Electric slewing mechanism specifications

Operating voltage Output Rated current IN cos φN CDF Insulation class Motor enclosure
[kW] [A] [%]
380-415 V 50 Hz 0,4 2 0,6 40 F IP55
Tab. 41

Depending on the load capacity and outreach of the slewing jib crane, the motor is operated with a maximum fre‐
quency of 17, 23, 29, 32, 34 or 46 Hz.
Example: 17 Hz at 2000 kg x 5 m; 46 Hz ≦ 2000 kg x 2 m
A cover can also be fitted in addition to the slewing drive.

ACC (acceleration) dEC (braking) LSP (working frequency) HSP (working frequency)
Frequency inverter
[s] [s] [Hz] [Hz]
parameters
1-5 1,5 - 15 15 - default 15 - default
Tab. 42

Installing the geared motor, geared limit switch and electric enclosure

WARNING
Exposed gears
Danger to life and limb.
Beware of moving parts in the vicinity of the slewing mechanism during slewing motions, as there is a risk of
injury due to parts of the body being crushed or clothing or hair becoming entangled.

● Insert pinion (1) of geared motor (2) through the relevant bore hole from below and engage the pinion with
toothed wheel (3).
● Secure the geared motor with the four bolts. Ensure that you:
- introduce both long bolts (4) at the rear from above and secure them with locknuts (5).
- introduce both short bolts (6) from below and tighten them in the threaded bore holes of the bracket with a
tightening torque of 32 Nm.
● Install geared limit switch (7) by
- introducing it into the lower pivot pin and
- securing it with three bolts (8).
● Attach the electric enclosure:
- attach the enclosure with frequency inverter (9) with four bolts direct to the motor.
- also attach electric enclosure (10) to the motor with the mounting plate.
● Check the slewing arm and limit switch for correct operation after wiring the electric equipment according to the
circuit diagram.
211 277 44/031218

51
 Adjusting the geared limit switch

Item Contact Function

A Locking bolt
B Adjusting bolt
1 1/2 Right-hand slewing limiter
2 3/4 Left-hand slewing limiter
3 5/6 Right-hand EMERGENCY slewing limiter, crane de-energized
4 7/8 Left-hand EMERGENCY slewing limiter, crane de-energized
Tab. 43

Fig. 32

211 277 44/031218

52
 211 277 44/031218

5.10

5.10.1
1 2 3 4 5 6 7 8
POWERFEED
CRANE

Fig. 33
A A
FOR REQUIRED CABLE SIZE AND MAINS PROTECTION SEE OPERATING INSTRUCTIONS
Circuit diagram

: 063
: 44DIN4
L1
L2
L3
PE

Classification-No. : 141
Code Point
Norm
B -W01 BN BK GY PE CONNECTING LEAD : PROVIDED BY THE CUSTOMER B
1 3 5 STEEL STRUCTURE & CONNECTION TERMINAL
Electric cabling and wiring

-X015 1
PE
-Q014 2
ONLY EXISTING AT
CRANE SWITCH 3 -OM015.1 PILAR-MOUNT.SLEW.CRANE
* 2 4 6 STEEL STRUCTURE &
SLEWING CRANE
C -W02 BN BK GY PE
C
OPTIONAL
TERMINAL BOX -X1 1 2 3 PE
PE

05.09.2018 16:48
-OM015
75x80x57

D D

Observe legal Protection according to ISO 16016

-W03 BN BK GY PE TRAILING CABLE

PE

( AL1 ) L1
( AL2 )L2
( AL3 )L3
CRANE BRIDGE ENCLOSURE
E E

CAD Drawing, no manual Changes

SIA-Date
F Date 22.01.2016 Customer Standard-KBK Designation = 00D01 F
Drawn Tetter POWERFEED SLEWING CRANE Circuit Diagram + H0SG
04 Revision 04 05.09.2018 Tetter Check Order No. Dept. Format Lang. Ident No. SK DT Sheet 01
Issue Mod. Date Name Ch.Date Compiled f. Repl.from Repl.by 63170746 MHR22 3 EN 63170746 N 10 1 Sh.
1 2 3 4 5 6 7 8

53
 Refer also to the hoist unit circuit diagram for cabling and wiring.

5.10.2 Pillar-mounted slewing jib crane

Components:
● DT 16e recessed-type switch (three-phase current 20 A, 660 V,
IP 55),
● cold-resistant PVC flat cable 4 x 1,5,
● cable entry glands,
● connecting elements.
A supply cable with connecting elements from the mains connection
switch to the mains connection must be provided by the customer.
Power is normally supplied via the supply line embedded in the founda‐
tion, which is led through the hole in the floor up to the hole for the
switch when the pillar is erected (tool: wire loop).
Alternatively, the supply line can be led through the entry hole in the up‐
per cover plate.
The pillar can be earthed. Either the nut at the base of the crane or a
Fig. 34 connection on the isolating switch can be used to do this.
Ensure that the contact surfaces for all earth and equipo‐
tential bonding connections have bare metal.

Fig. 35 DT 16e recessed-type switch

Item Designation Item Designation Item Designation Item Designation

4 M4x16 countersunk screws,
1 Padlock opening 2 Cover 3 Knob removed 4
DIN 963
Tab. 44

Further steps:
1. Run the trolley to the tip of the jib.
2. Pull the flat cable into the cable carriers.
The cable carriers should be spaced at a distance of approx. 1 m with at least 30 mm sag on the flat cable.
The flat cable must form a loop between the first cable carrier and the entry gland in the pillar that is large
enough to ensure there is no pull in the cable when the jib is moved through its entire slewing range. It must not
rub against the bracket plate.

3. Screw flat cable entry gland into the threaded bore hole in the pillar.
4. Insert the flat cable and push it through.
5. Pull supply cable and flat cable through the hole of the mains connection switch and strip the end insulation
211 277 44/031218

by approx. 300 mm. (The power supply cable can be pulled in when the pillar is erected.) A wire loop can be
used as a tool.

54
 6. Pull all stripped conductors through the cover of the mains connection switch. Suitable entries must be provi‐
ded for this purpose. Connect both protective earth conductors to the 3-pole connector included in the
delivery. Also connect the additional earth cable with cable lug there.
7. Attach the earth cable with a screw, serrated lock washer and nut to one of the empty bore holes below the
isolating switch opening. The contact surface of the cable lugs must be "bright bare metal".
8. Connect the conductors to the switch. Slide the cover over the terminals on the switch. Ensure that the con‐
ductors are not forced into position when it is fitted.
9. Carefully push the mains connection switch into the opening and secure it with self-tapping screws.
10. Connect the flat cable on the hoist unit according to the relevant operating instructions.
11. On pillar-mounted slewing cranes with two jibs, clearly mark the switches to indicate which jib and hoist each
switch belongs to (arrows or similar).

Jib equipotential bonding

The equipotential bonding cable included in the delivery can be used to connect the pillar and jib. You can use the
self-tapping screws in the bore holes at the top of the pillar and in the jib supporting tube to do this.

5.10.3 Wall-mounted slewing jib

Components:
● DT 16a base-mounted switch (three-phase current 20 A, 660 V,
IP 55),
● cold-resistant PVC flat cable 4 x 1,5,
● cable entry glands,
● connecting elements.
A supply cable with connecting elements from the switch to the mains
connection must be provided by the customer.

Fig. 36

Fig. 37 DT 16a base-mounted switch

Further steps:
1. Run the trolley to the tip of the jib.
2. Pull the flat cable into the cable carriers.
The cable carriers should be spaced at a distance of approx. 1 m with at least 30 mm sag on the flat cable.
The flat cable must form a loop between the first cable carrier and the anchorage that is large enough to ensure
there is no pull on the cable when the jib is moved through its entire slewing range. It must not rub against the
211 277 44/031218

bracket plate.

3. Secure the flat cable in the cable carriers by tightening the grub screws.
4. Slip one flat cable entry gland over the flat cable. 55
 5. Fit the base-mounted switch where it is easily accessible.
6. Lay the power supply and the flat cable to the base-mounted switch, see  Fig. 36, Page 55. Fit the twist-
type cable entry gland in the base-mounted switch and secure it by tightening the counternut.
7. Connect the flat cable on the hoist unit according to the relevant operating instructions.

5.11 Pin retainer on the KBK trolley

Fig. 38 BoClip pin retainer

BoClip pin retainers are used to retain pins.

The BoClip can be fitted by hand without the need for any tools.

5.12 Suspending the hoist

If the Demag pillar or wall-mounted slewing jib crane is operated with a Demag chain hoist, the corresponding
chain hoist assembly and operating instructions (see  Tab. 2, Page 6) must be observed. In particular, the safe‐
ty instructions must be observed and followed.

WARNING
Overload
Danger to life and limb if the components are overloaded.
– Select the correct load capacity for the hoist unit to ensure that the track is not subjected to an overload.

Attach the hoist correctly as follows:

1. The hoist unit must be suspended in such a way that the opening for the electric supply line on the hoist unit
points towards the jib pivot axis.
2. Position the eyebolt between the trolley side plates, insert the pin and secure it.

WARNING
Danger of falling load.
Premature wear of the Demag pillar or wall-mounted slewing jib crane.
The hoist unit, load handling attachment and load must be flexibly suspended. Rigid connections cause uncon‐
trolled forces to be transmitted and lead to fatigue fracture.

DANGER
Incorrect direction of movement
Danger to life and limb if the direction of movement is wrong.
211 277 44/031218

The control devices must be checked for correct and proper operation following work on the main power supply
and before work begins. If the phases are not correctly connected, the switching elements and limit switches
may not function as intended.

56
 The control device (e.g. Demag DST, DSC control pendant) must be marked in such a way that the direction of
movement of the travelling hoist is clear and distinct. The arrow symbol on the switching elements must corre‐
spond to the direction of movement.

5.13 Maker’s plate and load capacity plate

WARNING
Overload
Danger to life and limb.
Higher loads than those specified on the load capacity plate must not be handled.
The load capacity specified on the jib must match the load capacity of the hoist unit.

The load capacity plates must be attached to both sides of the jib.
One maker’s plate must be attached to each crane.
Apply the adhesive load capacity and maker’s plates to the track and press them firmly onto the rail section. Apply
the transparent foil included in the delivery to the maker’s plate to protect the lettering.
Safety and warning information in the form of signs, labels and markings on the track must not be removed or
defaced. They must be maintained in complete and legible condition.
211 277 44/031218

57
 6 Options

6.1 Slewing limiter and jib locking device

6.1.1 General information on slewing limiter and jib locking device
If required, an adjustable slewing limiter can be supplied to limit the slewing range of the jib.
A combination of slewing limiter and jib locking device is possible. Further information on request.

6.1.2 Slewing limiter for pillar-mounted slewing jib cranes, fitted with brace

Fig. 39

Item Designation Item Designation Item Designation

1 M8x35 hexagon bolt (4 off, short) 5 M8 hexagon bolt (2 off, long) 9 Perforated plate
2 Buffer bracket 6 Locknut 10 Nut
Bolted connection between clamp section and perfo‐
3 Buffer 7
rated plate
4 Sliding nut 8 Clamp section
Tab. 45

Pillar size Distance between support bearings LA [mm] Slewing limiter

1 (140) 350 984 710 44
2 (205)/3 (258) 500 668 060 44
4 (296)/5 (372) 750 669 060 44
6 (435)/7 (515) 1000 670 060 44
Tab. 46

This type is suitable for jibs that consist of a hollow profile section as well as for I-beam sections.
– To install the unit, the buffer brackets first have to be unscrewed from the pre-assembled group of compo‐
nents by removing short M8x35 bolts (1). In addition, remove long bolts (5).
– Arrange perforated plate (9) between the jib and the top of the pillar with pre-assembled clamp sections (8).
– First secure clamp sections (8) to the jib with the two long M8 hexagon bolts (5) with a tightening torque of
25 Nm.
211 277 44/031218

– Then secure perforated plate (9) with bolted connection (7) to clamp sections (8) with a tightening torque of
42 Nm.
– Position buffer brackets (2) with buffers (3) on perforated plate (9) according to the required slewing angle
and secure them with a tightening torque of 25 Nm.
58
 6.1.3 Slewing limiter for low-headroom pillar-mounted slewing jib cranes

Fig. 40

Item Designation Item Designation Item Designation

1 M8x35 hexagon bolt 4 M16 threaded pin (2x on rear) 7 Perforated plate
2 Buffer bracket 5 M16 threaded pin (4x on side) 8 Sliding nut
3 Buffer 6 Locknut
Tab. 47

Pillar size Distance between support bearings LA [mm] Slewing limiter

1 (140) 350 ---
2 (205)/3 (258) 500 668 070 44
4 (296)/5 (372) 750 669 070 44
6 (435)/7 (515) 1000 670 070 44
Tab. 48

– To install the unit, first remove M8x35 hexagon bolts (1), locknuts (6) and buffer brackets (2) from the pre-
assembled group of components.
– Unscrew pre-installed M16 threaded pins (5) until perforated plate (7) can be inserted between the jib and
the top of the pillar.
– First fasten perforated plate (7) with the M16 threaded pins (5) using the bore holes on the side of the jib.
Tighten the threaded pins to a tightening torque of 120 Nm.
– Then fix perforated plate (7) to the jib with a tightening torque of 120 Nm using rear threaded pins (4).
– Position buffer brackets (2) with buffers (3) on perforated plate (7) according to the required slewing angle
and secure them with a tightening torque of 25 Nm.
211 277 44/031218

59
 6.1.4 Slewing limiter for low-headroom wall-mounted slewing jibs, fitted with brace

Fig. 41 Wall-mounted slewing jibs, fitted with brace

Fig. 42 Low-headroom wall-mounted slewing jibs

Item Designation Item Designation Item Designation

1a + 1b Locknut 4 M8x35 hexagon bolt 7 M8x30 hexagon bolt
2 Clamping plate 5 Buffer 8 Nut
3 Washer 6 Buffer bracket 9 Perforated plate
211 277 44/031218

Tab. 49

60
 Pillar size Distance between support bearings LA [mm] Slewing limiter
668 080 44 (from 11/2018)
1 (140) 350 715 875 46 (until 10/2018)
2 (205)/3 (258) 500 668 080 44
4 (296)/5 (372) 750 669 080 44
6 (435)/7 (515) 1000 670 080 44
Tab. 50

– To install the unit, first remove M8x35 hexagon bolts (4), locknuts (1a) and rear clamping plate (2) from the
pre-assembled group of components.
– Use clamping plate (2) to pre-install perforated plate (9) on the wall bracket with four M8x35 hexagon
bolts (4) at a height corresponding to the jib. Ensure that rotation of the jib is not obstructed by perforated
plate (9) and that the buffers are arranged so that their contact surfaces are in full contact with the jib if its
movement needs to be limited.
– Then fix perforated plate (9) in position by tightening the four M8x35 hexagon bolts (4) with a tightening tor‐
que of 25 Nm.
– Position buffer brackets (6) with buffers (5) on perforated plate (9) according to the required slewing angle
and secure them with a tightening torque of 25 Nm.

6.1.5 Slewing limiter for two jibs

Fig. 43 Combinations, working areas: jibs opposite each other (1), jibs next to each other (2)

Jib arrangement Pillar type Jibs fitted with a brace Raised jibs
Part no. Weight Part no. Weight
[kg] [kg]
2 (205) 715 661 46 4,15 715 660 46 3,95
Opposite each other
7 (515) 715 655 46 6,97 715 656 46 6,30
2 (205)
Next to each other 715 663 46 4,30 715 662 46 4,15
3 (258)
Tab. 51

The series slewing motion limiter can be used for all other arrangements.
The specified part numbers are for one jib.
211 277 44/031218

61
 6.1.6 Jib retaining mechanism for KBK steel profile sections

Fig. 44

Item Designation Item Designation Item Designation

1 Locknut 5 Ring 9 Locknut
2 Retaining bracket 6 Buffer bracket with buffer 10 Locking device
3 Washer 7 Hexagon bolt 11 Mounting bracket
4 Hexagon bolt 8 Latch 12 Hexagon bolt
Tab. 52

Installing the slewing limiter

● Pillar-mounted slewing jib cranes
- To install the assembly, first remove locknuts (1), rear bracket (2) washers (3) and hexagon bolts (4) from
the pre-assembled group of components.
- Use the clamping plate to pre-install ring (5) on the pillar with 2 hexagon bolts (4) at a height corresponding
to the jib. Ensure that rotation of the jib is not obstructed by ring (5) and that the buffers are arranged so that
their contact surfaces are in full contact with the jib if its movement needs to be limited.
- Then fix ring (5) in position by tightening the 2 hexagon bolts (4) with a tightening torque of 80 Nm.
- Position buffer brackets with buffers (6) on ring (5) according to the required slewing angle and secure them
with a tightening torque of 25 Nm.
● Wall-mounted slewing jib cranes:  "Slewing limiter for low-headroom wall-mounted slewing jibs, fitted with
brace", Page 60.

Installing the latch

● Position latch (8) in the required locking position on ring (5) or the perforated plate and secure it with hexagon
211 277 44/031218

bolts (7) and locknuts (9) with 25 Nm.

62
 Installing the locking device
● Attach locking device (10) to the jib section according to the size of the ring or perforated plate.
● First unscrew hexagon bolts (12) of mounting brackets (11) until they can be placed over the profile section.
● Tighten hexagon bolts (12) of mounting brackets (11) with 10 Nm (KBK 100) or 25 Nm (KBK I and KBK II).

Slewing motion locking devices for KBK steel profile sections

Designation Distance between support bearings [mm]

350 500 750 1000
Pillar-mounted slewing crane locking device, complete Part no. 715 980 46 715 985 46 715 990 46 715 995 46
WSK locking device, complete Part no. 715 900 46 715 876 46 715 877 46 715 878 46
Latch Part no. 668 275 44
Tab. 53

Slewing motion locking devices for aluminium sections on request.

211 277 44/031218

63
 6.2 Hoist trolley locking device on the KBK jib

Fig. 45

Item Designation KBK I profile section KBK II profile section

Weight [kg] Part no. Weight [kg] Part no.
155 Trolley locking device 6,0 715 195 46 6,4 715 210 46
Tab. 54

Installation on the profile section

The locking device for trolleys is pre-assembled and is attached to the profile section by means of bolted brack‐
ets. The tightening torque is 10 Nm.
The C-rail is then positioned and attached to the fitting. The distance of the rope lead-off to the KBK profile sec‐
tion can be adjusted by loosening and moving the C-rail. The free end of the rope must be led out over the rollers
and the handle must be attached at a suitable height.
Installing the pin
The extended trolley pin is a part of the locking device. It replaces the standard single trolley pin. One of the sin‐
gle trolley pins must be replaced on double-trolley units.
The extended pin can be installed in two positions:
● Short side: installed in a single trolley without a "single-trolley link",
● Long side: installed in a single trolley with a "single-trolley link".
Operation
The trolley is held when it travels into the locking device. The trolley is released by pulling the rope. 211 277 44/031218

64
 6.3 Canopy on the KBK jib

Fig. 46

Chain hoists L [mm] B [mm] Weight [kg] Part no.

KBK I DC 1-5, DCS 1-5 600 650 15,5 715 045 46
DC 1-5, DCS 1-5 600 650 17,5 715 048 46
KBK II
DC 10, DCS 10 650 750 21,5 715 049 46
Tab. 55

The canopy is supplied pre-assembled. It can be optionally fitted with a trolley locking device, see  "Hoist trolley
locking device on the KBK jib", Page 64.
To install the canopy, remove the bolted brackets attached inside the roof and fasten them at the required position
on the KBK profile section with a tightening torque of 10 Nm. Then fit the canopy to the bolted brackets.
211 277 44/031218

65
 7 Putting into service for the first time

7.1 Safety instructions when putting into service for the first time
The machine may only be handed over when its safety has been verified by means of a corresponding check
 "Checks on entering service, handover", Page 67.

WARNING
Safe operation of the machine is not yet ensured when it is first put into operation.
Machines may only be put into service if they have been installed/assembled according to the assembly instruc‐
tions.
– Machines may only be put into operation by qualified personnel.
– Check installation/operation of the safety devices before commissioning.
– Check to ensure that the mains voltage and frequency and the air pressure match the details specified on
the rating plate.
– Move the trolleys by hand and check that they can be moved without resistance by hand over the entire
length of the track section.
– Ensure sufficient working clearance before starting assembly work.
– Secure and fence off the working and danger zone.
– Wear protective equipment.
– Adequate illumination must be available for safe operation.
Requirements for illuminating workplaces are laid down in DIN EN 12464.

Only trained specialist personnel may be employed when the installation is first put into operation since:
● it may be necessary to render safety devices or features inoperative when adjustments or function checks are
carried out,
● work may need to be performed in the danger zone when the installation is first put into operation.
If the Demag pillar or wall-mounted slewing jib crane is operated with a Demag chain hoist, the corresponding
chain hoist assembly and operating instructions (see  Tab. 2, Page 6) must be observed. In particular, the
safety instructions must be observed and followed.

7.2 Inspection regulations

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
Compliance with all inspection regulations is an essential aspect of ensuring safe operation of the machine.
Required tests and inspections must be carried out.
All inspections must be arranged and documented by the owner at the specified intervals/points of time. The re‐
sults of the tests must be entered in the test and inspection booklet  Tab. 2, Page 6.
– Inspection according to national regulations, e.g. according to the rules and regulations of the German So‐
cial Accident Insurance (DGUV).
The owner is responsible for ensuring that power-driven cranes are inspected by an expert engineer before
they are first put into service and before they are put into service again after major modifications have been
carried out. This also applies to manually operated or semi-powered cranes that have a load capacity of
more than 1000 kg.
– Adjustment, maintenance and inspection activities and inspection deadlines including specifications con‐
cerning the replacement of parts/assemblies prescribed in the operating instructions must be observed.
This work may only be carried out by specialist personnel.
211 277 44/031218

66
 7.3 Inspections before putting into service for the first time
The owner is obliged to carry out the following checks before the unit is put into operation for the first time:
● Check continuity of the PE conductor connection;
● Check emergency-stop device;
● Check the direction of movement of the hoist unit;
● Check that pin connections are properly secured;
● Check travel wheels for smooth running;
● Check that trolleys can be moved without resistance by hand over the entire length of the track section;
● Trolleys must not move out of a position of rest on their own accord either when loaded or unloaded;
● Jibs must not swing from a position of rest on their own accord;
● Check operation of the hoist unit brake;
● Check operation of the limit switch for electric limit switch cut-off;
● Check electric switchgear and wiring.

7.4 Checks on entering service, handover

WARNING
Unauthorised operation
Danger to life and limb if the machine is operated without previous inspection.
Machines may only be put into service if they have been checked for compliance with the corresponding acci‐
dent prevention regulations.

By means of suitable measures carried out by the owner or on his behalf, the owner must ensure that the load
handling attachments and machinery ready for operation function in complete safety before they are first put into
service. The specified measures must allow for the static and dynamic features of the machinery.
The following checks must be carried out when the installation enters service:
● The supporting structure must be in good condition and the load capacity of the hoist unit must be checked.
● Safety devices must be complete and effective.
● Clearances and safety distances must be maintained.
● The emergency-stop device must be checked by actuating the emergency stop.
When the unit is first put into operation, it must be checked to ensure that it is used as intended in all possible
applications, in each case with the maximum permissible load. Operation of the safety devices must be checked
(e.g. by lifting an overload). At the same time, the behaviour of the hoist unit must be checked when it is not used
correctly.
Various checks of the machine must be carried out before it is handed over:
● Check to ensure it is suitable for operation
● Acceptance inspection
The test and inspection records can be compiled as soon as safe operation of the Demag pillar or wall-mounted
slewing jib crane is ensured.
The test and inspection records (test and inspection booklet; observe relevant national regulations) must be hand‐
ed over when the machine is handed over.
The machine may be used as intended after it has been handed over.
211 277 44/031218

67
 8 Operation

8.1 Safety instructions for operation

WARNING
Incorrect operation
Risk of injury due to incorrect operation.
Incorrect operation can result in severe injury or damage to property. The equipment may only be operated by
authorised and instructed personnel in compliance with all accident-prevention and safety regulations. National
regulations for the use of cranes and lifting appliances must be observed and followed.
– The owner must arrange for operating personnel to be trained.

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 a suspended load.
– Loads must not be lifted above persons.
– Wear protective equipment.

If the Demag pillar or wall-mounted slewing jib crane is operated with a Demag chain hoist, the corresponding
chain hoist assembly and operating instructions (see  Tab. 2, Page 6) must be observed. In particular, the
safety instructions must be observed and followed.

WARNING
Non-compliance with operating regulations/industrial safety regulations
Danger to life and limb if relevant regulations are disregarded.
Machinery may only be operated in compliance with relevant national operating regulations, e.g. the rules and
regulations of the German Social Accident Insurance (DGUV).
– Attach a copy of the relevant operating regulations, part no. 214 748 44, at a suitable place where opera‐
tors can read them at any time (e.g. at the mains connection switch).

The machine must not be put into operation or must be taken out of service immediately if any defects or irregu‐
larities relating to safe operation or function are detected.
Safety devices must not be rendered inoperative or modified contrary to their intended use.
Ensuring safe operation
Special local conditions or special applications may lead to situations which were not known when this chapter
was written. In this case, the owner must ensure safe operation or take the machine out of service until measures
for safe operation have been clarified and implemented in agreement with the manufacturer or other relevant bod‐
ies.
In the event of a stoppage (e.g. if defects regarding safe and reliable operation are detected, in emergency situa‐
tions, in the event of operating malfunctions, for repairs and maintenance works, if damage is detected or after
finishing work), the operator must carry out all prescribed safety measures or observe that they are automatically
carried out.
Avoid naked flames, extreme heat (e.g. welding) and sparks when using cleaning agents and in the vicinity of
flammable parts or parts liable to deformation (e.g. wood, plastic parts, oil, grease in electric equipment); non-
compliance may result in a fire hazard, harmful gases may evolve or insulation may be damaged.
Cooling devices, such as ventilation openings, may not be rendered permanently inoperative (e.g. covered or
closed).
211 277 44/031218

68
 8.2 Switching on

8.2.1 Checks when starting work

Before starting work, the operator must be satisfied that the machine is in safe and correct operating condition.
Ensure that nobody is endangered by operation of the hoist unit before the machine is switched on or put into
operation. If the operator notices persons who may be exposed to a risk to their health or personal safety by oper‐
ation of the installation, he must stop operation immediately and may not resume operation until the persons are
outside the danger zone.
If there are any defects which endanger safe and reliable operation, the Demag pillar or wall-mounted slewing jib
crane must be taken out of service without delay. Defects relevant to safety in this sense are, for example:
● Damage to electric devices, cables or insulation,
● Delayed operation or failure of brakes and safety devices,
● Missing covers or housing parts or
● Damage to the chain or to supporting parts.
Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay.
This also applies if damage occurs to parts of machinery or equipment which makes an immediate stoppage nec‐
essary.
If the Demag pillar or wall-mounted slewing jib crane has been stopped by an emergency stop due to safety-rele‐
vant defects, it must be secured against being returned to operation until an experienced technician is satisfied
that the cause of the hazard situation has been eliminated and that operation of the machine is possible without
any hazard.
Before starting work:
● Wear protective equipment.
● Ensure that nobody is present in the danger zone of the equipment.

8.2.2 Function checks

Note for operators where the rules and regulations of the German Social Accident Insurance (DGUV) apply in the
Federal Republic of Germany:
In accordance with the DGUV, the crane operator must also check operation of the emergency limit stop device
when he or she starts work. This does not apply to slipping clutches used as an emergency limit stop device
which do not need to be checked when starting work.
The following main functions of the machine must be checked before work begins:

Component Function check

Control devices Unlatch the emergency-stop button on the control panel to enable the crane switch.
Limit switches Check the limit switch functions by carefully approaching the switching positions. This applies to the lifting limit switches
(see corresponding operating instructions).
Brakes Check the run-on paths of hoist unit brakes. The brakes must be adjusted if the brake paths noticeably increase.
See the corresponding operating instructions for brake adjustment.
Safety equipment Check emergency limit stop devices and emergency-stop devices.
Safety devices do not relieve the crane operator of his obligation to work with due care. Only correct functioning of the
safety devices can guarantee the necessary level of safety in the event of a crane operator error.
Control pendant Care must be taken to treat the control unit appropriately.
The crane operator selects the lifting and travel motions using the control pendant.
Tab. 56

DANGER
Malfunction following assembly work
Danger to life and limb if assembly work has not been carried out appropriately.
The control devices must be checked for correct and proper operation following work on the main power supply
and before work begins. If the phases are not correctly connected, the switching elements and limit switches
may not function as intended.
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69
 8.3 Operation

8.3.1 Safety during operation

WARNING
Overload
Danger to life and limb.
Higher loads than those specified on the load capacity plate must not be handled.
– Do not exceed the maximum permissible load capacity of the hoist.
– Only use load handling attachments which are adequately dimensioned.
– Only use load handling attachments for their intended purpose.

Important information for operation

Observe the following during operation:
– Take the machine out of service immediately if functional defects or irregularities are detected.
– The operator is obliged to check the machine for any visible damage at least once per shift and to report any
damage immediately.
– Do not render safety devices inoperative.
– Limit stops must not be approached in normal operation, e.g. emergency stop devices (emergency limit
switches), emergency limit stop devices (slipping clutch or emergency limit switch), track and limit buffers to
stop movement of the trolley, hook assemblies or bottom block against limit stops.
– Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing, parts of the
body or hair becoming entangled.
– Adequate illumination must be available for safe operation.
Requirements for illuminating workplaces are laid down in DIN EN 12464.

8.3.2 Load pick-up

– The load handling attachment and load must be flexibly suspended. Rigid connections cause uncontrolled
forces to be transmitted and lead to fatigue fracture.
– When attaching the load, ensure that the load or load attachment does not slip off the hook and that the load
does not fall over, fall apart, slip or roll off when it is picked up or set down.
– When the load is lifted, the hook must move to an upright position to ensure that the hook safety catch is not
subjected to a load by the load handling slings and, as a result, damaged.
– Do not use the equipment to transport persons.
– The load capacity specified on the load capacity plate indicates the maximum permissible load, which must
not be exceeded. This is the sum of the load capacity and load handling attachment. Only approved load
handling attachments may be used. The load capacity of the load handling attachment must not be excee‐
ded.

8.3.3 Moving the load

– For lifting and travel motions, adopt a position that provides a clear view of the danger zone or use a second
person who can observe the danger zone.
– Hoists/trolleys with push travel may only be moved by pulling or pushing on the load, bottom block or load
hook assembly. Never pull on the control pendant.
– Push-travel loads must be guided by hand. The load must never be thrown or hurled.
211 277 44/031218

– Do not handle suspended loads above persons.

– Do not pull or drag suspended loads at an angle.
– Do not pull free fixed or obstructed loads with the hoist.
70
 – Do not leave suspended loads unsupervised.
– Vibration from the load being transported (e.g. when the load is deposited on vibrating machinery) must not
be transmitted to the lifting equipment.
– Do not allow loads to drop when using magnet or vacuum lifting devices.
– Hoist units must be suspended in such a way that they do not collide with stationary equipment and struc‐
tures, e.g. when slewing cranes are turned.
– Do not pick the load up at full speed.
– Avoid inching (e.g. giving short pulses to the motor).

8.4 Possible adjustments

The pressure needed to move the jibs of slewing cranes that are moved
by hand and which have pivot bearings can be influenced by means of
three adjusting bolts (7). These bolts are located on upper pivot bearing
(3).

See also  "KBK I, II, I-beam section, aluminium profile section jib",
Page 48.

Fig. 47

8.5 Emergency stop

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.

If the Demag pillar or wall-mounted slewing jib crane is operated with a

Demag chain hoist, the chain hoist features an emergency-stop device
with which the lifting motion can be stopped in the event of a hazard.
The emergency-stop button is arranged in a clearly visible position on
the control pendant. Anybody who identifies an immediate danger of
personal injury must actuate the emergency stop without delay. This al‐
Fig. 48 Position of emergency stop (1)
so applies in the case of malfunctions and damage that occurs to parts
of the machine and equipment which makes it necessary to stop and
secure the machine immediately.
● To actuate the emergency stop, press the button until it reaches the end stop. It then locks automatically and
the hoist unit is shut down.
● To unlock the actuated emergency stop, turn the pushbutton in the direction of the arrows (clockwise) and re‐
lease it.
211 277 44/031218

Following an emergency stop, do not switch the machine on again until trained specialist personnel is satisfied
that:
● the cause which led to actuation of this function has been rectified and
● continued operation of the machine constitutes no further hazard.
71
 8.6 Taking the equipment out of operation

8.6.1 Taking the equipment out of service when faults occur

The machine must be switched off immediately if the following faults occur:
● If electric devices and cables as well as parts of the insulation are damaged.
● Brake and safety device failure.

8.6.2 Taking the equipment out of service at the end of the shift
The following measures must be carried out on finishing work:
● When work is finished, position load handling attachments, hook with fittings or bottom block outside the travel
area.
● Move the hoist unit into its resting position.
● Switch the hoist unit power supply off at the mains connection or isolating switch and turn off the compressed
air supply.

8.6.3 Taking the equipment out of service for maintenance and repairs
1. Switch off the mains connection or isolating switch and turn off the compressed air supply before starting any
maintenance and repair work.
2. Secure the mains connection switch with a padlock to prevent unauthorised or accidental re-connection to
the supply.
3. Only carry out maintenance work on the hoist unit when the load has been removed.
4. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.
5. Observe the relevant accident prevention regulations, instructions concerning intended use and statutory
regulations for operation and maintenance.
6. Observe relevant safety regulations (e.g. VDE regulations) when repairing electric equipment.

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72
 9 Maintenance work

9.1 Safety instructions for maintenance and repair work

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

DANGER
Live components
Danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐
nel", Page 8) in compliance with the safety regulations.
Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐
tected against unauthorised or accidental restoration of the power supply by means of a padlock.

WARNING
Inappropriate maintenance work
Danger to life and limb. Risk of material damage.
Maintenance and repair work may only be carried out by authorised, trained specialist personnel ( "Definition
of personnel", Page 8) in compliance with all safety regulations.
– Secure and fence off the working and danger zone.
– If an elevating work platform is used for maintenance work, only use appropriate attachments for the lifting
of persons which ensure that work is carried out in a safe and stable position.
– Only suitable, tested and calibrated tools and accessories may be used for maintenance work.
– Only use approved spare parts, see also  "Use of spare parts", Page 8.
– Wear protective equipment.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any unneeded machine parts or fittings and tools 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 may fall and cause severe injuries.
– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐
ments must be fulfilled. The electrode holder and earth must be connected to the same assembly when
welding work is carried out. Otherwise serious damage may be caused to the hoist. Trolleys must not be
welded or drilled.
– Customer-specific regulations must be observed.

CAUTION
Loose connections
Loose connections are a danger to life and limb and a risk of damage to the machine.
Metal nuts featuring a locking element (self-locking nuts) must not be replaced by normal nuts.

CAUTION
Risk of injury.
Oils and lubricants may pose a health hazard.
Contact with these media may result in serious damage to health (poisoning, allergies, skin irritations, etc.).
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73
 CAUTION
Risk of injury.
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.

9.2 Basic maintenance requirements

General information on maintenance/repairs

The specified inspection and maintenance intervals ( "Maintenance schedule", Page 77) apply to normal oper‐
ating conditions. All wearing parts must be checked in the course of the annual inspection.
If routine maintenance reveals that the maintenance intervals are too long, they must be adapted to the specific
operating conditions.
This check must be repeated at least once a year, or more frequently under extreme operating conditions.
Demag pillar and wall-mounted slewing jibs
Demag pillar and wall-mounted slewing jib cranes require little maintenance. However, approx. 1 – 2 months after
commissioning of an installation, all bolted connections and pin connections should be checked and retightened
or secured as necessary.
If the Demag pillar or wall-mounted slewing jib crane is operated with a Demag chain hoist, the corresponding
chain hoist assembly and operating instructions (see  Tab. 2, Page 6) must be observed. In particular, the
safety instructions must be observed and followed.

Electric components
Only fuse links with the specified amperage and tripping characteristics may be used in the electric circuits. De‐
fective fuse links must not be bridged.
Pay attention to the following when working on machinery or machine equipment:
1. Wear personal protection equipment.
2. Before starting any maintenance work, switch off the mains connection switch and protect it against unau‐
thorised or accidental re-connection to the power supply by locking it with a padlock.
3. Ensure that the hoist unit is switched off and check that it is de-energised.
4. Only carry out maintenance work on the hoist unit when the load has been removed.
5. Ensure that there is sufficient freedom of movement. Keep the working area clean and tidy. Loose parts or
tools left lying around may cause accidents.
6. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.
7. Observe the relevant accident prevention regulations, instructions concerning appropriate use and statutory
regulations for operation and maintenance.
8. Observe the relevant safety regulations when repairing electric equipment.
9. Reinstall safety devices as required by relevant regulations and check them for correct operation after finish‐
ing maintenance work.
Maintenance work which is not possible from the ground may only be carried out from work stands or platforms.
The danger zone below the hoist unit must be fenced off if there is a risk of falling objects.
Instructions for maintenance work in the course of operation
If maintenance work has to be carried out on the hoist unit in the course of operation, special safety precautions
must be taken depending on the operating situation. In each individual case, the owner or the person assigned by
him must check whether the maintenance work may be carried out in the course of operation without risk of per‐
211 277 44/031218

sonal injury and, taking into account the local conditions, must implement all necessary safety precautions.
Defective bolted connections must be replaced.
Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly
manner.
74
 9.3 Regular inspections

9.3.1 Required tests and inspections

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
Required tests and inspections must be carried out.
– An annual inspection, e.g. as specified in the rules and regulations of the German Social Accident Insur‐
ance (DGUV), must be carried out.
– Adjustment, maintenance and inspection activities and inspection deadlines including specifications con‐
cerning the replacement of parts/assemblies prescribed in the operating instructions must be observed.
This work may only be carried out by specialist personnel.

Cranes and equipment must be inspected by a trained maintenance fitter at least once a year. Regular inspec‐
tions mainly consist of visual inspections and function checks which should include a check to determine the con‐
dition of components and equipment regarding damage, wear, corrosion and any other safety devices.
Regular inspections must be carried out in accordance with national regulations. The results of inspections must
be entered in a test and inspection booklet.
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.
Defective parts and components and parts close to failure must be replaced.

Please also note  "S.W.P. measures for achieving safe working periods", Page 76 and  "Maintenance
schedule", Page 77.
All inspections must be arranged and documented by the owner.
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75
 9.3.2 S.W.P. measures for achieving safe working periods
The health and safety provisions of the EC Machinery Directive make it a legal requirement to eliminate special
hazards which may be caused by, for example, fatigue and ageing.
Cranes are designed for a limited service life, as is all other machinery. Ageing in this sense refers to the crane
structure and not to wearing parts.
This is influenced by
● fatigue,
● corrosion,
● accidents during operation and installation,
● overloads,
● insufficient maintenance.

Therefore, pay particular attention to the instructions and information in  "Maintenance schedule", Page 77 and
 "Required tests and inspections", Page 75, Regular inspections.
Slewing jib cranes are classified in lifting class H1 and loading group B3 to DIN 15 018. Various operating cycle
ranges result for the loading groups depending on the stress spectrum (S0 – S3, see  Tab. 57, Page 76).
The following table with an explanation of the S0 – S3 stress spectra can help you to assess the service life and
classification of the slewing crane in practical terms:
A stress cycle for the crane structure corresponds to a crane operating cycle.
Information on the hoist service life can be found in the corresponding operating instructions.

Stress spectra

Fig. 49

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

Max. stress cycles per day (to DIN 15 018, table 14) crane operating period: 10 years; 250 working days per year
Stress spectrum Loading group
B1 B2 B3
S0 very light 80 240 800
S1 light - 80 240
S2 medium - - 80
S3 heavy - - -
S0 4 12 24
An average cycle time of 3 mins. = 20 cycles/h (hook-up, lift, cross travel, long travel, S1 - 4 12
lower, deposit and back) results in an operating period in hours per day of: S2 - - 4
S3 - - -
Tab. 57
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76
 9.4 Maintenance schedule
Maintenance work Section Periodically After 50 - During the Every 4
200 annual in‐ years
operating spection
hours
Check operation of the brake
Before starting
Check operation of the limit switch for electric limit switch cut- work
off
Check electric switchgear and wiring monthly
 "Erecting the pillar", Page 42,
Anchor bolt connections  "Securing the bracket", X X
Page 44
 "KBK 100 jib", Page 46,
 "KBK I, II, I-beam section, alu‐
End cap with buffer bolted connections X X
minium profile section jib",
Page 48
Jib bearing bolted connections:
 "KBK 100 jib", Page 46 X X
Supporting pin keep plate
Jib bearing bolted connections:
X X
Bolts retaining the pivot pins
Bolted connection on the jib:  "KBK I, II, I-beam section, alu‐
Profile section connections on the supporting tube and on the minium profile section jib", X X
strut Page 48
Strut pin connection
X
Max. 1 mm wear
Wear of jib section running surfaces and edge of gap
Rail gap width for KBK 100/I: max. 20 mm, KBK II: max. 26 mm
X
Wear groove in KBK II section gap,
min. residual material thickness 2,7 mm
Check weld seams: bottom of crane, top of crane, jib connec‐
X
tion
Dirt accumulation X
End cap  "KBK 100 jib", Page 46, X
 "KBK I, II, I-beam section, alu‐
Internal buffer stop minium profile section jib", X
Page 48
Trolley: (max. 1 mm wear on load pin, max. 0,5 mm wear on
X
side cheeks)
Trolley travel wheels for wear and smooth running X
Slewing drive (if fitted): check bolted connection X
Slewing drive (if fitted): check for wear X
 "Electric slewing mechanism",
Slewing drive (if fitted): lubricate gear wheels Page 50 X
Slewing drive (if fitted): change gear oil, e.g. Mo‐
X
bil SHC Gear 320
 "Canopy on the KBK jib",
Check canopy (if fitted) for tight fit X
Page 65
Electric cabling and wiring: cable carriers for wear, plug con‐
X
nectors, switches and cables for damage
Wear on jib sliding bearing points  "KBK 100 jib", Page 46, X
Wear of supporting pins  "KBK I, II, I-beam section, alu‐ X
minium profile section jib",
Wear on pivot pins Page 48 X
Check securing elements (clips, bolts, etc.) for tight fit and cor‐
X
rosion
Check and apply or supplement corrosion protection, as re‐
X
quired
Check the hoist unit according to the relevant operating instruc‐
X
tions
Tab. 58
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77
 9.5 Maintenance work

9.5.1 Lubrication of pivot pins

The bearings of electric slewing jibs that have a bearing distance of

1000 mm are provided lubricating nipples. They must be initially lubrica‐
ted and then regularly lubricated every 3 months.

Fig. 50

211 277 44/031218

78
 10 Malfunctions/warnings

10.1 Safety instructions for malfunctions/warnings

WARNING
Incorrect fault elimination
Danger to life and limb. Risk of damage to the machine.
Faults may only be eliminated by authorised, trained specialist personnel ( "Definition of personnel", Page 8)
in compliance with the safety regulations.

DANGER
Live components
Danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐
nel", Page 8) in compliance with the safety regulations.
Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐
tected against unauthorised or accidental restoration of the power supply by means of a padlock.

If the Demag pillar or wall-mounted slewing jib crane is operated with a Demag chain hoist, the corresponding
chain hoist assembly and operating instructions (see  Tab. 2, Page 6) must be observed. In particular, the
safety instructions must be observed and followed.

Conduct when malfunctions occur

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 personal injury, damage and/or an operating hazard.
2. Switch the hoist unit power supply off at the mains connection or isolating switch and secure it against recon‐
nection.
3. Inform the person responsible at the location about the malfunction.
4. Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per‐
sonnel.

Conduct after a malfunction is eliminated

WARNING
Check for correct assembly
Before reconnecting the power supply, ensure that
– the malfunction and the cause of the malfunction have been eliminated.
– all safety devices have been fitted properly and are in perfect working order.
– nobody is present in the danger zone of the equipment.
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79
 11 Disassembly/disposal

11.1 General

WARNING
Before disassembly, follow the safety instructions in these operating instructions.

Remove parts in the opposite order to assembly.

Unless a return or disposal agreement has been concluded, separated components must be recycled 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. Further information
can be obtained from corresponding local authorities.

211 277 44/031218

80
 Index

A Pillar shaft 17
Anchor bolt 41, 43
S
Anchor rods 40
Shear forces 39
B Shear stress 43
Square sleeve 45
Base plate 16, 17, 21, 40
Stress cycle 76
Bearing 17, 21, 23
Stress spectrum 76
Bore hole template 17
Support superstructure 39, 43
C
T
Control device 37, 56, 69
Template 40
Cover plate 16, 21, 54
Tensile forces 39
Cycle time 76
Tensile stress 43
D
U
Dead load 76
Utilisation of the working area 17
Double trolley 47, 49, 64
Dowel pin 43
Duration of service 76
Dynamic and pulsating 39, 41

E
Eyebolt 56

F
Foundation level 40
Full load 76

I
Incorrect phase 56, 69
Installation gap 40
Installation report 41
Intermediate plate 41, 16

K
Keep plate 43

L
Line frequency 66
Line voltage 66
Loading group 16, 76
Lubrication 47

O
Operating time 76
Oscillation coefficient 39

P
211 277 44/031218

Partial load 76
Pictogram 10
Pillar base 16
81
 Original Ident. number / Language
EC conformity declaration for a machine 19978644 / 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 slewing jib crane

Serial no. nnnnnnnn
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
Applied harmonised standards and/or C standard drafts, in particular:

EN ISO 12100 Safety of machinery -

pl General principles for design
Risk assessment and reduction
EN 14492-2 Cranes - Power driven winches and hoists -
Part 2: Power driven hoists
EN 60204-32 Safety of machinery - Electrical
am

equipment of machines - Part 32:

Requirements for hoisting machines

Other applied technical regulations and specifications:

DIN 15018:1984-11 Cranes, steel structures

The relevant technical documentation according to Annex VII Part A 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, 06.03.2019

ppa. Thomas Wiesmann i.V. Franz Schulte

Head of Plant Wetter Knowledge Centers &
Core of Lifting

Industrial Equipment
U02241

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
EC conformity declaration for a machine 19978644 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
1217 2/ 2

Demag slewing jib crane

Serial no. nnnnnnnn

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

For assembly / first putting into service including function check

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

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

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

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

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

e
------------------------------------------------------------------------------------------------------------

For the load test in the scope of the acceptance test

pl
...................................., date ................................................

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

am

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

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

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

Industrial Equipment
U02241

Subject to change. No liability for errors or omissions

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.