8 Maintenance

8.1 Safety instructions The following sections contain a description of maintenance work that is necessary
for optimum and uninterrupted operation of the machine.

DANGER.
Live components

Electric current may cause danger to life and limb.

Work on electrical equipment may only be carried out by qualified personnel in
compliance with the safety regulations.

WARNING.
Risk of injury.

Inappropriate maintenance work may result in severe injury or damage

to property.
Maintenance work may only be carried out by authorised and instructed spe-
cialist personnel in compliance with all safety regulations.

WARNING.
Crushing hazard

Body parts can be crushed when loads are lifted or lowered.

When working on the machine, ensure
• that you do not enter the danger zone at any time and that no body parts/
limbs can be crushed during lifting or lowering operations.
• that there are no persons present in the immediate danger zone.

CAUTION.
Lubricants/oils

Risk of injury resulting from contact with the body/skin.

Oils and lubricants are a health hazard.
Contact with these media may result in serious damage to health (poi-
soning, allergies, skin irritation, etc.)
Pay attention to the manufacturer's safety data sheets and instructions.

CAUTION.
Risk of injury. Risk of slipping.

Leaking oils and lubricants are hazards due to the increased risk of slip-
© Demag Cranes & Components GmbH

ping.
Spilt oils and lubricants must be absorbed immediately by means of sawdust
or oil absorbent and disposed of in an environmentally compatible way.
Always:
1. Wear personal protection equipment.
2. Fence off the working area.
3. Before starting work, switch off the machine and secure it against switching on
again.
4. Switch off the power supply at the mains connection or isolating switch. Check
that the system is de-energised.
5. Ensure that there is sufficient freedom of movement.
6. Parts of the body can be crushed when working on the machine. Secure the
20694644.indd/100810

machine/machine parts against unintended movement and work with the utmost
care and caution.

55
 7. Keep the working area clean and tidy. Loose parts or tools left lying around may
cause accidents.
8. Reinstall safety devices as required by relevant regulations and check them for
correct operation after finishing maintenance work.
9. Only use genuine Demag spare parts.

8.2 Safety instructions for Maintenance measures are defined as regular maintenance, inspection and repair
work.
maintenance
Mechanical and electrical repairs and maintenance work may only be carried out
by appropriately trained personnel (experienced technicians).
Adjustment, maintenance and inspection activities and inspection deadlines includ-
ing specifications concerning replacement of parts/assemblies prescribed in the
operating instructions must be observed.

DANGER.
Live components

Electric current may cause danger to life and limb.

Work on electrical equipment may only be carried out by qualified personnel in
compliance with the safety regulations.
Ensure that all electrical components are de-energized before commencing work
on electrical installations and devices. When all work on the crane has been com-
pleted, operation of the crane must not resume until the owner has given approval
to this effect.
Unauthorised persons must be prohibited from carrying out work on machinery
or parts of the crane. Before starting all maintenance work, the crane must be
switched off, taken out of service and secured against accidental or unauthorised
operation (restarting). Ensure that all switches are locked.
It must be ensured that
• the crane is switched off, checked that it is de-energised 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 been
taken out of service for maintenance and repair purposes.
• operating and auxiliary materials as well as spare parts are disposed of in a
safe and environmentally sound way.

Instructions for maintenance work in the course of operation

© Demag Cranes & Components GmbH

The danger zone must be marked off with red/white safety chains or safety tape
and indicated with warning signs.
In each individual case, the owner or the person specified by him must check
whether the relevant work may be carried out in the course of operation without
risk of personal injury owing to the particular local conditions.
To avoid injury, only use calibrated and appropriate tools and auxiliary materials for
maintenance and repair purposes.
The danger zone must be fenced off if there is a risk of falling objects.
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 and
flammable parts or parts liable to deformation (e.g. wood, plastic parts, oil, grease)
in electrical installations – non-compliance may result in a fire hazard. Harmful
20694644.indd/100810

gases may evolve or insulation may be damaged.

56
 Additional instructions for repair work on electrical equipment
Only genuine fuse links with specified amperage and tripping characteristics may
be used.
Defective fuse links must not be repaired or bridged and must only be replaced by
fuse links of the same type.
Switch the crane off immediately if electrical power supply malfunctions occur.
Work on the electronic and electrical components or equipment may only be car-
ried out by qualified electricians.
If inspection, maintenance and repair work is to be carried out on parts of the prod-
uct, these must – if required by regulations – be isolated. First verify the safe isola-
tion of the parts from the supply before commencing work.
The electrical equipment of the crane must be inspected and checked at regular
intervals. Defects, such as loose connections, damaged cables and worn contactor
contacts must be rectified immediately.
Since the switching points of relays (time, frequency and monitoring relays) may
change due to ageing of the components after a longer period of operation, relay
switching points in circuits relevant to safety must be checked at regular intervals.
Electrical equipment must be replaced as a preventive measure on reaching the
limit of its theoretical duration of service (service life).
If work has to be carried out on live parts, a second person must be available to
actuate the emergency-stop button or mains connection switch/isolating switch in
order to disconnect the power supply 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, al-
ways 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 the
safety regulations).
© Demag Cranes & Components GmbH
20694644.indd/100810

57
 8.3 Taking the crane out of It must be possible to interrupt the electrical power supply to all drive units from
the operating position. This is done by actuating the emergency-stop button/switch
service in connection with the crane switch (load switch), with the exception of equipment
8.3.1 Emergency-stop button/switch such as magnet systems, for example.

8.3.2 Taking the crane out of At the end of work, the operating personnel must interrupt the power supply to the
service on finishing work crane. The installation is disconnected from the mains by switching off the mains
connection switch.
Cranes which are periodically exposed to the wind must be parked indoors at the
end of work.
Cranes operating exclusively outdoors are equipped with wind drift safety devices,
which must be engaged during longer interruptions and at the end of work. See
also section 3.8 “Operating conditions”.

8.3.3 Taking the crane out of The mains connection and/or isolating switches (when two or more cranes oper-
service for maintenance and ate on the same runway) must be switched off and secured against accidental and
repair unauthorised restoration of the power supply when maintenance and repair work is
carried out. See also chapter 2 “Safety instructions”.
Engage the wind drift safety device on cranes which are exposed to the wind.
Following completion of maintenance and repair work, operation of the installation
must not resume until the owner has given approval to this effect.

8.4 Regular inspections Cranes must be inspected by an experienced technician at least once a year. Reg-
ular inspections mainly consist of a visual inspection and a function check which
should include a check to determine the condition of components and equipment
regarding damage, wear, corrosion or other alterations and a check to determine
the integrity and efficiency of safety devices.
It may be necessary to remove parts in order to inspect wearing parts.
Load-bearing media and suspensions must be inspected along their entire length,
including those parts which cannot normally be seen. A function and brake test
with a load (test load that is close to the maximum permissible load capacity) must
be carried out.

i NOTE

Updating the test and inspection booklet

All inspections must be arranged and documented by the owner.

8.5 Maintenance schedule

i NOTE
© Demag Cranes & Components GmbH

The specified inspection and maintenance intervals apply to normal operating

conditions. If routine maintenance reveals that the intervals are too long, they
should be shortened according to the specific operating conditions.

Use only genuine Demag parts for repairs, see also section 1.6 “Spare parts”.
If required, our after-sales service can maintain your cranes. In this case, we rec-
ommend you conclude an inspection and maintenance agreement.
These operating instructions can be used to identify deviations/damage which may
impair regular crane operation.
See section 8.3 “Taking the crane out of service” when maintenance work is car-
ried out.
20694644.indd/100810

58
 The specified inspection intervals apply to cranes used in single-shift operation.
Cranes which are used in multiple-shift operation or which are exposed to special
ambient conditions, such as in hardening shops, galvanising plants, casting shops,
etc., require shorter inspection intervals.
The stress group and group of mechanisms classifications are documented in the
crane test and inspection booklet.
These operating instructions do not contain details of the daily and/or regular
checks and inspections. Refer to the corresponding operating/assembly instruc-
tions for the specific components (see co-relevant documents on page 2).
The electrode holder and earth must be connected to the same assembly when
welding 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
these or 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 pendant
• Power supply
• Crane runway
Other component assemblies, if fitted, must be checked according to their sepa-
rate documentation.

CAUTION.
Danger caused by loose connections

Loose connections are a danger to life and limb.

To compensate any settling, all bolted connections must be tightened one to
two months after the crane is first put into service and during routine inspec-
tions.

8.5.1 Check during operation

8.5.1.1 Travelling hoist Refer to the maintenance instructions and inspection intervals on the following
pages of these operating instructions, as well as the operating instructions of the
relevant hoist units (see co-relevant documents on page 2). In addition, any rel-
evant standards and directives must also be complied with.
The various sub-assemblies used are listed in the individual “Technical description”
© Demag Cranes & Components GmbH

sections of the relevant cranes.

The hoist units and travel carriages used are standard Demag products which
require little maintenance.
Components which are subject to wear (brakes, ropes, load hooks, etc.) must be
checked and repaired as specified in the relevant operating/assembly instructions.
The inspection intervals apply for single-shift operation.
20694644.indd/100810

59
 8.5.1.2 Crane bridge

Component Type of inspection Inspection criteria Inspection

interval
Months
3 6 12
Crane girder Visual check - check for mechanical damage,
- check weld seams for cracks x
- check corrosion protection
Travel rail/travel Àange Visual check - check for wear,
- check weld seams for cracks, x
- check Àange deformation
Limit stops Visual check - check for damage,
x
- check tight ¿t
Wind drift safety catch Visual check - check for damage,
- check tight ¿t, x
- Function check
Limit-switch cut-off Function check - check cut-off,
x
- check run-on path
Latching device Visual function check - see operating instructions x
Crane girder/end carriage Check tightening tor- - tightening torques/strength classes, see high-
bolted connections ques and strength class strength adhesive label near the bolted connec- x
tion for data
Connections/¿ttings Check tightening tor- - see section 3.5
ques x

Travel units Visual function check - see operating instructions of the components for
Flange wear maintenance instructions and inspection intervals x

© Demag Cranes & Components GmbH

20694644.indd/100810

60
 8.5.1.3 Control system The relevant international and national electrical codes of practice and regulations
must be observed in order to maintain the condition of the entire electrical equip-
ment.
Electrical power installations with a rated voltage of up to 1000 V must be in-
spected by an experienced technician in accordance with these guidelines and at
suitable intervals.

Component Inspection criteria Inspection inter-

val
Months
3 6 12
Isolating switch - check electrical function,
x
- check locking device
Crane switch/main - check actuation of emergency stop,
x
contactor - check main contactor cut-off
Control pendant - check for mechanical damage,
- check electrical functions, x
- check attachment of strain relief device
Wireless control systems - see manufacturer's operating instructions for maintenance x
Fuse links - check speci¿ed amperage and tripping characteristics,
x
- check close-tolerance bolts on screw cap for tight ¿t
Contactors - check for contact erosion,
- check connections for tight ¿t, x
- check easy movement of magnet system,
Transformers - check connections for tight ¿t x
Electrical components - check protective measures x
Control devices, electrical - check connections and devices for tight ¿t,
x
equipment - check electrical settings
Hoist limit switches, anti- - check function by approaching/tripping,
collision devices, by-pass - check run-on paths,
control system, reÀectors/ - check ¿ttings for tight ¿t,
x
light barriers - check correct connection orientation,
- regularly remove dirt accumulation (at shorter intervals, if required),
- carry out regular function checks (at shorter intervals, if required)
Load detectors - according to operating instructions x
Magnet installation, back- - maintenance according to operating instructions,
x
up battery, ¿ll level - Visual check
Warning devices - check functions,
- Visual check x

Drive control systems - see operating instructions

x
© Demag Cranes & Components GmbH

Timer, frequency, monitor- - check functions,

ing relays - check operating processes depending on time and frequency x
20694644.indd/100810

61
 8.5.1.4 Power supply

Component Inspection criteria Inspection

interval
Months
3 6 12
Power supply to the crane - refer to the operating instructions.for maintenance instructions x
Power supply line to the crab/ - refer to the operating instructions.for maintenance instructions
x
travelling hoist
Mobile control system - refer to the operating instructions.for maintenance instructions x
Fixed cabling and mobile - check for bearing damaged cables.
connecting leads - check union glands for tight ¿t and leaks.
- check connections on screw terminals/plug-and-socket connections for x
- tight ¿t.
check tight ¿t of strain relief device.
Warning and safety signs - condition
x
- legibility

8.5.1.5 Crane runway

Component Type of inspection Inspection criteria Inspection

interval
Months
3 6 12
Mains connection switch - check electrical function,
- check locking device x

Foundations Visual check - check for cracks in the Àoor x

Supports, brackets, Visual check/ - see section 3.6
travel rails, Àanges Tightening torques - check for cracks in welds, mech. deformation x

Rail joints Visual check - check for alignment and fastening. x

Track suspensions Visual check/ - check suspension rods for mechanical dam-
Tightening torques age,
x
- check securing elements of ball nuts,
- check connections
Limit stops Visual/function check - check for damage x
Corrosion protection Visual check x
© Demag Cranes & Components GmbH

The owner must be informed if inspection of the crane reveals excessive wear of
the travel wheels/wheel flanges.

CAUTION.
Danger caused by loose connections

Loose connections are a danger to life and limb.

To compensate any settling, all bolted connections must be tightened one to
two months after the crane is first put into service and during routine inspec-
tions.
20694644.indd/100810

62
 8.5.2 General overhaul

Activity Before first When Every 6 Once per

entering starting months year
service work

The general overhaul should coincide with the annual inspection On reaching the theoretical duration of service

Install crane-speci¿c Demag GO set X

8.6 Oil and grease

lubrication
8.6.1 Safety instructions
CAUTION.
Risk of slipping.

Leaking oils and lubricants are hazards due to the increased risk of slip-
ping.
Spilt oils and lubricants must be absorbed immediately by means of sawdust
or oil absorbent and disposed of in an environmentally compatible way.

i NOTE

Oil leaks/loss of oil in the course of operation may cause damage to or total
failure of the machine. If this occurs, stop the machine and notify Service.

8.6.2 Oil and grease filling All crane lubrication points are adequately greased. The gearbox is filled with oil.
Under normal operating conditions, the lubricant must be changed at least every 4
years.
Under exceptional operating conditions, such as at higher or lower ambient tem-
peratures, a type of oil used must be selected to match the specific temperature
conditions. Further information can be obtained from your local Demag contact.

i NOTE

Dispose of waste oil and grease in accordance with environmental protection

© Demag Cranes & Components GmbH

requirements.
If required, utilise the services of a waste disposal company.

For hoist unit oil and grease quantities, see:

Demag EKDR-Pro 3 - 10 rope hoist operating instructions 214 725 44
Demag EKDR-Com 3 - 10 rope hoist operating instructions 214 916 44
Demag EZDR-Pro 5 - 10 rope hoist operating instructions 214 961 44
Demag EZDR-Com 5 - 10 rope hoist operating instructions 214 965 44
Demag EZDR 20 rope hoist operating instructions 214 844 44
20694644.indd/100810

63
 8.7 GO general overhaul The owner is obliged to carry out a general overhaul when the theoretical duration
of service is reached (see “Regular inspections”, section 2.9).

WARNING.
Operating safety at risk.

Failure to carry out the general overhaul or carrying it out inappropri-

ately can lead to severe injury and/or damage to property.
Specified general overhaul intervals must be strictly complied with.

The theoretical duration of service D (hours at full load h) depends on the Group of
Mechanisms classification of the crane.
The owner must arrange for a GO general overhaul to be carried out when 90% of
the theoretical duration of service has elapsed. A general overhaul must be carried
out no later than when the end of the theoretical duration of service is reached.

i NOTE

During the general overhaul, the following parts must be replaced in addition
to the checks and work specified in the inspection and maintenance schedule.
• Gear wheels of the gearbox
• Gearbox bearings
• Motor
• Rope drum
• Gear oil
• Connecting elements
• Switchgear in the control system
See also section 8.5 and the corresponding information provided in the
operating/assembly instructions of the relevant components.

The small parts (screws, washers ...) to be replaced maintenance and assembly
work is carried out are not listed separately.
The general overhaul carried out by the manufacturer or a specialist company
authorised by him fulfills the condition for continued operation of the crane.
Therefore, the provisions of the relevant UVV accident prevention regulations and
BGV D8 are satisfied.
The installation may continue to be used when an expert engineer has certified
that the conditions for further utilisation have been met. Completion of the general
overhaul must be confirmed and a further period of utilisation in accordance with
© Demag Cranes & Components GmbH

FEM 9.755 must be entered.

i NOTE

The general overhaul may be carried out by Demag expert engineers or an

authorised specialist company.
The general overhaul carried out by the manufacturer or a specialist company
authorised by him fulfils the condition for continued operation of the machine.
20694644.indd/100810

64
 9 Sample checklist

Crane no._______________ Inspection regulations: see accident prev. regs BGV D6, VDE 0100 Part 726 and other relevant regulations
Notes

Power supply data: voltages, frequency (see approval drawing) checked

Bolted connections checked checked

in particular high-tensile bolts on the end carriage (high-tensile washers checked for
checked
correct ¿t: bevel facing the bolt head or nut)
Guide roller spacing adjusted, bolted connection (torque) checked checked
Buffers for crane, crab and track are ¿tted and in correct position as end stops checked
Crane and crab approach dimensions (see approval drawing) checked checked
Hook height (see approval drawing) checked, re-adjusted, as required checked

Gearboxes checked for leaks, air vent screws ¿tted checked

Chain/rope reeving, rope anchorage (rope wedge, rope clamp) checked checked
Chain/rope lightly oiled checked
Chain/rope and cable deÀectors ¿tted (if part of crane equipment) checked

Emergency and operating limit switches (lifting and lowering) adjusted checked
Long and cross-travel limit switches are adjusted (if applicable) checked
Optical crane anti-collision arrangement adjusted (if applicable) checked

E
Control pendant height and strain relief of Àoor control checked (if applicable) checked
Symbols on the control unit match the travel motions checked

PL
Direction symbols ¿tted (only for wireless controls)

Protective earth conductor checked for continuity, correct marking and connection
Cable entry glands correctly installed in contactor and terminal boxes
checked

Accessibility, marking and availability of “mains connection switch” & “emergency-off switch” checked
checked
checked
(if optimised, enter value into circuit diagram and
Control and regulating devices done
inform DCC)
M
(if optimised, enter value into circuit diagram and
Overload measuring system done
inform DCC)
(if optimised, enter value into circuit diagram and
Relay settings done
inform DCC)
(if optimised, enter value into circuit diagram and
Resistor settings done
inform DCC)
SA

Terminal strips (but no cage-clamp terminals) checked and tightened checked

Safety distances to other equipment and component parts are maintained checked
Check that there are no obstructions to track and power supply lines and their joints checked
Brake check carried out: Lifting and lowering (run-on allowed for) checked
Brake check carried out: Long and cross travel (run-on allowed for) checked
Speed checks: Lifting, lowering, long and cross travel checked

Crane signs (on crane and load handling attachments, payload included) checked
© Demag Cranes & Components GmbH

Paint ¿nish checked and reworked as required checked

Wind drift safety catch function (for outdoor cranes) checked checked
Cable drums (for cranes with load handling accessories) checked checked
(Strain relief, torque setting, travel direction, manoeuvrability, checked
cable length, 2 spare windings must be left on the drum in the lowest lifting position) checked
Warning devices (if ¿tted) checked
Insulation measurement
Earth-loop impedance measurement

Erection and assembly site/work area tidy (old parts & packaging disposed of as appropriate) done
Hand-over completed including power supply and permanently laid supply cable on:
Hand-over completed with temporary supply cable excluding power supply on:
20694644.indd/100810

Remarks:

Date: Name: Signature:

65
66
Notes

20694644.indd/100810 © Demag Cranes & Components GmbH

20694644.indd/100810 © Demag Cranes & Components GmbH

Notes

67