MHE-Demag - Component Torque Handbook

Foreword
This handbook only serves as a general service guideline for tightening torque of
common MHE-Demag components, and is not exclusively covering all the bolts and
nuts needed to be torqued according to the manufacturer’s recommendation. If you
have any query or doubt about the information in this booklet, kindly notify the source
immediately. Most of the information is extracted from respective catalogues or the
source and is indicated on each page. If you need more information, please refer to
the actual referenced catalogue/manual accordingly.

The torque unit used in this handbook is in Nm, unless otherwise stated.

Content

1. Torque Information for P-Hoist page 01

2. Torque Information for DR Hoist page 02
Adjusting Thrust Rocker for DR hoist page 03
3. Torque Information for DH Hoist page 04
4. Torque Information for DBR Hoist page 05
5. Torque Information for DK/PK Chain Hoist page 06
6. RU/HU/EUDK trolleys page 08
7. Torque Information for U11 – U56 Trolley page 10
8. Torque Information for DWS Wheel page 12
9. Torque Information for DRS Wheel page 13
10. Torque Information for RS Wheel page 14
11. Torque Information for KB, ZB Motor and B brake page 15
12. Torque Information for Rail Clip – Gantrail page 17
Torque Information for Rail Clip – Bemo page 18
13. Girder & End Carriages –Torque & Sequence page 19
14. Splice Joints – Torque & Sequence page 20
15. KBK System page 21
16. Demag DMR Hoist page 24

Date Issued : April, 2019

1. Torque Information for P Hoist
Details can be found in Catalogue no. 20604044
Tension
Rope Clamp Brake Cap Adjusting Nut
Spring
Hoist Model [30] [20;62] [20;59]
[34]
page 27 page 27 page 28 page 30
P100 14 6 25 50
P200 14 11 25 50
P400 28 25 60 87
P600 28 25 60 87
P1200 55 25 60 87
P2000 110 25 213 213
Table 1

Torque guideline for DR hoist

Page 1 of 30
2. Torque Information for DR Hoist
Details can be found in Catalogue no.21472944 page 47

Hoist Motor Rope Guide Wheel Lock Motor End

Hoist Model Flange Screw Screw Cap
[item 4] [item 5] [item 6] [item 12]
DR3 75 10 50 4
DR5 120 10 80 4
DR10 120 10 185 6
DR 20 Identify bolts size and refer bolts torque table
Table 2

Page 2 of 30
Adjusting Thrust Rocker for DR hoist

Flange thickness (mm) No of washer (pcs)

DR3 DR5 DR10 item 11 item 12
10 -12 10 - 17 9 9
10 - 14
13 - 16 18 - 23 7 7
6 6
15 - 20
17 - 21 24 - 29 5 5
22 - 27 3 3
21 - 27
30 2 2
28 - 30 28 - 30 1 1

L dimensions (to be shortened) mm

DR3 DR5 DR10
- 6.2 - 5.2 -7.5

Page 3 of 30
3. Torque Information for DH Hoist
Details can be found in Catalogue no. 20670644

Motor Adjusting Brake Rope Guide Rope

Hoist
Cap
Model Flange Nut Screw Clamp
[item 24] [item 38] [item 44] [item 14,15, 47] [item 17]

DH 200 68 M5 = 6 10 14
DH 300 68 M6 = 11 10 36
DH 500 117 M8 = 25 Refer to Page 10 70
DH 600 117 M8 = 25 16 10 70
DH 1000 284 M10 = 50 10 121
DH 2000 284 M12 = 86 10 121
Table 3

Torque guideline for DH hoist

Detail for this guideline please find in Document no 20670644

Page 4 of 30
4. Torque Information for DBR Hoist
Details can be found in Catalogue no. X112281-DBR-OWNER 7.1 , page 65

Bolt Type
Bolt Size
8.8 Class 10.9 Class 12.9 Class
M2 Hand Tight Hand Tight Hand Tight
M3 Hand Tight Hand Tight Hand Tight
M4 Hand Tight Hand Tight Hand Tight
M5 Hand Tight Hand Tight Hand Tight
M6 Hand Tight Hand Tight Hand Tight
M8 25 35 42
M10 49 69 83
M12 86 122 145
M14 136 190 230
M16 210 300 360
M18 290 410 495
M20 410 590 710
M22 560 790 950
M24 710 1000 1200
M27 1040 1460 1750
M30 1410 2000 2400
M33 1910 2700 3250
M36 2460 3500 4200

Table 4
For DBR Hoist series, the amount of torque to apply is depending on the bolt size
and type. Please refer to the Table 4 above for the right amount of torque.
These tightening torque values are for Screws DIN912, DIN931, DIN933 and Nuts DIN934, DIN935,
DIN982, DIN985, DIN98. Other tightening torque values must be specified in the drawings.

NOTE
It is recommended that the self-locking nuts (Nyloc nuts) should always be replaced
If is removed.

Page 5 of 30
5. Torque Information for DK/PK Chain Hoist
Torque information as per pictures shown:

Page 6 of 30
Page 7 of 30
6. RU/HU/EUDK trolleys
Details can be found in catalogue no. 20650144 Page 54-55

RU 3/RU 6 DK

RU 11/RU 22 DK

42 Nm

HU 11/HU 22 DK
EU 11/EU 22 DK

Page 8 of 30
RU 36 DK / RU 55 DK EU 36 DK / EU 55 DK 42 Nm

Tightening torque 160 Nm

Page 9 of 30
7. Torque Information for U11 – U56 Trolley
Bolt Type
Bolt Size Trolley Size Torque Catalogue No.
8 mm U11 18
U22,U34 20356944
10 mm 36
EU22, EU34
12 mm U56, RU56 55 20369144
10 mm DMR 36 TBA
12 mm DMR 55 TBA
Table 5

Grub screw is a small headless screw, used typically to attach or to lock between 2
parts, also commonly known as Set screw. The original grub screw from Demag is
coated with a layer of "micro-encapsulated locking agent", and during the installation
process where the technician may need to adjust the final position, the grub screws
must be tightened within 60 minute, or else, the grub screws must be replaced by
new ones.

U 11

Page 10 of 30
RU 56

Warning
The grub screw can be used once only. Once the grub screw is set, it should never
be loosened anymore. If the grub screws needed to be loosened for whatever
reason, it MUST BE REPLACED BY NEW SCREWS.

New Grub Screw Used Grub Screw

Page 11 of 30
8. Torque Information for DWS Wheel
Details can be found in Catalogue no. 21413344, pg 10-16

Flange
Bolt
Wheel Bearing
Connection
Range Housing
[item 12] [item 3]
DWS 400 300 300
DWS 500 300 300
DWS 630 720 580
Table 6

Page 12 of 30
9. Torque Information for DRS Wheel
Details can be found in Catalogue no. 21427644 pg 16-19 & 23

Flange
Bolt
Wheel Bearing
Connection Bolt Size
Range Housing
[item 4;6] [item 5;12]
DRS 112 55 60 M10 x 30
DRS 125 95 130 M12 x 35
DRS 160 230 330 M16 x 45
DRS 200 450 554 M20 x 60
DRS 250 TBA 580 M20 x 70
DRS 315 TBA 710 M24 x 50
Table 7

Page 13 of 30
10. Torque Information for RS Wheel
Details can be found in Catalogue no. 20259744 page 42 - 49

Bolts
[ item Torque
18;23;34]
M10 x 30 60
M12 x 35 130
M16 x 45 330
M20 x 60 554
M20 x 70 580
M24 x 50 710
Table 8

Page 14 of 30
11. Torque Information for KB, ZB Motor and B brake

Terminal Box
Motor Type Motor Size Fan cover
Cover
71 NA 3
100 NA 3
112 NA 3
125 NA 3
KB 140 NA 3.5
160 NA 3.5
180 NA 3.5
200 NA 5
225 NA 5
71 4 3
100 4 3
112 6 3
125 6 3
ZB 140 8 3.5
160 10.5 3.5
180 10.5 3.5
200 10.5 5
225 10.5 5
Table 9

Page 15 of 30
 B Brake ,Catalogue No. 21404144 page 13
Model Screw 1 Torque
B004 M4 1
B007 M4 1
B020 M5 2
B050 M5 2
B140 M6 3
Table 10

Page 16 of 30
12. Torque Information for Rail Clip
Gantrail Clips
Gantrail Bolt Type
Clip Model 4.6 Class 8.8 Class
2112 35 85
3112 35 85
3116 75 200
3120 160 390
7120 275 390
3124 275 600
3224 NA 600
9116 NA 125
9120 NA 250
9124 NA 450
9216 NA 150
9220 NA 250

Table 11

Page 17 of 30
Bemo Clips

Bemo Bolt Type

Clip Model 5.8 Class 8.8 Class
FM16 125 200
FM20 240 390
FM24 370 600
AM16 125 200
AM20 240 390
AM24 370 600
WDM16 NA 130
WM16R NA 130
WM20 NA 250
WM24 NA 450
SKL1 NA 250
SKL3 NA 200
KPO3 NA 240
KPO6 NA 240

Table 12

Page 18 of 30
13. Girder & End Carriages –Torque & Sequence
(For Engineered Cranes)

For more details, please check Black Diamond -> Working Instruction -> Demag
Work Norms -> Bolts -> Tightening Bolts

Page 19 of 30
14. Splice Joints – Torque & Sequence
(For Engineered Cranes)

Page 20 of 30
15. KBK System
Details can be found in Catalogue no. 20607644_180607 page 25
Bolt Size Required Torque Descriptions
KBK 100, I, I Ergo track suspension clamp
KBK I crane suspension eye
KBK 100 joint bolt set
M6 10 Nm
Hoist trolley locking device
Canopy
Extension locking device bolted bracket
KBK II-L, II, II Ergo, III track suspension clamp
KBK I joint bolt set
KBK II-H, III suspension
KBK II, II-H crane suspension eye
M8 25 Nm
Pressure clamp
Hoist trolley locking device
Canopy
Load bar for DS 1 rope winch, D-SH SpeedHoist and D-BE rope balancer
KBK 100, I suspension
Fastening upper suspension bracket with clamps to I-beam flange
Suspension from solid ceilings with U-bolt
Suspension from solid ceilings with threaded rods and counter-plates
45 Nm
M10 KBK III buffer
KBK III link bar
KBK I Ergo trolley fittings
Bolted connection for bracing frame
85 Nm KBK Ergo buffer additional stop
RF 100 PN travel drive counterweight
40 Nm
Motor with RF 100 PN travel drive torque bracket
KBK II-L, II joint bolt set
DRF trolley
M12
80 Nm KBK II Ergo end carriage on stiffener plate, L-shaped steel angle for fitting the mast
KBK III crab frame
KBK III crane end carriage
130 Nm KBK II Ergo trolley on trolley fittings, end carriage, extending frame
30 Nm KBK Ergo suspension counter-nut
60 Nm Halfen bolt
KBK II-H, II suspension
KBK Ergo suspension
Fastening upper suspension bracket with clamps to I-beam flange
120 Nm
Suspension from solid ceilings with U-bolt
Suspension from solid ceilings with threaded rods and counter-plates
M16 Classic crane end carriage suspension bracket on KBK II-H
KBK III joint bolt set 8.8 (until the end of 2010)
150 Nm
KBK III single-axle trolley
KBK III trolley
195 Nm Reinforcing section for KBK II current collector trolley maintenance section
Bolted connection for bracing frame
200 Nm KBK II-H, KBK III joint bolt set 10.9 (from the end of 2010)
250 Nm Reinforcing section for KBK II-H current collector trolley maintenance section
M20 120 Nm Halfen bolt
M24 200 Nm Halfen bolt
M30 120 Nm KBK Ergo suspension counter-nut

Page 21 of 30
Metal nuts featuring a locking element (self-locking nuts) are mainly used for KBK installations. Self-
locking nuts must not be replaced by other types of nut must be replaced when they have been
tightened and untightened five times.

Track Suspension System

KBK II-H suspension KBK III suspension M20 suspension

Please Note: All diagrams showed only partially extracted from catalogue 20607644. For complete
possible configurations, please refer to catalogue accordingly.

Joint Bolt Set

Connecting KBK100, I, II-L, & II track sections Connecting adapter joint bolt set KBK II-H profiles & III profiles with M16 - 10.9bolt set

bolt set)

Page 22 of 30
Buffer and End Cap
KBK 100, I, II-L, II, II-H end cap KBK III end cap, buffer stop

Internal Buffer Stop

Buffer/End Cap

Trolley & Link Bar

Please Note:
All diagrams showed only partially
extracted from catalogue 20607644. For
complete possible configurations,
please refer to catalogue accordingly.

Link Bar
Trolley

Note: Please read catalogue 20607644 or check with your superior if you cannot find
the information required.

Page 23 of 30
16. Demag DMR Hoist
Please refer to catalogue no. 21128344_181123 for details.

Item Demag DMR Hoist Page

1 Installing EK-DMR Low headroom monorail hoist 45-46
2 Installing/adjusting thrust rocker 46-48
3 Adjusting DualDrive two-wheel drive 50
Installing EK-DMR Low headroom monorail hoist with counterweights
4 51-52
(without thrust rocker)
5 Installing the protective cover 57
6 Installing the wire rope in the rope socket 58
7 DMR Geared Limit Switch 65-66
8 Fitting the wire rope clamp 84
9 Fitting the rope guide segments & rollers 86-87
10 Installing the fan cover and fan 96
11 Installing brake 101
12 Bore hole arrangement and maximum force per bolt 108-109

1. Installing EK-DMR Low headroom monorail hoist

150 Nm

35 Nm
F Travel unit side H Hoist unit side
1 Lower flange of crane girder 2 Travel wheels
3 Trolley leg 4 Guide rollers
5 Threaded pin 6 Adjusting ring on each connecting rod
7 Thrust rocker 8 Hexagon bolt

NOTE. Finally tighten the threaded pins on adjusting ring (6) no later than 30 minutes after first
tightening the threaded pins, as they are provided with a micro-encapsulated bolt-locking agent which
hardens after tightening and secures the threaded pins against loosening. If the threaded pins are
loosened after 60 minutes or later, they must be replaced with new ones or secured with Loctite 290.

Page 24 of 30
 2. Installing/adjusting thrust rocker
10 Nm
10 Nm

25 Nm

1 Thrust rocker cpl. I Pressure roller, part I

2 Adapter (only for EK-DMR 3) II Pressure roller, part II
3 Two-piece clip 4 Locknut
5 Hexagon bolt
7 Pressure spring
13 Tabs on the halves 14 Cable tie

3. Adjusting DualDrive two-wheel drive 28 Nm

NOTE. The DualDrive unit is not pre-tensioned when the EK-DMR monorail travelling hoist is
delivered. Themulti-V belt must be tensioned when the unit is first put into operation.
Turn preset bolt (A) eight times in the clockwise direction to apply the corresponding tension of 650 N
to the multi-V belt. Tighten retaining bolt (B).Tightening torque 28Nm. The multi-V belt is now
tensioned and the EK trolley is ready for operation.

Page 25 of 30
4. "Installing EK-DMR Low headroom monorail hoist with counterweights
(without thrust rocker) "

1.1 90 x 110 x 1 shim

1.2 90 x 110 x 1 shim
2.1 90 x 3 retaining ring
2.2 90 x 3 retaining ring
3 M10 x 95 hexagon socket bolt
4 M10 locknut
5 16 mm counterweights
30 Nm
6 M8 x 25 threaded pin
7 Sleeve, counterweight carrier

NOTE.
Finally tighten threaded pins (6) no later than 30 minutes after first tightening the threaded pins,
as they are provided with a micro-encapsulated bolt-locking agent which hardens after
tightening and secures the threaded pins against loosening. If the threaded pins are loosened
after 60 minutes or later, they must be replaced with new ones or secured with Loctite 290.

5. Installing the protective cover

4 Nm

Page 26 of 30
 6. Installing the wire rope in the rope socket

1 Rope wedge 2 U-bolt

3 Clamping plate 4 Washer
5 Nut 6 Rope socket

7. DMR Geared Limit Switch

You need to remove the cover on the foot flange to make adjustments to the geared limit switch by
unscrewing the four M8x35 hexagon socket bolts. When the geared limit switch has been adjusted,
re-install the cover and tighten the M8x35 hexagon socket bolts with a torque of 15 Nm.

Page 27 of 30
8. Fitting the wire rope clamp

9. Fitting the rope guide segments and rollers

All bolts tightening force is 6 Nm

1 Side section 1 2 Rope guide rollers

3 Segment I (with rope guide rollers) 4 Upper segment connection
5 Torque bracket 6 Segment II
7 Side section 2 8 Lower segment connection
11a-c Cover plates 12 Retaining bolt

Page 28 of 30
10. Installing the fan cover and fan

11. Installing brake

Page 29 of 30
12. Bore hole arrangement and maximum force per bolt

Page 30 of 30