Operating instructions

Demag D-SH SpeedHoist

42578744.eps

220903 EN/PDF 214 756 44 720 IS 852

 Manufacturer Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone (+2335) 92-0 · Telefax (+2335) 927676
www.demagcranes.com

Please fill in the following table before first putting the SpeedHoist into service.
This provides you with a definitive documentation of your SpeedHoist and important
information if you ever have to contact the manufacturer or his representative.

Owner

Where in use

Size

Serial number

Ident. no.

21475644K1.p65/220903

2
 0 Foreword 5
Contents
0.1 Copyright 5
0.2 After-sales service 5
0.3 Liability for Defects 6
0.4 Limitations of liability 6
0.5 Definitions 7
1 Safety instructions 8
1.1 Symbol description 8
1.2 Intended use 8
1.3 Inappropriate use 9
1.4 General safety information 9
1.5 Selection and qualification of operating and maintenance personnel 10
1.6 Safety instructions for installation and disassembly 10
1.7 Safety instructions when first putting the unit into service
after completing installation 11
1.8 Safety instructions for operation 11
1.9 Safety instructions for using power 12
1.10 Safety instructions for maintenance 12
2 Technical data of the SpeedHoist 14
2.1 Design overview 14
2.2 Explanation of size designation 14
2.3 Dimensions 15
2.4 Selection table 16
2.5 Hoist motor data 16
3 Technical data of the electronic control system 17
3.1 Control board 17
3.2 D Grip connection assignment 19
4 General 20
4.1 Inspection regulations 20
4.2 Noise emission measurement according to DIN 45635 20
4.3 Site of application 20
4.4 Packing and storage 20
4.5 Paint finish 21
4.6 Operating conditions 21
5 Description of the SpeedHoist 22
5.1 Design 22
5.2 Drive 22
5.3 Gearbox 22
5.4 Rope reeving elements 22
5.5 Limit switch 22
5.6 Frame 23
5.7 Electrical equipment 23
5.8 Trolley 24
6 D Grip description 26
6.1 Operating instructions regarding the D Grip for the Speedhoist 26
7 Putting into operation 28
7.1 Electrical equipment 28
7.2 Line connection 28
7.3 Connection of emergency stop device 29
7.4 Emergency limit switch 29
7.5 Setting the emergency limit switch actuator 29
7.6 Inspection before putting the unit into operation 30
7.7 Safety instructions 30
7.8 Putting the unit into operation 30
7.9 Starting operation 30
21475644K1.p65/220903

7.10 Putting the D Grip into operation 31

7.11 Assignment of buttons 32

3
 8 Taking the unit out of service at the end of the shift/maintenance 34
8.1 Emergency stop 34
8.2 Taking the unit out of service at the end of the shift 34
8.3 Taking the unit out of service for maintenance purposes 34
9 Inspections/maintenance/general overhaul GO 35
9.1 Inspection before starting work and during operation 35
9.2 Inspection and maintenance schedule 35
9.3 General overhaul GO 35
9.4 Wire rope 37
9.5 Fitting the wire rope 37
9.6 KDP 63 hoist motor brake 42
9.7 Gearbox 45
9.8 Adjusting the slipping clutch 45
10 Measures for achieving safe working periods S.W.P. 46
10.1 Calculating the actual duration of service S 47
10.2 Example: D-SH-80 in 1 Am 48
11 Circuit diagram 49
11.1 SpeedHoist circuit diagram 49
12 Free configuration of the digital outputs 50
12.1 Description 50
13 Adjusting the dynamics 51
14 Setting the parameters 52
14.1 Software terminal brief instructions 52
14.2 Operating terminal 54
14.3 Operation 56
14.4 Menu structure and parameters 57
15 Documentation of parameters 60
16 Fault finding and elimination 61
16.1 Fault finding, general 61
16.2 Error code table 61
16.3 Further fault information 64
17 Accessories 64
EC conformity declaration 65
18 Component parts 66
18.1 Gearbox with KDP 63 B2 motor 66
18.2 Rope drum/frame 68
18.3 KBK I, KBK II and Aluline classic 120 and 180 trolleys with load bar 70
18.4 KBK I, KBK II and Aluline classic 120 and 180 trolleys 71
18.5 CF 5 trolleys with load bar, flange width 50 – 91 mm 72
18.6 CF 5 trolleys, flange width 50 – 91 mm 73
18.7 RU trolleys with load bar, flange width 50 – 90 mm 74
18.8 RU trolleys, flange width 50 – 90 mm 75
18.9 Electrical components 76
18.10 D Grip and accessories 77
21475644K1.p65/220903

4
 0 Foreword

You have purchased a Demag product.

This SpeedHoist was manufactured in accordance with German and European
standards and regulations, e.g. EC Machinery Directive 98/37/EC, and state-of-the-
art engineering principles.
The SpeedHoist is of modular design.
The main assemblies include:
• Gearbox
• Hoist motor
• Integrated electrics
• Rope reeving elements
• D Grip
These operating instructions are designed to provide the operator with appropriate
instructions for safe and correct operation and to facilitate maintenance.
Every individual given the task of transporting, installing, commissioning, operating,
maintaining and repairing the SpeedHoist and its additional equipment must have
read and understood
• the operating instructions
• the safety regulations and
• the safety instructions in the individual chapters and sections.
The operating instructions must be available to the operating personnel at all times in
order to prevent operating errors and to ensure smooth and trouble-free operation of
our products.

0.1 Copyright These operating instructions must be treated confidentially. They should only be used
by authorized personnel. They may only be entrusted or made available to third
parties with the prior written consent of Demag.
All documents are protected within the sense of copyright law.
No part of this documentation may be reproduced, utilized or transmitted without
specific prior consent. Infringements are an offence resulting in obligatory compensa-
tory damages.
All industrial rights reserved.

0.2 After-sales service Our after-sales service will provide you with all technical information on Demag
products and their systematic application.
Should you have any questions regarding our products, please refer to one of our
after-sales service stations, the relevant representative or the manufacturer.
Kindly quote the serial or order number (see test and inspection booklet, load
capacity plate on the crane) in any correspondence or for spare part orders.
Specifying this data ensures that you receive the correct information or the required
spare parts.
21475644K1.p65/220903

5
 0.3 Liability for defects
0.4 Limitations of liability
6
These operating instructions must be read carefully before installing and putting the
SpeedHoist into operation.
We assume no liability for damage and malfunctions resulting from failure to comply
with the operating instructions.
Any liability claims for defects must be made by quoting the order number immedi-
ately on detecting the defect.
Any liability claims for defects are void in the event of:
• inappropriate use,
• faulty devices or equipment connected or attached to the system which are not
part of our scope of supplies and services,
• use of non-genuine spare parts and accessories,
• refurbishment or modification of the product unless approved in writing by Demag.
Wearing parts are not subject to liability for defects.
All technical information, data and instructions for operation contained in these oper-
ating instructions were up-to-date on going to print and are compiled on the basis of
our experience and to the best of our knowledge.
We reserve the right to incorporate technical modifications within the scope of further
development of the hoist units which are the subject of these operating instructions.
The information, illustrations and descriptions contained in these operating instruc-
tions are therefore only intended for information purposes.
The descriptions and illustrations contained in this documentation do not necessarily
correspond to the scope of delivery or any subsequent spare part delivery, either; the
drawings and illustrations are not to scale.
Only documentation belonging to the actual order is valid.
We assume no liability for damage and malfunctions caused as a result of operating
errors, non-compliance with these operating instructions or inappropriate repairs and
maintenance.
We expressly point out that only genuine Demag spare parts and accessories ap-
proved by us may be used. Accordingly, this also applies to other manufacturers’
parts used.
For safety reasons, the fitting and use of spare parts or accessories which have not
been approved and unauthorized modification and conversion of the product are not
permitted and exempt Demag from any liability for defects or damages resulting
therefrom.
With the exclusion of any further claims, our liability for defects and liability obligations
for any defects pertaining to the products supplied or faults in the documentation
delivered or any negligence on our part are exclusively based on the stipulations of
the original contract. Any further claims, in particular any and all claims for damages,
are excluded with the exception of legal claims in accordance with product liability
legislation.
21475644K1.p65/220903
 0.5 Definitions Owner
Owners (employer, company) are defined as persons who own the SpeedHoist and
who use them appropriately or allow them to be operated by suitable persons.

Operating personnel/operator
Operating personnel or operators are defined as persons entrusted by the owner of
the SpeedHoist with operation and/or transportation of the equipment.

Specialist personnel
Specialist personnel are defined as persons assigned by the owner of the
SpeedHoist to carry out special tasks such as installation, setting-up, maintenance
and fault elimination.

Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training,
knowledge and experience of electrical installations as well as knowledge of the rele-
vant standards, codes of practice and regulations, are able to assess the tasks given
to them and to identify and eliminate potential hazards.

Trained person
Trained persons are defined as persons who have been instructed and trained for the
tasks assigned to them and on the possible hazards resulting from incorrect handling
and who have been informed about the required protective devices, protective
measures, relevant regulations, codes of practice, accident prevention regulations
and operating conditions and who have proven their qualifications.

Experienced technician
Experienced technicians are defined as persons, who, owing to their technical
training and experience, have sufficient knowledge of the SpeedHoist and are familiar
with the relevant national industrial safety regulations, codes of practice, accident
prevention regulations, directives and generally accepted engineering standards
enabling them to judge the safe operating condition of the SpeedHoist.

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

BGV D8, § 23, for determining the S.W.P.)
An assigned expert engineer is defined as an experienced technician specifically
assigned by the manufacturer to determine the remaining duration of service
(service life) of the SpeedHoist (S.W.P. = safe working period) and to carry out a
general overhaul of the SpeedHoist.

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

BGV D6, § 28)
In addition to the expert engineers of the Technical Supervisory and Inspection
Board, an authorized expert engineer for the inspection of the SpeedHoist is defined
as an expert engineer authorized by the Industrial Employers’ Mutual Insurance
Association.

SpeedHoist
SpeedHoist units are systems used for lifting, lowering and moving loads. They can
also be used in cranes, crabs and travelling hoist units and rail systems.
21475644K1.p65/220903

7
 1 Safety instructions

1.1 Symbol description The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.

Hazard warning
This symbol appears in the operating instructions next to all instructions relating to
safety at work wherever a potential danger to life and limb exists.
Follow these instructions at all times and be particularly vigilant and cautious.
Pass on safety instructions to all persons entrusted with working on the SpeedHoist
including the track and power supply.
In addition to the safety instructions, observe all general safety regulations and
accident prevention regulations at all times.

Warning against dangerous electrical voltage

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

Warning against suspended load

Any person remaining in this danger zone may suffer serious injury or death. This
applies in particular to positive locked load handling attachments e.g. magnet and
vacuum systems. In each case the special safety and operating instructions con-
tained in the operating instructions for the load handling attachment in question must
be complied with.

Operating hazard for the installation

This symbol indicates information on the appropriate use of machinery.
In the operating instructions, it indicates all warnings which, if not complied with, may
result in damage to the SpeedHoist or the load.

1.2 Intended use SpeedHoist units are only intended for lifting. lowering and moving loads and may be
used as stationary or travelling units.
SpeedHoist units may only be operated when in perfect working order by trained
personnel in accordance with the relevant safety and accident prevention regulations.
This also includes compliance with operating and maintenance conditions specified in
the operating instructions.
The SpeedHoist is industrial equipment to be used with a rated voltage (see type
plate).
Power feed is via power supply lines (mobile cables, open or enclosed power con-
ductor systems, cable drums). These systems are live up to the terminals of the main
switch (mains connection switch, isolating switch).
The relevant isolating switch must be switched off when performing maintenance/
repair work. During operation or when the main switch is not switched off, electrical
components inside enclosures, motors, switchgear cabinets, terminal boxes, etc.,
carry dangerous voltages. This voltage may cause fatal injuries.
Serious personal injury or damage to property may occur in the event of:
• unauthorized removal of covers,
• inappropriate use of the SpeedHoist,
• incorrect operation,
• insufficient maintenance,
• exceeding the maximum permitted load. The rated safe working load is the maxi-
mum permitted load. Pay attention to the sum of the load to be lifted and the load
21475644K1.p65/220903

handling attachment.
• working on live parts.

8
 1.3 Inappropriate use Certain work and practices are prohibited when using the SpeedHoist as they may
involve danger to life and limb and result in lasting damage to the SpeedHoist, e.g.:
• Unsafe load handling (e.g. swinging the load).
• Do not handle suspended loads above persons.
• Do not pull or drag suspended loads at an angle.
• Do not pull free fixed or obstructed loads.
• Do not exceed the maximum permitted load and permitted load dimensions.
• Do not leave suspended loads unsupervised.
• Do not allow ropes to run over edges.
• Do not use the rope as a load bearing sling.
• Only move the SpeedHoist with push travel trolley by pushing on the D grip –
never pull on the helical cable.
• Do not allow loads to drop when the rope is in a slack condition.
• Do not subject the D grip to inappropriate mechanical loads.
• Transporting persons is not permissible.
• Do not manipulate electrical equipment.

1.4 General safety Persons under the influence of drugs, alcohol or medicines which affect reactions
must not install, put into service, operate, maintain, repair or disassemble the
information SpeedHoist.
Any conversions and modifications to the installation require the written consent of
Demag.
Work on electrical equipment of the SpeedHoist may only be carried out by qualified
electricians in accordance with electrical regulations. In the event of malfunctions,
SpeedHoist operation must be stopped, the SpeedHoist switched off and the rele-
vant main switches locked immediately. Defects must be rectified immediately.
National accident prevention regulations and codes of practice and general safety
regulations must be observed when operating our products. Important information
and instructions are marked by corresponding symbols.
Follow these instructions and/or safety regulations in order to avoid accidents and
damage. The operating instructions must be kept available at the place where the
SpeedHoist is in use at all times. They include significant aspects and appropriate
excerpts from the relevant guidelines, standards and regulations. The owner must
instruct his personnel appropriately.
If the safety instructions given in these operating instructions are not observed in any
way, personal injury or even death can result.
Observe general statutory and other obligatory regulations relating to accident
prevention and environmental protection and basic health and safety requirements
in addition to those included in these operating instructions. Such requirements may
also relate, for example, to the handling of hazardous materials or the provision/
wearing of personal protection equipment. Comply with these regulations and
general accident prevention regulations relevant for the place at which the
SpeedHoist is used and follow the instructions therein when working with the
SpeedHoist. The SpeedHoist may still constitute a danger to life and limb if it is not
installed, operated, maintained or used appropriately by personnel which have not
been trained or specially instructed. The operating instructions must, if required, be
supplemented by the owner with instructions and information (e.g. factory regula-
tions) relating to organization of work, working procedures, operating personnel, etc.
Supervising and reporting obligations as well as special operating conditions must
also be taken into consideration.
Personnel assigned to working with the SpeedHoist must have read and understood
the operating instructions and, in particular, the section on safety information. All
21475644K1.p65/220903

activities relating to the SpeedHoist which are not described in the operating instruc-
tions may only be carried out by specifically trained specialist personnel.
The owner must ensure that personnel work in a safety and hazard-conscious
manner in compliance with the operating instructions.

9
 The owner must ensure that the SpeedHoist is only operated when in proper working
order and that all relevant safety requirements and regulations are complied with.
SpeedHoist units must be taken out of service immediately if functional defects or
irregularities are detected. In the event of a stoppage (e.g. if defects regarding safe
and reliable operation are detected, in emergency situations, in the event of operating
malfunctions, for repairs and maintenance purposes, if damage is detected or after
finishing work), the operator/experienced technician must carry out all prescribed
safety measures. Personal protective clothing must be worn as necessary or as
required by regulations. Personnel must not wear loose clothing, jewellery including
rings or long hair loose. Injury may occur, for example, by being caught or drawn into
the mechanism. All safety and hazard information and recommendations on the
SpeedHoist, e.g. at access points and mains connection switches must be main-
tained in complete and legible condition. Emergency limit stop devices (e.g. slipping
clutch or emergency limit switch) must not be approached in normal operation.
Modifications, additions to and conversions of the SpeedHoist which may impair
safety in any way must not be carried out without the written approval of Demag.
This also applies to the installation and adjustment of safety devices as well as for
performing welds on load bearing parts. Safety devices must not be rendered
inoperative.
Only genuine Demag spare parts and accessories may be used.
Observe prescribed deadlines or those specified in the operating instructions for
routine checks/inspections.

1.5 Selection and qualifi- For independent operation or maintenance of the SpeedHoist, the owner may only
employ persons
cation of operating and
• who are at least 18 years of age,
maintenance personnel • who are mentally and physically suitable,
• who have been instructed in the operation or maintenance of the SpeedHoist and
have proven their qualification to the owner in this respect (in addition to theoreti-
cal training, instruction also includes sufficient practical operating experience as
well as acquiring the ability to identify defects which are a hazard to safe opera-
tion),
• who can be expected to carry out the work assigned to them reliably.
The owner must assign operating and maintenance personnel to their relevant tasks.

1.6 Safety instructions • Installation and disassembly work may only be performed by experienced techni-
cians.
for installation and
• Installation and disassembly work must be co-ordinated by the person carrying
disassembly out the work and the owner within the scope of their responsibility.
The working and danger zone must be made safe.
• The installation must be isolated in accordance with the relevant electrical regula-
tions.
• Customer-specific regulations must be observed.
• Only appropriate, tested and calibrated tools and equipment may be used.
• The electrode holder and earth must be connected to the same assembly when
welding work is carried out (if the current flow is returned via protective conduc-
tors, screening elements or anti-friction bearings, serious damage may be caused
to these or other components).
21475644K1.p65/220903

10
 1.7 Safety instructions • The working and/or danger zone must be made safe.
• First check that the voltage and frequency specified on the data plates match the
when first putting the
owner’s mains power supply.
unit into service after • All clearance dimensions and safety distances (see approval drawing) must be
completing installation checked before putting the unit into service.
• When putting the unit into service, it may be necessary to perform work in the
danger zone.
• In the course of putting the unit into service, it may be necessary to temporarily
render safety devices or features inoperative.
• It must be ensured that only trained personnel are employed for putting the unit
into service.

1.8 Safety instructions for
operation
21475644K1.p65/220903
The operator must check the function of the brakes and emergency limit stop and
emergency stop devices before starting work.
All instructions and measures described in the operating instructions with regard to
safe operation and items concerning general safety and accident prevention which
have to be observed before, during and after putting into service must be strictly
complied with. Any failure to comply can lead to accidents resulting in fatalities.
SpeedHoist units must be taken out of service immediately or not put into operation
if any defects relating to operating safety and reliability are detected.
Safety devices must not be rendered inoperative or modified in contradiction to their
intended use.
Only operate SpeedHoist units when all protective devices and safety-relevant equip-
ment, e.g. movable protective devices and emergency-stop devices, are fitted and
fully functioning.
Anybody who identifies an immediate danger of personal injury must actuate the
emergency-stop switch without delay. This also applies in the case of damage
occurring to parts of the installation and equipment which makes immediate stop-
page necessary.
After an emergency-stop, the operator must not switch on and restart the
SpeedHoist until an experienced technician is satisfied that the cause which led to
actuation of this function has been rectified and that continued operation of the
installation constitutes no further hazard.
SpeedHoist units must be switched off immediately in the event of the following
faults:
• In the event of damage to electrical devices and cables as well as parts of the
insulation.
• In the event of brake and safety device failure.
• The SpeedHoist is provided with a slipping clutch as overload protection.
In the event of overload, the following situations may occur:
1. The load is not lifted, the slipping clutch responds.
2. The load is lifted, however, after switching off the lifting motion, the load slowly
moves downwards. In this case, the load must be immediately deposited by
actuating the D grip.
Fault: The slipping clutch must be readjusted or overload has occurred.
Ensure that nobody is endangered by operation of the SpeedHoist before switching it
on or putting it into operation.
If the operator notices persons who may be exposed to a risk to health or personal
safety by operation of the equipment, he must suspend operation immediately and
may not resume operation again until the persons are outside the danger zone.
Before putting the SpeedHoist into operation, the operator must be satisfied that the
SpeedHoist is in safe and correct operating condition.
Work on SpeedHoist units may only be carried out when instructions to this effect
have been issued, when operation and function of the SpeedHoist have been ex-

plained and when the working and danger zone has been made safe. Cooling
devices, such as ventilation openings, may not be rendered permanently inoperative
(e.g. covered or closed).
Special local conditions or special applications can lead to situations which were not
known when these operating instructions were written. In such cases, special safety
measures must be implemented by the owner. 11
 1.9 Safety instructions for The SpeedHoist must only be operated if a protective earth conductor is connected.
In the event of damage to or interruption of the protective earth conductor connec-
using power tion, the SpeedHoist must be disconnected from the power supply without delay.

1.10 Safety instructions for
maintenance
Maintenance measures are defined as regular maintenance, inspection and repair
work.
Mechanical and electrical repairs and maintenance work may only be carried out by
appropriately trained personnel (experienced technicians).
Adjustment, maintenance and inspection activities and inspection intervals including
specifications concerning replacement of parts/assemblies prescribed in the operat-
ing instructions must be observed.
Ensure that all electrical components are de-energized before commencing work on
electrical installations and devices.
When all work on the SpeedHoist has been completed, operation of the SpeedHoist
must not resume until the owner has given approval to this effect.
Unauthorized persons must be prohibited from carrying out work on machinery or
parts of the SpeedHoist.
Before starting all maintenance work, the SpeedHoist must be switched off and tak-
en out of service and secured against accidental or unauthorized putting into opera-
tion (restarting). Switches must be locked.
It must be ensured that
• the SpeedHoist is switched off and checked that it is de-energized and, in special
cases, isolated,
• moving parts are stationary and stopped,
• moving parts cannot start moving while maintenance work is being carried out,
• the power supply cannot be accidentally restored as long as the SpeedHoist has
been taken out of service for maintenance and repair purposes.
• ensure that operating and auxiliary materials as well as replaced parts are dis-
posed of in a safe and environmentally sound way.

Instructions for repair work in the course of operation

The danger zone must be marked off with red/white safety chains or safety tape and
indicated with warning signs. In each individual case, the owner or the person speci-
fied by him must check whether the relevant work may be carried out in the course of
operation without risk of personal injury owing to the particular local conditions.
To avoid injury, only use calibrated and appropriate tools and auxiliary materials for
maintenance, inspection and repair purposes. If there is a risk of objects falling, the
danger zone must be made safe.
Maintain a sufficient safety distance to moving or rotating parts to prevent clothing,
parts of the body or hair becoming entangled.
Avoid naked flames, extreme heat and sparks in the vicinity of cleaning agents and
flammable parts or parts liable to deformation (e.g. wood, plastic parts, oil, grease) as
well as in electrical installations – non-compliance may result in fire hazard. Harmful
gases may evolve or insulation may be damaged.
21475644K1.p65/220903

12
 Additional instructions for repair work on electrical equipment
Only genuine fuse links with specified amperage and tripping characteristics may be
used. Defective fuse links must not be repaired or bridged and must only be replaced
by fuse links of the same type. Switch off the SpeedHoist immediately in the event of
electrical power supply malfunctions. Work on the electronic and electrical compo-
nents or equipment may only be carried out by qualified electricians. If inspection,
maintenance and repair work is to be carried out on parts of the product, these must
– if prescribed by regulations – be isolated. First verify the safe isolation of the parts
from the supply before commencing work. The electrical equipment of the
SpeedHoist must be inspected and checked at regular intervals. Defects, such as
loose connections, damaged cables and worn contactor contacts must be rectified
immediately.
Since it is possible that after a longer period of operation the switching points of re-
lays (time, frequency, monitoring relays) change due to ageing of the components,
the relay switching points in circuits relevant to safety must be checked at regular
intervals.
Electrical equipment must be replaced as a preventive measure on reaching the limit
of its theoretical duration of service (service life).
If work has to be carried out on live parts, a second person must be available to
actuate the emergency-stop button or mains connection switch/isolating switch in
order to disconnect the power supply in an emergency.
The second person must be familiar with resuscitation measures.
Only use insulated tools.
Before disconnecting and connecting electrical plug-and-socket connections,
always disconnect them from the supply (this does not apply to mains connections,
provided they do not represent a dangerous contact voltage in the sense of the
safety regulations).
21475644K1.p65/220903

13
 2 Technical data of the SpeedHoist

2.1 Design overview

1 2 3 4 8 3

5 6 7 9 10
42584644.eps

1 Electrical equipment cover 6 Rope drum

2 Gearbox housing 7 Drum axle
3 Frame 8 Rope guide
4 Fan cover 9 Cover plate
5 Lifting limit switch 10 Switching rod

2.2 Explanation of size D-SH 80

designation SWL 80 kg or 160 kg

Size D-SH 80
D-SH 160

Demag SpeedHoist
21475644K2.p65/220903

14
 2.3 Dimensions

215

M8

105
355

70

ø20
1)

45

150
Rope outlet highest 39 Rope outlet lowest 15
hook position hook position
93
124

15
291

167

105

M8

311 215

590

42586144.eps
21475644K2.p65/220903

1) Load bar, optional, part no.: 851 195 44 15

 SpeedHoist with two KBK I or KBK II trolleys
1/1 reeving
SWL 80 kg KBK I Load bar part no. 851 195 44

355

Load bar
93

90
45
150
853

850

Rope travel
m = highest m/n
n = lowest
hook position

42586244.eps

Size Reeving Hook path Foot hole distance

Highest hook position Lowest hook position

m m n
D-SH 80
1/1 2,2 109 163
D-SH 160

2.4 Selection table Size SWL FEM Lifting speed Motor size Weight
m/min

kg V1 kg

D-SH 80 80 max. 70
1 Am KDP 63 B 2 30
D-SH 160 160 max. 35

2.5 Hoist motor data Required supply cable conductor cross sections and fuse links

Motor size Group of P CDF n cos

mechanisms to
FEM
kW % rpm ϕN

KDP 63 B 2 1 Am 0,94 30 4750 0,67

1) The lengths of the supply lines are calculated on

Rated current IN and starting Mains connection Supply lines for 5% voltage drop
21475644K2.p65/220903

the basis of an earth-loop impedance of 200 mΩ. cos

current IA for 50 Hz delay fuse for 50 Hz and starting current IA for 50 Hz 1)

400 V DP 400 V DP 400 V (∆U 20 V)

ϕ
IN (A) IA (A) A mm2 m

4,2 to 1,5 x IN 0,67 10 1,5 153

16
 3 Technical data of the electronic control system

3.1 Control card

Emergency limit Low.

D Grip Grip occupied

24 V Emergency limit
Emergency limit Lift.
D Grip manual force

D Grip button right

D Grip signal LED

Encoder 24 V DC
D Grip button left

Emergency stop
D Grip 24 V DC

Encoder GND

Digital output
D Grip GND

Encoder B
Encoder A

24 V DC
24 V DC
24 V DC
GND

GND
n. a.
n. a.
n. a.
On
6 9
1 2 3 4 1 5 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

S1
J4 D-SUB-F J3 J6

L1 L2 L3 L4 L5 L6 L9 L10

2
ON
Emergency

1
S5
stop contactor C167

S3

J2 L7 L8
PE 0

2
1 2 3 4 5 6 7 8 9 10 11

4
A

6
J5 8

S4 S2
Inverter UZK+

Inverter UZK-
Inverter W
Inverter U

Inverter V
Motor W
Motor U

Motor V
Brake~
Brake~
PE

42579644.eps

3.1.1 Digital inputs/outputs J6 Designation Display

1 24V Incremental encoder 24V -
2 GND24V Incremental encoder GND -
3 Encoder A Incremental encoder A -
4 Encoder B Incremental encoder B -
5 24V 24V -
6 GND24V GND -
7 EOUT2 Digital output -
8 EDIN7 n.a. -
9 EDIN8 n.a. -
10 24V switch 24V limit switch -
11 EDIN4 Emergency limit lifting L5
12 EDIN5 Emergency limit lowering L4
13 Emergency stop Emergency stop -
14 24V 24V -
15 24V 24V -
16 GND24V GND -

LED’s L4 and L5 are used to indicate whether the corresponding inputs are active.

3.1.2 D Grip interface J3 Designation Display

1 24V-F 24V grip -
2 GND24V-F GND grip -
3 Manual force Manual force -
4 Button left Button left L2
21475644K2.p65/220903

5 Button right Button right L1

6 Grip occupied Grip occupied L6
7 Signal LED Signal LED grip -
8 EDIN6 n.a. L3

LED’s L1, L2, L3 and L6 are used to indicate whether the corresponding inputs are
active. 17
 3.1.3 Serial interface J4 Designation
1 GND
2 RxD/ TxD
3 RxD/ TxD
4 -
5 GND
6 -
7 15V
8 GND
9 Flash-Write Enable

DIP switch S1 is used to switch over data lines RxD and TxD of the serial interface.

Position 1 (basic position)

S1 1 2 3 4

On X X J4.3: RxD

Off X X J4.2: TxD

Position 2
S1 1 2 3 4

On X X J4.3: RxD

Off X J4.2: TxD

Select the basic position in connection with the operating terminal with extension
cable and in connection with a PC and the software terminal.

3.1.4 Brake / motor / inverter J2 Designation

interface 1 PE
2 Brake
3 Brake
4 Inverter U
5 Inverter V
6 Inverter W
7 Motor U
8 Motor V
9 Motor W
10 UZK+
11 UZK-

3.1.5 Rotary coding switch The SpeedHoist can be specifically adapted in its dynamics to the application by
means of the rotary coding switch (hex-switch) S2 (see section 13 "Adjusting the
dynamics”).

0
E

2
C

4
A

8
21475644K2.p65/220903

42579144.eps

18
 3.1.6 Indicators LED Designation Funktion

L7 (red) Group alarm If the monitoring functions of the software detect an error, this is
indicated by the LED being continuously on, otherwise the LED is off.

L8 (green) Operation indicator When the program has been correctly started, the LED must flash
steadily.

3.1.7 Emergency stop The emergency stop device is connected to inputs J6/13 and J6/14.

3.2 D Grip connection The following diagram shows the right-angle plug socket assignment, viewed from
the soldering side and the plug assignment in the grip viewed in the direction of the
assignment pins.

Connection assignment of the right-angle plug

Pin no. Colour Assignment

1 BN 24 V DC

2 BU GND
Manual force
3 WH
analogue
4 PK Button left

5 YE Switch right

6 GY Grip occupied
Power consumption
7 GN Status LED
Max. approx. 70 mA
8 --- ---
No load: approx. 50 mA
42534944.eps

Technical data
Supply:
Current consumption:
Digital signals:
Manual force analogue:
21475644K2.p65/220903
24 V DC
Max. approx. 70 mA, no load: approx. 50 mA
0/24 V DC
0...10 V DC not standardized

19
 4 General

4.1 Inspection regulations Notes on inspections in accordance with

UVV Winches, lifting and towing devices BGV D8
UVV Cranes BGV D6

The EC machinery directive requirements are therefore also complied with.

Inspection when putting the product into operation for the first time

If SpeedHoist units are used as cranes, an inspection must be carried out by an

expert engineer in accordance with relevant accident prevention regulations (BGV
D6, § 25) for cranes.
SpeedHoists used in accordance with relevant accident prevention regulations for
winches, hoists and towing devices (BGV D8) must be inspected by an experienced
technician.
The inspection in accordance with relevant accident prevention regulations for
winches, hoists and towing devices (BGV D8) mainly consists of a visual inspection
and a function check. It is designed to ensure that the equipment is in a safe condi-
tion and that any defects and damage, e.g. caused by inappropriate handling during
transport, are identified and repaired.
In addition, regulations specific to cranes must also be taken into consideration
during acceptance and other inspections in accordance with relevant accident
prevention regulations for cranes (BGV D6).

Routine inspections
Hoists and cranes must be inspected by an experienced technician at least once a
year. Routine inspections mainly consist of a visual inspection and a function check
which should include a check to determine the condition of components and equip-
ment regarding damage, wear, corrosion or other alterations and a check to deter-
mine the integrity and efficiency of safety devices and brakes. It may be necessary
to dismantle the unit in order to inspect wearing parts.
Load carrying means must be inspected along their entire length, including those
parts which cannot normally be seen.

The owner must arrange for all inspections to be carried out and documented in the
SpeedHoist test and inspection booklet.

4.2 Noise emission meas- The noise emission level (LpAF) is: < 70+2dB (A)
urement according to at a distance of 1 m from the SpeedHoist.
DIN 45635 These noise emission levels were measured under maximum load.
Structural influences such as
• transmission of noise via steel structures
• reflection of noise from walls, etc.
were not allowed for in the above measurements.

4.3 Site of application SpeedHoist units may only be used in buildings and enclosed areas.

4.4 Packing and storage The SpeedHoist is shipped as a complete unit, i.e. with the D Grip connected in
cardboard packaging. The D Grip still has to be fitted on the wire rope by means of
the rope socket and the rope wedge, at the correct working height.
Store the SpeedHoist and its accessories in a dry place.
21475644K2.p65/220903

20
 4.5 Paint finish SpeedHoist units are supplied in the following standard colours:
SpeedHoist RAL 5009 Azure blue
D Grip RAL 7035 Light grey

4.6 Operating conditions SpeedHoist units can be operated at:

• -10° to +40° C ambient temperature
• Air humidity up to 80%
• Air pressure up to 1000 m above sea level
Other operating conditions are also possible.
Please refer to the manufacturer for information on any modifications that may be
necessary.
See page 2 for the address.
21475644K2.p65/220903

21
 5 Description of the SpeedHoist

5.1 Design

1 2 3 4 8 3

5 6 7 9 10
42584644.eps

1 Electrical equipment cover 6 Rope drum

2 Gearbox housing 7 Drum axle
3 Frame 8 Rope guide
4 Fan cover 9 Cover plate
5 Lifting limit switch 10 Switching rod

5.2 Drive The hoist motor is a 2-pole Demag motor with a cylindrical squirrel-cage rotor and
integrated brake. The double-sided brake can be separately controlled and is re-
leased by means of a DC electromagnet. The brake engages when no voltage is
applied to the magnet coil. The motor is built according to ICE 34-1; insulation
class F, type of enclosure IP 55 according to ICE 34-5.

5.3 Gearbox The SpeedHoist is provided with a 3-stage helical gearbox. All stages are provided
with helical gearing. The first and the second stages of the gearbox are lubricated by
a mineral oil to DIN 51502 CLP 220.
The output stage is lubricated by gearbox grease (part no. 011 058 44).
A slipping clutch is fitted in the wheel of the first gear stage. It performs the function
of a load limitation and protects the SpeedHoist against extreme overloads.

5.4 Rope reeving elements The drum, rope sheaves and rope comply with DIN 15020 and the FEM design rules.
The rope is wound in one layer on the rope drum, the rope is prevented from escap-
ing from the rope groove by means of a rope guide.

5.5 Limit switch Limitation of motion at the upper and lower hook positions is effected by a double
limit switch. This double limit switch is actuated via two adjustable stops which are
fitted on the switching rod.
21475644K2.p65/220903

Additional operating limit switches are required when the end positions are ap-
proached regularly during normal operation.

22
 5.6 Frame The frame of the SpeedHoist consists of two end caps on both drum ends and two
crossbeams fitted in-between which are positively connected and bolted to each
other via the drum axle.
The gearbox housing is also connected positively and bolted to one end cap.
In addition, the end caps are provided with two M8 threaded bore holes on the upper
and lower sides, for foot or ceiling mounting and for fitting to trolleys.

5.7 Electrical equipment

5.7.1 General description The SpeedHoist is designed for fast load handling applications and offers various
benefits:
• Easy, intuitive operation owing to the D grip control handle
• Infinitely variable speed control
• Switchover between two different maximum speeds
• Very fast lifting and lowering speeds (up to 70 m/min)
• Servo support for lifting operations when no load is attached to the hook
• Individually adjustable dynamics (speed and acceleration) by means of rotary
coding switches, programming device or software
• Free digital output configuration
• Lifting and lowering motions cut-off in the limit positions
• Direction of rotation monitoring via integrated speed feedback
• Overload cut-off
• Electronic controls integrated in the electrical enclosure of the handling device
• Temperatures of motor and electronic equipment monitored
• Diagnosis support in the form of a flashing error code displayed on the handle and
by means of a terminal and error memory
• Integrated elapsed time counter

5.7.2 Overview The following schematic illustration provides an overview of all components required
for the control system.

External emer-
gency stop

Inverter D Grip

Control card

Motor Fan

Brake Pulse Limit switch Limit switch

21475644K2.p65/220903

generator for lifting for lowering

42578044.eps

23
 5.7.3 Inverter The inverter is the power section and provides infinitely variable speed control of the
SpeedHoist motor.

5.7.4 External emergency stop With the emergency-stop device, the lifting or lowering motions can be stopped in
the event of a hazard. The emergency-stop switch must be fitted externally, for ex-
ample on the load handling attachment or the crane pillar.

5.7.5 Control board The control board contains the “Intelligence” of the SpeedHoist. The inputs are
evaluated and processed here by a micro-controller control system.

5.7.6 Fan The fan is used to protect the motor and the electrics against overtemperature. As
standard, it is connected to the digital output of the control board and is controlled
depending on the temperature. If the output is to be used for other functions, the
fan must be connected to a permanent 24 V DC source (see section 12 “Free
configuration of the digital outputs”).

5.7.7 Lifting / lowering limit switches
5.7.8 Pulse generator
The limit switches are normally closed contacts, they feature a double design so that
the signal can be used externally as a floating contact. The second contacts are
linked with the control board.
The pulse generator is used to record the motor speed. A failure of the generator is
detected by the control system (see section 16 “Fault finding and elimination”).

5.7.9 Brake The brake is used to hold the load when the motor is at standstill.

5.8 Trolley The load capacity of the SpeedHoist must not exceed the load capacity of the trolley.
KBK I and KBK II trolleys as well as the trolleys of the Aluline 120 and 180 can be
used.
The SpeedHoist is fitted to the trolley via a separate frame.

5.8.1 Track When selecting a track, we suggest you specify our KBK and KBK Aluline crane
construction kit track sections (fig. 1) of special design. They feature a low dead-
weight. The cold-rolled track sections feature a smooth running surface and offer
the advantage of simple power supply by means of trailing cables or integrated
conductor lines.
The track radius on curved sections should always be as large as possible in order to
ensure good travel characteristics.
Ready-made curved sections are available for our special KBK track.
Resilient buffers should be mounted at travel wheel axle level at the ends of tracks in
order to prevent the trolley from derailing.

KBK I KBK II Aluline 120 Aluline 180

21475644K2.p65/220903

24 Fig. 1 40189744.eps 40189844.eps 42590244.eps

21475644K3.p65/220903

25
 6 D Grip description

6.1 Operating instructions

regarding the D Grip
for the Speedhoist

Right-angle plug

(5) “Button left” (1) “Grip occupied” display

display (3) “Switch right” display
(4) Button left
(2) Switch right
(6) Status LED

(7) Light barrier

Quick-release coupling

42534244.eps

The grip includes the following control and signal devices:

• “Grip occupied” light barrier with LED signal.
If light barrier (7) is interrupted by the operator’s hand (grip is occupied), this is
indicated by LED (1) being on. It is possible to output the “grip occupied” signal
as a digital output by programming a parameter to control an additional unit, if
required (see section 14 “Setting the parameters”).
• When the grip is released (“light barrier not interrupted”), the motion is stopped
and the brake is applied.
• Right switch (2) for switch-over between slow and fast final speed with LED
signal (3).
Switch off (LED (3) off): Slow final speed for precise positioning. Switch on (LED (3)
on): Fast final speed.
The final speeds can be adjusted by means of a rotary coding switch on the con-
trol electronics or by programming a parameter in the software (see section 3.1.5
“Rotary coding switch” and chapter 14 “Setting the parameters”).
When the unit is switched on, the right switch is always off.
• Button left (4) with LED display (5)
The button signal has various functions. It is used to acknowledge error messages
(see section 16 “Fault finding and elimination”). It can be looped through as a
digital output, i.e. as long as the button is held down, a 24 V DC signal is output
at the relevant output. The left button can also be used as a switch (latching) by
programming and output via a digital output (see section “Setting the parame-
ters”). It is also possible to interrupt the lowering or lifting motion by pressing the
left button so that the unit may travel in a rail without causing a movement in the
z direction, since when pulling on the grip, forces in the z direction are also
transmitted into the grip. The last function can also be enabled and disabled by
parameter programming.
• A further function (set in the factor) is the “servo support for lifting”. It is used to
support lifting operations when no load or an extremely small load is attached to
the hook. The lifting motion is started when the left button is actuated. When the
grip is pulled downwards at the same time, the motion is stopped and the unit can
be travelled within a crane system.
21475644K3.p65/220903

26
 6.1.1 Status LED
6.1.2 Calibrating mode and grip
replacement
6.1.3 Operation with the grip
21475644K3.p65/220903
• The status LED (6) indicates, for example, errors and supports rapid diagnosis.
Unsteady slow flashing: An error is displayed (see section 16 “Fault finding and
elimination”).
Continuously lit: During initalisation of the control system and the inverter after
• Switching on of the unit, the LED is continuously lit.
Fast steady flashing: The control system is in the mode for calibrating the grip.
When the connector on the grip is disconnected during operation (sensor broken
error is displayed), this is detected by the control system and when the unit is put
into operation again, the control system assumes calibrating mode. This is indicat-
ed by rapid flashing of status LED (6).
To adapt the grip to the control system (e.g. when the grip has been replaced),
calibrating mode must be completed. It becomes necessary when the right angle
plug on grip was disconnected during operation, a sensor broken error has actually
occurred or when the parameters were re-set to the factory setting (see section 14
“Setting the parameters”).
When the control system is in calibrating mode (LED (6) flashes fast and steadily),
the operator must push the grip once and hard in the lifting direction and then hard
in the lowering direction. To transfer the determined grip parameters to the control
system or the memory, hold down the left button (4) for more than 3 sec. until the
status LED goes out again. Only then is normal operation possible again.
When the grip must be replaced, proceed as follows:
1. Switch off the voltage
2. Disconnect the right-angle plug
3. Replace the grip
4. Switch on the voltage (broken sensor is detected)
5. Switch off the voltage
6. Fit the right-angle plug
7. Switch on the voltage (after the initialisation phase, the LED starts to flash steadily)
8. Continue as described above, ... control system in mode for calibrating
In general, load movements are only possible if the grip is covered by the operator’s
hand so that the “grip occupied” signal (1) lights up. Otherwise, manual forces do not
become effective. In addition, status LED (7) must be off. An upwards movement of
the load is caused by an upwards movement of the grip (intuitive operation). To lower
the load, move the grip downwards.
The speed of the load movement is proportional to the force with which the grip is
moved upwards or downwards. The measured force is limited at the top and at the
bottom by means of mechanical end stops.
27
 7 Putting into operation

7.1 Electrical Work on electrical equipment may only be carried out by qualified electricians or
trained personnel, see also section 1 Safety instructions.
equipment
Each SpeedHoist is provided with a wiring diagram showing details of the controls.
The wiring of the SpeedHoist complies in all respects with current DIN VDE and acci-
dent prevention regulations. Unauthorized intervention and modifications may result
in infringement of these regulations.
The switchgear is designed for extreme conditions. However, its life depends on
usage.

42586344.eps

7.2 Line connection

The required supply cable conductor cross sections, the maximum permissible sup-
ply cable length and the fuse links can be seen in the table in section 2.5.
Please note that the length of the supply line specified for a given cross section must
not be exceeded in order to avoid excessive voltage drop.
The wiring carried out in the factory includes an earth lead which is connected to all
parts of the equipment which relevant regulations require to be included in the pro-
tective measures.

• 380 V - 415 V - 5 %,-10% three-phase AC current (50 to 60 Hz) is required.

Connection of the supply cable: The SpeedHoist is fitted with a plug-and-socket
connection for the power supply. The bush enclosure supplied with the
SpeedHoist permits connection of a round-section cable or connection to an ex-
isting flat cable when used in conjunction with a flat cable union.
41915244.eps • Terminal assignment in the line connection plug:
Phase conductor (L1) Terminal 1
Phase conductor (L2) Terminal 2
Phase conductor (L3) Terminal 3
Protective earth conductor (PE) PE terminal
• Plug the connector of the control cable (helical cable) onto the pin connector of
the handle and screw tight
• If required, set the dynamics of the unit. To do this, use the hex-switch on the
control board (see section 13 “Adjusting the dynamics”).
21475644K3.p65/220903

28
 7.3 Connection of emer- For operation of the SpeedHoist, an external emergency stop device must be fitted.
gency stop device It is applied on terminals J6 13 and 14 of the control board.
Commercially available emergency stop switches or the switches offered as an op-
tion (mushroom-head pushbutton/trip-wire switch) may be used.
It is useful to determine the position of the emergency stop device in line with the
specific system, e.g. integrated in the operating elements of a load handling attach-
ment or of a lifting mast.

7.4 Emergency limit switch The emergency limit switch is located in the terminal box of the SpeedHoist. It auto-
matically switches off the SpeedHoist when the top or bottom hook position is
reached. The direction of movement can be reversed. The emergency limit switch
must not be approached in normal operation.

7.5 Setting the emergency To avoid damage to the SpeedHoist and to prevent accidents, the emergency limit
switch stops must be properly adjusted. Check the switching rod for smooth opera-
limit switch actuator tion. Caution when the SpeedHoist is freshly painted. The limit switch stops for the
emergency limit switch actuator on the switching rod are set by us for the maximum
hook path. They must be re-set for your operating conditions. To do this, the two
limit switch stops can be moved on the switching rod towards the rope drum centre.
If you wish to set the greatest possible lifting height for your specific operating condi-
tions, it is essential to observe the following:
The motor-side limit switch stop for the top hook position must be set so that when it
switches off the lifting movement, the distance between the top edge of the rope
socket and the bottom edge of the rope guide or the next obstacle is at least 10 cm.

Limit switch stop for top hook Limit switch stop for bottom
position hook position

42579244.eps

The limit switch stop for the bottom hook position must be set so that the lowest
point of the working area can be reached.
21475644K3.p65/220903

29
 7.6 Inspection before When putting the hoist into operation for the first time, the inspections in accordance
with section 9.3, table 1 must be carried out.
putting the unit into
operation
7.7 Safety instructions All fitting and assembly work must be completed in accordance with the operating
instructions and the hoist rope must be greased. Operation with defective or
damaged ropes result in a high risk of accident for persons and the SpeedHoist and
is therefore prohibited. Any change or modification which prejudices safety must be
reported to the nearest person responsible immediately. Elimination of faults may
only be carried out by experienced technicians.

7.8 Putting the unit into • Switch on the voltage.

operation Note: During the initialisation phase, the red signal LED in the grip is continously
lit. During the initialisation phase, an automatic zero balance is performed for the
D grip, therefore, the grip must not be covered by the operator’s hand during this
phase. The “Grip occupied signal” must not be applied for 10 sec.
• When the LED has gone out, the limit switches for lifting and lowering must be
approached one after the other to initialise the software fast-to-slow limit switches.
Only then is it possible to enable the fast speed by actuating the right button in the
D Grip.
• If after initialisation, the red status LED does not go out, see section 16 “Fault
finding and elimination”.

7.9 Starting operation See section 9.1

21475644K3.p65/220903

30
 7.10 Putting the D Grip into
operation
7.10.1 Grip height adjustment
7.10.2 Rope connection on D Grip
21475644K3.p65/220903
Set the D Grip to the required working height. Make this setting and connect the rope
to the D Grip at the place where the D-SH is used based on the description of the
following section 7.10.2.
• Unroll wire rope (7) until you reach the drum end stop.
• Remove split pin (protection against loss) from rope wedge (9) and rope wedge
from rope socket (1).
• Insert rope end into rope socket (1) from above, avoid twisting.
• Return rope end into rope socket in a loop from below.
• Insert rope wedge (9) into the rope loop and pull into the rope socket together with
the wire rope. Slightly tighten the wire rope.
• Slide rope socket (1) over rope holder (5) and push pin (4) through. Place a washer
(2) on each pin end and secure pin with split pins (3) against sliding out.
• Now set the working height for the D Grip by means of clamping the rope wedge
in the rope socket. Set the lowest handling range to the required working height in
this way. Note that the lowest end position of the basic unit is not approached in
normal operation.
Ensure that the free end of the rope is long enough to fasten rope clamp (6).
• Secure the free rope end with rope clamp (6).
Fit the rope clamp at a distance of approx. 10 mm to the rope stop on the free
rope end. This distance must not be reduced since this would result in the rope
slipping and, as a consequence, the load might drop.
• When a load is picked up, the rope wedge is pulled into the rope socket and re-
sults in a self-locking clamp-type connection.
• Shorten the wire rope, as required (see section 7.10.3).
42526744.eps 42526644.eps
31
 7.10.3 Shortening the wire rope
Cut any excessive rope length to the required
length with wire rope scissors.
42343244.eps
7.10.4 Putting the unit into operation
7.11 Assignment of buttons
32
Slide heat-shrinkable sleeve part no. 343 706 44 Shrink the sleeve by means of a hot air fan or a
over the shortened end of the rope. lighter onto the end of the rope.
42343344.eps 42343444.eps
• Switch on the power supply. Make sure that the light barrier is not interrupted
during the initialisation phase of the control system (status LED flashes) (by the
operator’s hand or objects). When the unit functions correctly, the status LED
goes out after approx. 2 – 3 sec. and the unit is ready for operation. If the status
LED continues to flash, see section 16 “Fault finding and elimination”.
• If required, adapt the parameters if the operating characteristics do not fulfil the
requirements of the user (see section 14 “Setting the parameters”).
Depending on the place where they are fitted, the buttons of the D Grip can be indi-
vidually assigned. The following adhesive symbols are provided for this purpose to be
fitted on the rear side of the cover foil.
Select the required symbols from the enclosed adhesive symbol sheet (see symbols
and their description in the tables), peel them off and fit them in accordance with the
button assignment in the correct position, with the guide tab in the rear side of the
cover foil. Remove the protective foil from the rear side of the cover foil and fix the
cover foil on the clean front of the D Grip (front must be free of grease and dirt).
Press on well and then check the functions of the buttons.
Cover foil
Rear side
Symbol
Front
Guide tab
42539944.eps
21475644K3.p65/220903
 Symbols of the adhesive symbol sheet
1 2 3 4 5 6 7 8 9 10 11 12 13

Dummy
A without
symbol

Dummy
B without
symbol

Dummy
C without
symbol

42540144.eps

Designation of the symbols

1 2 3 4 5 6 7 8 9 10 11 12 13
Unlatch Attached
On - off, Latch Brakes; Release Speed Dummy
Manual (enable Speed; load
A non-latch- Switch-off Connect (status Brake brake; increased; Vacuum without
actuation change of normal run weight
ing fixed) fixed released fast run symbol
status) (mass)
Turn load
Turn load Lift by Lower by
handling Acoustic Movement Movement
handling means of means of Dummy
Turntable; attach- signal turning to turning to Transport Lock,
B Insert Remove attach- rope rope without
general ment encoders the right, the left, position closed
ment reeving reeving symbol
counter- (horn) limited limited
clockwise mech. mech.
clockwise
Tilt lifting Tilt lifting Push Adjust Adjust Turn fork Dummy
Retract
Unlock, Lower fork Lift fork device device frame or Push slide Push slide prongs; prongs; or frame without
C frame or
opened carrier carrier (fork) to (fork) to fork to the left to the right increase reduce counter- symbol
fork
the front the rear forwards distance distance clockwise
Measuring Decreasing Manual Manual
value measuring control for control for
Turn fork Release Increasing
Fix load Push off Release; constant; value; Brake, Two-hand loading loading
D or frame load Fix, clamp measuring
retainer load lift off characteri- decreasing general operation and and
clockwise retainer value
stic charac- conveying conveying
constant teristic equipment equipment
21475644K3.p65/220903

33
 8 Taking the unit out of service at the end of the shift/maintenance

8.1 Emergency stop Every SpeedHoist features an emergency-stop device with which all motions can be
stopped in the event of a hazard.
The device must be fitted in the freely accessible working range of the SpeedHoist.
To actuate the emergency-stop button, press the button until it reaches the end stop.
It then locks automatically.
To unlock the actuated emergency-stop button, turn the push button in the direction
of the arrows and release.
It is also possible to use emergency stop switches that are actuated by a trip wire.
The emergency-stop device must only be reset after the hazard and its cause have
been eliminated.

8.2 Taking the unit out of When the work has been completed, position the D Grip outside the travel area.
Switch off the power supply at the mains connection or isolating switch.
service at the end of
the shift
8.3 Taking the unit out of Maintenance work on the SpeedHoist must not commence before the load has been
removed and the mains switch/isolator switched off.
service for mainte-
The relevant accident prevention regulations and statutory regulations must be ob-
nance purposes served for operation and maintenance.
Required tests and inspections must be carried out.
Adhere to: section 1 Safety instructions and information in the maintenance schedule,
section 9.3, table 1.

21475644K3.p65/220903

34
 9 Inspections/maintenance/general overhaul GO

9.1 Inspection before The operator must carry out inspections in accordance with table 1 before starting
work. SpeedHoist units must be taken out of service immediately if any defects
starting work and relating to operating safety and reliability are detected.
during operation Such defects are e.g.:
• brake or emergency-stop device failure,
• damage to the rope
• unusual noises, etc.

9.2 Inspection and mainte- The specified inspection and maintenance intervals (table 1) apply to normal
SpeedHoist service conditions.
nance schedule
If routine maintenance reveals that the intervals are too long or too short, they should
be adapted to the specific operating conditions.
For repairs, only use genuine Demag parts (see section 18 “Component parts list”).
The use of spare parts not approved by Demag renders any liability and liability for
defects claims void.

9.3 General overhaul GO The theoretical duration of service D (hours at full load h) depends on the Group of
Mechanisms classification of the SpeedHoist (see section 10, table 3).
Upon expiration of 90 % of the theoretical duration of service, the owner must
arrange for a general overhaul GO to be carried out. A general overhaul must be
carried out on reaching the end of the theoretical duration of service, at the latest.
During the general overhaul the following parts must be replaced in addition to the
checks and work specified in the inspection and maintenance schedule (see table 1).
• Gearing
• Gearbox bearings
• Motor shaft
• Motor bearings
• Connecting elements
• Gear oil
The small parts (screws, washers ...) to be replaced during maintenance and assem-
bly work are not listed separately.
The general overhaul carried out by the manufacturer or an authorized specialist
company fulfils the condition for continued operation of the SpeedHoist.
Thus the relevant accident prevention regulations and the BGV D8 are complied
with.
Further utilization is approved when an expert engineer has entered the conditions
for further utilization into the test and inspection booklet. The completion of the
general overhaul must be confirmed in the test and inspection booklet and a further
period of utilization in accordance with FEM 9.755 must be entered.
The general overhaul may be carried out by expert engineers of Demag or an
authorized specialist company.
21475644K3.p65/220903

35
 Table 1
Inspection and maintenance schedule

Check when putting into operation for the first time and when See Before putting When Every 6 Once per
section into operation starting months year
starting operation operation
Check rope securing devices and rope guide X X

Check electrical switchgear and wiring 7.1 X X

Check operation of emergency limit switch X X X

Check strain relieving elements, control cables and D Grip for damage X X X

Check operation of the brake X X X

Check quick-release coupling on D Grip X X X

Check operation of external fan X X

Check during time of operation

Check path of rotor displacement Every 3 years

Check all bolted connections, nuts, welds, etc. X

Examine wire rope for damage and broken wires 9.4 X X

Oil rope 9.5.2 X

Examine load hooks for cracks, cold deformation and wear X

Check hook safety catch for deformation X

Check securing elements (clips, bolts, etc.) for tight fit and corrosion X

Check and apply or supplement corrosion protection, as required X

Replace oil/grease Every 4 - 5 years

Clean and oil limit switch rods X

Check plastic parts of limit switch for corrosion X

Check electrical enclosure seals X

Check operation of external fan X

General overhaul
The general overhaul should coincide with the annual inspection On reaching the theoretical duration of service

Fit SpeedHoist specific Demag GO set 9.3 X

The small parts (screws, washers ...) to be replaced during maintenance and assembly work are not listed separately. The tasks
specified in the inspection and maintenance schedule must be carried out during a GO.

The specified maintenance intervals apply to normal SpeedHoist service conditions.

If the annual calculation of the actual duration of service S indicates that the theoreti-
cal duration of service D will be reached before a period of 8 – 10 years, regular
maintenance work must be adapted to the operating conditions and maintenance
must be carried out at shorter intervals.
For repairs, only use genuine Demag parts (see section 18 “Component parts list”).
21475644K3.p65/220903

36
 9.4 Wire rope For safety reasons, wire ropes must be discarded when the number of visible broken
wires at the worst spot has reached the following figures (see table 2), counted over
a reference length of rope of 6 times or 30 times the rope diameter, whichever gives
the worst result.
A wire rope must be discarded immediately if a strand is broken, if it is found to suffer
from swelling, bruising, kinks, permanent bends or corrosion, or if it is worn or
damaged.
In order to discover broken strands more easily, the load must be removed from the
unit and the rope bent manually along its entire working length, the bending radius
being approximately that of the rope sheaves,
Wire ropes for SpeedHoist units can be supplied ex stock direct from our stores or
through our distributors.

Wire ropes must be replaced (according to DIN 15020, sheet 2, page 3 (table 2)) when the following numbers of broken
wires are visible
Size Rope Rope dia. Number of broken wires over length of rope Number of broken wires over length of rope
construction 6 x rope diameter 30 x rope diameter
as in fig.
Number of Length of rope Number of Length of rope
mm broken wires mm broken wires mm
1
D-SH 5 3 30 6 150
2

9.5 Fitting the wire rope Before a rope is reeved, the whole length of the rope should be rolled out on the
ground as shown in fig. 2. Any twisting of the rope should be strictly avoided.

RH = right-hand ordinary lay rope Incorrect Correct

Fig. 2 41116144.eps

Fitting the rope, see section 9.5.4.

Fig. 1 92069044.eps
Secure the rope end with rope clamps fitted at the beginning of the drum. (rope end
protrudes approx. 3 cm from the clamp).
RH = right-hand ordinary lay rope

Tightening torque of rope clamp 3 Nm

For construction, application and reeving of wire ropes for the SpeedHoist, see sec-
tion 9.5.1.

Fig. 2 42579544.eps

9.5.1 Construction, application and Range D-SH

reeving of wire ropes
Wire rope dia. mm 5

See figure 1 2

Length of rope 6,0 m part no. 826 623 44 1) 826 435 44 2)

1) Specify any special lengths/special constructions in your order
2) Special rope for return load
21475644K3.p65/220903

9.5.2 Lubrication Grease the rope with a gear oil, e. g. C-LP 220.
Ensure that the oil reaches the interior of the rope construction.

37
 9.5.3 Removing the rope

42586444.eps 42586544.eps 42586644.eps

42586744.eps 42586844.eps 42586944.eps

21475644K3.p65/220903

42587044.eps 42587144.eps 42587244.eps

38
 42587344.eps 42587444.eps 42587544.eps

42587644.eps 42587744.eps 42587844.eps

21475644K3.p65/220903

42587944.eps 42588044.eps 42588144.eps

39
 9.5.4 Fitting the rope

Tightening torque 2,8 Nm

Secure the rope end with rope clamps fitted at the
beginning of the drum. (Rope end protrudes approx.
3 cm from the clamp).
42588244.eps 42588344.eps

Prior to assembly, grease the rope drum, the rope

guide, the guide section and the sleeve with a
suitable lubricant (part no. 011 058 44, 60 g).

42588444.eps 42587844.eps

Tightening torque 5 Nm
21475644K3.p65/220903

Prior to assembly, grease the internally toothed rim

of the rope drum (part no. 011 058 44, 60 g).

42587744.eps 42587644.eps 42588544.eps

40
 42588644.eps 42587344.eps 42588744.eps

Tightening torque 40 Nm

42587044.eps 42588844.eps 42586844.eps

Tightening torque 25 Nm
21475644K3.p65/220903

42586644.eps 42586544.eps 42586444.eps

41
 9.6 KDP 63 hoist motor Functioning of the brake on the hoist motor can be tested by interrupting the D Grip
light barrier. When the light barrier is interrupted, the brake is released, when the light
brake barrier is enabled, the brake is applied.

9.6.1 Measuring the path of rotor
displacement
This work may only be carried out by specialist personnel.
Observe relevant safety regulations and the section on safety instructions.
It is imperative that the brake displacement is measured at regular intervals.
The brake disk must be replaced when the maximum displacement of 1,2 mm is
reached.

42588944.eps 42589044.eps

The brake displacement must be between min.

0,3 mm and max. 1,2 mm.
Measure brake displacement in braking and running
position at both openings of the brake casing. Use
both measurements to calculate mean value.
When the brake displacement is > 1,2 mm, the
brake disc must be replaced (see 9.6.2 Replacing
the brake disc).
If the measurement is within the above tolerances,
re-assemble motor.

Remove plug and measure rotor displacement

using depth gauge of sliding calliper.

41106444.eps
21475644K3.p65/220903

42
 9.6.2 Replacing the brake disc This work may only be carried out by specialist personnel.
Observe relevant safety regulations and the section on safety instructions.

Loosen and remove the 4 nuts. Remove brake cover.

41106544.eps 40991044.eps

Pull cables out slowly until resistance is felt. Remove armature disc.
Remove friction plate with lip seal.

40990944.eps 40991444.eps 40991244.eps

Remove brake disc and thin seal, fit new brake disc
and seal.

Long hub side must face motor.

Fitting the lip seal

Fit lip seal to friction plate.

40991344.eps 40991144.eps
21475644K3.p65/220903

43
 Ensure correct fit of lip seal. The cable duct
Fit friction plate with lip seal. Fit armature disc. must lie in the recess of the lip seal.

40991244.eps 40991444.eps 40990744.eps

Seal

Fit brake casing.

Keep cables pulled tight during assembly.
Subsequently remove assembly guide.

Cable duct
Seal in brake enclosure must
always be in contact with the cable
duct.

Use two 6 mm dia. bolts or pins as assembly aid

to guide the brake springs (when fitting).

40991544.eps 40990844.eps

Tighten the 4 nuts with a tightening torque of

3 Nm and fit plugs (1).

41107544.eps

42589144.eps 42589244.eps
21475644K3.p65/220903

44
 9.7 Gearbox Oil lubrication of the first and second gearbox stages
All SpeedHoist lubrication points are adequately greased. The gearbox is filled with
oil.
Under normal operating conditions, the lubricant must be changed every 4 years, at
the latest.
Under exceptional conditions, e.g. increased ambient temperatures, we recommend
that the lubricant be changed to suit these conditions.

Oil change
Open the SpeedHoist gearbox. Clean gear parts and gearbox casing thoroughly with
commercially available cleaning agents. Then reassemble the gearbox. Re-fill with
fresh gear oil before closing the gearbox.
Required quantity of oil = 0,2 litres

Oil grades
At an ambient temperature of approx. -10 °C up to +50 °C, gear oil with a viscosity
of 220 mm²/s at 40 °C with mild high-pressure additives is used.
DIN 51 502 CLP 220, e.g. BP ENERGOL GR–XP 220, Esso Spartan EP 220, SHELL
Omala Oel 220, Mobilgear 630 or Aral Degol BG 220.
At higher or lower ambient temperatures, the type of oil used should be adapted to
the specific conditions.

Dispose of waste oil in accordance with environmental protection requirements.

Grease lubrication of the third gearbox stage

The third gearbox stage of the SpeedHoist is lubricated with grease (approx. 60 g).
We recommend that the grease filling be replaced every 4 years at the latest.
To do this, dismantle the drum and clean toothed rim in the drum thoroughly with
commercially available cleaning agents. Then grease the toothed rim with the new
grease.
Required quantity of grease = 60 g, part no.: 011 058 44 (60 g)

9.8 Adjusting the slipping Under normal operating conditions, the slipping clutch does not need to be adjusted.
The clutch runs in the oil bath and the linings are virtually wear-free. The slipping
clutch clutch is initially set in the factory. Adjustment of the slipping clutch may only be
carried out by authorized specialists. An increase of the tripping torque which
exceeds the factory setting is not permitted.

A new safety nut must be fitted each time the clutch lining is replaced.
21475644K3.p65/220903

45
 10 Measures for achieving safe working periods S.W.P.

The safety and health provisions of EC directive 98/37/EC make it a legal require-
ment to eliminate special hazards which may be caused by, for example, fatigue
and ageing.
This requirement is also reflected in the third supplement to German accident pre-
vention regulations BGV D8 of 1.4.1996. This requirement obliges the owner of
serial hoist units to determine the actual duration of service of the SpeedHoist on
the basis of the operating hours, load spectra and/or recording factors. This is
based on FEM 9.755/06.1993 Measures for achieving safe working periods for
powered serial hoist units (S.W.P.).
The objective of this rule is to determine measures for achieving safe working
periods (S.W.P.) over the entire duration of service, although, according to the
state-of-the-art, hoist units are designed for specific periods of operation.
Premature failure cannot, however, be ruled out.
The following items have been taken from FEM rule 9.755 with reference to the
SpeedHoist:
1. The actual duration of service determined on the basis of operating time and
load must be documented at least once per year.
2. The actual duration of service S is calculated as: S = kmi x Ti x f
3. The load kmi (actual factor of the load spectrum) must be estimated.
4. The operating time Ti (number of operating hours) can be estimated or read on
an elapsed time indicator (see section 14.4.2).
5. The value determined for operating time Ti using an elapsed time indicator must
be multiplied by the type of recording factor f = 1,1.
6. The value determined for the estimated operating hours and load spectrum must
be multiplied by the type of recording factor f = 1,2.
7. A general overhaul must be carried out on reaching the theoretical duration of
service.
8. All checks and inspections and the general overhaul must be arranged by the
owner of the SpeedHoist.

A general overhaul is defined as:

Inspection of the machinery for the purpose of detecting all defective components
and/or components and parts close to failure and the replacement of all such com-
ponents and parts. Following a general overhaul, the machinery is in a condition
similar to that of the same machinery in new condition as far as the principle of
operation and performance values are concerned.
For SpeedHoist units classified according to FEM 9.511, the following theoretical
durations of service apply (converted into full load hours):
Table 3:
1Am
[h] 800
The actual duration of service is considerably increased if the SpeedHoist is only
operated with partial load. For a SpeedHoist operated on average with half load, for
example, this results in an 8-fold increase in the actual duration of service, with
operation at one quarter of the full load, a 64-fold increase.
21475644K4.p65/220903

46
 10.1 Calculating the actual The actual duration of service S of the SpeedHoist can be determined as follows:
duration of service S S = kmi x Ti x f

kmi : Actual load spectrum factor

Ti : Number of operating hours
f : Factor depending on the type of recording

10.1.1 Estimating the load spectrum
factor kmi (by the owner)
To simplify estimation, each type of load can be grouped into km load spectrum
modules. The types of load are simplified and quoted as 1/4, 1/2, 3/4 load and full
load.
Dead loads are added to the loads. Loads up to 20 % of the rated load capacity
are not taken into consideration.
The operating time for each type of load is divided up within the inspection interval
(e.g. 1 year) in terms of percentage.
The following bar diagram shows the km load spectrum modules for the load con-
ditions without load up to full load in time increments of 5 and 10 %. Larger shares
of the time period must be correspondingly added together.

0,05
0,10
Load 0,021
Full load 0,042
0,0062
3/4-load 0,0125
0,0008 km values
1/2-load 0,0016
Dead load
1/4-load
No load Time
5 10 5 10 5 10 5 10 40
100 [%]

The load spectrum factor kmi can be obtained by adding together the individual km
load spectrum modules.

10.1.2 Calculating the number of The operating time can be calculated by means of the integrated elapsed time indi-
hours of operation (operating cator or according to the following method:
time) Ti (by the owner) Operating time per inspection interval:

(Lifting + Lowering) x cycles/h x working time/day x days/inspection interval

Ti =
60 x hoist speed
Only lifting and lowering movements are counted, long and cross travel times are
not taken into consideration.

10.1.3 Factor depending on the type f = 1,1 for calculating the operating hours using an elapsed time indicator
of recording f f = 1,2 for estimating the operating hours and the load spectrum
21475644K4.p65/220903

47
 10.2 Example: Hoist speed : 50 m/min 1)
No. of cycles per hour : 100 cycles/h
D-SH – 80 in 1Am
Lifting and lowering : (1+1) m/cycle = 2 m/cycle
Operating time per day : 8 h/day
Days per inspection interval : 250 days/inspection interval

In the operating time as calculated above, the SpeedHoist has transported the
following loads:
0,05 km values

5 % of time with full load 3 · 0,0125 = 0,0375

30 % of time with ½ load 0,0016+0,0008 = 0,0024

15 % of time with ¼ load
50 % of time without load
5 30 15 50 Time
100 [%]

Adding the load spectrum modules km together results in the load spectrum factor:

kmi = 0,09

Thus, the actual duration of service amounts to:

S = kmi x Ti x f = 0,09 x 133,3 x 1,2 = 14,4 hours

For classification in FEM group of mechanisms 1Am (see SpeedHoist data plate)
with a theoretical duration of service of 800 hours (see table 4) the hoist has a theo-
retical remaining duration of service of 785,6 hours.
Documentation
Enter these values in your test and inspection booklet.
This entry may appear as follows:

Table 4
Date Operating Load [%] km factor Load factor Actual Theoretical Remaining
hours duration duration of service duration of
of service service

from until Ti value [h] full 3/4 1/2 1/4 none kmi f S [h] D [h] group of D-S [h]
mechanisms
3.1.-- 30.12.-- 133,3 5 - 30 15 50 0,09 1,2 14,4 800 / 1Am 785,6
0,05 - 0,0375 0,0024 -
21475644K4.p65/220903

48 1) Unit infinitely variable, therefore assumed mean speed

21475644K4.p65/220903

L1

L2

L3

PE

-X12 PE 1 2 3
-X11 PE 1 2 3

PE L1 L2 L3
11 Circuit diagram

-U011
DK2 INVERTER PPMK/SKIIP
11.2 SpeedHoist circuit diagram

U V W +15V UZK-

D-GRIP
-X1 1 2 3 4 5 6 7
-X2 1 2 3 4 5 6 7

2 2

1 1 M

-S014A
-S014B
1DC

-M017 Fan
-W1 GN WH BN RD BU -W2 BN BU WH PK YE GY GN -W3 BN WH

J2 9 8 7 6 5 4 J6 12 11 10 J2 10 11 J3 1 2 3 4 5 6 7 J6 6 7
-U013
D-SH CONTROL LOGICS A track
+24V GND B track
Emergency stop Fan, permanent J6 1 2 3 4 J5
J2 1 2 3 J6 13 14 J6 15 16
RD
BU
OG
BK

YE YE

10

W1 V1 U1 PE
-M012 G
M
3AC
-G013

42580044.eps
49
 12 Free configuration of the digital outputs

12.1 Description The control system is provided with a digital output J6.6 which can be freely config-
ured, i.e. the user may set the signal to be output at the respective digital output.
To do this, the operating terminal or the appropriate software is required (see sec-
tion 14 “Setting the parameters”) by means of which the function of the outputs can
be selected from a given selection list.
1. Button left
2. Switch left
3. Grip occupied
4. Release brake
5. Overload
6. Switch fan
7. Emergency limit switch for lifting
8. Emergency limit switch for lowering
9. Group alarm
The factory setting is: 6 (fan).

The fan is connected to digital output J6.6 in the factory. Depending on the internal
device temperature, the fan is switched on and off. If the digital output is to be used
for other purposes, the fan must be re-connected. It is then always on when the
SpeedHoist is switched on.
The following changes must be made in the connection assignment:
1. 24-V connection cable of the fan: from J6.6 to J6.16
2. Gnd connection cable of the fan: from J6.7 to J6.15

12.1.1 Button left The left button is looped through to the digital output. A 24 V DC signal is applied to
the digital output as long as the left button in the grip is held down. If the button is
not pressed, 0 V are applied to the output.

12.1.2 Switch left The switch is of latching design. When the control system is switched on, the digital
output is 0. If the left button is pressed and released again, 24 V DC are applied to
the output. If the button is pressed and released once again, the output signal is 0
again.

12.1.3 Grip occupied The “Grip occupied signal” is output at the digital output. If the operator’s hand
covers the grip, 24 V DC are applied to the output. If the grip is not covered, 0 V
are applied. The signal can be used, for example, to release the brake of a travel
drive.

12.1.4 Release brake A 24 V DC signal is applied to the digital output when the brake is released, other-
wise 0 V DC are applied.

12.1.5 Overload In the event of overload, a 24 V DC signal is applied to the output, otherwise
0 V DC are applied.

12.1.6 Switch fan The fan is controlled depending on the temperature. Fan on, corresponds to
24 V DC at output, fan off corresponds to 0 V DC.

12.1.7 Emergency limit switch for A 24 V DC signal is applied to the digital output when the limit switch for lifting has
lifting been approached, otherwise 0 V DC are applied.

12.1.8 Emergency limit switch for A 24 V DC signal is applied to the digital output when the limit switch for lowering
lowering has been approached, otherwise 0 V DC are applied.
21475644K4.p65/220903

12.1.9 Group alarm A 24 V DC signal is applied to the digital output in the event of an error, otherwise
0 V DC are applied.
It is also possible to control an external signal encoder.

50
 13 Adjusting the dynamics

The dynamics of the SpeedHoist can be specifically adapted to each individual

application. The parameters Max. speed 1, Max. speed 2 and Acceleration are
varied for this purpose.
This is done either by means of the rotary coding switch (hex-switch), see figure in
section 3.1 switch S2 on the control board or via the serial interface. In this case,
the operating terminal which is available as an option is required (see section 17
“Accessories”). Alternatively, the software terminal which runs on a PC/laptop may
also be used for this purpose.
First the setting via the hex-switch will be explained. Programming parameters via
the serial interface is dealt with in section “Setting the parameters”.
To change the dynamics, it is necessary to remove the electrical equipment cover
of the SpeedHoist.
Before you remove the cover, switch off the power supply.
Attention, the discharge time of the link capacitors of the inverter is approx. 3 min.
The rotary coding switch (S2) is situated on the control board, it has 16 different
positions (1, 2, ..., F). Using a small screwdriver, the switch can be moved to the
required position.
When the hex-switch is in the 0 position, the dynamics are adjusted by means of
the above-mentioned operating terminal or the software terminal (see section 14
“Setting the parameters”).
Any other positions result in a fixed assignment of the dynamics parameters in ac-
cordance with the table below.

Combinations: Speed - acceleration

Acceleration

100 % 70 % 50 %

Creep hoist 1 : 4
70 m/min (4800 rpm)
1 2 -
17,5 m/min (1200 rpm)
50 m/min (3430 rpm)
- 3 4
12,5 m/min (860 rpm)
35 m/min (2400 rpm)
- 5 6
8,75 m/min (600 rpm)
Creep hoist 1 : 8
70 m/min (4800 rpm)
7 8 -
8,75 m/min (600 rpm)
Speed

50 m/min (3430 rpm)

- 9 A (10)
6,25 m/min (430 rpm)
35 m/min (2400 rpm)
- B (11) C (12)
4,38 m/min (300 rpm)
Creep hoist 1 : 2
70 m/min (4800 rpm)
D (13) - -
35 m/min (2400 rpm)
50 m/min (3430 rpm)
- E (14) -
25 m/min (1715 rpm)
35 m/min (2400 rpm)
- - F (15)
17,5 m/min (1200 rpm)
21475644K4.p65/220903

51
 14 Setting the parameters

14.1 Software terminal brief

instructions
14.1.1 Description The software terminal kit is intended for setting the parameters of the SpeedHoist
and may be used as a replacement of the hand-held terminal. It comprises:
• a CD ROM with the “SoftTerm.exe” program, this description as well as
• a cable.
A PC or a laptop is required. Windows 3.10/95/98/NT/ME/2000 are supported as
operating systems.

14.1.2 Cable and connection The enclosed cable is used for connecting the control system with the PC/laptop.

Connection assignment:

RS232 Software terminal cable PC

Interface D Sub
(Com 1, 2)

1 1
2 2 RxD
3 3 TxD
4 4
5 5 GND

7 7
6 6
8 8
9 9

42577544.eps

For connection to the control system, the electrical equipment cover on the
SpeedHoist must be opened. Connect one end of the cable to the Dsub9 connec-
tor of the control board and the other end to the COM1 or COM2 interface of the
PC/laptop.

Before you remove the cover, switch off the power supply.
Attention
The discharge time of the link capacitors of the inverter is approx. 3 min.
21475644K4.p65/220903

52
 14.1.3 Start program To start the software terminal, call up the SoftTerm.exe program. The following
window appears:

42583544.eps

The program is operated by using the mouse or the keyboard.

Using the mouse Using the keyboard Meaning

Esc or F As hand-held terminal

Return or Enter on num. block As hand-held terminal

Arrow keys As hand-held terminal

Alt X or select the window with the

Exit program
tab key and actuate the space bar

Select with the tab key and set

Select interface
with the space bar

Select the COM interface to which the cable is connected to start communication.
Then actuate the F or the Esc key. The name of unit and the version number of the
firmware are then displayed in the window. If it is not the case, see Possible causes
of errors.
The operation is identical with operation using the hand-held terminal.

14.1.4 Possible causes of missing Possible cause Remedy

communication
Incorrect COM interface selected Select another COM interface or re-connect cable

Control system is switched off Switch on control system

21475644K4.p65/220903

Cable not connected or not connected appropriately Connect cable appropriately

Incorrect cable Check cable

Cable defective Obtain new cable

53
 14.2 Operating terminal

RUN ERROR

42520944.eps

The SpeedHoist can be adapted to specific requirements using the Demag operat-
ing terminal. For the SpeedHoist, default values are factory-preset (see section 16
“Documentation of parameters”). The operating unit features the following keys:

• Arrow up (↑)
• Arrow down (↓)
• Arrow right (→)
• Arrow left (←)
• Return (↵)
• Escape (F)

The meanings of the individual keys are described in this section.

Open the electrical equipment cover of the SpeedHoist to connect the operating
unit.

Before you remove the cover, switch off the power supply. Attention, the discharge
time of the link capacitors of the inverter is approx. 3 min.

On the control board, a 9-pole D Sub interface is provided for connecting the oper-
ating unit with extension cable.
Note: Only use the cable supplied by Demag to avoid damage (see section 17
“Accessories”).

Putting the operating terminal into operation

1. Switch off the SpeedHoist power supply
2. Open electrical equipment cover
3. Switch on the power supply
4. Connect the operating terminal type UPBT2-A00 with its extension cable to the
D-SUB interface.
5. The correct mode (VT100) is set if the operating terminal shows a flashing cursor
field in the top left corner of the menu field.
21475644K4.p65/220903

If the operating terminal indicates “Connecting DRIVE” in the first line, the mode
for setting the parameters of Demag inverters is set.

54
 Changing to the VT100 mode
To change to the “VT100” mode, proceed as follows:
1. Disconnect connector
2. Reconnect connector and press and hold down the (↵) key, release it after
approx. 3 sec.
3. The following menu appears:
Beenden/Exit
Save & Exit
Connect PARCOM
:
:
Mehr/More
Select “Mehr/More” with the arrow keys and press (↵).
4. The following menu appears:
Test/Setup (1)
EXIT!
SAVE & EXIT
:
:
VT100 Setup
:
:
Select “VT100 Setup” with the arrow keys and press (↵).
5. The following menu appears:
EXIT!
SAVE & EXIT
Enabled = 0
:
:
Select “Enabled = 0” with the arrow keys. Then press (↵) and set to Enabled = 1
with (↑). Now press (↵) and move to “SAVE & EXIT” with (↑) and press (↵).
6. Switch off the power supply
7. Repeat items 4 and 5 under “Putting the operating terminal into operation”
After you have pressed (F) twice, the terminal displays:
DEMAG D-SH
ID: 49090844
x.xx y.yy
In the third line, you will find the version number of the relevant application software
on the left and the version number of the parameter software on the right:
The version is encoded as follows:
Version number.Modification index

If no connection is established, check the position of DIP switch S1. It must be

switched as follows:

Basic setting

S1 1 2 3 4
21475644K4.p65/220903

On X X J4.3: RxD

Off X X J4.2: TxD

55
 14.3 Operation
14.3.1 Navigating Access menu items on the same menu level (vertical direction) with (↑)(↓). To move
from a main menu to a sub-menu (horizontal direction), actuate the (↵) key. On
every level, you reach the next higher level with the (F) key. To return to the original
item, it may be necessary to actuate the (F) key several times.
A distinction is made between diagnosis variables (which are displayed only) and
parameters (which are displayed and can be changed, as required).

Diagnosis variables
For diagnosis variables, the name of the variable is given in the first and the second
line, in the third line the current value with unit is indicated.
Diagnosis variables are, e.g.: – E Grip occupied,
– E Switch right,
– A Diagnosis output
etc.
Parameters
For the parameters, the name of the parameter is given in the first and the second
line, in the third line the current value with unit is indicated. If the parameters can be
changed, you enter edit mode by pressing the (↵) key.
The cursor moves to the current value.
In the fourth line, the value range for changing the parameter is displayed.
The value can be changed step by step upwards or downwards using the
(↑)(↓) keys.
The changes have an immediate effect on the characteristics of the unit. If you quit
edit mode with the (F) key, the original value is restored.
If you quit edit mode with the (↵) key, the currently set value is saved. If no key is
pressed for approx. 10 sec., edit mode is also quit and the current value is saved.
Edit mode is not available for parameters which are only displayed.
Parameters are, e.g.: – Max. speed,
– Acceleration,
– Assignment digital output,
etc.

14.3.2 User levels There are two user levels:

• User level (user mode)
• Service level (service mode)
The user mode becomes active when the control system is switched on or when
an incorrect password is entered (see section 14.4.1 “Password entry”). The differ-
ent levels have a different number of parameters and different access authorization.
21475644K4.p65/220903

56
 14.4 Menu structure and The figure below shows the menu tree and the parameters and diagnosis variables
available on the user level.
parameters

• E Grip occupied
• E Reserve
Demag • E Grip switch right
Inputs/outputs • E Grip switch left
Speedy Diagnosis
• E Limit switch for lifting
ID: 49090844 • E Limit switch for lowering
• A Digital output
• A Release brake

• Setpoint speed value

• Actual speed value
• Link voltage
• Slip
Measuring values • Temperature
• Manual force
• Manual force input value
• Manual force zero point
• Hex-switch value
• Set acceleration

• Fault
• EEPROM memory status
System • Overload
• Speed controller enable
• Error memory

Operating data • Operating hours

• Max. speed right switch on

• Max. speed right switch off
Operating parameters • Acceleration
• Digital output assignment
• Special function left button

Device parameters • Rough analogue value max. value

Sensors
• Rough analogue value min. value

Functions • Reset, loading default values

• Language selection
Setup
• Password entry

42578144.eps

14.4.1 Setup: Language selection

Here you may choose between German and English. To do
this, change to edit mode and select the requested language.
Password entry
Demag service engineers can access further menu items by
entering a password. To do this, change to edit mode and
enter the password using the (↓)(↑) and (←)(→) keys.
User mode becomes active again when the control system is
switched on or when an incorrect password is entered.
21475644K4.p65/220903

57
 14.4.2 Diagnosis
Inputs/outputs Here the statuses of the digital inputs and outputs are displayed.

E Grip occupied Indicates the status of the light barrier in the grip. When the grip is covered with the
operator’s hand, the status indicated must be “yes”.
The signal can be brought out as a digital output (see menu item “Operating param-
eters”, page 59).

E Reserve Not used at present.

E Grip switch right Indicates whether the right operating switch in the grip is activated.
The signal can be brought out as a digital output (see menu item “Operating
parameters”, page 59).

E Grip switch left Indicates whether the left operating button in the grip is activated.
The signal can be brought out as a digital output (see menu item “Operating
parameters”, page 59).

E Limit switch for lifting Indicates whether the limit switch for lifting is active.
The signal can be brought out as a digital output (see menu item “Operating
parameters”, page 59).

E Limit switch for lowering Indicates whether the limit switch for lowering is active.
The signal can be brought out as a digital output (see menu item “Operating
parameters”, page 59).

A Digital output Indicates whether the digital output is active.

A Release brake Indicates whether the digital output “Release brake” is active.

Measuring values Here various measuring values are displayed.

Setpoint speed value Here the current setpoint speed value supplied to the inverter by the control system
is displayed.

Actual speed value Here the current, measured actual speed value is displayed.

Link voltage Displays the current value of the link voltage of the inverter.

Slip Displays the current slip.

Temperature Current temperature measured on the control board.

Manual force Displays the current value of the manual force measured in the grip in %. Depend-
ing on the force, this value must change considerably when the grip is moved up-
wards and downwards.

Manual force input value Here the analogue value of the grip converted to digital is displayed. With the help
of this value, it is easy to determine whether the sensor is still operating.

Manual force zero point Displays the value which was measured for the automatic zero point balance.

Hex-switch value Displays the position of the rotary coding switch as decimal and hexadecimal value.

Set acceleration Shows the currently set acceleration in percent of the max. acceleration.
21475644K4.p65/220903

58
 System status Status and fault messages are displayed here to facilitate fault finding (see also sec-
tion 15 “Fault finding and diagnosis”).

Error In the event of an error, it is indicated here in clear text.

EEPROM memory status Here the current status of the EEPROM memory, in which the parameters are
saved, is displayed.

Speed controller enable Indicates whether the speed controller has received the enable signal.

Error memory The error memory contains max. 10 entries. A continuous index 1...10 is displayed,
the error code, e.g. E03 and the operating hours completed at the time the error
occurred.
When the menu item is selected, the error that was entered last is displayed first
(index 01). Press the enter key to view the previous errors. You will then move to
Edit mode and you can view the previous error entries (index 02...10) with the arrow
keys (up/down). The error code table is contained in section “Fault finding”.

Operating hours Here the current operating hours are displayed.

14.4.3 Operating parameters The operating behaviour of the SpeedHoist can be influenced by the parameters
which are set here.

Max. speed right switch on When the rotary coding switch on the control board is in position 0, the max. speed
can be set with this parameter if the right switch is activated (LED on).

Max. speed right switch off When the rotary coding switch on the control board is in position 0, the max. speed
can be set with this parameter if the right switch is de-activated (LED off).

Acceleration When the rotary coding switch on the control board is in position 0, the acceleration
can be set with this parameter.

Digital output assignment With this parameter, a specific function can be assigned to the digital output.

• Button left
• Switch left
• Grip occupied
• Release brake
• Overload
• Switch fan
• Emergency limit Lifting
• Emergency limit Lowering
• Group alarm

The meaning is explained in section “Free configuration of the digital output”.

21475644K4.p65/220903

59
 Special function left button
Off:
Stop movement:
Servo lifting:
14.4.4 Device parameters
Sensors
Rough analogue value max. value
Rough analogue value min. value
Functions
Reset, loading default values
15 Documentation of parameters
60
With this parameter, a special function can be assigned to the left button.
• Off
• Stop movement
• Servo lifting
No special function assigned
When the left button is pressed, the upwards and downwards movements are
stopped. The movement is enabled again only when the button is released.
An upwards movement is started by actuating the left button. When the grip is
pulled downwards at the same time, the motion is stopped again and the unit can
be pulled on the grip in the horizontal direction.
Max. value of the digitally converted input voltage
Min. value of the digitally converted input voltage
All parameters can be reset to the factory settings here (see section 15
“Documentation of parameters”).
Note: Following the reset, the control system assumes calibrating mode
(see section 6.1.2 “Grip calibrating mode”).
The currently set parameters of the control system can be documented in the fol-
lowing table.
Parameter Factory setting Current value:
Max. speed right switch on 4800
Max. speed right switch off 1200
Acceleration 100
Digital output assignment Switch fan
Special function left button Servo lifting
Language selection German
21475644K4.p65/220903
The factory setting is restored by a reset of the parameters.
 16 Fault finding and elimination

16.1 Fault finding, general The SpeedHoist offers various possibilities of rapidly diagnosing errors and faults:
a) A flash code is output by the status LED in the grip.
b) Error display in clear text in the operating terminal or the software terminal
c) Read-out of error memory via operating terminal or software terminal
d) LEDs on the control board
e) Diagnosis displays via operating terminal or software terminal

Error Possible cause Remedy

a Unit not functioning, red status LED in grip flashes - No calibrating for grip carried out yet - See section Calibrating of grip
steadily
b Unit not functioning, LEDs in grip are not on after - No line voltage - Replace line fuse
the grip has been actuated - System switched off - Switch on main switch
- Broken wire in supply line - Check supply line
c Unit not functioning, status LED in grip flashes - Monitoring function has detected an error See error code table
irregularly
If the measures under a are not successful, remove the equipment cover for further fault finding

Before you remove the cover, switch off the power supply.
Note the discharge time of the link capacitors in the inverter is approx. 3 min.

d No LED on inverter on See item a) See item a)

16.2 Error code table Faults which have been detected by the internal monitoring feature are indicated by
the status LED. The errors are indicated by the number of flashes of the status LED
(see table). For example: Three flashes indicate an inverter error.

LED on

LED off
0,5s 0,5s 0,5s 3 sec. 0,5s 0,5s 0,5s 3 sec. 0,5s 0,5s 0,5s etc.
42057544.eps

As an alternative, the faults are displayed in clear text via the terminal (see section
14 “Setting the parameters”). In addition, an error memory containing the last 10
detected errors can be read out.
The following table shows the assignment of flashing code, error code and the
meaning of errors. Some error messages can be acknowledged with the left button,
the others require a restart of the unit when the cause has been eliminated.

Error code Error message Flashing of status LED Reset

E00 None

E01 Sensor grip 1x Program restart

E02 Light barrier 2x Acknowl. left button

E03 Inverter 3x Program restart

E04 CAN 4x Program restart

E05 Rotary encoder 5x Acknowl. left button

E06 Emergency limit switch 6x Program restart

E07 Brake 7x Acknowl. left button

21475644K4.p65/220903

E08 Overcurrent 8x Acknowl. left button

E09 Brake resistor 9x Program restart

E10 Earth fault current 10x Acknowl. left button

E11 Undervoltage 11x Acknowl. left button

E12 Emergency stop relay 12x Program restart

61
 E01 SENSOR GRIP:
This error occurs when the analogue value drops below the sensor threshold
Possible cause Check/remedy

a Grip connector loose or off Check tight fit of right-angle plug, correct as required and tighten
union nut
b Helical cable defective Check conductors WH, BN and BU for continuity: replace helical
cable if necessary
c Power supply for grip missing If the status LED does not flash, measure voltage on the control
board between J3.8 and J3.7. It must be 24 V, otherwise replace
the control board
d Grip electronics defective When the unit is at rest, the voltage between SJ3.6 and J3.7 is less
than 1 V, replace grip
e Sensor error Error only occurs during operation, after resetting the unit, the error
is eliminated, it only re-occurs after lowering, replace grip

E02 LIGHT BARRIER:

This error only occurs, if for a specific time (10 minutes), there has been no change between the statuses grip occupied and grip not
occupied or vice versa
Possible cause Check/remedy

a Lense covered or light barrier permanently interrupted by an
obstacle
b Lenses of light barriers soiled
c Light barrier no longer correctly aligned
Remove obstacle and check change in status. If it is o.k.,
acknowledge error with left button, if not o.k., proceed with b)
Interrupt the light barrier in the grip and check whether the status of
the LED changes, if not, clean lenses and check again, if o.k.,
acknowledge error, otherwise proceed with c)
Replace grip

E03 INVERTER:
This error occurs when the inverter does not send an enable signal
Possible cause Check/remedy

a Data line between control board and inverter defective Replace cover with inverter

E04 CAN:
This error occurs when there is a fault in the communication between the inverter and the control board
Possible cause Check/remedy

a Plug of data line defective Replace cover with inverter

b Data cable defective Replace cover with inverter

c Data bus malfunctioning Check position of data line

E05 ROTARY ENCODER:

Error while detecting the direction of revolution
Possible cause Check/remedy

a Motor direction of revolution changed over caused by incorrect Check connections of motor lines (J2.4/5/6) and correct, as
connection required
b Signal connections of pulse genertor changed over Check connection of pulse encoder (J6.13, J6.14) and correct, as
required
c Power supply for pulse generator defective Measure on terminals J6.15 and J6.16 whether 24 V are applied. If
not, replace control board
d Pulse generator defective Replace pulse generator
21475644K4.p65/220903

E06 EMERGENCY LIMIT SWITCH:

Possible cause Check/remedy

a
62
 E07 BRAKE:
The error occurs if the inverter cannot control the brake
Possible cause Check/remedy

a Electrical defect of brake Replace brake

b Mechanical defect of brake Replace brake

c Brake control defective Replace control board

d Brake cable defective Replace brake

E08 OVERCURRENT:
Possible cause Check/remedy

a Load too high Do not overload the unit

E09 BRAKE RESISTOR:

Possible cause Check/remedy

a Brake resistor defective Replace brake resistor

E10 EARTH FAULT CURRENT:

Possible cause Check/remedy

a Fault to earth Replace inverter

E11 UNDERVOLTAGE:
Possible cause Check/remedy

a Phase error Check power supply

E12 EMERGENCY STOP RELAY:

Possible cause Check/remedy

a Emergency stop relay defective Replace control board

b Enable circuit defective Replace control board

21475644K4.p65/220903

63
 16.3 Further fault information
No. Error event Cause and elimination of the error

1 Load drifts, if the light barrier in the grip is interrupted
2 Manual force does not return to the value 0 (deviates significantly)
3 No connection to terminal
- Take hand out of light barrier range, wait approx. 5 sec. and repeat test. IIf
the same effect occurs again, start new zero balance by switching on/off
the unit
- Check whether the swivel cap is fitted correctly. The cable entry gland
must be on the side opposite the grip buttons
- The terminal was directly connected, use special extension cable

- An incorrect extension cable was used

- An old terminal was used which does not support the VT100 mode, use
new terminal or update old terminal
4 Program has not started (L8 does not flash steadily) - During switching on of the unit, the parameter programming interface was
occupied
5 When the grip is covered by the operators's hand, the 'Light barrier' error - Parameters not initialised. Carry out a reset under the "Functions" menu
signal is immediately indicated (flashes 2x) item
6 Program not started although the parameter programming cable is not - Emergency stop actuated
connected - If emergency stop is not used, the jumper J6.13 - J6.14 must be wired
7 Status LED remains permanently on after the unit has been switched on - Set S5.2 on the control board to "On"
and initialisation has been completed (approx. 10 sec), unit is however not
ready for operation

17 Accessories

The operating terminal is intended for displaying and setting the SpeedHoist
parameters.
Part no.
• Operating terminal with extension cable 650 090 45
• Operating terminal, separate 537 414 84
• Extension cable for operating terminal 609 000 44
• Programming tool (software terminal kit, software incl. cable) 491 440 44
• Cable for programming tool 492 440 44
• CD with software (software terminal) 492 441 44
• Plug protection for D Grip 773 235 44
21475644K4.p65/220903

64
 1 Page(s) Page 1
EC conformity declaration
Ident. no.
Demag D-SH SpeedHoist
in accordance with EC directive 89/336/EEC, Annex I, 98/37/EU,
199 136 44
Annex II A and 73/23/EEC, Annex III Issue 0603 EN

Hereby we,

Demag Cranes & Components GmbH

declare that the product

Demag D-SH SpeedHoist

of serial design ready for use1) with or without the relevant serial trolleys has been
declared in conformity with the provisions of the following relevant regulations:

EC EMC directive 89/336/EEC

amended by 92/31/EEC and 93/68/EEC
EC Machinery Directive 98/37/EC
EC Low voltage Directive 73/23/EEC
amended by 93/68/EEC

Applied harmonised standards:

EN 292-1, 292-2 Safety of machinery
EN 60034-1 Rating and performance for rotating electrical machines
EN 60034-5 Types of enclosures for rotating electrical machines
EN 60204-32 Electrical equipment, requirements for hoists
EN 60529 Types of enclosure (IP code)
EN 60947-1 Low voltage switchgear
EN 61000-6-2 Electromagnetic compatibility – Resistance to interference
EN 61000-6-4 Electromagnetic compatibility – Interference emission
EN 50178 Installation of electronic equipment in power systems

Applied standards and technical specifications:

FEM 9.511 Classification of mechanisms
FEM 9.661 Sizes and design of rope reeving arrangements
FEM 9.683 Travel and hoist motor selection
FEM 9.751 Power-driven series hoist mechanisms, safety
FEM 9.755 Measures for achieving safe working periods

Wetter, 1 June 2003

Place and date of issue

ppa. Gersemsky ppa. Hoffmann

21475644K4.p65/220903

Technik HT GZ Handlingtechnologie

1) Hoist ready for service includes a scope of parts as specified in Works standard 012 313 99.

# = Modifications compared Class. no.

to previous issue Normung 715 IS 813
65
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. Not liable for errors or omissions.
 18 Component parts

18.1 Gearbox with KDP 63 B2 motor

18 19 20 21

15 14 15 16 17

3 4 7 10 6 11 12 13

27 28 29 19

25 26
43 45
22 23 24
40 4142

28 9 3
39 46

34 38

31 32 33 35 36 37
44

55 56

48
54
53
52
51 65
50
49
47

58
57
66 67

59 63 64
58 62 61
21475644K5.p65/220903

60

66 42589944.eps
 18.1 Gearbox with KDP 63 B motor
Item no. Part no. Quantity Designation Material Standard

2 83625744 1 Plug with O-ring

3 32143699 4 Hex.socket cylind.screw M 6 X 40 10 Nm 10.9 A2F DIN 912
4 83410644 1 Gearbox housing DK 1 T.2 1)
6 34149999 4 Shim 12X 18X0,5 St2K50 DIN 988
7 83413944 1 Gearbox seal DK 1 1)
8 83414744 1 Lock nut M12X1 LH
9 34272199 1 Retaining ring 32X1,5 FEDST DIN 472
10 36055199 1 Grooved ball bearing 6201 WLZ-ST !L DIN 625
11 34272199 1 Retaining ring 32X1,5 FEDST DIN 472
12 83413844 1 Pressure ring DK 1
13 33974099 2 Dished washer 40 X20,4X1,5 B 50CRV4 DIN 2093
14 82641844 1 Gearwheel Z 61 M 0,8 B 15
15 83426044 1 Coupling set DK 1 XX
16 82641744 1 Pinion shaft Z 28 m1 B 24
17 35474699 1 Key AB 5X 5X 32 C 45 K DIN- 6885
18 36055199 1 Grooved ball bearing 6201 WLZ-ST !L DIN 625
19 71521144 2 Bush 7 X 12 X10
20 83410844 1 Gearbox housing DS1 T.1 1)
21 34264844 1 Bleeding valve AM10X1
22 36055199 1 Grooved ball bearing 6201 WLZ-ST !L DIN 625
23 34247099 1 Retaining ring 20X1,75 FEDST !L DIN 471
24 82641444 1 Gearwheel Z 73 M 1 B 20
25 34348699 1 Supporting plate 20X 28X2 Fedst DIN 988
26 36055499 1 Grooved ball bearing 6204 WLZ-ST !L DIN 625
27 82641644 1 Drive shaft Z15 M1,25
28 35425599 1 Key B 6X 6X 16 C 45 K DIN 6885
29 36677999 1 Oil seal A 25X 40X 7 NBR !L DIN 3760
31 34251199 1 Retaining ring 10X1 FEDST DIN 471
32 82641144 1 Gearwheel Z 29 M 0,8 B 18
33 82640444 1 Sleeve 10/12X 16 X 8,5
34 15245399 1 Key A 4X 4X 12 C 45 K DIN 6885
35 34272199 1 Retaining ring 32X1,5 FEDST DIN 472
36 36055199 1 Grooved ball bearing 6201 WLZ-ST !L DIN 625
37 36677999 1 Oil seal A 25X 40X 7 NBR !L DIN 3760
38 12439584 1 Rotor KD 63B/D-BE
39 36816299 1 Grooved ball bearing 6002 2RS WLZ-ST !L DIN 625
40 34255944 2 Dished washer 31,7X20,4X0,40
41 34272199 1 Retaining ring 32X1,5 FEDST DIN 472
42 36722599 1 O-ring 94,97X 1,78 N NBR 70 DIN- 3771
43 12418984 1 Stator KDP 63B2 ES AB 230V50HZ
44 31921399 4 Hex.socket cylind.screw M 5 X 10 10 Nm 10.9 A2F DIN 912
45 30249799 4 Stud M 5 X 33X 13 10.9 A2F DIN- 939
46 12481384 1 Cable duct KD63
47 36722599 1 O-ring 94,97X 1,78 N NBR 70 DIN- 3771
48 12485584 1 Brake set KD63/400V50 c/w items 46, 49 - 58
49 12473484 1 Friction plate B002/B003
50 12482884 1 Brake disk KD63
51 12480984 1 Sealing disk KD63
52 12482084 1 Anchor plate KD63
53 12474884 1 Lip seal KD63
54 12482384 1 Retaining plate KD 63
55 12482784 1 Brake spring guide KD 63
56 15246199 2 Pressure spring 1,2 X 7,3X 46,5 D-180U DIN- 2098
57 12484484 1 Housing WS-BR.400V50HZ c/w item 60
58 34301144 2 Plug 5,4X 5,3
59 33703099 4 Hexagonal nut M 5 5 Nm 8 A2F DIN 6923
60 12481084 1 Pass through cable KD63
61 82643444 4 Sheet-metal D-BE 80
62 31882599 4 Hex.socket cylind.screw M 4 X 12 2 Nm 8.8 A2F DIN 912
63 15245699 4 Spacer pin SW 7x45
64 15245599 4 Spacer sleeve 4,3X22, 2
65 12496484 1 Fan 3314 H 24V DC
66 82643244 1 Fan cover KD63 D-BE
67 32168599 4 Hex.socket cylind.screw M 4 X 45 1 Nm 8.8 A2F DIN 912

21475501.tbl
21475644K5.p65/220903

1) Quantity 0,1 litre, part no. 472 902 44 (1,0 kg). 67

 18.2 Rope drum/frame

4 8 5 6 8
1 2 3

7
5 5 15 16
6

5 14

10 13 4

9 45 1

40 41 42 42 41 40

11 12

43 44 43
30 31
25 26 33 19

17 19 18 22 23
24

27

32

34 33 33

36
21475644K5.p65/220903

37

68 42579344.eps
 18.2 Rope drum/frame

Item no. Part no. Quantity Designation Material Standard

1 34045599 3 Washer 6,4X 11 X 1,6 140HV A2F DIN 433

2 32154199 2 Hex.socket cylind.screw M 6 X 30 10 Nm 10.9 A2F DIN 912
3 82644344 2 Rod TYP SWM-10, 201
4 83431144 2 Longitudinal girder DS1-H 7
5 15054599 4 Threaded pin M 8 X 8 45H DIN 916
6 83437544 2 Setting ring DS1
7 82644444 1 Rod 8X320,5
8 34347999 2 Lock washer 7 Fedst DIN 6799
9 82644144 1 End shield A/D-BE
10 32141599 1 Hex.socket cylind.screw M 6 X 22 10 Nm 8.8 A2F DIN- 912
11 15054399 1 O-ring 132 X 3,55 N NBR 70 DIN 3771
12 83437644 1 Cover DS1
13 31817999 4 Cylinder screw M 5 X 20 4.8 A2F DIN 84
14 82644244 1 End shield B/D-BE
15 30044244 1 Lock nut M10 VB.RIPP 40 Nm
16 34255544 1 Plug 30,9X 8,6
17 34348999 1 Supporting plate 12X 18X1,2 Fedst DIN 988
18 15054299 1 O-ring 100 X 3,55 N NBR 70 DIN 3771
19 36816299 2 Grooved ball bearing 6002 2RS WLZ-ST !L DIN 625
22 82642044 1 Rope drum D-BE
23 32200299 2 Countersunk screw M 4 X 12 2,8 Nm 8.8 A2F DIN 7991
24 82642344 1 Rope clamp D-BE
25 82642444 1 Rope guide D-BE
26 83434144 1 Drum axle DS1-H 7
27 82642644 1 Guide element 1/1, 2/1
30 82642544 1 Sleeve D-BE
31 82662044 6m Wire rope 5 X6000+Endbef
31 00000001 6m Hook AH 2,5/1
32 34065399 1 Washer A 6,4X 12 X1,6 140HV A2F DIN 125
33 31958899 4 Hex.socket cylind.screw M 6 X 12 5 Nm 10.9 A2F DIN 912
34 82644644 1 Sheet-metal D-BE 80 Wendelltg
36 34260944 2 Key ring 25
37 89566844 2 Cable clip RD 11
40 15246299 2 Pressure spring 1,1 X10,9X 55,9 D-179M DIN- 2098
41 34347999 2 Lock washer 7 Fedst DIN 6799
42 34147999 2 Shim 8X 14X1 St2K50 DIN 988
43 87461044 2 Switching element SED SPRG
44 83437444 1 Switching lever DS1
45 50468644 1 Screw conn. compl. PG16 RD K

21475502.tbl
21475644K5.p65/220903

69
 18.3 KBK I, KBK II and Aluline classic 120 and 180 trolleys with load bar

1,2
1,2

3
4 6 7
4 3
8
5
3
4

42579444.eps

Item no. Part no. Quantity Designation Material Standard

1 98061044 2 Travel unit with bolt KBKI KBK I, 1)

2 98211044 2 Travel unit with bolt KBKII KBK II, 1)
3 34045499 4 Washer A21 X 37 X3 140HV A2F DIN 125
4 34064399 4 Washer 20 X 32 X 4 KBK I St A2F DIN 1440
4 34064399 1 Washer 20 X 32 X 4 KBK II St A2F DIN 1440
5 83005744 2 Tube 20 X 2 X 22 KBK I
6 85119544 1 Crossbeam D-BE / DS1
7 32147199 4 Hex.socket cylind.screw M 8 X 22 25 Nm 10.9 A2F DIN- 912
8 33950599 4 Washer 8 X 16 X 2 St A2F DIN 1440

21475503.tbl
21475644K5.p65/220903

70 1) For component parts see pages 71

 18.4 KBK I, KBK II, Aluline classic 120 and 180 trolleys

KBK I trolley KBK II trolley

1
1

41400944.eps 41401044.eps

KBK I trolley
Item no. Part no. Quantity Designation Material Standard

1 98061044 1 Travel unit with bolt KBKI

22266417.tbl

KBK II trolley
Item no. Part no. Quantity Designation Material Standard

1 98211044 1 Travel unit with bolt KBKII

22266418.tbl

Aluline classic 120 trolley Aluline classic 180 trolle

1 1

42589744.eps 42589844.eps

Aluline classic 120 trolley

Item no. Part no. Quantity Designation Material Standard

1 85505044 1 Travel unit ALULINE 120

21475504.tbl

Aluline classic 180 trolley

21475644K5.p65/220903

Item no. Part no. Quantity Designation Material Standard

1 85508044 1 Travel unit ALULINE 180

21475505.tbl

71
 18.5 CF 5 trolleys with load bar, flange width 50 – 91 mm

1
1

2
3

42589644.eps

Flange width 50 – 91 mm
Item no. Part no. Quantity Designation Material Standard

1 84020544 2 Click-Fit travel unit CF 5 Azurblau 1)

2 32147199 4 Hex.socket cylind.screw M 8 X 22 25 Nm 10.9 A2F DIN- 912
3 33950599 4 Washer 8 X 16 X 2 St A2F DIN 1440
4 41686646 1 Crossbeam travel unit CF5 H7

21475506.tbl
21475644K5.p65/220903

72 1) For component parts see pages 73

 18.6 CF 5 trolleys with load bar, flange width 50 – 91 mm

1
2

5 8

41665545.eps

Flange width 50 – 91 mm
Item no. Part no. Quantity Designation Material Standard

1 84020544 1 Click-Fit travel unit CF 5 Azurblau c/w items 2 - 5

2 34287544 1 Securing clip SL 10 SXN08
3 84001544 1 Fuse-element CF8
4 84002244 1 Setbolt 10 X64,8Nut
5 84002744 1 Tube 16 X 2,8 X 29
6 84002544 1 Bracket supporting eye CF5/8
7 84002144 1 Setbolt 12H11X 30 Nut
8 34287644 1 Securing clip SL 12 SXN08

21475511.tbl
21475644K5.p65/220903

73
 18.7 RU trolleys with load bar, flange width 50 – 90 mm

2
1
3

2
5
4

42589544.eps

Item no. Part no. Quantity Designation Material Standard

1 83961044 4 Side plate trv.whl.univ.w/o g.rim 1)

2 83961944 2 Crossbeam RU 3 DS 1 1)
3 83005244 1 Crossbeam DS1-H 7 KBK
4 32147199 4 Hex.socket cylind.screw M 8 X 22 25 Nm 10.9 A2F DIN- 912
5 33950599 4 Washer 8 X 16 X 2 St A2F DIN 1440

21475508.tbl 21475644K5.p65/220903

74 1) For component parts see pages 75

 18.8 RU trolleys, flange width 50 – 90 mm

41665744.eps

Item no. Part no. Quantity Designation Material Standard

2 83961044 2 Side plate trv.whl.univ.w/o g.rim c/w items 4 - 6

4 83960744 1 Capacity plate 450KG
5 83961544 2 Universal travel wheel RU 3DK
6 83970744 2 Bush 12,1X 27 X 9
7 33460199 2 Hexagonal nut M16 X1,5 50 Nm 8 A2F DIN 985
8 56302344 12 Washer 16,5X 25 X 4
9 83961944 1 Crossbeam RU 3 DS 1 c/w items 7, 8, 10, 11
10 83961644 1 Pin cross beam RU 3/DS1
11 83961844 2 Tube 26,9X 2,65X 31

22266412.tbl
21475644K5.p65/220903

75
 18.9 Electrical components

5 4 6

10

11

9 8 7

1 2 3

42589344.eps

Item no. Part no. Quantity Designation Material Standard

1 82643144 1 Cover D-BE 80

2 32001499 2 Hex.socket cylind.screw M 6 X 25 6 Nm 10.9 A2F DIN 912
3 36714599 2 O-ring 5 X2 B NB 70 DIN 3770
4 83422144 1 Seal DK 1 3 X 605
5 82644544 1 Intermediate ring D-BE 80
6 46980144 1 Switchgear set 400/ 24V50HZ VDE Main-/creep lift 1) 2)
7 83605644 2 Plug-in unit PG16
8 83605144 1 Slide-in connection piece 20/3
9 83605244 2 Plug-in unit, dummy PG21
10 60080699 1 Counter nut PG21 M CUZN E2E DIN 46320
11 50468644 1 Screw conn. compl. PG16 RD K

21475509.tbl
21475644K5.p65/220903

1) Suitable for 380 V, 400 V 415 V operating voltage.

76 2) With crane switch.
 18.10 D Grip and accessories

4
2

5 3

9
8 10

11
13 18
12

19

14 12 13

15

16 17 20
42578244.eps

Item no. Part no. Quantity Designation Material Standard

1 77324744 1 Cable box 6-8MM,Winklig

2 77323544 1 Protective plate
3 77325544 1 Sub-assembly D-Grip 1D Solo
4 77325144 2,8m Helix cable M.Dose D-BP
5 60078544 1 Rope clamp 5 - 6,5M 5
6 15183799 1 Rope socket kpl 5 ST37 DIN 15315
7 34327299 2 Oval-head screw M 5 X10 4.8-H-A2F DIN 7985
8 65007145 1 Round cable 7X 0,34 Gesch. 1)
8 77206844 1 Cap DSM5
9 77203944 1 Helix cable entry fitting DSM5
10 77324844 1 Cable terminal 6.6-8.0 SW
11 77326244 2 Swivel joint half D-BP
12 32154699 2 Hex.socket cylind.screw M 8 X 40 25 Nm 10.9 A2F DIN 912
13 15056599 2 Hexagonal nut M 8 8 A2F DIN 985
14 77324644 1 Cap unlocking
15 35185399 2 Self-tapping screw ST 3,5X13 -C-H ST A2F DIN 7981
16 77305944 1 Capacity plate D-BP 55KG
17 15056399 2 Hexagonal nut M 5 8 A2F DIN 985
18 77325944 1 Mark D-Grip
19 77322444 1 Covering foil
20 34426999 2 Cylinder pin 6 H 8X 50 1.0718KA2F DIN 7
21475644K5.p65/220903

21475510.tbl

1) Supplied per metre, state length required when ordering.

77
 Printed in Germany PDF 220903

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