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Operating instructionsCranes

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Contents 1. Demag cranes operating instructions 206 764 44Foreword

2. Demag cranes operating instructions 206 765 44Safety instructions

3. Demag cranes operating instructions 206 768 44OperationTaking the crane out of serviceWeather influence and dirt accumulation

4. Demag cranes operating instructions 206 769 44Maintenance

5. Demag cranes operating instructions 206 770 44Service and spare part supply

6. Demag cranes operating instructions 206 771 44Disassembly and disposal

7. Demag cranes operating instructions 206 772 44Sound pressure levelElectromagnetic compatibility EMC

8. Demag cranes operating instructions 206 773 44Detailed drawing and inspection documents

9. Demag cranes operating instructions 206 774 44Packing and storage

10. Demag cranes operating instructions 214 737 44Technical data, see crane test and inspection bookletTechnical descriptionAssembly and installationPutting into service for the first time following installationSample checklist

Title Ident. no.

Demag cranes operating instructionsForeword

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You have purchased a Demag crane.

This crane was manufactured in accordance with German and Europeanstandards and regulations and state-of-the-art engineering principles,e.g. EC Machinery Directive 98/37/EC.

Demag cranes are of modular design. The main assemblies include:

• Crane bridge

main girders

end carriages

motors

gearboxes

• Crab/travelling hoist

load handling attachments

hoist unit

trolleys

motors

gearboxes

• Electrical equipment

power supply system

regulating equipment

control equipment

control switches

ground-level station

These operating instructions are designed to provide the owner with appropriateinstructions for safe and correct operation and to facilitate maintenance.

Every individual given the task of transporting, installing, commissioning, operating,maintaining and repairing our cranes and additional equipment must have read andunderstood

• the operating instructions

• the safety regulations and

• safety instructions in the individual chapters and sections.

The operating instructions must be available to the operating personnel at all times inorder to prevent operating errors and to ensure smooth and trouble-free operation ofour cranes.

These operating instructions must be treated confidentially. They should only be usedby authorized personnel. They may only be entrusted or made available to thirdparties with the prior written consent of Demag. All documents are protected withinthe sense of copyright law.

No part of this documentation may be reproduced, utilized or transmitted withoutspecific prior consent. Infringements are an offence resulting in obligatory compensa-tory damages. All industrial rights reserved.

Our after-sales service will provide you with all technical information on Demagproducts and their systematic application.

Should you have any questions regarding our products, please refer to one of ourafter-sales service stations, the relevant representative or to our main office.

Kindly quote the serial or order number (see test and inspection booklet, cranecapacity plate) in any correspondence or for spare part orders. Specifying this dataensures that you receive the correct information or the required spare parts. Thetelephone number of our head office in Wetter is given e.g. in the publication“Operating instructions Demag cranes, Service and spare part supply”.

Foreword

Manufacturer

Copyright

After-sales service

Demag Cranes & Components GmbH

P.O. Box 67 · D-58286 WetterTelephone (+49/2335) 92-0 · Telefax (+49/2335) 927676www.demagcranes.com

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Liability for defects These operating instructions must be read carefully before installing and puttingcranes into operation.We assume no liability for damage and malfunctions resulting from failure to complywith the operating instructions.Any liability claims for defects must be made by quoting the order number immedi-ately on detecting the defect.

Liability claims for defects are void in the event of:

• inappropriate use,

• faulty devices or equipment connected or attached to the system which are notpart of our scope of supplies and services,

• use of non-genuine spare parts and accessories,

• refurbishment or modification of the product unless approved in writing by Demag.

Wearing parts are not subject to liability for defects.

All technical information, data and instructions for operation contained in these oper-ating instructions were up-to-date on going to print and are compiled on the basis ofour experience and to the best of our knowledge.

We reserve the right to incorporate technical modifications within the scope of furtherdevelopment of the cranes which are the subject of these operating instructions. Theinformation, illustrations and descriptions contained in these operating instructionsare therefore only intended for information purposes.

The descriptions and illustrations contained in this documentation do not necessarilycorrespond to the scope of delivery or any subsequent spare part delivery, either; thedrawings and illustrations are not to scale.

Only documentation belonging to the actual order is valid.

We assume no liability for defects, damage and malfunctions caused as a result ofoperating errors, noncompliance with these operating instructions or omitted and/orinappropriate repairs and maintenance.

We expressly point out that only Demag spare parts and accessories approved by usmay be used. Accordingly, this also applies to other manufacturers’ parts supplied byus.

For safety reasons, the fitting and use of spare parts or accessories which have notbeen approved and unauthorized modification and conversion of the crane are notpermitted; we assume no liability for defects or damages resulting therefrom.

With the exclusion of any further claims, our liability for defects and liability obligationsfor any defects pertaining to the products supplied or faults in the documentationdelivered or any negligence on our part are exclusively based on the stipulations ofthe original contract. Any further claims, in particular any and all claims for damages,are excluded with the exception of legal claims in accordance with product liabilitylegislation.

Limitations of liability

Definitions Owner

Owners (employer, company) are defined as persons who own the crane and whouse it appropriately or allow it to be operated by suitable persons.

Operating personnel

Operating personnel are defined as persons entrusted by the owner of the crane withoperation of the crane.

Specialist personnel

Specialist personnel are defined as persons assigned by the owner to carry outspecial tasks such as installation, setting-up, maintenance and fault elimination.

Qualified electrician

Qualified electricians are defined as persons who, owing to their technical training,knowledge and experience of electrical installations as well as knowledge of the rele-vant standards, codes of practice and regulations, are able to assess the tasks givento them and to identify and eliminate potential hazards.

Trained person

Trained persons are defined as persons who have been instructed and trained for thetasks assigned to them and on the possible hazards resulting from incorrect handlingand who have been informed about the required protective devices, protective meas-ures, relevant regulations, codes of practice, accident prevention regulations andoperating conditions and who have proven their qualifications.

Experienced technician

Experienced technicians are defined as persons, who, owing to their technical train-ing and experience, have sufficient knowledge of cranes and are familiar with therelevant national industrial safety regulations, codes of practice, accident preventionregulations, directives and generally accepted engineering standards enabling themto judge the safe operating condition of cranes.

Assigned expert engineer (in the Federal Republic of Germany according toUVV BGV D8 § 23 (VBG* 8) for determining the S.W.P.)An assigned expert engineer is defined as an experienced technician specificallyassigned by the manufacturer to determine the remaining duration of service(service life) and to carry out the general overhaul of serial hoists (S.W.P. = safe work-ing period).

Authorized expert engineer (in the Federal Republic of Germany according toUVV BGV D6 § 28 (VBG 9)).

In addition to the expert engineers of the Technical Supervisory and InspectionBoard, an authorized expert engineer for the inspection of cranes is defined as anexpert engineer authorized by the Industrial Employers’ Mutual Insurance Associa-tion.

Cranes

Cranes are systems used for lifting, lowering and moving loads. This definition alsoapplies to rail-mounted lifting equipment.

* VBG = German Industrial Employers’ Mutual Insurance Association responsible for the prevention of accidents

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Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.



Demag cranes operating instructionsSafety instructions

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Safety instructions

Symbols

Appropriate use

The following symbols and recommendations indicate potential safety hazards orcauses of damage or provide useful information.

Hazard warning

This symbol appears in the operating instructions next to all instructions relating tosafety at work wherever a potential hazard to life and limb exists.

Follow these instructions at all times and be particularly careful and cautious.

Pass on safety instructions to all persons entrusted with working on the crane, therunway and the power supply system.

In addition to the safety instructions, observe all general safety regulations at all times.

Warning against electrical hazards

Contact with live parts can result in immediate death. Protective covers (e.g. coversand enclosures) marked with this sign may only be opened by qualified electricians.Before opening, all relevant operating, control, feed or other voltages must be dis-connected.

Warning against suspended load

Any person remaining in this danger zone may suffer serious injury or death.This applies in particular to non-positive locked load handling attachments e.g. mag-net and vacuum systems. In each case the special safety and operating instructionscontained in the operating instructions for the load handling attachment in questionmust be complied with.

Operating hazard for the installation

This symbol in the operating instructions indicates all warnings which, if not compliedwith, may result in damage to the crane or the load.

Cranes are only intended for lifting, lowering and moving loads and may be used bothas stationary or travelling units.

Cranes may only be operated when in perfect working order by trained operatingpersonnel in accordance with the relevant safety and accident prevention regulationsand codes of practice. This also includes compliance with the operating and mainte-nance conditions specified in the operating instructions. It is assumed that the linevoltage and frequency at the power feed to the crane is within the permissible toler-ances according to DIN IEC 38.

Cranes are industrial equipment designed to be operated with rated voltages of up to1000 V. Any use exceeding the scope of the operating conditions specified in theoperating instructions and/or agreed in the contract between manufacturer and own-er is not permitted.

Power feed is via a power supply system (mobile cables, open or enclosed conduc-tor systems, cable drums). These systems are live up to the terminals of the mainswitches (mains connection switch, isolating switch) (see fig. 411 270 44). The rele-vant main switches must be switched off and secured when maintenance/repair workis carried out.

During operation or when main switches are not switched off, electrical componentsinside enclosures, motors, switchgear cabinets, terminal boxes, etc., carry dangerousvoltages, which can cause potentially fatal injuries.

Serious personal injury or damage to property may occur in the event of:

• unauthorized removal of covers,

• inappropriate use of the crane,

• incorrect operation,

• insufficient maintenance,

• exceeding the maximum permitted load(The rated load capacity/S.W.L. is the maximum permitted load. Pay attention tothe sum of the load to be lifted and the load handling attachment.),

• working on live parts.

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41127044.eps

Mains connectionswitch on the cranerunway (workshop,building)

Isolating switchfor drives

Isolating switch formagnet installations withstand-by battery

Contactor

Current collector

Switch

Push-button

Fuse link

Crane switchMain contactor withremote actuation

-K012

Power supply systemConductor linesFlat cablesCable drum

After actuating an EMERGENCY-OFF switch or an EMERGENCY-STOP button inthe event of danger, such switches/buttons must not be reset until the cause of thedangerous situation has been eliminated.

Crane power feedSwitch and main switch arrangement(single-pole arrangement shown)

Example

3/PE-TN-S-system according to DIN VDE 0100 Part 300(control and special voltages are generated viatransformers)1 mains connection switch (emergency off/emergency stop)2 power supply system3 isolating switch for drives4 isolating switch for special circuits5 isolating switch for magnet installations6 control pendant (emergency stop button)

EMERGENCY-OFFquickest-possible switchoff in the event of unex-pected danger(s)

EMERGENCY-STOPstops a dangerousmovement

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Isolating switchSpecial circuit forlighting equipment,temperature controldevices,...

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Prohibited practices Certain work and practices are prohibited when using the crane as they may involvedanger to life and limb and result in lasting damage to the crane, e.g.:

• Unsafe load handling (e.g. swinging the load).

• Handling suspended loads above persons.

• Pulling or dragging suspended loads at an angle.

• Pulling free fixed or obstructed loads.

• Exceeding the maximum permitted load and permitted load dimensions.

• Leaving suspended loads unsupervised.

• Running load-supporting means (chains and ropes) over edges.

• Using load-supporting means (chains and ropes) as a load bearing sling.

• Subjecting the control pendant to inappropriate mechanical loads

• Allowing loads to drop when the load-supporting means are in a slack condition.

• Failing to pick up loads from a solid base, but, for example, from a load handlingattachment.

• Transporting persons, unless lifting devices are specifically approved for transport-ing persons.

• Manipulating electrical equipment.

Persons under the influence of drugs, alcohol or medicines which affect reactionsmust not install, operate, put into service, maintain or repair cranes.

Any conversions and modifications to the installation must meet safety requirements.Work on electrical equipment of cranes may only be carried out by qualified electri-cians in accordance with electrical regulations. In the event of malfunctions, craneoperation must be stopped, switched off and the relevant main switches lockedimmediately. Defects must be rectified immediately! The crane may not be put intooperation again until the cause of the defect has been rectified.

National accident prevention regulations and codes of practice and general safetyregulations must be observed when operating our cranes. Important information andinstructions are marked by corresponding symbols. Follow these instructions and/orsafety regulations in order to avoid accidents and damage.

The operating instructions must be kept available at the place where the crane is inuse at all times.

They include significant aspects and appropriate excerpts from the relevantguidelines, standards and regulations. The owner must instruct his personnelappropriately.

Any failure to comply with the safety instructions stated in these operating instruc-tions can result in death or personal injury.

Observe general statutory and other obligatory regulations relating to accident pre-vention and environmental protection and basic health and safety requirements inaddition to those included in these operating instructions. Such requirements mayrelate, for example, to the handling of hazardous materials or the provision/wearing ofpersonal protection equipment. Comply with these regulations and general accidentprevention regulations relevant for the place at which the crane is used and follow theinstructions therein when working with the equipment. The crane may still constitutea danger to life and limb if it is installed, operated, maintained or used improperly bypersonnel that have not been trained or specially instructed.

The operating instructions must, if required, be supplemented by the owner withinstructions and information (e.g. factory regulations) relating to organization of work,working procedures, operating personnel, etc. Supervising and reporting obligationsas well as special operating conditions must also be taken into consideration.

General safety information

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Personnel assigned to working with the crane must have read and understood theoperating instructions and, in particular, the chapter on safety information. All activi-ties relating to cranes which are not described in these operating instructions mayonly be carried out by specialist personnel specifically trained for the particular crane.

The owner must ensure that personnel work in a safety and hazard-consciousmanner in compliance with the operating instructions. The owner must ensure thatthe cranes are only operated when in proper working order and that all relevant safe-ty requirements and regulations are complied with.

Cranes must be taken out of service immediately if functional defects or irregularitiesare detected. In the event of a stoppage (e.g. if defects regarding safe and reliableoperation are detected, in emergency situations, in the event of operating malfunc-tions, for repairs and maintenance purposes, if damage is detected or after finishingwork), the operator/experienced technician must carry out all prescribed safetymeasures (e.g. for cranes operating outdoors, ensure wind drift safety catch is fitted)or observe that they are automatically carried out.

Personal protective clothing must be worn as necessary or as required by regula-tions. Personnel must not wear loose clothing, jewellery including rings or long hairloose. Injury may occur, for example, by being caught or drawn into the mechanism.

All safety and hazard information and recommendations on the crane, e.g. at accesspoints and mains connection switches must be maintained in complete and legiblecondition. Inching must always be avoided. Emergency limit stop devices (e.g. slip-ping clutch or emergency limit switch) must not be approached in normal operation.

Modifications, additions to and conversions of the crane which may impair safety inany way must not be carried out without the written consent of Demag Cranes &Components. This also applies to the installation and adjustment of safety devices aswell as for performing welds on load bearing parts. Safety devices must not berendered inoperative. Only genuine Demag Cranes & Components spare parts andaccessories may be used. Observe prescribed deadlines or those specified in theoperating instructions for routine checks/inspections.

For independent operation or maintenance of the crane, the owner may only employpersons

• who are at least 18 years of age,

• who are mentally and physically suitable,

• who have been instructed in the operation and maintenance of the crane and haveproven their qualification to the owner in this respect (in addition to theoreticaltraining, instruction also includes sufficient practical operating experience as wellas acquiring the ability to identify defects which are a hazard to safe operation),

• who can be expected to carry out the work assigned to them reliably.

The owner must assign operating and maintenance personnel to their relevant tasks.

Selection and qualificationof operating personnel

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Safety instructions forinstallation and disassembly

Safety instructions whenfirst putting equipment intoservice after completinginstallation

• Installation and disassembly work may only be performed by experiencedtechnicians.

• Installation and disassembly work must be coordinated by the person carryingout the work and the owner within the scope of their responsibility.

• The danger zone must be made safe.

• The installation must be isolated in accordance with the relevant electricalregulations.

• Customer-specific regulations must be observed.

• Only appropriate, tested and calibrated tools and equipment may be used.

• The electrode holder and earth must be connected to the same assembly whenwelding work is carried out. If the current flow is returned via protective conduc-tors, screening elements or anti-friction bearings, serious damage may be causedto these or other components.

• The working area/danger zone must be made safe.

• First check that the voltage and frequency specified on the data plates match theowner’s mains power supply.

• All clearance dimensions and safety distances (see approval drawing) must bechecked before putting the equipment into service.

• Work may need to be carried out in the danger zone when putting the crane intoservice.

• In the course of putting the crane into service, it may be necessary to render safe-ty devices or features inoperative when carrying out adjustments or functionchecks.

• It must be ensured that only trained personnel are employed for putting the craneinto service.

• To compensate any settling, all bolted connections must be tightened one to twomonths after first putting the crane into service.

The operator must check the function of the brakes and emergency limit stop devic-es before starting work.

All instructions and measures described in the operating instructions with regard tosafe operation and items concerning general safety and accident prevention whichhave to be observed before, during and after putting into service must be strictlycomplied with. Any failure to comply can lead to accidents resulting in fatalities.

Cranes must be taken out of service immediately or not put into operation if anydefects relating to operating safety and reliability are detected. Safety devices mustnot be rendered inoperative or modified in contradiction to their intended use.

Only operate cranes when all protective devices and safety-relevant equipment, e.g.movable protective devices and emergency-stop devices, are fitted and fullyfunctioning.

Anybody who identifies an immediate danger of personal injury must actuate theemergency-stop button without delay. This also applies in the case of damage occur-ringto parts of the installation and equipment which makes immediate stoppage neces-sary.

After an “emergency-stop”, the operator must not switch on and restart thecrane until an experienced technician is satisfied that the cause which led toactuation of this function has been rectified and that continued operation ofthe installation constitutes no further hazard.

Safety instructions foroperation

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Cranes 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 theinsulation.

• In the event of brake and safety device failure.

• In the event of damage to the

– hoist ropes

– hoist chains

– load hooks

– load handling attachments

– other components in the power train

If the lifting movement is switched off while the load is being lifted, this may indicateresponse by the load detector. In this case a load already lifted must be depositedimmediately. For a description of the function “Load measuring”, see the enclosedpublication “Load detectors”.

Before switching on/putting into operation of the crane it must be ensured thatnobody is endangered by operation of the crane.

If the operator notices persons who may be exposed to a risk to health or personalsafety by operation of the crane, he must suspend operation immediately and maynot resume operation again until the persons are outside the danger zone.

Before putting the crane into operation, the operator must be satisfied that the instal-lation is in safe and correct operating condition.

Work on cranes may only be carried out when instructions to this effect have beenissued, when operation and function of the crane have been explained and when theworking and danger zone has been made safe. Cooling devices, such as ventilationopenings, may not be rendered permanently inoperative (e.g. covered or closed).

Special local conditions or special applications can lead to situations which were notknown when this chapter was written. In such cases, special safety measures mustbe implemented by the owner.

Maintenance measures are defined as regular maintenance, inspection and repairwork.

Repairs and maintenance work may only be carried out by appropriately trained per-sonnel (experienced technicians).

Adjustment, maintenance and inspection activities and inspection deadlines includingspecifications concerning replacement of parts/assemblies prescribed in the operat-ing instructions must be observed.

Ensure that all electrical components are de-energized before commencing work onelectrical installations and devices. When all work on the crane has been completed,operation of the crane must not resume until the owner has given approval to thiseffect.

Unauthorized persons must be prohibited from carrying out work on machinery orparts of the crane. Before starting all repair and maintenance work, cranes must beswitched off, taken out of operation and secured (switches must be locked) againstaccidental or unauthorized putting into operation (restarting).

It must be ensured that

• the crane is switched off and checked that it is de-energized and, in special cases,isolated,

• moving parts are stationary and stopped,

• moving parts cannot start moving while maintenance work is being performed,

• the power supply cannot be accidentally restored as long as the crane has beentaken out of service for maintenance and repair purposes.

• Ensure that operating and auxiliary materials as well as spare parts are disposedof in a safe and environmentally sound way.

Safety instructions formaintenance

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Instructions for repair work in the course of operation

The danger zone must be marked off with red/white safety chains or safety tape andindicated with warning signs.

In each individual case, the owner or the person specified by him must checkwhether the relevant work may be carried out in the course of operation without riskof personal injury owing to the particular local conditions.

Use only calibrated and appropriate tools and auxiliary materials for maintenance andrepair work.

If there is a risk of objects falling, the danger zone must be made safe.

Maintain a sufficient safety distance to moving or rotating parts to prevent clothing,parts of the body or hair becoming entangled.

Avoid naked flames, extreme heat and sparks in the vicinity of cleaning agents andflammable parts or parts liable to deformation (e.g. wood, plastic parts, oil, grease)as well as in electrical installations – noncompliance may result in fire hazard.Harmful gases may evolve or insulation may be damaged.

Additional instructions for maintenance work on electrical equipment

Only use genuine fuse links with specified amperage and tripping characteristics.

Defective fuse links must not be repaired or bridged and must only be replaced byfuse links of the same type.

Switch off the crane immediately in the event of electrical power supply malfunctions!

Work on the electronic and electrical components or equipment may only be carriedout by qualified electricians.

If inspection, maintenance and repair work is to be carried out on parts of cranes,these must – if prescribed by regulations – be isolated. First verify the safe isolation ofthe parts from the supply before commencing work.

The electrical equipment of the crane must be inspected and checked at regularintervals. Defects, such as loose connections, damaged cables and worn contactorsmust be rectified immediately.

Since it is possible that after a longer period of operation the switching points ofrelays (time, frequency and monitoring relays) change due to ageing of the compo-nents, the relay switching points in circuits relevant to safety must be checked atregular intervals.

Electrical equipment must be replaced as a preventive measure on reaching the limitof its theoretical duration of service (service life).

If work has to be carried out on live parts, a second person must be available in orderto actuate the emergency-stop button or mains connection switch/isolating switch forvoltage disconnection in an emergency.

The second person must be familiar with resuscitation measures.

Only use insulated tools!

Before disconnecting and connecting electrical plug-and-socket connections,always disconnect them from the supply (this does not apply to mains connections,provided they do not represent a dangerous contact voltage in the sense of thesafety regulations).

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Prescribed crane safetyfeaturesSafety features covered by the ECmachinery directive

• In accordance with the EC machinery directive, our hoists with a lifting capacity ofat least 1000 kg have an overload protection feature.

General

• Buffers at the ends of crane girders and runways designed accordingto DIN 15018

• Brake devices for all drives, active also in the event of mechanism standstill,emergency stop, emergency off and power failure

• Hoist units for handling molten masses:Hoist units fitted with two separate brakes. Hoist units for permitted load capaci-ties up to 25 t only have to be fitted with one brake if the normal operating loadcapacity does not exceed 2/3 of the permitted load capacity

Cranes with floor-level control

• For max. long and cross-travel speeds up to 63 m/min

• Lockable mains connection switch (on the runway)

• Lockable isolating switch (on the crane)

• Remotely-controlled crane switch main contactor in conjunction with a lockableemergency-stop button

• Emergency limit switch for highest and lowest hook position

• Operating limit switch for highest and lowest hook position if the end positions areapproached in normal operation (must be possible to check function of the emer-gency limit switch)

• Long and cross-travel limit switches if the limits of travel are approached in normaloperation

Additional requirements for cranes with remote control

• Recommended long and cross-travel speeds less than or equal to 80 m/min(higher speeds are possible)

• Long and cross-travel limit switches to switch off fast travel speeds before limits oftravel are reached

• Warning device

Additional safety features which maybe present depending on operatingcriteria (examples)

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Demag cranes operating instructionsOperationTaking the crane out of serviceWeather influence and dirt accumulation

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Operation

Prevention ofaccidents

Control devices

Obligations of the operator

Control unitFloor control – remote control

Picking up loads

Observe relevant national safety regulations and codes of practice whenoperating and maintaining the crane.

In the interests of safety, therefore, it is essential that these regulations and codes ofpractice are explained carefully to all persons assigned to operating/maintainingcranes.

The safety regulations and codes of practice must be available to the operator at alltimes.

Observe the following instructions and recommendations.

• The operator must check the function of the brakes and emergency limit stopdevices – with the exception of slipping clutches – before starting work.

• The operator must visually inspect the crane for obvious defects.

• The operator must pay attention to the assignment of the control device and cranein the case of remotely controlled cranes.

• The operator must inform the safety officer/supervisor responsible and his succes-sor when crane operators are changed about all defects.

• The operator must stop operation of the crane immediately if any defects whichprejudice safety or endanger the crane/crane equipment are detected.

• Control devices must only be actuated from the cab/control position.

• The crane must not be parked above or below sources of heat.

Switch the crane on by unlatching the emergency-stop button(crane switch actuation).

The operator must ensure that

• all control devices are in zero position before enabling the energy supply to thedrives,

• the control devices are in zero position and the energy supply is disabled beforeleaving the cab/control position,

• the remote control unit is secured against unauthorised operation (switching-on)before putting the unit down.

The operator selects the lifting and travel motions, and if necessary the functions ofthe additional facilities, by means of the control unit. The control unit must be treatedwith care. Recharge the rechargeable batteries of remote control units in good time.

Higher loads than those specified on the safe working load plate must not bepicked up.

The deadweight of load handling attachments which are not a permanently connect-ed integral part of the crane is part of the payload. When attaching the load, ensurethat loads are picked up in such a way that they cannot accidentally fall over, fallapart, slide or roll away. In this context, refer to the relevant regulations and codes ofpractice pertaining to the application and loading of chain and rope slings.

The operator must not move loads attached by hand until he has received a clearsign from the person attaching the load, the marshaller or another responsible per-son appointed by the owner.

If signals have to be used for communication with the operator, they must be agreedbetween the person responsible and the operator.

The operator must not handle loads if he recognizes that they are not appropriatelyattached.

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Observing the loads

The operator must keep the control unit within hand´s reach as long as a load issuspended from the crane.

End positions which are limited by emergency limit stop devices or slipping clutchesonly must not be approached in normal operation.

If the hoist operating limit switches fail and the emergency limit switches areapproached, the hoisting or lowering motion and the crane switch main contactor areswitched off (double-circuit system).

A load already lifted can then only be deposited by additionally pressing the“Emergency limit switch check” button.

The fault must be eliminated before starting up the crane again.

Press the emergency-stop button immediately if the lowering speed is too high (falling load), which may occur in the case of malfunctions. Stop crane operation untilthe fault is completely eliminated. If possible without danger, safely deposit loadsbeforehand.

The operator must guide push-travel and semi-driven cranes in such a way that hecan bring travel and slewing motions to a stop without danger.

The operator must observe the load or, in the case of no load, the load handlingattachments during all crane movements. If it is not possible to observe the load orthe load handling attachments, the operator may only control the crane in accord-ance with the signs given by a marshaller. This does not apply to program-controlledcranes. The operator must give warning signs as required. The operator should nottransport loads above persons. He must not transport loads above persons whenusing load handling attachments which retain the load by means of magnet, frictionor suction forces without an additional load securing device.

The crane and crab are fitted with elastic buffers to limit the forces transmitted bythe crane and/or crab when approaching the long or cross-travel limit stops and/oradjacent cranes/crabs.

Adjacent cranes and crabs or travelling hoists are also fitted with appropriate elasticbuffers. The condition of buffers must be inspected regularly (cracks and lastingdeformation indicate that they no longer function correctly).

Move the crane to the predetermined parking position on finishing work.

Set down and switch off load handling attachments such as grabs or magnets.

Finally, switch the crane off and engage the wind drift safety devices, if fitted(see also section “Taking the crane out of service on finishing work”).

Buffers

Finishing work

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Taking the crane out of service

Emergency-stopbutton

Taking the craneout of service onfinishing work

Taking the craneout of service formaintenance andrepair purposes

It must be possible to interrupt the electrical power supply to all drive units from theoperating position. This is done by actuating the emergency-stop button in conjunc-tion with the crane switch (load switch), with the exception of facilities such as e.g.magnet systems.

The operating personnel must interrupt the power supply to the crane on finishingwork. The installation must be isolated from the mains power supply by turning off themains connection switch.

Cranes which are periodically exposed to the wind must be parked in the building onfinishing work.

Cranes operating exclusively outdoors are equipped with wind drift safety deviceswhich must be engaged during longer crane downtimes and on finishing work. Seealso chapter “Weather influence and dirt accumulation”.

The mains connection and/or isolating switches (when two or more cranes operateon the same runway) must be switched off and secured against accidental andunauthorized restoration of the power supply when maintenance and repair work isperformed. Also refer to the “Safety instructions” chapter.

Engage the wind drift safety device on cranes which are exposed to the wind.

Following completion of maintenance and repair work, operation of the installationmust not resume until the owner has given approval to this effect.

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Weather influence and dirt accumulation

General

Cranes sometimes operatingoutdoors

Our cranes are intended for use in the following operating conditions:

• Ambient temperatures of 0 to 40° C

• Air humidity up to 80%

• Installation height up to 1000 m above sea level

Other operating conditions are possible after clarification of the measures required tobe taken.

Crane operation must be stopped if safe crane operation (controlled handling ofcrane, load handling attachments and load) can no longer be guaranteed due toadverse weather conditions.

First deposit loads safely.

During thunderstorms it is forbidden to walk on crane runway(s) and crane(s). It is alsoforbidden to leave the cab, if fitted.

A wind drift safety device is not necessary for cranes operating mostly indoors andonly some of the time outdoors.

When a storm or strong winds are approaching, the operator must move the craneinto shelter in the building in good time.

Cranes operating all or most of the time outdoors are equipped with wind drift safetydevices. The wind drift safety device(s) must be engaged on finishing work, duringlonger interruptions to work or when a storm or strong winds are approaching.

Cranes operating outdoors should be kept under shelter when not in operation.

For safety reasons all runways must be kept clear of oil, grease and/or dirt, as suchcontamination impairs the start-up and braking of cranes and trolleys.

For the same reason all runways must also, if necessary, be cleared of ice and snowbefore starting operation.

Check the function of current collectors and the power supply before starting up and,if necessary, de-ice them in a disconnected state.

Viscous oil (e.g. in gear units) impair or prevent crane or trolley start-up. De-ice frozenbrakes on lifting and travelling drives before starting work or, if necessary, after longdowntimes and apply the brakes “warm”.

Precautionary measures to ensure safe crane operation are the responsibility of theowner.

Cranes operating outdoors

Influence of weather anddirt on runways


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050503 EN/PDF 206 769 44 720 IS 100

Demag cranes operating instructionsMaintenance

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Maintenance

If required, our after-sales service will carry out maintenance of your cranes. In thiscase, we recommend you conclude an inspection agreement.

These operating instructions must be used to identify deviations/damage which couldimpair regular crane operation.

Observe the contents of the “Taking the crane out of service for maintenance andrepair purposes” section in the “Taking the crane out of service” chapter whenperforming maintenance and repair work.

The specified inspection intervals apply to cranes in single-shift operation. Craneswhich are used in multiple-shift operation or which are exposed to special ambientconditions in hardening shops, galvanizing facilities, casting shops, etc. requireshorter inspection intervals.

The stress group and group of mechanisms classifications are documented in thecrane test and inspection booklet.

The prescribed regular daily checks and inspections are not included in these operat-ing instructions. These specifications are included in the operating instructions of thecomponent assemblies fitted.

Maintenance work must only be performed by specialist personnel.

Training by the manufacturer is required for some maintenance activities.

The electrode holder and earth must be connected to the same assembly whenwelding work is carried out. If the current flow is returned via protective conductors,screening elements or anti-friction bearings, serious damage may be caused to theseor other components.

Crane component assemblies to be inspected are listed as follows, e.g.

• crab with hoist unit and travel carriages

• crane bridge with end carriages

• control system

• regulating devices

• control devices

• control unit

• power supply system

• crane runway

Other component assemblies, if fitted, are documented separately and must bechecked.

To compensate any settling, all bolted connections must be tightened one to twomonths after first putting the crane into service.

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Crane bridge

Crab or travelling hoist Refer to these operating instructions on the following pages for maintenance instruc-tions with inspection intervals. Furthermore the relevant standards and regulationsmust be complied with.

The component assemblies fitted are listed in the “Technical description” chapter ofthe individual cranes.

The hoist units and travel carriages used are standard Demag products which requirelittle maintenance.

Components which are subject to wear (brakes, ropes, load hooks, etc.) mustbe checked and inspected as specified in the relevant operating instructions andrepaired as required.

Inspection intervals are applicable for single-shift operation.

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Control system Observe the relevant international and national electrical codes of practice andregulations to maintain the entire electrical equipment in good working condition.

According to these codes of practice and regulations, power supply systems witha nominal voltage up to 1000 V must be inspected by a qualified electrician atsuitable intervals.

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travel wheels/wheel flanges.

To compensate any settling, all bolted connections must be tightened one totwo months after first putting the crane into service and during routineinspections.

Crane runway

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050503 EN/PDF 206 770 44 720 IS 100

Demag cranes operating instructionsService and spare part supply

Service and spare part supply

Manufacturer Demag Cranes & Components GmbH


Please specify the following information when contacting the After-sales ServiceDepartment:

Order number, serial number, year of manufacture.

Orders for spare parts should be addressed to your local Demag subsidiary oragency.


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050503 EN/PDF 206 771 44 720 IS 100

Demag cranes operating instructionsDisassembly and disposal

Disposal Waste materials resulting from assembly, installation, maintenance, repair anddisassembly work must be disposed of appropriately and in accordance withthe relevant laws, regulations and codes of practice.

Disassembly Observe relevant safety regulations and codes of practice when disassemblingDemag cranes, see also “Safety instructions” chapter.

Disassembly may only be carried out by appropriately instructed personnel.

The owner must appoint a person to supervise the disassembly work, issue instruc-tions and monitor the measures to be carried out.

Isolate the installation in accordance with the relevant electrical regulations andcodes of practice.

Secure the disassembly area to prevent adjacent cranes accidentally being driven intoit and mark off with barriers at floor level.

Replace the gear unit air vent screws by plug screws.

Only use reliable tools and disassembly tools, equipment and auxiliary materials (alsosee the “Assembly and installation” chapter).

If the crane is to be used again, select tools for disassembly and carry out thedisassembly work so that no damage occurs.

Refer to the approval drawing for the weight of the crane.

To avoid danger of accidents, disassembly is carried out in reverse order to assem-bly, also see the “Assembly and installation” chapter of these operating instructions.

Disassembly work must not commence until all persons concerned have beeninformed.

After completion of the disassembly work, the owner or the person assigned by himmust give approval for further use of the working area.

Demag Cranes & Components has experienced specialist personnel and equipmentavailable.


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050503 EN/PDF 206 772 44 720 IS 100

Demag cranes operating instructionsSound pressure levelElectromagnetic compatibility EMC

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Sound pressure level ofcranes

Sound pressure level

41120044.eps

Measuring point

Sound source

Sound pressure reduction inrelation to distance to sourceof sound

1 m

4 m

-3 dB(A)

-6 dB(A)

2 m

Table for logarithmic addition of twosound pressure levels

The sound emitted by the drives on the crane does not exceed the sound pressurelevel of 85 dB(A) permitted at the operator’s workplace.

Approximate calculation

The total sound pressure level of a crane is calculated from the sound pressure levelsof the individual components such as,

• hoist unit

• cross-travel drive(s)

• long-travel drives

• further individual components such as slewing gear, for example, depending onthe mode of operation

Calculation of the total sound pressure level of the crane is based on the soundpressure levels specified in the operating instructions of the individual components.The sound pressure level of the individual components is measured according toDIN 45635.

Influence of distance to source of sound on the sound pressure level

To take structural influences into account, for example the reflection of sound wavesfrom walls, a reduction of approx. 3dB(A) in the sound pressure level is calculatedeach time the distance to the source of sound is doubled (empirical value in normalenclosed areas).

Sound pressure level summation

Several sources are measured in such a way that pairs of sound sources are takentogether to be measured in stages and added logarithmically to make up a sum totallevel.

Further sound sources can then be added logarithmically to the previously calculatedsum total level.

Add the sound pressure level increase calculated from the sound pressure leveldifference to the largest previously calculated sound pressure level.

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Total sound pressure level for the crane installation = 75.4 dB(A)

Explanation

1) Superimposition of hoist unit and cross-travel drive (a + b)

Calculated difference: 72 dB(A) - 68 dB(A) = 4 dB(A)

This difference according to the table for logarithmic addition results in a soundpressure level increase of ∆ dB(A) = 1.5 dB(A) over the higher level.

This results in a total sound pressure level for the hoist unit and cross-travel unit of(72 dB(A) + 1.5 dB(A) = 73.5 dB(A) (a).

2) Total sound pressure level of the long-travel units (c)

Both long-travel units have a sound pressure level of 68 dB(A). According to thetable for logarithmic addition, this results in a sound pressure level increase of3 dB(A). Therefore, the total sound pressure level for the long-travel units amountsto (68 dB(A) + 3 dB(A) = 71 dB(A) (b).

3) Superimposition of [(a + b) + (c)]

Calculated difference: 73.5 dB(A) - 71 dB(A) = 2.5 dB(A)

This, according to the table for logarithmic addition, results in a sound pressurelevel increase of ∆ dB(A) = 1.9 dB(A) over the higher level.

4) Total sound pressure level of the crane:

The total sound pressure level is ultimately calculated to be73.5 dB(A) + 1.9 dB(A) = 75.4 dB(A)

Example for calculating the total sound pressure level of a crane installation

Crane span 12000

Cross travel unit (b)

Hoist drive (a)

Long-travel drive (c) Long-travel drive (c)

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1) Single sound pressure level2) Sum of sound pressure levels for two long-travel drives

Consequences for cranes

New European guidelines for electromagnetic compatibility.

Electromagnetic compatibility (EMC) is defined as the ability of an electrical or elec-tronic device to function without failure in an electromagnetic environment withoutinfluencing other devices or causing interference in the surroundings beyond certainlimits.

When investigating the electromagnetic interference which is caused by operating anelectrical device or which may affect it, a distinction is made between sources ofinterference and potentially susceptible devices. A source of interference is a genera-tor (transmitter) of electromagnetic interference which is either directly emitted ordissipated to the environment via cables and wiring. A source of interference may be,for example, switched inductivity in a contactor, an electronic device (pulse-controlledAC converter) or lightning. A potentially susceptible device absorbs part of the elec-tromagnetic energy and suffers interference or may even be damaged. Many elec-tronic devices are both sources of interference and susceptible devices.

EMC regulations and standards specify a maximum level of interference which anelectronic device must not exceed as a source of interference when installed andused in a certain environment, or against which the device must be resistant.

All equipment supplied or put into service as of 1 January 1996 which meets therequirements of the EMC guideline must be marked with the CE conformity symbol ofthe European Union. The basis for the declaration of conformity are the documentedEMC measurements which have to be compiled within the scope of the quality assur-ance system. They must document that the product or alternative product meets thespecified requirements in accordance with the EMC guidelines. This documentedqualification has to be proven each time the product is modified. To achieve thespecified EMC, manufacturers are required to fit devices with filters or to providescreening.

Plant and switchgear manufacturers and owners are obliged to design and implementinstallations in line with EMC requirements. Unavoidable interference energy must bedissipated directly to earth (ground). Coupling must be avoided as far as possible.

In state-of-the-art electronic systems, more and more devices are being used whichoperate at low voltages and high pulse frequencies. Additional HF interferencesuppression measures are required for these installations. Allowing for EMC as earlyas possible saves costs. The implementation of decoupling measures in good time isalso important as measures which are not allowed for at the planning stage areimpossible to create at a later date.

Therefore, before an item of equipment or an installation is built, a concept must bedeveloped which defines the interfaces and includes the quantitative specifications forthese interfaces.

This is simply general information and recommendations which should be taken intoconsideration.

Detailed information can be found in the relevant electrical engineering standards andregulations.

Electromagnetic compatibility


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050503 EN/PDF 206 773 44 720 IS 100

Demag cranes operating instructionsCrane inspections

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National inspection regulations must be observed.

The accident prevention regulations for cranes specify that an inspection must becarried out by an expert engineer before first putting the crane into service as well asafter substantial modifications. They also regulate routine inspections.

The instructions for carrying out inspections refer to the accident prevention regula-tions for winches, hoists and towing devices, according to which the already elapsedpercentage of the theoretical safe working period stated by the manufacturer forcrane hoist units must be allowed for.

The results of the inspections must be documented in the crane test and inspectionbooklet.

The already elapsed percentage of the theoretical safe working period stated by themanufacturer must also be documented in the crane test and inspection booklet.

Cranes are machinery in accordance with the European Machinery Directive98/37/EC.

It specifies possibilities for the manufacturer to fulfil his obligations within the frame-work of the EC conformity declaration in compliance with Annex V of Directive98/37/EC.

Technical competence for inspections lies within the responsibility of the manufacturerand the owner.

Comprehensive inspections before putting the crane into operation for the first timeare required for the procedural steps described in directive 98/37/EC.It is the task of the manufacturer to employ experts for this work, i.e. experts of thecrane manufacturer or experts in compliance with § 28 of the accident preventionregulations for “Cranes” (BGV D6).

Type, scope and execution of inspections

The inspections must be based on the general safety and health requirements of di-rective 98/37/EC, harmonised European standards, and if these are not available, onthe accident prevention regulations for “Cranes” (BGV D6), the referenced accidentprevention regulations and the generally accepted engineering standards.

Inspections when putting the crane into operation for the first time

Inspections when putting the crane into operation for the first time comprise:

Preliminaryinspection: The expert engineer determines whether the crane has been de-

signed and calculated so that appropriate use for the planned serv-ice life is possible without any hazard of personal injury.

It should also include:

- Classification and load assumptions

- Calculation procedures and information on the forces to bedissipated

- Material selection,

- Stability verifications (if applicable)

- Compliance with the basic health and safety requirements ofEC directive 98/37/EC

- Checking the layout drawing for compliance with the calculationdocuments

- Checking the circuit diagrams (electrical, hydraulic and pneuma-tic equipment)

Inspection regulationsInspection regulations for the FederalRepublic of Germany

Crane inspections

Inspection of cranes

1. Inspections within the responsi-bility of the manufacturer

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Type test: During the type test, the authorized expert engineer verifies thatquality control has been effective and that the crane has beenmanufactured in accordance with the documents checked in thepreliminary inspection.

It should also include checks of:

- Compliance of the components production with the engineeringstandards,

- Reports / documents of non-destructive tests and requiredwelders certificates,

- Works test certificates / certificates, parts lists for materials,certificates, etc.

Inspection when putting the crane into operation for the first time:

This inspection applies to cranes that are delivered not ready for operation, i.e. whichhave to be erected or integrated.

Inspection of cranes must be carried out in accordance with § 25, section 2 of theaccident prevention regulations for ”Cranes” (BGV D6) by an expert engineer in ac-cordance with these accident prevention regulations (BGV D 6, § 28).

This inspection covers appropriate erection, equipment and readiness for operation, i.e. items which do not fall under the machinery directive, such as

- crane access ladders not fitted on the crane, access ladders tocontrol stations,

- platforms and walkways not fitted on the crane,

- crane runways, rail systems and runway limit stops,

- working and traffic areas as well as safety distances.

The expert engineer must also verify that

- the planned rated and test loads are safely picked up and

- the resulting forces can be dissipated,

- the crane operates without fault and the safety devices are ef-fective.

Acceptanceinspection: Acceptance inspections must be carried out on cranes that are

ready for operation, in the case of bridge cranes at the locationwhere they are erected or integrated. It must be ensured that dur-ing the inspection no persons are subject to any avoidable hazard.

After completion, erection or integration, the authorized expertengineer confirms that the crane has been manufactured, erectedor integrated appropriately, the planned rated and test loads canbe safely picked up and resulting forces can be dissipated, thecrane operates without fault and the safety devices are effective.

The inspection after substantial modifications is carried out in accordance with § 25,section 2 of the accident prevention regulations for ”Cranes” (BGV D 6).

The routine inspections of cranes are carried out in accordance with § 26 of the sameaccident prevention regulation.

Release for operation following the acceptance or commissioning inspection is con-firmed by the expert engineer in the crane test and inspection booklet, in the CE con-formity declaration with the additional specification of the test loads used.

2. Inspections within the responsi-bility of the owner


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050503 EN/PDF 206 774 44 720 IS 100

Demag cranes operating instructionsPacking and storage

Appendix

Packing and storage The drives and electrical equipment are packed in foil (in accordance with theshipping instructions) when cranes are transported on trucks or on open wagons.

For sea transport on trailers or wagons, cranes are also completely covered bytarpaulins.

Packing and shipping for export are carried out in accordance with the relevantexport packing regulations.

For interim storage, ensure that the cranes are kept indoors and are protected fromdamp.

Compliance with and execution of more wide-ranging packing and storage instruc-tions will be effected subject to agreement.


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Demag cranes operating instructionsTechnical data, see crane test and inspection bookletTechnical descriptionAssembly and installationPutting into service for the first time following installationSample checklist

050503 EN/PDF 214 737 44 720 IS 100

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Demag cranes are overhead lifting equipment constructed of standardised compo-nent assemblies. Their steel structure is designed and built according to DIN 15018and other relevant standards.

Technical description

41097844.eps

6,3t

3 22

3

7

6

5

75 1

4

Main component assemblies of Demag cranes

6

8

41124244.eps

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3

2 8 1 4 75 56

ELKE

EDKE

1 Crab or travelling hoist with drive 4 Control pendant 7 Electrical equipment crane2 Crane girder 5 Power supply system 8 Electrical equipment crab3 End carriage with drive 6 Crane runway – with hoist limit switch

– with load detector



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65548

EKKE

EKKE





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All component assemblies of Demag cranes are described in these operatinginstructions.

Refer to the type designations and sizes in the approval drawing and, if applicable,the crane test and inspection booklet in order to find the individual component as-semblies in the enclosed publications more easily. Here you can also find informationon the classification of the crane supporting structure and the hoist unit.

The enclosed documentation has been compiled to match your crane installation.

41272945.eps

ZKKE

General

5

6

7 5 3 64

3 2 2 1 8

ZKKW

Katze SW.tif

1 Crab with drive 4 Control pendant 7 Electrical equipment crane2 Crane girder 5 Power supply system 8 Electrical equipment crab3 End carriage with drive 6 Crane runway – with hoist limit switch


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The steel structure of the single/double-girder crane is designed according toDIN 15018. For classifications, see the approval drawing and the crane test andinspection booklet.

The crane girder and the travel units are connected by high-tensile bolts.

The perfect crane alignment geometry – essential for good operating characteristics –is guaranteed by exact measurement and precise adjustment in the factory.

The main girders are rolled sections (ELKE) or box-section welded steel constructionswhich are bending and torsion-resistant.

The crab or travelling hoist runs on the bottom flange of the main girder.

For the technical description, see the enclosed operating instructions.

The crab or travelling hoist runs on the upper flange of the main girder.

For the technical description, see the enclosed operating instructions.

The crab or travelling hoist runs on two rails mounted on the top flanges of the gird-ers. For the technical description, see the enclosed operating instructions for thedouble-rail crab.

Depending on type, the crab is driven by a central drive or by an individual travel drive(see approval drawing).

Refer to the approval drawing and the crane test and inspection booklet for the travelunits used and to the relevant enclosed operating instructions/component parts listsfor a technical description.

Crane girder

Monorail crab

Double-rail crab

Cantilever crab

Long travel units

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at floor level with a control pendant or remote control

Refer to the approval drawing and the test and inspection booklet for the type ofcontrol system fitted to the crane.

Crane control system

Mobile floor control

41127244.eps

Remote control

41127344.eps

Fixed-point floor control

This mobile floor-level control pendant can travel along the crane girder and is locat-ed independently of the crab. It allows the operator to move freely, to avoid obstaclesand to maintain safety distances at an optimum position in relation to the load. Thistype of control is suitable for travel speeds up to 63 m/min (applies to the FederalRepublic of Germany).

Remote systems allow the operator to control the crane from any position. In additionthe operator can adopt the most suitable position to observe the load and avoidhazardous areas.

This type of control is suitable for travel speeds up to 80 m/min (applies to theFederal Republic of Germany).

The fixed-point floor control system is used where the operating or travel path runsparallel to the crane runway. In this case direct load guidance by the operator is notalways possible.

This type of control should be used only for cranes with small span dimensions andis suitable for travel speeds up to 63 m/min (applies to the Federal Republic ofGermany).

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The contents of this chapter must be read and noted before assembly andinstallation!Refer to “Safety instructions for installation and disassembly” in the“Safety instructions” chapter.

A coordinator must be appointed before assembly and installation. Knowledge ofinstallation procedures and appropriate tools are absolutely essential for carrying outassembly and installation work.

Modifications to our component assemblies require our prior written approval. Theelectrode holder and earth must be connected to the same assembly when weldingwork is carried out. If the current flow is returned via protective conductors, screeningelements or anti-friction bearings, serious damage may be caused to these or othercomponents.

Assembly and installation work may involve an increased risk of accident.We recommend you have assembly and installation work carried out by our trainedspecialists.

Process cranes should only be installed by or with the support of Demag.

The condition of this crane when delivered depends mainly on the crane span dimen-sion and the length of the end carriages. Cranes with a maximum span of 20 m or amaximum end carriage length of 3 m are normally supplied assembled complete withthe crab/travelling hoist and cabling and wiring fitted.

Cranes with a span of more than 20 m and end carriages measuring more than 3 mare supplied as component assemblies such as:

••••• crab/travelling hoist complete

••••• crane end carriages with attached travel drives

••••• main girder (with attached walkway, if fitted) with housing for electrical equipment,if fitted

••••• mounting elements (C-rails, clamps, bolted connections) for power supply andisolating switches.

Based on VDI directive 3576, issue 10/86, point 5 “Assembly and installation toler-ances for crane runway(s)”.

The existing crane runway must correspond to the dimensions for tolerancecategory 2.

Assembly and installation

Delivery

Crane runway tolerances

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First place the main girder on beams at a height at which the travelling hoist can bemounted on level ground. In addition, refit the travelling hoist power supply and themobile control system which may have been removed for transport reasons.

Secure the main girder against falling over – risk of accident

The counterbores in the end carriages and the compensating washers fixed in themain girder must be free of rust, dirt, oil, paint and other contaminants prior toassembly.

In accordance with the stencilled assembly marks, place the end carriages in positionagainst the main girder and secure them.

Use a pin to check alignment of the bore holes for the high-tensile bolted con-nections (never use fingers – risk of injury).

Fit a high-tensile washer onto each high-tensile steel bolt included in the scope ofsupply and insert the bolts into their respective holes from the inside by passing themthrough the access holes in the end carriages. Fit the second high-tensile washer toeach bolt and ensure that the bevelled side of the washer faces the bolt head/nut.

Then tighten the nuts using a torque wrench to the tightening torques specifiedin the table.

Lost or damaged high-tensile bolts, high-tensile nuts and high-tensile washersmust only be replaced by items bearing the high-tensile symbol (HV) accordingto DlN standards 6914, 6915, 6916 and material designation as illustrated(see chapter high-tensile bolted connection).

Make sure that

• black bolts are only used with black nuts and black high-tensile washers,

• galvanized bolts are only used with galvanized nuts and galvanized washers as aset from one manufacturer.

Place a washer under the head of each bolt and under each nut as indicated inchapter “High-tensile bolted connection”.

Ensure that the side of the washer stamped with HV faces away from the bolthead or the nut to avoid cracks forming in the bolts.

Assembling thecrane suppliedas componentassemblies

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For tightening torques, see table “High-tensile bolted connections” page 13

Only permanently marked connecting elements with the following DIN designa-tions may be used:

Preferred range M 16 (black).

1) Hexagon bolt M 16 x 85, DIN 6914Property class 10.9 HVDemag part no. 316 098 99

The mounting position of the screws depends on the crane type and varies,see adhesive label on the end carriage

2) Washer 17 x 37 x 4, DIN 6916Property class C 45 V HVDemag part no. 316 211 99

3) Hexagon nut M 16, DIN 6915Property class 10 HVDemag part no. 316 207 99

Bevel under bolthead


41780544.eps

Bevel on nutside

Bevel on nutside

2

23

1

HV mark

Bolted connectionsEnd carriages with top connection

The mounting position of the screwscan vary, i.e. depending on modeland crane type, the screws can befitted from the top or bottom.

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For tightening torques, see table “High-tensile bolted connections” page 13

Bevel on nut side

Bevel on nut side



HV mark

Distance washers (4) are tacked to the main girder.

65120644.eps

Only permanently marked connecting elements with the following DIN designa-tions may be used:

Preferred range M 20 (black).

1 Hexagon bolt M 20 x 85 x 46, DIN 6914

Property class 10.9 HV

Demag part no. 316 160 99

1 Hexagon bolt M 20 x 190, DIN 6914



1 Hexagon bolt hex. close-tolerance bolt M 20 X 80, DIN 6914



2 Washer 21 x 37 x 8, DIN 6916

Property class C 45 V HV


3 Hexagon nut M 20, DIN 6915

Property class 10 HV


4 Distance washer 22 x 50 x 10,

Minimum tensile strength 520 N/mm2


1 2 4 2 3

End carriages with side connection

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Solid shaft bolts (without high-tensile bolts) with metric standard thread to DIN 13,part 13. Tightening torques to VDI 2230, sheet 1, July 1986.

For other friction coefficients see VDI 2230, sheet 1, table 1, page 70, July 1986.µtotal = 0,12 as average friction value in the thread.

Standardbolted connections

Friction values for material combinations

µk = friction value between bolt head and counter-surface

daerhT 5M 6M 8M 01M 21M 61M 02M 42M 72M 03M

ssalcytreporP euqrotgninethgiT

8.8

80,0kµ 3,4 4,7 81 63 16 541 003 015 057 0001

01,0kµ 9,4 5,8 5,02 14 17 071 053 006 088 0911

21,0kµ 5,5 9 32 64 97 591 093 076 0001 0531

41,0kµ 1,6 4,01 52 15 78 512 034 047 011 0051

9.01

80,0kµ 3,6 9,01 62 25 09 512 024 037 0701 0541

01,0kµ 3,7 5,21 03 06 401 052 094 058 0521 0071

21,0kµ 1,8 41 43 86 711 082 065 069 0041 0091

41,0kµ 9,8 5,51 73 57 031 013 026 0601 0551 0012

9.21

80,0kµ 4,7 5,21 13 16 501 052 005 058 0521 0071

01,0kµ 5,8 5,41 53 17 121 003 085 0001 0541 0002

21,0kµ 5,9 5,61 04 97 531 033 056 0211 0561 0522

41,0kµ 4,01 81 34 78 051 073 027 0421 0581 0052

Tightening torques

kµ lairetamdaehtloB lairetamgnihctaM

80,0 denrutrodesserp,kcalb,leetS yrd,tuc,thgirb,gMIA

1,0 delio,denrutrodesserp,kcalb,leetSdelioroyrd,desserp,dezinavlag,leetS

yrd,tuc,thgirb,leetSyrd,tuc,thgirb,STG/GG

21,0 yrd,desserp,kcalb,leetS yrd,tuc,thgirb,leetS

41,0 delio,desserp,kcalb,leetSyrd,desserp,dezinavlag,leetS

yrd,tuc,thgirbSTG/GGyrd,tuc,dezinavlag,leetS

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High-strength hexagon head bolts with large widths across flats for structural steelbolting according to DIN 6914 to 6918. With metric standard thread according toDIN 13, part 12 and 15 (supporting material steel).

1) Values to DIN 15018 part 1 page 20 of November 19842) Values to DIN 18800 part 7 page 3 of May 1983 and DAst 010 of June 1976

Assembly prestressing forces FM and tightening torques MA for locking bolts and nutsaccording to Works standard 011 891 99 and 011 892 99 (VERBUS RIPP systemand DURLOCK)

Rm = Minimum tensile strength in N/mm²

See relevant drawings and maintenance instructions for product-specifictightening torques.

High-strength boltedconnections

Verbus Ripp / Durlockbolted connections

daerhT ytreporPssalc

secrofgnissertserPFM Nkni

euqrotgninethgiTMA mNni

)1

deliodnakcalb

)2

desinavlagpid-tohhtiwdetacirbuldna

2SoM

)1

deliodnakcalb

)2

desinavlagpid-tohhtiwdetacirbuldna

2SoM

61M

9.01

3,39 001 482 052

02M 6,541 061 455 054

22M 1,081 091 267 056

42M 8,902 022 859 008

72M 8,272 092 0241 0521

daerhT ssalcytreporP dessertserPsecrof

FM Nni

MeuqrotgninethgiT A lairetamgnitroppusrofmNnileetS

uC21iDlADGGGG,GG²mm/N008<mR

5M

)9.01(001

0009 11 9 9

6M 00621 91 61 81

8M 00232 24 53 54

01M 00073 58 57 57

21M 00045 031 511 021

61M 000201 033 003 033

02M9.21

)KCOLRUD(009081 027 027 -

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The assembly tools and lifting tackle must be suitable for the deadweight of thecrane. Refer to the approval drawing for the weight.

An installation jig (fig. 651 207 44) clamped to the upper flange can be used forinstalling the crane.

Alternatively, nylon or wire rope slings appropriate for the weight of the crane mustbe used (ensure edges are protected).

Single-girder crane

65120744.eps

Double-girder crane

41127744.eps

The assembly tools and lifting tackle must be suitable for the deadweight of thecrane.

Alternatively, nylon or wire rope slings appropriate for the weight of the crane mustbe used. Refer to the approval drawing for the weight.

Use appropriate means to prevent the main girders being pressed together whenlifting double-girder cranes (ensure edges are protected).

Example for installing the crane on the crane runway

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Putting into service for the first time following installation

Adjust the limit switches to allow for run-on. Adjust any additional operating limitswitches fitted to hoist units so that they operate before the emergency limit switchescome into operation.

Optimize the factory settings of all adjustable control units to meet specific applicationrequirements. The settings must be entered into the circuit diagram by the personresponsible for commissioning and notification of the settings sent to the designdepartment of Demag.

Check the protective earth conductor along its entire length for correct marking andconnection.

Check that the fuse links fitted are of the correct amperage and have the correcttripping characteristics, see specifications in the equipment list.

Replace the plug screws of the gearboxes with the air vent screws provided.

When installation has been completed, check the clearance of the crane and crab ortravelling hoist along their entire length of travel.

Carefully check, for example, that the crane travels smoothly over splices in therunway, that the current collectors have good contact, that the power supply systemruns easily and that safety distances to parts of the building and machinery aremaintained.

To compensate any sagging, all bolted connections must be tightened oneto two months after first putting into service and during routine inspections.

SAM

PLE

Sample checklistCrane no._________________


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20676344_030505(cranes)

Documents

demag cranes

operating personnel

operating errors

operating instructionscranes2

safety instructions

prior written consent

crane test

safety regulations