ar & & me KEMENTERIAN ENERGI DAN SUMBER DAYA MINERAL REPUBLIK INDONESIA DIREKTORAT JENDERAL MINYAK DAN GAS BUMI SERTIFIKAT KELAYAKAN PENGGUNAAN PERALATAN Nomor: 196/PA/SKPP/DJM.1/2014 Direktur Jenderal Minyak dan Gas Bumi berdasarkan: ‘Undang Undang Nomor 22 Tahun 2001; ‘Mijn Polio Reglement Stb. 1930 No. 341; Peraturan Pemerintsh Nomor 19 Tahun 1973; Peraturan Pemerintsh Nomor 17 Tahun 1974; Peraturan Pemerintah Nomor 11 Tahun 1979; eraturan Menteri Pertembangan dan Energi Nomor O6P/O7A6/M. PE/1981 Pasa 8, ‘Keputusan Direicur Jenderal Minyak dan Gas Bumi Nomor 84, K/S8/DJM/1998 Pesal 5 ayat 1; dan Buku Laporen Hasil Pemeriksaan Telmis oleh Perusahaan Jasa Inspeksi Teknik PT Survindotama Persada Gengan Cerlifcate of inspection No, 022/STP-EMOVTUCO!-MGCRIV/14 tanggal 21 Nei 2014, menyataken bahwa: PESAWAT ANGKAT engantteangan Sree een + xxonMobi Ok ndonesia nc. Kabel wire ope) 4. Pemikometel fccranal Stop: Pama” -Mangions = 128mm, (x8) FMRC, 2PL Chote TSi8 Sees jn G Nearer Trerteare Hoek Bec 30m smoust te | BiblePonbuat MRE Demag $tpetens | Ovemnad Crane k Hunames iteve/tere Lees 1 2otant bean span 170m mula gunakan tla cn derganbobon bag Panang Span Danae amy a eto Towable | ache | Brame | Sua toa) iT : . 2 35 ire ; c 30 : 3 iro pias a 35 2 dengan ketentuan: oe pesawat Angkat ini hanya dapat dioperasiken sesuai dengan beban kerja aman di atas oleh Operator dan Rigger yang telah mempunyai Sertfkat Bidang Miges: ~ Eegnitobil Ol indonesia Ine. beanggung jawab sepenunnya atas keselamatan pengoperesian peralatan Pesawat ‘Angkat tersebut; ~ ExponMobil Oi Indonesia Ine, harus memasang tabel beban dalam kabin sebagai petunjuk pengoperasian yang aman, ExoaMobil Oil Indonesia Ine, harus melakukan pemelinaraan dan pemeriksaan berkala terhadep Pesawat Angkat ‘sesuai peraturan perundang-undangan, spesifiasi teknis dan standar yang diac, - Badan Usaha/Bentuk Usaha Tetep yang akan menggunakan Pesawat Angkat ini, sebelum cigunakan harus Imelakukan pemesksaan temadep cipenuninya ketentuan peraturan perundangan yang beriaku, spesifiasi teknis ddan standar yang ciacu: dan - Sertifkat Kelayakan Penggunaan Peralatan Pesawat Angkat ini dapat dtinjau Kembali apatite cikemudian hav terdapat hanal yang menyebabken Pesawat Angkat tidak layak Gan tidak aman untuk dioperasikan, Diteritkan dt Jakarta ‘Tanggal 21 JUL 204 Beriaku sampai dengan : 21 Mei 2017 JR JENDERAL MINYAK DAN GAS BUMI JR TEKNIK DAN LINGKUNGAN KIGAS 4 198403 1001 \Se \-, Ss Ge Oe ie CP ee SS §S 23 EF Te 2 2 2aaa cl, APO Mechanical Dept. CRANE INSPECTION REPORT TAG NO. T-510. UP.NUMBER. —: 50168-S-012 _, _ CAP/YEAR BUILD : 3.0tons /1875 - 1976. SCHEDULED — : 22- Sept20t6. 4 MOD/SERNO — : EKP/775- 160-76. INSP. DATE, (04 - Oct-2016. J ceRTNO 196/PAISKPP/DIM-T/2014 USER/LOCT. — : 05-Apr2016: ancch Shep PLA CERT VALID: 21-May-2017 Remarks. 1. checked the Crane condition. 2. Checked Hoist Rope condition. 3, Tested hoisting and lowering system. 4 4, Tested chain link for long travelling system. t 6. Tested limit switches and safety devices function & operation. | WIRE ROPE SERVICE RECORD a i as me Recommended ‘The crane is acceptable for operation, ‘The Crane shall not be used for side pull and sudden acceleration of the moving lead. Only certified operator must operate the crane. j Daily check is required before the crane put into service. Crane InspectnTecnnicen ane inspection Technician (Owner Where in use Type designation Main hoist moter No. Seria! No. Creep hoist motor No. Soe a StenaruRe, Peel a boon bs eta aeosane Con iponent pans list for vravel cartieges fest ang Inspection Booklet for Electric Rope Hoist ‘Component Perts, Control Handle DS (10 4) verponent Parts, Control Handle DS (25 A) sonent Perts, Push Button Panel DWS2 Assembly Instructions for Control Handle DS 12011 DZM 81.10-001 ZE-91.81-007 DZE 91.81-008 OTE 91.81-006 DZM 91.81.03, “or erection, and before puttin: nation given on pages 4 to 13. urthermore, all relevant re dhered to. 9 your Demag gulations for elec: electric hoist type P into service, please read the infor- trical installation and prevention of accidents must beMe Assemblies 1.1. Motor ‘The Demag motor is a combination of elecitic motor and breke which operetes on the sliding cotor principle. is designed in accordance with the VOE specifications and with the design rules of the FEM, to meet the high demends made on electric hoists By fitting en intermediate reduction gear with brake motor an additional hoisting speed (1/10 of the main hoisting speed) car be obtained, Creep speed units may be fited at 2 later stage if required, 1.2. Reduction Gear The torque of the motor is transmitted to the reduction geer by means of a coupling which is flexible in both radial and axial directions. Load peaks are absorbed when the hoist is switched on and off. The closedthousing accommodetes all the gears, which are hardened, mounted on ball bearings, and rotate in an oil bath, Scumne Gaomeveosr 1.3. Rope Drive The drum, rope sheaves and rope comply with the FEM design rules, and with DIN stendard 15020. The load hook is provided with 2 safety catch. Ti drum is mounted at the centre on bell bearings 1.4. Combination of Main Assemblies ‘The central drive of the drum is one of the important features of this design. The casing and foot-carrying rings, which are adjustable for the ranges P 100 to ? 600, unite ihe motor fecuction gear, and rope drive. B different foot Positions and 8 rope leed-offs enable 64 com. = binations to be obteined. For the ranges P1000 = and P 1600, 2 different foot positions and {5 2 rope lead-offs ere normally available. = The new variable system enables 9 combination Fig. 5 Jof the assemblies themselves so. thet the coneet unit can be selected io sult any operating conditions E pe of enclosure is IP 5 in accordance with DIN $0050. The max. permissible ambient temperatures range irom —25" to +70" C. Fig.6 os ows Foot-mounted hoists FP Monorail hoists, standard headroom UP Monorail hoists, low headioom KP Double-rail erabs 2PEitvencow Clirmoveoey Ech Demag electric rope hoist is accompanied by 2 wiring diagram showing control date. Werk on electrical 2.1. Electrical Equipment e:uipmert must only be carried out by qualified electricians or rained personnel. Cut the mains supply off hela,” cimmencing work on the hoist, lation ofthe electric rope hoists complies in all espects with she intrnationel accident prevention regula. It must be ensured that this compliance is not defeated by unauthorized interference. The switchgear is designed for extreme conditions, its life. depends on how the equipment is operated. Operetors $*2ul6 be informed ihat they should avoid inching (i.e. giving shon impulses 10 the motor t0 obtain shor sees ents) 2s far a8 possible when lifting loads to prevent excessive contact burning and thus premature cesucceey of she switchgear. An adeitional creep epeed unit and 3 two-speed trevel motor are of eat assistance to oneen in avoicing impulse switching as far es possible, 22, Connection to the Supply First check whether the voltege and frequency stamped on the dete plate tally with thet of your mains supply voltage chenging motors are wited in our works for the voltage for which the hoist wes ordered. The motors ate -connerted fer the higher voltage if two voltages, e. g. 220/380 V. were specified in the order. If connecvon ie veers 6 1025 48 ses Pieri sere 18 io to as 2 1S ao were 4s to ts TS Pe - WERE 16 1010 S$ 3% 45 e iene te totes 8 = wre 2016 16 a8 48 ec pres is is ase 13 tones is teas 18 = Pa moors 3516 16 a8 97 as = Ptosiezoe = Gonore, 3s is is as ty 3S = roe non nore 3 ie i as 1738 rasrae wnonep a 2 2 «mas Peorer = Rnonsr 2 > > of 2S P28 = znoner 3 0 0 4 as Poors pa unaKar 50 2 2 6 as as as Peinpaxe — Feioparz = anaker oo 8 08 7g OE Peas Peveyraaoiraas 2enener $0 3 35 6 28 oN 38 + Prove;P 120 -Pot2 wnakee 6 8 50 10 9 4 ay a5 P1025/P 1032 P 616/P 620 2N2KEP 63 50 50 10 nu o4 7m 4 P1020 P 625/P 632 2eN2K4P 63 50 50 10 aos a7 ea, OF : 3020 wrycer 4 8 6 se . Plowyero2 anvase bo 6 3 is es 3g OR g Prose soso wenzKer 8 8 8 6 ow 6 og? | re ‘=o om274 28. 23. 2:10. 2101 2i1, 212, 213, 214, 3a 32 321. 322. 3.23, OQ wrmessuo ay |) Bireoctser Demag Electric Rope Hoist, Description of the Design Motor Reduction Gear Rope Drive Combination of Main Assembl Control Switches Models Putting the Demag Hoist Type P into Service Electrical Equipment Connection to the Supply Supply Line Cross Sections and Fuse Links Protective Conductor Direet Control DS Type Control Hendie Assembly Instructions fot OS Type Control Hanifle Contactor Controt Push Button Pendant DWSa Assembly Instructions for OWSa Push Button Pendants Lubrication Rope Reeving Methods Emergency Limit Switch Heavy-Duty and Emergency Limit Switch Emergency Limit Switch Adjustment Travel Carriages/Runways General Instructions Adjustment of Travel Carriages RU, HU EU Maintenance Maintenance Schedyle Wire Rope and Wire Ripe Tensioner Adjustment of she Tension Spring Coristruction, Application, and Reeving of Wire Ropes Fitting the Rope Tensioner Bottom Blocks and Guide Pulleys Brake Reduction Gears Ball and Roller Bearings Supporting Screws Limit Switches Rope Lead-off and Foot Position Creep Speed Unit ‘Subsequent Fitting of a Creep Unit to Hoists Special Tools Contents 4relat 1. Description of the Design The design of the hoists complies with the “Rules for the Design of Serial Lifting Equipment” issued by the Fégéra. wn DIN 100s, % "7 Marwtenton (FEM (Federation of European Handing Eauipment Manutotwrers ee, with DIN 15020. ‘The Demag electric hoist type P is with the FEM and DIN groups: s manufactured in six ranges, ech rnge comprising six variants in accordence Ranges 100 200 400 600 1000 1600 Fem. om 2 group rou Variants 212 425, Peay 18m 180 210 420 632 1050 1680 Ib 1m 120 208 216 625 ioe0 1683 ta ee 132 208 412 620 1032 1650 W 2h 135 205 410 616 1025 1620 u an 120 20 408 612 1020 1632 wv an ie 203 406 610 1016 1625 v an 12 4 167 18 1920 21222324 25 eae Driving shaft 10. Rope anchorage and wedge 17 Rotor return spring Gears and pinions 11 Coupling flexible in both” 18 Stator with whehegs Gear box radial and axial directions) 18_Sliding rotor Hollow shaft 12 Drum bearing support, 20° Limit switch and Foot-carrying ring, motor end terminal board gear bor end 13° Limit switch operating red. 21. Broke end coe Brom bearing suppor, with adjustable tappets 22. Broke cover gear bor end 14 Casing 23 Broke and fen gise Wire rope 18 Foot-earrying ring, 24 Broke fing with lining Rope guide and pressure ring motor end 25 Brake adjusting nut Rope drum 16 Motor-end cep.Main Assemblies 1.1, Motor The Demag motor is a combination of electric motor and brake which operates on the sliding rotor principle. Itis designed in accordance with the VDE specifications and with the design rules of the FEM, to mest the high demands made on efecttic hoists, By fisting an intermediate reduction gear with brake moter an additional hoisting speed (1/10 of the main hoisting speed) cen be obtained, Creep speed units may be fited at a later stage if required. 1.2. Reduction Gear / 3 The torque of the motor is wensmitted to the ceduction ila ti gear by means of e coupling which is flexible in both / 5 radial and axial directions, Eo te = Load peaks are absorbed when the hoist is switched on sree,’ Eleeeamrn fae 1 end off. The closed’housing accommodates al the gears, epee : i 6 which are hardened, mounted on ball besrings, and mel Tien. 7 18 rotate in an oll Bath ei Noemi 1.3. Rope Drive ‘The drum, rope sheaves and rope comply with the FEM design rules, and with DIN standard 15020. The ledd hook is provided with 2 safety catch. 7? drum is mounted at the centre on ball bearings, ‘i e res 1.4. Combination of Main Assemblies The central drive of the drum is one of the as $EES important features of this design. The casing ¢ and foot-carrying sings. which ate adjustable for the ranges P 100 10 P 600, unite the motor, reduction gear, and rope drive. & different foot positions end & rope leed-offs enable 64 com- | binations to be obteined. For the ranges P 1000 and P 1600, 2 different foot positions end 2 rope leed-ofts are normally available. The new variable sysiem enables 2 combination Sof the assemblies themselves so thet the Eicorrect unit can be selected 1 suit any operating conditions, Creep speed unit 51.5. Control Switches ‘The DS and DWSa control switches are designed for use fin industry according to VDE 0860, their protective in- sulation complies with VDE 0700, DIN 10050. The max. permissible ambient temperatures range rom —25" to +70" C. Foot-mounted hoists FP Monorail hoists, standard headioom UP Monorail hoists, low headroom KP Doubie-rail crabs 2° 321, Electrical Equipment Exch Demag electric rope hoist is accompanied by @ witing diagrem showing control Seeman! must only be carvied out by qualified electrician yoo mmencing work on the hoist. A ana of the electric cope hoists complies inal respects with the in national accicent prevention reguis. Toe must be ensured that this compliance is not defeated br unauthorized interference data. Work on electrical! ined Personnel. Cut the mains supply off bene 22. Connection to the Supply Fist check whether the vohage and frequency stamped on ihe ata plate tally with that of your m, Voltage changing motors are wired in ou s'ar-connerted for the higher voltage if tu 380 V. were specified in the ord, Cagrans eee Gwer voltage (e. 9. 220 V) the motorverminclons ae ene must be changed to dei C'aGram autached tothe inside of the switehgesr cove’ arene culled supply line sections and fuse links can be seen from rable hereunder. Please riot thst the length Soe SuPpY line specitied fore given cross secon rant meee rranreedilnlorderaa avolsiexceasheivoie Sig2 which might prevent the conical rotor of the mone none na ing Into tunsing position when the merase fine oor Re CFOs section can be cslevisted scooraine oe ie example printed below the tebie it the serole line is tonger than ingieated. Ines at ieBulations require tht it must be possible to disconnect all oles of flexible and sliding contact supply seg means ofa mains switch, The mains switch mucin eek ageinst unauthorized or accidental neater nei mounted in an easily accessible place near tothe Itting sea oe tors are If connection is itl as per wiring 1. Supply Line Cross Sections and Fuse Linke Delay action ross sections end max. lengins f main rain fuses Supply cas of copper st Svoagemen Nominl amstreges 3 Utor sing core fotor ‘2 under 2209 380" 500V 220V_sapy 5007 Version Version GUM | (utp. usen x L Type AC EA [iar = mit in Aoowt , aeas Pai6'P 930 bases e Waetete ate aa Pe Tlaasl yaa P25 P 125: 122 ere 18 10 10 as = were 16 10 100s = $e Sseiiol ia ees) ge = 15/6 Pe wo 25 as = fa ee Sr Velie ents pega = zee 306 gS = wes 20 38 18 oe = P 208 MAGr si 1 Ae (ae) asp: - Fae atendemere = a te | as = ree aomeaziops 25 ic is sae? ~ MnOKME | 25 30 ao a ae ~ BnoKsF 25 3 2 85 | a anoKar 25 2 2d P 610? 612 P 808 BING RAF "S01 a4 oe Pl gy os PeI8.P 620 Phe reegie kee (a Gs tae = § |S P 625 PAUP REE 50 ge * Pr016P i020 pera 2N2K2P 63 50 300 Promo esersm | dsnaxar os sp | fo 3 P1080 EeSiee | gitaKar os 60 eS = P 1020 BaTeeP 90 ws | te aa 23 = piooeie, | Ke? 6 om es ie eS if of Prosore 1080 Ze KEP a 6Conten Peg: 1. Demag Electric Rope Hoist, Description of the Design a 1.1. | Motor E 1.2, Reduction Gear 3 1.3. Rope Drive 3 1.4, Combination of Main Assemblies 3 1.5. Control! Switches 3 1.6. Models 3 2. Putting the Demag Hoist Type P - into Service 4 24. Electrical Equipment 4 2.2. Connection to the Supply 4 22.1. Supply Line Cross Sections and Fuse Links 4 23. Protective Conductor 5 2.4, Direct Control 5 28. 0S Type Control Handle 6 2.5.1. Assembly Instructions for DS Type Control Honisle 6 28. Contactor Centro! ? 27. Push Button Pendent DWSe 7 27.1. Assembly Instructions for DWSe Push Button Pendants 8 28. Lubsication 8 28.. Rope Reeving Methods 8 210. Emergency Limit Switch 10 2.10.1, Heavy-Duty and Emergency Limit Switch 10 2.411. Emergency Limit Switch Adjusiment 10 242. Travel Cerriagas/Runways 10 2.13. General Instructions " 2.14 Adjustment of Travel Carriages RU,HUEU 11 3. Maintenance 44 3.1. Maintenance Schedule 14 3.2. Wire Rope and Wire Ripe Tensioner 15 3.2.1, Adjustment of the Tension Spring 15 3.2.2. Coristruction, Application, and Reeving of Wire Ropes 16 3.2.3. Fitting the Rope Tensioner 18 3.3. Bottom Blocks and Guide Pulleys 20, 34, Brake 204 38. Reduction Geers 29 3.6. Ball and Roller Bearings 30 3.7. Supponing Serews 30 3.8. Limit Switches 20 Rope Lead-off and Foot Position x Creep Speed Unit 32 5.1. Subsequent Fitting of a Creep Unit to Hoists 32 Special Toots 3342.5.1. Assembly Instructions for DS Type Control Handle Work on-the control hendle must only. be carried out by a trained electrician, Loosen top protective cap (1) ‘with a screwdriver. Noiches, 210 provided in the e2p (1) for inserting e serewcriver. When sssembling, snap cap (1) into eH housing (2) 1 ensure complete insulation. f Tik retaining stieup (5) 52 Retease sieevical connections 2nd remove cam switch element (3). When fitting the DS contro! handle to an electric hoist with limit ewiteh: Remove the connecting bridges (i any) between terminals $1-$2 ang 71-72 from the cam switch element (3) en S| Lit housing (2). The eam switeh clement (3) in the handle (4) is easly accessibie from all ides Seal stiapert end of cable with insulating tape in order 1 prevent talcum powder coming out of the sheathing, Push pans 1, 2.18, 8 over special tlesibe pipe (13), Insert the clamping bush (8) into the pipe (13) and place {he reaining cove (11), an the ide opposite 10 the nui (10), ‘between pans (5) and (8). Assemble the pare 5. 8, and § By tightening the four screws Provided. Only use pans Brovides for toction relief of the control cabie, Eto For conneciifn 10 the electric hoist end tor contro cable rection relief proceed os, follows: screw in threaded bush (95), push special Hesible pipe (13) over threaded bush (18), snd See ste with hose clip (16). ‘Secure the fexible cebie (7) by tightening grub serew (17) (for reliet from trsetion causec by control cable ceadweign:)ost oo lain nonst —man wses Supply ines oF coppet at am oitape de. varia cana rat Nominal amperages 4 U forstering cute under mov 360V SOV 20Vseov —_soov Version version version (aun feutey (au2sv) N c Tee ALA Ammo om mm om Mein hein 2 1625/0 1632. — wiaoker 100 6 63 16 2010 37 6 38 moter Precop reso — B820K6P 100 6 63 18 210 37 § 39 #1663 = 3em0K6P 10 6 63 18 2010788 = P7632 wenaxer 160 60 80 9 32 16 «6 10 90 = Preso/P 1650 36)24KGP 180 80 80 35 3 15a TOO = Pte63/P 1660 36/20K6P 160 80 80 35 18 a 100 main noist — PicieP 102 «sense 63 3S OSSSCS*SC Cs mas motor S #1035 zen7sep 6 35 35 65] 28k 28 oe (slip ing) eroaye roo © eNTS4P 63 3S 358s 28 = P1050, wn7ssp 2 35 351033 #8 a Pie2s/ersi2 —SeRtSEP 125 @ 80 1 35 6 a9 4 = P1640 seaescr 125 8 8 16 35 6 39 4 aS ~ PLESO/P 1663. S6Q4SEF 125 8 80 16 210 se 65. = P1680 aeaesér 125 8 80 2 37 10 ae Creep hoist PPR Pa ware 6 8 6 «15> 100 1S >100 48> 100 motor 2 P2 were 10 «8S BT 11> 100 18> 100 Gaviret PA PB wsrs 10 6 6 15 37 152100 15> 100 cage) = Pe. wres 18 «10 1001820 1S Bh 15> 100 P10... P10...5 P10 waxes 16 10 10 «18 21 1S 18> 100 P16... P18..1S Pas winks 25 16 16253218 TS> 100 Fusé links for cross travel motor = 10 Example for calculating the cross sections of cables exceeding the lengths indicated in the table: - P 116, 220 V, required length 52m 3 Pecreneoer known tross section * required length _ 2.5 x 52 See Geese ‘known length of line 32 ey Te 2.3. Protective Conductor The wiring carried out in our works includes an earth lead which is connected to all those paris of the equipment which relevent regulations require to be included in the protective measures. The protective conductor marked green/yellow in the supply line must be connected t marked ©. ‘The correct sequence of the phase connections must be checked when the electric hoist is switched on for the first time. The loed hook must go up if the control switch button is pressed for lifting; otherwise, disconnect the hoist from the supply and reverse two phases. 1 earth terminal 2.4. Direct Control a For direct control, Demag control handles type DS, with the control cable connected to them, are supplied sepere- tely with the hoist. For reasons of stendardizetion, control cables not longer than 5 m are supplied uniform in length: beyond 5 m, they are supplied in the length as ordered. Cut the control cable to length as required so that the bottom edge of the control handle is approx. 1.20 m above floor level. The installation material for connection to the hoist is supplied with the control handles; for trection relief of the control cable see section 2.5. illustration 12. The special flexible pipe relieves the control cable of traction and at the same time protecis it against mechanical camac! | Several control handles may be linked together: the required coupling blocks and self-tapping screws are supplied Z with the handle to be used for hoist travel or as 2 crane switch. The arrow symbols on the control handle trigger must comply with the respective hook and travel movements, {Strong mineral (2. g. hydrochloric or sulphuric) acid may tend to corrode control handle casings, Such hendles ishould be replaced in due time,—— 25. DS Type Control Handle 2.5.1. Assembly Instructions for DS Type Control Hendle Work on-the control ha ‘adie must only be carried out by 2 treined electrician, Loosen top protective cap (1) with a screvedriver, Notches ate provided in the cap (1) for fingering / screwdriver, When snap eap (1) into 9 ensure 2E complete insulstion, ee mdb He, Litt housing (2). The eam at switch element (3) in the } wera handle (2) is easiy accessible Bisa from all sides Seal stipped end of cable with insulating tape in order 18 prevent taleum powder ‘coming out of the sheathing, Push pant 1, 2. 14, 9 over special texible pipe (13), Lnsert the clamping bush (8) into the pipe (13) and place @ fetsining cord (31), on the ide opposite to the mut (10), between pans (5) and (8), Assemble the pars 5, 8, nd 9 by tightening the ‘our screws Provided. Only use pans Provided for vaction elie! of the contro cable. 2 i 7 Lit eap (1) and remove the 3 Serews in the housing (2), Tit reraining stieup (5), Release elecwical conncesions and remove eam switeh element (3). When fitting the DS contro! handle to an electric heise with limit switeh Remove the connecting bridges (i any) switch element (3) the elecwie bois and for control cable, twoction relief proceed ot follows: screw in thresded bush (18), push special Nexible pipe (13) ever headed bush (15), sng s2¢ ste with hose elp (18). Secure the Wesible ceute (7) by tightening grub serew (77) or relief from weesion caused by convrel cable deadweight).Fig. 14 2 control handles are connected by means of two coupling blocks (1) (see illustrations 13 and 14). The coupling block is secured to the control handle by using self-tepping screws, Thé control handle or push-button pendant just be fited at 2 convenient height for the operator. The standard height for the control handle is 1.20'm (4ft) above ground level. 2.6. Contactor Control The switchgear casing for foot-mounted hoists is supplied separately. The switchgear casing for travelling hoists is mounted on the carriage. For the supply cable, the césing includes an entry gland fitted in the works. ‘The casings are protected in accordance with type of enclosure IP 55, which means protection against detrimental internal deposition of dust and against hose water from all directions. Attention should be paid that the cover is tightly closed in order to ensure thet the type of enclosure is adhered to. Each motor has fuse links assigned to it; these must not be replaced by fuse links of a capacity higher than that indicated in the table of section 2.2.1., a5 otherwise short-circuit protection for the switchgear is not ensured. ‘The control circuitis supplied from a transformer, one side of which is connected to earth in accordance with relevant regulations for such equipment. Therefore, the connection between the trensformer and the protective conductor fe removed. The fuse links provided fer the control circuit must not be replaced by fuse links of higher because this would defeat the shor-circuit protection for the transformer. The hoist movements are controlled by means of DWSa pendants equipped with 2, 4, or 6 double-pressure switching assemblies and one emergency cut-out button. A DWSa pendant used for the contiol of an electric hoist with heavy-duty end emergency limi switch must incorporate a check button (P) The strainer cords should be secured to the engle sections provided at the bottom of the casing. The push Sutt Pendents should be suspended in such 2 way that the bottom edge is approx. 1.20 m above floor level and that the arrow symbols on the buttons for hoist iravel indicate the direction of the respective movements. 2.7. Push Button Pendant DWSa Fig. 15 Fig. 18 = 'n the works or subsequently, DWSa pendants can be equipped with key-opereted contact, signal lamp, and 2dditional push bution (2). Two push button pendants of equal length can be linked together by using 1wo connecting str raSecure ubber-sheathed cable by means of clip (1), Garelully atange the cable leads and bunch’ ikey % together, using pattern (2) Moun! 'g Instructions for Cable Entry Rubber Seal Asrngeien of pars tobe fied: ss istaion 13 The pane shown shoud befits loo The ruber sea (6) hos tee eter soe fo win tho range embossed onthe cobs ake fy than thet gues most be ura Sis arts) to (6) on to eat (1) bt insring th ater ito te ean (2), Remove outrun tom the er of ete (1) ad pst ee yoo that pnovoten about S ann es eee Ensue that he cp in the housing igh fied othe eae Se seb en comoren, re stiog rin 3). wastes (4) and at (6) in | the con (2). Between tp (Bsn eh Oe Leet aherth later hee bree aoe F cables having an outside diemerer seal, The collar(s) having a smaller P of about 3 mm must renee GrEi fei G ls 3 Draw rubber sea! (6) over glend nut (5) and neck of cap (2) by pulling the lower bead Fee? | E cunel the ioneeet eee Fis snugly into the gap of about 3 mm lett between cep (2) and nut (5). Je crable the rubber seal to freely flex 10 cable movements, i a t should be pushed ‘about 10 mm further in the direction of the cep. 3. Lubrication '\ brivation saints of Dem ees are filled with of 2% the oil level in the gearboxes bef 29 hoists Type P are edequately greased. All reduction gears for he mein end creep fore putting the hoist into service, '@ rope tensioner and rope drurn with special Grease OG 67, and the rope with high-quality gear oil Sea maaailitate transport, the ait vent screw on the gear casin, gis closed by means of a plestic cap. © cep must be removed before putting the hoist inte eervinn Rope Reeving Methods Gas5 teereomr $80 Gruen Shon: Gaspsoveoey Bs 7008 rcExwmesseaer E}irmnoveo 5” se AYE Kr E The rope endis retained by means of 2 wedge end en anchorage which, depsncing ‘onthe hoist model, is eithe oe a area ny oc Inanrporated in zpecial erosshead, The rope and is provelly seaured Ue Sort axached tothe drum casing a rpof the snchorage (ee ig. 21) 30 that under luau the wedge remoing visbl above the anchorage and the dead end protrudes downwards by not ess thee Oem (4°). For replacement of wire ropes please refer to section 3.2. Fe tre method of securing he rope end by means of tis anchorage is absolutely reliable and in confourmy the Fae acd eerie In addtional safety device (according 10 DIN 15020) preventing the deze! oh fron Beeaee eetipic fied as shown in fig. 21. Any additonal clips clamped on to both pans of the rope ‘would caus! Divises and uneven sess in the rope and thus lead to its premature destruction. Erie clip above the hook fittings, on the deed end of single-fall ropes, prevents the wedge fom sipping OU! wher the hook is supported. eee2.10. Emergency Limit Switch The self-resetting emergency limit switch with motor terminal board is housed in the main hoist motor casing, The switch automatically cuts the hoist motor off after the hook has reached its top or bottom position, The emergenc limit switch, must not be used for operstional limitation of the hoisting motion, 2.10.1. Heavy-Duty and Emergency Limit Switch An aégitional heavy-duty limit switch must be provided if limitation of the hoisting motion is en operations! require meri. The two lim. switches must be arceanged in such 2 way thet the heavy-duty limit switch is tipped fet anh the emergency limit switch subsequently if the heavy-duty limit switch should fail, Relevant accident prevention regulations require that operators daly check the correct functioning of the emergency limit switch, In order to facilitate this, @ check button (P) has been incorporated in the control switch: by pushing this button and switching the hoist motor on at the seme time fer lifting, the heavy-duty limit switch can be snonteg and the hook be lifted until the emergency limit switch is opereted. The check bution must also be pressed for lowering the hook below the heavy-duty limit switch 2.11, Adjustment of the Emergency Limit Switch Correct acjusiment of the limit switch teppets is important, as otherwise the hoist could be damaged and accidents might occur, The limit switch operating rod must be checked for smooth operation (care should be taken wren tezainting the holst). The tappets of the limit switch operating rod are adjusted in our works to operste in accordonne rth the longest possible hook path; they must be readjusted to suit local requirements, To this effect, the tonnes nthe rod cen be shitfiod towards the cente of the drum. 288 note the following for adjusting the emergency limit switch 10 the longest hook path obtainable under local conditions: The teppet at the motor end must be set in such a way that there is 2 minimum distance of 10 em (é in.) from the upper edge of the bottom block to the lower edge of the hoist cesing or the lowest obstruction respectively efter the hoisting motion hss been cut off by the emergency jimit switch and the rope drum come t08 sereait. The leopet et the gearbox end must be set to cut out the lowering movement before the hook reaches the ground. The t3ppet retaining screws must be well tightened after the setting hes been cerried out 2.42. Travel Cerrieges/Runways The section of beams selected for 2 monorail hoist track must never be smaller than the minimum sections indicated in our technical literature; othenwise the lower flanges of such tack beams would be liable to deformation. Track curv radii must not be less than those spetified by us, but should always be made as large 28 possible in ories © facilitate smooth hoist travel. Special attention should be paid to the proper bending of beams for curved weere, Gradients should not exceed 2%. Hoist travel on track besms mustin no way be obstructed by protruding suspension bolts, screw heads, burt straps, clamping plates, e1c. ng stops (part No. 96336244) must be fitted at either end of the runwey in such @ way that only the connecting 20lts of the carriages bump against the end stops. Dimensions for Mounting End Stops on Runweys Stender I section RSJ according to DIN 1025, sheet | Dimensions in mm Mode! 180." 200 220 240 260 259 300 320 30 360 260 400 425 50 475 500 550 600 Ue 81928 [aa 12d dad ep ae aT NS We Wes SS) ke ph ae 40 MOP SY) SA? 36, Hs ise ss gp tS = 160 160 159 158 357 156 155 154 153 152 151 120 =a vPoe = — — 126 126 125 426 123 1M 120: 119°nNe 47 We = — Bl) xP oe = = C49 40 39 (58 37 $8 3 33. az igi 50 al i 185 15¢ 163152 151150 3 = = + 160 160159" 158 157 = — — 140 999 138 137 134733 932130 ee ee et sae ew day, 443022 20 == 203 202 200 199. 187 195 365 193 1d 120137 1 58 53 50 8 == 200 198 195 152 180 =n reas yane@aSNaBEN*) UPana nh eas an Opposite end Drive end End stop arrangement stop arrangement UP 1.22 Stunning faces of rails or tack beams must not be painted as this would badly affect hoist travel. Rells and wack oms should be kept clean: oll, grease, ice, and ditt deposits on the running faces would cause travel wheels to skidse gaeae of monoral hoists can be adapted to different rack beam sections by rearranging the washers plac bon the suspension bolts (see tables below), Br Yeni Slackened for eariage adjustment or mounting purposes must be well tightened again and secur by sefinting the lock washers and split pins, ape hoists must never be used when waveling for tating off Inads of for dragging them slong the ground. The spe of the cartiage should always be slowed dovin before the buffer stops are reached; othorene damage or accider might occur. : secures, monorail cariages are supplied with an atached counterweight box. In order to bring trenspor cos Sere the box is cispaiched empty: it must, therefor, be filled with scrap and sealed wih econ by the custom soeeeeane Cartage is put into service. This counteibalancing of the hoist should be done win gn care. Th 2p proximate weight of the filling for the counterweight box can be seen from the table below Approx. Counterweight (kg) AK HK Ex HK EK HK Ek HK ek ze aren) 4ryy Br non ar 1250) 300 2/5 P2002 P20 4/1 400 2/3 400 4/1 P 600 2/1 P00 4/1 P 10002) P00 4/1 3545 85100, e810 ~—200—250 170-250 240-220 240320 460670 aes ony aber FERS) ara KPARS WPA“) ond KPBS FUGTT a om a B a 8 {7 Beis in bacies ony soph PRE Bm 2.13. General'Instructions high-tensile bolts or screws (8.8) must be used and secured by means of lock From below rare stist be suspension mounced (toot postion €)insuchaway thatthe fourteisining ores me oes Boersma Lepped holes of the overhead structure, tis necessey to Intioduce the screw rene yess atfeck eth Us lock washer into the hol of the foot before the actual mounting operstion commen eel gists working ouptoors should be provided with a cover for protection against etmoveherie influence; monorail hoists should be kept under shelter if they are at rest for any considerable length of tine 2.14. Adjustment of Travel Carriages RU. HU, £U ance beeeStiNa monorail hoists 2/1, 4/1, and 4/2 t0 different standard I section ASJ, check Clear. ance between travel wheel flanges and track beam flange after erection; permissible macnnn: om on either side. Table 1 for electric rope hoists 2/1 and 4/2 ik Carriage: max. load t 2 z 4(5)*) 8 e 125, for heist anges. 271 100 F200 P25 22 F600 # 3000 for hoist ngs 6/2 eS #200, P00 #800 1000 Agjusabiew beams 180— 280— 180-280 280 360 360— G00— s60— BOM zs —a0D eS 250° 400 260° «400 34) 47898600 00 Max flangethicnness mm 303020 3 Length of suspension eye b mm 138138 134 198450160 7507 950 208208 Spacer bush 27h hmm 28 4928S OSSCava Ga be ge ap Spacer bush 4/2 hmm - — 2 oe gs oS Spacer both 2 Neg ae ee eae) ay PEST oe fe ee ee ee i Suspension bol, cis fon Sts Paes Gls Fal, leis es ‘Ariangemen of washers onthe wo suspension boke Wesbers Toto quaniy 2610 2616 3544 2817 210 BEG ania eR aa AP oe thes 48k ag eye Wester astibction pois a8 aeic Ayes SG Apele a wee 1 meevocosmrenyt (0 Be2 9 salle ela ees ge ee taahitear 4 sid 12000080 7 20°49 y22 =e es et = Bettie dbiecn, 120 $8 5 3 2 is gts Lola a 5 = Bowen] ~ } peerage! Gad ac aia 2 8 ye ete See — Geneneey ~~ SPRon does forewings 1260 193 1 5 2 1 5 § § 2 9 _ femme a cap 1 Fereee im ia is i gy cle = PLE OEL? incl — a Neem seine 130 125 106 — 08 1 3 34 = = Bee : : te Se mii eeyee rae | ah a) gece 4 atin (MO 772775 $4 $ CIT tra tte F pepen 19M aS ig) a Bice. bat vu. pode eg Ge ha = = SEE perrgmomene 120 14s Sled abi ge Beis Weg Sie feetircimane 100 1858 2 4 20s 653 942 823 IT E ean | (eee Re eee = ae (eo A SS mca eto aime tye) ee Vas ee ec iese ES Spe a f jou ee een sees vp eee 1B) 0S Ss Se SS El sate toe ethene 2 hae Teg eed eels) Oe ey pie Oeapt and 4/2 | lectic rope hoist — | de of crv i negara fl tl A Bea Cc 9.23 able 2 for electric rope hoists 4/1 2 319 8094 128 P1093 F290 Paco P 600) hes i 120-250 240-200 230. 360-275 500-600 «25-600 Aa Honge thickness mm 30 30 3030 3 3 33 ngth of suspension aye mm 18138 des elee 150750 208 bush by me 28 0 38 2233568 bush by mm = E = = 35 pe tind acs ar a ee eae see Ssuidel ba ded gUM an NCS Jal aa Ci a sal Taaleuneanracap PaO N|R aie UETRIN AAG SRA Sze aaa ier distribution points, & (8) € a fF € a § € a c a ae ao ee ee oo Sete jeg = 2 | Sees ; Fa 2 elie ished reed Cio eee Ver rs SR Al sae tre epgierateeee te neers ewe Reva reese Aas = Sd Side ye Eb Cue aie ee) Tamet i= b Bee aCe = aes ~ = = So Wed 1S] ae 131 & iF. 4 2 ros --- eae S Gorda st 4a! => = SWS) ee RO te eae ek al ty Sel ee ha aes fae = 3) tS ital ae ed cleats moet | ap 7 a 2) ae tl 2 se a Bape ve 2 bbs Sia ff us ob tg EMER bene pines | SS => feds Fah) ae Tor eleevie holsts 277 (472) ana 71; flange waath 300 abe ge Fe z Ta aOR Ts at ranges P 100 200 P 200 P £09 =P 600 PECO P1000 ce inmean $0 ta ee ee ri app soo | 300" Tino 308300 -3ta 300 oats mt | se sca ee Took cmepaaa en ieee ae : hE it ee =p |B esisiboid a aN a8, AUD) ae Toes silent oe i er ar a a a ieee a Eas Tas é poems oes ce ates ae ; ‘Gaaker oo nieve PIR 1} On bala way Bon PARE2/0 anes aft | ap A I T fen ey ee o { a As #1 came] : s Brenton Fig. 24 Sone t= Adjustment of Travel Carriages AK, Hk, EK Table 1, for stondard I section RSJ according to DIN 1025, sheet 1 Carriages: max. load ~ fi 2 4(5)") 4(5)") 8 (10) 4) B 12.57) abe Nees * 1002/1, 2002 20047 4002/1 4004/1 e027 00a roo 4/1 wee 21 haieaatiee bare t 720-329 340-0 780-360 9S0-ATS 380-475 509800 es0—800 fae tinue means wo ae me aan Sef ae Maipcomecion bok emm -a58g08”~=~ae”~«OSC«aSCCe mae tm te” aai~i«aSC StS ‘Acangement aT waaha oh e wo conneeion BOW Ti) sod we tang bake GE WAE af wash a Gi Man connesion Gotda.nm 30 <90~«SSC«S bet Teal aor F ane zenyelozeucl a Sahel aes ae + dani G2) Reuining tote Goudia.nm 203 «203~=~«S*S”*~«SSSSCSSC Tent yo ae a2 222 aaa ‘ashe diniboton pine as 1a CARERS EE A PAS INICCIEE WASDALE [Soe Tan ene Seo areata | ao ees Bet ge eeecebeetbe Eo eee ne eed Heroine lune daa AP eee eprenr= ame decd eter eee | agate boda = Sbemetwert trp 19 5 8/3 3 2 7. lae = See A ion angrewining 1300 125 4 5S 3 4 6 6 17 ---+-- eee ee Sot ae eal ae oi capes a ey a a Saulemmaer 139 By Jom es 3 323 2522 2252 Hoje if bln fait Gpat or ete ots = eee aginmingy 10 ma 7 22020 8 @ D1 ge 22 TILE seageibwen tao te ¢ ov lalas ct mes THY os shiny el rae = Sao Tidnmmsetetae igs ie fos 3 8 3 F2 2 6622 DLal Seeuevitiemowee Tuy 170 2 3 4 8 8 3 Gls! ea 8! 8 Seman os 1475 178 & hoe h Baja n tip tities es | 2 ee yea ode cvelclantel a - 54s ape = esac ete Sita Gia CMe hcdeiteees to 3 2 > DD DDI ff is 3 Table 2 for ange width 300 Caniage: mas oad z z 7) #6) ecoy sy forint ranges Pia awairi P200 477 P0027 —PeoDan —P soa $3002) Peooan _P19002/1 ‘jumble wo bean wih i xe 300 ~0]S~ OSC 3 Nass fenge otciesr Ee 7 2 2 3 8 Nicene oan ie 33 mss seni Som Ea 37” Saat leieear ioe bt << cane 30 20 e Ressong beh farmm 23 2 3 3 2 Washer Teal quaniiy ae aes gee asa Theloess i i i i A Gheliisiow onmameemen—Ayanday 3 2 3 3 3 dion bol ond scaring bol 2 2 2 2 i ; c i i i 1 i {| Gua in brctes only apply io F212") Dawa in trackers only apoly WP 425") ang RP 42S M2Z4/1__*) and KP 42S H 22 2/1 13See CFP MEETS ORCC: erauterty? Ror* On altel hofs mus net commencebbtors ne load has be ply cut off, * Firnnermore. for the operation and maimenance of electic ks regu eat accident prevention and cite clticial tegutations must be stictly adhered no eee 2nd checks required in addition to thoke listed in our main. $ qenanes schedule hereunder must be caved out wahour req Excerpts of relevant rules forthe prevention of accidents are given in the Test Bock accompan; 19 the hoist, 3.1, Maintenance schedule 1st servicing atter zi every funher 3 12 ara Fonths months Servicing checks Tonths years {hitck braves, should load sli adjust bakes") Q Cheek broking path and readjust of required 2 Check operation of limit switches ge Con EEE (teving devices forthe contol cable, ihe cable ha 2nd the contol switch housing pans for darn a Cet errine eg oe wa woken wien aa cage 5 = Clean and oink switch ods = 5 z Examine ope stung pens and rope gude = > = Greate rope ope dm, andvope guide = Pe = = s ® = Cheeta fa gers and ett pecersry = 3 = Ceretully examine boted connections, ns, svat welon ee 5 10 = ‘Sami condo of nd an, ae of wind i sey ven woo) = n 5 sf Seecueny spel Ines (in and vous coment susp, ain ne cae oe of busbars especially the carbon contacts and wavel wheels of collector x Eger 2c 889! buts Snes with sant pans, the tunnel: shaoe entry } Gisr | sets and le pa se aTBeshent he are! sanes ages a tue speci Sneak alee Carat eine na pens cache nd cd = F {fee relevant standard specitieations) is = 13 Corefully check siectric hoist ‘coupling and the gears ef ho: a "08h and long vavel mote fo Se ee = 4 EE Carefully exemine crane-and hoist carriage (or crab) travel wheels, = sei ‘and in particule: the condition of the flanges and sealing devices of the anti. = 2 ECan out check of eleticn switching gon and nataiavon = 8 FE Shang ot on the towing sens mam hai ceap hol ove bars ‘ravel unit, and cross wevel unit of doubie-al crabs, ” TE Change grease inane crs vavel gearbox and ihe ms r $294 f the las stage of gearing onthe monoral hist caninges 1h storementioned maintenance intervels apply i normal Service conditions (group Ib according 10 FEM) prevail IF the hoist is subject to conditions specition vor Higher group these intervals should be shonened secainolt soecutine meinienance reveals thot the intervels are 00 long oF too short, they should be adepted to the loce! 2perating conditions,3.2. Wire Rope and Wire Rope Tensioner (Rope Guide with Plastic Pressure Aing) re wits rope and its tensioner are wear pants: litle but regular greasing adds to the life of these pans, v ust be cleaned before the grease is applied. Do not apply too much fresh grease. Replacement of Wire Ropes and Wire Rope Tensioners For sefety reasons, the wite ropes of Demag Eleciric Hoists must be discarded when the number of visible br Gvss in the worst spot has reached the following figures counted over a reference length of rope of 6 vines 30 times the rope diameter respectively (see table below). Aumite rope must be discarded forthwith it a strand is br:ken,ifit is found to suffer from swelling, bruises, k manent bends or corrosion, or if it is badly worn or damaged. aeieRiter gales service can supply. you-with wite ropes that have proved their reliabifty especially with De shin, wnen ordering please state the wire rope part umber, which can be seen from the Component pers and the serial number and model of hoist. Wire ropes are due for discarding if the following numbers of broken *) own vsaz0" hee | Ee Ep ae i is ig e } # YR g : : uo z $ 2 fo 2 is : cis z { 2B # eo 0 i z Bog 3 8 B s #0 = Removal of the Old Wire Rope 1. Lower hook block on to a firm stand, which should be a little higher than the lowest position in which the ln switch cuts off the movement 2. Remove rope tensioner (ill. 32) as follows: Withdraw slotted joint piece (3) from rope guide (2). Remove tension spring of pressure ring (1) by means of the rope gt (see ill, 33) i Diéw rope guide and pressure ring aut of the drum casing aperture from below. 3, Carefully wind the lest turns off the drum, and unscrew the three rope clamps Dismantle the other rope end securing device (rope wedge). fe clamping tool for plastic pressure rine 3.2.1. Adjustment of the Tension Spring Fig. 32 BS Fig. 33 Fo Prem tae array . Peo ra a2 3 Presui ong oot rovices tor 3800") Rope eam ne We one Dene tng wage Fitting the New Wire Rope 7. Before 2 new rope is reeved, the whole length of it should be rolled out on the ground under the hoist as shown ip illustration 8. Any twisting of the rope should be strictly avoided fig. 34) 2: Secure one rope end by means of the three clamps provided on the drum; commence this operation at the spot erked “A” on the drum: clamping must begin about 3 cm (71/") from the rope end z 3% Switch hoist 10 "Up" unl about turns are on the drum. During this operation the rope shuld be Kept properly {aut by @ workman wearing thick gloves or using rags to protect his hands, Incorree: 2 ¢ 8 oe Correct a Fer construction, application, and reeving of wire ropes for eleciria holsts soe table on page 15,