Download
Share
Print this page
DEMAG DC-II Operating And Maintenance Instructions Manual
  1. Manuals
  2. Brands
  3. DEMAG Manuals
  4. Chain Hoists
  5. DC-II
  6. Operating and maintenance instructions manual
DEMAG DC-II Operating And Maintenance Instructions Manual

DEMAG DC-II Operating And Maintenance Instructions Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
Operating and
Maintenance Instructions
CHAIN HOIST DC-II
07 June 2024
21157444

Advertisement

loading
Need help?

Need help?

Do you have a question about the DC-II and is the answer not in the manual?

Questions and answers

Related Manuals for DEMAG DC-II

Summary of Contents for DEMAG DC-II

  • Page 1 Operating and Maintenance Instructions CHAIN HOIST DC-II 07 June 2024 21157444...
  • Page 2 IS classification number This document and the information contained herein, is the exclusive property of Demag Cranes & Components and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Demag Cranes & Components...
  • Page 3 Product owner form Fill in the following form before first putting the unit into service. This provides you with important information if you ever have to contact the manufacturer or his representative. Owner Where in use Crane type Year of manufacture Load capacity Crane serial number Chain hoist model code...
  • Page 4 OPERATING AND MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS TABLE OF CONTENTS Introduction............................10 About this information........................10 1.1.1 How to use this information..................... 10 1.1.2 Copyright notice........................10 1.1.3 Definition of terms........................10 1.1.4 Definition of personnel......................12 1.1.5 Symbols and conventions....................... 13 1.1.6 Related information.........................
  • Page 5 TABLE OF CONTENTS OPERATING AND MAINTENANCE INSTRUCTIONS Product code............................38 3.2.1 Demag product code.......................38 Technical data............................. 38 3.3.1 Product range for DC-Com II....................38 3.3.2 Product range for DC-Pro II.....................39 3.3.3 Hoist classification........................39 3.3.4 Chain hoist motor data......................39 3.3.5 Mains connection circuit breaker and supply lines..............40 Dimensions............................40...
  • Page 6 OPERATING AND MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS Programming parameters with the pendant controller..............68 4.7.1 Chain hoist parameters......................68 4.7.2 Using parameter-programming mode, travel drive E22-C/E...WD........... 69 Adjusting the lower hook position.....................71 Commissioning........................... 73 Safety during commissioning......................73 5.1.1 Responsibilities of commissioning personnel................73 Commissioning preparation.......................74 5.2.1 Commissioning environment requirements................74...
  • Page 7 Chain set scope of supply..................... 116 7.10.6 Available chains........................118 7.10.7 Replacing the chain set......................119 7.10.7.1 Chain hoist with geared limit switch...................122 7.10.7.2 Fitting the retaining ring.....................123 7.10.7.3 Fitting the chain anchorage for 2/1 reeving in DC-II 10............124 7.10.7.4 Fitting the limit stop......................125...
  • Page 8 Transportation, storage and dismantling..................157 Transporting the product........................157 Transport inspection.........................157 Packaging............................157 Storing the product...........................157 Returning the product to use......................158 Dismantling the product........................158 APPENDIX I: Recommended tightening torques..................159 APPENDIX II: DC-II 1–DC-II 10 solo hoist circuit diagram................160...
  • Page 9 TABLE OF CONTENTS OPERATING AND MAINTENANCE INSTRUCTIONS...
  • Page 10 1.1.2 Copyright notice This document and the information contained herein, is the exclusive property of Demag Cranes & Components GmbH and represents a non-public, confidential and proprietary trade secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Demag Cranes &...
  • Page 11 1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS CSA means "Canadian Standards Association". CSA is an independent organization for the testing and certification of products. The CSA standard guarantees high quality and safety and grants access to the North American market. The subscripted and the subscripted means for use in both the USA and Canada.
  • Page 12 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION Rated capacity Load that the product is designed to lift for a given operating condition (for example, configuration, position of the load). Secondary brake Some chain hoists can have two similar brakes, one of which is redundant or a "secondary brake."...
  • Page 13 1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS Experienced technician Experienced technicians are defined as persons who, owing to their technical training and experience, have sufficient knowledge in the field of the machine. They must be familiar with the relevant national industrial safety regulations, codes of practice, accident prevention regulations, directives, and accepted engineering standards enabling them to judge the safe operating condition of machines.
  • Page 14 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION Symbol Description Product conforms to the ATEX directive Product conforms to the ATEX directive Measurement inspection Visual inspection Tools needed Operational inspection Grease brush lubrication needed Oil can lubrication needed Grease gun lubrication needed Noise check Ground symbol...
  • Page 15 Additional documents can be ordered from the relevant Demag office. Table 1. Additional documents Documents Part no.
  • Page 16 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION About this product 1.2.1 Intended use The machine may only be used as intended and in compliance with the requirements for the owner and the following limitations as specified in these operating instructions. Any other use may result in a danger to life and limband/or cause damage to the machine and load.
  • Page 17 1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS warranty. Seller does not accept, shall not have any responsibility and disclaims any liability for accidents, injury or physical or property damage arising as a consequence of such unauthorized modifications and/or incorporation of Third Party Products. Further, e.g.
  • Page 18 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION Item Designation Section Voltage and frequency "Chain hoist motor data" "Operating conditions" Type of enclosure and insulation class "Chain hoist motor data" Ambient temperature "Operating conditions" "Product range" Motor type and oil grade "Chain hoist motor data" "Changing the gear oli"...
  • Page 19 1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS • Product reference data: details of the product, its ownership, and persons who are qualified to work with it. • Faults that have been noticed in daily inspections, together with corrective actions. • Records of inspections and lubrication. •...
  • Page 20 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) Health, safety and the environment (HSE) Safety messages and signals This section includes explanations of the safety symbols, signs, signals, and labels used on the product and in the documentation. 2.1.1 Signal words The following signal words and symbols are used to identify safety messages in these...
  • Page 21 2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS (HSE) Mechanical hazard symbols Falling load hazard Hand entanglement Slipping hazard Falling hazard hazard Crushing hazard Electrical hazard symbols Electrical hazard Material hazard symbols Harmful substance Ignition hazard hazard Thermal hazard symbols Hot surface hazard Noise hazard symbols Noise hazard...
  • Page 22 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) Radiation hazard symbols Strong magnetic field hazard 2.1.3 Mandatory action symbols Mandatory action symbols specify actions to be taken to avoid a hazard. Mandatory actions are indicated by white symbols on a blue background. All personnel working on or in proximity of the machine must understand and follow the information that is given in all mandatory action symbols.
  • Page 23 2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS (HSE) NOTE Always keep safety labels visible. Check the condition of safety labels daily. Before operating the machine, replace safety labels and instructions that are damaged, have come loose, or that do not meet the legibility requirements for safe viewing distance. 2.1.6 Safety label locations Any pictograms, signs or labels on the machine must be obeyed and must not be removed.
  • Page 24 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) • Daily checks and minor lubrication must be carried out by operators or maintenance personnel. These checks are important for catching small faults before they become major faults. • Maintenance actions, excluding the daily actions that are performed by operators, must be done by service personnel who are authorized by the owner of the product.
  • Page 25 2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS (HSE) • When working with lubricants, clothing must prevent direct skin contact with the lubricant • Choose the clothing with consideration to the temperature at the working site • For work on explosion-proof products, clothing and equipment must be suitable for the hazardous area.
  • Page 26 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) WARNING! FALLING HAZARD Lifting personnel with an aerial work platform includes a risk of falling from heights, which can cause death or serious personal injury. Each person on the aerial work platform must always wear a safety harness and be attached to the platform.
  • Page 27 2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS (HSE) • Galvanizing plants or electroplating facilities • Hygiene areas • Low or high temperature applications On request, suitably optimized equipment and important information for safe, low-wear operation can be supplied for these applications. Reduced duty factor at increased ambient temperatures If chain hoists are operated at ambient temperatures that differ from mentioned in preceding table, the duty factor must be reduced:...
  • Page 28 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) All modifications and corrections that are not authorized in the product manuals or which may affect the maintenance, operation, safety, and availability of the product need to be approved in writing by the manufacturer before implementation.
  • Page 29 2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS (HSE) Figure 2. Emergency stop button with push-pull mechanism You can restart the machine and operate the controls only after the emergency stop button is reset to the normal reset position.
  • Page 30 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) Using the emergency stop button WARNING UNCONTROLLED MOVEMENT HAZARD Using the emergency stop can cause the machine to move or operate in an uncontrolled manner. This can cause death, serious injury, or property damage. Only use the emergency stop button in an emergency situation.
  • Page 31 2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS (HSE) All motions can be stopped with the emergency stop button (1) in the event of a hazard. Anybody who identifies an immediate danger of personal injury or serious malfunctions must actuate the emergency stop without delay.
  • Page 32 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) WARNING STORED ENERGY HAZARD When the product is switched off, there may still be stored energy in the electrical, hydraulic, or pneumatic systems, rotating parts, linearly moving parts, or in the load. Unintended release of energy can cause death, serious injury, or property damage.
  • Page 33 Trolley, bridge, or other moving structures associated with the hoist. Sound pressure level (L ) to DIN 45635 at a distance of one meter from the chain hoist is: Chain hoist DC-II 1-250 DC-II 2-250 DC-II 5-500 DC-II 10-1000 Lifting speed up to...
  • Page 34 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE) Hydraulic system maintenance Pneumatic system maintenance Electric system maintenance Battery maintenance Tire maintenance 2.11 Environmental information Environmental impacts have been taken into account in designing and manufacturing this product. To prevent environmental risks during use, follow the instructions and local regulations for disposal of waste material.
  • Page 35 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) Demag Cranes & Components GmbH is fully aware of its obligations under Regulation (EC) No 1907/2006 of the European Parliament and of the Council of 18 December 2006 concerning the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), and under the UK REACH in the United Kingdom.
  • Page 36 EU/UK customers when a product contains SVHCs in a concentration above 0.1 % weight by weight. Some Demag products do include small quantities of SVHCs, such as lead which is typically used in brass and in certain electric components.
  • Page 37 3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS Product description Main parts of the chain hoist 12 13 16 15 23 22 25 24 1. Electric equipment cover 16. Slipping clutch 2. Control system 17. Round-section steel chain 3. Service cover 18.
  • Page 38 OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION Product code 3.2.1 Demag product code Hoist type Structural Frame size Load Reeving Hook path Hoist speed Supply Hook lead Hoist hook Trolley type Trolley Max. flange Drive type and feature design capacity V/Hz off [opt.]...
  • Page 39 3.3.3 Hoist classification The added A and Dh classes are based on EN 14492-2 and ISO 4301. A DC-II chain hoist is designed load cycle-based and not time-based with full load working hours. Load cycle-based is much more demanding regarding the design of the product than just time-based.
  • Page 40 OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION 3.3.5 Mains connection circuit breaker and supply lines WARNING ELECTRIC SHOCK HAZARD In case of a short circuit, all phases must be disconnected from the power supply. Otherwise, an electric shock can occur, which could lead to death, serious injury, or damage to the equipment.
  • Page 41 Wear of the mechanical brake is reduced by electric and regenerative braking of the motor. The brakes of DC-II 1–DC-II 5 chain hoists are maintenance-free for up to 10 years, and the brakes of DC-II 10 chain hoists for up to 5 years.
  • Page 42 Therefore urgently recommend that the Demag special chain be used to ensure safe operation. 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.
  • Page 43 3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS NOTE For more information, see "Electric accessories" document for integrating 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, for more information, see "Polu box electric accessories"...
  • Page 44 OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION The display appears after 3 s 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 log book.
  • Page 45 3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS The shock and impact-resistant housings are of made high-quality thermoplastic and are resistant to fuels, salt water, greases, oils, and alkaline solutions with IP65 enclosure. Strong mineral acids (hydrochloric or sulphuric acid) can, however, corrode switch housings. To avoid corrosion, they must be replaced in good time.
  • Page 46 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION Installation Safety during installation WARNING SPECIALIST SKILLS REQUIRED Incompetent installation can be unsafe, or cause unsafe and unreliable operation of the product that can cause death, serious injury, or property damage. Only personnel who are authorized and properly trained may install the product. Local regulations and the instructions and warnings that are provided in product documentation must be obeyed.
  • Page 47 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS Installation personnel must make sure that these safety-related requirements are fulfilled • Use fall protection procedures. • Obey local safety regulations. • Make sure that you have all the appropriate personal protective equipment. Use them when required.
  • Page 48 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION • Personnel must be aware of any risk of accident that is posed by the site. • Personnel must familiarize themselves with the signs and warnings on the product. • Personnel must familiarize themselves with use and safety instructions of needed tools, like manlifts and lifting equipment.
  • Page 49 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS 4. If the hoist has been stored for a long time or has been transported by sea, do the following checks. 4.1 Make sure that the motors are dry. 4.2 Check that brake lining is undamaged. 4.3 Make sure that parts are lubricated.
  • Page 50 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION NOTE Before lifting the hoist, read the instructions in "Evaluating the weight of the hoist", "Lifting equipment", and "Before lifting". 4.2.7 Before lifting WARNING FALLING LOAD HAZARD Using lifting equipment contrary to instructions poses several risks, which can cause in death, serious injury, or property damage.
  • Page 51 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS 2. Dispose of the packing material in an environmentally compatible way. For more information, see "Transportation, storage and dismantling". 3. Connect the pendant controller. For more information, see "Connecting the controller". 4. Check that the hoist is equipped with a suitable suspension bracket. For more information, see "Suspension of the chain hoist".
  • Page 52 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION Connecting the pendant controller to the control cable If the chain hoist is not supplied with the pendant controller fitted, connect the DSC pendant controller to the control cable and lock the connection with the bayonet lock. The pendant controller is of plug-in design.
  • Page 53 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS 2. Pull the bend protection sleeve (1) off the pendant controller. 3. Slide the bend protection sleeve (1) upwards on the control cable, insert the control cable into the pendant controller, and turn the bayonet lock until it locks. •...
  • Page 54 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION WARNING FALLING HAZARD The chain hoist may fall, which can cause death, serious injury, or damage to the equipment. Do not use chain hoists that have a fixed suspension, such as a suspension bracket or suspension hook, for inclined pull of loads.
  • Page 55 2. Attach the suspension bracket to the supporting structure or the trolley. 3. Insert the pin through the suspension points on the hoist and the suspension bracket. For frame size DC-II 10, also insert the pin through the spacer tube. 4. Secure the pin with the retaining clip.
  • Page 56 4.6.2 Circuit diagrams NOTE The circuit diagrams for the chain hoist are shown in "APPENDIX: DC-II 1–DC-II 10 solo hoist circuit diagram." For more information on circuit diagrams with E11–E34 travel drives, see E11–E34 DC travel drive assembly instructions (II).
  • Page 57 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS 4.6.3 Control board Terminal Item Designation Function strip Plug-and-socket connector Motor Plug-and-socket connector Brake Relay Fast or slow Relay Lifting or lowering Relay Lifting or lowering Transformer Label with: • Serial no. "SN..." Serial number •...
  • Page 58 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION RJ45 connector 1. Pin 1 Function Control cable X3 Trolley X5 Special F1 Special F1 Crane forwards Crane forwards Crane reverse Crane reverse Emergency stop Emergency stop Controller supply Controller supply Lift 24 V AC from chain hoist Lower Pendant controller reference potential Traveling hoist right...
  • Page 59 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS 4.6.4 Control cable The control cable is protected by a flexible strain relief sleeve. If you need to adjust the suspension height of the pendant controller, you can unlock the self-locking clamp mechanism on the strain relief sleeve, and move the pendant controller to the preferred height. The part of the control cable that is not needed is stored under the service cover.
  • Page 60 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION 1. Unscrew the screws of the service cover. 2. Open and disconnect the service cover. 3. Remove and open the bag with the control cable. 4. Take the control cable out of the bag.
  • Page 61 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS 5. 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 pendant controller reaches the correct height. “y” “x” x = Control cable locking mechanism engaged y = Control cable locking mechanism released 6.
  • Page 62 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION 3. Open the service cover and electric equipment cover, loosen the screw on the sleeve compartment and thread the control cable out of the chain hoist. For more information, see "Replacing the control cable". 4.6.6.2 Installing the support sleeve on DSC pendant controllers 1.
  • Page 63 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS 2. Loosen the hose clip on the connecting sleeve and disconnect the plug from the DSK pendant controller. 3. Slide the bend protection sleeve and the hose clip onto support sleeve (3) with new control cable (4).
  • Page 64 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION 4.6.6.5 Installing the sleeve compartment on the rubber sleeve cable 1. Push the seal (1) into position against sleeve compartment (2). 2. Connect the new control cable to the chain hoist. 3. Attach the sleeve compartment to the chain hoist with the screw (3). 4.
  • Page 65 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS Component parts Item Designation Comprising Part no. 11-pole + PE flat cable 720 139 45 Socket enclosure Mounting frame Connector enclosure cpl. 720 187 45 VC-AMS8 pin insert Flat cable union Bayonet lock VC-MP-1-R-M25 bush enclosure Connector adapter cpl.
  • Page 66 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION X40 plug connector pin assignment Signal Conductor Conductor Signal Special F2 Right Left Lower Control voltage Lift (24 V, STS) Emergency stop Reverse Forwards Special F1 4.6.8 Mains connection Figure 13. 1. Sealing sleeve 4.
  • Page 67 12. Insert the mains cable into the opening in the gearbox housing and secure it with the strain relief clamp. For DC-II 1–DC-II 5 units, the strain relief clamp must be turned to match the shape of the cable (flat or round cable).
  • Page 68 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION WARNING! INCORRECT DIRECTION OF MOVEMENT Indirect direction of movement can result in danger to life and limb. If the 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 power supply plug.
  • Page 69 4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS 4.7.2 Using parameter-programming mode, travel drive E22-C/E...WD 1. Emergency stop 3. Lower button 2. Lift button 1. Press the emergency stop (1). 7-segment displays 8. 2. Press and hold the lift button (2) and unlock emergency stop (1).
  • Page 70 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION 6. To scroll through the menu items faster, press the lower button (3). Each figure represents a parameter. For more information, see "Chain hoist parameters". 7. To select the displayed parameter, press the lift button (2). For more information, see "Chain hoist parameters".
  • Page 71 The chain hoists are provided with a hook path of 5 m or 8 m as standard. Frame size Tightening torque of the limit stop [Nm] DC-II 1–DC-II 5 DC-II 10 1. Lower the hook on the floor. 2. To stop the chain hoist, actuate the emergency stop or the mains connection switch, and...
  • Page 72 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION 3. Remove the chain collector box. For more information, see "Removing the chain collector box". 4. Remove the limit stop on the chain collector box end. 5. Attach the limit stop directly behind the buffer. NOTE The unloaded chain fall behind the limit stop must consist of at least five chain links.
  • Page 73 5 COMMISSIONING OPERATING AND MAINTENANCE INSTRUCTIONS Commissioning Safety during commissioning WARNING SPECIALIST SKILLS REQUIRED Incompetent commissioning can be unsafe, or cause unsafe and unreliable operation of the product that can cause death, serious injury, or property damage. Only personnel who are authorized and properly trained may commission the product. Local regulations and the instructions and warnings that are provided in product documentation must be obeyed.
  • Page 74 OPERATING AND MAINTENANCE INSTRUCTIONS 5 COMMISSIONING Commissioning preparation 5.2.1 Commissioning environment requirements • Mark the operating area where you carry out the commissioning tasks, such as test loading. • Identify possible collision hazards of the crane to structures, obstacles, equipment, or personnel.
  • Page 75 5 COMMISSIONING OPERATING AND MAINTENANCE INSTRUCTIONS Activity Section Check Check the operation of the lifting-motion operating limit "Checking the operating limit switches" switch. Check the operation of the lowering-motion operating limit "Checking the operating limit switches" switch. "Checking the cut-off buffers and cut-off springs" Check the cut-off buffer, the cut-off spring, and the operating limit switch actuator.
  • Page 76 OPERATING AND MAINTENANCE INSTRUCTIONS 5 COMMISSIONING 1. Make sure that any safety devices that have been bypassed for testing purposes are restored to full operational status. Never bypass a safety device for normal operation. 2. Turn off all controllers and main isolation switches that are on the ground level. 3.
  • Page 77 6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS Operation Safety during operation DANGER CRUSHING HAZARD Persons within the operating area of the machine could become crushed by a falling load or moving machinery. This will cause death or serious injury. Before starting and while operating the machine, make sure that there are no unauthorized persons on the machine or in the operating area.
  • Page 78 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION • Operators must learn the hand signals for directing the product movements. • Operators must be familiar with proper rigging procedures. • Operators must carry out daily inspections. • Operators must follow local regulations. Operators must not •...
  • Page 79 6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS Check that all warning signs are in place. Check that the warning signs are in good condition and can be read easily. 6.2.2 Checking the operation with the emergency stop button pressed down WARNING! UNCONTROLLED MOVEMENT HAZARD If the emergency stop button is faulty, the product might move unexpectedly during the following checks.
  • Page 80 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION 7. Check the geared limit switch operation (if equipped) If the hoist is equipped with a rotating geared limit switch, check the operation of the limit switch. The cutting points (upper and lower limits) of the geared limit switch must be adjusted before starting to operate the hoist.
  • Page 81 6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS Activity Section Check Check the cable and the controller housing for damage. Activity Section Check Check the hook and the hook safety latch. "Load hook dimensions and wear" Safe load handling practices WARNING FALLING LOAD HAZARD Knots or blockages in the chain can cause the chain to break and the load to fall.
  • Page 82 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION 6.4.2 Attaching the load WARNING FALLING LOAD HAZARD Improper attachment of the load can cause death, serious injury, or property damage. Always follow instructions provided by the lifting device manufacturer when using non- fixed load-lifting attachments. Never use the ropes, chains, or belts of the product as a sling to attach to the load.
  • Page 83 6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS • Avoid short, jerky motions. Unnecessary short starts cause the hoisting motor to overheat quickly. • Do not switch the controller back and forth unnecessarily because it causes wear. • Do not swing the load intentionally. •...
  • Page 84 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION Lifting off-center balanced loads The center of gravity of an off-center balanced load is usually towards the heavier end of the load. As long as the contents of the container cannot move around, the balance of the load stays the same.
  • Page 85 6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS 6.4.6 Load swing The operator must use the correct techniques to properly control the load and prevent uncontrolled movements such as load swing or rotation. If the load tends to rotate or swing, a third person can guide the load with a tag line, if it is safe.
  • Page 86 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION 3. Stop over the setting point. You can stop both the load and the equipment simultaneously over the setting point. NOTE You may have to repeat these actions several times to completely eliminate the load swing.
  • Page 87 6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS 6.5.2 Moving loads • 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, or cranes may only be moved by pulling or pushing the load, bottom block, or load hook assembly.
  • Page 88 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION WARNING! ENTANGLEMENT HAZARD Safety gloves or other clothes may get entangled with the load or chain, which could cause serious injury. Be careful when handling the movements by hand. 6.6.2 Controlling speed with the controller Pendant controllers are usually equipped with two-stage control buttons for moving the load.
  • Page 89 6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS 6.6.4 Lifting a load with push button control Attach the load securely to the lifting device and position the hoisting machinery directly above the load. If the controller has a hoist or crane selection switch, be sure to select the correct hoist or crane.
  • Page 90 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION 4. To decrease the lowering speed, gradually release the down push button when the load approaches the ground. Take into account the possible preset deceleration ramp. 5. Fully release the down push button when there is slack in the lifting accessory but before the lifting device hits the load.
  • Page 91 6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS Shutting down the equipment WARNING MACHINE MALFUNCTION HAZARD Operating a defective product can cause death or serious injury. Remove the product from service immediately if it is defective. After every working shift, do the following procedure and checks to ensure that the product is left in safe condition.
  • Page 92 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE Maintenance Safety during maintenance WARNING SPECIALIST SKILLS REQUIRED Incompetent maintenance work can be unsafe, or cause unsafe and unreliable operation of the product that can cause death, serious injury, or property damage. Installation must be carried out only by authorized service personnel or an experienced service technician who is authorized by the manufacturer or representative of the manufacturer.
  • Page 93 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS Maintenance preparation 7.2.1 Maintenance environment • Prevent unauthorized persons and bystanders from walking on or below the work site. To prevent injuries from possible falling components or tools, ensure that the secured area is spacious enough.
  • Page 94 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE Inspection intervals that provided in the instructions are general guidelines. Depending on the use of the product, the required inspection intervals can also be shorter than instructed here. If the working environment or product use changes, the inspection and maintenance intervals must be revised.
  • Page 95 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS Recording with devices (for example, load spectrum recorder): Load spectra and the corresponding operating hours are recorded by suitable devices. The actual duration of service S is obtained by evaluating the recorded data. When information is recorded by devices, recording factor f = 1.0. (that is, the value is used without any changes, FEM 9.755, 3.1.) Documentation and suitable counting devices (for example, operating time counter): The actual load spectra and the load spectrum factors (Km1 to Km4) and the relevant...
  • Page 96 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE Calculating the number of hours of operation (operating time) T (by the owner) The operating time can be calculated by an operating time counter or according to the following method: Operating time for each inspection interval: (lifting + lowering) x cycles/h x operating time/day x days/inspection interval 60 x lifting speed Only lifting and lowering motions are counted, long, and cross-travel times are not considered.
  • Page 97 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS Factor depending on the type of recording Recording Recording operating hours and load spectrum factor [f] Operating hours recorded using an operating time counter and the load spectrum recorded with a load spectrum recorder and documented in the log book.
  • Page 98 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE Thus, the actual duration of service amounts to S [h] = k • With operating time read 0.119 x 167 x 1.1 = 21.9 For classification in FEM group of mechanisms 1Am (see chain hoist data plate) with a theoretical duration ofservice of 800 hours (see following table) the hoist has a theoretical remaining duration of service of 778.1 hours.
  • Page 99 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS Duty class/Group of mechanisms M2/1Cm M3/1Bm M4/1Am M5/2m M5+/2m+ M6/3m M7/4m M8/5m Duration of service and full load 1600 1900 3200 6300 12500 hours [h] The actual duration of service is considerably increased if the chain hoist is only operated with partial loads.
  • Page 100 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE Where: Partial load Load capacity Dead load Load capacity Number of load cycles with this load (Partial load + dead load) Number of all load cycles with all loads The values that are given in the following diagram are based on the information given in ISO 4301-1.
  • Page 101 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS Factor depending on the type of recording Recording Recording operating hours and load spectrum factor [f] Crane operating data are recorded by a special, purpose-built system, which always operates automatically when the crane is in use. The crane operator does not have a possibility to switch off the recording system.
  • Page 102 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 5% x 4/4 10% x 3/4 20% x 1/2 15% x 1/4 50% x 0 B = Loading L = Load t = Time Adding the load spectrum modules k together results in load spectrum factor k = 0.1688 Thus, the Design Working Period amounts to A [h] = k •...
  • Page 103 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS A general overhaul is defined as: Inspection of the machinery for 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 machinery is in a condition similar to that of the same machinery in new condition as far as the principle of operation and performance values are concerned.
  • Page 104 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE the classification of the chain hoist according to ISO 4301‑1/FEM 9.755. The actual duration of service should be determined every year according to ISO 12482. You can arrange to have the actual service life that is 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 service has elapsed.
  • Page 105 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 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 operating area clean and tidy. Loose parts or tools left lying around can cause accidents. 6.
  • Page 106 The small parts (screws, washers and so on) to be replaced when maintenance and assembly work is carried out are not listed separately. 1) Every ten years for DC-Pro II used according to FEM classification; during the annual inspection for DC-Com II. 2) Every 5 years for DC-II 10 3) For use according to FEM classification...
  • Page 107 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS General overhaul The general overhaul should coincide with the annual When 90% of the theoretical duration of service is reached. For more inspection. information, see "Measures for achieving safe working periods in Germany" and/or "Measures for achieving safe working periods according to ISO 12482''. Fit chain hoist-specific GO set The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not listed separately.
  • Page 108 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 Chain hoist DC-II 1–DC-II 5 DC-II 10 Suspension bracket short...
  • Page 109 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS Suspension ring Chain hoist DC-II 1–DC-II 5 DC-II 10 Min. dimension e for suspension ring turned 90° [mm] 19.5 (chain hoist parallel to girder) Maintaining the electric equipment cover 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.
  • Page 110 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 4. To remove the pin (6), remove the retaining spring (5) from the pin. When you remove the pin, hold the chain collector box (7). 5. Place the chain collector box (7) on the ground. Maintaining the limit switches 7.9.1 Checking the operating limit switches...
  • Page 111 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 7.9.2 Checking the operating limit switch for lifting A = Not compressed B = Compressed with slow lifting speed reaching end stop C = Compressed with full lifting speed reaching end stop 1. Raise the hook assembly or the bottom block until it is approximately 10 cm below the highest hook position.
  • Page 112 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 7.9.4 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 assembly come into contact with the chain hoist guide plate. To check the function of optional geared limit switch: 1.
  • Page 113 If the guide plate is worn more than the specified dimensions or if there are visible cracks, replace the guide plate. Dimension Frame size [mm] [mm] [mm] [mm] DC-II 1 16.0 16.8 DC-II 2 DC-II 5 19.4 21.0 DC-II 10 26.7 28.8...
  • Page 114 Otherwise the chain must be replaced. NOTE Demag is stamped on every 12th link of genuine Demag chains. We strongly recommend that you use genuine Demag chains to ensure that the safety and the service life of the chain hoist are guaranteed.
  • Page 115 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS If the chain does not run smoothly over the chain drive mechanism after fitting a new chain, contact after-sales service. DC-II 1 Chain hoist DC-II 5 DC-II 10 DC-II 2 Chain designation (d x t) [mm] 4.2 x 12.2...
  • Page 116 If a lifted load is dropped, the falling load can cause death, serious injury, or property damage. When the chain is replaced in DC-II 10 units that have 2/1 reeving, the chain anchorage must also always be replaced. The relevant parts are included in the chain sets. If a single chain is purchased by the meter, the chain anchorage must be separately ordered and installed.
  • Page 117 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS The chain must be replaced when the permissible chain wear limit is reached. For more information, see "Checking the chain wear". A chain set is always supplied when a new standard RDC/TDK chain is ordered. The chain set includes the listed parts. •...
  • Page 118 Chain grade meter test force Chain hoist size force rupture [kg] [kg] [mm] [kg] [kN] [kN] Demag DAT standard chain, high-strength DC-II 1 4.2 x 12.2 0.38 13.8 DC-II 2 DC-II 5 5.3 x 15.2 RDC/TDK 0.62 DC-II 10 1250 2500 7.4 x 21.2...
  • Page 119 If a lifted load is dropped, the falling load can cause death, serious injury, or property damage. When the chain is replaced in DC-II 10 units that have 2/1 reeving, the chain anchorage must also always be replaced. The relevant parts are included in the chain sets. If a single chain is purchased by the meter, the chain anchorage must be separately ordered and installed.
  • Page 120 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 3. Remove the chain collector box (7). Place the chain collector box down. For more information, see "Removing the chain collector box." 4. Remove the guide plate (7). With 2/1 reeving, also remove the oval chain anchorage pin.
  • Page 121 For more information, see the listed sections. • Chain hoist with geared limit switch • Fitting the retaining ring • Fitting the chain anchorage for 2/1 reeving in DC-II 10 • Fitting the limit stop • Steps after replacing the chain set DC-II 1...
  • Page 122 Figure 17. Chain guide for DC-II 10 without geared limit switch Figure 18. Chain guide for DC-II 10 with geared limit switch The chain guide for DC-II 10 has a larger opening on chain hoists that are equipped with a geared limit switch. For more information, see "Spare part manual."...
  • Page 123 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 7.10.7.2 Fitting the retaining ring DANGER FALLING LOAD HAZARD An incorrectly installed chain will result in a broken chain and a falling load. A broken chain and a falling load will cause death, serious injury, or property damage. When the chain is installed, make sure that it is introduced in the same position and with the same alignment.
  • Page 124 If a lifted load is dropped, the falling load can cause death, serious injury, or property damage. When the chain is replaced in DC-II 10 units that have 2/1 reeving, the chain anchorage must also always be replaced. The relevant parts are included in the chain sets. If a single chain is purchased by the meter, the chain anchorage must be separately ordered and installed.
  • Page 125 NOTE The limit stop must be fitted so that the extra length of chain is positioned between the hook assembly and the limit stop. In this case, a geared limit switch is required for DC-II 10 units with 2/1 reeving.
  • Page 126 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 7.10.8 Chain guides Figure 19. DC-II 1–DC-II 2 chain guide 1. Chain guide 3. Lower chain entry plate 2. Upper chain entry plate Figure 20. DC-II 5 chain guide 1. Chain guide 3. Lower chain entry plate 2.
  • Page 127 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 7.10.9 Lubricating the chain WARNING MOVING MACHINERY HAZARD Contact with moving parts of the chain hoist, such as the chain or hook, can cause serious injury or death. When you operate the chain hoist, watch out for any moving components. WARNING IRRITATING SUBSTANCE HAZARD The machine contains several chemical substances, which can cause skin irritation and...
  • Page 128 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 4. Lubricate the chain. Start applying the lubricant on the chain from the top, close to the chain hoist. Then proceed from top to bottom of the chain. Apply a substantial amount of lubricant over the full length of the chain.
  • Page 129 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS Chain lubrication intervals Nbr of sprockets Falls 1-fall 2-falls 1-fall LH 2-fall LH Hoist type Grease 12000 6000 4000 3000 [cycles] Cycle = One work cycle, from pick-up to release of the load. LH = Low headroom hoist.
  • Page 130 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 7.11 Load hook 7.11.1 Load hook dimensions and wear Chain hoist DC-II 1–DC-II 10 DC-II 1–DC-II 10 DC-II 1–DC-II 10 Hook type Standard hook Self-locking hook Stainless steel hook Load Capacity [kg] 1250 2600...
  • Page 131 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 7.11.4 Replacing DC-II 1–DC-II 10 hook assembly DANGER FALLING LOAD HAZARD Incorrect assembling of the hook assembly will cause loads to drop. A dropping load will cause death, serious injury, or property damage. Make sure that you install the parts in the right order and orientation.
  • Page 132 8. Position the load hook (7) with the O-ring (6) under parts 1, 2, 3, 4, and 5. 9. Fit the hook assembly bolted joint (9). Tighten the bolted joint to the correct tightening torque. Tightening torques [Nm] DC-II 1 DC-II 2 DC-II 5 DC-II 10 Hook assembly 11.5...
  • Page 133 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS NOTE For instructions on removing and installing the chain, see "Replacing the chain." 1. Hook 7. Cut-off spring 2. Ball thrust bearing 8. Chain 3. Nut 9. Hook assembly cover 4. Rated capacity plate 10.
  • Page 134 7 MAINTENANCE 4. Assemble the hook assembly covers (9) with two bolts (10) and two nuts (3). Tighten to the correct tightening torque. Tightening torques [Nm] DC-II 10 Bottom block with external cut-off springs 52.0 7.12 Buffers and cut-off springs 7.12.1...
  • Page 135 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 7.12.2 Buffer and cut-off spring arrangement H, I, J, K A, B, C, D, E ød1 ød2 1. Cut-off buffer 3. Damping plate 2. Buffer plate 4. Cut-off spring NOTE The cut-off springs must be replaced on 60-Hz chain hoists that have operating limit switches: V8 spring ➔...
  • Page 136 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE Plate Height Chain collector Switch dia. d1/ Load hook side Lifting speed box side equipme Size Reeving Product range dia. d2 [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no. 0BES 717 534 45 717 534 45 DC-Com II 1BES...
  • Page 137 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS Plate Height Chain collector Switch dia. d1/ Load hook side Lifting speed box side equipme Size Reeving Product range dia. d2 [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no. 0BES 715 534 45 DC-ProFC VS4/VS6/VS12 0BES...
  • Page 138 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 2. Disconnect the chain hoist from the main power supply network. 3. Open the electric equipment cover. 4. Detach the brake. For more information, see "Replacing the brake." Take notes or a photograph of the orientation of the brake. You must install the brake in the same orientation.
  • Page 139 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 4. Locate the brake check hole (1) in the brake assembly. 5. Measure the depth of the brake check hole gap with a caliper. 6. Compare the measured brake wear value with the maximum value for brake wear. You can find the value on the brake.
  • Page 140 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 4. Check that the brake data of the replacement brake matches with the data of the original brake. You can find the brake data on the brake. 5. Unplug the brake cable from the control board.
  • Page 141 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 7. Remove the brake carefully. 8. Install the new brake on the shaft in the same orientation as the removed brake. Attach the brake with the three screws. 9. Plug in the brake cable. 10.
  • Page 142 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 7.14 Slipping clutch 7.14.1 Checking the slipping clutch The slipping clutch provides the function of an emergency limit stop device and overload protection for the chain hoist. The slipping clutch is initially adjusted in the factory. Under normal operating conditions, the slipping clutch does not need to be readjusted.
  • Page 143 Overload protection must be provided for chain hoists with a rated capacity of 1000 kg or more. All DC-II chain hoists have the overload protection. The setting that is made in the factory installation meets the requirements of EN 14492-2 (direct acting rated capacity limiters) for slipping clutches that are used as overload protection.
  • Page 144 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 4. To tighten the slipping clutch and to increase torque, turn the adjustment tool clockwise in the adjusting screw. NOTE Make sure that you do not over-tighten the adjusting screw. Over-tightening the adjusting screw can damage the springs of the slipping clutch.
  • Page 145 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 7.15 Maintaining the gearbox 7.15.1 Gear oil DC-II 1 Chain hoist size DC-II 5 DC-II 10 DC-II 2 Oil quantities 0.35 0.90 Gearbox cover [Nm] 10.0 Tightening torques Drain plug [Nm] 35.0 Service cover [Nm] 10.0...
  • Page 146 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 1. If a load is attached to the hook, remove the load. 2. Disconnect the chain hoist from the main power supply network. 3. Open the electric equipment cover and the service cover. 4. Remove the chain collector box. For more information, see "Removing the chain collector box."...
  • Page 147 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS 7.16 Replacing the contactor on the control board Locking tab Contactor 1. Unclip the contactor retaining mechanism by pressing the locking tab (1) with your thumb. Carefully bend the locking tab (1) away from the contactor. 2.
  • Page 148 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 5. You can insert the replacement contactor into the socket in one position only. Push the contactor into the contactor socket (3) until both locking tabs (1) click into position. 7.17 Replacing the relay on the control board Control board Contactor Relay...
  • Page 149 7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS NOTE If relays must be replaced, note the following: • Contact pins of the new relays must not be bent. • When new relays have been fitted on the control board, the spring clip must be installed from above.
  • Page 150 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE 3. Take the control cable out of the bag. 4. Turn and disconnect bayonet lock (2) and remove the control cable plug connector. 5. Unscrew the electric equipment cover, and let the cover hang down on the suspension wires.
  • Page 151 Adjust the height of the pendant controller. For more information, see "Pendant controller height adjustment." 7. Reassemble the electric equipment cover and the service cover in reverse order. Tightening torques [Nm] DC-II 1 DC-II 2 DC-II 5 DC-II 10 Electric equipment cover 10.0...
  • Page 152 OPERATING AND MAINTENANCE INSTRUCTIONS 8 TROUBLESHOOTING Troubleshooting Safety during troubleshooting DANGER ELECTRIC SHOCK HAZARD Incompetent electrical work will be unsafe or cause unsafe and unreliable operation of the product that will result in death, serious injury, or property damage. Work on electric equipment must be done by qualified specialist personnel in compliance with the safety regulations.
  • Page 153 8 TROUBLESHOOTING OPERATING AND MAINTENANCE INSTRUCTIONS 7-segment display NOTE The symbols are shown one after the other. • Contact after-sales service if the cause of the fault cannot be eliminated with the given measures. The 7-segment display is located on the underside of the chain hoist behind a window. Warning messages start with a lightning symbol.
  • Page 154 OPERATING AND MAINTENANCE INSTRUCTIONS 8 TROUBLESHOOTING Malfunction or Display Possible cause Solution event – – Operating status: Lowering V1 – – Operating status: Lifting V2 – – Operating status: Lowering V2 – – Operating status: Lifting start-up – – Operating status: Lowering start-up Upper limit position Upper limit switch actuated.
  • Page 155 8 TROUBLESHOOTING OPERATING AND MAINTENANCE INSTRUCTIONS Display Malfunction or event Possible cause Solution Check mains connection and fuse link; A mains phase is missing or the check connection cable for interruption; motor is blocked. check mains connector in the service SLIP LIFTING start-up: No enclosure.
  • Page 156 OPERATING AND MAINTENANCE INSTRUCTIONS 8 TROUBLESHOOTING Display Malfunction or event Possible cause Solution Check error message by actuating and unlocking the emergency stop. Then actuate Drive blocked Lowering. If necessary, remove suspended Chain hoist is blocked. load. Brake blocked Check and, if necessary, replace the brake. Speed measurement failure.
  • Page 157 9 TRANSPORTATION, STORAGE AND OPERATING AND MAINTENANCE INSTRUCTIONS DISMANTLING Transportation, storage and dismantling Transporting the product When transporting the product or its components, take the following precautions: • Load and transport the product with caution and using appropriate methods, making proper preparations and taking appropriate caution.
  • Page 158 OPERATING AND MAINTENANCE INSTRUCTIONS 9 TRANSPORTATION, STORAGE AND DISMANTLING • Oil all bare machine parts (rust protection). • Check the general condition of all parts of the packing at regular intervals. If necessary, refresh or renew rust protection. • If stored in a damp location, the installation parts must be packed tight and protected against corrosion (desiccant).
  • Page 159 Improper attachment and loose connections can cause death, serious injury, or property damage. Mainly metal nuts with a locking element, self-locking nuts, are used for chain hoists. Do not replace self-locking nuts with normal nuts. Tightening torques [Nm] Size DC-II 1 DC-II 2 DC-II 5 DC-II 10 Reeving Motor 25.0...
  • Page 160 OPERATING AND MAINTENANCE INSTRUCTIONS APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST CIRCUIT DIAGRAM APPENDIX II: DC-II 1–DC-II 10 solo hoist circuit diagram...
  • Page 161 APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST OPERATING AND MAINTENANCE INSTRUCTIONS CIRCUIT DIAGRAM...
  • Page 162 OPERATING AND MAINTENANCE INSTRUCTIONS APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST CIRCUIT DIAGRAM...
  • Page 163 APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST OPERATING AND MAINTENANCE INSTRUCTIONS CIRCUIT DIAGRAM...
  • Page 164 OPERATING AND MAINTENANCE INSTRUCTIONS APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST CIRCUIT DIAGRAM...
  • Page 166 DEMAG CRANES & COMPONENTS GMBH Standort Wetter Ruhrstraße 28 58300 Wetter info@demagcranes.com +49 2335 92-0 +49 2335 92-7676 www.demagcranes.com...

This manual is also suitable for:

Dc-ii 1Dc-ii 2Dc-ii 5Dc-ii 10Dc-ii 1-250Dc-ii 2-250 ... Show all