Scribd Logo
Upload

Welcome to Scribd!

  • 001 04 (01) KU AU 81 T 0060 003 Rev00 H8102 Operating Instructions Demag

    Uploaded by

    Eugenio Letelier Bettancourt
    391 views100 pages
    Operating Instructions Demag

    Original Title

    001 04(01) KU AU 81 T 0060 003 Rev00 H8102 Operating Instructions Demag

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document
    Operating Instructions Demag

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    391 views100 pages

    001 04 (01) KU AU 81 T 0060 003 Rev00 H8102 Operating Instructions Demag

    Uploaded by

    Eugenio Letelier Bettancourt
    Operating Instructions Demag

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 100
    ce Operating instructions Demag DH 200, 300, 400, 500, 600, 1000, 2000 hoist units 1297 €N 208 706 44 72018819, Manufacturer Mannesmann Dematic AG P.O, Box 67, D-58286 Wetter Telephone (+28 35) 92-0, Telefax (+28 85) 92 76 76 Please filin the folowing table before frst putting the rope hoist into service. ‘This provides you with a definitive documentation of your Demag rope hoist and in ‘portant information if you ever have to contact the manufacturer or his representative, Owner Where in use Model Serial number Main hois/E6 creep hoist motor number Main hois/F4 creep hoist motor number Main hoist motor number Fro merospeed unt Creep hoist motor number Creep hoist gearbox number Travel drive unt number Operating voltage Control voltage Frequency ‘Accompanying documents Component parts list for control pondant DH 200 22038044 721 ISB13. DH so0/FG. 22230244 721 1S813, DH 400/F6. 22272644 721 1S813, DH SO0FG.. zeeso7 44 721 18813, DH GO0IFG. 22073144 721 ISB13. DH 10006, 22031244 721 18813, DH 2000/F... rope cia. 28 22235044 721 1S813. DH 2000/FG... rope cia. 25 22205544 721 18813, ‘Component parts list for control pendant Dsk 22298144 721 18.951 Component parts list for control pendant DsE 22067544 721 1S981 Component parts list for control pendant pst 22214244 721 1951 Test and inspection booklet 20609144 72018100 (Operating instructions for Dematik MGS/MIKA, (206 689.44) 20697944 720 S819 (Operating instructions for Dematik ZMS/FAW-1 (206 880.44) 20662644 720 IS819 SGDM hoist unt olay Function description with wiring dlagram 20270844 714 18952 (Operating instructions for DH drum brake 20639444 720188231 Type FB (overspeed brake) HB (holding brake) Technical data DH, UDH and KDH hoist units DH 200-2000 20265444 = 714 18813, EZDH/EZLDH double-ral crabs DH 300-2000 20285444 714 S813. 2 ee Contents Foreword Copyright Alter-sales service Guarentee Limitations of fabilty Defritions Safety instructions, ‘Symbols ‘Appropriate use Prohibited practices General safety information ‘Selection and quaiication of operating and maintenance personnel ‘Sefety instructions for installation and cisassernbly Safety instructions wien fist putting the hoist into service after completing installation Sefety instructions for operation Sefety instructions for maintenance Technical data Designation Explanation of size designation ‘Selection erteria Hoist motor data EUDH, EKDH, EZDH, EZLDH travel motor data ‘Mounting code for ordering a mechanical microspeed uit Setting hook dimension C DH 200 ~ DH 2000 hoist units KDH 200 H 16 low-headroom monorail hoist KDH low-headroom monorail hoist LUDH Standard-headroom monorail hoist EZDH/RS douibo-ral crabs EZLDH/RS double-ral crab ‘Mounting flange positions and rope lead-offs General Inspection reguiations. Hoist units operating outdoors Packing and storage Paint fish Operating conditions Description Design Motor (Goarbos/rope reeving components ‘Arrangement of the major assembles Geared imit switches Control pendant Models Load detectors for Demag DH hoist units Runways Troleys ‘Assembly Electrical equipment Connection to the electrical supply Checking the direction of movernent Control DST, DSE, DST control pendants ‘Assemby instructions for DSK control pendant ‘Assombiy instructions for DSE control pendant Strain relief with wite cord Connecting the control cable and strain rolof for DSE control pendant | ‘Assembly instructions for DST control pendant Fitting the wire rope Construction, application and reeving of wire roves ope reeving methods for the Demag DH host unit ope reeving on DH hoist unit and UDH standarc-headroom ‘monoral hoist Rope reaving on KDH low-headroom monorail hoist MGS/MKA-2 load detector, OH 200 ~ DH 1000 ZMS/FAW-1 load detector, DH 200 ~ DH 2000 48 8 5104 5105 5.106 5.10.7 6a ena B12 5.113 5.12 5124 5.12.2 5.123 8.124 813. 5138.4 5.132 514 8144 5.15 ASA 5.15.2 5.153 as 84 a5 ast 852 863 354 ass ass 861 862 art ar2 873 Lubccation Fiting the rope socket Fiting the rope guide DH 200 - 2000 Fitting the rope guide DH 300 ~ 600, 2000 with toothing adjustment, ‘Assembly and adjustment of EUDH standerc-heacroom monoral hoist troleys Ascomby of the trey Aalusting the monorail roley Changing the travel dive on UDH hoists ‘Assembly anc adustment of EKDH lowheedroom monoral hoist trolleys ‘Assembly ofthe toley ‘Adjusting the trolly fr sizes 9,6 and 10 (size 10 when combined with Derg OH 500/600 4/1 hoist uni ‘Agustin ttoley size 10 when combined with Demag DH 1000 2/1 hoist unit Changing the travel drive on KDH hoists ‘Assembly and adjustment of EKDH 200 2/1 and 4/1 low-headroom menoral hosts ‘Asser of the trolley ‘Adjusting the trey ‘Counterweight box fing for EKDH trolleys Dimensions for attaching end stops to runways FG 06 -FG08- FG 10 microspeed units Brake Main hoist motor Changing the hollow shaft ofthe FG G8 and FG 10 Domag DH hoist units andl travel drive units for arduous conditions Putting the Demag DH hoist unit into service DGS 3 and DGS 4 geared imit switches Determining the cut-out point for the geared limit switch Setting instructions for DGS 3 and DGS 4 goared limit switches 81 emergency limit snitch for top hook postion ‘$2 main iting motion Emit switch ‘$8 emergency limit snitch for bottom hook positon ‘84 operating mit switch for battom hook position Inspection when putting the hoist into operation Safety instructions. Starting operation ‘Taking the Demag hoist unit out of sorvico Emergency-stop switcn ‘Taking the hoist out of service at the end of the shift ‘Taking the hoist out of service for maintenance purposes Inspections/maintenance/general overhaul GO Inspection before starting work and during operation inspection and maintenance schedule General overnaul GO Wire rope BH main hoist motor, KBF travel dive motor and KBA microspeed motor brake ‘Adjusting the brake Fitting a new brake ining ‘Adjusting the brake Fitting a new brake ining Fitting new KBH brake springs Air gap KDF 63 travel motor brake KDF 68 motor Replacing the brake disk KH 100/112 hoist motor KMEF 80, 90 and 100 travel motor ‘Adjusting the brake with shims Replacing the brake cup Replacing the fan BB288 2B 8 SBRsese Bess 0 Foreword ceE 0.1 Copyright 88 — Gearbox 94 8.8.1 Main hoist gearbox (two, three or four-stage planetary gearbox) 94 88.2 FG 06, 08 and 10 mechanical mcrospood units, AFM 03, ‘AFM 04, AFM 05, AFM 06, AF 08, AF 10, AF 12 travel drives 96 8.8.3 Output stage, standard and low-headroom monorail hoists 96 884 Troley se 4 a7 885 Travel drive 97 89 Aniiicton beorings 97 89.1 Motor bearings 97 8.10. Load:-bearing bolted connections 97 8.11 Mul-button pendant control switches, 97 9 Measures for achieving safe working periods 98 9.1 Calculating the actual duration of service S 98 8.1.1 Estimating the load spectrum factor k,, (by the owner) 99 9.1.2 Calculating the number of hours of operation (operating tine) T, by the owner 99 9.1.8 Factor depending on type of recording t 400 9.1.4 Example with hook travel counter 100 9.2 Example with FWL load spectrum recorder 101 You have purchased a Mannesmann Dematic product, This hoist unit was manufac- tured in accordance with Germen and European standards and regulations, 0.9, EC Machinery Directive 89/392/EEC, and state-of-the-art engineering principies. Demag host units are of modular design. ‘The main assemblies inckide: the gearbox the hoist motor the integrated electrics ‘© the rope drive mechanism the control pendant ‘These operating instructions are designed to provide the operator with appropriate instructions for eafe and correct operation and to facitate maintenance. very individual given the task of transporting, instaling, commissioning, operating, "maintaining end repairing our hoist units and addlional equipment must have read ‘and understood * the operating instructions * the satety reguiatons and *safoty instructions inthe inctvidual chapters and sections. “The operating instructions must be available to the operating personne! at all times in ‘order to prevent operating errors and to ensure smooth and troube-tee operation of our products. ‘These operating instructions must be treated confidentially. They should only be used by authorized personnel. They may only be entrusted or made available to third patios with the prior writen consent of Mannesmann Dematic, All documents are protected within the sense of copyright lw. 'No part of this documentation may be reproduced, utized or transmitted without ‘specific prior consent. Iniringements are an offence resulting in obigatory compensa- tory damages, All industria rights reserved. 0.2 After-sales service 0.3 Guarantee 0.4 Limitations of liability ur after-sales service wil provide you with all technical information on Meanesmann Dematic products and their systematic application ‘Shouid you have any questions regarding our products, please refer to one of our after-sales service stations, tho rlavant representative orto our main office. Kindly quote the serial or order number (see test and inspection booket, hoist unit data plate) in any correspondence or for spare part orders, Specifying this data ensures thet you receive the correct information or the required spare pars, ‘The relevant after-sales service station of Mannesmann Demat is specified for x- ‘ample on the back page of the test and inspection booklet. ‘These operating instructions must be read carafuly before instaling and putting hoist Units into operation. We assume no libilty for damage and malfunctions resulting from fallure to comply ‘withthe operating instructions. Guarantee claims must be made by quoting the order number immediately on ‘detecting the defect. ‘The quarantee is cancelled, for example, in the event of: * inappropriate use, * faulty devices or equipment connected or attached to the hoist unit which are not part of our scope of supplies and services, ‘* IPcorrect or inappropriate application ofthe cables and wiring vihich are not part of ‘our scope of supplies and services, * incorrect or inappropriate connection of the cables and wing which are not part Of our scope of supplies and services, ‘= se of non-genuine spare parts and accessories, ‘© refurbishment or modification ofthe hoist unit uniess approved in writing by Mannesmann Dematic. ‘Wearing parts are not subject to the guarantee. ‘Alltechnical information, data and instructions for operation contained in these oper ating instructions were up-to-date on acing to print and are compiled on the basis of Cour experlnce and tothe best of our knowledge ‘We reserve the igh o incorporate technical modifications within the scope of futher 1.3 Prohibited practices 1.4 General safety information A Certain work and practices are prohibited when using the hoist unites they may in vvolve danger to life and limb and regut in lasting damage to the hoist unt, .9, ‘+ Unsafe load handling e.g, swinging the load ‘+ Do not handle suspended loads above persons. ‘+ Do not pull or drag suspended loads at an angle. ‘+ Do not pul free fixed or obstructed loads with the hoist unit ‘+ Do not exceed the maximum permitted load and permitted load dimensions, + Do not leave suspended loads unsupervised, ‘+ Donnot alow the rope to run over edges. ‘+ Dornot use the rope as a load bearing sing. ‘+ Aways move the hoist unit with push travel trolley by puling on the load, the bot- tom block. or the load hook assembly ~ never pull on the control pendant ‘© Donnot alow loads to drop when the rope isin a slack condition. ‘© Dornot subject the contro unt to inappropriate mechanical loads * Transporting persons with the hoist unit is not permitted unless hoist units are specifically approved for transporting persons. * Donot tamper with or manipulate elatrcal equipment. Persons under the inluence of drugs, aleohol or medicines which affect reactions: "must not install, operate, put into service, maintain, repair or disassemble hoist units. ‘Any conversions and moaications tothe installation require the writen consent of Mannesmann Demat \Work on electrical equipment of hoist units may only be carried out by qualified elec: tricians in accordance with eloctrical rogulations. Inthe event of malfunctions, hoist Unit operation must be stopped, the hoist switched off and the relevant main switches locked immaciately. Detects must be rectifed immediately, "National accicent prevention regulations and general safety regulations must be ob- served when operating our products. Important information and instructions are ‘marked by corresponding symbols. Folow these instructions and/or safely regula tions in order to avoid accidents and damage. The operating instructions must be kept avalible atthe plave where the hoist unit sin use at all times. They include significant aspects and appropriate excerpts from the relevant guidelines, standards ‘and reguiations. The owner must instruct his personnel appropriately. ‘Any faire to comply with the safety instructions stated in these operating instructions ‘can result in death or personal injury. (Observe general statutory and other obligatory reguiations relating to accident pre- vontion and environmental protection and basic heaith and safely requirements in ‘ckdition to those included in these operating instructions, Such requirements may also reste, for example, to the handing of Nazardous materials or the provision/wear- ing of personal protection equipment. Comply with these regulations and general accident prevention regulations relevant forthe place at which the hoist unit is used _and folow the instructions therein when working with the hoist unt. The hoist unit ‘may stil constitute @ danger to fe and limb if itis not installed, operated, maintained Cr used appropriately by personnel which have nat been trained or specially instruct- ed. The operating instructions must, i required, be supplemented by the owner with instructions and information (e.g. factory regulations) relating to organization of work, ‘working procedures, operating personnel, ete. Supervising and reporting obligations as well as special operating conditions must also be taken into consideration. Personnel assigned to working wit the hoist unit must have read and understood the ‘operating instructions and, in partcuia, the chapter on safety information. {All activites relating to hoist units which are not described in these operating instruc tions may only be carried out by specialist personnel spectically trained for the pertc- ular hoist uni. “The oviner must ensure that personnel work in a safety and hazard-conscious man nor in compliance with the operating instructions. 10 1.5 Selection and qualifica- tion of operating and maintenance personnel [a] 1.6 Safety instructions for installation and disas- sembly [a] ‘The owner must ensure that the hoist unit is only operated when in proper working Corder and that all relevant safety requirements and rogulatons are complied with, Hoist units must be taken out of service immediately if functional defects or regular ties are detected. Inthe event of a stoppage (@.9. If defects regarcing safe and roliable ‘operation are dotected, in emergncy situations, in the event of operating malfunc- tions, for repairs and maintenance purposes, if damage is detected or after finishing ‘work, the operator/experiencad technician must carry out al prescribed safely meas Ures. Personal protective clothing must be worn as necessary or as recuited by regu- lations. Personnel must not wear loose clothing, jewellery including rings or long hair loose, Injury may occur, for example, by boing caught or drawn into the mechanism All safety and hazard information and recommendations on the hoist uit, e.g, at ‘access ponts end mains connection switches must be maintained in complete and legible condition. inching (6. ging short pulses to the motor) must always be avoid- ed. Emerganoy limit stop dovices (8.9 sipping clutch or emergency lmit switch) must ‘Rot be approached in normal operation. ‘Modifications, additions to and conversions of the hoist unit which may impair safoty in any way must not be carried out without the written consent of Mannesmann De- ‘matic. This also applies to the subsequent installation of safety devices 2s well as for performing welds on load bearing parts. Safety devices must not be rendered inoper- ative, (Only genuine Mannesmann Dematic spare parts and accessories may be used. Observe prescribed deadiines or those specitied in the operating instructions for rou- tine checksinspections. For independent operation or maintenance of the hoist unit the owner may only em= Ploy persons: * who are at east 18 years of age, ‘© who are mentally and physically sutable, ‘= who have been instructed in the operation or maintenance of the hoist unit and have proven their qualification to the owner in this respect (in action to theoretical training, instruction also includes sufficient practical operating experiance as well ‘88 acquiring the abilty to identify defects which are a hazard to safe operation), *= who can be expected to cary out the work assigned to them reliably ‘The owner must assign operating and maintenance personne! ther relovant tasks. * Installation and dlisassembly work may only be performed by experienced techni- cians. * Installation and disassembly work must be coordinated by the person carrying out ‘the work and the owner within the scope of their responsi. © The working and danger zone must be made safe, ‘+ The installation must be isolated in accordance with the relavant electrical regula tons. * Customer-spectic reguations must be observed. + Only appropriate, tested end calibrated tools and equipment may be used, *+ The electrode holder and earth must be connected to the same asserily when weiding work is carried cut. I the current flow is retuned vi protective conduc- ‘ors, screening elements or anti-riction bearings, serious damage may be caused to these or other components. 1.7 Safety instructions when first putting the hoist into service after completing installation A 1.8 Safety instructions for operation AN ‘© The working area or danger zone must be made safe. ‘+ Fist check that the voltage and frequency specified on the deta plates match the: ‘owner's mains power supply. ‘All clearance dimensions and safety cistances (see approval drawing) must be checked before putting the hoist into service. ‘© When putting the hoist unit into service, it may be necessary to perform work in the danger zone. + Inthe course of putting the hoist unit into service, it may be necessary to tempo- ratily rencer safely devices or features inoperative. ‘+ It must be ensured that only trained personne! are employed for putting the hoist Unit into sarvice. “The operator must check the function ofthe brakes and emergency limit stop and emergency stop dovices before stating work. ‘A\ instructions and measures described in the operating instructions with regard 10 safe operation and items concerning general safety and accident prevention which have to be observed before, durng and after putting nto service must be strictly complied with, Any faiure to comply can lead to accidents resulting in ftaities, Hoist units must be taken out of sorvica immediately or not put into operation if any otects relating to operating safety and retabilly are detected. Safety devices must not be rendered inoperative or modified in contradiction to their intended use. COniy operate hoist units when all protective devices and safoty-relevant equipment, 8. movable protective devices and emergency-stop devices, are ited and fully ‘functioning, Anybody who identifies an immediate danger of personal injury must actuate the femergency-stop button without delay. Thi also apples in the cage of darnage occur- ring to parts ofthe instalation and equipment which makes immediate stoppage ‘necessary, After an “emergency-stop", the operator must not switch on and restart the hoist unit unti an experienced technician is satisfied that the cause which fed to actuation ofthis function has been rectified and that continued operation of the instal- lation constitutes no further hazard, Hoist units must be switched off mmeactately in the event ofthe folowing faults: ‘Inthe event of damage to electrical devices and cables as well as parts of the insulation ‘Inthe event of breke and safety device failure. ‘+ Ifthe lifting motion is switched cif during lifting ofthe load, this may indicate tig- ‘gering of the overfoad protection device. In this case, the iting motion must be intertupted and a ifted load must be immoaciately deposited. For a descration ofthe load measuring function, see enclosed documentation on load detectors. Ensure that nobody is endangered by operation of the hoist unit before switching on! putting into operation of the hoist unit If the operator notices persons who may be exposed to a risk to health or personal salety by operation ofthe hoist unit, he must suspend operation immediately and may ‘not resume operation again until the persons are outside the danger zone, Bofore puting the hoist unt into operation, the operator must be satisfied thatthe installation is in safe and correct operating condition. ‘Work on hoist units may only be carried out when instructions to this effect have been lesued, when operation and function ofthe hoist unit have been explained and when the working and danger zone has been made sate, Cooling devices, such as ventilation openings, may not be rendered permanently inoperative (e.g. covered or closed), ‘Special local concitions or special applications can lead to situations which were not known when this chapter was written. In such cases, special safely measures must be implemented by the owner. 1" 12 1.9 Safety instructions for maintenance Maintenance measures are defined as regular maintenance, inspection and repair work, ‘Mechanical and electrical ropairs and maintenance work may only be carried out by ‘appropriately trained personnel (experienced technicians} ‘Adjustment, maintenance and inspection activites and inspection deadlines including ‘specifications concerning replacement of parts/assemlies prescribed in the operat- ing instructions must be observed. Ensure that all electrical components are de-energized before commencing work on em [rao [wat | wit > [mito rep tealre nero ingloep tng [oop tingle it sn Hook eimension © nm __[ Hook mension © torseo-a2 | es-200 | 90 | se | soo | sao A briazs-ar2 | “cos | ooo _| oe | oro | 010 risi0-s0e | @6-200 [ea | a0 | soo | 00 oHei0 ‘os | _s0 | a9 | oo | 610 wste-690 [100-200 | su | aap} 580 | sw | Oasa0.01 | 100-200 | mao | m0 7 Di6#0- 620 |" 08 ooo | oo | oaasca | “as | so | seo D570 512 oH Si0- 308 gig | 100-905 | ass | ass | so | on eg | 0-908 | 7m | zo Dirsa2- 520, 110-200 ew | eo | _dusso-oao_| Wr | So | 0 | atone 1040 | Tagg” | 20 | 880 | Go | ceo [onst6-srzH2 Sale \ Heir sie-srane | 082 r DISTG- niece oes | rio-aos | 1120 | via | 700 | 7 | “SIS. SRR wo | 2.6.4 UDH Standard-headroom monorail hoist Trot Se Se an we Se wi wath wou wh who wah ‘ito exeoitiog | cxevlitng | cep itieg | ceepiting ceep'tiog | coop iting Hook cimension Hook cimension © ores | — 1080 1190 ‘50 3 : busi0-05_| 180 4220 980 1040 F425 412] —1oe0 1100 20 60 7 : i410 4180 4220 990 1010 Drss2-505 | —ta90 1200 Toss iio Daaa0-32 | Tos Toe : ousie-si2_| 1465 446s 00 iieo__| _oa3i0-308 | 4120 1120 ‘r1980-e20 | — i200 ‘290 65 iio] ora29-a12 os 7070 DHsi6 rd 446 1140 180 Diai6 4120 1130 Diss - 59] —ra00 i220 to | SH 1089-1080 | s645 1800 400 vaso |_onsie-5i2_| 1420 1330 Delton 1025 | 18s 1038 1480 1635 | “orto 520 | —ta00 1220 ‘oHi6 120 120 eoroszai 21 EZDH/RS: Fig. 6. EZLDH/RS soasontesoe seas 2.6.5 EZOH/RS double-rail crabs ‘Wheel beck S125 ope roving am a an ae wih ‘cat va woul wih wot ep iting ep iting roep thes coi ceepiing

    You might also like