DEMAG Electric Chain Hoist Demag DC-COM 2 250 1/1 H5 V7.2/1.8

Remove guide half sections (1) (four M 6 bolts)

Remove bottom block retaining bolts (2) and remove the bottom block

Insert the new chain into the bottom block in the same position and orientation (chain must operate without any twist)

Re-assemble the bottom block and tighten bolts (2) to a torque of 52 Nm

Check correct fit of the four cut-off springs (3) in new halves (4) of the bottom block

Install new guide half sections (1) and tighten bolts (5) to a torque of 5,5 Nm

Perform a function check (run against the operating limit switches and check against the 7-segment display)

Sign off on the bottom block standard replacement

Check brake wear depending on the year of manufacture of your chain hoist:

● When the max. brake displacement is reached (see  Tab. 64, Page 88), the brake must be replaced immediately.

● For brake displacement up to 0,5 mm, the brake can still be used until the next maintenance is due.

As of year of manufacture 04/2009

Since 04/2009 – depending on the size of model – brakes have been gradually equipped with a plug inside the brake housing to enable brake wear to be measured without the need to remove the brake. Brake wear is measured by the air gap.

Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching on again.

● Open the electric equipment cover.

● Unscrew brake plug screw (1) from the brake.

Dispose of waste oil in accordance with environmental protection requirements.

Under normal operating conditions, the lubricant must be changed at least every 10 years.

Under exceptional conditions, e.g. increased ambient temperatures, we recommend that oil changes be adapted to suit these conditions.

CAUTION: Safe operation cannot be ensured if oils are used that are not approved.

Drain the old oil at operating temperature.

Turn the gearbox in such a way that the oil is drained.

The flushing oil should have a viscosity of 46-68 mm2/s at rated temperature.

Enter the quantity of flushing oil used

Warning: Ensure the power is off before starting the procedure

Unclip the contactor retaining mechanism by pressing locking tab (A) with your thumb. This carefully bends locking tab (A) away from the contactor.

Turn contactor (B) using your other hand until the mechanism no longer holds it.

Unclip second locking tab (A) on the opposite side (as described in step 1 above).

Using your other hand, remove contactor (B) by pulling it away from the board.

Push the replacement contactor into contactor socket (C) until both locking tabs (A) click into position.

Note: The contactors are also socket-mounted for sizes DC 1 to 5 manufactured as of 02/2011 and can be individually replaced.

Sign off on the contactor replacement

DANGER: Live components. Danger to life and limb. Work on the electric equipment may only be carried out by a qualified electrician or by trained personnel.

Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching on again.

Open and disconnect the service cover.

Remove and open bag (1) with the control cable.

Take the control cable out of the bag.

Turn and disconnect bayonet lock (2) and remove the control cable plug connector.

Unscrew electric equipment cover.

Loosen screw (3) on the control cable locking mechanism and remove the locking mechanism. Remove the control cable.

Install the new control cable in reverse order.