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Operating instructions/accessories/component parts

1. C I I 13 IN y 14 4 m mM A z A Y M y E i D y 8 Fs Ka PE O T i 1 43229644 eps Fig 23 Item Designation Terminal strip Function 1 Plug and socket con X8 Motor nector 2 Plug and socket con X6 Brake nector Relay Fast slow Relay Lifting lowering 5 Relay Lifting lowering from 2009 47 48 Item Designation Terminal strip Function 6 Contactor On off 7 Transformer 8 Plug and socket con X1 Line nector 9 Fork light barrier Pulse generator 10 IR transmitter diode IR interface 11 7 segment LED Multi function display e g elapsed operating time counter status indicator error code display 12 Plug and socket con X4 Lifting limit switch nector 13 Dummy plug X5 Optional trolley 14 Plug and socket con X3 Control cable nector SN Serial number Label with Serial no SN Modification version MV Production date calendar week year Tab 28 42741844 xml eps Fig 24 Pin 1 1 4
2. Item Display Malfunction event Possible cause Remark 1 4 1 SLIP LIFTING start up No A mains phase is missing or the motor is blocked Check mains connection and fuse link check connection lifting cable for interruption check mains connector in the service No lifting with load enclosure Chain hoist overloaded or undervoltage Reduce load to the permissible load capacity Ensure ap propriate mains voltage 2 4 2 SLIP LIFTING V1 Cut out Limit switch contact is no longer actuated is displayed when the limit switches function correctly in the upper limit position The slipping clutch acts as an emergency stop device if there is a malfunction Limit switch contact connection and operation must be in spected by an experienced technician 3 4 3 SLIP LIFTING V2 Cut out Limit switch contact is no longer actuated is displayed when the limit switches function correctly in the upper limit position The slipping clutch acts as an emergency stop device if Fast lifting with load is there is a malfunction switched off Limit switch contact connection and operation must be in spected by an experienced technician Chain hoist overloaded Reduce load to the permissible load capacity 4 4 4 Defective internal data Defective control system Replace control system memory 6 4 6 No speed information Hardware monitoring malfunction Repeat lifting process if the load does not move have the brake and control
3. Tightening torques Nm DC Com 1 DC Com 2 DC Com 5 DC Com 10 Electric equipment cover 9 5 Service cover 5 5 7 5 Control cable locking mechanism 11 0 Tab 67 95 96 9 Malfunctions warnings 9 1 Safety instructions for malfunctions warnings WARNING Inappropriate fault elimination Danger to life and limb Risk of damage to the machine Faults may only be eliminated by qualified instructed personnel Definition of personnel Page 10 in compli ance with the safety regulations DANGER Live components Danger to life and limb Work on electric equipment may only be carried out by qualified specialist personnel Definition of person nel Page 10 in compliance with the safety regulations Switch off the electric power supply before starting work The mains connection or isolating switch must be pro tected against unauthorised or accidental restoration of the power supply by means of a padlock WARNING Risk of burns Risk of burns from contact after the chain hoist has been in operation Do not touch hot motor housings Allow the motor to cool down before elmininating the fault Conduct when malfunctions occur 1 Bring the machine to an immediate standstill by actuating the emergency stop without delay if malfunctions occur that result in an immediate danger of personal injury damage and or an operating hazard 2 Switch the chain hoist off at the mains connection switch or isolating switch
4. Item Part no Qty Designation Material Standard 53 71792033 1 Service cover set DC 2 5 5 Nm 53 71892033 1 Service cover set DC 5 5 5 Nm 53 71592033 1 Service cover set DC10 7 5 Nm 54 71881033 1 Control cable set 5m 11 Nm 54 71880933 1 Control cable set 8m 11 Nm 54 72003745 1 DC control cable 11m 11 Nm 56 77330033 1 DSC control pendant 57 71880433 1 Emergency stop set rubber cap DSC S 58 72027145 1 Bag Hose cpl 65 75371033 1 DSC protection Bending impact 21480104 tbl 214802ET indd 291113 214 802 44 291113 Index A Actual load spectrum factor 66 Actual duration of service 66 AC asynchronous motor 28 B Bayonet lock 35 31 95 Bend protection sleeve 35 Buffer 52 Buffer plate 52 87 C Cable collector 38 Canopy 27 Chain wear 76 Contactor control 29 Continuity of the PE conductor connection 33 Control cable locking mechanism 37 Control cable snag protection 36 Counterweight compensation 41 Cut off spring 87 D Damping plate 52 E Elapsed operating time counter 30 F Factor depending on the type of recording 66 Infrared interface 29 L Load spectrum factor 66 N Number of operating hours 66 O Operating limit switches 29 P Phase sequence 43 R R S T network 43 Rating plate 2 Reeving 41 Retaining clip 41 S Self locking nuts 33 Special fittings 41 Starting and stopping frequency 64 Strain relief attachment 42 Strain relief hose 31 Switching cycles 30 Swivel lock
5. Cordon off a large area around the working zone WARNING A 3 7 2 3 7 3 3 7 4 Damage caused during transport The chain hoist may be damaged or destroyed by inappropriate transport Attach lifting and handling equipment only at the correspondingly marked points Scope of delivery If special designs or additional options are ordered or the latest technical modifications are incorporated the ac tual scope of supply may differ from the data and information as well as from the illustrations described here If you have any questions please contact the manufacturer Transport inspection e Check the delivery to ensure it is complete and for any transport damage immediately on receipt e f any transport damage is visible from the outside do not accept the delivery or only on condition Note the scope of damage in the shipping documents delivery note of the forwarding company Lodge a claim e Lodge a claim for any defects as soon as they are detected since claims for damages may only be asserted within the relevant claim notification periods Packing Demag chain hoists the accessories and the trolleys are shipped in cardboard packing If no agreement has been made on the return of the packing material separate the materials according to type and size and make them available for further use or recycling Environmental protection e Always dispose of packing materials in an environmentally compatible way and according t
6. 214 802 44 291113 214 802 44 291113 8 5 7 2 Buffer arrangement Buffer variants A B 42770445 XML eps Fig 61 1 Buffer 2 3 Buffer plate Cut off spring Chain hoist range Load hook side Chain collector box side DC Pro 1 10 DC Com 1 10 with operating limit switch E DC Pro 1 10 C D DC Com 1 10 without operating limit switch E F DC Pro 1 10 G H DC Pro 15 J K Tab 63 87 88 8 5 8 8 5 8 1 8 5 8 2 Brake Brake assignment Load capacity Chain hoist Reeving Motor size Brake Max brake displacement kg DC Com mm 80 125 1 ZNK 71 B 8 2 160 250 2 ih BK03 315 500 5 ZNK 80 A 8 2 0 6 630 1000 ZNK 100 A 8 2 10 BK07 1250 2000 2 1 ZNK 100 B 8 2 Tab 64 Check brake wear Check brake wear depending on the year of manufacture of your chain hoist e When the max brake displacement is reached see Tab 64 Page 88 the brake must be replaced immedi ately e For brake displacement up to 0 5 mm the brake can still be used until the next maintenance is due As of year of manufacture 04 2009 427717044 xml eps Fig 62 Since 04 2009 depending on the size of model brakes have been gradually equipped with a plug inside the brake housing to enable brake wear to be measured without the need to remove the brake Brake wear is meas ured by
7. Demag Cranes amp Components GmbH PO Box 67 58286 Wetter Germany Phone 49 0 2335 92 0 Fax 49 0 2335 92 7676 www demagcranes com Reproduction in whole or in part only with prior consent of Demag Cranes amp Components GmbH 58286 Wetter Germany Subject to change Not liable for errors or omissions Printed in Germany
8. CIO QC Tool 43214444 eps Fig 11 All important service work can be carried out at a central point the service enclosure The relevant connectors for power supply control pendant and travel drive are arranged under the impact resistant plastic cover The chain is also lubricated from this point In addition any control cable length that is not required is kept under the cover The plastic cover also provides mechanical protection for the components fitted under it The functions are indica ted by pictograms fitted on the outside of the service cover Control pendant control cable height adjustment The control cable is protected by a flexible easily bent strain relief hose Its suspension height can be specifically adapted to the requirements at the workplace at any time by means of an adjusting mechanism To do this it is not necessary to cut the cable conductors or to shorten the strain relief hose The length of control cable that is not needed is stored under the service cover The strain relief hose is fixed at the selected suspension height by means of a self locking clamp mechanism The control pendant can be adjusted to a different suspension height by unlocking the clamp mechanism The strain relief hose for the control pendant consists of an abrasion resistant fabric hose with flame protection impregnation The control cable is reinforced by means of elastic rubber filler material in the gripping area 0 8
9. We recommend that the contactor or the control module be replaced when the relevant display value has been reached Replacing the contactor on the control board Page 92 S W P measures for achieving safe working periods General The safety and health provisions of the EC Machinery Directive make it a legal requirement to eliminate special hazards which may be caused for example by fatigue and ageing This requirement is also reflected in the third supplement to German accident prevention regulations UVV BGV D8 of 1 4 1996 This requirement obliges the owner of serial hoist units to determine the actual duration of service of the chain hoist 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 over the entire duration of service although according to the state of the art the chain hoists 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 electric chain hoist 1 The actual duration of service determined on the basis of operating time and load must be documented at least once per year 2 Operating time T number of operating hours can be estimated or read on an elapsed time indi
10. ire duc ca rg x 88 olipping clutch i as inter e e e RR RE DURUM TORRE HER E UE HERE E e Be PE CINE TAE 90 Checking the slipping clUtch 2 nire mceeet eit e En ete edere eed eie deed ea cede ee ede e ede 90 Adjusting the slipping cl tel 2r oen e treated ee oe de re eere Deae etude 90 Gearbox oil CHANGE 0 91 Replacing the contactor on the control board sssssssssseseenen een nennen enne nene nnnm 92 Replacing the control cable iiiter eee eee eee de ee E ic hie Ee U AEAN Ede ede EHE e ede ed 94 9 1 9 2 9 3 9 4 9 5 10 10 1 Malfunctions warhings rre cierre eint ten eet Di ere dee eoa AA 96 Safety instructions for malfunctions warnings sss emen nennen nee nennen nnne nen nennen 96 Jenner 96 Operating statuses general Messages aie ieaiai ieie eene nnnm nere enne neret nennen nennen nen nennen 97 Warnirig messages oir ee t Dh ep Ace la taxe bee podra pend pe tp sae dee E duda dus 98 Error messages tasto aee ite ud aar dette a e eps 99 Disassembly disposal 1 1 2 ai aldeas 100 General alitas 100 AOS A eea EO 101 A E O 101 Spare PAUSA A AA A iati t 102 ND A A A es a ee Ss 102 Motion A O Ac 103 Parts 0n the gearbox i
11. kg kg 160 2m M5 200 2 4 2x12 2 ZNK 71 B 8 4 21 22 24 LLL 1Am M4 250 1 1 4 0 2 0 4 8 2 4 4 5 and 8 315 2m M5 400 5 5 3x15 2 ZNK 80 A 8 4 27 28 30 RA 1Am M4 500 Tab 7 4 Since 04 2006 the designation for sizes DC 10 and DC 20 have been changed to DC 10 1 1 and DC 10 2 1 respectively 9 Replacement gearboxes for DC Com units delivered until 12 2013 will be supplied with higher FEM classification as of 01 2014 6 Larger hook paths on request 7 Motor key data Hoist motor data Page 20 8 ZNK 71 A 8 2 with 380 415 V 50 Hz only for first delivery a ZNK 71 B 8 2 motor is supplied for replacement requirements 19 20 3 4 3 4 1 Electric key data Hoist motor data Size Motor size No of Py CDF Ny Starts h Min max currents and start up current 9 polos d IN min IN max Imax 19 lan max COS on kW rpm A A A 220 240 V 50 Hz 3 CE 11 8 0 05 20 720 240 1 75 2 10 2 10 1 45 0 48 DC Com 1 ZNK 71 B 8 2 2 0 18 40 2950 120 2 10 2 80 2 80 2 75 0 46 8 0 07 20 695 240 1 80 2 10 2 35 1 45 0 52 DC Com 2 ZNK 71 B 8 2 2 0 30 40 2880 120 2 30 2 80 3 20 2 75 0 55 8 0 10 20 720 240 1 90 1 90 2 15 2 50 0 46 DC Com 5 ZNK 80 A 8 2 2 0 41 40 2910 120 3 60 4 70 5 50 4 70 0 49 8 0 19 20 705 240 2 80 3 10 3 65 1 90 0 48 ZNK 100 A 8 2 2 0 75
12. 0 46 2925 40 20 oos 140 048 720 20 CE D 68300 Wetter 71847045 12 42770344 eps 120 Made in Germany Fig 1 Example of a rating plate The metric system is used in this document and all figures are shown with a comma as the decimal separator Item Designation 1 Manufacturer See above g Model code Page 18 27 perhaps Selection table Page 19 3 Serial no calendar week year of manufacture 4 Load capacity group of mecha Model code Page 18 nisms Selection table Page 19 Available hoist chains Page 77 5 Chain type hook path Model code Page 18 Selection table Page 19 6 Voltage frequency Hoist motor data Page 20 1 Type of enclosure insulation Operating conditions Page 27 class gt Hoist motor data Page 20 8 Ambient temperature Operating conditions Page 27 Selection table Page 19 9 Motor Type Hoist motor data Page 20 10 Electric key data Hoist motor data Page 20 11 Conformity symbol 12 Manufacturer s address See above Tab 2 214 802 44 291113 214 802 44 291113 Table of contents 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 2 1 2 2 2 3 24 2 5 2 6 2 7 2 8 2 9 3 1 3 2 3 3 3 4 3 4 1 3 4 2 3 4 3 3 5 3 6 3 7 3 7 1 3 7 2 3 7 3 3 7 4 3 7 5 3 8 3 8 1 3 8 2 3 8 3 3 9 4 1 4 2 4 3 4 4 4 4 1 A PT Em 7 DGOsComich ain OS di ed
13. 40 2850 120 3 50 4 00 4 50 4 85 0 65 DC Com 10 8 0 37 20 735 240 ZNK 100 B 8 2 2 1 50 40 2955 120 380 415 V 50 Hz 3 CE 11 8 0 05 20 700 240 0 95 1 10 1 10 1 20 0 66 ZNK 71 A 8 2 12 2 0 18 40 2840 120 1 20 1 40 1 40 2 60 0 57 DC Com 1 8 0 05 20 700 240 1 00 1 20 1 20 1 45 0 48 ZNK 71 B 8 2 2 0 18 40 2840 120 1 20 1 60 1 60 2 75 0 46 8 0 10 20 675 240 1 00 1 20 1 35 1 45 0 52 DC Com 2 ZNK 71 B 8 2 2 0 37 40 2825 120 1 30 1 60 1 85 2 75 0 55 8 0 18 20 665 240 1 10 1 10 1 25 2 50 0 46 DC Com 5 ZNK 80 A 8 2 2 0 72 40 2745 120 2 10 2 70 3 20 4 70 0 49 8 0 27 20 690 240 1 60 1 80 2 10 1 90 0 48 ZNK 100 A 8 2 2 1 10 40 2745 120 2 00 2 30 2 60 4 85 0 65 DC Com 10 8 0 57 20 675 240 3 90 4 60 5 40 2 30 0 42 ZNK 100 B 8 2 2 2 30 40 2790 120 5 40 6 30 7 70 5 10 0 49 500 525 V 50 Hz 3 CE 8 0 05 20 720 240 0 75 0 95 0 95 1 45 0 48 DC Com 1 ZNK 71 B 8 2 2 0 18 40 2925 120 0 90 1 25 1 25 2 75 0 46 8 0 10 20 675 240 0 80 0 95 1 10 1 45 0 52 DC Com 2 ZNK 71 B 8 2 2 0 37 40 2825 120 1 10 1 25 1 45 2 75 0 55 8 0 18 20 665 240 0 90 0 90 1 00 2 50 0 46 DC Com 5 ZNK 80 A 8 2 2 0 72 40 2745 120 1 70 2 15 2 55 4 70 0 49 8 0 27 20 690 240 1 30 1 40 1 70 1 90 0 48 ZNK 100 A 8 2 2 1 10 40 2745 120 1 70 1 80 2 00 4 85 0 65 DC Com 10 8 0 57 20 675 240 3 30 3 70 4 30 2 27 0 42 ZNK 100 B 8 2 2 2 30 40 2790 120 4 15 5 00 6 10 5 13 0 49 Tab 8 9 DC Com 2 10 CDF 15 25 until 12 2013 10 max
14. Required tests and inspections must be carried out An annual inspection e g as specified in German accident prevention regulations UVV BGV D8 Sec tion 23 2 and BGV D6 1 must be carried out Adjustment maintenance and inspection activities and inspection deadlines including specifications con cerning the replacement of parts assemblies prescribed in the operating instructions must be observed This work may only be carried out by specialist personnel Hoists and cranes must be inspected by an experienced technician at least once a year Regular inspections mainly consist of a visual inspection and a function check which should include a check to determine the condition of components and equipment regarding damage wear corrosion or other alterations and a check to determine the integrity and efficiency of safety devices Regular inspections must be carried out in accordance with BGV D6 and BCG 905 Principles for the inspection of cranes in Germany It may be necessary to remove parts in order to inspect wearing parts Defective parts and components and parts close to failure must be replaced Load bearing media and suspensions must be inspected along their entire length including those parts which cannot normally be seen A function and brake test with a load test load that is close to the maximum permissible load capacity must be carried out Please also see S W P measures for achieving safe working periods Page
15. ircuit diagram d control boards lagrams an ircuit di DC Com 1 10 solo hoist c C 5 9 5 9 1 LLLGZ vV 208 VLC 8 L 9 S y S LT LEN QPOOLLE9 N3 666 CYVONVIS 90 oud 00 CT Sriooiee toa ida Y paydiwog O E 100 PON enssi 10 39905 10 ys ON juep Buo 30uJ0j dq ON 43940 sjuauoduio s SOUL 49349 uyny 9002 Y0 60 10 e 10 19 LINN LSIOH NIVA avo uny IT uny 90079080 Z0 y ZO 4 1 000 uonpubisag DVINA Jeujjsn vO0ZLL91 Er Tonal 6007 LOETI OY 0 1 sauny jonuow ou uwoug Qv ul e i Ej 208 3 i E 1 SION 3 3 1 L 7 gt INZ SION 3 B ISX 8 gigx vigx Lig 98x sex ear zie 18 8 4 W 9 ej zp 9 g 2 af a Wow oW oum ay sep gw 2 3 T Y gp OU x T i 5 E YE e LOVINOO OUNISOMAHL ONE ANANG LNN TAAVYL TWN ALNI BITIOSINOO s ar EVO 1041NO Od z 9 nom X Ho a0 n Hoy i 9 od el el sl el el sh el co ale C go uo ux EC x ap d c ux iz TN A TR NEL 4 FEPER ATTE as 8 4 9 A o a Hie vin eux ex vx Vox vix euxTeux ist A z y n i 3 5 a g JP 5 3 3 2 8 g 2 j a 3 2 3 i Egg 388 os ers aJ ol v8 naju sE 80 SIS i L0 sis 5 90 sis S0 sls 3 WSIS el RSE 0
16. 120 1 45 1 75 2 05 2 70 0 52 220 240 V 60 Hz 3 CE CSA 8 0 11 15 815 240 2 50 2 70 3 00 1 25 0 51 DC Com 2 ZNK 71 B 8 4 4 0 22 25 1705 120 2 50 2 50 2 90 2 30 0 55 8 0 22 15 860 240 3 10 3 50 4 00 1 70 0 48 DC Com 5 ZNK 80 A 8 4 4 043 25 1755 120 3 80 4 60 5 45 2 70 0 51 380 400 V 60 Hz 3 CE 1 8 0 11 15 815 240 1 70 1 70 2 00 1 25 0 51 DC Com 2 ZNK 71 B 8 4 4 0 22 25 1705 120 1 45 1 60 1 80 2 30 0 55 8 0 22 15 860 240 2 00 2 25 2 40 1 70 0 48 DC Com 5 ZNK 80 A 8 4 4 0 43 25 1755 120 2 60 2 75 3 30 2 70 0 51 440 480 V 60 Hz 3 CE CSA 1 8 0 11 15 815 240 1 25 1 35 1 50 1 25 0 51 DC Com 2 ZNK 71 B 8 4 4 0 22 25 1705 120 1 25 1 25 1 45 2 30 0 55 8 0 22 15 860 240 1 55 1 75 2 00 1 70 0 48 DC Com 5 ZNK 80 A 8 4 4 0 43 25 1755 120 1 90 2 30 2 70 2 70 0 51 575 V 60 Hz 3 CSA 17 8 0 11 15 815 240 0 95 1 10 1 25 0 47 DC Com 2 ZNK 71 B 8 4 4 0 22 25 1705 120 0 95 1 10 2 30 0 57 8 0 22 15 860 240 1 20 1 35 1 70 0 44 DC Com 5 ZNK 80 A 8 4 4 0 43 25 1755 120 1 45 1 70 2 70 0 49 Tab 10 16 maximum rated current for lowering motion 17 Temporary voltage tolerances of 10 and temporary frequency tolerances of 2 are possible Motors are rated to insulation class F 214 802 44 291113 214 802 44 291113 3 4 2 Mains connection delay fuse links CAUTION 3 4 3 For safety reasons we recommend the use of 3 pole automatic circuit breakers circuit break
17. 71870833 1 Gearbox set DC COM 5 V4 2 500 V 525 V 50 Hz 575 V 60 Hz 3 71570533 1 Gearbox set DC COM 10 V4 1 1 1 reeving 3 71570733 1 Gearbox set DC COM 10 V4 1 2 1 reeving Year of manufacture 2007 to 07 2008 3 71773433 1 Gearbox set DC Com 1 V8 2 3 71773533 1 Gearbox set DC Com 2 V4 2 3 71870933 1 Gearbox set DC Com 5 V4 2 3 71570533 1 Gearbox set DC COM 10 V4 1 1 1 reeving 3 71570733 1 Gearbox set DC COM 10 V4 1 2 1 reeving As of year of manufacture 08 2008 3 71773433 1 Gearbox set DC Com 1 V8 2 3 71774033 1 Gearbox set DC Com 2 V6 1 5 3 71890433 1 Gearbox set DC Com 5 V4 5 1 1 3 71570533 1 Gearbox set DC COM 10 V4 1 1 1 reeving 3 71570733 1 Gearbox set DC COM 10 V4 1 2 1 reeving 4 71897433 1 Suspension set DC 1 5 4 71597433 1 Suspension set DC10 Year of manufacture 2004 to 2006 5 47997646 1 Gear oil seal DC Com1 2 DC Com 1 2 5 5 Nm 0 35 litre 5 47997746 1 Gear oil seal DC Com5 DC Com 5 5 5 Nm 0 5 litre 5 71591933 1 Gear oil seal DC10 DC Com 10 5 5 Nm 0 9 litre As of year of manufacture 2007 5 71791933 1 Gear oil seal DC Com1 2 DC Com 1 2 5 5 Nm 0 35 litre 5 71891933 1 Gear oil seal DC Com5 DC Com 5 5 5 Nm 0 5 litre 5 71591933 1 Gear oil seal DC10 DC Com 10 5 5 Nm 0 9 litre 6 71894733 1 Adjusting nut pulse wheel DC 1 2 5 6 71594733 1 Adjusting nut pulse wheel DC10 DC Com 1 2 5 7 71887133 1 Brake set 180V 380 V 415 V 50 Hz 5 5 Nm 7 71887233 1 Brake set 216V 440 V 480 V 60 Hz 5 5 Nm 7 71887333 1 Brake set DCS 1 5 104V 220
18. 90 04 20 Ida Stoore 104 Iday Y paldiuog STU awo apoq POW anssi 10 US iq yS ON juep u j0uu04 deg ON JepiQ sjuauoduio y saue4 X99349 uyn 9002 v0 SO 10 ey 10 wos601q uonoeuuooJelu uyny UNDI uyny 9007 9080 Z0 ay 20 3 uon2euuo uonpubisag DVIAq3G Jawoysny y00e 191 En TeneL 6007 20 C SOY 0 4 es ES T g a El 3 4 sion S 1 S 1 000 aog HOUNS LNN g a 8 a 9x ax a ISIOH NWHO O8d 00 EI uoy gt 19 3 og 1 000 8 3 F R ex x X z 8 Is m S E i X 1 000 1x 1 000 5i 9rd ANANG 2 9 LNN TAVAL NEUE YITIOWINO z 9 amp e m 3 d Bip 3 1500 S st 3 gIN6O El a 8 i ISF 8 1SIX 91N60 g 2 Y iex 3 zB E zi 8 zos Bj St E gi 9IN60 o Sat v V SNOILONYLSNI NILVYJdO 335 NOLLOJLOYA SNIVW ONY 3ZIS 378v GSYINOSY N04 EN o 8 D 42 a JX S J JX e T XhGQ O2 Ef i 46 214 802 44 291113 5 9 2 5 9 3 Circuit diagram with E11 E34 DC travel drive For further circuit diagrams with E11 E34 travel drives see Tab 3 Page 7 E11 E34 DC travel drive assembly instructions Il For further information on E11 E34 travel drives see Tab 3 Page 7 E11 E34 DC travel drive assembly in structions I For further information on cross travel limit switch part no 716 663 45 see Tab 3 Page 7 E 11 E 34 DC travel drive assembly instructions I Control board
19. 95 T Theoretical duration of service 68 Tri state signals 29 Ww Wear of a single chain link 75 Wear or deformation of the chain 74 Welding work 32 62 113 DEMAG A TEREX BRAND MN E EEEF Original Ident number Language EC conformity declaration for a machine 19961044 EN according to Directive 2006 42 EC Annex IIA Issue Page 0110 1 1 C Hereby we Demag Cranes amp Components GmbH RuhrstraBe 28 58300 Wetter declare that the electrically driven hoist for lifting loads Demag DC chain hoist Serial no nnnnnnnn ready for service as a series product or manufactured to order with a cable connected control pendant wireless control unit complies with all relevant requirements of EC Machinery Directive 2006 42 EC The safety objectives of Low Voltage Directive 2006 95 EC are achieved The product additionally complies with the following relevant directives provisions EC EMC Directive 2004 108 EC Applied harmonised standards and or C standard drafts in particular EN 14492 2 Cranes Power driven winches and hoists Part 2 Power driven hoists EN 60204 32 Safety of machinery Electrical equipment of machines Part 32 Requirements for hoisting machines The relevant technical documentation according to Annex VII Part A of Directive 2006 42 EC has been compiled and will be made available to authorised national authorities by the designated authorised representative in response to a ju
20. B 8 2 2 0 36 40 3480 120 1 80 2 00 2 20 2 75 0 54 8 0 12 20 870 240 1 55 1 55 1 75 2 50 0 45 DC Com 5 ZNK 80 A 8 2 2 0 49 40 3510 120 3 00 3 50 4 10 4 70 0 48 8 0 23 20 855 240 2 30 2 50 2 80 1 90 0 47 ZNK 100 A 8 2 2 0 90 40 3450 120 2 70 2 90 3 30 4 85 0 64 DC Com 10 8 044 20 885 240 5 75 6 40 7 10 2 30 0 41 ZNK 100 B 8 2 2 1 80 40 3555 120 7 30 8 90 10 00 5 10 0 48 440 480 V 60 Hz 3 CE CSA s 9 8 0 06 20 870 240 0 96 1 15 1 15 1 45 0 47 DC Com 1 ZNK 71 B 8 2 2 0 22 40 3525 120 1 15 1 55 1 55 2 75 0 45 8 0 09 20 845 240 1 05 1 25 1 40 1 45 0 51 DC Com 2 ZNK 71 B 8 2 2 0 36 40 3480 120 1 35 1 70 1 95 2 75 0 54 8 0 12 20 870 240 1 15 1 15 1 30 2 50 0 45 DC Com 5 ZNK 80 A 8 2 2 0 49 40 3510 120 2 20 2 80 3 30 4 70 0 48 8 0 23 20 855 240 1 65 1 85 2 20 1 90 0 47 ZNK 100 A 8 2 2 0 90 40 3450 120 2 10 2 40 2 70 4 85 0 64 DC Com 10 8 0 44 20 885 240 4 10 4 80 5 60 2 30 0 41 ZNK 100 B 8 2 2 1 80 40 3555 120 5 60 6 60 8 00 5 10 0 48 575 V 60 Hz 3 CE CSA s 19 8 0 06 20 870 240 1 10 1 10 1 22 0 49 DC Com 1 ZNK 71 B 8 2 2 0 22 40 3525 120 1 20 1 20 3 50 0 41 8 0 09 20 845 240 0 80 0 90 1 65 0 60 DC Com 2 ZNK 71 B 8 2 2 0 36 40 3480 120 1 00 1 15 2 75 0 55 8 0 12 20 870 240 0 95 1 10 2 50 0 45 DC Com 5 ZNK 80 A 8 2 2 0 49 40 3510 120 1 80 2 10 4 70 0 48 8 0 23 20 855 240 1 30 1 50 2 20 0 46 ZNK 100 A 8 2 2 0 90 40 3450 120 1 60 1 80 5 70 0 73 DC Com
21. Meaning of the parameters Page 49 7 segment display o Tab 34 7 segment display 0 gt 1 9 7 segment display 214 802 44 291113 214 802 44 291113 Fig 29 42771846 xml eps Tth step Press the Lifting button to select the currently displayed parameter The value selection menu for the parameter opens at the same time The currently set values are symbolically displayed with the characters A b C etc For the meaning of the characters see Meaning of the parameters Page 49 8th step To set a different value press the Lowering button until the required value is shown in the display 9th step The value is again selected by using the Lift ing button the system then also returns to pa rameter selection mode 7 segment display A b C 7 segment display 7 segment display Tab 35 42771847_xml eps Fig 30 10th step The unit returns to normal operating mode when the Emergency stop button is pressed All changes are first saved 7 segment display Tab 36 51 52 5 11 Adjusting the lower hook position 42599945 xml eps Fig 31 Item Designation Item Designation 1 Buffer limit switch option 4 Limit stop 2 Damping plate 5 Unloaded chain
22. Not all features of the mounting code can be combined 3 Since 04 2006 the designation for sizes DC 10 and DC 20 have been changed to DC 10 1 1 and DC 10 2 1 respectively 214 802 44 291113 214 802 44 291113 3 3 Selection table Load ca Size 4 Reeving Group of mechanisms 5 Chain size Lifting speed Standard Motor size 7 Max weight pacity DIN EN 14492 hook path 9 for hook path Chain from 01 2014 until 12 2013 at 50 Hz at 60 Hz H 4m 5m 8m hoist kg DC Com FEM ISO FEM ISO mm m min m min m kg kg kg 80 4m M7 3m M6 100 1 8 0 2 0 9 6 2 4 ZNK 71 A 8 2 8 125 3m M6 2m M5 4 2x12 2 21 22 24 160 200 2 6 0 1 5 7 2 1 8 ZNK 71 B 8 2 2m M5 1Am M4 250 11 315 3m M6 2m M5 400 5 5 3x15 2 4 5 1 1 5 4 1 3 4 5and8 ZNK 80A 8 2 27 28 30 2m M5 1Am M4 500 630 3m M6 2m M5 800 ZNK 100A 8 2 47 48 52 2m M5 1Am M4 1000 10 7 4x21 2 4 0 1 0 4 8 1 2 1250 3m M6 2m M5 1600 211 ZNK 100 B 8 2 63 65 73 2m M5 1Am M4 2000 Tab 6 Lifting speeds until 09 2008 no longer available Load ca Size Reeving Group of mecha Chain size Lifting speed Standard Motor size Max weight pacity nisms hook path for hook path Chain DIN EN 14492 at 50 Hz at 60 Hz H 4m 5m 8m hoist kg DC Com FEM ISO mm m min m min m kg
23. Protective sleeve with fitting material 720 085 45 Tab 24 214 802 44 291113 214 802 44 291113 5 6 3 Control pendant height adjustment 43215344 eps Fig 15 x Control cable locking mechanism engaged Control cable locking mechanism released lt 1 Undo the screws of the service cover Open and disconnect the service cover Remove and open the bag with the control cable Take the control cable out of the bag eu NBC Seo IS Slide the latch of the control cable locking mechanism upwards and hold it in place At the same time pull the control cable until the correct height has been reached for the control pendant 6 Ifthe control pendant is positioned too low pull on the control cable hose behind the service cover Slide the latch of the control cable locking mechanism downwards and lock the retainer by a short strong pull on the control cable above the control pendant 7 Lay the remaining control cable in loops and store it in the bag The bag must be located behind the edge of the chain collector box Close the service cover tightening torque 5 5 Nm 37 38 5 6 4 Mobile control system 42711245 eps MS i Component parts 7 N Item Designation comprising Order no IA 1 11 pole PE flat cable 7
24. TDK 0 62 22 35 10 DC 10 1250 2500 7 4x 21 2 1 20 43 70 Properties High strength ageing resistant material with a high degree of surface hardening galvanised with additional surface treatment blue chro P mated colour silver Material Ni Mo special chain steel to EN 818 7 part 5 3 1 Lubrication GPOOH 30REN SO GFB grease Demag Corrud special chain Application e g DC1 2 250 4 2 x 12 2 ae 0 38 13 8 22 galvanising electro DC 5 500 5 3 x 15 2 0 62 22 35 10 lating faciliti RDC TDK pareces DC 10 1250 2500 7 4 x 21 2 1 20 43 70 Properties Ageing resistant corrosion free Corrud DS micro layer corrosion protection black coated colour black Stabylan 2001 Material Ni Mo special chain steel to EN 818 7 part 5 3 1 Lubrication Acid resistant chain grease e g GLEITMO 582 Demag HS7 special chain Application e g DC1 2 160 4 2 x 12 2 0 38 12 5 19 3 foundry dust em DC 5 400 5 3 x 15 2 RSX DS 0 62 19 8 30 8 5 ery blasting DC 10 800 1600 74x212 1 20 38 7 60 Properties Ageing resistant blue chromated with deeper surface hardening Material Ni Mo special chain steel to EN 818 7 part 5 3 1 Lubrication Dry or with dry lubricant e g Ceplatlyn 300 Demag RS6 special chain DC1 2 125 23 160 24 4 2 x 12 2 0 38 10 16 Application e g 23 24 foodstuffs sector DCS 200 25 250 24 5 3 x 15 2 RSA S 0 62 16 25 15 DC10 40029 50029 80029 1000 9 7 4x 21 2 1 20 32 50 Properties Non rusting chain not hardened bright Material Stainless s
25. V 240 V 50 60 Hz 5 5 Nm 7 71887433 1 Brake set 258V 500 V 525 V 50 Hz 575 V 60 Hz 5 5 Nm DC Com 10 7 71587133 1 Brake set DC10 180V 380 V 415 V 50 Hz 5 5 Nm 7 71587233 1 Brake set DC 10 216V 440 V 480 V 60 Hz 5 5 Nm T 71587333 1 Brake set DC DCS10 220 V 240 V 50 60 Hz 5 5 Nm T 71587433 1 Brake set DC10 258V 500 V 525 V 50 Hz 575 V 60 Hz 5 5 Nm 8 71885633 1 Insert plug 63 71511345 1 Cover plate DC10 Kit 21480102 tbl 105 12 4 Chain drive 14 12 11 12 15 12 11 1 1 reeving 2 1 reeving 14 11 i 16 E 11 EE L Doc 12 e f Fil i 11 ES wA 12 16 17 42764346 eps 214802ET indd 291113 214802ET indd 291113 Item Part no Qty Designation Material Standard 11 71795033 1 Chain set DC DCM 1 2H 5 4 0 Nm 11 71795133 1 Chain set DC 1 2H 8 4 0 Nm 11 71895033 1 Chain set DC DCM 5H 5 4 3 Nm 11 71895133 1 Chain set DC 5H8 4 3 Nm 11 75395033 1 Chain set DC10 1 1 H 5 7 4 Nm 11 75395133 1 Chain set DC10 1 1 H 8 7 4 Nm 11 75263733 1 Chain set DC 10 5m 1 1 for GGS 1 11 75263833 1 Chain set DC 10 8m 1 1 for GGS 1 12 71596033 1 Chain set DC10 2 1 H 5 DC 10 2 1 7 4 Nm 12 71596133 1 Chain set DC10 2 1 H 8 DC 10 2 1 7 4 Nm 12 75263933 1 Chain set DC 10 5m 2 1 for GGS 1 12 75264033 1 Chain set DC 10 8m 2 1 for GGS 1 14 71588033 1 Limit
26. cut out of the drive if slip occurs increase the service life and protect the slipping clutch against overload and incorrect use The gear box is maintenance free for up to 10 years Chain drive The special Demag chain is of high strength ageing resistant material with a high degree of surface hardening galvanised with additional surface treatment The dimension tolerances of this chain have been precisely adapted to the chain drive We therefore urgently recommend that the Demag special chain be used to ensure safe opera tion The maximum service life of the chain can only be reached if the specified regular lubrications are correctly carried out The entire chain drive is always replaced when a chain is replaced A chain set which can be easily replaced is available for this purpose The chain set offers the following benefits e the optimum duration of service is ensured for the chain e certainty that the individual chain drive components are replaced when necessary e reduction in service costs by replacement and installation in one step the motor and gearbox do not need to be disassembled Electric equipment Control system The chain hoist is fitted with a 24 V contactor control system The contactor control system is supplemented by an electronic system with programmed functions This electronic system detects the control commands that are trig gered by the operator with the control pendant Permissible control commands generate
27. elements for recycling e Separate and dispose of any other components by material type Electric scrap electronic components lubricants and other auxiliary materials are subject to special disposal regulations and may only be disposed of by certified companies National disposal regulations must be considered regarding environmentally friendly disposal Further information can be obtained from corresponding local authorities 214 802 44 291113 214 802 44 291113 11 Accessories 11 1 Assemblies 42778445 xml eps Fig 75 Item Description Size Order no Bottom block with cut off springs e g for hot applications consisting of 1 Bottom block cut off springs grooved pins with round head load capacity DC Com 10 2 1 715 431 45 plates Return sprocket assembly consisting of DC Com 1 2 717 808 45 2 1 return sprocket 1 pin 1 retaining ring 1 supporting washer 2 thrust wash DC Com 5 718 808 45 ers 2 needle roller assemblies DC Com 10 715 808 45 Cut off spring e g for hot applications consisting of DC Com 1 2 717 250 45 3 2 cut off sleeves 1 pressure spring each for V1 and V2 DC Com 5 718 250 45 for DC 10 2 1 reeving 2x part no DC Com 10 715 250 45 Tab 71 101 12 Spare parts 12 1 Overview 51 7 6 52 50 54 102 8 12 11 53 14 1 1 reeving 2 1 reeving ES 13
28. for Demag DC chain hoists without electric trolleys are used for such applications DSE 10C units are used for applications with electric trolleys Please refer to the information contained in the DC electric accessories document Tab 3 Page 7 for inte grating DC chain hoists into existing installations with contactor control A Polu box with integrated contactor control is needed to control pole changing AC motors with or without a brake of long and cross travel units see Polu box electric accessories document Tab 3 Page 7 7 segment display for operating status and fault display 43216145 eps Fig 7 The 7 segment display is arranged on the control board under the electric equipment cover and after the electric equipment cover has been removed can be read through the window on the lower side of the chain hoist illustra tion differs from scope of delivery The 7 segment display is supplied as standard for e DC Com 1 5 manufactured from 2007 e DC Com 10 29 30 4 4 3 The following data can be read e Software version gt Fig 8 Page 30 Operating hours Fig 9 Page 30 Operating statuses Operating statuses general messages Page 97 e Warning messages gt Warning messages Page 98 Error messages gt Error messages Page 99 Display of software v
29. of the strain relief hose Control pendant DSC control pendants lifting lowering or DSE 10C control pendants 2 to 3 axes must be used for manual ca ble connected control of the chain hoist Both control pendants feature the same plug in connection for the control cable The control cable and the control pendant are connected by means of a bayonet lock The shock and impact resistant DSC and DSE 10C housings are of made high quality thermoplastic and are re sistant to fuels salt water greases oils and alcaline solutions IP65 enclosure Strong mineral e g hydrochloric or sulphuric acids may however corrode pendant switch housings To avoid this they must be replaced in good time The rubber button caps may be subject to premature wear under aggressive operating conditions contact with corrosive substances or special chemicals Replace any damaged button caps in good time 31 5 1 DANGER zu 5 2 DANGER gt DANGER Assembly General These assembly instructions enable the owner to install re install or replace the DC Com unit himself The owner must appoint a coordinator who is authorised to issue instructions before assembly work commences Despite detailed information errors cannot be excluded when the installation is assembled by the customer For this reason we recommend that this work be carried out by our trained specialists or by persons authorised by us The wiring of the Demag chain hoist compli
30. sales service 214 802 44 291113 214 802 44 291113 Please keep the serial or order number see test and inspection booklet load capacity plate on the crane for any correspondence or spare part orders Specifying this data ensures that you receive the correct information or the required spare parts Demag Cranes amp Components GmbH Telephone 49 0 180 5741268 www demagcranes com 11 12 2 1 2 2 2 3 Safety General information on safety The Safety chapter provides an overview of all important safety aspects for optimum protection of personnel as well as for safe and reliable operation of the machine When it is placed on the market the machine is built according to generally accepted engineering standards and is considered to be safe to operate It may still be a cause of danger if it is not used correctly or as intended by suitably trained personnel Knowledge of the contents of the operating instructions is one of the requirements necessary to protect personnel from hazards and to avoid malfunctions and therefore to operate the machine safely and reliably Any conversions modifications or additions to the machine are prohibited unless approved by Demag in writing Safety signs on the equipment Any pictograms signs or labels on the machine must be obeyed and must not be removed Pictograms signs or labels that are damaged or no longer legible must be replaced immediately 43229044 xml eps F
31. secure connection can only be guaranteed by tightening to the specified tightening torque Bolted connections must not be lubricated as otherwise the specified tightening torque values will be too high Check to ensure that pin connections are correctly fitted All installation and assembly work must be completed in accordance with the operating instructions and the hoist chain must be greased Operation with defective or damaged chains results in a high risk of accidents with per sonal injuries and damage to the chain hoist and is therefore prohibited Any change or modification which prejudices safety must be reported to the nearest person responsible immedi ately Repairs may only be carried out by experienced technicians Ensure that all attachment points are freely accessible for inspections and servicing or that free access can be provided The control device e g control pendant must be marked in such a way that the direction of movement is clear and distinct The arrow symbol on the switching elements must correspond to the direction of movement Electric safety The chain hoist operating instructions must be referred to when Demag chain hoists are used These operating instructions only contain standard circuit diagrams Depending on the chain hoist type an order specific circuit diagram may apply Protective earth conductor The protective earth conductor in insulated leads and cables must be coloured green and yellow along its enti
32. the installation enters service e The supporting structure must be in good condition and the load capacity of the chain hoist must be checked e Safety devices must be complete and effective e Clearances and safety distances must be maintained e The emergency stop device must be checked by actuating the emergency stop When the unit is first put into operation it must be checked to ensure that it is used as intended in all possible applications in each case with the maximum permissible load Operation of the safety devices must be checked e g by lifting an overload At the same time the behaviour of the chain hoist must be checked when it is not used correctly Various checks of the machine must be carried out before it is handed over e Check to ensure it is suitable for operation e Acceptance inspection The test and inspection records can be compiled as soon as safe operation of the chain hoist is ensured The test and inspection records test and inspection booklet observe relevant national regulations must be hand ed over when the machine is handed over The machine may be used as intended after it has been handed over 214 802 44 291113 214 802 44 291113 7 Operation 7 1 Safety instructions for operation WARNING Incorrect operation Risk of injury due to incorrect operation Incorrect operation may result in severe injury or damage to property The equipment may only be operated by authorised and in
33. the opening in the gearbox housing to the side 3 Remove chain guide 10 with the sprocket from the output shaft to do this slide the complete assembly in the direction of the motor until the sprocket is free the worn chain can then be removed from the service enclosure Proceed in reverse order to install the new chain set Pay attention to the following points 79 80 Chain hoist with geared limit switch 42792644 xml eps Fig 49 A Chain guide for DC 10 without geared limit switch B Chain guide for DC 10 with geared limit switch Tab 56 The chain guide has a larger opening on chain hoists that are equipped with a geared limit switch See also Chain drive Page 106 Output shaft distance rings e Ensure that the complete quantity of distance rings is fitted on the output shaft when the chain guide is installed Item Designation 1 Cap 2 Retaining ring 3 Chain guide DC Com 1 2 3 off 4 Distance ring DC Com 5 1 off DC Com 10 2 off Tab 57 output shaft before you install the chain sprocket d Apply Molykote or a similar lubricant to the splines of the 4 42776944 xml eps Fig 50 Fitting the retaining ring e The stamped burr of retaining ring 1 must face the motor The re taining
34. x h2 min 16 055 20 71 26 315 342 lt L2 20 24 28 45 a1 hi L4 82 94 116 159 43229244 eps di 15 17 20 41 8 Fig 55 Max test force kN 6 13 25 50 Max hook force kN 13 25 50 100 Hook safety catch Tab 59 If the hook safety catch has to be replaced turn the nut on the bolt until at least two turns of the thread can be seen on the other side of the nut The bolted connection must only be tightened enough to allow the hook safety catch to move freely Checking the return sprocket The return sprocket must be checked every month to ensure that it turns easily To do this any load bars attach ed to the bottom block have to be removed Check to ensure the bottom blocks moves easily during lifting and lowering operations Abrupt movements of the bottom block indicate wear We recommend that the return sprocket should be replaced every second time the chain is replaced 27 Permissible deviation 10 28 Permissible deviation 5 83 8 5 6 4 Replacing the hook with fittings for 1 1 reeving 42768245 xml eps Fig 56 Remove the existing hook Remove both bolts 4 from the new hook Remove the upper half of the hook assembly DANGER Load may be dropped Incorrect assembly may cause loads to be dropped During assembly ensure that chain link sections 1 are positioned with their collar in bearing 2 Grease the bearing and bearing seat that retaining
35. 10 8 0 44 20 885 240 3 00 3 50 2 33 0 43 ZNK 100 B 8 2 2 1 80 40 3555 120 3 90 4 70 5 60 0 60 Tab 9 13 DC Com 2 10 CDF 15 25 until 12 2013 14 x maximum rated current for lowering motion 15 Temporary voltage tolerances of 10 and temporary frequency tolerances of 2 are possible Motors are rated to insulation class F 21 22 Lifting speeds until 09 2008 no longer available Size Motor size No of P CDF Ny Starts h Min max currents and start up current poles IN min IN max Imax 19 VP hi max COS on KW rpm A A A 220 240 V 50 Hz 3 CE 8 0 09 15 665 240 2 10 2 20 2 50 1 25 0 52 DC Com 2 ZNK 71 B 8 4 4 0 18 25 1405 120 2 10 2 10 2 40 2 30 0 56 8 0 18 15 710 240 2 60 2 90 3 30 1 70 0 49 DC Com 5 ZNK 80 A 8 4 4 0 36 25 1455 120 3 10 3 80 4 50 2 70 0 52 380 415 V 50 Hz 3 CE 8 0 09 15 665 240 1 20 1 30 1 45 1 25 0 52 DC Com 2 ZNK 71 B 8 4 4 0 18 25 1405 120 1 20 1 20 1 40 2 30 0 56 8 0 18 15 710 240 1 50 1 70 1 90 1 70 0 49 DC Com 5 ZNK 80 A 8 4 4 0 36 25 1455 120 1 80 2 20 2 60 2 70 0 52 500 525 V 50 Hz 3 CE 17 8 0 09 15 665 240 1 00 1 05 1 15 1 25 0 52 DC Com 2 ZNK 71 B 8 4 4 0 18 25 1405 120 0 85 0 95 1 10 2 30 0 56 8 0 18 15 710 240 1 20 1 35 1 50 1 70 0 49 DC Com 5 ZNK 80 A 8 4 4 0 36 25 1455
36. 2 44 291113 214 802 44 291113 il The contactors are also socket mounted for sizes DC 1 to 5 manufactured as of 02 2011 and can be individually replaced 93 94 8 5 12 DANGER A Replacing the control cable 43227844 eps Fig 69 Live components Danger to life and limb Work on the electric equipment may only be carried out by a qualified electrician or by trained personnel 214 802 44 291113 214 802 44 291113 1 Disconnect the chain hoist from the power supply mains connection switch and secure it against switching on again Open and disconnect the service cover Remove and open bag 1 with the control cable Take the control cable out of the bag Turn and disconnect bayonet lock 2 and remove the control cable plug connector Unscrew electric equipment cover Oy Ow d neo a Loosen screw 3 on the control cable locking mechanism and remove the locking mechanism Remove the control cable Install the new control cable in reverse order It must be ensured that e the groove on the connector holder lines up with the swivel lock in the electric enclosure and e that the two pins on the enclosure line up with the bayonet lock Assemble the control pendant Connecting the control pendant Page 35 Adjust the height of the control pendant Control pendant height adjustment Page 37
37. 2 440 V 480 V 60 Hz 9 5 Nm 2 71794633 1 Motor set DC2 240V60Hz 8 2 220 V 240 V 60 Hz 9 5 Nm 2 71794733 1 Motor set DC2 380V60Hz 8 2 380 V 400 V 60 Hz 9 5 Nm DC Com 5 until 09 2008 2 71874133 1 Motor set 240V50Hz 220 V 240 V 50 Hz 9 5 Nm 2 71874233 1 Motor set 415V50Hz 380 V 415 V 50 Hz 9 5 Nm 2 71874433 1 Motor set 575V60Hz 500 V 525 V 50 Hz 575 V 60 Hz 9 5 Nm 2 71874533 1 Motor set 460V60Hz 440 V 480 V 60 Hz 9 5 Nm 2 71874633 1 Motor set 240V60Hz 220 V 240 V 60 Hz 9 5 Nm 2 71874733 1 Motor set 380V60Hz 380 V 400 V 60 Hz 9 5 Nm DC Com 5 as of 10 2008 2 71867133 1 Motor set DC5 240V50Hz 8 2 220 V 240 V 50 Hz 9 5 Nm 2 71867233 1 Motor set DC5 415V50Hz 8 2 380 V 415 V 50 Hz 9 5 Nm 2 71867333 1 Motor set DC5 575V60Hz 8 2 500 V 525 V 50 Hz 575 V 60 Hz 9 5 Nm 2 71867433 1 Motor set DC5 480V60Hz 8 2 440 V 480 V 60 Hz 9 5 Nm 2 71867533 1 Motor set DC5 240V60Hz 8 2 220 V 240 V 60 Hz 9 5 Nm 2 71867633 1 Motor set DC5 380V60Hz 8 2 380 V 400 V 60 Hz 9 5 Nm DC Com 10 2 71584133 1 Motor set 240V50Hz A 220 V 240 V 50 Hz 25 Nm 2 71584233 1 Motor set 415V50Hz A 380 V 415 V 50 Hz 25 Nm 2 71584433 1 Motor set 575V60Hz A 500 V 525 V 50 Hz 575 V 60 Hz 25 Nm 2 71584533 1 Motor set 460V60Hz A 440 V 480 V 60 Hz 25 Nm 2 71584633 1 Motor set 240V60Hz A 220 V 240 V 60 Hz 25 Nm 2 71584733 1 Motor set 380V60Hz A 380 V 400 V 60 Hz 25 Nm 2 71583233 1 Motor set DC10 16 B 50Hz 380 V 415 V 50 Hz
38. 20 139 45 1 Socket enclosure il Mounting frame 2 2 Connector enclosure cpl 720 187 45 VC AMS8 pin insert 3 Flat cable union Bayonet lock 4 VC MP 1 R M25 bush enclosure oe 3 Connector adapter cpl 720 087 45 s VC TR1 2M bush frame e 5 VC TFS8 socket insert 4 Cable collector 720 065 45 5 DSE 10C control pendant 773 352 45 6 Control cable locking mechanism Tab 25 H4 H5 H8 H11 height adjustable standard control cables are used to gether with the cable collector X40 plug connector pin assignment Signal Cond PIN Cond Signal B4 B8 11 Reference potential 24 V PE PE B3 B7 B2 B6 Special 2 horn B1 B5 10 Right Left A4 A8 Lowering Lifting 8 AS A7 9 Wis STO Emergency stop 2 A2 A6 Reverse Forwards 1 A1 A5 Special 1 F1 F2 Tab 26 42724246 eps 214 802 44 291113 39 LLLGC PV 208 vc 40 5 7 5 7 1 DANGER A Suspending the chain hoist Supporting structure Overload Danger to life and limb if the supporting structure is overloaded The support superstructure must be designed for the maximum load caused by operation of the chain hoist when it is used as intended Hoist units that have a load capacity greater than or equal to 1000 kg must be provided with overload protection to DIN EN 14492 2 DC Com chain hoists are used with a slipping clutch which directly acts as overload protection The slipping
39. 25 Nm 2 71583433 1 Motor set DC10 16 B 60Hz 500 V 525 V 50 Hz 575 V 60 Hz 25 Nm 2 71583533 1 Motor set DC10 16 B 60Hz 440 V 480 V 60 Hz 25 Nm 2 71583733 1 Motor set DC10 16 B 60Hz 380 V 400 V 60 Hz 25 Nm 62 26564933 1 Winding head can DC1 2 62 71821033 1 Winding head can DC 5 62 71521033 1 Winding head can DC10 21480101 tbl 103 104 12 3 Parts on the gearbox 4 DC 1 5 WAY QI a 3 4 DC 10 42763847 eps 214802ET indd 291113 214802ET indd 291113 Item Part no Qty Designation Material Standard Year of manufacture 2004 to 2006 3 71773633 1 Gearbox set DC COM 1 V8 2 380 V 415 V 50 Hz 380 V 400 V 60 Hz 3 71773733 1 Gearbox set DC COM 1 V8 2 440 V 480 V 60 Hz 3 71773833 1 Gearbox set DC COM 1 V8 2 220 V 240 V 50 60 Hz 3 71773933 1 Gearbox set DC COM 1 V8 2 500 V 525 V 50 Hz 575 V 60 Hz 3 71770533 1 Gearbox set DC COM 2 V4 2 380 V 415 V 50 Hz 380 V 400 V 60 Hz 3 71771133 1 Gearbox set DC COM 2 V4 2 440 V 480 V 60 Hz 3 71771233 1 Gearbox set DC COM 2 V4 2 220 V 240 V 50 60 Hz 3 71771333 1 Gearbox set DC COM 2 V4 2 500 V 525 V 50 Hz 575 V 60 Hz 3 71870533 1 Gearbox set DC COM 5 V4 2 380 V 415 V 50 Hz 380 V 400 V 60 Hz 3 71870633 1 Gearbox set DC COM 5 V4 2 440 V 480 V 60 Hz 3 71870733 1 Gearbox set DC COM 5 V4 2 220 V 240 V 50 60 Hz 3
40. 2741845_xml eps Fig 25 Pin 1 1 RJ45 Function assignment connec tor PIN Control cable X3 14 Trolley X5 13 1 Special F1 Special F1 2 Crane forwards Crane forwards 3 Crane backwards Crane backwards 4 Emergency stop Emergency stop 5 Control pendant supply Control pendant supply 6 Lifting 24 V AC from chain hoist 7 Lowering Control pendant reference potential 8 Trolley right Trolley right 9 Trolley left Trolley left 10 Special F2 Special F2 Tab 29 Function assignment PIN Lifting limit switch X4 12 1 E 3 Lifting 3 a Lowering Tab 30 214 802 44 291113 214 802 44 291113 5 10 Programming parameters with the control pendant 5 10 1 General Parameters can be programmed to adapt the chain hoist to specific application requirements The parameters can be programmed using the control pendant together with the 7 segment display on the underside of the chain hoist 5 10 2 Meaning of the buttons 1 2 3 42742845 xml eps Fig 26 1 Lift Accept selection 2 Lower Move to next parameter or se 3 Emergency stop End parameter pro lection value gramming changes are saved Tab 31 5 10 3 Meaning of the parameters From software version SW 2 10 the following parameters can be programmed Display of parameter no Parameter name Display of parameter va
41. 4 802 44 291113 214 802 44 291113 T 3 Operation 7 3 1 Safety during operation DANGER Danger of broken chain and falling load The chain may break and loads may fall if the emergency limit position limiter is frequently approached The chain hoist slipping clutch provides the emergency limit position limiter function for chain hoists that are not fitted with an operating limit switch or which have a defective operating limit switch This emergency limit position limiter may only be approached in exceptional cases i e it must not be approached in normal operation High additional loads occur in the chain when the slipping clutch is tripped For this reason the operating limit switch for lifting function must be checked every day WARNING Overload Danger to life and limb Higher loads than those specified on the load capacity plate must not be handled Do not exceed the maximum permissible load capacity of the hoist A Only use load handling attachments which are adequately dimensioned Only use load handling attachments for their intended purpose WARNING Movable parts may start moving Danger to life and limb The control pendant is designed to be suspended from its connecting cable It may only be used as suspended equipment It must not be deposited in on transport containers workbenches etc or in any other way Important information for operation Observe the following during operation Take the
42. 582 493 615 DC Com 10 ZNK 100 B 8 2 582 615 2 1 ZNK 100 B 8 2 552 632 585 665 Size Reeving Trolley at right angles to the girder Parallel to girder U11 405 425 455 400 420 450 DC Com 1 2 CF5 395 415 445 390 410 440 U11 452 487 517 447 482 512 DC Com 5 1 1 CF5 442 477 507 437 472 502 U11 545 578 667 569 602 672 DC Com 10 U22 557 590 679 571 614 703 2 1 U22 U34 649 679 679 663 703 803 Tab 16 19 Higher lifting speeds may require the use of larger chain collector boxes see Buffer arrangement Page 87 24 20 Dimensions C and C1 decrease when a short suspension bracket is used by 38 mm for DC Com 1 5 and by 33 mm for DC Com 10 214 802 44 291113 214 802 44 291113 3 6 Noise emission sound pressure level Sound pressure level Las to DIN 45635 at a distance of 1 m from the chain hoist is Type DC Com 1 DC Com 2 DC Com 5 DC Com 10 Lifting speed up to m min 8 6 4 5 4 Sound pressure level dB A 65 65 694 694 Tab 17 These noise emission levels were measured under maximum load The following structural influences were not considered in the above measurements e transmission of noise via steel structures e reflection of noise from walls etc 3 7 Transport packing and storage 3 7 1 Safety instructions WARNING A Falling parts Risk of injury from falling parts during transport loading and unloading operations Do not walk under the suspended load Keep a sufficient safety distance
43. 65 and Maintenance sched ule Page 68 Updating the test and inspection booklet e All inspections must be arranged and documented in the test and inspection booklet by the owner Special operating conditions Premature wear of the chain Danger of falling load Special operating conditions or the design of the chain hoist may make it necessary shorten the maintenance and inspection intervals If for example the unit always brakes heavily at the same position and with a heavy load increased wear may occur on the chain links that are in the area of the chain or return sprocket when the brake is applied Service life of the contactor The switchgear is subject to wear when the chain hoist is operated Its service life has been rated for the specified loading group Premature wear may occur if the equipment is frequently started and stopped 214 802 44 291113 214 802 44 291113 8 3 4 8 3 4 1 DC chain hoist Motor size Display value C for Unom 380 575 V Display value C for Unom 220 240 V 1 80 80 ZNK 71 2 80 60 5 ZNK 80 60 50 10 ZNK 100A 50 20 10 ZNK 100 B 20 Tab 41 Display value C specifies the expected service life of the contactor multiplied by 100000 This value was deter mined under normal operating conditions For other conditions the service life of the contactor may be shorter or longer Display of software version operating hours number of cycles Page 30
44. 8 2 67 56 ZNK 100 A 8 2 34 29 80 DC Com 10 ZNK 100 B 8 2 z z 38 61 26 43 59 Tab 13 Supply cables for lifting speeds until 09 2008 no longer available Voltage 220 240 V 380 415 V 500 525 V 220 240 V 380 400 V 440 480 V 575V Frequency 50 Hz 60 Hz Size Motor size mm3 m mv m mm m mm m mm m mm3 m mm m DC Com 2 ZNK 71 B 8 4 100 100 1 5 15 100 15 100 1 5 15 100 15 100 1 5 100 DC Com 5 ZNK 80 A 8 4 67 56 Tab 14 18 The lengths of the supply lines are calculated on the basis of an earth loop impedance of 200 mQ 23 3 5 Hook dimension C 42652549 xml eps Fig 5 A DC Com with short suspension bracket E CF 5 trolley G U11 U34 trolley optional at right angles to the girder at right angles to the girder a y CF 5 trolley U11 U34 trolley B DC of with Jong suspension bracket j parallel to the girder H parallel to the girder Tab 15 Size Reeving Motor size 19 C C1 C C1 Chain collector Chain collector H4 H5 H8 H4 H5 H8 Short suspension bracket 2 Long suspension bracket 2 DC Com 1 2 ZNK 71 315 335 365 353 373 403 DC Com 5 ij ZNK 80 362 395 425 400 435 465 ZNK 100 A 8 2 493 526 460
45. DEMAG A TEREX BRAND Oe B 3 0 Operating instructions accessories component parts Demag DC Com 1 10 chain hoist PU D IN 42647546_xml eps 291113 en GB 214 802 44 720 IS 817 Original operating instructions Manufacturer Demag Cranes amp Components GmbH PO Box 67 58286 Wetter Germany Telephone 49 0 2335 92 0 Fax 49 0 2335 92 7676 www demagcranes com Email info demagcranes com Please fill in the following table before first putting the unit into service This provides you with definitive documentation of your Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative Owner Where in use Size Serial number Year of manufacture Operating voltage Control voltage Frequency Wiring diagram number Tab 1 Demag Cranes amp Components GmbH 1 Type DC PRO 1 Tve 4 H5 125 2 Serial no Year of manu Fabrik Nr 93927369 Baujahr 1 2009 3 Tragrinigkeie 125 Kg FEMISO 4m M7 4 Thain 4 49 23pmr Hookpath Kette 4 2x12 2RDC Hakenweg 5 0 m 5 3 380 415 50 Hz 6 IP 55 Iso KL ISN cl F 7 Temp 40 C 8 N A 9 m min ch 10 KW YA Cos v t Amin c 8 0 0 18 1 60
46. EID dba 74 Chain set scope of supply isinisi soinen i raene ae a trie eo Ere eie teehee enue HL eee HE riri eq oie deo HE o eo Li gren debuts 76 Available hoist chains Leonem Aa E ERE ERR RR 77 Replacing the chain Set vicios gei eee E Le Hd Pee godere de ee E Aa td eade dea sed ede e ede und 78 Lubricating thie holst chialp oii e Etre AA ae e eei eb RU erp rhet gee 82 Load NOOK E X 83 Checking the load hook t eu tee ee e RH RE TAI HR T e ede ERR e RR is 83 Hook safety catch iieri eec eaa ge e nein eee HE de be Ee iei ee Eee Pe etd cu ede ede Led cede eg 83 Checking the returncsprocket tii CH I ee ub 83 Replacing the hook with fittings for 1 1 reeviNQ oooonnncnnnncnnnnncccnnncnnnncccnnnorncc cnn nennen menn rennen 84 Replacing the bottom block standard with internal cut off springs for 2 1 reeving sees 85 Replacing the bottom block option with external cut off springs for 2 1 reeving ss 86 Buffer only with optional operating limit switches DC Com 1 10 with 1 1 reeving een 86 Checking the cut off buffers cut off springs eene nnnen eren nene Ennn Enn en nene 86 Butter ATAN MEN Edi tmn nr p m ir E HR URINE HET E e PUER e A RR errado 87 LI 88 Br ke assigntmient tet eire ede ton e texte deme eise 88
47. a a a R a L h L 4 y g E B i E a a A 432160E19_xml eps Fig 74 Display examples Item Display Malfunction event Possible cause Remark 1 E 1 Chain hoist is blocked Hardware error of control system Check error message by actuating and unlocking the emer gency stop Then actuate Lowering If necessary remove suspended load Defective electronic monitoring Replace hoist control system Defective On off contactor Replace contactor Replacing the contactor on the con Contact wear trol board Page 92 2 E 2 Chain hoist is blocked Drive blocked Check error message by actuating and unlocking the emer gency stop Then actuate Lowering If necessary remove suspended load Speed measurement failure Replace hoist control system 3 E 3 Hoist unit overspeed or Lowering speed too high Reduce load to the permissible load capacity Check mains load cannot be held Low connection and fuse link check connection cable for inter ering with load is switched ruption check mains connector in the service enclosure off 5 E 5 Chain hoist is blocked Hardware error of control system Check error message by actuating and unlocking the emer gency stop Then actuate Lowering If necessary remove suspended load Defective electronic monitoring Replace hoist control system 6 E 6 Chain hoist is blocked Hardware error of control system Check error message by actuating and unlocking the emer gency stop Then actuate Lowering If nec
48. a 14 12 15 11 16 23 18 23 21 25 31 11 12 16 17 56 57 42764247 eps 214802ET indd 291113 214802ET indd 291113 12 2 Motor 42763744 eps Item Part no Qty Designation Material Standard 1 71785033 1 Fan set DC 2 4 Nm ZNK 71 1 71885033 1 Fan set DC 5 4 Nm ZNK 80 1 71585033 1 Fan set ZNK 100A 4Nm 1 71585133 1 Fan set ZNK 100B 4Nm DC Com 1 2 71784133 1 Motor set 240V50Hz 220 V 240 V 50 Hz 9 5 Nm 2 71784233 1 Motor set 415V50Hz 380 V 415 V 50 Hz 9 5 Nm 2 71784433 1 Motor set 525V50Hz 500 V 525 V 50 Hz 575 V 60 Hz 9 5 Nm 2 71784533 1 Motor set 460V60Hz 440 V 480 V 60 Hz 9 5 Nm 2 71784633 1 Motor set 240V60Hz 220 V 240 V 60 Hz 9 5 Nm 2 71784733 1 Motor set 380V60Hz 380 V 400 V 60 Hz 9 5 Nm DC Com 2 until 09 2008 2 71774133 1 Motor set 240V50Hz 220 V 240 V 50 Hz 9 5 Nm 2 71774233 1 Motor set 415V50Hz 380 V 415 V 50 Hz 9 5 Nm 2 71774433 1 Motor set 575V60Hz 500 V 525 V 50 Hz 575 V 60 Hz 9 5 Nm 2 71774533 1 Motor set 460V60Hz 440 V 480 V 60 Hz 9 5 Nm 2 71774633 1 Motor set 240V60Hz 220 V 240 V 60 Hz 9 5 Nm 2 71774733 1 Motor set 380V60Hz 380 V 400 V 60 Hz 9 5 Nm DC Com 2 as of 10 2008 2 71794133 1 Motor set DC2 240V50Hz 8 2 220 V 240 V 50 Hz 9 5 Nm 2 71794233 1 Motor set DC2 415V50Hz 8 2 380 V 415 V 50 Hz 9 5 Nm 2 71794433 1 Motor set DC2 575V60Hz 8 2 500 V 525 V 50 Hz 575 V 60 Hz 9 5 Nm 2 71794533 1 Motor set DC2 480V60Hz 8
49. alogues U11 U34 DC DCM DK trolley 203 569 44 RU EUS6 trolley 203 691 44 DC electric accessories 203 656 44 POLU box electric accessories 203 682 44 Clamp fitted buffer 203 313 44 DC Pro 1 15 chain hoist 214 741 44 DC Pro 16 25 chain hoist 211 033 44 me DC Com chain hoist 214 802 44 Ee n instructions component DCS Pro chain hoist 214 827 44 DC Di chain hoist 211 068 44 DC Wind chain hoist 211 010 44 PGS parallel gripper 214 095 44 Crane hook adapter 211 240 44 KDDC UDDC articulated trolley 211 159 44 E11 E34 DC travel drive I 214 810 44 E11 E34 DC travel drive Il circuit diagrams 211 229 44 DRC DC radio control system 214 689 44 DRC DC radio control system quick step instructions 211 045 44 DC geared limit switches 211 011 44 KDC chain hoist 211 017 44 ee hgusungnt c Dimen D protective sleeve 203 673 44 Friction force checking device 206 973 44 DC PWM 3ST signal converter 211 094 44 DSC EX control pendant 214 832 44 DSE10 C control pendant 214 998 44 DC tandem box 211 108 44 VG11 34 EU11 34 dual output gearbox 211 122 44 DC 1 15 guide plate accessories 211 095 44 DSC strain relief device 211 092 44 DC test and inspection booklet 214 745 44 Test and inspection booklet Certificates 235 309 44 Tab 3 Symbols signal words Important safety information and instructions are marked by corresponding symbols and signal words in these in structions Safety instructions and information must be followed Exercise pa
50. ance work which is not possible from the ground may only be carried out from work stands or platforms The danger zone below the chain hoist must be fenced off if there is a risk of falling objects Instructions for maintenance work in the course of operation If maintenance work has to be carried out on the chain hoist in the course of operation special safety precautions must be taken depending on the operating situation In each individual case the owner or the person assigned by him must check whether the maintenance work may be carried out in the course of operation without risk of per sonal injury and taking into account the local conditions must implement all necessary safety precautions Replace damaged or deformed spring clip fasteners and split sleeves Defective bolted connections must be replaced Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly manner 63 64 il After finishing maintenance work Re install safety devices as required by relevant regulations and check them for correct operation after finishing maintenance work Carry out a test run at partial load after the chain hoist has been fully re assembled Ensure that the chain runs smoothly during the test run 8 3 Regular inspections 8 3 1 Required tests and inspections WARNING A il 8 3 2 CAUTION 8 3 3 Non compliance with operating and maintenance regulations Danger to life and limb
51. and secure it against switching on again 3 Inform the person responsible at the location about the malfunction 4 Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per sonnel Conduct after a malfunction is eliminated WARNING Check for correct assembly Before reconnecting the power supply ensure that Malfunction and cause of malfunction have been eliminated All safety devices have been fitted properly and are in perfect condition and working order Nobody is present in the danger zone of the equipment 9 2 7 segment display The 7 segment display is located on the underside of the chain hoist behind a window Warning messages start with a lightning symbol Movement in the opposite direction is possible the warning message does not need to be acknowledged using the emergency stop m 43226544 eps Fig 70 214 802 44 291113 214 802 44 291113 Error messages start with an E for error Before any further movement is possible the error message must be acknowledged using the emergency stop 43226644 eps Fig 71 Safety function failur e If a safety function fails the equipment must not be operated until it is repaired Malfunctions The chain hoist can only function when it is correctly connected to the power supply In the event of a failure therefore first check cables strain relief and power supply connections Malfun
52. anged and documented by the owner at the specified intervals points of time Inspection in accordance with relevant national regulations e g UVV BGV D6 for cranes UVV BGV D8 for winches hoists and towing devices in Germany The owner is responsible for ensuring that power driven chain hoists are inspected by an expert engineer before they are first put into service and before they are put into service again after major modifications have been carried out This also applies to manually operated or semi powered chain hoists that have a load capacity of more than 1000 kg Adjustment maintenance and inspection activities and inspection deadlines including specifications con cerning the replacement of parts assemblies prescribed in the operating instructions must be observed Please refer to gt Noise emission sound pressure level Page 25 for sound pressure level measurement values to DIN 45 635 This work may only be carried out by specialist personnel 53 6 3 Inspections before putting into service for the first time The owner is obliged to carry out the following checks before the unit is put into operation for the first time Activity Section Check Check continuity of the PE conductor connection X Check emergency stop device X Check direction of movement Mains connection Page 42 X Check 7 segment display T segment display for operating status and fault display X Page 29 Dis
53. ant national industrial safety regu lations codes of practice accident prevention regulations directives and generally accepted engineering stand ards enabling them to judge the safe operating condition of machines Assigned expert engineer in the Federal Republic of Germany according to BGV D8 Section 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 machine S W P safe working period and to carry out a general overhaul of the machine Authorised expert engineer according to BGV D6 Section 28 in the Federal Republic of Germany In addition to the expert engineers of the Technical Supervisory and Inspection Board an authorised expert engi neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers Mu tual Insurance Association Test and inspection booklet A test and inspection booklet filled in with all details must be available for the hoist according to BGV D6 Section 28 in the Federal Republic of Germany The results of the regular tests and inspections must be entered into the test and inspection booklet and must be certified by the inspector Test and inspection booklet order no Tab 3 Page 7 After sales service If you have any questions on our products or need technical information please contact our after
54. ating regulations e g BGV D6 for cranes in Germany If required apply a copy of the relevant operating regulations part no 214 748 44 at a suitable place where operators can read them at any time e g at the mains connection switch The machine must not be put into operation or must be taken out of service immediately if any defects or irregu larities relating to operating safety and reliability or functions are detected Safety devices must not be rendered inoperative or modified contrary to their intended use 55 Ensuring safe operation Special local conditions or special applications may lead to situations which were not known when this chapter was written In this case the owner must ensure safe operation or take the machine out of service until measures for safe operation have been clarified and implemented in agreement with Demag or other relevant bodies In the event of a stoppage e g if defects regarding safe and reliable operation are detected in emergency situa tions in the event of operating malfunctions for repairs and maintenance purposes if damage is detected or after finishing work the operator must carry out all prescribed safety measures or observe that they are automatically carried out Work on electric equipment may only be carried out by qualified electricians 7 2 Switching on 7 2 1 Checks when starting work Before starting work the operator must be satisfied that th
55. ation operator or maintenance trained maintenance fitter of the installation the owner may only employ persons who are at least 18 years of age e who are mentally and physically suitable e who have been instructed in the operation and maintenance of the installation and who have proven their quali fication to the owner in this respect 214 802 44 291113 214 802 44 291113 Personal protection equipment When work is carried out on or with the installation the following protective equipment is recommended to be worn according to the owner s hazard assessment e Protective clothing closely fitting working clothes low tear strength no loose sleeves no rings or any other jewellery etc e Safety shoes to protect against falling parts and against slipping e Safety helmet to be worn by everybody in the danger zone Emergency stop device DSC DSM C DRC DC fl e ER i E en 43213845 eps Fig 3 Position of the emergency stop 1 The machine is fitted with an emergency stop device 1 to prevent damage and injuries This is located on the control unit The emergency stop operating function must be checked regularly 16 2 9 Regular inspections The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation and regional regulations In Germany this is specified by the accident prevent
56. bb nidis iai tactile chats ates 28 Drive and brake 2 S ee rre ERE e en eee 28 Gearbox and slipping clutcli es iecore ea nee Hee i a dede decr ei ose eder oa ed e eeu 28 en ngu EE 28 Electric equipment iniisa 28 Control SM iii cn 283 4 4 2 4 4 3 4 5 4 6 4 7 5 1 5 2 5 3 5 4 5 5 5 6 5 6 1 5 6 2 5 6 3 5 6 4 5 7 5 7 1 5 7 2 5 8 5 9 5 9 1 5 9 2 5 9 3 5 10 5 10 1 5 10 2 5 10 3 5 10 4 5 11 6 1 6 2 6 3 6 4 7 1 7 2 7 2 1 7 2 2 7 3 7 3 1 7 3 2 7 3 3 7 3 4 7 3 5 7 3 6 7 3 7 7 4 7 segment display for operating status and fault display o nooconnncnninncnonncccnnnannnncccnnnnrncc nan rn nn emen 29 Display of software version operating hours number of cycles ssssseeeeee emen 30 Central service Enclosure i nns A i i eu Ee EE ey 31 Control pendant control cable height adjustment emen menn ener nennen 31 ere nipllr er E 31 Assembly eere eie ede eu ee E et nOD ees 32 A eid Bice a ah ae ese M M 32 Safety instructions f r assembly rete Sie edi ee tos ei ett beat aaron eects Sheen 32 DC Com chain hoist tightening torques ooncccnnnnicnnnoninnocccnnannccnnonnn nono nennen nennen nene en nnne nennen nnns eterne nennen 34 Installation procedure eee een pedes opa 34 Conriectirig thie control pendant sneinen lt iet ee e deat dec eee ee ee i
57. cator 3 Load kmi load spectrum must be estimated 4 The value determined for operating time T using an elapsed time indicator must be multiplied by the type of recording factor f 1 1 5 The value determined for the estimated operating hours and load spectrum must be multiplied by the type of recording factor f 1 2 6 The actual duration of service S is calculated as S kmi x T xf 7 Ageneral overhaul must be carried out when the theoretical duration of service is reached 8 All checks and inspections and the general overhaul must be arranged by the owner of the hoist unit 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 components and parts Following a general overhaul the machi nery 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 electric chain hoists classified according to FEM 9 511 the following theoretical durations of service apply converted into full load hours Group of mechanisms 1Cm 1Bm 1Am 2m 2m 3m 4m Duration of service full load hours 200 400 800 1600 1900 3200 6300 h Tab 42 65 66 8 3 4 2 8 3 4 3 The actual duration of service is considerably increased if the chain hoist is only operated with partial loads For a h
58. changes Drain the old oil at operating temperature Turn the gearbox in such a way that the oil is drained The flushing oil should have a viscosity of 46 68 mm s at rated temperature The quantity of flushing oil used should be approxi mately twice that specified for lubrication Then flush the gears by switching the hoist on and allowing the hook to run several times over the entire length of its lifting path Then drain the flushing oil and refill the gearbox with new oil Please refer to the table above for the required oil quantities See spare parts for the order no DC 1 10 Remove control unit with plug and socket connections 2 under electric equipment cover 3 Now re move the screws of gearbox cover 1 91 92 8 5 11 Replacing the contactor on the control board 42776847 XML eps Fig 68 1 Unclip the contactor retaining mechanism by pressing locking tab A with your thumb This carefully bends locking tab A away from the contactor 2 Then turn contactor B using your other hand until the mechanism no longer holds it 3 Then unclip second locking tab A on the opposite side as described in step 1 above 4 Using your other hand remove contactor B by pulling it away from the board The replacement contactor can only be inserted into the socket in one position Push the contactor into contactor Socket C until both locking tabs A click into position 214 80
59. circumstances e DC1 10 with 1 1 reeving hook assembly use of cut off springs optional for very high mechanical demands on the buffers e g frequenct contact with sharp edges for extreme ambient conditions high temperature applications foundries etc e DK10 bottom block with external cut off springs optional for extreme ambient conditions high temperature applications foundries etc Reduced duty factor at increased ambient temperatures If DC chain hoists are operated at ambient temperatures that differ from Tab 19 Page 27 the duty factor must be reduced Ambient temperature 20 C to 45 C gt 45 C to 50 C gt 50 C to 55 C gt 55 C to 60 C Chain hoist range Duty factor DC Pro DCM Pro 20 40 15 35 15 25 10 20 DC Com 1 DC Com 2 10 15 25 15 25 15 25 10 20 Tab 20 27 28 4 1 4 2 4 3 4 4 4 4 1 Technical description Drive and brake A robust pole changing AC asynchronous motor is used as the hoist motor The brake is arranged on the load side in such a way that the load is safely braked and held if the slipping clutch is tripped The brake is released electrically Pressure springs ensure that the brake is applied automatically when power to the motor is switched off or if there is a power failure The motor is automatically switched off and at the same time the brake is applied when the slipping clutch is tripped and if errors occur The lif
60. clutch must be adjusted according to the load capacity of the chain hoist For information on adjustment see Friction force checking device document Tab 3 Page 7 According to DIN EN 14492 2 the force limitation factor for DC chain hoists with a load capacity equal to or great er than 1000 kg is Poa 1 6 Specification of the supporting structure must allow for the static and dynamic forces that occur when the overload protection device is tripped 214 802 44 291113 214 802 44 291113 5 7 2 Suspension bracket 43215244 eps 1 DC Com 1 5 suspension bracket opened 3 DC Com 10 2 1 reeving 2 DC Com 10 1 1 reeving a Spacer tube WARNING Overload Danger to life and limb if the components are overloaded The suspension support structure for the chain hoist must be designed to accommodate the loads DANGER Chain hoist may fall Danger to life and limb and risk of damage Do not move the chain hoist or leave it unsupervised when the suspension bracket is open The chain hoist is delivered with the long suspension bracket fitted to the chain hoist The short suspension brack et can be ordered to achieve an improved C dimension Assembly 1 Remove the retaining clip and pin on one side 2 Attach the suspension bracket DC 10 according to the reeving arrangement to the superstructure trolley 3 Insert the pin through the suspension and the suspension bracket and through additional spacer
61. corresponding check gt Checks on entering service handover Page 54 WARNING Machines may only be put into service if they have been installed assembled according to the assembly instruc 0 Safe operation of the machine is not yet ensured when it is first put into operation tions Machines may only be put into operation by qualified personnel Check installation operation of the safety devices before commissioning Check to ensure that the mains voltage and frequency match the details specified on the rating plate Move the trolleys by hand and check that they can be moved without resistance by hand over the entire length of the track section if fitted Ensure sufficient working clearance before starting assembly work Secure and fence off the working and danger zone Wear protective equipment Only trained personnel may be employed when the installation is first put into operation since e it may be necessary to render safety devices or features inoperative when adjustments or function checks are carried out work may need to be performed in the danger zone when the installation is first put into operation 6 2 Inspection regulations WARNING Non compliance with operating and maintenance regulations Danger to life and limb Compliance with all inspection regulations is an essential aspect of ensuring safe operation of the machine Required tests and inspections must be carried out All inspections must be arr
62. ctions may also be caused by in correct transmission of commands from the control pendant Therefore check the control pendant and the control cable for damage and the plug in connector on the pendant and in the service enclosure for correct fit The symbols are shown one after the other e Please contact our after sales service if the cause of the fault cannot be eliminated with the given measures 9 3 Operating statuses general messages 1 2 3 4 C 5 mmm n n n L n 6 T 7 8 i 9 z a 7 i 432160A28_xml eps Fig 72 Item Display Malfunction event Possible cause Remark 1 A No lifting no lowering No power supply display is dark Check mains connection and fuse link check connection cable for interruption check mains connector in the service enclosure Check PE phase for correct connection 2 8 No lifting no lowering Emergency stop actuated Unlock emergency stop by turning it Cables not connected or defective Check and replace connections as required Plug connections not connected or defective Check and replace plug connections as required 3 Flashing READY No lifting no lowering Two phases of the mains connection cable must be Incorrect motor direction of rotation changed First disconnect unit from the power supply Thermal contact open Check motor plug connector X8 f
63. da 104 Chain driya iin aia 106 Hook assembly PER MEE 108 Bottom block with internal cut off springs Standard ooooonnnncccononicnoncconnonccnnnornn nn cn non norn cnn rr enne 109 Bottom block with external cut off springs OPtiOM oooococcccnnniccnnnnonnocccnnnorcnnnarnn nn cn nn nro nennen nennen nnne 110 Electric equipmieritiCOVer oet ti 111 Control pendant control cable service cover cccccecececeeeeeeeeeeeceneeaeceecesnaeeeeeesecaaeaeeeeseeaeaeeeeseceaeeeeseeeaeeeeeeeees 112 E ee ed en ede EN 113 214 802 44 291113 214 802 44 291113 General DC Com chain hoist You have purchased a Demag quality product This chain hoist was manufactured to European standards and regulations in accordance with state of the art en gineering principles The EC machinery directive requirements are satisfied DC Com documents Further documents are available for sub assemblies components in addition to these operating instructions The corresponding documents are supplied as necessary or can be ordered separately also for special designs or if additional options are ordered which differ from these operating instructions Documents 1 Order no Demag DCS Pro 1 0 chain hoist 203 525 44 Demag DC Com chain hoist 203 571 44 CF5 DC DCM trolley 203 568 44 Technical data cat
64. e 83 X Check hook safety catch for deformation X Check hook bearing for wear X Check rubber lip in the bottom block gt Replacing the bottom block stand ard with internal cut off springs for 2 1 X reeving Page 85 Check sprocket of chain guide chain sprocket of bottom block gt Chain drive Page 73 x chain guide guide plate Check that the chain and chain collector box are properly secured X Check the chain for deformation damage cracks pitting reduc gt Checking the hoist chain Page 74 tion in the thickness of the links or increase in pitch due to wear X elongation caused by deformation Check securing elements clips bolts etc for tight fit and corro x sion Check and apply or supplement corrosion protection as required X Check the electric enclosure and gearbox for leakage X Check trolley crossbar and condition of buffers Checking the cut off buffers cut off X springs Page 86 Oil change Gearbox oil change Page 91 Every 10 years 2 General overhaul The general overhaul should coincide with the annual inspection When 90 of the theoretical duration of service is reached S W P measures for achieving safe working periods Page 65 Fit chain hoist specific Demag GO set X The small parts screws washers to be replaced when maintenance and assembly work is carried out are not listed separately The checks and work speci fied in the inspection and maintenance schedule must be car
65. e it in the recess in the chain collector box Remove retaining spring 4 from pin 5 and remove the pin While doing so hold the chain collector Place chain collector box 6 on the ground 8 5 4 Operating limit switches standard for DC Com 10 with 2 1 reeving 8 5 4 1 Checking operating limit switches DANGER Danger of broken chain and falling load The chain may break and loads may fall if the emergency limit position limiter is frequently approached 71 72 8 5 4 2 The chain hoist slipping clutch provides the emergency limit position limiter function for chain hoists that are not fitted with an operating limit switch or which have a defective operating limit switch This emergency limit position limiter may only be approached in exceptional cases i e it must not be approached in normal operation High additional loads occur in the chain when the slipping clutch is tripped For this reason the operating limit switch for lifting function must be checked every day If an operating limit switch is defective the hoist motor is switched off when the electronic speed monitoring func tion of the slipping clutch is tripped For this reason cut off in the upper hook position is not a reliable indicator for correct operation of the operating limit switch If cut off by the operating limit switch fails a warning message is output see Warning messages Page 98 Checking the operating limit switch for lifting raise the
66. e machine is in safe and correct operating condition Ensure that nobody is endangered by operation of the machine before it is switched on or put into operation If the operator notices persons who may be exposed to a risk to their health or personal safety by operation of the in stallation he must stop operation immediately and may not resume operation until the persons are outside the danger zone The chain hoist must be taken out of service without delay if there are any defects which endanger safe and relia ble operation Defects relevant to safety in this sense are for example e Damage to electric devices cables or insulation e Delayed operation or failure of brakes and safety devices Missing covers or housing parts or e Damage to the chain or to supporting parts Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay This also applies if damage occurs to parts of machinery or equipment which makes an immediate stoppage nec essary If the chain hoist has been stopped by an emergency stop due to safety related defects it must be secured against being returned to operation until an experienced technician is satisfied that the cause of the hazard situa tion has been eliminated and that operation of the machine is possible without any hazard Before starting work e Wear protective equipment e Ensure that nobody is present in the danger zone of the equipment 7 2 2 Function checks Instr
67. e met for continued operation of the chain hoist Therefore the provisions of the relevant UVV accident prevention regulations and BGV D8 are satisfied The equipment may continue to be used when an expert engineer has entered the conditions for further utilisation into the test and inspection booklet Completion of the general overhaul must be confirmed in the test and inspec tion booklet and a further period of utilisation in accordance with FEM 9 755 must be entered 8 4 Maintenance schedule Activity Section Before first put Before starting During the an ting into opera work nual inspection tion Check continuity of the PE conductor connection X Check emergency stop device X X Check direction of movement Mains connection Page 42 X Check 7 segment display gt 7 segment display for operating sta tus and fault display Page 29 X X gt Display of software version operating hours number of cycles Page 30 Check chain lubrication under arduous conditions the chain must Available hoist chains Page 77 X X X be lubricated more frequently Check function of the lifting motion operating limit switch Checking operating limit switches X X X Page 71 Check function of the lowering motion operating limit switch Checking operating limit switches X X Page 71 Check cut off buffer cut off spring operating limit switch actuator Checking the c
68. e must not be tripped by DC Com chain hoists that are not fitted with operating limit switches Emergency stop DSC DSM C DRC DC 43213845 eps Fig 33 Position of the emergency stop 1 DC Com not in connection with DSM C 59 60 WARNING 7 5 7 5 1 7 5 2 7 5 3 Unauthorised negligent or accidental switching on Danger to life and limb Check to ensure that the reason for the emergency stop has been eliminated before the machine is switched on again The emergency stop device must not be used to switch the machine off in normal operation Every chain hoist is fitted with an emergency stop device with which all motions can be stopped in the event of a hazard The emergency stop button is arranged in a clearly visible position on the control pendant Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay This also applies in the case of damage that occurs to parts of the machine and equipment which makes it necessary to stop and secure the machine immediately e To actuate the emergency stop press the button until it reaches the end stop It then locks automatically and the chain hoist is shut down e To unlock the actuated emergency stop turn the pushbutton in the direction of the arrows clockwise and re lease it Following an emergency stop do not switch the machine on again until a trained perso
69. e working area clean and tidy Store any unneeded machine or installation parts and tools in such a way that there is no risk of them falling Fit components correctly and as intended Comply with specified bolt tightening torques Incorrectly fitted components may fall and cause severe injuries Welding work may only be carried out by persons who are specially qualified DIN welding work require ments must be fulfilled The electrode holder and earth must be connected to the same assembly when welding work is carried out Serious damage may otherwise be caused to the hoist Customer specific regulations must be observed Live components Danger to life and limb Work on electric equipment may only be carried out by qualified specialist personnel Definition of person nel Page 10 in compliance with the safety regulations 214 802 44 291113 214 802 44 291113 Switch off the electric power supply before starting work The mains connection or isolating switch must be pro tected against unauthorised or accidental restoration of the power supply by means of a padlock Mechanical safety All bolted connections must be correctly tightened Self locking nuts must not be replaced by other types of nut Self locking nuts must be replaced when they have been tightened and untightened five times The clamping torque of a self locking nut must not be lower than the loosening torque specified by EN ISO 2320 A sufficiently
70. ear If the chain hangs at angle when no load is attached to it for example this usually indicates wear of an individual chain link Measure the diameter of the chain link material in the chain link contact area using a calliper gauge if required For minimum link diameter values see Tab 53 Page 75 Measuring with a calliper gauge on 11 chain links D a a a N et Dds oo ee oe ADDR OR DR UR UE RR V UV UVA X 40460845 XML eps A partial load must be suspended from the load hook when measuring the chain over 11 links Measurements on 11 chain links may be taken in steps of 2 x 3 and 1 x 5 chain links The sum total of the 3 readings taken i e a a a4 must not exceed the specified limit a Otherwise the chain must be replaced Demag is stamped on every 12th link of genuine Demag chains Do you find that on fitting a new chain it does not run smoothly over the sprocket Please contact our after sales service centre We strongly recommend that you use genuine Demag chains This will ensure that the safety and service life of the chain hoist is guaranteed Fig 45 Demag chain hoist DC1 2 DC5 DC 10 Chain designation d x t mm 4 2x 12 2 5 3 x 152 7 4 x 21 2 Limit dimensions according to DIN 685 part 5 Measurement over the outside of 11 chain links maximum dimension a a a a3 mm 144 7 180 3 253 Overall length of 1 chain link inside max l
71. ee e eee 15 Regular InSpections s steer Ead ek HER e be e eei tes 16 TFechnical data 5nd teet aee dete decet eth ce piunt tian eret desunt qe dete cede n RE URL ud 17 DES UI A E eE ae E Eaa aee a EA Er EAT EEE 17 Model God6e 4 te A repere re aep be e t e es A UE rte atas 18 Selecto a le er eet ia i rete det A eec Poeno uc eee ee peel 19 Electric Cy c 20 Hoist Motor data E 20 Mains connection delay t se links o tee e RENE RN ERR pM eH 23 SeyAcurcaE X 23 Hook dimenslon G teer rer Ee rn ERE HR DER REM AE A rr nien 24 Noise emission sound pressure level 2 ode tette a ein 25 Transport packing arid storage sssrini ctr rire reet err ic 25 Satety INSIructOns ECC See ee ee ee i es 25 Scope ORGSMVEMY C P n Gace 25 Trarisport inspection eret ee re ee A ee 25 Packing ios oet debet putate ettet faded t Utt erae eliam Se ae rsen t aite int peo eL UTI ders 25 otorage u s A A eae rec AG ee Te endete e Oe AE e ee e tds 26 MEIN M 26 IUe 26 HOUSING AA re E pe i Oe e be ren e m y ee e ERE e e e ttes 26 Surface protection and paint finish rice ecce rei 26 Operating CONITIONS 3 t eed eoi ie E ite eee epu 27 iTechnical description 3 21 de tet tei eem aet tete teda ta a
72. erating conditions section the owner must implement special measures after consulting Demag Use of the control pendant Powered lifting and lowering and if applicable cross travel and long travel motions are controlled by means of the corresponding control elements on the control unit The slow speeds are intended for attaching the load lifting it free and depositing it Loads can be precisely positioned at slow speeds Short transport times can be achieved at higher speeds They are suitable for travelling without a load or with a safely suspended load if no hazard can be caused by the faster motion sequences il Inching flick switching must be avoided as it causes increased wear and load sway 2 4 Hazards that can be caused by the machine The machine has been subjected to a risk analysis The design and execution based on this analysis corresponds to state of the art engineering principles However residual risks remain DANGER Live components Danger to life and limb Electric energy may cause very severe injuries Danger of death caused by electric current if the insulation or individual components are damaged Switch the machine off and secure it against restoration of the power supply before any maintenance cleaning or repair work is carried out Switch the power supply off before any work is carried out on the electric equipment Check to ensure that the components to be replaced are de energised Do n
73. ers to DIN EN 60898 1 tripping characteristic B or C instead of separate fuse links This arrangement ensures that all phases are disconnected from the power supply in the event of a short circuit Voltage 220 240 V 380 415 V 500 525 V 220 240 V 380 400 V 440 480 V 575 V Frequency 50 Hz 60 Hz Size Motor size A A A A A A A ZNK 71 A 8 2 DC Com 1 ZNK 71 B 8 2 6 6 DC Com 2 ZNK 71 B 8 2 6 6 6 6 6 DC Com 5 ZNK 80 A 8 2 10 10 ZNK 100 A 8 2 DC Com 10 ZNK 100 B 8 2 10 10 z 16 10 6 Tab 11 Mains connection fuse link for lifting speeds until 09 2008 no longer available Voltage 220 240 V 380 415 V 500 525 V 220 240 V 380 400 V 440 480 V 575V Frequency 50 Hz 60 Hz Size Motor size A A A A A A A DC Com 2 ZNK 71 B 8 4 6 6 6 6 6 6 6 DC Com 5 ZNK 80 A 8 4 Tab 12 Supply cables Supply cables 18 for 5 voltage drop Ay and starting current Voltage 220 240 V 380 415 V 500 525 V 220 240 V 380 400 V 440 480 V 575 V Frequency 50 Hz 60 Hz Size Motor size ma m mm m mm7 m mm 7 m mm m mm m mm m ZNK 71 A 8 2 DC Com 1 ZNK 71 B 8 2 89 76 458 DC Com 2 ZNK 71 B 8 2 1 5 100 100 1 5 100 100 1 5 1 5 1 5 1 5 1 5 DC Com 5 ZNK 80 A
74. ersion operating hours number of cycles Display of software version 0 8s 0 8s 0 8s 43216445 xml eps Fig 8 Example Software version 1 01 The software version is displayed every time power is switched on or after an emergency stop from software ver sion 1 01 Display of operating hours 0 8s 0 8s 0 8 s 0 2s 0 2s 0 2s U 2L C incur mE 43216045 xml eps Fig 9 Example 123 hours of operation The display appears after 3 seconds without any lifting motion If the control board has to be replaced we recommend if technically possible that the details for the number of operating hours be read off and documented in the test and inspection booklet The elapsed operating time coun ter starts at zero if a replacement control board is installed Display of the number of cycles of the K1 contactor 0 8s 0 8s 0 8s m 0 2s l 0 2s 0 2s L ee 7 C o gt lt H123 gt 43226445_xml eps Fig 10 Example C 15 corresponds to 15 x 100000 1 5 m K1 switching cycles The display alternates between showing this information and the number of hours of operation C 5 corresponds to 5 x 100000 500000 K1 switching cycles For preventive maintenance see gt Service life of the contactor Page 64 214 802 44 291113 214 802 44 291113 4 5 4 6 4 7 Central service enclosure De MAN N a J
75. es in all respects with current DIN VDE and accident prevention regu lations Unauthorised intervention and modifications eliminate compliance with these regulations Live components Danger to life and limb It must be possible to switch off the power supply by means of a device to disconnect the power supply e g mains connection or isolating switch with a padlock The chain hoists are supplied with power from an AC power network The voltage and frequency of the AC pow er network must match the data specified on the rating plate of the chain hoist Safety instructions for assembly Incorrect assembly Danger to life and limb Incorrect installation may result in severe injury and or damage to property Therefore this work may only be carried out by authorised instructed personnel who are familiar with the principle of operation of the machine in compliance with all safety regulations Ensure sufficient working clearance before starting assembly work Secure and fence off the working and danger zone Ifan elevating work platform is used for assembly only use appropriate attachments for the lifting of per sons which ensure that work is carried out in a safe and stable position Only suitable tested and calibrated tools and accessories may be used for assembly or disassembly work Wear protective equipment Be careful when working on open components that have sharp edges Risk of injury A Keep th
76. esion t mm 128 15 9 22 4 Measurement of the chain link diameter minimum dimension d 0 9 x d mm 3 8 4 8 6 7 Tab 53 The limit dimensions apply to all hoist chains listed in gt Available hoist chains Page 77 75 Measuring with a chain gauge on 11 chain links A la ON 0 y 0 10x28 o 10 5x28 2 1 i e p eA o 8 7x24 2 p o f 0 7x21 o 7 4x21 2 e O p p f y 5x15 o 5 3x15 2 24 O SY a k 4x12 Pa v2 4 2x12 2 H SAN o 3 6x10 61 WS P SY le IS te o V o P SN ei 42648247_XML eps Fig 46 It does not yet need to be discarded The chain does not yet need to be replaced A DC DK PK new chain 2 The chain needs to be replaced if the measuring pin can no longer be inserted into the 11th chain link B PK old chain 3 Measuring pin 1 Chain gauge part no 836 025 44 4 11 th chain link the chain is ready to be discarded The chain must be replaced Tab 54 A partial load must be suspended from the load hook when measuring the chain over 11 links 8 5 5 5 Chain set scope of supply The chain must be replaced when the permissible chain wear limit is reached to determine the wear limit of the chain see Checking the hoist chain Page 74 A chain set is always supplied when a new standard RDC TDK chain is ordered The chain set includes the following parts e Chain e S
77. essary remove suspended load Defective electronic monitoring Replace hoist control system 7 E 7 Hoist unit Motor runs in Direction of hoist unit cannot be switched Check error message by actuating and unlocking the emer wrong direction Chain gency stop hoist is blocked Then actuate Lowering If necessary remove suspended load Replace hoist control system 8 E 8 Lifting is switched off Brake defective or slipping clutch incorrectly adjus Check brake and slipping clutch ted If there is no fault replace electronics 9 E 9 9 Chain hoist is blocked Emergency stop circuit of control system defective Check error message by actuating and unlocking the emer gency stop Then actuate Lowering If necessary remove suspended load Replace hoist control system Tab 70 Hardware faults are displayed with two characters by software version 1 60 and higher 99 100 10 Disassembly disposal 10 1 General WARNING Before disassembly follow the safety instructions in gt Maintenance repair Page 62 of these operating in structions Refer to Assembly Page 32 of these operating instructions for information on removing track sections trol leys and current collector trolleys Other parts are removed in reverse order to assembly Unless a return or disposal agreement has been concluded separated components must be recycled after proper removal e Scrap any remaining metallic material e Dispose of plastic
78. fall 3 Buffer plate Tab 37 Ensure that the hook assembly touches the ground in the lower hook position when determining the hook path lifting height The chain hoists are provided with a hook path of 4 m 5 m or 8 m as standard Secure the limit stop to the 5th link at the dead unloaded end of the chain Follow the order of assembly See also Buffer arrangement Page 87 Tightening torques Nm DC 1 DC2 DC 5 DC 10 Limit stop 40 4a Tab 38 To reduce the hook path proceed as follows 1 2 Position the hook as shown in the diagram Stop the chain hoist by actuating the emergency stop or the mains connection switch and secure it against Switching on again Remove the chain collector box Removing the chain collector box Page 71 Remove the limit stop on the chain collector box end Attach the limit stop directly behind the damping plate The unloaded chain fall behind the limit stop must con sist of at least 5 chain links Place the chain in the collector box and re connect it to the chain hoist Switch the chain hoist on and check adjustment of the lower hook position by moving the hook and run the chain once through over entire adjusted hook path 214 802 44 291113 214 802 44 291113 6 Putting into service for the first time 6 1 Safety instructions when putting into service for the first time The machine may only be handed over when its safety has been verified by means of a
79. fie nas 35 Control Cable ives 36 Control cabl techinical data 2 S eme dl ea 36 Handling the control cables iid ee A ee dee UA Ped 36 Control pendant height adjustment oe eee cence cnet teeter non cnn non nn cnn rn rre 37 Mobile CONTO system etti Ed ede Sdn ere qa ete ee e dee d deer Pon Gade Hebe Dti 38 ou spendirig thie chaln holst 3 3 rer the tte en fee Bn re a et ete be lege decer tebe eden 40 Supporting SItr cture zaii iganna eed de iere ai ctc p re ded ideal tt edet trt a de ue 40 Suspension bracket 2 eset re dea 41 Mains Connection sonene nan RE EMT Ee BL ete e o B E p d ER REP EXER ERR ER Re DERE Orne aA De Dag 42 Circuit diagrams and control boards sssssssssee eene nennen ennemi rre 44 DC Com 1 10 solo hoist circuit diagram sessese eee eene nennen nennen nnn emeret nennen 44 Circuit diagram with E11 E34 DC travel drive essen rn rn nn rre rre 47 Control board e ee eer hr e dude dla Na Heo hh mote eo eer TERRE aged PRESA HER AE RAE EAS t ER CR e led xps 47 Programming parameters with the control pendant sssssessese eene nennen nemen enne en 49 e cM M 49 M aning ofthe delitosct M c 49 Meaning of the parameters o CE I duet Bie ed tee Qa e te Ht ette Le du es UE CENE Ule d dents 49 Starting parameter progra
80. for the conformity inspection Liability and warranty All information included in these instructions has been compiled on the basis of the relevant regulations state of the art engineering principles and our many years of experience These instructions must be read carefully before starting any work on and with the chain hoist especially before it is put into service for the first time The manufacturer assumes no liability for any damage which results from the following non compliance with the instructions e inappropriate use e untrained personnel e unauthorised conversions e technical modifications Wearing parts are not subject to liability for defects We reserve the right to incorporate technical modifications within the scope of improving the operating character istics and further development of the product Copyright These instructions are only intended to be used by people who work with or on the chain hoist Any and all content texts drawings images and any other information are protected within the sense of copyright law and are subject to further industrial rights Any misuse is an offence No part of this documentation in whole or in part may be reproduced distributed shown in public or used in any other way without specific prior consent Infringements are an offence resulting in obligatory compensatory dam ages Further rights reserved All industrial rights reserved Use of spare parts We urgent
81. g strikes e The power supply line and the electric cabling and wiring must be checked with particular care and at shorter intervals e The control system of the chain hoist consumes approx 1 1 VA when at standstill Taking the equipment out of service for maintenance and repairs 1 Switch off the mains connection switch or isolating switch before commencing maintenance work 214 802 44 291113 214 802 44 291113 Secure the mains connection switch with a padlock to prevent unauthorised or accidental reconnection to the supply Only carry out maintenance work on the chain hoist when the load has been removed Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out Observe the relevant accident prevention regulations instructions concerning intended use and statutory regulations for operation and maintenance Observe relevant safety regulations when repairing electric equipment 61 62 8 Maintenance repair 8 1 Safety instructions for maintenance and repair work The following sections contain a description of maintenance work that is necessary for optimum and uninterrupted operation of the equipment DANGER Live components Danger to life and limb Work on electric equipment may only be carried out by qualified specialist personnel Definition of person nel Page 10 in compliance with the safety regulations Switch off the electric power supply before startin
82. g work The mains connection or isolating switch must be pro tected against unauthorised or accidental restoration of the power supply by means of a padlock WARNING Risk of burns Risk of burns from contact after the chain hoist has been in operation Do not touch hot motor housings Allow the motor to cool down before performing any maintenance or repair work WARNING Inappropriate maintenance work Danger to life and limb Risk of material damage Maintenance and repair work may only be carried out by authorised instructed personnel Definition of per sonnel Page 10 in compliance with the safety regulations Secure and fence off the working and danger zone If an elevating work platform is used for maintenance work only use appropriate attachments for the lifting of persons which ensure that work is carried out in a safe and stable position A Only suitable tested and calibrated tools and accessories may be used for maintenance work Only use approved spare parts see also Use of spare parts Page 9 Wear protective equipment Be careful when working on open components that have sharp edges Risk of injury Keep the working area clean and tidy Store any unneeded machine or installation parts and tools in such a way that there is no risk of them falling Fit components correctly and as intended Comply with specified bolt tightening torques Incorrectly fitted components may fa
83. gearbox 27 Rotor 8 Brake springs 18 Suspension bracket 28 Fan 9 Brake magnet 19 Suspension pin 29 Fan cover 10 Gearbox housing 20 Service cover 30 Mounting points Tab 4 2 Illustration differs from scope of delivery 17 18 3 2 Model code E K D DC Com 10 2000 211 H5 V6 1 5 380 415 50 24 6 200 220 480 Travel drive voltage range voltage V Max flange width of the trolley mm Travel speed m min Frequency Hz Chain hoist voltage range V Lifting speed m min V 2 stage Main creep lifting VS Stepless VS at nominal load up to VSmax in the partial load range Hook path m Reeving Load capacity kg Size 9 DC Pro product range DC Pro product range DC Pro 2 stage chain hoist Demag chain hoist DC ProDC 2 stage chain hoist for direct control DCM Pro 2 stage Manulift DC ProCC 2 stage chain hoist for conventional contac DCS Pro Variable speed chain hoist tor control DCMS Pro Variable speed Manulift DC ProFC Variable speed chain hoist for control by DCRS Pro Stepless rocker switch means of an external frequency inverter DC Com product range DC Com 2 stage chain hoist D Articulated trolley Long trolley K Low headroom hoist U Standard headroom monorail hoist 11 Trolley size load capacity kg 100 22 34 56 R Push travel trolley E Travel drive Cc F 5 Click fit push travel trolley Tab 5
84. ghtening torques Nm DC Com 1 DC Com 2 DC Com 5 DC Com 10 Reeving 1 1 2 1 Motor 9 5 25 0 Fan cover 4 0 Gearbox seal 5 5 Brake 5 5 Operating limit switches 3 0 Control set 3 0 Electric equipment cover 9 5 Service cover 5 5 7 5 Limit stop 4 0 4 3 7 4 Anchorage halves 10 5 Guide plate 5 5 Hook assembly 6 8 9 5 25 0 Bottom block with external cut off springs 55 0 Bottom block with internal cut off springs BENT biok nalves SEM Guide section halves 5 5 Control cable locking mechanism 11 0 Tab 22 Loose connections Loose connections are a danger to life and limb and a risk of damage to the machine Metal nuts featuring a locking element self locking nuts are mainly used for Demag chain hoists Self locking nuts must not be replaced by other types of nut Installation procedure 1 oN o0 b o mw Unpack and dispose of the packing material in an environmentally compatible way Transport packing and storage Page 25 Check the delivery is complete Transport inspection Page 25 Connect the control pendant if necessary Connecting the control pendant Page 35 Which suspension bracket is suitable for suspension Suspending the chain hoist Page 40 Adjust the height of the control pendant Control pendant height adjustment Page 37 Connect to the power supply Mains connection Page 42 Set the lowest hook position if necessary Adjusting the lower hook positi
85. he chain collector box Removing the chain collector box Page 71 e Check as described above for the Operating limit switch for lifting Optional geared limit switch If an optional geared limit switch is fitted the hoist unit must be switched off before the bottom block or hook as sembly come into contact with the chain hoist guide plate To check this function the upper hook position must be approached at high lifting speed without a load When the hoist unit has been switched off there must be a mini mum distance of at least 20 mm between the bottom block or hook assembly and the chain hoist guide plate Checking the operating limit switch actuator The operating limit switch actuator must be checked for any external damage e g a bent actuator plate 214 802 44 291113 214 802 44 291113 8 5 5 8 5 5 1 8 5 5 2 Chain drive Checking the sprocket wheel Fig 40 Chain sprocket wear Checking the chain guide Ul 42774644 XML eps Fig 41 Example of a defective chain guide Since the chain sprocket is usually replaced together with the chain set no further check is necessary under normal conditions However if you notice any uneven or harsh running in the chain drive mechanism this may indicate wear The chain guide must be removed and degreased to enable the chain sprocket to be inspected properly If the chain sprocket shows signs of wear from the chain or chipping on its sides the chain se
86. he risk assessment and operating in structions which must be compiled by the manufacturer of the installation in compliance with the Machinery Direc tive 214 802 44 291113 214 802 44 291113 1 5 1 6 1 7 For operation of the installation the manufacturer of the installation must provide additional operating instructions as the result of the risk assessment as required and inform the owner about any remaining hazards A declaration of incorporation is enclosed for a chain hoist supplied as partly completed machinery which is as sembled with additional parts to form a machine that is ready for operation The declaration of incorporation refers to the scope of delivery of the partly completed or non assembled machinery The owner must take additional measures to satisfy the safety requirements for the machine before the unit is put into operation Installation of a partly completed or non assembled chain hoist to create machinery ready for operation must be carried out in compliance with the information provided by the manufacturer for the machinery Installation and operating instructions for the chain hoist contained in this document must be observed A conformity inspection in accordance with the Machinery Directive must be carried out for the assembled ma chine when it is ready for operation and a declaration of conformity must be produced The information contained in the declaration of incorporation for the chain hoist may be used
87. hoist motor fan is still turning while there is no lifting motion e The 7 segment display shows the SLIP LIFTING V1 warning gt Warning messages Page 98 When the slipping clutch function has been checked the limit stop must be fitted again to the section of chain which is not under load Adjusting the slipping clutch The slipping clutch is adjusted to the load capacity of the chain hoist during the final inspection in the factory An increase of the tripping tor que which exceeds the factory setting is not permitted see also gt Suspending the chain hoist Page 40 For DC Com chain hoists that have a load capacity 2 1000 kg the set ting meets the requirements of EN 14492 2 for slipping clutches used as overload protection Overload protection must be provided for load capacities 1000 kg If an acceptance check of the hoist or crane installation is carried out a load of 110 of the rated load capacity must be lifted without adjust ment of the slipping clutch as part of the dynamic overload test A load gt 160 must not be lifted EN 14492 2 Direct acting rated capacity limiters 42657745_XML eps Fig 66 The slipping clutch is protected against overload by slip monitoring which means that it does not have to re ad justed until a general overhaul is carried out If owing to the operating conditions or due to malfunctions the ad justment needs to be checked a friction force checking device
88. hook assembly B E or bottom block until it is approximately 10 cm below the highest hook position Then raise it to the highest hook position at creep lifting speed until the chain hoist automatically switches off oo 9 0 oo e 1 1 reeving o or T It must only be possible to compress the buffer or cut off springs on the hook assembly by a small amount after the unit has switched off e 2 1reeving It must only be possible to compress the upper part of a bottom block with internal cut off springs onto the lower part by a small amount so that approx 20 mm of the black part of the bottom block remains visible Fig 39 Buffer with limit switch not actuated A buffer with limit switch actuated B defective buffer with limit switch actuated C X 42768545 eps It must also only be possible to compress the springs on a bottom block with external cut off springs by a small amount after the unit has switched off If the buffer or cut off springs are strongly compressed it may be assumed that the hoist motor will not be Switched off by the limit switch but by the speed monitoring function of the slipping clutch This may cause the chain to break if the limit position is frequently approached Checking the operating limit switch for lowering The Operating limit switch for lowering must be checked at least once per year Proceed as follows Remove t
89. ig 2 Intended use The machine may only be used as intended and in compliance with the requirements for the owner and the fol lowing limitations as specified in these operating instructions Any other use may result in a danger to life and limb and or cause damage to the machine and or load e Chain hoists are only intended for lifting lowering and moving loads and may be used as stationary or travel ling units e The suspension support structure for the chain hoist must be designed to accommodate loads resulting from operation of the chain hoist The maximum safe working load is the load capacity specified on the capacity plate This must not be exceeded The maximum permitted load capacity of the chain hoist includes the load and any load handling attachment e The machine may only be installed used operated maintained and removed by trained personnel when it is in perfect working order Personnel must meet the requirements according to Operating personnel require ments Page 14 e Intended use includes compliance with the safety instructions as well as any other instructions on assembly and disassembly commissioning function and operation maintenance and fault elimination as well as compli ance with the instructions on the machine safety devices any possible remaining hazards and protection against hazards e The machine may only be used subject to the permissible technical data Technical data Page 17 e The machi
90. imum rated current for lowering motion 11 Temporary voltage tolerances of 10 and temporary frequency tolerances of 2 are possible Motors are rated to insulation class F 12 ZNK 71 A 8 2 with 380 415 V 50 Hz only for first delivery a ZNK 71 B 8 2 motor is supplied for replacement requirements 214 802 44 291113 214 802 44 291113 Size Motor size No of Py CDF Ny Starts h Min max currents and start up current 13 poles ly min IN max Imax 14 Tally max COS on kW rpm A A A 220 240 V 60 Hz 3 CE CSA s 9 8 0 06 20 870 240 2 10 2 50 2 50 1 45 0 47 DC Com 1 ZNK 71 B 8 2 2 0 22 40 3525 120 2 50 3 35 3 35 2 75 0 45 8 0 09 20 845 240 2 10 2 50 2 80 1 45 0 51 DC Com 2 ZNK 71 B 8 2 2 0 36 40 3480 120 2 70 3 30 3 85 2 75 0 54 8 0 12 20 870 240 2 30 2 30 2 60 2 50 0 45 DC Com 5 ZNK 80 A 8 2 2 0 49 40 3510 120 4 40 5 60 6 60 4 70 0 48 8 0 23 20 855 240 3 35 3 75 4 40 1 90 0 47 ZNK 100 A 8 2 2 0 90 40 3450 120 4 20 4 80 5 40 4 85 0 67 DC Com 10 8 0 44 20 885 240 ZNK 100 B 8 2 a 2 1 80 40 3555 120 380 400 V 60 Hz 3 CE 15 8 0 06 20 870 240 1 35 1 60 1 60 1 45 0 47 DC Com 1 ZNK 71 B 8 2 2 0 22 40 3525 120 1 70 2 00 2 00 2 75 0 45 8 0 09 20 845 240 1 40 1 60 1 70 1 45 0 51 DC Com 2 ZNK 71
91. ing the load spectrum modules km together results in the load spectrum factor kmi 0 119 Thus the actual duration of service amounts to S h kmi x T x f e With operating time read 0 119 x 334 x 1 1 43 72 e With estimated operating time 0 119 x 333 3 x 1 2 47 6 For classification in FEM group of mechanisms 1Am see DC Com data plate with a theoretical duration of serv ice of 800 hours see table below the hoist has a theoretical remaining duration of service of e With operating time read 756 28 hours e With estimated operating time 752 4 hours Documentation Enter these values in your test and inspection booklet or crane installation test and inspection booklet This entry may appear as follows Date Operating hours Load 96 km factor Load spec Actual dura Theoretical Remaining trum factor tion of serv duration of use ice service Use From To T value full 3 4 1 2 1 4 none Kmi f S D h Group D S h h of mech h 5 10 20 15 50 3 1 30 12 Read 334 0 119 1 1 43 72 800 1Am 756 28 0 05 0 042 0 025 0 002 5 10 20 15 50 3 1 30 12 Estimated 333 3 0 119 1 2 47 6 800 1Am 752 4 0 05 0 042 0 025 0 002 Tab 48 67 8 3 5 GO general overhaul The chain hoists are designed for a period of use of at least 10 years until the first general overhaul is carried out This is based on the condition that the specified group of mechanisms is not e
92. ion If routine maintenance reveals that the intervals are too long they should be adapted to the specific operating conditions Electric components Only fuse links with the specified amperage and tripping characteristics may be used in the electric circuits De fective fuse links must not be bridged Pay attention to the following when working on machinery or machine equipment 1 Wear personal protection equipment 2 Before starting any maintenance work switch off the mains connection switch and protect it against unau thorised or accidental reconnection to the power supply by locking it with a padlock 3 Ensure that the chain hoist is switched off checked that it is de energised and in special cases isolated 4 Only carry out maintenance work on the chain hoist when the load has been removed 5 Ensure that there is sufficient freedom of movement Keep the working area clean and tidy Loose parts or tools left lying around may cause accidents 6 Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out 7 Observe the relevant accident prevention regulations instructions concerning appropriate use and statutory regulations for operation and maintenance 8 Observe the relevant safety regulations when repairing electric equipment 9 Reinstall safety devices as required by relevant regulations and check them for correct operation after finish ing maintenance work Mainten
93. ion V sealing ring 1 of the brake must be re greased with anti friction bearing grease without any solid lubricant 89 90 8 5 9 8 5 9 1 8 5 9 2 Tightening torques Nm DC 1 2 5 10 Brake 5 5 Electric equipment cover 9 5 Tab 65 Slipping clutch Checking the slipping clutch The slipping clutch provides the function of an emergency limit stop de vice and overload protection for the chain hoist The slipping clutch is initially adjusted in the factory Under normal op erating conditions the slipping clutch does not need to be re adjusted The slipping clutch must be checked as part of the annual inspection The slipping clutch may only be adjusted by authorised specialists An increase of the tripping torque which exceeds the factory setting is not permitted Check operation of the slipping clutch as follows SS gt X SS e The chain collector must be disconnected in order to remove the limit stop Removing the chain collector box Page 71 Remove the limit stop Fig 53 Page 81 from the section of chain which is not under load and fit it above the hook assembly Run the limit stop against the guide plate at creep speed The operating limit switches if fitted must not be actuated while this is being done DADA ES SL EAS 42657644 XML eps Fig 65 If the slipping clutch is working correctly the following will be observed e the
94. ion regulations for winches hoists and towing devices BGV D8 and the accident prevention regulations for cranes BGV D6 for example These specify that e the machine must be inspected before it is put into operation e the machine must be inspected regularly e the elapsed share of the theoretical safe working period must be calculated e arecord of tests and inspections must be kept The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe new regulations at all times If no comparable inspection regulations or requirements apply at the place where the machine is operated we recommend compliance with the above mentioned regulations 214 802 44 291113 214 802 44 291113 3 3 1 Technical data Design overview 43213945 xml eps Fig 4 Single fall design Item Designation Item Designation Item Designation 1 Electric equipment cover 11 Chain guide 21 Adjusting mechanism for control cable 2 Control system 12 Chain sprocket 22 Sea buffer for operating limit switch 3 Elapsed operating time counter 13 Round section steel chain 23 den M With load capacity Window 2 14 Slipping clutch 24 Motor shaft Pulse wheel for speed monitoring 15 Dished washer pack 25 Winding head cap Magnet brake 16 Slipping clutch adjusting nut 26 Stator R pean DC 1 5 two stage helical gearbox 7 Brake disc with linings 17 DC 10 three stage helical
95. ive voltage drop and malfunctions during start up of the motor caused by undervoltage Connection to the electric supply e First check to ensure that the voltage and frequency specified on the rating plate match your mains supply Ensure that the mains connection cable is not connected to the power supply and secured against accidental restoration of the power supply e Remove the service cover to connect the supply cable Use the mains connection set included in the delivery for the plug connection to the mains connection cable 214 802 44 291113 214 802 44 291113 e Cut sleeve 1 to match the shape of the mains cable e n the area marked 7 to 13 for round cable in the area marked 18x7 to 20x8 for flat cable The system is de signed for cable cross sections of 4x1 5 mm or 4x2 5 mm e Slide sleeve 1 onto the mains cable Make sure sleeve 1 tightly encloses the cable for the specified enclo sure requirements Connect the mains cable on connector 2 to terminals L1 L2 L3 and to the PE If required use the wire end sleeves included in the delivery e Slide connector 2 into housing 3 until it latches and close housing 3 with sleeve 1 e Then insert connector 2 into the control system until the housing 3 latches with the card bracket e Finally insert the mains cable into the opening in the gearbox housing and secure it with the strain relief clamp For DC Com 1 to 5 units the strain relief clamp must be tur
96. ll and cause severe injuries Welding work may only be carried out by persons who are specially qualified DIN welding work require ments must be fulfilled The electrode holder and earth must be connected to the same assembly when welding work is carried out Otherwise serious damage may be caused to the hoist Trolleys must not be welded or drilled Customer specific regulations must be observed CAUTION Loose connections Loose connections are a danger to life and limb and a risk of damage to the machine Metal nuts featuring a locking element self locking nuts are mainly used for Demag chain hoists Self locking nuts must not be replaced by other types of nut 214 802 44 291113 214 802 44 291113 CAUTION Risk of injury Oils and lubricants may pose a health hazard Contact with these media may result in serious damage to health poisoning allergies skin irritations etc CAUTION Risk of injury Leaking oils and lubricants are hazards due to the increased risk of slipping Spilt oils and lubricants must be absorbed immediately by means of sawdust or oil absorbent and disposed of in an environmentally compatible way 8 2 Basic maintenance requirements General information on maintenance repairs The specified inspection and maintenance intervals Maintenance schedule Page 68 apply to normal chain hoist operating conditions All wearing parts must be checked in the course of the annual inspect
97. lue Remark 0 4 Default 2 Hoist only V2 speed i V1N2 Y v2 E Default Control pendant is locked when several keys are actuated 3 Lock the control pendant Priority is given to the first button that is pressed if the lifting and Y lowering buttons are actuated together Fs Default 4 Time controlled start up Speed dependent start up e g for tandem operation Y Time controlled start up 5 6 E 7 ES 8 E 9 x Tab 32 49 50 5 10 4 Starting parameter programming mode Fig 27 42771844 xml eps 1st step Actuate emergency stop 2nd step Press and hold down the Lifting button and unlock emergency stop Wait for approx 10 seconds 3rd step When P is displayed release the Lifting button 7 segment display 8 Tab 33 7 segment display displays a dot 7 segment display P Fig 28 42771845 xml eps 4th step P disappears after approx 2 seconds Press the Lifting button again and hold it down until o for O K is displayed 5th step Release the button Parameter programming mode is now active When parameter programming mode has been activated figures 0 to 9 are each succes sively displayed for 2 seconds 6th step Press the Lowering button to scroll through the menu items faster Each figure represents a parameter see
98. ly recommend that only spare parts and accessories approved by us be used Only then can we ensure the safety and normal service life of the installation Spare parts not approved by us may cause unpredictable hazards damage malfunctions or complete failure of the chain hoist The use of unauthorised spare parts may render null and void any claims for warranty service damages or liabili ty against the manufacturer or his appointed personnel dealers and representatives 10 1 8 1 9 1 10 Definition of personnel The manufacturer is the person who 1 manufactures the equipment under his or her own name and places it on the market for the first time 2 resells other manufacturers equipment under his or her own name whereby the reseller is not considered to be the manufacturer provided the name of the manufacturer as in 1 appears on the equipment 3 imports the equipment into the country and places it on the market for the first time or 4 exports equipment to another member state of the European Union and hands it over direct to a user in that country Owner Owners employer company are defined as persons who own the machine and who use it as intended or allow it to be operated by suitable and trained persons Operating personnel operator Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper ate the machine This person must be trained by the owner in accordance wi
99. ly where the machine is in operation must be observed and complied with in addition to the safety instructions contained in these operating instructions The owner and any personnel authorised by him are responsible for correct operation of the machine and for clearly defining responsibilities for installation operation maintenance and cleaning The operating instructions must be followed in full and without any limitations Special local conditions or applications may lead to situations which are not considered in these operating instruc tions In such cases the required safety measures must be defined and implemented by the owner Necessary measures may also relate for example to the handling of hazardous materials or tools and the provision wearing of personal protection equipment The operating instructions must if required be supplemented by the owner with instructions relating to organisation of work working procedures authorised personnel supervising and reporting obligations etc For further information see Safety instructions for operation Page 55 Furthermore the owner must ensure that e any further working and safety instructions resulting from the hazard assessment of the machine workplaces are specified in operating procedures e personnel who work with or on the machine are provided with appropriate first aid equipment Personnel must be trained in the use of the first aid equipment e the operating instructions a
100. machine out of service immediately if functional defects or irregularities are detected The operator is obliged to check the machine for any visible damage at least once per shift and to report any damage immediately Do not render safety devices inoperative Do not approach limit stops in normal operation e g emergency stop devices emergency limit switches emergency limit stop devices slipping clutch or emergency limit switch track and limit buffers to stop move ment of the crab or crane hook assembly or bottom block against limit stops Continuously approaching these limits may result in severe damage and may even break the hoist chain Pay attention to all regulations regarding the correct loading of chains Donotreach into rotating parts and maintain a sufficient safety distance to prevent clothing parts of the body or hair becoming entangled 7 3 2 Load pick up The load handling attachment and load must be flexibly suspended Rigid connections cause uncontrolled forces to be transmitted and lead to fatigue fracture To protect the chain from unwanted torsion when the load turns movement of the hook assembly bottom block must not be restricted The bottom block must not be twisted or turned over for 2 1 reeving arrangements chain links facing the same direction must be arranged opposite each other without being twisted When attaching the load ensure that the load or load attachment does n
101. mming mode seen nnnm nennen nnne neret nennen enne nennen 50 Adjusting the lower hook position isoon anaiai ne eene rr 52 Putting into service for the first time oo nnociinnnnnnnnninicninnnnannccnnnccnn nana rca criar nennen rennen nnne 53 Safety instructions when putting into service for the first time mem 53 greet oce uii 53 Inspections before putting into service for the first time sse emen 54 Checks on entering service handover cccccceceeeeeeeeee cee eeee ene ce cess ae aeaeeeecaaeaeceeegeaeaeeeeeeseaaeaesesseeaeaeeeesagenaeeeeeeeees 54 orn MCN 55 Safety instructions for Operation deese eed iet pe ehe i Re d AVEC EE TERN Ee cede Pese Ud eue deu dod cn 55 SWITCHING ON tic 56 Checks when starting WOIK 2 oreet e ated Mese db ete axe eere A idees 56 FUNCION checks uU Recte o LEO Ne de tee RR 56 A E 57 Safety d ring operation ses tec eee e ob o oe tiet a EP IR e tee M D da ri et dep erem ase eeu de aes 57 Horae cui ope E 57 Moving thie load ito eibi eds cesa ee een era bci pe ea hoe etes area 58 Load distributiori roo eni eo Ree ete e Fea ien e e ide eG me eed pei p e E Lees 58 Emergency stop device operating function eessseseeeeenen nennen emen enne entren ren nene 59 slipping clutch operating function iii ies nee
102. n et HR TRUM REO INR Une E UTR ERU iE aaa 7 DC Comiidocumient 2 ene ede e eic sie leis 7 Symbols signal WOrds oi sao 3 a dette ent IR t PER P ERREUR YR aus ER IRE etd land cati n 7 Information on the operating instructions ssessseseseeennenneeen nennen ennemi enne etnnr rennen enne enn 8 Liability and Warranty 9 9o 9 Use of spare parts erint A Eee de Ee LE e E d A igen ee edt eed Foe bed edd evi ener 9 Definition Of Personnel E 10 Test and inspection booklet ir e ia 10 Aftersales adem 10 Safely m eer RT eee tad es ee e te ee edt en Pe en eer teen 12 General information on safety a ciiin ideo 12 Safety sighs oni the equiptrient aieo cene itecto n be a dee iet ce pct osuere dete redet eu rho do eve duce kn ud 12 lae PE 12 Hazards that can be caused by the machine sssssssssseeenee een eene nennen rr 13 Responsibility ot the OWPner ici iot eee t ay e Re Todd edi EH de Te e edid 14 Operating personnel requirements sess eene menn nennen nere entren nene enne eren nnne 14 Personal protection quipmient reu eB ten elite AH 15 Emergencysstop device a eom o Hee aed id ded d i nee P e e eerte
103. n is satisfied that e the cause which led to actuation of this function has been rectified and e continued operation of the machine constitutes no further hazard Control pendant Demag chain hoists can be equipped with various control pendants as required Refer to the relevant documents for operation of the control pendant and button assignments see Tab 3 Page 7 Taking the equipment out of operation Taking the equipment out of service when faults occur The machine must be switched off immediately if the following faults occur e f electric devices and cables as well as parts of the insulation are damaged e Brake and safety device failure Taking the equipment out of service at the end of the shift The following measures must be taken when finishing work or leaving the working area e Position the hoist unit outside the travel area e Move the unloaded hoist unit into its resting position e Actuate the emergency stop e Switch the hoist unit power supply off at the mains connection or isolating switch The chain hoist must be disconnected from the power supply when finishing work or leaving the working area However if the chain hoist is continuously connected to the power supply the following must be considered e The chain hoist is not protected against unauthorised or accidental switching on and therefore it is not pro tected against unintended movements e Damage may be caused by an electric surge if lightnin
104. n sleeve 1 firmly onto the control pendant The control pendant can be attached to the chain hoist or installed as a travelling unit see Mobile control sys tem Page 38 35 36 5 6 5 6 1 5 6 2 Control cable Control cable technical data D 1 A 2 E 3 42647550 XML eps Fig 13 Handling the control cable 43215644 eps Fig 14 Item Designation 1 Hose pocket 2 Control cable retaining latch 3 Control cable retaining bolt tightening torque 11 Nm Hook path H4 H5 H8 H11 Cable lengths 0 8m 2 8m 0 8 m 3 8 m 3 8m 6 8m 6 8m 9 8m Tab 23 The control pendant is supplied with standard cable lengths The height can be adjusted by 2 or 3 m Longer control cable lengths can be provided for example by using a 2TY control cable and DST C or DSE C control pendants Ergonomic workplace e The suspension height can be adjusted by means of a self locking mechanism at any time to suit individual re quirements e Adjust the suspension height of the control pendant in such a way that the operating elements are arranged at elbow height to obtain an ergonomic operating position Do not allow the control cable to be wound around the chain when lifting motions are performed Optional snag protection can be used for the upper part of the control cable Designation Order no
105. ne must be maintained regularly and appropriately by trained personnel in line with the specified deadlines and checked according to Maintenance schedule Page 68 Wearing parts must be replaced in good time e UVV BGV D8 Section 23 2 and BGV D6 1 guidelines must be not be ignored No liability for inappropriate use The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac ceptable according to these operating instructions In particular the manufacturer assumes no liability for damage due to inappropriate or any other prohibited use of the machine in the sense of the Intended use section No liability for structural modifications The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of de livery or the installation or use of third party accessories equipment or sub assemblies that are not approved by the manufacturer 214 802 44 291113 214 802 44 291113 Depending on the type and scope of the machine it may be necessary to have an inspection carried out by an expert engineer before it is handed over to the owner DC chain hoists are designed for operation at temperatures from 20 C to 45 C At extreme temperatures and in aggressive atmospheres or conditions differing from those specified in the Op
106. ned to match the shape of the cable depending on the cable type flat or round cable Check continuity of the earth lead connection after the mains cable has been connected and before the chain hoist is put into operation e The mains connector must never be disconnected under load d All housing parts must be securely latched to ensure the unit is sealed Phase sequence for connection to the AC power network The chain hoist is configured for connection to clockwise R S T phases The lifting and lowering buttons corre spond to the movements of the load hook if the R S T mains phases are connected to L1 L2 L3 in the specified sequence Then check the direction of movement as described below If the phase sequence of the connection cable is unknown connection with the correct phases is established in this way Checking the direction of movement The chain hoist must be connected to the power supply to check whether all phases are correctly connected Switch on the power supply unlock the emergency stop and actuate the Lifting pushbutton on the control pend ant The load hook must now move upwards WARNING Incorrect direction of movement Danger to life and limb if the direction of movement is wrong Ifthe direction of movement is not correct disconnect the power supply at the mains connection switch and check to ensure that it is not live Swap phases L2 and L3 of the supply cable at the mains connection switch 43
107. ng Do not allow loads to drop when the chain is in a slack condition Vibration from the load being transported e g when the load is deposited on vibrating machinery must not be transmitted to the lifting equipment Chain hoists must be suspended in such a way that they do not collide with stationary equipment and struc tures e g when slewing cranes are turned Do not pick the load up at full speed Avoid inching e g giving short pulses to the motor Load distribution CAUTION Premature wear of the chain guide and chain Danger of falling load Avoid uneven loads on the chain falls This results in dam age to the chain guide and causes the chain to break Blocked chains or large play between the chain and the chain sprocket will destroy the chain guide Eliminate any knots or blockages in the chain before lifting lowering 42774544 XML eps Fig 32 214 802 44 291113 214 802 44 291113 7 3 5 7 3 6 7 3 7 7 4 Emergency stop device operating function When the emergency stop is actuated the hoist motor is immediately disconnected from the electric power sup ply the mechanical brake is applied and it brings any movement to standstill Operation can only be resumed by unlatching the emergency stop when no lifting or lowering commands are ap plied off position interlock The effectiveness of the emergency stop function depends on the good operating condition of the mechanical brake U
108. ns ac cording to Operating conditions Page 27 the chain should be checked once a year see inspection and maintenance schedule If routine maintenance reveals that the intervals are too long they should be adapted to the specific operating conditions Visual inspection of the chain Carry out a visual inspection of the chain before starting work If the chain displays deformation damage cracks pitting from corro sion reduction in the link thickness or increase in pitch dimension due to wear or elongation as a result of plastic deformation the chain must be replaced immediately 43410044 XML eps Fig 43 Chain wear p Maximum guide plate dimensions mm a b c d DC 1 2 160 55 168 68 DC 5 19 4 6 8 21 0 8 9 DC 10 26 7 94 28 8 12 0 Tab B2 00000 If a check or inspection reveals that it is worn beyond the specified di 214 802 44 291113 214 802 44 291113 Measuring wear or deformation of the original Demag chain Two methods can be used to measure wear or deformation of the original Demag chain e Measuring with a calliper gauge wear of a single chain link Fig 44 Page 75 on 11 chain links gt Fig 45 Page 75 e Measuring with a chain gauge on 11 chain links Fig 46 Page 76 Measuring wear of a single chain link with a calliper gauge 42726244 xml eps Fig 44 The chain link contact areas must be visually checked for traces of w
109. nusually long braking distances may indicate excessive wear of the brake In this case the brake must be inspected by an experienced technician without delay Slipping clutch operating function The chain hoist is fitted with a slipping clutch that is tripped if an overload occurs The brake is then automatically applied and the motor is switched off Only lowering motion remains possible after the slipping clutch has tripped Therefore an overload cannot be lifted from the ground A load that is already suspended can be safely deposited by actuating the lowering button When the lowering motion has been completed lifting is possible again If the slipping clutch already trips at rated load the slipping force must be measured by an experienced technician and re adjusted as required Lifting path limiter operating function Only motion in the opposite direction remains possible after the lifting path limiter has tripped The lifting path is limited by limit stops at the ends of the chain Consequently the slipping clutch acts as an emergency stop de vice the brake is automatically applied and the motor is switched off A warning message is shown on the display if the emergency stop device is tripped Operating limit switch contacts prevent travel against the emergency limit stop device they are actuated by elastic buffers on the limit stop and switch the motion off before the emergency limit stop device is reached The emergency limit stop devic
110. o locally applicable disposal regulations e f required utilise the services of a recycling company 25 26 3 7 5 3 8 3 8 1 3 8 2 3 8 3 Storage Until they are installed the equipment and accessories must be kept closed and may only be stored under the following conditions e Do not store outdoors e Store in dry and dust free places relative air humidity max 60 e Do not expose to aggressive media e Protect against direct sunlight e Avoid mechanical vibrations e Storage temperature 25 to 70 C Avoid strong temperature fluctuations condensation Oil all bare machine parts rust protection e Check the general condition of all parts of the packing at regular intervals If required refresh or renew rust protection e f stored in a damp location the equipment must be packed tight and protected against corrosion use desic cant Materials Linings We only use asbestos free slipping clutch and brake linings Housing The housing of the chain hoist is made of strong and light weight die cast aluminium The fan cover on the motor the service cover the electric equipment cover and the movable chain collector box are of particularly impact re sistant plastic material Surface protection and paint finish As standard the chain hoist is provided with corrosion protection powder coating paint finish and supplied in the following colours Paint finish Chain hois
111. ofar as they are relevant for the scope of delivery are met by application of the following harmonised standards or C standard drafts EN 14492 2 Cranes Power driven winches and hoists Part 2 Power driven hoisis EN 60204 32 Safety of machinery Electrical equipment of machines Part 32 Requirements for hoisting machines The safety objectives of Low Voltage Directive 2006 95 EC are achieved The product additionally complies with the following relevant directives provisions EC EMC Directive 2004 108 EC The special technical documentation according to Annex VII Part B of Directive 2006 42 EC has been compiled and will be made available to authorised national authorities by the designated authorised representative in response to a justified request Authorised representative for technical documentation Hans J rg B ttcher Demag Cranes amp Components GmbH 58286 Wetter Wetter 11 02 2014 p 7142 2 pra ul d Ah ppa Dr Rainer Harkort ppa Dirk Schulte Head of Plant Wetter Handling Technology amp Drives Engineering amp Development U02241 Material Handling Reproduction in whole or in part only with prior consent of Demag Cranes amp Components GmbH 58286 Wetter Subject to change No liability for errors or omissions The current addresses of our sales offices subsidiaries and agencies worldwide can be found on the Demag Cranes amp Components GmbH homepage at www demagcranes com Contact
112. oist unit 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 Calculating the actual duration of service S The actual duration of service S of the electric chain hoist can be determined as follows S k xT xf Kmi Actual load spectrum factor T Number of operating hours f Factor depending on the type of recording Calculating the number of hours of operation operating time T by the owner The operating time can be calculated by means of an elapsed time indicator or according to the following method Operating time per inspection interval T lifting lowering x cycles h x operating time day x days inspection interval 60 x lifting speed Tab 43 Only lifting and lowering movements are counted long and cross travel times are not considered Estimating load spectrum factor Km by the owner To simplify estimation each type of load can be grouped together into k load spectrum modules The types of load are simplified and quoted as 1 4 1 2 3 4 load and full load Dead loads are added to the loads Loads up to 20 of the rated load capacity are not considered The operating time for each type of load is divided up within the inspection interval e g 1 year in terms of per centage The following bar diagram shows the k load spectrum modules for the load conditions without load
113. on Page 52 Carry out checks before putting the unit into operation for the first time Inspections before putting into service for the first time Page 54 The equipment is ready for operation Operation Page 55 214 802 44 291113 214 802 44 291113 5 5 Connecting the control pendant 3 43215144 eps Fig 12 The control pendant is of plug in design The connector on the end of the control cable is locked in the bayonet sleeve and can be turned If a connector is not locked it can be pulled out and must be locked again by pressure Unless the chain hoist is supplied with the control pendant fitted connect the DSC control pendant with the con trol cable and lock the connection with the bayonet lock as follows 1 2 3 Lift bend protection sleeve 1 on the control pendant off the two pins Then pull bend protection sleeve 1 off the control pendant Slide bend protection sleeve 1 onto the control cable Plug the control cable into the control pendant and turn the bayonet lock until it is locked Ensure that groove a on the connector holder lines up with swivel lock b in the control pendant housing and that the two pins c on the control pendant housing line up with bayonet lock d Slide bend protection sleeve 1 over the control pendant again Pay attention to the positioning markers Press bend protectio
114. or achieving safe working periods sssseseeeeeneen eene rennen 65 Genertal 5 2 enn tiim qt aee dt 65 Calculating the actual duration of service S ssssssssssessseeeeeeenee eene nennen enn en nene enne ener 66 Example DC Com 10 1000 1 1 H5 VA 1 in JAM sssssseeeenen enne nennen nnne errem 66 GO general overhaul t te tenete rie e ea GA I eee eon Suse A neta 68 Maintenance Schedule wis 3 25 22 tta tac pep Rc t LER Dev Dep i tue oo ne an viaaa ERROR Rn 68 Maintenance WOTK iere et nee te EAR ie e lite E a e Ht oe eai Hn dr Ee ie eed 70 SUSPENSE AAA ea A Aia ici 70 Electric equipment Cover i niece ic 70 Removing the chain collector DOX soii ero EE DR ROTE eis dee 71 Operating limit switches standard for DC Com 10 with 2 1 reeving sseeen em 71 Checking operating limit switches esses nmm erret eren nene enne neret 71 Checking the operating limit switch actuator sssseen nennen nnnm nnne nnne nennen nene 72 Chain drive ieri tete HU te e E ER laste ea d HI t E Ue ERE eee rete 73 Checking the sprocket wheel eerie retired ePi RR RE Dr eee need ipd Reden ede eo Pig pee eei uns 73 Checking he eha guide 47 eee deett A A cestode ds doves dat dpascondst cia 73 Checking the guide plate chain entry plate ooooooncnnnncccnnncicnnccconnorononn nino ro nocn nn cnnnnr nemen rr 74 Checking the hoist Chains cere aee e Ne REESE CERRO R
115. or continuity between ter minals 4 and 8 Upper or lower limit position has been reached Actuate opposite direction When the voltage is switched on or the emergency Release button and actuate it again stop is unlocked a button is already actuated i Check connections of the control cable on the pendant and Control cable interrupted in in the service enclosure Check control cable for continuity 4 r Operating mode Lifting V1 5 L Operating mode Lowering V1 6 n Operating mode Lifting V2 7 u Operating mode Lowering V2 8 e Operating mode Lifting start up 8 i Operating mode Lowering start up Tab 68 97 98 9 4 Warning messages In general all warning messages are generated by comparison of the actual and theoretical speed There may be various causes for a difference in speed e incorrectly adjusted slipping clutch a binding brake or e a dirty or defective speed sensor These causes may result in frequent warning messages Various measures must be taken to eliminate the warning messages clean the speed sensor with compressed air e g dirt accumulation on the photo cell check and if necessary adjust the slipping clutch check and if necessary adjust the brake air gap 2 ad 43 aa l I 7 4K 48 48 432160B19_xml eps Fig 73 Display examples
116. ot remove any safety equipment or render it inoperative by modifications WARNING Crushing hazard Body parts can be crushed when loads are lifted or lowered Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered WARNING Suspended load Falling parts Danger to life and limb if lifted loads are dropped Keep out of the danger zone at all times Keep a sufficient safety distance Never step under a suspended load Certain work and practices are prohibited when using the machine as they may involve danger to life and limb and result in lasting damage to the machine Observe the safety instructions in the sections e Assembly Page 32 e Putting into service for the first time Page 53 e Operation Page 55 e gt Maintenance repair Page 62 13 14 2 5 2 6 Responsibility of the owner Information on safety at work refers to the regulations of the European Union that apply when the machine is manufactured The owner is obliged to ensure that the specified industrial safety measures comply with the latest rules and regulations and to observe new regulations during the entire service life of the machine Local industrial safety legislation and regional regulations and codes of practice applicable at the site of operation of the machine must be observed outside the European Union General safety accident prevention and environmental protection regulations that app
117. ot slip off the hook and that the load does not fall over fall apart slip or roll off when it is picked up or set down 57 7 3 3 7 3 4 When the load is lifted the hook must move to an upright position to ensure that the safety catch is not sub jected to a load by the load handling slings and as a result damaged Do not use the equipment to transport persons The load capacity specified on the load capacity plate indicates the highest permissible load which must not be exceeded This is the sum of the load to be lifted and the load handling attachment Only approved load handling attachments may be used The load capacity of the load handling attachment must not be excee ded Moving the load For lifting and travel motions adopt a position that provides a clear view of the danger zone or use a second person who can observe the danger zone Push travel hoists trolleys cranes may only be moved by pulling or pushing the load bottom block or load hook assembly Never pull on the control pendant Push travel loads must be guided by hand The load must never be thrown or hurled Do not handle suspended loads above persons Do not pull or drag suspended loads at an angle The chain drive mechanism may be damaged at angles of 4 or more Do not pull free fixed or obstructed loads with the chain hoist Do not leave suspended loads unsupervised Do not allow the chain to pass over edges and do not use the chain as a load bearing sli
118. part no 836 708 44 must be used Inspection and adjustment may only be carried out by an experienced technician in compliance with the Friction force checking device document Tab 3 Page 7 214 802 44 291113 214 802 44 291113 8 5 10 il CAUTION Gearbox oil change 9 e it 1 I S i E RUNS Fu E Sous 3 Ne 1 NS 1 O g 0 0 42767844_XML eps Fig 67 Chain hoist size DC 1 2 DC5 DC 10 Oil quantities 0 0 35 0 50 0 90 r Gearbox cover Nm 5 5 Tightening torques Service cover Nm 5 5 7 5 Tab 66 Dispose of waste oil in accordance with environmental protection requirements Oil lubrication Under normal operating conditions the lubricant must be changed at least every 10 years Under exceptional conditions e g increased ambient temperatures we recommend that oil changes be adapted to suit these condi tions Oil grades Demag special oil with wear minimising additives range of viscosity 10W 30 part no 664 020 44 for slipping clutch without speed monitoring Malfunctions of the slipping clutch may occur if oils are used that are not ap proved Contact the manufacturer for ambient temperatures lower than 20 C or higher than 45 C Safe operation cannot be ensured Malfunctions of the slipping clutch may occur if oils are used that are not approved and safe operation can then no longer be ensured General remarks on oil
119. pin 3 is correctly fitted when the hook and fittings are assembled Tighten housing bolts 4 according to the tightening torque table Tightening torques Nm DC Com 1 DC Com 2 DC Com 5 DC Com 10 Hook assembly 6 8 9 5 25 0 Tab 60 84 214 802 44 291113 214 802 44 291113 8 5 6 5 Replacing the bottom block standard with internal cut off springs for 2 1 reeving XAO 43217544 eps Fig 57 1 Remove guide half sections 1 four M 6 bolts 2 Remove bottom block retaining bolts 2 and remove the bottom block 3 Insert the new chain into the bottom block in the same position and orientation chain must operate without any twist 4 Re assemble the bottom block and tighten bolts 2 to a torque of 52 Nm 5 Check correct fit of the four cut off springs 3 in new halves 4 of the bottom block 6 Install new guide half sections 1 and tighten bolts 5 to a torque of 5 5 Nm 7 Apply the load capacity plate 8 Perform a function check run against the operating limit switches and check against the 7 segment display Tightening torques Nm DC 10 Tm i Bottom block halves 52 0 Bottom block with internal cut off springs Guide section halves 5 5 Tab 61 Bottom block as of approx 09 2009 As of approx 09 2009 the bottom block is provided with rubber lips 1 atthe chain ent
120. play of software version operating hours number of cy cles Page 30 Check chain lubrication under arduous conditions the chain must be lubricated Available hoist chains Page 77 X more frequently Check function of the lifting motion operating limit switch Checking operating limit switches Page 71 X Check function of the lowering motion operating limit switch gt Checking operating limit switches Page 71 X Check cut off buffer cut off spring operating limit switch actuator gt Checking the cut off buffers cut off springs Page 86 X Checking the operating limit switch actuator Page 72 Check control cable and control pendant housing for damage X Check operation of the brake X Check hook and hook safety catch Checking the load hook Page 83 X Tab 39 6 4 Checks on entering service handover WARNING Unauthorised operation Danger to life and limb if the machine is operated without previous inspection Machines may only be put into service if they have been checked for compliance with the corresponding acci dent prevention regulations By means of suitable measures carried out by the owner or on his behalf the owner must ensure that the load handling attachments and machinery ready for operation function in complete safety before they are first put into service The specified measures must allow for the static and dynamic features of the machinery The following checks must be carried out when
121. procket e Chain guide with plate and cap e Chain guide plate e Buffers for upper and lower hook position e Tube of Demag chain grease e Retaining ring The chain guide is pre assembled the chain is already fitted in the chain guide 214 802 44 291113 214 802 44 291113 8 5 5 6 Available hoist chains Genuine Demag chain is a round section steel chain tested to EN 818 7 which is subject to the regulations for round section steel chains used in hoist applications issued by the Main Association of Industrial Employers Mu tual Insurance Societies Central Department for Accident Prevention and the test criteria for round section steel chains used in hoist applications and the inspection regulations to DIN 685 part 5 of Nov 1981 as well as BGV D8 and BGV D6 CAUTION Pay attention to reduced load capacities For non standard operating conditions the special chains listed below are available for special ambient condi tions Chain hoist Max load capacity for reeving Dimension Stamp Weight per Production Minimum Minimum size chain quality metre test force breaking elongation 1 2 force at rupture kg kg mm kg kN kN 76 Demag RDC TDK standard chain DC 1 2 250 4 2x 12 2 0 38 13 8 22 DAT DC5 500 5 3x 152 RDC
122. r DC 10 units with 2 1 reeving 41058847 XML eps Fig 53 Furher procedure after replacing the chain set If the chain has to be replaced because it has reached its wear limit the return sprockets are usually also worn and have to be replaced For this reason the condition of the return sprockets must be checked when the chain is replaced We recommend that the return sprocket should be replaced no later than every second time the chain is replaced Fit the hook assembly bottom block Load hook Page 83 Lubricate the chain Available hoist chains Page 77 Lubricating the hoist chain Page 82 Adjust the bottom hook position if necessary Adjusting the lower hook position Page 52 Fit chain collector box Removing the chain collector box Page 71 Ifthe chain hoist is fitted with an optional geared limit switch it must be re adjusted each time the chain is replaced see DC geared limit switch document Tab 3 Page 7 81 8 5 5 8 il CAUTION 82 Tightening torques Nm DC 1 2 DC5 DC 10 Reeving 111 11 2 1 Service cover 5 5 7 5 Limit stop 4 0 4 3 Chain anchorage halves Guide plate 5 5 Tab 58 Lubricating the hoist chain After fitting before a test load is lifted and before the hoist is put into operation as well as during normal opera tion when no load is attached the chain link contact areas mu
123. re length The protective earth conductor must not be connected to mounting bolts or screws Earth junctions and connections must be protected against accidental loosening e g by using serrated lock washers to DIN 6798 It must be possible to disconnect each individual connection Protective earth conductors must not carry any current in normal operation The same number of protective earth connection points must be provided as electric power infeed and outfeed points Continuity of the PE conductor connection must be checked Mains connection switch A mains connection switch must always be provided for the mains power supply line to the machine The mains connection switch must be arranged to disconnect all poles of your DC Com chain hoist from the mains supply Ensure that the mains connection switch is installed in an easily accessible position in the vicinity of your machine and that it is clearly marked Isolating switch If two or more lifting appliances are fed from a common supply line each one should be provided with an isolating Switch This makes it possible to carry out maintenance work on individual units without affecting operation of the rest of the system Power supply The power supply line cable to be used depends on the motor size see the Hoist motor data section 33 34 5 3 CAUTION 5 4 DC Com chain hoist tightening torques Ti
124. re always kept available in the immediate vicinity of the machine for installation op erating maintenance and cleaning personnel e personnel are trained in accordance with the work to be performed e the machine is only operated when in safe and proper working order e the safety devices are always kept freely accessible and are checked regularly e national regulations for the use of cranes and lifting appliances are observed e any specified regular checks and inspections are carried out on time and are documented The owner is urged to develop procedures and guidelines for any malfunctions to instruct users and to affix these instructions at a suitable place where they can be easily seen Operating personnel requirements Only authorised and trained personnel may work on the installation The personnel must have received instruction on the installation functions and any hazards that may occur Every individual given the task of working on or with the installation must have read and understood the instruc tions before any work starts Persons under the influence of drugs alcohol or medicines which affect their reactions must not work on or with the installation Age and job specific regulations relevant at the place where the installation is operated must be observed for the selection of any personnel Personnel are obliged to report to the owner without delay any changes to the installation that impair safety For independent oper
125. ried out during the general overhaul Tab 49 21 DC 10 every 5 years 22 For use according to FEM classification 70 8 5 8 5 1 8 5 2 Maintenance work Suspension If a check or inspection reveals that these components are worn beyond the specified dimensions or if cracks can be seen in these parts they must be replaced at once Suspension bracket 43218944 eps Fig 36 Suspension ring 42599450 XML eps Fig 37 Electric equipment cover Chain hoist DC1 2 5 DC 10 Suspension bracket short long short long Suspension bracket min dimen sion e Tab 50 mm Chain hoist 15 3 14 4 DC1 2 5 25 2 24 3 DC 10 Suspension ring turned 90 chain hoist parallel to girder min dimen sion e mm 17 55 24 3 Tab 51 The electric equipment cover must be held in place when it is opened Do not allow the electric equipment cover to fall against its retainer When the electric equipment cover is closed again ensure that the retainer does not snag and does not block the inspection window 214 802 44 291113 214 802 44 291113 8 5 3 Removing the chain collector box 43227644 eps Fig 38 Unscrew and remove service cover 1 Place bag 2 with the control cable on the top of the chain hoist Disconnect spring 3 and plac
126. ring is correctly installed if it can be easily turned on the out put shaft after assembly DANGER Danger of broken chain and falling load An incorrectly installed chain may result in a broken chain and falling loads When the chain is installed ensure that it is introduced in the same position and with the same alignment The chain must operate without any twist Fig 51 214 802 44 291113 214 802 44 291113 Fitting the chain anchorage for 2 1 reeving on DC 10 41058846 XML eps Fig 52 e Fitthe chain anchorage before bolting the guide plates into position for DC 10 hoists with 2 1 reeving Bolt chain anchorage halves 1 together fig A e Insert the bolted chain anchorage into the opening of the gearbox housing fig B e Fit pins 2 the pins are retained by the fitted guide plates Fitting the limit stop e Attach the limit stop to the 5th link at the dead unloaded end of the J chain pay attention to the tightening torque e Ifthe chain hoist is operated with a replacement chain that is longer than suitable for the standard capacity of the chain collector an addi tional limit stop must be fitted to the chain between the hook assem e bly and the buffer plate The limit stop must be fitted in such a way that the extra length of chain is positioned between the hook assem bly and the limit stop In this case a geared limit switch is required S 12 Y fo
127. rticular caution to ensure that accidents injuries and damage are avoided in such cases Locally applicable accident prevention regulations and general safety regulations must also be followed 1 The documents can be ordered from the relevant Demag office The following symbols and instructions warn against possible injuries or damage and are intended to assist you in your work DANGER This symbol indicates an immediate hazard which can result in serious injury or death Follow these instructions at all times and be particularly careful and cautious WARNING This symbol indicates a possibly hazardous situation which might result in serious injury or death Follow these instructions at all times and be particularly careful and cautious CAUTION This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage Follow these instructions at all times and be particularly careful and cautious Operating hazard for the machine e This symbol indicates information on the appropriate use of the machine e This symbol in the operating instructions indicates all warnings which if not complied with may result in mal functions or damage 1 4 Information on the operating instructions These operating instructions are designed to provide the owner and operator with useful instructions for transport ing putting into service operating and maintaining our chain hoists These operating inst
128. ructions are an integral part of the machine Persons entrusted with the various types of work must know and comply with the safety regulations and the oper ating instructions The machine may only be operated by personnel who are fully familiar with the operating instructions In particu lar they contain the Safety section and the relevant safety instructions in the working sections of these operat ing instructions The operating instructions must be available to operating personnel at all times to prevent operating errors and to ensure smooth and trouble free operation of our products They must be kept in the immediate vicinity Demag chain hoists are delivered ready for operation as a complete machine with a control pendant or as partly completed machinery without a control pendant Complete machine Based on Machinery Directive 2006 42 EC the chain hoist is also designated as a machine in the sense of a complete machine in the following For a chain hoist delivered ready for operation in the sense of a complete machine we confirm conformity with the requirements of Directive 2006 42 EC by means of the attached EC declaration of conformity Partly completed machinery These instructions inform the manufacturer of an installation with a chain hoist about basic technical information e some typical risks e the assembly and operation of the chain hoist The instructions contained in this document may be used as the basis for t
129. ry points The rubber lips should be checked for wear and correct fit during the annual inspection 42778544 xml eps Fig 58 85 8 5 6 6 86 8 5 7 8 5 7 1 Replacing the bottom block option with external cut off springs for 2 1 reeving 2 77 HT SONES POD LO SEI VI Y Dn IL A LM TD Ja P Hs IT m LZ ZR P TIN NS A LS EA CSS EINEN M 43217444 eps Fig 59 Tightening torques Nm DC 10 Bottom block with external cut off springs 55 0 Tab 62 Buffer only with optional operating limit switches DC Com 1 10 with 1 1 reeving Checking the cut off buffers cut off springs 42715146 XML eps Fig 60 1 Buffer wear Visually check the buffers in the course of the annual inspection Check for damage cracks and tears 2 Missing buffer plate Ensure that the component parts are installed in the right order when new buffers are installed see also Buffer arrangement Page 87 A missing buffer plate for example will result in premature wear of the buffer 3 Wear of external cut off springs Visually check the external cut off springs in the course of the annual inspection Check the sleeves of the springs for cracks and damage The individual windings of the springs must not cross over each other
130. sls n mss LUN n 2 STWNOIS TOUINOD INN ISOH NAO ONG TOUINOD INN ISOH HOLAS INT ERAMOS 8 AAA e T G Ef Fig 20 44 45 8 L S t HM S LN 97001189 N31 262 QYVONVLS 90 oud 20 Aqu 9ri00 9 woJj day 3 paidwoy TUI 9uoN E oW ans lo S id ys ON juep bury youuoj de ON J8pIQ syuauoduio saue4 49049 un 9007 050 Lo ey 10 IS JINA G31vW3d0 ATWONYW TOMLNOD ttt uny UNDIG ugny 90079080 z0 y 20 J 91N60 uooubisaq DVIA3GQ Jawoysng vooz 191 900 Jewel 6007 L0 1 TY 0 j F 8 EY g a El OLS AONZOMING giO ACQQO 3 ERREUR ERI NP 10 18000 0 sIS SNO OAOE Mee NLT FIO vos Ads OH WITOUNGD HO LEGO rose g q E a pe S n amp 8 B c 9 Hi 0 8 amp 9 9 e 1SLX ee 4 3 5 f t 9 8 v SIX 050 8 El A NS r EAE f m ses 388 f l Sg b EB i re ee eee eee eee o o p T zos ESE 950 YFTIOULNOD ELE ES v v SNL Em NAO 01S ANDAN o 8 loe gt G 8 T e oe t ir LLLGZ PV 208 VLC LLLGZ vV 208 vc 8 L 9 S y s 09N 97001189 N31 262 GYVONVLS
131. st be lubricated with gear grease part no 665 009 44 The chain link contact areas must be relubricated appropriately after being cleaned at intervals depending on the service and load conditions A dry film lubricant should be used in environments where abrasives occur em ery sand etc For non standard lubrication see Available hoist chains Page 77 Premature wear of the chain Danger of load being dropped due to broken chain The chain must be lubricated along its entire length Even chain links which are covered e g in the chain anchorage hook assembly limit stop or crab frame must be fully lubricated DC 1 10 chain hoist 42650744_XML eps Cut off the tip of the grease tube and insert the grease tube at the lubri cation point Insert grease into the chain guide by pressing the tube while you run the chain to its end positions to ensure complete and even lubrication of the chain 214 802 44 291113 214 802 44 291113 8 5 6 8 5 6 1 8 5 6 2 8 5 6 3 Load hook Checking the load hook Load capacity kg 125 250 500 1250 2000 a Chain hoist DC Com 1 2 5 I Reeving 1 1 2 1 N Load hook Type TO10 T020 T04 V5 al 28 34 40 50 amp A2nom 2 22 8 25 4 33 7 43 3 a2 max 25 08 27 94 37 07 47 3 Pos b1 16 21 27 29 PEN i h1 20 26 1 34 44 2 Dimensions mm h2nom 22 16 9 218 27 7 36
132. stified request Authorised representative for technical documentation Hans J rg B ttcher Demag Cranes amp Components GmbH 58286 Wetter Wetter 11 02 2014 p He Ca ppa I SAK Lh ppa Dr Rainer Harkort ppa Dirk Schulte Head of Plant Wetter Handling Technology amp Drives Engineering amp Development U02241 Material Handling Reproduction in whole or in part only with prior consent of Demag Cranes amp Components GmbH 58286 Wetter Subject to change No liability for errors or omissions Original Ident number Language DEMAG Declaration for fitting partly completed machinery 19961244 EN ATEREX BRAND MM EE E HH 20 according to Machinery Directive 2006 42 EC Annex IIB Issue Page 0110 1 1 Hereby we Demag Cranes amp Components GmbH RuhrstraBe 28 58300 Wetter declare that the electrically driven hoist hoist with trolley for lifting loads lifting and moving loads Demag DC chain hoist Demag DC chain hoist with trolley Serial no nnnnnnnn supplied as partly completed machinery is intended to be incorporated into machinery and its initial bringing into service is prohibited until the machinery into which this partly completed machinery is to be incorporated has been declared in conformity with all relevant provisions of EC Machinery Directive 2006 42 EC insofar as this machinery is subject to the scope of application Basic requirements of the EC Machinery Directive ins
133. structed personnel in compliance with all accident prevention and safety regulations National regulations for the use of cranes and lifting appliances must be observed and followed The owner must arrange for operating personnel to be trained WARNING Crushing hazard There is a risk of injury due to parts of the body being crushed sheared or clothing or hair becoming entangled when loads are lifted or lowered Do not touch the chain Do not reach between the upper and lower chain entry point Donot reach into the area of the Manulift coupling when the quick release coupling is connected Do not reach between the load hook opening and the load handling attachment when loads are lifted There must be nobody present in the immediate danger zone when the load is set down WARNING Risk of burns There is a risk of burns from contact when the chain hoist is in operation Do not touch hot motor housings WARNING Suspended load Falling parts IN Danger to life and limb if lifted loads are dropped Keep out of the danger zone at all times Keep a sufficient safety distance Never step under a suspended load Loads must not be lifted above persons Wear protective equipment WARNING Non compliance with operating regulations industrial safety regulations Danger to life and limb if relevant regulations are disregarded Machinery may only be operated in compliance with relevant national oper
134. switch set DC 10 3 Nm 15 71527933 1 Chain anchorage 2 1 set DC 10 2 1 16 71795333 1 Buffer set DC 1 2 16 71895333 1 Buffer set DC5 16 71595333 1 Buffer set DC10 17 71798633 1 Chain collector set DC1 2 5m 17 71798733 1 Chain collector set DC1 2 8m 17 71898633 1 Chain collector set DC5 5m 17 71898733 1 Chain collector set DC5 8m 17 71598633 1 Chain collector DC10 1 1 5m 17 71598733 1 Chain collector DC10 1 1 8m DC 10 2 1 H5 17 71535045 1 Chain collector flexible 20 m DC 10 2 1 H8 21480105 tbl 107 108 12 5 Hook assembly 18 18 18 18 21 42764045 eps Item Part no Qty Designation Material Standard 18 71778033 1 Hook fittings set DC Com 2 6 8 Nm 18 71878033 1 Hook fittings set DC Com 5 9 5 Nm 18 71578033 1 Hook fittings set DC Com10 25 Nm 21 71851633 1 Hook safety catch set DC1 5 21 71551633 d Hook safety catch set DC10 T04 21480106 tbl 214802ET indd 291113 214802ET indd 291113 12 6 Bottom block with internal cut off springs standard e a Sy lin Ol Ae O a all MDMA 26 m mcr I ILA P m ama 0 11 1 UM To 23 24 gt 23 A 23 Ie F 23 25 42764145 eps Item Part no Qty Designation Material Standard 23 71598533 1 Bottom block set DC 2 1 24 71544233 1 Bottom block half set DC10 2 1 25 83865633 1 Hook safet
135. switching commands for the contactors to control the hoist motor The electronic system monitors the control sequence specified by the operator based on the speed feedback from the drive shaft the operating limit switch contacts and if applicable 214 802 44 291113 214 802 44 291113 4 4 2 from the thermal contacts in the motor In there are any discrepancies the chain hoist is automatically brought to a safe status and warning or error messages are generated The positively disconnected emergency stop contact on the control pendant immediately opens the circuit for the contactor supply so that the motor is de energised and the brake is applied As standard the control system features the following characteristics Operating limit switches for lifting and lowering optional for DC Com 1 10 with 1 1 reeving standard for DC Com 10 with 2 1 reeving e Plug in connections for control pendant power supply motor connection brake operating limit switches e Connection for the E11 E34 trolley control system e 7 segment display for operating hours operating status and error messages e Infrared interface for wireless transmission of service data e Replaceable socket mounted contactor e Signal transmission in steps with 24 V tri state signals for controlled DC chain hoists half wave evaluation Demag control pendants are connected via plug in connectors for manual control Compact DSC control units which are optimised for
136. system checked by an experienced tech nician T 4 7 SLIP LOWERING start up A mains phase is missing or the motor is blocked Check mains connection and fuse link check connection No lowering cable for interruption check mains connector in the service enclosure 8 4 8 SLIP LOWERING V1 Low Chain blocked Check chain entry point replace chain if required ab 15 switched off lower Limit switch contact is no longer actuated is displayed when the limit switches function correctly imit pu IS not h The slipping clutch acts as an emergency stop device if Vs i A ut out in the there is a malfunction lower limit position Limit switch contact connection and operation must be in spected by an experienced technician 9 4 9 SLIP LOWERING V2 Low Chain blocked Check chain entry point replace chain if required IRR 3 switched off lower Limit switch contact is no longer actuated is displayed when the limit switches function correctly imit ponnien b nor h The slipping clutch acts as an emergency stop device if c 1 D ut out in the there is a malfunction lower limit position Limit switch contact connection and operation must be in spected by an experienced technician Tab 69 214 802 44 291113 214 802 44 291113 9 5 Error messages 1 i 2 3 4 5 a l a O E a
137. t RAL 5009 Azure blue Load hook and suspension bracket RAL 9005 Jet black Trolley RAL 5009 Azure blue Tab 18 214 802 44 291113 214 802 44 291113 3 9 CAUTION Operating conditions Operational safety risk Safe operation is only possible under the specified conditions Contact the manufacturer if the operating condi tions differ from those specified After sales service Page 10 The chain hoist and the trolley can be operated at Ambient temperature 20 C to 45 C Humidity max 80 relative humidity Height up to 1000 m above sea level Type of enclosure IP55 Electromagnetic compatibility Resistance to interference in industrial environments Interference emission for residential commercial and light industrial environ ments Tab 19 Demag chain hoists operating outdoors should be provided with a cover for protection against the weather or chain hoists trolleys and travel drives should be kept under shelter if they are not in use Special operating conditions may be agreed with the manufacturer in individual cases Such operating conditions may occur in the following applications for example e Galvanising or electroplating facilities e Hygiene areas e Low or high temperature applications On request suitably optimised equipment and important information for safe low wear operation can be supplied for these applications Stronger cut off springs need to be used under certain
138. t e rete s ies tet D See 59 Lifting path limiter operating TUNCtION o o oonncccnnnncocinicannnonccnnnrncc corn a enne nennen nennen nnne eterne nennen 59 aera AC D 59 214 802 44 291113 214 802 44 291113 7 5 7 5 1 7 5 2 7 5 3 8 1 8 2 8 3 8 3 1 8 3 2 8 3 3 8 3 4 8 3 4 1 8 3 4 2 8 3 4 3 8 3 5 8 4 8 5 8 5 1 8 5 2 8 5 3 8 5 4 8 5 4 1 8 5 4 2 8 5 5 8 5 5 1 8 5 5 2 8 5 5 3 8 5 5 4 8 5 5 5 8 5 5 6 8 5 5 7 8 5 5 8 8 5 6 8 5 6 1 8 5 6 2 8 5 6 3 8 5 6 4 8 5 6 5 8 5 6 6 8 5 7 8 5 7 1 8 5 7 2 8 5 8 8 5 8 1 8 5 8 2 8 5 9 8 5 9 1 8 5 9 2 8 5 10 8 5 11 8 5 12 Taking the equipment out of operation enne nnne eren nennen nnn ener rennen enr en nnns 60 Taking the equipment out of service when faults occur essssseseeneeene eene nennen nene enne nnns 60 Taking the equipment out of service at the end of the shift emnes 60 Taking the equipment out of service for maintenance and repairs men 60 Maintenance leopard 62 Safety instructions for maintenance and repair work ssssssseeee eene ene rre 62 Basic maintenance requirements 2 pe onere urere tte Lec edge cupientes cerei dere De eR nun 63 Regular inspection unte MED pdt a ipio oet hue el feta 64 Required tests and inspections 4 it ile 64 Special operating conditions mitin eee ee ER EE I e HE SH Poe Idae dee dad 64 Service life of hE contacto ono ttt tec tte ecce adu ada plu Dedit enc hdd ill 64 S W P measures f
139. t must be replaced without delay The chain drive can move easily on the drive shaft i e lateral play of approx 2 mm is normal A defective chain guide must be replaced im mediately Open the service cover e Check the chain guide for any damage e g ruptured guide section halves or loose bolts 73 74 8 5 5 3 8 5 5 4 Checking the guide plate chain entry plate mensions or if cracks can be seen on the guide plate it must be re placed Multiple fitting and removal of the guide plate retaining bolts may dam age the thread in the aluminium housing in such a way that a tight fit of the bolts can no longer be ensured A Guide plate accessories set is available to do this part no 717 830 45 see also DC 1 15 guide plate accessories document Tab 3 Page 7 42774745 xml eps Fig 42 Load hook side A chain collector box side B Checking the hoist chain Checking wear or deformation of the original Demag chain In addition to selecting the correct hoist unit for the given application owners of chain hoists are obliged by rele vant regulations such as DIN 685 part 5 to check the round section steel chain continuously in operation to ensure optimum operating safety and therefore to avoid any accidents For single shift operation operation according to FEM classification and for chain hoist operating conditio
140. teel AISI 316 V4A 1 4401 Lubrication Food safe lubricant e g Paraliq chain spray Tab 55 23 For max 25 50 cycles per day 4 For max 10 cycles per day 25 For max 12 25 cycles per day 26 For max 5 cycles per day 77 78 8 5 5 7 Replacing the chain set 43227444 eps Fig 47 Before starting any maintenance work switch the hoist off and secure it against reconnection to the power supply To replace the chain set proceed as follows 1 2 Open and remove service cover 1 Place bag 2 with the control cable on the chain hoist pull out mains cable union 3 with fitted mains cable 4 and place to one side if a travel drive is fitted remove the connecting cable from the strain relief arrange ment Loosen cap 5 with a screwdriver lever off Remove chain collector box 6 and set it down Removing the chain collector box Page 71 214 802 44 291113 214 802 44 291113 43227544 eps Fig 48 1 Remove guide plate 7 2 Remove retaining ring 8 using ring pliers either use straight or offset pliers access through the opening in the gearbox housing on the side of the motor or from the service enclosure DC Com 1 to 5 In the area power supply insert DC Com 10 Fold cover 9 of
141. th the tasks to be performed Trained person Trained persons are defined as persons who have been instructed and trained for the tasks assigned to them and on the possible hazards resulting from inappropriate conduct Personnel must be informed about the required pro tective devices protective measures relevant regulations codes of practice accident prevention regulations and operating conditions and must provide verification of their competence This person must be trained by the owner in accordance with the tasks to be performed Specialist personnel Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks such as installation setting up maintenance and fault elimination This person must be trained by the owner in accordance with the tasks to be performed Qualified electrician Qualified electricians are defined as persons who owing to their technical training knowledge and experience of electric machines as well as knowledge of the relevant valid standards codes of practice and regulations are able to assess the tasks given to them and to identify and eliminate potential hazards This person must be trained by the owner in accordance with the tasks to be performed Experienced technician Experienced technicians are defined as persons who owing to their technical training and experience have suffi cient knowledge in the field of the machine They must be familiar with the relev
142. the air gap Disconnect the chain hoist from the power supply mains connection switch and secure it against switching on again e Open the electric equipment cover e Unscrew brake plug screw 1 from the brake Check brake wear with feeler gauge 2 see Tab 64 Page 88 214 802 44 291113 214 802 44 291113 Until year of manufacture 03 2009 42651044 XML eps Fig 63 Disconnect the chain hoist from the power supply mains connection switch and secure it against switching on again Open the electric equipment cover e Disconnect brake connector e Dismantle brake Measure brake wear with calliper gauge as follows e Measure the distance from the back of the brake to the brake disc with a depth gauge or calliper gauge when the brake is not actuated e Measure the distance from the back of the brake to the brake disc with a depth gauge or calliper gauge when the brake is actuated to do this press the brake disc against the springs until it stops e Use both measured values to calculate the difference this difference is the brake displacement Assembly and maintenance 42791644 xml eps Fig 64 When the brake is installed make sure that the area of the V sealing ring 1 on the brake base is lightly greased Ensure that no grease penetrates inside the brake The continuous sealing lip must be in full contact with the back of the brake In the course of the annual inspect
143. ting drive first decelerates by switching from fast speed 2 pole winding to creep speed 8 pole winding Mechanical braking occurs when the creep lifting speed has almost been reached The mechanical brake is applied as soon as the emergency stop is actuated regardless of the lifting speed Wear of the mechanical brake is significantly reduced by electric and regenerative braking of the motor Gearbox and slipping clutch A Drives B Brakes 1 Slipping clutch 4 Speed detection 2 Motor 5 Brake 3 Chain drive 6 Gearbox Tab 21 The slipping clutch is arranged between the motor shaft and the gear box input shaft In connection with the limit stops on the chain it per forms the function of the emergency limit stop device for the highest and lowest hook position and protects the Demag chain hoist against overload The additional electric operating limit switches standard for DC Com 10 with 2 1 reeving optional for DC Com 1 10 with 1 1 reev ing for the highest and lowest hook positions prevent the slipping clutch from being approached as an emergency limit stop device during normal operation The slipping clutch also fulfills the EC Machinery Di rective requirements for a load control device for load capacities as of 1000 kg The brake arranged on the load side prevents the load from slowly Aer US KM CGPS dropping when the unit is at rest Monitoring of the slipping clutch and Fig 6 Parts in which the load is borne automatic
144. tube a for DC 10 and secure with the retaining clip hoist will hang at an angle if the suspension bracket is installed incorrectly Suspension of the chain hoist at an angle results in premature wear of the chain drive If special fittings are installed on the chain hoist make sure that they are counter balanced il Make sure that the suspension bracket is fitted to match the reeving arrangement of the chain hoist The chain 41 42 5 8 Mains connection 43215446 xml eps Fig 19 Item Designation Item Designation Item Designation Strain relief attachment F A DC Com 1 5 1 Sealing sleeve 4 Mains connection Strain relief attachment B DC Com 10 2 4 pole connector 5 Recess for round cable 3 Connector enclosure 6 Recess for flat cable Tab 27 The mains connection cable the mains connection fuse links and any devices to disconnect and switch the po werfeed must be available on site in order to connect the unit to the power supply A 4 lead cable with a PE earth conductor which complies with the table in gt Hoist motor data Page 20 is required for the power supply Please note that the length of the supply cable specified for a given cross section must not be exceeded in order to avoid excess
145. uctions for users where the BGV DO06 accident prevention regulations apply In accordance with BGV DO6 the crane operator must also check operation of the emergency stop device when he or she starts work This does not apply to slipping clutches used as an emergency stop device which do not need to be checked when work begins BGV D06 Section 30 DC chain hoists are fitted with a slipping clutch as an emergency stop device which does not need to be checked by the crane operator therefore a device to by pass the limit switches which are approached during normal operation is not fitted The following main functions of the machine must be checked before work begins Activity Section Check Check emergency stop device X Check 7 segment display gt 7 segment display for operating status and fault X display Page 29 Display of software version operating hours num ber of cycles Page 30 Check chain lubrication under arduous conditions the chain must be lubricated more fre Available hoist chains Page 77 X quently Check function of the lifting motion operating limit switch Checking operating limit switches Page 71 X Check cut off buffer cut off spring operating limit switch actuator Checking the cut off buffers cut off springs X Page 86 Check control cable and control pendant housing for damage X Check operation of the brake X Check hook and hook safety catch gt Checking the load hook Page 83 X 56 Tab 40 21
146. up to full load in time increments of 5 and 1096 Larger shares of the time period must be correspondingly added together Load spectrum factor Km can be obtained by adding together the individual k load spectrum modules Diagram N N oo o ig e g 8 B8 8 8 B e 414 o S e o o o o 3 4 4 1 24 1 4 t 0 5 y uw 96 43230144 eps Fig 34 B Loading L Load t Time 1 Dead load Tab 44 Factor depending on the type of recording e f 1 1 For calculating the operating hours using an elapsed time indicator included in the DC Com standard scope of delivery e f 1 2 For estimating the operating hours and the load spectrum Example DC Com 10 1000 1 1 H5 V4 1 in 1Am Lifting speed 4 1 m min No of cycles per hour 10 cycles h 214 802 44 291113 214 802 44 291113 Lifting and lowering 2 2 m cycle 7 4 m cycle Operating time per day 8 h day Days per inspection interval 250 days inspection interval Tab 45 Calculation 10 4 8 250 T 60 4 Tab 46 With operating time read 334 With estimated operating time 333 3 In the operating time as read estimated above the chain hoist has transported the following loads 5 x4 4 m S ss Ss 10 96 x 3 4 2096 x 1 2 15 96 x 1 4 50 96 x 0 t 9 5 10 20 15 50 La 100 43230244 eps Fig 35 B Loading L Load t Time Tab 47 Add
147. ut off buffers cut off springs Page 86 X x x Checking the operating limit switch actuator Page 72 Check control cable and control pendant housing for damage X X X Check operation of the brake X X X Check hook and hook safety catch Checking the load hook Page 83 X X X Check load handling attachments for deformation cracks damage X caused by corrosion safety device malfunctions Read the C switching cycles gt Service life of the contactor Page 64 X Read operating hours to determine the remaining safe working pe 7 segment display for operating sta riod tus and fault display Page 29 X gt S W P measures for achieving safe working periods Page 65 68 Check electric switchgear and wiring X 214 802 44 291113 214 802 44 291113 Activity Section Before first put Before starting During the an ting into opera work nual inspection tion Check operation of the slipping clutch Checking the slipping clutch X Page 90 Check adjustment of the slipping clutch Adjusting the slipping clutch X Page 90 Check brake wear Brake Page 88 Every 10 years 21 22 Grease brake V sealing ring X Check suspension suspension bracket and securing elements Suspension Page 70 x clip etc Check fastening bolts on hook assembly bottom block X Check hooks for cracks deformation and wear Checking the load hook Pag
148. xceeded by the actual dura tion of service When the actual duration of service has reached the theoretical duration of service relevant for the given group of mechanisms further operation of the chain hoist is only permitted after a general overhaul has been carried out The theoretical duration of service D hours at full load h depends on the Group of Mechanisms classification of the chain hoist The actual duration of service should be determined every year according to FEM 9 755 You can arrange to have the actual service life calculated as part of the annual inspection by our after sales service The owner must arrange for a GO general overhaul to be carried out when 90 of the theoretical duration of serv ice has elapsed if the chain hoists are correctly classified after 8 to 10 years A general overhaul must be carried out by the end of the theoretical duration of service During the general overhaul the following parts must be replaced in addition to the checks and work specified in the inspection and maintenance schedule e Gearbox housing with installed gear parts e Gear oil and gearbox cover with seal e Connecting elements e Shaft sealing rings bearings plugs e Brake The small parts screws washers etc to be replaced when maintenance and assembly work is carried out are not listed separately The general overhaul carried out by the manufacturer or a specialist company authorised by him satisfies the requirement to b
149. y catch set GR 5 x5 26 75262033 1 Load capacity plate set DC10 2 1 21474017 tbl 109 12 7 Bottom block with external cut off springs option 28 29 oD 28 30 28 31 42778044 eps Item Part no Qty Designation Material Standard 28 Bottom block with cut off springs 1 29 83785233 1 Bottom block half set DK10 6 8 Nm 30 83865033 1 Load hook DC16 25 DK10 20 31 83865633 1 Hook safety catch set GR 5 x5 32 83592833 1 Load capacity plate set DK10 21474019 tbl 110 1 See section 11 214802ET indd 291113 214802ET indd 291113 12 8 Electric equipment cover IL DJ 7 W 7 Ls LT 50 51 52 51 42763945 eps Item Part no Qty Designation Material Standard 50 77326033 1 Control set DC1 15 230V 220 V 240 V 50 60 Hz 3 Nm 50 77306033 1 Control set DC1 15 400V 380 V 415 V 50 Hz 380 V 400 V 60 Hz 3 Nm 50 77336033 1 Control set DC1 15 575V 500 V 525 V 50 Hz 575 V 60 Hz 3 Nm 50 77316033 1 Control set DC1 15 460V 440 V 480 V 60 Hz 3 Nm 51 71792133 1 Elec equip cover set DC 2 9 5 Nm 51 71892133 1 Elec equip cover set DC 5 9 5 Nm 51 71592133 1 Elec equip cover set DC10 9 5 Nm 52 71582533 1 Contactor set DC Com 10 21480103 tbl 111 112 12 9 Control pendant control cable service cover 54 58 53 42764451 eps

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