Руководство по эксплуатации крана demag

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  Distributed by Tri-State Equipment Company Inc. Email: sales@tsoverheadcrane.com Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226 Operating instructions / Accessories / Component parts Demag DC-Com 1 – 10 chain hoist 181209 en GB 21480244 720 IS 817…
• Page 2
  Please fill in the following table before first putting the unit into service. This provides you with a definitive documentation of your Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative.

• Page 3: Table Of Contents

  Table of contents General…………………………….7 DC-Com chain hoist …………………………7 DC-Com documentation ………………………… 7 Symbols/signal words…………………………7 Information on the operating instructions ……………………8 Liability and warranty…………………………8 Copyright …………………………….9 Use of spare parts …………………………. 9 Definition of personnel…………………………9 Test and inspection booklet……………………….

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  Mobile control system…………………………47 Line connection …………………………… 48 Circuit diagrams and control cards ……………………..50 5.9.1 Circuit diagram DC-Com 1 — 10 solo hoist ……………………. 50 5.9.2 Circuit diagram with E 11 — E 34 travel drive ………………….53 5.9.3 Control card …………………………..
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  8.5.6.5 Replacing the (optional) bottom block with external switch-off springs, reeving 2/1 ……….91 8.5.7 Buffer (only with optional operating limit switches for DC-Com 1-10 reeving 1/1) ………… 91 8.5.7.1 Checking the swich-off buffer / switch-off spring ………………….. 91 8.5.7.2 Buffer design …………………………..
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  Accessories …………………………..107 11.1 Assemblies …………………………..107 Spare parts …………………………..108 12.1 Overview …………………………… 108 12.2 Motor …………………………….109 12.3 Parts on gearbox …………………………110 12.4 Chain drive …………………………..112 12.5 Hook assembly ………………………….. 114 12.6 Bottom block with internal switch-off springs (standard) ………………115 12.7 Bottom block with external switch-off springs (option) ………………..

• Page 7: General

  Important safety information and instructions are marked by corresponding symbols and signal words. The safety instructions must be followed. Exercise particular caution to ensure that accidents, injuries and damage are avoided in such cases. The documents can be ordered from the relevant Demag office.

• Page 8: Information On The Operating Instructions

  The relevant local accident prevention regulations for the application and general safety instructions must also be complied with. The following symbols and instructions warn against possible personal injuries or damage to property and are in‐ tended to assist you in your work. DANGER This symbol indicates an immediate hazard which can result in serious injury or death.

• Page 9: Copyright

  We reserve the right to incorporate technical modifications within the scope of improving the operating characteristics and further development of the product. Copyright These operating 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.

• Page 10: Test And Inspection Booklet

  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 these data ensures that you receive the correct information or the required spare parts. Demag Cranes & Components GmbH Telefon +49 (0)180 / 5 — 741268 www.demagcranes.com…

• Page 11: Safety

  Modifications of any kind and additions to or conversions of the machine must not be carried out without the written consent of Demag. Safety signs on the equipment Any pictograms, signs or labels on the machine must be obeyed and must not be removed.

• Page 12: Hazards Which May Be Caused By The Machine

  DC-Com chain hoist are designed for operation at temperatures of -20 °C up to +40 °C. At extreme temperatures and in aggressive atmophere or under conditions deviating from the section «Operating conditions», special meas‐ ures must be taken by the owner in agreement with 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.

• Page 13: Responsibility Of The Owner

  ● ⇒ «Operation», Page 61 ● ⇒ «Maintenance/repair», Page 68 Responsibility of the owner Information on safety at work refers to the regulations of the European Union that apply when the machine is man‐ ufactured. 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.

• Page 14: Personal Protection Equipment

  ● who are mentally and physically suitable, ● who have been instructed in the operation and maintenance of chain hoists and who have proven their qualification to the owner in this respect. Personal protection equipment When work is carried out on or with the machine, the following must always be worn: ●…

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  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.

• Page 16: Technical Data

  Technical data Design overview Fig. 4 Single-fall design Item Designation Item Designation Item Designation Electrical equipment cover Chain guide Adjusting mechanism for control cable Switch-off buffer for operating limit Control Sprocket switch Operation hours counter Round section steel chain Hook assembly with capacity plate Slipping clutch Motor shaft Window…

• Page 17: Model Code

  Stepless = VS at nominal load up to VS in the partial load range Hook path [m] Reeving Load capacity [kg] Size DC-Pro 2-stage chain hoist (Demag chain hoist) DC-ProDi 2-stage chain hoist for direct control DCM-Pro 2-stage Manulift DC-ProFi Variable speed chain hoist for control by…

• Page 18: Selection Table

  Selection table Reeving Group of mecha‐ Hoist speed Standard Max. weight Size Motor size nisms at hook path hook path Chain hoist DIN EN 14492 at 50 Hz at 60 Hz [kg] DC-Com FEM / ISO [m/min] [m/min] [kg] [kg] [kg] 3m/M6 8,0/2,0…

• Page 20: Electrical Key Values

  N min. N max. N max. φN [kW] 220-240 V, 50 Hz, 3 ~ (CE) 0,05 1,75 2,10 2,10 1,45 0,48 DC-Com 1 ZNK 71 B 8/2 0,18 2950 2,10 2,80 2,80 2,75 0,46 0,07 1,80 2,10 2,35 1,45…

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  N min. N max. N max. φN [kW] 220-240 V, 60 Hz, 3 ~ (CSA) 0,06 2,10 2,50 2,50 1,45 0,47 DC-Com 1 ZNK 71 B 8/2 0,22 3525 2,50 3,35 3,35 2,75 0,45 0,09 2,10 2,50 2,80 1,45…
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  Hoist speeds until 09/2008 (no longer available) Size Motor size No. of Starts/h Min. / max. currents and starting current poles N min. N max. N max. φN [kW] 220-240 V, 50 Hz, 3 ~ (CE) 0,09 2,10 2,20 2,50 1,25 0,52 DC-Com 2…

• Page 23: Mains Connection Delay Fuse Links

  440-480 V 575 V Frequency 50 Hz 60 Hz Size Motor size ZNK 71 A 8/2 DC-Com 1 ZNK 71 B 8/2 DC-Com 2 ZNK 71 B 8/2 DC-Com 5 ZNK 80 A 8/2 ZNK 100 A 8/2 DC-Com 10 ZNK 100 B 8/2 Tab.

• Page 24: Hook Dimensions C

  Hook dimensions C DC-Com chain hoist with suspension bracket Fig. 5 DC-Com with short suspension bracket (option‐ DC-Com with long suspension bracket Size Reeving Motor size Short suspension bracket Long suspension bracket Chain collector box Chain collector box H4 / H5 H4 / H5 DC Com 1/2 ZNK 71 ……

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  U 22 U 22 / U 34 Tab. 16 Dimensions C and C1 decrease when the short suspension bracket is used: for DC-Com 1-5 by 38 mm and for DC-Com 10 by 33 mm, see also ⇒ «Suspension», Page 34.

• Page 26: Noise Emission / Sound Pressure Level

  3.7.4 Packing Demag chain hoists, the accessories and the trolleys are shipped in cardboard packing. If no agreement on the return of the packing material has been made, separate the material according to type and size and make it available for further use or recycling.

• Page 27: Storage

  3.7.5 Storage Keep the equipment and accessories locked and stored only under the following conditions: ● Do not store it outdoors. ● Store in dry and dust-free places, relative air humidity: max. 60%. ● Do not expose it to aggressive media. ●…

• Page 28: Operating Conditions

  Tab. 19 Demag chain hoists operating outdoors should be provided with a canopy against the weather. Chain hoists, trolley and travel drive should be kept under shelter if they are not used for a considerable length of time. Special operating conditions may be agreed with the manufacturer in individual cases. However, in this case we recommend that the DC-Pro chain hoist be used.

• Page 29: Technical Description

  Demag chain hoist against overload. The additional electrical operating limit switches (DC-Com 10 reeving 2/1 as standard, DC-Com 1-10 reeving 1/1 optional)) for the highest and lowest hook position prevent the slipping clutch from being approached as an emergency limit stop device during normal operation. The slipping clutch also fulfills the EC directive requirements for a load control device from a load capacity of 1000 kg on.

• Page 30: Chain Drive

  As standard, the control system features the following characteristics: ● Operating limit switch for lifting and lowering (DC-Com 1 — 10 reeving 1/1 optional, DC-Com 10 reeving 2/1 as standard); ● Plug-type connections for control pendant, power supply, motor connection, brake, operating limit switches;…

• Page 31: 7-Segment Display For Operating Status And Error Display

  (arrow, lower side of electrical equipment cover) after the electrical equipment cover has been removed (figure deviating from scope of supply). The 7-segment display is supplied as standard with: ● DC-Com 1 — 5 from year of manufacture 2007 ● DC-Com 10 The following data can be read: ●…

• Page 32: Central Service Enclosure

  Display of the operating hours Fig. 10 The display appears after 3 sec. without any lifting motion (example for 123 operating hours) Display of the number of cycles of the K1 contactor Fig. 11 Alternatively displayed with the operating hours. C 5 corresponds to 5 x 100.000 = 500.000 K1 switching cycles Example: C 15 corresponds to 15 x 100.000 = 1,5 m K1 switching cycles For preventive maintenance see ⇒…

• Page 33: Control Pendant Height Adjustment / Control Cable

  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. From this point, the chain is also lubricated. In addition, any control cable length that is not required is kept under the cover.

• Page 34: Suspension

  Standard suspension Fig. 14 DC-Com 1-10 chain hoists are supplied with a long suspension bracket as standard. An optional short suspension bracket can be supplied. The suspension bracket facilitates installation, since the chain hoist can be directly suspended from the trolley. It is not necessary to dismantle existing trolleys.

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  Assigment of standard suspensions 160- 315- 1250- Chain hoist load capacity [kg] 1250 2500 Reeving Trolley size Trolley Flange Flange Crossbar diameter DC 1 DC 2 DC 5 DC 10 load capacity width thickness [kg] [mm] [mm] [mm] See ⇒ Fig. 14, Page 34 RU 3 60-90 58-143…

• Page 36: Trolley

  Overload There is danger to life and limb due to a possible excessive load of the trolley. The load capacity of Demag chain hoists must not exceed the load capacity of the trolley. I beam track The use of I beams with parallel or sloping flanges according to DIN 1025 as tracks is possible.

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  EU 56 DC Tab. 26 For further possible applications see Technical data Demag DC-Com chain hoist . ● If the EU 56 DC travel drive is used with small flange widths it is necessary to fit supporting rollers to the trolleys.
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  KBK track Fig. 17 When selecting a track, we suggest you specify our KBK crane construction kit track section of special design. They feature in particular quiet running characteristics, a low rolling resistance and a low deadweight. The cold-rolled track sections feature a smooth running surface and offer the advantage of simple power supply by means of trailing cables or integrated conductor lines.

• Page 39: Fitting

  Despite detailed information, mistakes when fitting by the customer cannot be excluded. For this reason, we rec‐ ommend this work be carried out by our trained specialists or by persons authorized by us. The wiring of the Demag chain hoist complies in all respects with current DIN VDE and accident prevention regu‐ lations.

• Page 40
  The arrow symbol on the control elements must correspond to the direction of movement. Electrical safety The chain hoist operating instructions must be referred to when Demag chain hoists are used. These operating instrutions only contain standard circuit diagrams. Depending on the type of chain hoist an order- specific circuit diagram may apply.

• Page 41: Tightening Torques Dc-Com Chain Hoist

  Loose connections Loose connections mean danger for life and limb or risk of machine damage. 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.

• Page 42: Connecting The Control Pendant

  Connecting the control pendant 43215144.eps Fig. 18 The control pendant is of plug-in design. The connector at 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 fitted control pendant, connect the DSC control pendant with the control cable and lock the connection with the bayonet lock, proceed as follows: Lift the bend protection sleeve (1) on the control pendant off the two pins.

• Page 43: Suspending The Chain Hoist

  Suspending the chain hoist 5.6.1 Supporting structure DANGER Overload There is a danger to life and limb due to overloading the supporting structure. The supporting structure must be designed for the maximum load of the chain hoist when being used appropriately. According to DIN EN 14492-2, hoist units with a load capacity ≥…

• Page 44: Suspension Bracket

  5.6.2 Suspension bracket 43215244.eps Fig. 19 DC-Com 1 — 5 suspension bracket opened DC-Com 10 reeving 2/1 DC-Com 10 reeving 1/1 Spacer tube WARNING Overload There is a danger to life and limb due to overloading the components. – The suspension / supporting structure for the chain hoist must be designed for the loads.

• Page 45: Control Cable

  Control cable 5.7.1 Techncal data of the control cable Item Designation Tightening torque [Nm] Hose pocket Operating buttons of the control cable stop Screw of the control cable stop Hook path Cable lengths 0.8 m — 2.8 m 0.8 m — 3.8 m 3.8 m — 6.8 m 6.8 m — 9.8 m Tab.

• Page 46: Height Adjustment Of The Control Pendant

  5.7.3 Height adjustment of the control pendant Fig. 22 Control cable stop fixed Control cable stop loose Loosen the screws of the service cover. Open and disengage the service cover. Remove and open the pocket with the control cable. Take the control cable out of the bag. Slide the operating button of the control cable stop upwards and hold it.

• Page 47: Mobile Control System

  5.7.4 Mobile control system Component parts Item Designation comprising Part no.: 11-pole + PE flat cable 720 139 45 Socket enclosure Fitting frame Connector enclosure cpl. 720 187 45 Pin insert VC-AMS8 Flat cable union Bayonet lock Bush enclosure VC-MP-1-R-M25 Connector adapter cpl.

• Page 48: Line Connection

  Line connection Fig. 25 Seal, sleeve DC-Com 1 — 5 strain relief attachment 4-pole connector Recess for round cable Connector enclosure Recess for flat cable Strain relief attachment DC-Com 10 strain relief attachment Line connection To connect the chain hoist to the power supply, the mains connection cable, the mains connection fuse links and the devices for disconnecting and switching the powerfeed must be available on site.

• Page 49
  ● For a round cable in the marking area of 7 to 13, for a flat cable in the marking area of 18 x 7 to 20 x 8. Cable cross-sections 4×1,5 mm or 4×2,5 mm are taken into account. ●…

• Page 50: Circuit Diagrams And Control Cards

  Circuit diagrams and control cards 5.9.1 Circuit diagram DC-Com 1 — 10 solo hoist Fig. 26…

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  Fig. 27…
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  Fig. 28…

• Page 53: Circuit Diagram With E 11 — E 34 Travel Drive

  5.9.2 Circuit diagram with E 11 — E 34 travel drive For further circuit diagrams with E 11 — E 34 travel drive see ⇒ Tab. 3, Page 7 Technical data E 11 — E 34 DC travel drive. For further information on the E 11 — E 34 travel drive see ⇒ Tab. 3, Page 7 Assembly instructions E 11 — E 34 DC travel drive.

• Page 54
  Item Designation Terminal strip Function Contactor On / Off Transformer Plug-and-socket con‐ Line nector Fork light barrier Pulse generator IR transmitter diode IR interface 7-segment LED Multi-function display, e.g.: Elapsed operating time counter, status indicator, error code display Plug-and-socket con‐ Lifting limit switch nector Dummy plug…

• Page 55: Setting Parameters With The Control Pendant

  5.10 Setting parameters with the control pendant 5.10.1 General It is possible to set parameters in order to adapt the chain hoist to specific applications. The parameters are set by means of the control pendant in connection with the 7-segment display on the bottom side of the chain hoist. 5.10.2 Meaning of keys Fig.

• Page 56: Starting Parameter Setting Mode

  5.10.4 Starting parameter setting mode Fig. 32 1st step: 2nd step: 3rd step: Actuate “Emergency stop”. Press and hold down the “Lift” key and unlock When “P.” is displayed, release the “Lift” key. the emergency stop. Wait for approx. 10 sec‐ onds.

• Page 57
  Fig. 34 7th step: 8th step: 9th step: Actuate the “Lift” key to select the currently dis‐ To set a different value, actuate the “Lower” key The value is selected by means of the “Lift” key, played parameter. At the same time, the value until the required value is shown in the display.

• Page 58: Setting The Lower Hook Position

  As standard, the chain hoists are provided with a hook path of 4 m, 5 m or 8 m. Fix limit stop to the 5th link at the dead (unloaded) end of the chain. ● Pay attention to assembly sequence! See also ⇒ «Buffer design», Page 92 Tightening torques [Nm] DC-Com 1 DC-Com 2 DC-Com 5 DC-Com 10…

• Page 59: Putting Into Service For The First Time

  Putting into service for the first time Safety instructions when first putting the unit into service The machine may only be handed over, if its safety has been verified by a corresponding inspection ⇒ «Inspections when first putting into service, handing over», Page 60. WARNING When first putting into service, safe operation of the machine is not yet guaranteed.

• Page 60: Inspection Prior To Putting Into Service For The First Time

  Inspection prior to putting into service for the first time Before putting into service for the first time, the owner is obliged to carry out the following inspections: Action Section Inspec‐ tion Check continuity of the PE conductor connection Check emergency stop device Check direction of movement ⇒…

• Page 61: Operation

  Operation Safety instructions for operation WARNING Inappropriate operation There is a risk of injury in the case of inappropriate operation. Inappropriate operation may result in serious personal injury and / or material damage. The unit may only be operated by authorized, instructed personnel in compliance with all accident prevention and safety regulations. National regulations for the use of crane and lifting equipment must be observed and complied with.

• Page 62: Switching On

  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 responsible bodies. In the event of a stoppage (e.g. if defects regarding safe and reliable operation are detected, in emergency situations, in the event of operating malfunctions, for repairs and maintenance purposes, if damage is detected or after finishing work), the operator must carry out all prescribed safety measures or observe that they are automatically carried out.

• Page 63: Operation

  Action Section Inspec‐ tion Check emergency stop device Check 7-segment display ⇒ «7-segment display for operating status and error display», Page 31, ⇒ «Software version, operating hours, number of cycles, operating statuses», Page 31 Check chain lubrication (under arduous conditions, the chain must be lubricated ⇒…

• Page 64
  – Pay attention to regulations pertaining to the correct loading of chains. – Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing, parts of the body or hair becoming entangled. Load pick-up – The load handling attachment and load must be flexibly suspended. Rigid connections cause uncontrolled forces and lead to fatigue fracture.
• Page 65
  Load distribution CAUTION Premature wear of the chain guide and chain Danger of load drop Avoid unequal loading of the chain falls. This results in chain breakage and damage of the chain guide. Blocked chains or excessive play between chain and chain sprocket destroys the chain guide.

• Page 66: Emergency Stop

  ● continued operation of the machine constitutes no further hazard. Control pendant Depending on the requirements the Demag chain hoist can be equipped with different control pendants. The oper‐ ation of the control pendant and the assigment of buttons can be seen in the corresponding brochures, see…

• Page 67: Taking Out Of Service

  Taking out of service 7.5.1 Taking out of service in the case of faults The machine must be switched off immediately in the event of the following faults: ● In the event of damage to electrical devices and cables as well as parts of the insulation. ●…

• Page 68: Maintenance/Repair

  Loose connections Loose connections mean danger for life and limb or risk of machine damage. 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.

• Page 69: Basic Information On Maintenance

  CAUTION Risk of injury! Oils and lubricants may be dangerous to health. Contact with these media may lead to serious damage to health (poisoning, allergy, skin irritation etc.). CAUTION Risk of injury! Leaking oils and lubricants are hazard sources due to increased slippery. Released oils and lubricants must immediately be absorbed by means of sawdust or oil absorbent and disposed of in an environmentally sound way.

• Page 70: Routine Inspections

  Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly manner. Routine inspections 8.3.1 Prescribed inspections WARNING Non-compliance with operating and maintenance instructions Danger to life and limb. Prescribed tests and inspections must be carried out. –…

• Page 71: Measures For Achieving Safe Working Periods S.w.p

  8.3.3 Measures for achieving safe working periods S.W.P. 8.3.3.1 General The safety and health provisions of the EC Machine 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 (VBG of 1.4.1996.

• Page 72: Example: Dc-Com 10-1000 1/1 H5 V4/1 In 1Am

  Calculating the number of operating hours (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: (Lifting+lowering) x cycles/h x operating time/day x days/inspection interval 60 x hoist speed Tab.

• Page 73
  Calculation 10 • 4 • 8 • 250 60 • 4 Tab. 47 With operating time read: 334 With operating time estimated: 333,3 In the operating time as read / estimated above, the chain hoist has transported the following loads: Fig.

• Page 74: General Overhaul Go

  8.3.4 General overhaul GO 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 exceeded by the actual duration of service.

• Page 75
  ⇒ „Measures for achieving safe working periods S.W.P.“, Page 71 Fit chain hoist-specific Demag GO set The small parts (screws, washers …) to be replaced during maintenance and assembly work are not listed separately. During the general overhaul, the checks and work specified in the inspection and maintenance schedule must be carried out.

• Page 76: Maintenance Work

  Maintenance work 8.5.1 Suspension If a check or inspection reveals that the dimensions are lower or higher than those specified due to wear or if cracks can be seen in these parts, they must be replaced at once. Suspension bracket Chain hoist DC 1/ 2 / 5 DC 10…

• Page 77: Dismantling The Chain Collector Box

  8.5.3 Dismantling the chain collector box Fig. 43 – Unscrew and disengage the service cover (1). – Place the bag (2) with control cable on the top of the chain hoist. – Disengage the spring (3) and place it in the recess in the chain collector box. –…

• Page 78: Checking The Operating Limit Switch Actuator

  For chain hoists without operating limit switch or with defective operating limit switch, the slipping clutch of the chain hoist perfoms the function of the emergency limit stop device. This emergency limit stop device may only be ap‐ proached in exceptional cases, i.e. it must not be approached in normal operation. When the slipping clutch is tripped, high additional loads are exerted on the chain.

• Page 79: Chain Drive

  8.5.5.4 Checking the hoist chain Checking the discarding status of the original Demag chain In addition to selecting the correct hoist unit, owners of hoist units are obliged by DIN 685 part 5 regulations to constantly check the round section steel chain in order to ensure optimum operating safety and, therefore, to avoid serious accidents.

• Page 80
  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.
• Page 81
  Measuring with a chain gauge Fig. 49 DC / DK / PK new chain uring pin can no longer move into the 11th chain link. PK old chain Measuring pin The discarding status has not yet been reached. It is not yet necessary to replace the chain. It is 11.

• Page 82: Scope Of Supply Chain Set

  ● Chain guide with plate and cap, ● Chain guide plate, ● Buffers for upper and lower hook position, ● Demag chain grease tube, ● Retaining ring. The chain guide is pre-assembled, the chain is already fitted in the chain guide.

• Page 83: Available Hoist Chains

  Available hoist chains The original Demag chain is a round section steel chain tested to EN 818-7 which is subject to the directives for round section steel chains in hoisting operation of the Main Association of Industrial Employers’ Mutual Insurance Societies, Central Department for Accident Prevention and to the test criteria for round section steel chains in hoisting operation and to the inspection regulations according to DIN 685 part 5 Nov.

• Page 84: Replacing The Chain Set

  8.5.5.7 Replacing the chain set Fig. 50 Before starting maintenance work take the hoist out of service and secure against restarting. To replace the chain set, proceed as follows: Open and disengage the service cover (1). Place bag with control cable on chain hoist (2); pull out and deposit mains cable union (3) with fitted mains cable (4), if a travel drive is fitted, remove the connection cable from the strain relief;…

• Page 85
  DC-Com 1 to 5: In the area of the power supply insert; DC Com 10: Fold the cover of the opening in the gearbox housing (9) to the side.
• Page 86
  Spacer rings for the output shaft ● When fitting the chain guide, the complete number of spacer rings must be fitted on the output shaft. Item Designation Retaining ring Chain guide DC Com 1/2 Spacer ring DC-Com 5 DC-Com 10 Tab.

• Page 87: Lubricating The Hoist Chain

  Fitting the limit stop ● Fix limit stop to the 5th link at the dead (unloaded) end of the chain paying attention to the tightening torque. ● If the chain hoist is operated with a chain that is longer than suitable for the standard capacity of the chain collector box, an additional limit stop must be fitted to the chain between the hook assembly and the buffer plate.

• Page 88: Load Hook

  8.5.6 Load hook 8.5.6.1 Checking the load hook [kg] 1250 2000 Chain hoist DC-Com Reeving Load hook Type T010 T020 22,8 25,4 33,7 25,08 27,94 37,07 42,9 26,1 Dimensions [mm] 16,9 21,8 27,7 16,055 20,71 26,315 32,3 Max. test force [kN] Fig.

• Page 89: Replacing The Hook Assembly, Reeving 1/1

  – that the retaining pin (3) is correctly fitted when the hook assembly is assembled. – Tighten the 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 25,0 Tab.

• Page 90: Replacing The (Standard) Bottom Block With Internal Switch-Off Springs, Reeving 2/1

  Fit the new guide halves (1) and tighten the screws (5) with 5,5 Nm; Apply load capacity plate; Perform function check (run against operating limit switches and check 7-segment display). Tightening torques [Nm] DC-Com 1 DC-Com 2 DC-Com 5 DC-Com 10…

• Page 91: Replacing The (Optional) Bottom Block With External Switch-Off Springs, Reeving 2/1

  Reeving Bottom block with external switch-off springs 55,0 Tab. 61 8.5.7 Buffer (only with optional operating limit switches for DC-Com 1-10 reeving 1/1) 8.5.7.1 Checking the swich-off buffer / switch-off spring Fig. 62 Buffer wear: In the course of annual inspection visually check the buffers. Check for damage and cracks.

• Page 92: Buffer Design

  Chain collector box Chain collector box Load side Load side Load side Load side side side side side Tab. 62 Operating limit switch for lifting and lowering (DC-Com 1 — 10 reeving 1/1 optional, DC-Com 10 reeving 2/1 as standard);…

• Page 93
  DC-Com buffer arrangement Size Reeving Hoist speed Standard Motor size Buffer / switch-off springs Chain collector box size hook path see figure at hook path Chain Load hook Chain collec‐ at 50 Hz at 60 Hz hoist side tor box side [kg] DC-Com [m/min]…

• Page 94: Brake

  8.5.8 Brake 8.5.8.1 Brake assignment Chain hoist Reeving Motor size Brake Max. brake displacement [kg] DC-Com [mm] 80 — 125 ZNK 71 B 8/2 160 — 250 BK03 315 — 500 ZNK 80 A 8/2 630 — 1000 ZNK 100 A 8/2 BK07 1250 — 2000 ZNK 100 B 8/2…

• Page 95
  During assembly, make sure that the area of the V ring on the brake base is slightly greased. Ensure that no grease penetrates into the inside of the brake. The continuous sealing lip must be in full contact on the brake rear side. Tightening torques [Nm] DC-Com 1 / 2 / 5 / 10 Brake Electrical equipment cover…

• Page 96: Slipping Clutch

  8.5.9 Slipping clutch 8.5.9.1 Checking the slipping clutch The slipping clutch performs the function of an emergency limit stop de‐ vice and protects the chain hoist against overloads. The slipping clutch is initially set in the factory. Under normal operating conditions, the slipping clutch does not need to be adjusted.

• Page 97: Gearbox / Oil Change

  8.5.10 Gearbox / oil change Fig. 68 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 con‐ ditions, e.g. increased ambient temperatures, we recommend that oil changes be adapted to suit these conditions. Oil quality Universal gear oil Shell Donax TD 10W-30 with wear-minimising additives, range of viscosity 10W-30.

• Page 98: Replacing The Contactor On The Control Card

  8.5.11 Replacing the contactor on the control card Fig. 69 Carefully unlock the locking arms on both sides of the contactor using a screwdriver. Pull off the contactor. Contactor socket without contactor Lower side of the contactor The spare contactor can only be inserted in the socket in one position. Press contactor onto the contactor socket until both locking arms latch into place.

• Page 100: Replacing Cables

  8.5.12 Replacing cables 8.5.12.1 Replacing the control cable Fig. 70…

• Page 101
  ● that the two pins on the enclosure match the bayonet lock. Fitting the control pendant ⇒ «Connecting the control pendant», Page 42. Height adjustment of the control pendant ⇒ «Height adjustment of the control pendant», Page 46. Tightening torques [Nm] DC-Com 1 DC-Com 2 DC-Com 5 DC-Com 10…

• Page 102: Faults / Warnings

  Faults / Warnings Safety instructions for faults / warnings WARNING Inappropriate fault elimination Danger to life and limb. Danger of machine damage. Faults may only be eliminated by qualified instructed personnel(⇒ «Definition of personnel», Page 9 ) in compliance with the safety instructions. DANGER Live components Danger to life and limb.

• Page 103: 7-Segment Display

  7-segment display The 7-segment display is located on the bottom side of the chain hoist behind a window. Warning messages Warning messages start with the lightning symbol. Movement in the opposite direction is possible, the warning message does not have to be acknowledged by means of the emergency stop. Fig.

• Page 104: Warning Messages

  Warning messages Possible cause Remarks Check mains connection and fuse link; check A mains phase is missing or the motor is connection cable for interruption; check mains blocked. connector in the service enclosure. Reduce load to the permissible load capacity. Chain hoist overloaded or undervoltage.

• Page 105: Error Messages

  Error messages Possible cause Remarks Check error message by actuating and unlocking the emergency stop. Hardware error of control system. Then actuate Lowering. If necessary, remove suspended load. Fig. 84 Chain hoist is blocked. Monitoring electronics defective. Replace hoist control system. Tab.

• Page 106: Disassembly / Disposal

  Disassembly / Disposal 10.1 General WARNING Before disassembly, follow the safety instructions in ⇒ «Maintenance/repair», Page 68 of these operating instruc‐ tions. For information on removing track sections, trolleys and current collector trolleys refer to chapter ⇒ «Fitting», Page 39 of these operating instructions. 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: ●…

• Page 107: Accessories

  Accessories 11.1 Assemblies Fig. 92 Item Description Size Part no.: Bottom block with switch-off springs (e.g. for hot applications) consisting of: DC-Com 10 2/1 715 431 45 bottom block, switch-off springs, grooved pins with round head, capacity plates DC Com 1/2 717 808 45 Return sprocket assembly: 1 return sprocket, 1 pin, 1 retaining ring, 1 supporting washer, 2 thrust washers,…

• Page 108: 12 Spare Parts

  12 Spare parts 12.1 Overview 1/1 reeving 2/1 reeving 42764247.eps…

• Page 109: 12.2 Motor

  71585033 Fan set ZNK 100A 4 Nm 71585133 Fan set ZNK 100B 4 Nm DC-Com 1 71784133 Motor set 240V50Hz 220 V — 240 V, 50 Hz, 9.5 Nm 71784233 Motor set 415V50Hz 380 V — 415 V, 50 Hz, 9.5 Nm…

• Page 110: 12.3 Parts On Gearbox

  12.3 Parts on gearbox 42763845.eps…

• Page 111
  Suspension set DC 1- 5 71597433 Suspension set DC10 Year of manufacture 2004 until 2006 71773133 Gear oil/seal DC-Com 1,2 DC-Com 1/2; 5,5 Nm; 0,35 litres 71873133 Gear oil/seal DC-Com5 DC-Com 5; 5,5 Nm; 0,5 litres 71591933 Gear oil/seal DC10 DC-Com 10;…

• Page 112: 12.4 Chain Drive

  12.4 Chain drive 1/1 reeving 2/1 reeving 42764346.eps…

• Page 113
  Item Part no. Qty. Designation Material Standard 71795033 Chain set DC 1/ 2 5m 4.0 Nm 71795133 Chain set DC 1/ 2 8m 4.0 Nm 71895033 Chain set DC 5 5m 4.3 Nm 71895133 Chain set DC 5 8m 4.3 Nm 71595033 Chain set DC 10 5m 1/1 7.4 Nm…

• Page 114: 12.5 Hook Assembly

  12.5 Hook assembly 42764045.eps Item Part no. Qty. Designation Material Standard 71778033 Hook fi ttings set DC-Com 2 6.8 Nm 71878033 Hook fi ttings set DC-Com 5 9.5 Nm 71578033 Hook fi ttings set DC-Com10 25 Nm 71851633 Hook safety catch set DC1-5 71551633 Hook safety catch set DC10 T04 21480106.tbl…

• Page 115: Bottom Block With Internal Switch-Off Springs (Standard)

  12.6 Bottom block with internal switch-off springs (standard) 42764145.eps Item Part no. Qty. Designation Material Standard 71598533 Bottom block set DC 2/1 71544233 Bottom block half set DC10 2/1 83865633 Hook safety catch set S. 5 x5 75262033 Load capacity plate set DC10 2/1 21480107.tbl…

• Page 116: Bottom Block With External Switch-Off Springs (Option)

  12.7 Bottom block with external switch-off springs (option) 42778044.eps Item Part no. Qty. Designation Material Standard Bottom block with switch-off spring 83785233 Bottom block half set DK10 6.8 Nm 83865033 Load hook DC16/25 DK10/20 83865633 Hook safety catch set S. 5 x5 83592833 Capacity plate DK10 21474019.tbl…

• Page 117: 12.8 Electrical Equipment Cover

  Item Part no. Qty. Designation Material Standard DC-Com 1 — 5 77222033 Control set DC1-5, 230V 220 V — 240 V, 50/60 Hz; 3 Nm 77202033 Control set DC1-5, 400V 380 V — 415 V, 50 Hz / 380 V — 400 V, 60 Hz; 3 Nm…

• Page 118: 12.9 Control Pendant, Control Cable, Service Cover

  12.9 Control pendant, control cable, service cover 42764446.eps Item Part no. Qty. Designation Material Standard 71792033 Service cover set DC 2 5.5 Nm 71892033 Service cover set DC 5 5.5 Nm 71592033 Servicehaubenset DC10 7.5 Nm 71881033 Control cable set 5m 11 Nm 71880933 Control cable set 8m…

• Page 119: Index

  Index Power supply 36 Actual duration of service 71 Actual load spectrum factor 71 R-S-T network 49 Actuator plate 58 Reeving arrangement 44 AC asynchronous motor 29 Retaining clip 44 Rolling resistance 38 Bayonet lock 33, 42, 101 Bend protection sleeve 42 Self-locking nuts 40 Buffer 58 Special fittings 44…

• Page 120
  Distributed by Tri-State Equipment Company Inc. Email: sales@tsoverheadcrane.com Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226…
• Page 122
  Class. no. # = Modifications compared to Normung DCC previous issue 715 IS 817 Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. Not liable for errors or omissions.
• Page 123
  Class. no. # = Modifications compared to Normung DCC 715 IS 817 previous issue Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. Not liable for errors or omissions.
• Page 124
  The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found on the Demag Cranes & Components homepage Distributed by Tri-State Equipment Company Inc. Email: sales@tsoverheadcrane.com Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226…

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Demag Standard Crane manual

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Standard solutions made by Demag offer outstanding quality, efficiency and reliability at the highest level. Every crane and every crane component reflects decades of crane expertise and reliability as a partner for the industry.