DEMAG DC-II 1 Manuals

Manuals and User Guides for DEMAG DC-II 1. We have 1 DEMAG DC-II 1 manual available for free PDF download: Operating And Maintenance Instructions Manual

DEMAG DC-II 1 Operating And Maintenance Instructions Manual (166 pages)

Brand: DEMAG | Category: Chain Hoists | Size: 9 MB

Contact Information
2
After-Sales Service
2
Table of Contents
4
Introduction
10
About this Information
10
How to Use this Information
10
Copyright Notice
10
Definition of Terms
10
Definition of Personnel
12
Specialist Personnel
12
Qualified Electrician
12
Symbols and Conventions
13
Related Information
15
About this Product
16
Intended Use
16
Conditions of Warranty
16
Product Identification
17
Standards and Directives
18
Log Book
18
Health, Safety and the Environment (HSE)
20
Safety Messages and Signals
20
Signal Words
20
Hazard Symbols
20
Mandatory Action Symbols
22
Prohibited Action Symbols
22
Product Safety Labels
22
Safety Label Locations
23
Responsibilities of the Owner
23
Preventing Work-Related Hazards
23
Preventive Maintenance
23
Personal Protective Equipment
24
Fall Protection
25
Working at Heights
25
Incident Reporting
26
Conditions for Product Use
26
Operating Conditions
26
Prohibited Use
27
Changes to the Product
27
Emergency Stop
28
Using the Emergency Stop Button
30
Main Isolation Switch
31
Lockout-Tagout-Tryout Procedure
31
Fire Safety
32
Emissions
33
Measured Sound Levels
33
Personnel Requirements
33
Environmental Information
34
Product Life-Cycle Stages
34
Handling Waste Material
34
Disposing of Electronic Products Securely
35
Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH)
35
Product Description
37
Main Parts of the Chain Hoist
37
Product Code
38
Demag Product Code
38
Technical Data
38
Product Range for DC-Com II
38
Product Range for DC-Pro II
39
Hoist Classification
39
Chain Hoist Motor Data
39
Mains Connection Circuit Breaker and Supply Lines
40
Dimensions
40
Materials and Coating
40
Drive and Brake
41
Gearbox and Slipping Clutch
41
Chain Drive
42
Electric Equipment
42
Control System
42
7-Segment Display for Operating Status and Fault Display
43
Display of Software Version, Operating Hours, Number of Cycles
43
Central Service Enclosure
44
Pendant Controller
44
Installation
46
Safety During Installation
46
Responsibilities of Installation Personnel
47
Installation Preparation
48
Installation Environment Requirements
48
Tool Requirements for Installation
48
Preparing for Installation
48
Evaluating the Weight of the Hoist
49
Lifting Equipment
49
Lifting Points on the Hoist
49
Before Lifting
50
Installation Procedure
50
Connecting the pendant Controller to the Control Cable
52
Suspending the Chain Hoist
53
Supporting Structure
54
Attaching the Chain Hoist to the Supporting Structure or the Trolley
55
Electrical Connections
56
Safety During Electrical Work
56
Circuit Diagrams
56
Control Board
57
Limit Switch Connector
58
Control Cable
59
Adjusting the Suspension Height of the pendant Controller
59
Installing the Support Sleeve on DSC, DSK or DST pendant Controllers
61
Disassembling the DSC pendant Controller
61
Installing the Support Sleeve on DSC pendant Controllers
62
Installing the Support Sleeve on DSK pendant Controllers
62
Installing the Support Sleeve on DST pendant Controllers
63
Installing the Sleeve Compartment on the Rubber Sleeve Cable
64
Mobile Control System
64
Mains Connection
66
Connecting the Chain Hoist to the Electric Supply
67
Phase Sequence for Connection to the AC Power Network
67
Checking Directions of Motion
67
Programming Parameters with the pendant Controller
68
Chain Hoist Parameters
68
Using Parameter-Programming Mode, Travel Drive E22-C/E
69
Adjusting the Lower Hook Position
71
Commissioning
73
Safety During Commissioning
73
Responsibilities of Commissioning Personnel
73
Commissioning Preparation
74
Commissioning Environment Requirements
74
Commissioning Tool Requirements
74
Preparing for Commissioning
74
Commissioning Instructions
74
Commissioning Inspections
74
Checks before First Use
75
Finishing Commissioning
75
Operation
77
Safety During Operation
77
Operating Environment
77
Responsibilities of the Operator
77
Checks before Operating
78
Checking the Hoist before Every Working Shift
78
Checking the Operation with the Emergency Stop Button Pressed down
79
Checking the Operation with the Controller Enabled
79
Starting the Equipment
80
Setting up the Controller
80
Operational Checks
80
Safe Load Handling Practices
81
Load Evaluation
81
Attaching the Load
82
Lockable Hook
82
Handling a Load
82
Load Balancing
83
Shock Loading
84
Load Swing
85
Preventing Load Swing
85
Controlling the Equipment
86
Picking up the Load
86
Moving Loads
87
Controlling Load Movements
87
Moving the Manual Push Trolley
87
Controlling Speed with the Controller
88
Moving the Load with the Controller
88
Lifting a Load with Push Button Control
89
Lowering a Load with Push Button Control
89
Combining the Movements
90
Detaching a Load
90
Slipping Clutch Operation
90
Hoisting Limit Switch Operation
90
Shutting down the Equipment
91
Maintenance
92
Safety During Maintenance
92
Maintenance Preparation
93
Maintenance Environment
93
Preparing for Maintenance
93
About Maintenance
93
Maintenance Intervals
93
Service Personnel
94
Measures for Achieving Safe Working Periods in Germany
94
Calculating Actual Duration of Service S According to FEM 9.755 (Germany)
95
Example of Duration of Service S According to FEM 9.755 (Germany) for Chain Hoist Size 10 1250 Kg 1/1 H5 V8/2 in 1Am
97
Measures for Achieving Safe Working Periods According to ISO 12482
98
Determining the Remaining Service Life According to ISO 12482
99
Example for Determining the Remaining Service Life According to ISO 12482 for Chain Hoist Size 10 1250 Kg 1/1 H5 V8/2 in 1Am
101
GO General Overhaul
102
General Overhaul in Germany According to DGVU and ISO 12482 (FEM 9.755)
102
General Information on Inspection and General Overhaul According to ISO 12482
103
Theoretical Duration of Service
103
Basic Maintenance Requirements
104
Electric Components
104
Working on Machinery or Machine Equipment
104
Instructions for Maintenance Work in the Course of Operation
105
After Finishing Maintenance Work
105
Maintenance Schedule
105
Routine Inspections
107
Required Tests and Inspections
107
Special Operating Conditions
107
Service Life of the Contactor
108
Maintaining the Suspension
108
Maintaining the Electric Equipment Cover
109
Removing the Chain Collector Box
109
Maintaining the Limit Switches
110
Checking the Operating Limit Switches
110
Checking the Operating Limit Switch for Lifting
111
Checking the Operating Limit Switch for Lowering
111
Optional Geared Limit Switch
112
Checking the Operating Limit Switch Actuator
112
Maintaining the Chain Drive
112
Checking the Chain Sprocket
112
Checking the Chain Guide
112
Checking the Guide Plate or the Chain Entry Plate
113
Checking the Chain Wear
113
Inspecting the Chain Visually
113
Measuring Chain Wear or Deformation
114
Measuring Wear of a Single Chain Link with a Caliper Gauge
114
Measuring Wear over 11 Chain Links with a Caliper Gauge
114
Measuring Wear over 11 Chain Links with a Chain Gauge
116
Chain Set Scope of Supply
116
Available Chains
118
Replacing the Chain Set
119
Chain Hoist with Geared Limit Switch
122
Fitting the Retaining Ring
123
Fitting the Chain Anchorage for 2/1 Reeving in DC-II 10
124
Fitting the Limit Stop
125
Steps after Replacing the Chain Set
125
Chain Guides
126
Lubricating the Chain
127
Lubricating the Chain with a Grease Tube
127
Lubrication Intervals of the Chain
128
Load Hook
130
Load Hook Dimensions and Wear
130
DC-Pro II Hook Safety Latch
130
Checking the Return Sprocket in the Hook Block
130
Replacing DC-II 1-DC-II 10 Hook Assembly
131
Replacing the Bottom Block with External Cut-Off Springs, 2/1 Reeving
132
Buffers and Cut-Off Springs
134
Checking the Cut-Off Buffers and Cut-Off Springs
134
Buffer and Cut-Off Spring Arrangement
135
Brake
137
Maintaining the Brake
137
Checking the Brake Wear
138
Replacing the Brake
139
Slipping Clutch
142
Checking the Slipping Clutch
142
Adjusting the Slipping Clutch
142
Maintaining the Gearbox
145
Gear Oil
145
Changing the Gear Oil
145
Replacing the Contactor on the Control Board
147
Replacing the Relay on the Control Board
148
Replacing the Control Cable
149
Finishing Maintenance
151
Troubleshooting
152
Safety During Troubleshooting
152
7-Segment Display
153
Troubleshooting When the Display Indicates Malfunction
153
Operating Statuses and General Messages
153
Warning Messages
154
Error Messages
155
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
160
APPENDIX II: DC-II 1-DC-II 10 solo Hoist Circuit Diagram
160

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DEMAG DC-II 1 Operating And Maintenance Instructions Manual (166 pages)

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