Operating instructions / Accessories / Component parts

Demag DC-Pro 1 - 15 chain hoist Demag Manulift DCM-Pro 1 - 5 chain hoist

43213744.eps

210610 en GB

214 741 44

720 IS 817

Original operating instructions
Manufacturer Demag Cranes & Components GmbH P.O. Box 67 58286 Wetter Phone: +49 (0) 2335 92-0 Telefax +49 (0) 2335 92-7676 www.demagcranes.com E-mail: info@demagcranes.com Please fill in the following table before first putting the unit into service. This provides you with a definitive documentation of your Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative.
Owner Where in use Size Serial number Year of manufacture Operating voltage Control voltage Frequency Wiring diagram number Tab. 1

Item 1 2 3 4 5 6 7 8 9 10 Fig. 1 Example type plate 11 12 Tab. 2

Designation Manufacturer Chain hoist type Serial no., calendar week, year of manufacture SWL, group of mechanism Chain type, hook path Voltage, frequency Type of enclosure, insulation class Ambient temperature Motor type Electrical key values Conformity symbol Manufacturer address see above ⇒ "Mounting code", Page 19, ⇒ "Selection table", Page 20 ⇒ "Available hoist chains", Page 93, ⇒ "Mounting code", Page 19, ⇒ "Selection table", Page 20 ⇒ "Hoist motor data ", Page 22 ⇒ "Operating conditions", Page 30, ⇒ "Hoist motor data ", Page 22 ⇒ "Operating conditions", Page 30 ⇒ "Selection table", Page 20, ⇒ "Hoist motor data ", Page 22 ⇒ "Hoist motor data ", Page 22 see above ⇒ "Mounting code", Page 19, ⇒ "Selection table", Page 20

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214 741 44/210610

Table of contents

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 3.6 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.8 3.9 4 4.1 4.2 4.3 4.4
214 741 44/210610

General........................................................................................................................................................................ 7 DC-Pro chain hoist ...................................................................................................................................................... 7 DC-Pro documentation ................................................................................................................................................ 7 Symbols / signal words................................................................................................................................................ 7 Information on the operating instructions .................................................................................................................... 8 Liability and warranty................................................................................................................................................... 9 Copyright ..................................................................................................................................................................... 9 Use of spare parts ....................................................................................................................................................... 9 Definition of personnel............................................................................................................................................... 10 Test and inspection booklet....................................................................................................................................... 11 Customer service ...................................................................................................................................................... 11 Safety ........................................................................................................................................................................ 12 General...................................................................................................................................................................... 12 Safety signs on the equipment .................................................................................................................................. 12 Intended use.............................................................................................................................................................. 12 Hazards which may be caused by the machine ........................................................................................................ 13 Responsibility of the owner ....................................................................................................................................... 14 Operating personnel requirements ............................................................................................................................ 14 Personal protection equipment.................................................................................................................................. 15 Emergency stop device ............................................................................................................................................. 15 Regular inspections ................................................................................................................................................... 15 Technical data ........................................................................................................................................................... 18 Design overview ........................................................................................................................................................ 18 Mounting code ........................................................................................................................................................... 19 Selection table ........................................................................................................................................................... 20 Electrical key values .................................................................................................................................................. 22 Hoist motor data ....................................................................................................................................................... 22 Mains connection delay fuse links ............................................................................................................................. 24 Supply lines ............................................................................................................................................................... 25 Hook dimensions C ................................................................................................................................................... 26 Noise emission / sound pressure level ...................................................................................................................... 28 Transport, packing and storage................................................................................................................................. 28 Safety instructions ..................................................................................................................................................... 28 Scope of delivery ....................................................................................................................................................... 28 Transport inspection .................................................................................................................................................. 28 Packing...................................................................................................................................................................... 28 Storage ..................................................................................................................................................................... 29 Surface protection and painting................................................................................................................................. 29 Operating conditions ................................................................................................................................................. 30 Technical description................................................................................................................................................. 31 Drive and brake ......................................................................................................................................................... 31 Gearbox and slipping clutch ..................................................................................................................................... 31 Chain drive ............................................................................................................................................................... 32 Housing .................................................................................................................................................................... 32 Electrical equipment .................................................................................................................................................. 32 Control ....................................................................................................................................................................... 32 7-segment display for operating status and error display.......................................................................................... 33 Software version, operating hours, number of cycles, operating statuses ................................................................ 33

4.5 4.5.1 4.5.2 4.5.3

3

....11 5.................................................................................................................................................3 5.......... 71 Functional tests .........7 5................................1 7..............................................................3 6............................................................1 7......................5...............................................4 5.................................................... 40 Assembly ......................................................2..1 5................................................................................................................................................................................................................................................................ 43 General...........................................................................................................1 7............................................................................... 45 Connecting the control pendant .......6..........................................................................9 4..3 5......................................................................................................................................... 64 Starting parameter setting mode .............................................6 5.................................. handing over .............................................................................................................. 50 Techncal data of the control cable ...............................................2 7.................................................................... 54 Circuit diagrams and control cards ................................................................................................................6........................15 solo hoist .................................................................................................................................................................2 6.............10.............. 62 Setting parameters with the control pendant .........................3 5............................................................................7 4..............E 34 travel drive . 76 Taking out of service ...................................................... 49 Control cable ................................2 5.....2...........................................................1 Central service enclosure ...................................................................................................................4...................................................................................................................................................... 48 Screw plug..........................3.............................................................. 45 Assembly procedure............................1 6..................................... 34 Control pendant height adjustment / control cable ..................................................................................11............................................ 56 Circuit diagram DCM-Pro 1 .................2 7........1 5.............2 5.... 70 Safety instructions for operation .......... 64 General......................1 5................................ 48 Suspension bracket .....................................................................................................8 4..................................................................... 64 Meaning of parameters ................................ vent valve .....1 5.............................................8.............................. 70 Switching on ....... 67 Putting the unit into service for the first time ......................................................................................................................................4 5..............................................................................10............3............................................................................................. 75 Emergency stop ............................................................... 71 Operation................................... 52 Line connection ...................................................................................................................... 68 Inspection regulations ...... 51 Mobile control system.............................................................................................11 5 5... 56 Circuit diagram DC-Pro 1 ......................................................................................................................................................................................................................................................................................................................... 65 Setting the lower hook position ...............................1 5.................4 5..................................................................2 5......................... 46 Suspending the chain hoist ............................................................................................3 5......... 77 .............................................................................................................................................................5 5.8.............12 6 6...................................................................4 7...................................................................................................................................................................................... 48 Supporting structure ...........................10 4..............................................................................................................................6 4..9 5.............2 5....................................................... 68 Inspections prior to putting into service for the first time ................................................2 5....................................4 5.....11.......................................................................................................... 36 Suspension............................................................................................................. 69 Inspections when first putting into service............................................................................................................................................... 68 Safety instructions when first putting the unit into service .............................5 solo hoist ............................................................................................................................................................................................4 7 7.....................................10... 77 Taking out of service in the case of faults .......................................11.............................................................................................................................................8........................................................................................................................................................3 7................................... 71 Inspections when starting work ...........................................8 5............ 59 Circuit diagram with E 11 .......................................10....5 4 7................. 62 Control board........................................................................... 43 Tightening torques DC-Pro chain hoist ............ 35 Manulift DCM with quick-release coupling .............................................. 72 214 741 44/210610 General............................. 69 Operation................................................11................ 38 Trolley.......................................................................................... 35 Control pendant ...............................................................................2 7.................................. 72 Manulift ........................10 5....................... 64 Meaning of keys .. 43 Safety instructions for assembly........................................................................ 50 Handling the control cable ............................................................. 50 Height adjustment of the control pendant..............................................................................8...............................................

.......7......................5........................................................................ 108 Buffers ............5..........10...........................................................5..5.....................................................................................5........................................... 109 Checking the switch-off buffer / switch-off spring ......................5................1 8................. 100 Checking the load hook ............................................. 87 Operating limit switches ...10..............................................2 8..................................... 113 Slipping clutch ...........4 8.................................................................. .... 107 Replacing the gearbox ............................7...............5..5. 118 214 741 44/210610 5 ...............................................5 8....3............................................... 78 Basic information on maintenance ........ 118 Replacing the control cable .....5.................................. 87 Checking the operating limit switches ...5........................................................7 8....................................................................... 110 Brake ....................................................................................... 80 Calculating the actual duration of service S ..................................5. option for DC 10) with external switch-off springs.........................................1 8............3......... 101 Replacing the bottom block (standard for DC 10) with internal switch-off springs..........................................................................................................................................................................................................5. 77 Maintenance / repair............................................2 8........3 8..........................................................................................5.. 79 Routine inspections ....................5............................................5... 94 Lubricating the hoist chain..........3........3 8 8..9 8......................................................................................5.................................................................................. 115 Checking the slipping clutch ..............................................................3........................................................................................5...........................................................................................................................2 8.................... 89 Checking the sprocket wheel ......................................................... 84 Inspection and maintenance schedule .............................................1 8............................................................................................................................................................. 86 Suspension.......................................2 8..................................................5........................... 103 Manulift ...............1 8...............................................1 8..........5..............................................................5.........13..............1 8...................................................................................7 8................... 109 Buffer design ................................ 80 General....................4 8....................................................5....................... 82 General overhaul GO ......................................................................................................7.2 7..............................5..P.................................................1 8.........................................6........................3....................... 103 Checking the quick-release coupling...........5 8..................................................................................................................................................5.......3 8.............................................................................................................3...............................................................................4 8.. 108 Load handling attachments ................ 113 Brake assignment...8.............................3 8......5.................2 8........1 8....1 8.................................... 117 Replacing cables .............................................................................................................................3 8.....................................2 8.......................5.....6 8.................. 115 Adjusting the slipping clutch ....5.................................................................5................................................................................................................................................................................................ 80 Service life of the contactor .5 8....................................... 113 Check brake wear ............................................ 102 Replacing the bottom block (standard for DC 15.........................................................................................................3................. 92 Available hoist chains ........11 8......................5..................6................................................... 105 Replacing the switching elements ......................................9..................5...... reeving 1/1.........................5.............................................................................. 84 Maintenance work ............................................................................................................1 8......................................3 8................... 77 Taking the unit out of service for maintenance and repairs..................10 8.......5....................5.................................. 104 Fitting the chain to the control unit ............. 80 Prescribed inspections .................8 8.....................W............................................................................................................................ 86 Electrical equipment cover ....................................5.................................6...............................................................................................................................5.......2 8............... 81 Example: DC-Pro 10-1250 1/1 H5 V8/2 in 1Am ..........................5...........................3..............5.........................4 8..........................................................................................7................................... 100 Replacing the hook assembly...............................5.3.............5.....................5.................5........................................6 8...............................5.............................................5............... 98 Load hook...... 89 Checking the chain guide .......................................5...................5............................2 8..............................................................5..............................................5........................................5 8............................................................................... 87 Checking the operating limit switch actuator ...................... reeving 2/1 ... 89 Checking the guide plate ..........................................................5............................................5 8...............................................13 8................................5..8 8........................................2 8................................................................ 103 Replacing the chain ..................................9....12 8............6......................................................................... 88 Chain drive ........................2 8....................... 93 Replacing the chain set ............6.......................................................3............................7.....................................3 8..........7....................4.........................................................................................2 8...........4.......................................................................3 8....... 115 Gearbox / oil change ............ 100 Checking the return sprocket .................................................... reeving 2/1...........5............ 90 Scope of supply chain set ..................................................................................................................... 116 Replacing the contactor on the control card ....................................1 8..... 86 Dismantling the chain collector box ............................ 78 Safety Instructions for maintenance / repair ..............7...........................................................................................................................................8.......................1 Taking the hoist out of service on finishing work ............................................................ 89 Checking the hoist chain ............................................................ 80 Measures for achieving safe working periods S............................................4 8.................................................................................5................5.4 8...6 8...............................................................................

..................10 Replacing the helical cable.....................................................................................................5........................................................6 12.......... 140 Index............................................................................................................................................ 127 Spare parts .....................8 12..........................................................................5 12.................1 12 12.................................7 12......................................................................................................................... 123 Warning messages............................................................................................................................... 128 Motor ........................................................................................................................................................................................ 128 Overview ...................... 122 7-segment display .......................1 11 11........................................................................................ 130 Chain drive .............................................................................................................................................................. service cover ......................................1 9..................................................8........ 123 General messages ..................... 127 Components ...............................................................................................................................................................................................................................5 10 10........................................................................................... 141 6 214 741 44/210610 ......................................13.................................................................................................................................................. control cable.. 126 Accessories ..................... 125 Disassembly / Disposal ...................... 136 Electrical equipment cover ................................................................................................... 134 Bottom block with internal switch-off springs (standard) ...2 9 9............................................................................................................................................................................................................................ 120 Faults / Warnings ........................................................................................................................................................................................3 12...................... 135 Bottom block with external switch-off springs (option) ..............4 12............................3 9.....................1 12......... 129 Parts on gearbox ......................................................................................................................2 9.......... 132 Hook assembly ................................................................................................................................2 12... 138 Control pendant....................................................................................................................................................9 12................................. 126 General...................................... 122 Safety instructions for faults / warnings ... 124 Error messages .............................................. 137 Manulift ..............................................................................................................................................................................................................................................................................4 9..........................................................................................

If re‐ quired.2 DC-Pro documentation Further documents are available for sub-assemblies/components in addition to these operating instructions. 1. powder-coated) KBK Aluline (anodized) KBK 0 + 25 trailing cable power supply KBK 0 + 25 power supply lines Clamp-fitted buffers DC-Pro 1 .3 214 741 44/210610 Symbols / signal words Important safety information and instructions are marked by corresponding symbols and signal words.Dimensions Friction force checking device DC PWM/3ST signal converter DSC-EX control pendant DSE10-C control pendant DC protective sleeve DC tandem box VG11-34 EU11-34 dual-output gearbox DSC strain relief Test and inspection booklet Tab. The requirements of the EC directive are complied with. 3 DC test and inspection booklet Certificates Part no. 1) The documents can be ordered from the relevant Demag office.25 chain hoist Demag DCS-Pro 1 .10 chain hoist Demag DC-Com chain hoist CF5-DC/DCM trolley U11-DC/DCM/DK trolley E11-E34 DC travel drive (circuit diagrams) Technical data / Catalogues RU/EU56 trolley Electrical accessories DC Electrical accessories POLU box KBK classic (steel. 7 .: 203 525 44 203 571 44 203 568 44 203 569 44 203 698 44 203 691 44 203 656 44 203 682 44 202 976 44 203 245 44 202 487 44 202 386 44 203 313 44 214 741 44 211 033 44 214 802 44 214 827 44 211 068 44 211 010 44 214 095 44 214 810 44 211 017 44 211 159 44 214 689 44 211 045 44 211 011 44 206 973 44 211 094 44 214 832 44 214 998 44 203 673 44 211 108 44 211 122 44 211 092 44 214 745 44 235 309 44 1. even if special designs or additional options deviating from these operating instructions are ordered.25 chain hoist Operating instructions / Compo‐ nent parts DC-Com chain hoist DCS-Pro chain hoist DC-Di chain hoist DC-Wind chain hoist PGS parallel grippers E11-E34 DC travel drive KDC chain hoist KDDC/UDDC articulated trolley DRC-DC radio remote control DRC-DC quick-step instructions DC geared limit switch Assembly .1 General 1.1 DC-Pro chain hoist You have purchased a Demag quality product.Setting . Documents1) Demag DC-Pro 1 . the corresponding documents are supplied or can be ordered separately. This chain hoist was manufactured to European standards and regulations in accordance with state-of-the-art en‐ gineering principles.15 chain hoist DC-Pro 16 .

Complete machine Based on Machinery Directive 2006/42/EC. putting into service. we confirm conformity with the requirements of Directive 2006/42/EC by means of the attached EC declaration of conformity. DANGER This symbol indicates an immediate hazard which can result in serious injury or death. may result in mal‐ functions or damage. Exercise particular caution to ensure that accidents.The safety instructions must be followed. 1. These operating instructions are an integral part of the machine. injuries and damage are avoided in such cases. Operating hazard for the machine ● This symbol indicates information on the appropriate use of the machine. In particular. CAUTION This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage. They must be kept available in the immediate vicinity. – Follow these instructions at all times and be particularly careful and cautious. The following symbols and instructions warn against possible personal injuries or damage to property and are in‐ tended to assist you in your work. Demag chain hoists are supplied ready for operation as complete machine with a control pendant or as incomplete machine without control pendant. 8 214 741 44/210610 .4 Information on the operating instructions These operating instructions are designed to provide the owner and operator with useful instructions for transpor‐ tation. The operating instructions must be available to the operating personnel at all times in order to prevent operating errors and to ensure smooth and trouble-free operation of our products. WARNING This symbol indicates a possibly hazardous situation which might result in serious injury or death. Persons entrusted with this work must know and comply with the safety regulations and the operating instructions. For a chain hoist delivered ready for operation in the sense of a complete machine. The relevant local accident prevention regulations for the application and general safety instructions must also be complied with. ● This symbol in the operating instructions indicates all warnings which. this includes the "Safety" chapter and the relevant safety instructions in the working sections of these operating instructions. if not complied with. – Follow these instructions at all times and be particularly careful and cautious. – Follow these instructions at all times and be particularly careful and cautious. the chain hoist will in the following also be designated as machine in the sense of a complete machine. operation and maintenance of our chain hoists. The machine may only be operated by personnel who are fully familiar with the operating instructions.

● untrained personnel. 1. images and any other information are protected within the sense of copyright law and are subject to further industrial rights. We reserve the right to incorporate technical modifications within the scope of improving the operating characteristics and further development of the product. and inform the owner about remaining hazards. drawings. Only then can we ensure the safety and normal service life of the installation. ● unauthorized conversions. the information contained in the declaration of incorporation for the chain hoist may be used.7 Use of spare parts We urgently recommend that only spare parts and accessories approved by us be used. state-of-the-art engineering principles and our many years of experience. A conformity inspection in accordance with the Machinery Directive must be carried out for the assembled machine which is ready for operation and a declaration of conformity must be produced. in order to meet the safety requirements for the machine. These operating instructions must be read carefully before starting any work on and with the chain hoist. For a chain hoist as incomplete machine which is assembled with additional parts to form a machine that is ready for operation. The information for assembly and op‐ eration of the chain hoist contained in these instructions must be complied with. ● inappropriate use. No part of this documentation. in whole or in part. The information contained herein may serve as basis for the risk analysis and the operating instructions which must be prepared by the manufacturer of the installation in compliance with the Machinery Directve. Before putting into operation the owner must take additional measures. ● technical modifications. For the conformity inspection. a declaration of incorporation will be enclosed. may be reproduced. Assembly of an incomplete or non-assembled chain hoist resulting in a machine ready for operation must be carried out in compliance with the information of the manufacturer for the machine. the manufacturer of the installation must provide additional operating instructions as the result of the risk analysis. Any and all content. texts. 1. shown in public or used in any other way without specific prior consent. The manufacturer does not assume any liability for damage resulting from the following: ● non-compliance with the operating instructions. ● the assembly and operation of the chain hoist. 9 . Wearing parts are not subject to liability for defects. Any misuse is an offence. For the operation of the installation. All industrial rights reserved. especially before it is put into service for the first time. Infringements are an offence resulting in obligatory compensatory damages. as required.5 Liability and warranty All information included in these operating instructions has been compiled on the basis of the relevant regulations. ● some typical risks. Further rights reserved.6 Copyright These operating instructions are only intended to be used by people who work with or on the chain hoist. distributed. The declaration of incorporation refers to the scope of delivery of the incomplete or non-assembled machine.Incomplete machine These instructions inform the manufacturer of an installation with a chain hoist on: ● basic technical notes. 214 741 44/210610 1.

W. They must be familiar with the relevant national industrial safety regulations. manufactures equipment under his name and places it on the market for the first time. service. if the name of the manufacturer (under 1. The person must be trained by the owner in accordance with the tasks to be performed. resells equipment of others under his name. damage.Spare parts not approved by us may cause unpredictable hazards.P. The use of unauthorized spare parts may render any claims for guarantee. 4. Qualified electrician Qualified electricians are defined as persons who. The person must be trained by the owner in accordance with the tasks to be performed. maintenance and fault elimination. however the reseller shall not be considered as manufacturer. 10 214 741 44/210610 . accident prevention regulations and operating conditions and must provide verification of their competence.) An assigned expert engineer is defined as an experienced technician specifically assigned by the manufacturer to determine the remaining duration of service (S. setting-up.W. are able to assess the tasks given to them and to identify and eliminate potential hazards. Assigned expert engineer (in the Federal Republic of Germany according to BGV D8. protective measures. relevant regulations. codes of practice. for determining the S. dealers and representatives null and void. accident prevention regulations. The person must be trained by the owner in accordance with the tasks to be performed.) appears on the equipment. Personnel must be informed about the required pro‐ tective devices. Owner Owners (employer. imports equipment to Germany and places it on the market for the first time or exports equipment into another member state of the European Union and makes it directly available to a user. codes of practice. 3. owing to their technical training. Experienced technician Experienced technicians are defined as persons who. Trained person Trained persons are defined as persons who have been instructed and trained for the tasks assigned to them and on the possible hazards resulting from inappropriate conduct. § 23.8 Definition of personnel Manufacturer The manufacturer is the person who 1. have sufficient knowledge in the field of the machine. directives and generally accepted engineering standards enabling them to judge the safe operating condition of machines. company) are defined as persons who own the machine and who use it appropriately or allow it to be operated by suitable and trained persons. codes of practice and regulations. malfunctions or complete failure of the chain hoist. Specialist personnel Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks such as installation. = safe working period) and to carry out a general overhaul of machines. damages or liability against the manufacturer or his appointed personnel. 1. The person must be trained by the owner in accordance with the tasks to be performed. 2.P. knowledge and experience of electrical installations as well as knowledge of the relevant valid standards. Operating personnel/operator Operating personnel or machine operators are defined as persons entrusted by the owner of the machine with operation of the equipment. owing to their technical training and experience.

9 Test and inspection booklet A test and inspection booklet filled in with all details must be available for the hoist (in the Federal Repblic of Germany according to BGV D6. 1. Test and inspection booklet ident.10 Customer service Our after-sales service will provide you with technical information on our products. no.Authorized expert engineer (according to BGV D6.: ⇒ Tab.com 214 741 44/210610 11 .741268 www. § 28). Demag Cranes & Components GmbH Telephone +49 (0)180 / 5 . etc. Please keep the serial or order number (see test and inspection booklet. 1. § 28 in Germany) In addition to the expert engineers of the Technical Supervisory and Inspection Board. Page 7. Specifying this data ensures that you receive the correct information or the required spare parts. 3.demagcranes. The results of the regular tests and inspections must be entered into the test and inspection booklet and must be certified by the inspector. load capacity plate on the crane) for any correspondence or spare part orders. an authorized expert engineer for the inspection of machines is defined as an expert engineer authorized by the Industrial Employers’ Mutual Insurance Association.

2 Safety 2. 12 No liability in the case of structural modifications . The maximum safe working load is the load capacity specified on the capacity plate. it may cause hazards if it is used inappropriately by personnel which have not been trained specially. Wear parts must be ex‐ changed in good time. lowering and moving loads and may be used as stationary or travelling units. the manufacturer assumes no liability for damage due to inappropriate or any other prohibited use of the machine in the sense of the "Intended use" section. ● The suspension/support structure for the chain hoist must be designed for loads caused by operation of the chain hoist. ● Chain hoists are only intended for lifting. operated. maintained and removed by trained personnel when in perfect working order. Knowledge of the contents of the operating instructions are one of the requirements necessary to protect personnel from hazards and to avoid malfunctions and.1 General The "Safety" chapter provides an overview of all important safety aspects for optimum protection of personnel as well as for safe and reliable operation of the machine. The personnel must meet the requirements according to ⇒ "Operating personnel requirements".3 Intended use The machine may only be used as intended and in compliance with the requirements for the owner resulting from these operating instructions and the following limitations. ⇒ "Technical data". ● The machine may only be installed. Page 84 by specially trained personnel. function and operation.2 Safety signs on the equipment Any pictograms. ● The machine must be maintained appropriately at the specified regular intervals and inspected according to ⇒ "Inspection and maintenance schedule". maintenance and fault elimination as well as compli‐ ance with the instructions on the machine safety devices. Page 14. any possible remaining hazards and protection against hazards. 214 741 44/210610 No liability for inappropriate use The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐ ceptable according to these operating instructions. The maximum permitted load of the chain hoist includes the load and the load handling attachment. At the time of placing it on the market the machine has been built according to the state-of-the-art and is considered as safe to operate.eps Fig. ● The machine may only be used in compliance with the permissible technical data. In particular. signs or labels on the machine must be obeyed and must not be removed. ● The accident prevention regulations UVV/BGV D8 §23 (2) and/or BGV D6 (1) must be complied with. 2 2. therefore. This must not be exceeded. 2. However. ● Appropriate use includes compliance with the safety instructions as well as any other instructions on assembly and disassembly. Any other use may result in a danger to life and limb and/ or cause damage to the machine and/or the load. signs or labels that are damaged or no lon‐ ger legible must be replaced immediately. Page 18. 43229044. Pictograms. used. commissioning. to operate the machine safely and reliably. Modifications of any kind and additions to or conversions of the machine must not be carried out without the written consent of Demag.

Page 43 ● ⇒ "Putting the unit into service for the first time". DC-Pro chain hoists are designed for operation at temperatures of -20 °C up to +45 °C. Do not remove safety equipment or render it inoperative by modifications. The slow speeds are intended for attaching the load. Short transport times can be achieved at higher speeds. Page 68 13 .4 Hazards which may be caused by the machine The machine has been subject to a risk analysis. At extreme temperatures and in aggressive atmophere or under conditions deviating from the section "Operating conditions". DANGER Live components Danger to life and limb. special meas‐ ures must be taken by the owner in agreement with Demag. cross-travel and long-travel motions are controlled by means of the corresponding control elements on the control unit. cleaning or repair work. If the insulation or individual components are damaged. Loads can be precisely positioned at slow speeds. Persons must keep out of the danger zone. or the installation or use of accessories. Do not walk under the suspended load. Please note the safety instructions in the chapters: ● ⇒ "Assembly". Depending on the type and scope of the machine. Check the components to be replaced for being de-energized. Switch off the power supply when carrying out any work on the electrical installation. – – – WARNING Crushing hazard The lifting or lowering of loads may cause crushing hazards for parts of the body. They are suitable for travelling without a load or with a safely suspended load if no hazard can be caused by the faster motion sequences.The manufacturer is not liable for unauthorized structural modifications which have not been agreed with him. 2. there is danger to life caused by electrical current. switch off the machine and secure against restarting. – – 214 741 44/210610 Before carrying out maintenance. as it causes increased wear and load sway. Use of the control pendant Powered lifting and lowering and. lifting it free and depositing it. if applicable. when lifted loads fall down. Electrical energy may cause serious injuries. equipment or sub-assemblies of other manufacturers that are not approved by the manufacturer. WARNING Suspended load! Falling parts! There is danger to life and limb. an inspection must be carried out by an expert engineer before handing it over to the owner. Keep a sufficient safety distance. When lifting or lowering loads. This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of delivery. Nevertheless there are residual risks! The machine is operated at high electrical voltage. The design and execution based on this analysis corresponds to state-of-the-art engineering principles. it must be ensured that no persons are in the immediate danger zone. Certain work and practices are prohibited when using the machine as they may involve danger to life and limb and result in lasting damage to the machine. Inching must be avoided.

Personnel are obliged to report to the owner without delay any changes to the machine that impair safety. etc. The operating instructions must be followed in full and without any limitations. ● personnel who work with or on the machine are provided with appropriate first-aid equipment. The personnel must be trained in the use of the first-aid equipment. Age and job-specific regulations relevant at the place where the machine is operated must be observed for the selection of any personnel. The owner is urged to develop procedures and guidelines to cover malfunction situations. maintenance and cleaning personnel. be supplemented by the owner with instructions relating to the organization of work. to the handling of hazardous materials or tools and the provision/wearing of personal protection equipment. ● the machine is only operated when in safe and proper working order. The owner and any personnel authorised by him are responsible for correct operation of the machine and for clearly defining responsibilities for installation. 14 . if required. ● the safety devices are always kept freely accessible and are checked regularly. Furthermore. the owner must ensure that ● any further working and safety instructions resulting from risk assessment of the machine workplaces are specified in operating procedures. authorized personnel. The operating instructions must.5 Responsibility of the owner Information on safety at work refers to the regulations of the European Union that apply when the machine is man‐ ufactured. to instruct users and to apply these instructions at a suitable place in a readily legible manner. The personnel must have received instruction on the machine functions and any hazards that may occur. ● the personnel are trained in accordance with the work to be performed. Local industrial safety legislation and regional regulations and codes of practice must be observed outside the European Union. supervising and reporting obligations. accident prevention and environmental protection regulations that apply where the machine is in operation must be observed and complied with in addition to the safety instructions contained in these operating instructions. the required safety measures must be defined and implemented by the owner. ● the specified regular checks and inspections are carried out on time and are documented. Persons under the influence of drugs. In such cases. 2. 214 741 44/210610 For independent operation (machine operator) or maintenance (trained maintenance fitter) of the DC-Pro chain hoist. maintenance and cleaning. for example. Page 70 ● ⇒ "Maintenance / repair".● ⇒ "Operation". Necessary measures may also relate. ● the operating instructions are always kept available in the immediate vicinity of the machine for installation. Page 70. operation. the owner may only employ persons ● who are at least 18 years of age. Page 78 2. working procedures.6 Operating personnel requirements Only authorised and trained personnel may operate the machine. Every individual given the task of working on or with the machine must have read and understood the operating instructions before any work is started. alcohol or medicines which affect their reactions must not work on or with the machine. The owner is obliged to ensure that the specified industrial safety measures comply with the latest rules and regulations and to observe new regulations during the entire service life of the machine. For further information please refer to ⇒ "Safety instructions for operation". ● the national regulations for the operation of cranes and lifting applinces are observed. General safety. Special local conditions or applications can lead to situations which are not considered in these operating instruc‐ tions. op‐ erating.

2. no rings or any other jewellery. ● who have been instructed in the operation and maintenance of chain hoists and who have proven their qualification to the owner in this respect.). 2. ● a record of tests and inspections must be kept. ● the machine must be inspected regularly. In Germany. this is specified by the accident prevention regulations for winches. 15 214 741 44/210610 . etc. 2. ● Safety shoes to protect against heavy falling parts and against slipping.8 Emergency stop device Fig. This is located on the control unit. the following must always be worn: ● Protective equipment. ● the elapsed share of the theoretical safe working period must be calculated.9 Regular inspections The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation and regional regulations.7 Personal protection equipment When work is carried out on or with the machine. 3 Position of the emergency stop device (1) To prevent damage and injuries. no loose sleeves. closely-fitting working clothes (low tear strength.● who are mentally and physically suitable. ● Safety helmet for all persons in the danger zone. lifting and towing devices (BGV D8) and the accident prevention regulations for cranes (BGV D6). The emergency-stop operating function must be checked regularly. These specify that ● the machine must be inspected before it is put into operation. for example. the machine is fitted with an emergency-stop device (1).

16 214 741 44/210610 . we recommend compliance with the above-mentioned regulations. If no comparable inspection regulations or requirements apply at the place where the machine is operated.The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe new regulations at all times.

214 741 44/210610 17 .

4 Single-fall design Item 1 2 3 4 5 6 7 8 9 10 Tab.5 two-stage helical gearbox DC 10 and DC 15 three-stage helical gearbox Suspension bracket Suspension bolt Service cover Item 21 22 23 24 25 26 27 28 29 30 Designation Adjusting mechanism for control cable Switch-off buffer for operating limit switch Hook assembly with capacity plate Motor shaft Winding head cap Stator Rotor Fan Fan cover Mounting points 18 .3 Technical data 3.1 Design overview Fig. 4 214 741 44/210610 Designation Electrical equipment cover Control Operation hours counter Window Pulse wheel for speed monitoring Magnet brake Brake disk with linings Brake springs Brake magnet Gearbox housing Item 11 12 13 14 15 16 17 18 19 20 Designation Chain guide Sprocket Round section steel chain Slipping clutch Dished washer pack Slipping clutch adjusting nut DC 1 .

415 / 50 24/6 200 220 .2 Mounting code E K L D DC-Pro 10 2000 2/1 H5 V6/1.5 380 . flange width of trolley [mm] Travel speed [m/min] Frequency [ Hz ] Voltage range chain hoist [V] Hoist speed [m/min] V VS Hook path [m] Reeving Load capacity [kg] Size 2) DC-Pro DCM-Pro DCS-Pro DCMS-Pro DCRS-Pro D L K U 22 34 56 R E C F 5 Tab.3.480 Voltage range / Voltage travel drive[V] Max. 5 Push-travel trolley Travel drive Click-Fit (push-travel trolley) 2-stage chain hoist (Demag chain hoist) 2-stage Manulift Variable speed chain hoist Variable speed Manulift Rocker switch stepless DC-Com 2-stage chain hoist basic version DC-ProDi DC-ProFi 2-stage chain hoist for direct control Variable speed chain hoist for control by means of an external frequency inverter 2-stage = Main / creep lifting Stepless = VS at nominal load up to VSmax in the partial load range Articulated curve-running trolley Long monorail hoist Low headroom hoist Standard-headroom monorail hoist 11 Trolley size load capacity [kg • 100] Not all features of the mounting code can be combined. 19 . 214 741 44/210610 2) The designations of sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 since 04/2006.

8 28.0/1.0/4.8 28.0 24.2 3m/M6 4m / M7 2m+ 8) / M5+ 1/1 4m / M7 4.8 9.4 19.2 5.0 24.0/2.0/2.0/6.6 9.0/2.0/3.0 6.7 x 24.0/1.2/1.8/7.2 4m / M7 5.4x21.0/3.8/7.6/2.4x21.0 7) 8.0 6.0/6.2/1.8/7.6/2.6 28.6/2. 5) Motor data ⇒ "Hoist motor data ".2 5.0/2.0 16.3x15.2x12.0/2.4/3.7 x 24.2 7.0 16.0 16.2 3m/M6 4m / M7 3m/M6 2m+ 8) / M5+ 4m / M7 2m+ 8) / M5+ 5. 4) Larger 214 741 44/210610 .3x15.6/2.4x21.3.2 4.4x21.2 7.4x21.5 7.0/6.0/2.2 5.0/6.2x12.0/3.5 12.3x15.0 8.0 12.0 6.0 16.8 9.0 16.0 24.4 19.0 24.8 28.2/4.0 24.0/2.0/4.2x12.5 8.4 19.2/1. for replacement requirements.8 14.0/6.2 8.2 9.2 8.4x21.8 14.2 3m/M6 2m+ 8) / M5+ 15 4m 9) / M7 2/1 1/1 2/1 1/1 2m+ 4m / M7 1Am 10) / M4 3m 11) / M6 3m/M6 8) 12) 7) 7) Standard hook path4) H [m] Motor size 5) 4m [kg] ZNK 71 A 8/2 6) ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 A 8/2 6) Max.5 8.2/4.2 7.8 [kg] 80 DC-Pro 1 2 5 1 100 2 5 1 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 A 8/2 6) ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 71 B 8/2 5 and 8 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 4 5 and 8 4 5 and 8 4 5 and 8 4 5 and 8 4 ZNK 100 B 8/2 125 2 5 2 160 5 2 200 5 10 2 250 5 10 5 315 10 5 400 10 5 500 630 10 800 4m / M7 12.8/1.0/3.0 6.6/2.2 4.2 4.8/7.0/4. 6 10 15 10 15 10 15 103 103 103 / M5+ 2m+ 8) 12) / M5+ 4m 13) / M7 2/1 1Am 10) / M4 3m 9) / M6 2m+ 8) 11) / M5+ 4.3x15.4 19.0 12.3x15.2/4.6/2.2 9.2 4.2/4.8 28.2 8.4/3.4 9.2x12.0 7) 8.0/2.0/4.0/3.2 Chain size Hoist speed at 50 Hz [m/min] 8.0 16.6 28.7 x 24.6 7.0 7) 8.0/4.6/2.6/2.0 1000 8.2 9.8 28.4 14. weight at hook path 5m [kg] 22 28 22 28 22 28 22 28 22 28 48 22 28 48 28 48 56 28 48 56 28 48 56 48 56 48 56 48 56 103 103 105 65 56 105 65 105 65 105 65 105 8m [kg] 24 30 24 30 24 30 24 30 24 30 52 24 30 52 30 52 60 30 52 60 30 52 60 52 60 52 60 52 60 110 73 60 110 73 110 73 110 73 110 at 60 Hz [m/min] 9.0 8.6 28.0/3.0/6. hook paths on request.2x12.2/1.2/4.7 x 24.2 7.2 8. Page 22.2 3) The 20 designations of sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 since 04/2006.3 SWL Selection table Size 3) Chain hoist Reeving Group of mecha‐ nisms DIN EN 14492 FEM / ISO [mm] 4.4/3.3x15.0/6.4 7.0 7) 8.2 9.6/2.4 14.3x15.0 7) 8.8 14.7 x 24.8/7.2 7.4/3.0 24.8/7.2 9.0/1.4 19.0/4.2x12. the motor is replaced by the ZNK 71 B 8/2 motor.8/7.2/1.2 5.0 7) 8.4 14. 6) ZNK 71 A 8/2 with 380-415 V / 50 Hz only for initial delivery.0/2.6 7.2 7.6/2.4 19.4 7.0 24.2 9.2 7.0/1.8/7.8 28.0/2.2 7.2 5.2/4.2 9.0 4.4x21.4 7.2/1.0 8.0 12.0/1.0/6.2 8.4/3.0/2.6/2.2 7.0 24.2 9.0/2.0/2.2 5.5 1250 10 15 1600 2000 2500 3200 Tab.0/1.5 12.6/2.4/3.2 5.3x15.0/1.0 7) 6.4x21.0 6.8/7.6/2.4x21.0/6.0 24.3x15.

2/4.0/4.8 and 4.0 / M5+ 4m / M7 Hoist speeds until 03/2007 (no longer available) SWL Size Chain hoist [kg] 160 200 250 315 400 500 Tab.6/2.0/3. 8 SWL Size Manulift [kg] 200 250 Tab.0/2.0/4.6/2.0 at 60 Hz [m/min] 14. operating limit switch for lowering on request (the lower end position must not be approached in normal operation).0 16) 125 2 5 2 5 2 5 2. 7 3m/M6 4m / M7 2m+ 17) 8.2/4.4 19.0 16.4 19. weight at hook path 2.2/4.2/1.6/2. Page 22.0/4.4 19.2 9. 15) ZNK 71 A 8/2 with 380-415 V / 50 Hz only for initial delivery.8 and 4.0 24.0/2.0 16.0/1.0/6.4/3.0/6.4/3.8 Hook path H [m] Motor size 14) Max.0 16) 8. 214 741 44/210610 21 .0/2.6 Hook path H [m] 2.0/3.2 9.6 5 and 8 ZNK 80 A 8/2 19) 28 30 DC-Pro Reeving Group of mecha‐ nisms DIN EN 14492 FEM / ISO Hoist speed at 50 Hz [m/min] at 60 Hz [m/min] Standard hook path18) H [m] Motor size 14) Max.6/2.0 8.2/4. 16) Only with operating limit switch for lifting. 9) Chain drive FEM 2m+ according to EN 818-7 10) Chain drive FEM 1Cm according to EN 818-7 11) Chain drive FEM 1Am according to EN 818-7 12) Chain drive FEM 1Bm according to EN 818-7 13) Chain drive FEM 3m according to EN 818-7 14) Motor data ⇒ "Hoist motor data ". 9 DCM-Pro 5 1/1 Reeving Group of mecha‐ nisms DIN EN 14492 FEM / ISO 4m / M7 Hoist speed at 50 Hz [m/min] 12.3 m [kg] 30 5 1/1 2m+ 17) / M5+ 6. 19) ZNK 80 A 8/2 only for initial delivery.0/4.SWL Size Manulift Reeving Group of mecha‐ nisms DIN EN 14492 FEM / ISO Hoist speed at 50 Hz [m/min] 8. weight at hook path 5m [kg] 8m [kg] 7) Only with operating limit switch for lifting.8 m [kg] 28 4.8 m [kg] 4. weight at hook path 2.3 ZNK 80 A 8/2 19) Motor size 14) Max.0 14. operating limit switch for lowering on request (the lower end position must not be approached in normal operation).3 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 200 250 Tab.0 at 60 Hz [m/min] 9. the motor is replaced by the ZNK 71 B 8/2 motor. 18) Larger hook paths on request. 8) 2m+ corresponds to 1900 hours operation at full load.4 19.3 m [kg] 24 30 24 30 24 30 24 30 [kg] DCM-Pro 1 ZNK 71 A 8/2 15) 80 22 28 22 28 22 28 22 28 2 5 1 4m / M7 1/1 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 A 8/2 15) 24.8 28.8 9.0 16.0 16.8 4m / M7 12. the motor is replaced by th ZNK 80 B 8/2 motor.0/2.5 7.8 28.8/7. for replacement requirements. for replacement requirements.8/7. 17) 2m+ corresponds to 1900 hours operation at full load.

60 1.40 1.45 2.70 2.70 3.45 2.95 1.85 4. 50 Hz.10 1.40 1.51 0.40 2.35 3.77 0.40 3.10 1.05 0.56 0.66 0.35 1.45 2.60 1.57 2.60 2.20 1.77 0.46 0.81 0.63 0.48 0.57 2.1 Electrical key values Hoist motor data Size Motor size No. cos φN 220-240 V. the motor is replaced by the ZNK 71 B 8/2 motor.72 0.40 1.00 1.60 1.58 0.18 0.50 2.90 1.51 0. 3 ~ (CE) 21) ZNK 71 A 8/2 22) DC-Pro 1 ZNK 71 B 8/2 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 500-525 V.57 2.35 2.77 0. 50 Hz.25 0.10 1.10 0.75 1.10 3.10 0.18 0.54 0. [A] 1.50 4.10 1.10 1.25 1.77 0.77 0.10 3.10 0.18 0.10 0.75 1.70 4.00 5.20 1.20 0. 10 ZNK 100 B 8/2 20) I 22 21) The max = maximum rated current for lowering operation.45 3.10 0.80 1.90 0. for replacement requirements.54 0.90 3.58 0.20 2.20 1.70 2.3.10 5.60 1.35 2.54 0.30 5.85 4.25 1.27 1.37 0.80 4.75 2.10 0.85 4.50 3.20 1. 71 A 8/2 with 380-415 V / 50 Hz only for initial delivery.75 2. of poles PN [kW] 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 0.80 2.51 0.77 0.60 1.45 2.4 3. currents and starting current IN max.60 1.80 3.85 4.50 2.70 3.70 4.45 2.10 2.46 0.75 1.10 2.00 5.50 3.60 2.75 1.15 1.72 0.45 3.90 6. 3 ~ (CE) 21) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 380-415 V.60 1.77 Starts/h IN min.58 0. 50 Hz.4.30 0.50 4.40 2.15 1.90 1.81 0.80 2.37 0. 22) ZNK 214 741 44/210610 .57 2.95 4.95 1.20 3.63 0.20 1.20 3.80 3.10 1.45 1.75 1.45 2.63 0.57 0.05 0.81 IA/IN max.27 1.56 0.60 0. Motors are designed in compliance with insulation class F. / max.20 2.30 0.80 2.15 1.40 2.80 1.57 2.45 3.58 0.80 3.90 6.30 0.15 0.80 2. tolerance of the voltage range must not exceed ± 10%.40 1.15 1.40 6.18 0.10 5.00 1. 3 ~ (CE) 21) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 Tab.75 0. [A] 2.18 0.85 1.18 0.40 0.80 3.20 3.10 3.45 3.75 1.30 0.46 0.48 0.95 1.80 2.30 1.20 1.18 0.30 0.05 0.72 0.10 2.37 0.00 1.80 6.10 1.95 1.56 0.48 0.27 1.30 CD F [%] 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 nN rpm 720 2925 675 2825 665 2745 690 2745 675 2790 675 2790 700 2840 720 2925 675 2825 665 2745 690 2745 675 2790 675 2790 720 2925 675 2825 665 2745 690 2745 675 2790 675 2790 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 0.40 Min.50 0.95 5.20 1.90 2.00 1.00 1.40 6.05 0.40 Imax 20) [A] 2.57 2.

50 2.45 3.76 0.55 6.76 0.22 0.62 0.53 0.60 7.45 2.95 1.00 6.80 IA/IN max.62 0.68 2.50 1.90 1.00 1. of poles PN [kW] CD F [%] 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 nN rpm 870 3525 825 3425 815 3345 840 3345 825 3390 825 3390 870 3525 825 3425 815 3345 840 3345 825 3390 825 3390 870 3525 825 3425 815 3345 840 3345 825 3390 825 3390 870 3525 825 3425 815 3345 840 3345 825 3390 825 3390 Starts/h IN min.68 2.75 1.80 1.75 1.85 4.32 1. 3 ~ (CE) 24) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 1.76 0.60 3.00 1.00 6. / max. 3 ~ (CE/CSA) 24) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 575 V.45 0.60 4.75 1.53 0.75 1.22 0.76 0.Size Motor size No.50 2.00 1.10 2.70 3.30 3.50 0.57 0.25 1.75 1.80 - 380-400 V. 11 23) I ZNK 100 B 8/2 24) The max = maximum rated current for lowering operation.00 1.22 0.22 0.90 2.50 0.44 0.44 0.60 0.85 4.45 0.85 4.45 3.80 2.30 0.75 1.45 1. 3 ~ (CSA) 24) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 214 741 44/210610 DC-Pro 15 Tab.15 1.35 2.22 0.80 1.20 2.68 2.30 1.40 0. cos φN 220-240 V.32 1.10 1.85 4.40 4.80 0.95 2.20 3.25 1.90 4.06 0.68 2.80 0.76 0.90 7.68 2.70 4.00 2.06 0.15 1.57 0.70 1.05 1.40 2.44 0.15 1.62 0.65 1.70 2.11 0.83 0.80 3.45 3.45 0.75 2. tolerance of the voltage range must not exceed ± 10%.20 1.70 4.11 0.55 0.50 3.40 1.95 3.30 3.85 3.05 1.35 2.50 5.10 3.50 3.50 6.80 3.06 0.11 0.47 0. 60 Hz.46 0.40 3.30 0.86 0.80 0.22 0.30 1.00 1.58 0.60 2.50 1.10 5.10 1.80 3.80 3.80 0.40 4.50 3.90 1.75 1.30 2.60 4.86 0. 23 .55 0.70 2.63 0.90 4.30 7.60 4. 60 Hz.22 0.45 2.68 2.62 0.90 8. currents and starting current IN max.50 0.88 0.83 440-480 V.15 1.86 0.70 4.25 1. [A] 2.15 1.68 2.65 1. [A] 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 1.75 1.68 2.70 2.10 2.80 0.80 2.80 2. Motors are designed in compliance with insulation class F.45 2.65 1.00 4.60 1.70 4.25 3.80 0.75 1.50 1.30 0.86 0.62 0.76 0.60 1.85 0.87 0.85 4.80 3.85 0.70 4.50 Min.80 0.06 0.45 2.60 2.30 7.60 0.70 1.15 0.44 0.90 2.65 0.30 0.80 3. 60 Hz.55 2.35 1.45 2.20 3.45 2.55 0.00 3.00 3.35 2.57 0.45 3.40 3. 3 ~ (CE/CSA) 24) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 0.50 2.40 2.00 1.90 6.00 4.25 1.47 0.00 1.53 0.80 1.80 0.47 0.45 2. 60 Hz.11 0.90 8.00 1.80 0.90 7.57 0.35 2.50 6.40 Imax 23) [A] 2.76 0.85 4.32 1.40 1.30 5.90 0.54 0.22 0.48 0.45 2.60 2.32 1.00 1.10 5.15 1.

47 0.56 0.00 1.57 0. to DIN EN 60898-1.35 2.2 Mains connection delay fuse links Voltage Frequency Size DC-Pro 1 DC-Pro 2 DC-Pro 5 DC-Pro 10 DC-Pro 15 Tab. [A] 2.50 1.15 1.90 Imax 25) [A] 2.91 1.00 1.Hoist speeds until 03/2007 (no longer available) Size Motor size No. 50 Hz.14 0.47 0. / max.90 2.35 0.56 0.00 2. 60 Hz. 3 ~ (CE) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 440-480 V.14 0. 12 ZNK 80 A 8/2 240 120 3.50 3.15 2.10 4. 3 ~ (CSA) DC-Pro 5 DCM-Pro 5 Tab.56 0.80 4.35 2.00 1.10 4.45 3. cos φN 220-240 V.90 1.35 2.10 4.90 1. 13 Motor size ZNK 71 A 8/2 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2 10 10 16 10 10 6 6 6 10 16 15 10 15 10 6 6 6 6 [A] 220-240 V 380-415 V 50 Hz [A] [A] [A] [A] 500-525 V 220-240 V 380-400 V 60 Hz [A] [A] 440-480 V 575 V CAUTION For safety reasons we recommend using 3-pole automatic circuit breakers / circuit breakers ( acc. 3 ~ (CE/CSA) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 575 V.15 2.10 4.20 2.20 5. 3 ~ (CE) 26) ZNK 80 A 8/2 380-415 V.47 0.50 3.17 0.56 0. 60 Hz.35 3.40 1.56 0.57 0.46 0.4.30 2. tripping characteristics B or C) instead of individual fuses. currents and starting current IN max.00 4. tolerance of the voltage range must not exceed ± 10%.56 0. Motors are designed in compliance with insulation class F.10 4.40 5.35 2.00 0.40 0.40 1. 50 Hz. Mains connection fuse link for hoist speeds until 03/2007 (no longer available) Voltage Frequency Size DC-Pro 5 DCM-Pro 5 Tab. of poles PN [kW] DC-Pro 5 DCM-Pro 5 8 2 8 2 8 2 8 2 8 2 8 2 8 2 0.00 7.10 4.10 4. 60 Hz.35 2.48 0.14 0. 50 Hz.10 1. 14 Motor size ZNK 80 A 8/2 [A] 10 220-240 V 380-415 V 50 Hz [A] 6 [A] 6 [A] 10 [A] 6 500-525 V 220-240 V 380-400 V 60 Hz [A] 6 [A] 6 214 741 44/210610 440-480 V 575 V 24 25) I 26) The max = maximum rated current for lowering operation.57 0.10 1.70 6. . 3 ~ (CE) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 500-525 V.48 0. 3 ~ (CE/CSA) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 380-400 V.25 2. 3 ~ (CE) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 220-240 V.55 1. Thus all poles are disconnected from the energy source in the case of a short circuit.35 2. 60 Hz.30 2.65 IA/IN max. [A] 2.67 CD F [%] 20 40 20 40 20 40 20 40 20 40 20 40 20 40 nN rpm 710 2880 710 2880 710 2880 860 3480 860 3480 860 3480 860 3480 240 120 240 120 240 120 240 120 240 120 240 120 26) Starts/h IN min.50 5.67 0.50 Min.05 2.67 0.48 0.17 0.95 1.17 0.17 0.67 0.70 3.60 3.

5 [m] 43 [mm2] 1.5 [m] 100 575 V [mm2] 1. 16 Motor size ZNK 80 A 8/2 [mm2] 1.3 Supply lines Supply lines 27) for 5% voltage drop ΔU and start-up current IA Voltage Frequency Size DC-Pro 1 DC-Pro 2 DC-Pro 5 DC-Pro 10 DC-Pro 15 Tab.4.5 [m] 100 [mm2] 1.5 43 52 1.5 94 38 46 1.3.5 89 1.5 [m] 100 60 Hz 214 741 44/210610 27) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.5 78 90 100 1.5 100 1.5 31 34 1.5 100 1.5 61 73 100 1.5 [m] 51 220-240 V 380-415 V 50 Hz [mm2] 1. 25 .5 1. 15 Motor size ZNK 71 A 8/2 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2 1.5 100 [mm2] [m] 220-240 V 380-415 V 50 Hz [mm2] [m] [mm2] [m] [mm2] [m] [mm2] 500-525 V 220-240 V 380-400 V [m] 440-480 V [mm2] [m] 575 V [mm2] [m] 60 Hz Supply lines for hoist speeds until 03/2007 (no longer available) Voltage Frequency Size DC-Pro 5 DCM-Pro 5 Tab.5 26 29 2.5 75 78 45 36 1.5 500-525 V 220-240 V 380-400 V [m] 100 440-480 V [mm2] 1.5 76 1.5 [m] 100 [mm2] 1.

29) For higher hoist speeds a larger chain collector may be required. Page 110 214 741 44/210610 .8 m DCM-Pro 5 4.8 m DCM-Pro 1/2 4.eps Fig. see ⇒ "Buffer design".3 m DC-Pro 5 DCM-Pro 5 2.5 Hook dimensions C DC-Pro chain hoist and DCM-Pro Manulift with suspension bracket 43214045. 5 A B Size DC-Pro with short suspension bracket DC-Pro with long suspension bracket Reeving Motor size C28) C D C129) DCM-Pro Manulift with short suspension bracket DCM-Pro Manulift with long suspension bracket Long suspension bracket C28) C129) Chain collector box size S 364 694 764 416 1 2 H5 373 H8 403 Short suspension bracket Chain collector box H5 H8 365 DC-Pro 1 / 2 DCM-Pro 1/2 2. 17 ZNK 100 B 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2 1/1 ZNK 80 … ZNK 71 … 326 656 726 378 708 778 472 564 493 582 582 632 395 425 335 746 816 505 597 580 - - - 435 526 615 465 615 665 - 688 H9 663 H4 663 H16 783 H8 783 H26 863 H13 863 28) The 26 C dimension is increased by 42 mm for chain hoists with v = 16/4 or v = 12/3. the C dimension is increased by 131 mm for DC 10 chain hoists with v=24/6. the C dimension is increased by 111 mm for DC 5 chain hoists with v=24/6.3.3 m ZNK 100 A 8/2 DC-Pro 10 2/1 1/1 DC-Pro 15 2/1 Tab.

8m DCM-Pro 1/2 4.eps Fig.DC-Pro chain hoist with trolley 43214245. 31) The C dimension is increased by 42 mm for chain hoists with v = 16/4 or v = 12/3. see ⇒ "Buffer design". Page 38. U22. U 34 trolley transverse to girder U 11. U 34 trolley parallel to girder Parallel to girder 30) C31) H5 425 415 425 415 425 415 487 477 487 477 487 477 578 590 667 679 679 H8 455 445 455 445 455 445 517 507 517 507 517 507 667 679 667 679 729 410 400 740 770 710 838 462 452 792 840 862 890 581 593 581 593 685 676 692 784 800 H9 759 H9 775 H4 759 H4 775 H16 879 H16 895 H8 879 H8 895 H26 1004 H26 975 H13 1004 H13 975 S 1 C132) Chain collector box size 2 H5 419 409 419 409 419 409 481 471 481 471 481 471 602 614 691 703 703 H8 449 439 449 439 449 439 511 501 511 501 511 501 691 703 691 703 753 C132) Transverse to girder 30) Chain collector box size 1 2 DC-Pro 1 / 2 DCM-Pro 1/2 2.8 m DCM-Pro 5 4. the C dimension is increased by 131 mm for DC 10 chain hoists with v=24/6. see also ⇒ "Suspension". U22. 32) For higher hoist speeds a larger chain collector may be required.3m DC-Pro 5 DCM-Pro 5 2.3 m ZNK 100 A 8/2 DC-Pro 10 2/1 ZNK 100 B 8/2 ZNK 100 B 8/2 1/1 ZNK 80 … ZNK 71 … U 11 CF 5 U 11 CF 5 U 11 CF 5 U 11 CF 5 U 11 CF 5 U 11 CF 5 U 11 U 22 U 11 U 22 U 22 U 34 U 22 U 34 RU 56 ZNK 100 B 8/2 2/1 416 406 746 776 716 844 468 458 798 846 868 896 557 569 557 569 661 644 660 752 768 H9 727 H9 743 H4 727 H4 743 H16 847 H16 863 H8 847 H8 863 H26 972 H26 943 H13 972 H13 943 - 1/1 DC-Pro 15 U 22 U 34 RU 56 Tab. 6 E F Size CF 5 trolley transverse to girder CF 5 trolley parallel to girder Reeving Motor size Trolley C31) S G H U 11. the C dimension is increased by 111 mm for DC 5 chain hoists with v=24/6. 18 214 741 44/210610 C and C1 decrease when the short suspension bracket is used: for DC-Pro 1-5 by 38 mm and for DC-Pro 10 by 33 mm. Page 110 30) Dimensions 27 .

Bring your claim to attention.7. ● reflection of noise from walls. ● In the case of transport damage visible from the outside. ● Claim any defects not immediately detected immediately on detecting the defects. If no agreement on the return of the packing material has been made. If you have any questions.6 Noise emission / sound pressure level The sound pressure level acc. were not allowed for in the above measurements.2 Scope of delivery If special designs or additional options are ordered or latest technical modifications are incorporated. 214 741 44/210610 28 . Sling lifting and handling equipment only at the correspondingly marked points. Do not walk under the suspended load. Structural influences such as ● transmission of noise via steel structures. 3.7 3. Environmental protection: ● Always dispose of packing material in an environmentally sound way and according to the locally applicable disposal regulations. since claims for damages may only be asserted within the valid time for complaints.3. – – WARNING Transport damage The chain hoist may be damaged or destroyed by inappropriate transport. ● If required.1 Transport. Spaciously close off the working area. 19 [m/min] [dB (A)] DC-Pro 1 8 65+2 DC-Pro 2 16 65+2 DC-Pro 5 12 69+2 DC-Pro 10 12 69+2 DC-Pro 15 8 69+2 These noise emission levels were measured under maximum load. Note scope of damage in shipping documents / delivery note of the forwarding company.7. the actual scope of supply may deviate from the data and information as well as from the illustrations described here. Keep a sufficient safety distance.3 Transport inspection ● Check the delivery for completeness and transport damage immediately upon receipt. a recycling company must be charged with the disposal.7. packing and storage Safety instructions WARNING Falling parts During transport and loading or unloading there is a danger of injury due to parts falling down. to DIN 45635 (LpAF) at a distance of 1 m from the chain hoist is: Type Hoist speed up to Sound pressure level Tab. do not accept the delivery or only under reserve. 3. separate the material according to type and size and make it available for further use or recycling. 3.7. 3.4 Packing Demag chain hoists. etc. the accessories and the trolleys are shipped in cardboard packing. please contact the manufacturer.

If required. ● Avoid strong temperature fluctuations (condensed water). ● If stored in damp locations. ● Store in dry and dust-free places. refresh or renew preser‐ vation. the equipment must be packed tight and protected against corrosion (desiccant).5 Storage Keep the equipment and accessories locked and stored only under the following conditions: ● Do not store it outdoors. relative air humidity: max.3. the chain hoist is supplied with corrosion protection (powder coating/paint finish) in the following colours: Colours Chain hoist Hook assembly Load hook and suspension bracket Trolley Tab. ● Protect it against solar radiation. ● Check the general condition of all parts of the packing at regular intervals. 20 RAL 5009 RAL 1007 RAL 9005 RAL 5009 Azure blue Daffodil yellow Jet black Azure blue Other colours are possible.8 Surface protection and painting As standard. 3. 214 741 44/210610 29 .7. ● Oil all blank machine parts (rust protection). ● Avoid mechanical vibrations. ● Do not expose it to aggressive media. 60%. ● Storage temperature: -25 to +70 °C.

Interference emissions for residential. ● DC1-10 reeving 2/1 DK10 aluminium bottom block with external switch-off springs (optional) . galvanizing plants. trolley and travel drive should be kept under shelter if they are not used for a considerable length of time. 80 % relative humidity. Page 30. Under certain ambient conditions. Special operating conditions may be agreed with the manufacturer in individual cases. up to 1000 m above sea level.for extreme ambient conditions (hot atmospheres. low-wear operation may be supplied for these applications.for very high mechanical demands on the buffers. e. etc. 21 Demag chain hoists operating outdoors should be provided with a canopy against the weather.g. ● low-temperature or hot applications. Reduced duty factor at increased ambient temperature If the DC chain hoist is operated at ambient temperatures deviating from ⇒ Tab. galvanizing plants. Page 11 The chain hoist and the trolley can be operated at: Ambient temperature: Humidity: Height: Type of enclosure: Electromagnetic compatibility: -20 °C to +45 °C.for extreme ambient conditions (hot atmospheres. foundries. Chain hoists. application of cut-off springs is required: ● DC1-10 reeving 1/1 hook assembly .Use of switch-off springs (optional) .). the duty factor must be reduced: Ambient temperature Chain hoist range DC-Pro DCM-Pro DC-Com 1 DC-Com 2-10 Tab. max. etc. ● hygiene areas. for example: ● galvanizing or electroplating plants. IP55. frequent contact with sharp edges. commercial and light-industrial environ‐ ments. . Resistance to interference in industrial environments. 21.9 CAUTION Operating conditions Operating safety at risk Safe operation is only possible at the specified operating conditions. 22 20 / 40 15 / 25 15 / 35 15 / 25 -20 °C to +45 °C > +45 °C to +50 °C > +50 °C to +55 °C > +55 °C to +60 °C Duty factor [%] 15 / 25 15 / 25 10 / 20 10 / 20 30 214 741 44/210610 .). ● DC 15 hook assembly / standard aluminium bottom block with external switch-off springs. foundries. In the case of other operating conditions please contact the manufacturer ⇒ "Customer service". suitable optimised equipment and important information for safe. Tab. Such operating conditions may occur for the following applications.3. On request.

4 Technical description 4. The brake arranged on the load side prevents load sinking when the unit is at rest.1 Drive and brake A robust pole-changing AC asynchronous motor is used as hoist motor. it performs the function of the emergency limit stop device for the highest and lowest hook position and protects the Demag chain hoist against overload. The slipping clutch also fulfills the EC directive requirements for a load control device from a load capacity of 1000 kg on. Pressure springs ensure automatic brake application when the motor current is switched off or in the event of a power failure. 23 Fig. Monitoring the slipping clutch and automatically switching off the drive in the event of slip increase the service life and protect the slipping clutch against overload and incorrect use. The brake for DC 1 . 7 Parts in which the load is borne The slipping clutch is arranged between the motor shaft and the gearbox input shaft.5 chain hoists is maintenance-free for up to 10 years. the load is safely braked and held. The motor is automatically switched off and at the same time the brake is applied in the upper and lower end positions of the lifting path. the brake for DC 10 and DC 15 chain hoists for up to 5 years. When the emergency-stop button is actuated. Electrical or regenerative braking of the motor considerably recudes wear of the mechanical brake. when the slipping clutch is tripped and in the event of error statuses. 214 741 44/210610 31 . 4. The additional electrical operating limit switches for the highest and lowest hook position prevent the slipping clutch from being approached as an emergency limit stop device during normal operation. The gearbox and the slipping clutch are maintenance-free for up to 10 years.2 Gearbox and slipping clutch A 1 2 3 Driving Slipping clutch Motor Chain drive B 4 5 6 Brakes Speed detection Brake Gearbox Tab. First the hoist drive decelerates by switching from the fast speed (2-pole winding) to the creep lifitng speed (8-pole winding). Mechanical braking is performed when the creep lifting speed is almost reached. The bake is released elec‐ trically. mechanical braking is immediately performed independent of the lifting speed. In connection with the end stops on the chain. The brake is arranged on the load side so that after an eventual tripping of the slipping clutch.

4 Housing The housing of the chain hoist is of strong light-weight die-cast aluminium. ● 7-segment display for operating hours. For controlling pole-changing AC motors (with or without brake) of cross and long travel units the Polu box with integrated contactor control is required. always the entire chain drive is replaced. In the event of any discrepancies. operating status and error messages. 4. This electronic system detects the control commands that are tripped by the operator with the control pendant. it is not necessary to dismantle the motor or the gearbox. ● Replaceable contactor with socket for DC-Pro 10 and DC-Pro 15. The dimension tolerances of this chain have been precisely adapted to the chain drive. ● Plug-type connections for control pendant. For Demag DC chain hoists without electric trolleys. if applicable. the service cover and the movable chain collector box are of particularly impact-resistant plastic material. power supply.5 4. Demag control pendants are connected via plug-in connectors. The positively disconnected emergency stop contact of the control pendant immediately opens the circuit for the contactor supply so that the motor is de-energized and the brake is applied. For this purpose a chain set that can easily be replaced is available. 3.E 34 trolley control system. galvanised with additional surface treatment. please note the information in the brochure "DC electrical accessories" ⇒ Tab. from the thermal contacts of the motor. The electronic system monitors the control sequence specified by the operator based on the speed feedback from the drive shaft.3 Chain drive The special Demag chain is of high strength ageing-resistant material with a high degree of surface hardening. Page 7.5. ● reliable decision for replacing the individual chain drive components. ● Infrared interface for wireless transmission of service data. The contactor control system is supplemented by an electronic system with programmed functions. ● Signal transmission in steps with 24 V tri-state signals for controlled DC chain hoists (half-wave evaluation).1 Electrical equipment Control The chain hoist is provided with a 24-V contactor control system. see brochure "Elec‐ trical accessories Polu box "⇒ Tab. As standard. ● Connection for the E 11 . We therefore urgently recommend that the Demag special chain be used to ensure safe operation. 32 214 741 44/210610 .4. The fan cover on the motor. 3. For manual control. the DSE-10C for applications with electric trolleys. For integrating the DC chain hoist in existing installations with contactor control. The maximum service life of the chain can only be reached. 4. if the specified regular lubrications are appropriately carried out. the control system features the following characteristics: ● Emergency limit switch for lifting and lowering. motor connection. When a chain is replaced. Permissible control commands generate switching commands for the contactors to control the hoist motor. brake. operating limit switches. ● reduction in service costs by replacement in one installation process. the compact DSC optimised for this application is used. Page 7. The chain set offers the following benefits: ● the optimum duration of service is ensured for the chain. the operating limit switch contacts and. the chain hoist is automatically brought to a safe status and warning or error messages are generated.

01).5. Example: Software version 1. Page 124. it can be read through the window on the lower side of the chain hoist (arrow. The following data can be read: ● Software version ⇒ Fig. ● Operating statuses ⇒ Fig. Page 34.4. Page 34. operating statuses Display of the software version Fig.3 Software version. ● Warning messages ⇒ "Warning messages". Page 33.5. 4. 8 The 7-segment display is arranged on the control card under the electrical equipment cover. power is switched on or after an emergency-stop. Page 125.01 214 741 44/210610 33 . 9 Every time. number of cycles. the software version is displayed (from software version 1. 12. 10. ● Operating hours ⇒ Fig. lower side of electrical equipment cover).2 7-segment display for operating status and error display 43216145. 9. operating hours.eps Fig. ● Error messages ⇒ "Error messages".

6 Central service enclosure 43214444. without any lifting motion (example for 123 operating hours) Display of the number of cycles of the K1 contactor Fig. stop pressed 3 5 7 Tab. 10 The display appears after 3 sec. 24 4 6 8 LOWERING start-up LOWERING V1 LOWERING V2 43216046. 11 Alternatively displayed with the operating hours.eps Fig.000 = 500.000 = 1. C 5 corresponds to 5 x 100. Page 80 Display of operating statuses No. 13 214 741 44/210610 . 12 4.Display of the operating hours Fig. 2 Function Emerg. 1 Function Flashing: READY FOR OPERA‐ TION LIFTING start-up LIFTING V1 LIFTING V2 No.5 m K1 switching cycles For preventive maintenance see ⇒ "Service life of the contactor".000 K1 switching cycles Example: C 15 corresponds to 15 x 100.eps 34 Fig.

To avoid this. The control pendant can be adjusted to a different suspension height by unlocking the clamp mechanism. hydrochloric or sulphuric) acids may. Both control pendants feature the same plug-in connection for the control cable. the DSC control pendants (lifting/lowering) or the DSE-10C (2 to 3 axes) are to be used. any control cable length that is not required is kept under the cover. the chain is also lubricated. it is not necessary to cut the cable conductors or to shorten the strain relief hose. The shock and impact-resistant DSC and DSE-10C housings of high quality thermoplastic are resistant to fuels. The control cable that is not required is accommodated under the service cover.8 m) of the strain relief hose. Replace any damaged button caps in good time. control pendant and travel drive are arranged under the impact-resistant plastic cover. The relevant connectors for power supply. 4. salt water. Its suspension height can be specifically adapted to the requirements at the workplace at any time by means of an adjusting mechanism.7 Control pendant height adjustment / control cable The control cable is protected by a flexible.g. The strain relief hose is fixed at the selected suspension height by means of a self-locking clamp mechanism. The service cover of the DC-Pro 15 is made of sheet metal without any pictograms.8 Control pendant For manual cable-connected control of the chain hoist. The rubber button caps may be subject to premature wear under aggressive operating conditions (contact with corrosive substances or special chemicals). The functions are described by pictograms fitted on the outside of the service cover. corrode pendant switch housings. The control cable is reinforced by means of rubber-elastic filler material in the gripping area (0. The strain relief hose for the control pendant consists of an abrasion-resistant fabric hose with flame-protection impregnation. In addition. To do this. oils and alcaline solutions. 214 741 44/210610 35 . they must be replaced in good time. type of enclosure IP 65. Strong mineral (e. easily bent strain relief hose. The plastic cover also provides mechanical protection for the components fitted under it. The control cable and the control pendant are connected by means of a bayonet lock. From this point.All important service work can be carried out at a central point. greases. however. the service enclosure. 4.

Type of enclosure IP 65. when no load is applied. The rigid link between the DSM-C control unit and the load handling attachment provides a direct connection between the operator’s hand and the load. The shock and impact-resistant housing of high quality thermoplastic is resistant to fuels. 2 switching stages are available: ● Slow lifting or lowering is obtained by pressing the rocker until a stop is felt. The handle can thus conveniently be gripped with the left or right hand. ● Fast lifting or lowering is obtained by pressing the rocker down completely. 43214544. salt water. The lifting and lowering movements are marked by arrow symbols. Serial load hook 1 CAUTION Swivel lock Removing the swivel lock (1) means danger to life and limb. The R/H and L/H rockers (lifting and lowering) which both have the same functions. 3. positioning and moving the load horizontally. 14 36 214 741 44/210610 .9 Manulift DCM with quick-release coupling The Manulift DCM is equipped with the DSM-C control unit.eps Fig. The swivel lock of the load handling attachment must not be removed. greases and alkaline solutions.4. Power is supplied to the DSM-C control unit through a wear-resistant helical cable. The rocker is actuated with the thumb without the fist having to be opened. For further possible applications see Technical data Demag DC-Pro chain hoist ⇒ Tab. The integrated quick-release coupling allows the load handling attachments to be removed and replaced within seconds. oils. Page 7. ● Mechanical interlocking of the switching elements prevents movement in opposite directions being switched on simultaneously. Convenient operation is mainly due to: The spade handle for guiding.

max.Accessories Fig. dia. 214 741 44/210610 37 . 3. 3. to be gripped 430 mm Coupling pin E 1 2 3 Pantograph tongs Swivel lock Length adjustment Closing eye For further information see brochure "PGS parallel gripper" ⇒ Tab. Page 7. Page 7 and "Technical data Demag DC-Pro chain hoist" ⇒ Tab. belt sling width 45 mm. 15 A B C D Gripping hook Pantograph tongs Belt sling.

25 Designation Size DC 1-5 DC 10 DC 15 DC 1-5 DC 10 DC 15 DC 15 Part no.4 18. Chain hoists with short or long suspension brackets can be combined with the trolleys from ⇒ Tab. 16 DC-Pro 1-10 chain hoists are supplied with a long suspension bracket as standard. Page 39. Optional suspension Fig.5 Dimensions [mm] H 62. since the chain hoist can be directly suspended from the trolley.: L Suspension ring.4 20. for suspension parallel to track girder 718 278 45 715 278 45 721 278 45 718 910 45 715 910 45 721 910 45 721 870 45 92 124 170 92 124 170 B 18 22 35 22 36 44.5 214 741 44/210610 Suspension hook. 17 Item 1 2 3 4 No fig. For the DC-Pro 15 only one suspension bracket is available.5 105 147 104 152 193 h 19. Page 38 38 .5 27 38 D 31 53 84 25 36 40 d 8. 16.4. Tab. 26. folding Suspension bracket for KBK III Contour as (5) in ⇒ Fig. It is not necessary to dismantle existing trolleys. The short suspension bracket is included for an optimum C dimension.10 Suspension Standard suspension Fig. The suspension bracket facilitates installation.

Page 38 34) up 214 741 44/210610 39 . 16.Assigment of standard suspensions Chain hoist SWL [kg] Reeving Trolley size Trolley SWL [kg] RU 3 450 450 RU 6 700 850 RU / EU 11 DK RU / EU 22 DK RU / EU 36 DK RU / EU 55 DK CF 5 U / EU 11 DC U / EU 22 DC U / EU 34 DC RU /EU 56 DC KBK 100 Trolley I II III Articulated frame (dou‐ ble trolley) I II III 100 Load bar I II III 100 Crab frame I II III Tab.200 kg 38) DC 10 with RU / EU 56 on request 39) up to 500 kg 40) Suspension bracket for KBK III = contour as (5) in ⇒ Fig. 16. Page 38 1+2 1 1+2 1+2 33) 1 33) 1+2 1 1 1350 2600 3600 5500 550 1100 2200 2200 3400 5600 3+4 3+4 5 5 34) 5 1+2 1+2 3+4 35) 1 1 3+4 36) 5 3 38) 3 38) 5 37) 5 2 2 2 3+4 39) 3 1 1 1 3 3 40) 3 1 1 1 3 40) 33) up to 400 kg to 2500 kg 35) DC 10 .1250 1/1 with U / EU 22 DC 36) DC 10 . 26 100 300 600 1300 400 1200 2600 200 600 1400-2200 2600 200 600 1200/2400 3300 3 3 40) 40) 80125 Flange width [mm] 60-90 58-143 144-300 58-143 144-300 58-300 58-143 144-300 82-300 106-300 106-186 187-300 50-91 58-200 201-310 82-200 201-310 82-310 98-200 201-310 30 55 30 40 1 15 22 30 22 16 Flange thickness [mm] 12 20 18 20 18 Crossbar diameter [mm] 21 30 35 30 38 34 45 51 56 70 82.5 16 30 1+2 1 1+2 1 1+2 DC 1 80250 DC 2 160500 1/1 DC 5 3151250 12502500 2/1 10001600 1/1 20003200 2/1 DC 10 DC 15 See ⇒ Fig.2500 2/1 with U / EU 34 DC 37) up to 2.

I beam tracks should be bent with the utmost care in order to obtain a clean. screw heads. The load capacity of Demag chain hoists must not exceed the load capacity of the trolley. automatic installations). 18 WARNING Overload There is danger to life and limb due to a possible excessive load of the trolley. see ⇒ Tab.4. Resilient buffers should be mounted at travel wheel axle level at the ends of tracks in order to prevent the trolley from derailing (e. The curve radii should be as large as possible in order to ensure good travel characteristics. 27 EU 11 DC EU 22 DC EU 34 DC EU 56 DC 550 1100 2200 2200 3400 5600 [mm] 50-91 58-310 82-200 201-310 82-310 98-310 2000 43) 2000 Rmin [mm] 800 1000 [mm] 58-310 82-200 201-310 82-310 98-310 2500 43) 3000 Runway girder Electric travel Flange width41) Rmin [mm] 2000 Plastic Plastic42) Spheroidal graphite cast iron Spheroidal graphite cast iron Travel wheel material 41) Max. Page 7. I beam track The use of I beams with parallel or sloping flanges according to DIN 1025 as tracks is possible. 40 flange width 500 mm (except CF 5) travel rollers optional 43) From flange width 106 mm 42) Steel 214 741 44/210610 . Demag clamp-fitted buffers).11 Trolley Fig. 3. joint flanges. clamping plates. Contact the manufacturer or his representative for frequent curve travel operation (e. Curve radii for trolleys The specified curve radii apply for normal applications. For further information on the trolleys and the power supply. regular curve. etc. Hoist travel on I beam tracks must in no way be obstructed by protruding suspension bolts.g.g. Curve radii in mm Trolley size SWL Push travel Flange width41) [kg] CF 5 U 11 DC U 22 DC U 34 DC RU 56 DC Tab.

28 U 22 DC EU 56 DC E 22 DC ZBF 71 A 8/2 EU 56 DC ZBF 80 A 8/2 EU 56 DC ZBF 71 A 8/2 For further possible applications see Technical data Demag DC-Pro chain hoist. m/min V12/4 Trolley EU 56 DC EU 56 DC Travel drive ZBF 80 A 12/4 ZBF 80 A 12/4 ZBF 80 A 12/4 ZBF 80 A 12/4 Trolley U 11 DC U 11 DC EU 56 DC U 11 DC U 11 DC EU 56 DC U 11 DC U 11 DC EU 56 DC U 11 DC U 11 DC EU 56 DC U 11 DC U 11 DC EU 56 DC V24/6 Travel drive E 11 DC E 11 DC ZBF 71 A 8/2 E 11 DC E 11 DC ZBF 71 A 8/2 E 11 DC E 11 DC ZBF 71 A 8/2 E 11 DC E 11 DC ZBF 71 A 8/2 E 11 DC E 11 DC ZBF 71 A 8/2 Trolley EU 56 DC EU 56 DC EU 56 DC EU 56 DC V40/10 Travel drive ZBF 80 A 8/2 ZBF 80 A 8/2 ZBF 80 A 8/2 ZBF 80 A 8/2 - 315 10 5 1/1 EU 56 DC EU 56 DC - 400 10 5 10 10 10 15 10 2/1 1/1 2/1 1/1 10 15 10 15 10 15 10 15 15 2/1 U 34 DC E 34 DC 500 630 800 1000 1250 EU 56 DC ZBF 80 A 12/4 1600 2000 2500 3200 Tab. 214 741 44/210610 44) If DC-Pro 10 is combined with EU 56 DC.. ● If the EU 56 DC travel drive is used with small flange widths it is necessary to fit supporting rollers to the trolleys.SWL [kg] 80 to 200 200 250 Chain hoist size DC-Pro 44) 1-5 10 2-5 10 5 Reeving V14/3 Trolley Travel drive Possible cross-travel speeds in approx. 41 . we recommend the use of trolley buffers to dampen any collisions between the trolleys. a special crossbar is required.. . ● If several trolleys are operated on one girder.

They feature in particular quiet running characteristics. The cold-rolled track sections feature a smooth running surface and offer the advantage of simple power supply by means of trailing cables or integrated conductor lines. Special fittings on the KBK profile sections. screw heads. clamping plates. for terminal boxes or limit switches. 3. e. 42 214 741 44/210610 . 19 When selecting a track. Page 7. avoid any obstruction by sus‐ pension bolts. butt straps. see ⇒ Tab.g. we suggest you specify our KBK crane construction kit track section of special design. track switches and turntables. a low rolling resistance and a low deadweight. For further information on the trolleys and the power supply. KBK profile sections can also be used for more complex installations including curved sections.KBK track Fig.

– – – – – – – – – Before starting work ensure that sufficient working clearance is available. mistakes when assembling by the customer cannot be excluded.2 DANGER Safety instructions for assembly Inappropriate assembly Danger to life and limb.g. It must be possible to switch off powerfeed by means of a device for disconnecting the powerfeed (e. Wear protective equipment! Caution on open sharp-edged parts! Risk of injury! Ensure order and cleanliness at the workplace. we recommend this work be carried out by our trained specialists or by persons authorized by us. The chain hoists are supplied with power from an AC power network. mains connection or isolator switch with padlock). The requirements of DIN regarding welding work must be complied with. Customer-specific regulations must be observed. only systems designed for passenger transport should be used that provide for a stable position and work without any risk. The owner must appoint a coordinator who is authorized to issue instructions before assembly work commences. For this reason. DANGER Live components Danger to life and limb. Inappropriately fixed component parts may fall down and result in severe injuries. Only suitable. 43 .5 Assembly 5. The voltage and frequency of the AC power network must match the data specified on the rating plate of the chain hoist. Page 10 ) in compliance with the safety instructions. The wiring of the Demag chain hoist complies in all respects with current DIN VDE and accident prevention regu‐ lations. Unauthorized intervention and modifications result in eliminating compliance with these regulations.1 General These assembly instructions enable the owner to fit and/or refit or replace the DC-Pro himself. When using a working platform for assembly. Inappropriate assembly may result in serious personal injury and / or material damage. Otherwise serious damage may be caused to the hoist. Work on electrical equipment may only be carried out by qualified specialist personnel(⇒ "Definition of personnel". Therefore only authorized and trained personnel who is familiar with the operating principle of the machine may carry out this work in com‐ pliance with all safety regulations. Machine parts or fittings that are not required must be stored so that they cannot fall down. Appropriately fit component parts. tested and calibrated tools and accessories may be used for assembly or disassembly work. Despite detailed information. – DANGER Live components 214 741 44/210610 Danger to life and limb. Welding work may only be carried out by persons having a special qualification. Tighten screws with the prescribed tightening torque. 5. The electrode holder and earth must be connected to the same assembly when welding work is carried out. Secure working and danger zone.

Protective earth conductor The protective earth conductor in insulated leads and cables must be coloured green and yellow along its entire length. Power supply system The power supply line / cable to be used depends on the motor size. see section "Hoist motor data". control pendant) must be marked in such a way that the direction of movement is clear and distinct. It must be possible to disconnect each individual connection. Any change or modification which prejudices safety must immediately be reported to the nearest person responsible.g. Earth junctions and connections must be protected against self-loosening (e. Check that pin connections are properly secured. These operating instructions only contain standard circuit diagrams. Depending on the type of chain hoist an orderspecific circuit diagram may apply. Repairs may only be carried out by experienced technicians. Protective earth conductors must not carry any current in operation The same number of protective earth connection points must be provided as electrical power infeed and outfeed points. The clamping torque of a self-locking nut must not be lower than the screw-off torque specified by EN ISO 2320.g. without affecting operation of the rest of the system. Self-locking nuts must not be replaced by other types of nut. Mechanical safety All bolted connections must be correctly tightened. This switch must be arranged to disconnect all poles of the DC-Pro chain hoist from the mains supply. The mains connection or isolator switch must be secured against unauthorized or accidental reconnection by means of a padlock. Only by tightening to the specific tightening torque can a sufficiently secure connection be guaranteed. Electrical safety The chain hoist operating instructions must be referred to when Demag chain hoists are used. Ensure that the switch is installed in an easily accessible position near your machine and clearly marked. Ensure that all suspension fittings are freely accessible for checks and inspections or that free access can be pro‐ vided. Self-locking nuts must be replaced when they have been tightened and untightened five times. by using serrated lock washers to DIN 6798). 44 214 741 44/210610 . Bolted connections must not be lubricated as otherwise the specified tightening torque values will be too high. each one should be provided with an isolator switch. Continuity of the PE conductor connection must be checked. All assembly work must be completed in accordance with the operating instructions and the hoist chain must be greased. The protective earth conductor must not be connected to mounting bolts or screws. This makes it possible to carry out maintenance work on individual hoists. Mains connection switch A mains connection switch must always be provided for the main power supply line of the machine.Before starting work. The control device (e. the electrical supply must be switched off. Isolator switch If two or more hoists are fed from a common main supply line. The arrow symbol on the control elements must correspond to the direction of movement. Operation with defective or damaged chains results in a high risk of accident for persons and the chain hoist and is therefore prohibited.

5.5 25.5 5. The unit is ready for operation. Page 54.5 27. 29 Bottom block halves Guide halves 5-6 11. Adjust control pendant height ⇒ "Height adjustment of the control pendant".0 DC-Pro 1 DC-Pro 2 1/1 9.0 25 15 15 DC-Pro 5 DC-Pro 10 1/1 2/1 25.0 55.0 5.0 25 25 5.4 Assembly procedure 1. Check for completeness ⇒ "Transport inspection". 214 741 44/210610 45 . Page 48. packing and storage". Page 46.8 4. Page 69. 5. 2. Page 51.0 9. Metal nuts featuring a locking element (self-locking nuts) are mainly used for Demag chain hoists.3 10.5 7. as required ⇒ "Connecting the control pendant". Page 70. Adjust lower hook position as required ⇒ "Setting the lower hook position".0 DC-Pro 15 1/1 2/1 CAUTION Loose connections Loose connections mean danger for life and limb or risk of machine damage. 7. Connect control pendant. Page 67. Which suspension bracket is suitable for suspension? ⇒ "Suspending the chain hoist". 8.0 5.5 3. Page 28. Carry out inspections prior to putting the hoist into service for the first time ⇒ "Inspections prior to putting into service for the first time".5 5.5 4.0 52.5 11. 6. Unpack and dispose of packing material in an environmentally compatible way ⇒ "Transport.5. Connect to power supply ⇒ "Line connection".5 3.5 4. 3.3 Tightening torques DC-Pro chain hoist Tightening torques [Nm] Reeving Motor Fan cover Gearbox cover Gearbox housing 2-piece Gearbox screw plug Gearbox vent valve Brake Operating limit switches Control set Electrical equipment cover Service cover Limit stop Anchorage halves Guide plate Hook assembly Bottom block with external switch-off springs Bottom block with internal switch-off springs Screw for chain retainer halves (Manulift) Control cable lock Tab.0 6.5 1. 4. – Self-locking nuts must not be replaced by other types of nut.5 25 55. ⇒ "Operation". Page 28. 9.

5 Connecting the control pendant 43215144. 20 The control pendant is of plug-in design. Then pull the bend protection sleeve (1) off the control pendant. The connector at the end of the control cable is locked in the bayonet sleeve and can be turned. Press the bend protection sleeve (1) firmly onto the control pendant. Slide the bend protection sleeve (1) over the control pendant again.that the two pins (c) on the control pendant housing match the bayonet lock (d). If a connector is not locked. connect the DSC control pendant with the control cable and lock the connection with the bayonet lock. Page 52.eps Fig.the groove (a) of the connector holder matches the swivel lock (b) in the control pendant housing and . 2. Pay attention to the positioning help. Unless the chain hoist is supplied with fitted control pendant. Lift the bend protection sleeve (1) on the control pendant off the two pins. see ⇒ "Mobile control system". The control pendant can be fitted on the chain hoist as a stationary unit or installed as a travelling unit.. Plug the control cable into the control pendant and turn the bayonet lock until it is locked. proceed as follows: 1. it can be pulled out and must be locked again by pressure. 46 214 741 44/210610 . 3. Ensure that . Slide the bend protection sleeve (1) onto the control cable.5. 4.

214 741 44/210610 47 .

6.6. hoist units with a load capacity ≥ 1000 kg must be equipped with an overload pro‐ tection.6 5. 1/1 reeving DC-Pro 15. the force limitation factor for DC-Pro chain hoists with a load capacity ≥ 1000 kg is: ϕDAL = 1. 30 Designation Suspension bracket openend DC-Pro 10. 1/1 reeving DC-Pro 10. A) B) C) D) E) Tab. 21 Fig. According to DIN EN 14492-2.2 Suspension bracket Fig. According to DIN EN 14492-2. 5. Information on the adjustment see brochure "Friction force checking device" ⇒ Tab.5. 3. DC-Pro chain hoists are equipped with a slipping clutch which directly acts as overload protection. 2/1 reeving Item 1 2 3 4 Designation Suspension bracket Retaining clip Pin 214 741 44/210610 Spacer tube (DC-Pro 10) 48 . The slipping clutch must be adjusted to the load capacity of the chain hoist. 2/1 reeving DC-Pro 15. The supporting structure must be designed for the maximum load of the chain hoist when being used appropriately.1 DANGER Suspending the chain hoist Supporting structure Overload There is a danger to life and limb due to overloading the supporting structure.6 The static and dynamic forces which occur when the overload protection is tripped must be taken into account when designing the supporting structure. Page 7.

Suspension of the chain hoist at an angle results in premature wear of the chain drive. Do not move the chain hoist or leave it unsupervised when the suspension bracket is open. Fitting: 1. DC 15 according to the reeving) in the superstructure / trolley. See also ⇒ "Gearbox / oil change". The chain hoist is delivered with the long suspension bracket (DC-Pro 1-10) completely fitted to the chain hoist. The suspension / supporting structure for the chain hoist must be designed for the loads. The enclosed short suspension bracket (DC-Pro 1-10) can be fitted for an optimum C dimension. 31 DC-Pro 15 15 15 Fig. In the case of special fittings on the chain hoist. 5. Remove the retaining clip and pin on one side. Slide the pin through the suspension and the suspension bracket (for DC 10 additional spacer tube (4)) and secure with the retaining clip again. 3. vent valve Before putting the chain hoist into operation. – DANGER Falling down of the chain hoist There is danger to life and limb or of material damage. If the suspension bracket is fitted inappropriately. 2. remove the screw plug (1) (plug and O ring) and screw in the vent valve included in the supply. Suspend the suspension bracket (DC 10. Page 116 Tightening torques [Nm] Screw plug M16 Vent valve M16 Tab. make sure that an appropriate counterweight compensation is taken into account.WARNING Overload There is a danger to life and limb due to overloading the components. the chain hoist is suspended at an angle. 22 214 741 44/210610 49 . Make sure that the suspension bracket is fitted in accordance with the reeving arrangement of the chain hoist.7 Screw plug.

23 ● To ensure an ergonomic position for operation of the control pendant.8 m .8.eps Fig.8 5.8 m .6. Longer control cable lengths are provided. for example.8 m H5 0.: 720 085 45 Fig.8. A winding protection for the upper area of the control cable can be used as an option.2 Handling the control cable Do not allow the control cable to be wound around the chain when lifting motions are performed.8 m Tightening torque [Nm] 11 H11 6.2. Ergonomic workplace! ● The suspension height can be adjusted by means of a self-locking mechanism at any time to suit individual re‐ quirements. adjust the suspension height in such a way that the operating elements are arranged at elbow height.8 m H8 3.5. Designation Protective sleeve with fitting material Tab. 5.8 m . 42597646_XML. 24 50 214 741 44/210610 .8 m .8 m Hook path Cable lengths Tab. The adjust‐ able height variation is 2 or 3 m.3. with a 2TY control cable and DST-C or DSE-C control pendants. 32 The control pendant is supplied with standard cable lengths. 33 Part no.1 Control cable Techncal data of the control cable Item 1 2 3 Designation Hose pocket Operating buttons of the control cable stop Screw of the control cable stop H4 0.9.

3. Lay the remaining control cable in loops and store it in the pocket. Take the control cable out of the pocket. 51 . Slide the operating button of the control cable stop downwards and fix the stop by a short. Control cable stop fixed Control cable stop loose Undo the screws of the service cover. 25 x y 1. pull the control cable until the correct height has been reached for the control pendant. At the same time.3 Height adjustment of the control pendant Fig. 6. Close the service cover (tightening torque 5. Remove and open the pocket with the control cable.8. 214 741 44/210610 7. strong pull on the control cable above the control pendant. 4. 2. 5. The pocket must be behind the edge of the chain collector box.5. pull on the control cable hose hanging behind the service cover. Slide the operating button of the control cable stop upwards and hold it. If the position is too low. Open and disengage the service cover.5 Nm).

Fig. Fitting frame Pin insert VC-AMS8 Flat cable union Bayonet lock 3 Connector adapter cpl. STS) Backward Special 1 (F1/F2) 52 214 741 44/210610 Fig.4 Mobile control system Component parts Item 1 Designation Flat cable 11-pole + PE Socket enclosure 2 Connector enclosure cpl. the height-adjustable standard control ca‐ bles H4. 27 .5.8. 35 Con‐ duc‐ tor PE 8 4 3 2 1 B4 B3 B2 B1 A4 A3 A2 A1 PIN B8 B7 B6 B5 A8 A7 A6 A5 Con‐ duc‐ tor 11 10 7 9 6 5 Signal Reference potential (24 V) Right Lowering Control voltage (24 V.: 720 139 45 For use of the cable collector. 34 Cable collector DSE10-C control pendant Control cable lock 720 065 45 773 352 45 720 087 45 720 187 45 comprising Part no. Bush enclosure VC-MP-1-R-M25 Bush frame VC-TR1/2M Socket insert VC-TFS8 4 5 6 Tab. 26 X40 plug connector connections Signal PE Special 2 (horn) Left Lifting Emergency stop Forward Tab. H5. H8. H11 are used.

214 741 44/210610 53 .

36 .5 Strain relief attachment DC-Pro 10 Strain relief attachment DC-Pro 15 Item 1 2 3 Designation Seal. sleeve Connector 4-pole Connector enclosure Item 4 5 6 Designation Line connection Recess for round cable Recess for flat cable 214 741 44/210610 54 Tab.9 Line connection Fig. 28 Item A) B) C) Designation Strain relief attachment DC-Pro 1 .5.

insert the mains cable into the union on the gearbox housing and fix it with the strain relief clamp. the chain hoist must be switched. use the wire end sleeves included in the delivery. switch off the power supply on the mains connection switch and check that the unit is deenergized. Make electrical connection ● First check whether the voltage and frequency specified on the capacity plate match your mains supply. ● Use the mains connection set included in the scope of delivery to produce the plug-and-socket connection for the mains connection cable. unlock the emergency stop and actuate the pushbutton for "Lifting" on the control pendant. ● For a round cable in the marking area of 7 to 13. For DCPro 1 to 5 units. Ensure that the mains connection cable is at zero voltage and secured against accidental restoration of the power supply. a 4-lead cable with an earth lead (PE). which complies with the table in ⇒ "Hoist motor data ". ● Then place the connector (2) into the control system until the enclosure (3) latches with the board bracket. ● Finally. Checking the direction of movement To check whether all phases are correctly connected. Cable cross-sections 4x1. this is the way to establish the connection with the correct phases. L2. L3 and to the PE. Then check the movement directions as described in the following. the mains connection cable. – – If the direction of movement is incorrect.To connect the chain hoist to the power supply. If required. Please note that the length of the supply cable specified for a given cross section must not be exceeded in order to avoid excessive voltage drop and malfunctions during start-up of the motor caused by undervoltage.5 mm2 are taken into account. Change over leads L2 and L3 of the supply cable on the mains connection switch. Make sure the sleeve (1) tightly encloses the cable to comply with the type of enclosure. Switch on the power supply. check the continuity of the earth lead connection. For connection of the mains phases R-S-T to L1-L2-L3 in the specified sequence. ● All enclosure parts must be securely latched to ensure the unit is sealed. ● Slide the sleeve (1) onto the mains cable. ● The mains connector must never be disconnected under load. ● After connection of the mains cable and before putting the chain hoist into operation. For power supply. the lifting and lowering buttons correspond to the movements of the load hook. 214 741 44/210610 55 . for a flat cable in the marking area of 18 x 7 to 20 x 8. ● Slide the connector (2) into the enclosure (3) until it latches and close the enclosure (3) with the sleeve (1). the strain relief clamp must be turned to suit the cable contour depending on the cable type (flat or round cable). If the phase sequence of the connection cable is unknown. the mains connection fuse links and the devices for disconnecting and switching the powerfeed must be available on site.5 mm2 or 4x2. Phase sequence for connection to the AC power network The chain hoist is configured for connection to a R-S-T network turning clockwise. Page 22 is required. ● Cut the sleeve (1) to suit the geometry of the mains cable. WARNING Incorrect direction of movement There is a danger to life and limb due to an incorrect direction of movement. The load hook must now move upwards. ● Connect the mains cable on the connector (2) to terminals L1. ● Remove the service cover to connect the supply cable.

5.10.10 5.1 Circuit diagrams and control cards Circuit diagram DC-Pro 1 . 29 214 741 44/210610 .15 solo hoist 56 Fig.

30 57 .214 741 44/210610 Fig.

58 214 741 44/210610 Fig. 31 .

32 59 .5.2 Circuit diagram DCM-Pro 1 .10.5 solo hoist 214 741 44/210610 Fig.

60 214 741 44/210610 Fig. 33 .

34 61 .214 741 44/210610 Fig.

3.5.4 Control board Fig.10. 3.10. 716 663 45. see ⇒ Tab. Page 7 Assembly instructions E 11 . Page 7 Technical data E 11 . part no.E 34 travel drive For further circuit diagrams with E 11 . 3.3 Circuit diagram with E 11 .E 34 DC travel drive. 5.E 34 travel drive see ⇒ Tab. For further information on the cross-travel limit switch. Page 7 Assembly in‐ structions E 11 . 35 Item 1 2 3 4 5 Designation Plug-and-socket con‐ nector Plug-and-socket con‐ nector Relay Relay Relay Terminal strip X8 X6 Function Motor 214 741 44/210610 Brake Slow / Fast Lifting / Lowering Lifting / Lowering (from 2009) 62 .E 34 DC travel drive. For further information on the E 11 .E 34 DC travel drive.E 34 travel drive see ⇒ Tab.

status indicator. e. 37 Pin 1 (1) 214 741 44/210610 63 .Item 6 7 8 9 10 11 12 13 14 SN. 37 Designation Contactor Transformer Plug-and-socket con‐ nector Fork light barrier IR transmitter diode 7-segment LED Plug-and-socket con‐ nector Dummy plug Plug-and-socket con‐ nector Serial number Terminal strip Function On / Off X1 Line Pulse generator IR interface Multi-function display. 36 Pin 1 (1) 7 8 9 10 Tab. error code display X4 X5 X3 Lifting limit switch Trolley (optional) Control cable RJ45 connec‐ tor PIN 1 2 3 4 5 6 Fig. 39 Lifting limit switch X4 (12) Lift (BN) Lift (BK) Lower (BN) Lower (BK) Fig. 38 Control cable X3 (14) Special F1 Crane forward Crane backward Emergency stop Supply control pendant Lifting Lowering Trolley right Trolley left Special F2 Function assignment Trolley X5 (13) Special F1 Crane forward Crane backward Emergency stop Supply control pendant 24 V AC from chain hoist Reference potential control pendant Trolley right Trolley left Special F2 Function assignment PIN 1 2 3 4 Tab. Tab.g..: Elapsed operating time counter..

for tandem operation) n. n. 3 Interlocking of the control pendant Y. If “Lifting” and “Lowering” are actu‐ ated together.5.1 Setting parameters with the control pendant General It is possible to set parameters in order to adapt the chain hoist to specific applications.3 Meaning of parameters From software version SW 2. 38 1 Tab. Factory setting Speed-dependent start-up Time-controlled start-up Display of parameter value Remarks 4 5 6 7 8 9 Tab.11.10. 41 64 214 741 44/210610 . 40 "Lifting" .Move to next parame‐ ter or selection value 3 "Emergency stop" .g. the following parameters can be programmed: Display of parameter no. 5. Factory setting V1/V2 V2 Factory setting Control pendant is interlocked when several pushbuttons are actuated. Time-controlled start-up (e. Y.2 Meaning of keys Fig.11 5.End parameter programming (changes are saved) 5.11. 0 1 2 Parameter name Hoist only V2 speed n. the pushbutton actu‐ ated first has priority. The parameters are set by means of the control pendant in connection with the 7-segment display on the bottom side of the chain hoist. Y.Accept selection 2 "Lowering" .11.

7-segment display: 0. The parameter programming mode is actice now. each. Wait for approx. 39 1st step: Actuate “Emergency stop”. When the parameter programming mode has been activated. release the "Lift" key.) is displayed. Press the "Lift" key and hold down again until "o." (for O. 5th step: Release key." is displayed.K. Fig.4 Starting parameter setting mode Fig. 10 sec‐ onds. 7-segment display: (display spot) 3rd step: When "P.11. figures "0. Each figure represents a parameter. → 1. 2nd step: Press and hold down the "Lift" key and unlock the emergency stop. Tab. 6th step: Press the "Lower" key to move faster through the menu items. 40 4th step: "P." are displayed successively for 2 seconds. ··· 9. 42 7-segment display: P.5. 43 214 741 44/210610 65 . 7-segment display: (display dark) Tab. 2 seconds." to "9." extinguishes after approx. Page 64. 7-segment display: 7-segment display: o. see ⇒ "Meaning of parameters".

Page 64. "C.". the unit switches back to normal oper‐ ation. 42 66 214 741 44/210610 . 7-segment display: Tab.Fig. the value until the required value is shown in the display.". "b. b. 45 Fig. actuate the "Lower" key played parameter. Tab. C." etc. The currently set values are symbolically displayed with the characters "A. For the meaning of the characters. 7-segment display: 10th step: When the "Emergency stop" key has been actuated. 7-segment display: A. the system then also returns to parameter se‐ lection mode. 41 7th step: 8th step: Actuate the "Lift" key to select the currently dis‐ To set a different value. All changes are first saved. At the same time. 44 7-segment display: 9th step: The value is selected by means of the "Lift" key. selection menu of the parameter is opened. see ⇒ "Meaning of parameters".

5. As standard. Fix limit stop to the 5th link at the dead (unloaded) end of the chain.0 DC-Pro 2 DC-Pro 5 DC-Pro 10 4. Page 110 Tightening torques [Nm] Limit stop Tab. Switch on the chain hoist and check the setting of the bottom hook position by moving the hook and run the hook path setting once through its entire length. Dismantle the chain collector box ⇒ "Dismantling the chain collector box". it must be taken into account that in the bottom hook position the load hook rests on the floor. 7. 46 Designation Buffer (limit switch option) Actuator plate Buffer plate Item 4 5 Designation Limit stop Unloaded chain fall For determining the hook path / lifting height. 3. ● Pay attention to assembly sequence! See also ⇒ "Buffer design". 4. The unloaded chain fall behind the limit stop must consist of at least 5 chain links.12 Setting the lower hook position Fig. 67 . proceed as follows: 1. Page 87. 6. Stop the chain hoist by actuating the emergency stop or the mains connection switch and secure it against switching on again. Detach the limit stop on the chain collector side. Fix the actuating plate directly behind the buffer. the chain hoists are provided with a hook path of 5 m or 8 m. Place the chain into the collector box and refit to the chain hoist. 214 741 44/210610 Move the hook as shown in the figure. 47 DC-Pro 1 4.5. 43 Item 1 2 3 Tab.3 DC-Pro 15 To reduce the hook path. 2.

6. – Inspection in accordance with relevant national regulations. ● work may need to be performed in the danger zone when first putting into service. Machines may only be put into service.6 Putting the unit into service for the first time 6.g. if its safety has been verified by a corresponding inspection ⇒ "Inspections when first putting into service.1 Safety instructions when first putting the unit into service The machine may only be handed over. Before putting into operation check that the safety equipment is fitted / functioning. – – – – – – – Putting into service may be carried out by specialist personnel. Wear protective equipment! Only trained specialist personnel must be employed for first putting into service since: ● it may be necessary to render safety devices or features inoperative when carrying out adjustments or function checks. The owner is responsible for ensuring that powered chain hoists are inspected by an expert engineer prior to first putting into service and after major modifications have been carried out. handing over". For the values for noise emission measurement according to DIN 45635 please refer to ⇒ "Noise emission / sound pressure level". Check that the mains voltage and frequency match the data specified on the rating plate. UVV/BGV D6 for cranes. This also applies to manually operated or semi-powered chain hoists with a load capacity of more than 1000 kg. only.2 Inspection regulations WARNING Non-compliance with operating and maintenance instructions Danger to life and limb. maintenance and inspection activities and inspection deadlines including specifications concern‐ ing replacement of parts/assemblies prescribed in the operating instructions must be observed. hoists and towing devices in Germany. All inspections must be arranged at the specified time intervals / points of time and documented by the owner. safe operation of the machine is not yet guaranteed. Move the trolleys by hand and check that they can be moved without resistance by hand over the entire length of the track section (if existing). e. Page 28 This work may only be carried out by specialists. 68 214 741 44/210610 . Compliance with all inspection regualtions is an integral part of securing the safe operation of the machine. when assembly has been completed according to the assemly instructions. Before starting work ensure that sufficient working clearance is available. UVV/BGV D8 for winches. – – Adjustment. Prescribed tests and inspections must be carried out. before putting into service again. WARNING When first putting into service. Page 69. Secure working and danger zone.

Page 88 ⇒ "Checking the load hook". the test and inspection records can be prepared.g. At the same time the behaviour of the chain hoist in the case of misuse must be checked. Page 54 ⇒ "7-segment display for operating status and error display". observe the relevant country-specific regulations) are handed over. number of cycles. After the machine has been handed over. The following checks must be carried out when first putting into service: ● The proper condition of the supporting structure and the load capacity of the chain hoist. Page 87 ⇒ "Checking the operating limit switches". Machines may only be put into service. ⇒ "Software version. by lifting an overload). when they have been inspected according to the accident prevention regulations. operating hours. Page 33 ⇒ "Available hoist chains". The functioning of the safety devices must be checked (e. Page 109. ⇒ "Checking the operating limit switch actuator". operating statuses". all possibilities of intended use must be checked at the corresponding maximum permissible load. different inspections of the machine must be arranged for: ● Inspection for suitability for operation ● Acceptance test As soon as the safe operating status of the chain hoist is ensured. the owner is obliged to carry out the following inspections: Action Check continuity of the PE conductor connection Check emergency stop device Check direction of movement Check 7-segment display Section ⇒ "Line connection". Page 93 ⇒ "Checking the operating limit switches". the test and inspection records (test and inspection booklet.3 Inspections prior to putting into service for the first time Before putting into service for the first time. it may be used as intended. the owner ensures that the load handling attachments and machinery ready for operation function in complete safety before first being put into service. The specified measures must allow for the static and dynamic features of the machinery.6. Before handing over. ● The emergency stop device must be checked by actuating the emergency stop. Page 100 Inspec‐ tion X X X X Check chain lubrication (under arduous conditions. Page 33. 214 741 44/210610 When handing over the machine. Page 87 ⇒ "Checking the switch-off buffer / switch-off spring". handing over WARNING Impermissible operation There is danger to life and limb when the machine is operated without previous inspection. the chain must be lubricated more frequently) Check function of operating limit switch for lifting Check function of operating limit switch for lowering Check switch-off buffer / switch-off spring / operating limit switch actuator X X X X Check control cable and control pendant housing for damage Check operation of the brake Check hook and hook safety catch Tab. 69 . When putting into service for the first time.4 Inspections when first putting into service. 48 X X X 6. ● Clearances and safety distances must be complied with. ● Safety devices must be completely fitted and effective. By means of suitable measures carried out by the owner or on his behalf.

instructed personnel in compliance with all accident prevention and safety regulations.1 Safety instructions for operation WARNING Inappropriate operation There is a risk of injury in the case of inappropriate operation. Wear protective equipment! Do not touch the chain. 206 093 44. – – – – WARNING Non-compliance with operating regulations / regulations regarding industrial safety There is a danger to life and limb due to the non-compliance with valid standards.7 Operation 7.g. It is not allowed to lift loads above persons. Keep a sufficient safety distance. Persons must keep out of the danger zone. National regulations for the use of crane and lifting equipment must be observed and complied with. Cranes BGV D6 (VBG 9) in Germany. Machines may only be operated in compliance with the country-specific operating regulations. – WARNING Crushing hazard When lifting or lowering loads there is a risk of injury due to parts of the body being crushed or clothing or hair becoming entangled. e. Do not reach into the coupling area when changing the quick-release coupling of the Manulift. Persons must not stay in the immediate danger zone when depositing the load. WARNING Suspended load! Falling parts! There is danger to life and limb. The customer must arrange for the training of the operating personnel. . Do not reach between hook throat and load handling attachment when lifting loads.g. – If required. Do not walk under the suspended load. Do not touch the hot motor housing. apply a copy of the relevant operating regulations. 70 214 741 44/210610 The machine must not be put into operation or must be taken out of service immediately if any defects or irregularities relating to operating safety and reliability or function are detected. – – – – – WARNING Risk of burning There is a risk of burning when touching the chain hoist during operation. no. Do not reach into the upper or lower chain entry point. ident. at a suitable place where operators can read them at any time (e. at the mains connection switch). when lifted loads fall down. The unit may only be operated by authorized. Inappropriate operation may result in serious personal injury and / or material damage. Safety devices must not be rendered inoperative or modified in contradiction to their intended use.

Work on electrical equipment may only be carried out by qualified electricians. the operator must be satisfied that the machine is in safe and correct operating condition. for example: ● Damage to electrical devices. When the chain hoist has been stopped as a consequence of safety-relevant defects by an emergency stop. Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay.2 Functional tests Instructions for users within the scope of application of the BGV D06 accident prevention regulations: In accordance with BGV D06. This does not apply to slipping clutches used as an emergency-stop device which need not be checked when starting work (BGV D06. it must be secured against putting into operation again until an experienced technician is satisfied that the cause of the hazard situation has been eliminated and that operation of the machine is possible without any hazard. in the event of operating malfunctions. for repairs and maintenance purposes. In the event of defects which endanger safe and reliable operation.2. §30). therefore a device for by-passing the limit switches which are approached during normal operation is not fitted. if defects regarding safe and reliable operation are detected. Ensure that nobody is endangered by operation of the hoist before switching it on or putting it into operation. the crane operator must also check functioning of the emergency stop device when starting work.g. Before starting work the main functions of the machine must be checked: 214 741 44/210610 71 . cables or insulation. 7. DC chain hoists are fitted with a slipping clutch as an emergency-stop device which needs not be checked by the crane operator. in emergency situations. he must stop operation immediately and may not resume operation until the persons are outside the danger zone.1 Switching on Inspections when starting work Before starting work. ● Delayed functioning or failure of brakes and safety devices. Defects relevant to safety in this sense are. 7. the operator must carry out all prescribed safety measures or observe that they are automatically carried out.2 7. In this case. In the event of a stoppage (e.Ensuring safe operation Special local conditions or special applications can lead to situations which were not known when this chapter was written. if damage is detected or after finishing work). the owner must ensure safe operation or take the machine out of service until measures for safe operation have been clarified and implemented in agreement with Demag or other responsible bodies. This also applies in the case of damage occurring to parts of the machine and equipment which makes immediate stop‐ page necessary.2. If the operator notices persons who may be exposed to a risk to health or personal safety by operation of the installation. Before starting work: ● Wear protective equipment! ● Check that no persons are in the danger zone of the unit. the chain hoist must be taken out of service without delay. ● Missing covers or housing parts or ● Damage to the chain or to supporting parts.

. For chain hoists without operating limit switch or with defective operating limit switch. high additional loads are exerted on the chain. – – – WARNING Moving parts may start moving.e. number of cycles. Therefore the function "Operating limit switch for lifting" must be checked every day.1 DANGER Operation General Broken chains and load drop Frequent approaches of the emergency limit stop device may result in broken chains or load drops. Page 33 ⇒ "Available hoist chains". i. 49 X X X X X X 7. it must not be approached in normal operation. work benches etc. Page 100 Inspec‐ tion X X Check chain lubrication (under arduous conditions. operating statuses". or in any other way. Page 93 ⇒ "Checking the operating limit switches". Use the load handling attachments as intended. When the slipping clutch is tripped.3. This emergency limit stop device may only be ap‐ proached in exceptional cases. the slipping clutch of the chain hoist perfoms the function of the emergency limit stop device. Important information on operation Please follow the instructions below during operation: Safety during operation – – 72 Take the machine out of service immediately if functional defects or irregularities are detected. ⇒ "Software version.Action Check emergency stop device Check 7-segment display Section ⇒ "7-segment display for operating status and error display". operating hours. 214 741 44/210610 . Page 87 ⇒ "Checking the switch-off buffer / switch-off spring". Page 33. the chain must be lubricated more frequently) Check function of operating limit switch for lifting Check switch-off buffer / switch-off spring / operating limit switch actuator Check control cable and control pendant housing for damage Check operation of the brake Check hook and hook safety catch Tab. Danger to life and limb. The control pendant is designed for suspension from the connection cable. It must not be deposited in / on transport containers. It may only be used as suspended equipment. Please note the maximum permissible load capacities of the hoist. Higher loads than those specified on the load capacity plate must not be handled. WARNING Overload Danger to life and limb.3 7. Use load handling attachments which are sufficiently dimensioned. Page 109 ⇒ "Checking the load hook". The operator is obliged to check the machine for visible damage at least once per shift and to report damage immediately.

– – – – – Moving the load – – – – – – – – – – – – – 214 741 44/210610 During lifting and travelling motions the operator must take a position which provides a free view on the danger zone or a second person must be available who has a view on the danger zone. Do not allow the chain to pass over edges or to be used as a load bearing sling. 73 . move‐ ment of the hook assembly/bottom block must not be restricted. Hand-moved loads must be guided by hand. Only approved load handling attachments may be used. ensure that loads or the load handling attachment do not slip out of the hook or that loads do not fall over. It is the sum total of lifting load and load handling attachment. when slewing pivoting cranes. when the load is deposited on vibrating machinery) must not be transmitted to the crane. Never pull on the control pendant. Vibration from the load being transported (e. – – Load pick-up – The load handling attachment and load must be flexibly suspended. Pay attention to regulations pertaining to the correct loading of chains. track and end buffers for stopping motion of the trolley or crane. the hook must move to an upright position so that the safety catch is not loaded by the load handling slings and. When attaching the load. When the load is lifted. slip or roll off when being picked up and deposited. e. fall apart. Do not handle suspended loads above persons. To protect the chain from impermissible torsion when the load turns. parts of the body or hair becoming entangled. as a result. Rigid connections cause uncontrolled forces and lead to fatigue fracture. Continuous approaches of these limits may result in severe damage on the chain hoist up to chain breakage.– – Do not render safety devices inoperative. Avoid inching operation. bottom block or load hook assembly. chain links facing the same direction must be arranged opposite each other without being twisted. hook assemblies or bottom block against end stops. Do not pull free fixed or obstructed loads with the chain hoist. The load specified on the capacity plate indicates the highest permissible load which must not be exceeded. Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing.g. emergency stop devices (emergency limit switches). may be damaged. emergency limit stop devices (slipping clutch or emergency limit switch). The bottom block must not be twisted or turned over for 2/1 reeving arrangements. Hoists / trolleys / cranes with push travel may only be moved by pulling or pushing on the load. The load must never be thrown.g. Do not allow loads to drop when the chain is in a slack condition. Do not leave suspended loads unsupervised. e. Do not snatch the load at full speed. Limits must not be approached in normal operation. At an angle higher than 4° the chain drive may get damaged. The load capacity of the load handling attachment must not be exceeded.g. Do not pull or drag suspended loads at an angle. Chain hoists must be suspended in such a way that they do not collide with stationary equipment and structures. Transporting persons is not permitted.

the slipping force must be measured by an experienced technician and readjusted. lifting is possible again. – Eliminate any knots or blockage of the chains before lifting / lowering. Functioning of the lifting path limiter After the lifting path limiter has been tripped. i. 214 741 44/210610 74 . If the slipping clutch switches off already at rated load. 45 Functioning of the emergency stop device When the emergency stop is actuated. impermissible wear on the brake may be the cause. The load must always be transmitted to the Manulift in the centre below the quick-release coupling. as required. This results in chain breakage and damage of the chain guide. the switch must hang vertically even with suspended load. 44 CAUTION Premature wear of the chain guide and chain Danger of load drop Avoid unequal loading of the chain falls. The lifting path is limited by limit stops on the ends of the chain. the brake must be inspected by an experienced technician without delay. only the opposite motion is still possible. Fig. Resuming operation by unlatching the emergency stop is only possible. Blocked chains or excessive play between chain and chain sprocket destroys the chain guide. In this case. A load already suspended can be safely deposited by actuating the lowering button.Load distribution WARNING Load drop The continuous transmission of bending moments leads to breakage of the load carrying element and load drop. As a consequence. The effectiveness of the emergency stop function depends on the proper condition of the mechanical brake.e. Functioning of the slipping clutch The chain hoist is fitted with a slipping clutch that is tripped in the event of overload. they are actuated by elastic buffers on the limit stop and switch off the motion before the emergency stop device is reached. Furthermore no bending moments must be transmitted to the Manulift. If an unusually long braking distance is noted. the hoist motor is disconnected immediately from the electrical power supply. After the slipping clutch has been tripped only lowering is possible. Fig. if no lifting or lowering commands are applied (off-position constraint). The brake is then automatically applied and the motor is switched off. Operating limit switch contacts prevent travelling against the emergency stop device. the brake is automatically applied and the motor is switched off. the mechanical brake is applied and stops the movement. Tripping of the emergency stop device causes a warning message on the display. the slipping clutch becomes effective as an emergency stop device. It is therefore not possible to lift an overload from the ground. When the lowering motion has been completed.

2 Manulift Belt sling CAUTION Load falling down In order to ensure the safe use of the belt sling please note the following: – – – Fig. The permissible jaw capacity is indicated by a coloured mark. and dry. – – The belt sling is used for handling asymmetrical or large-area parts (e. 47 For gripping. The sling must not come into contact with chemicals. discs). Pantograph tongs CAUTION Load falling off In order to ensure the safe use of the pantograph tongs please note the following: – – – – Loads must always be gripped in the centre. The jaw capacity of the tongs must be suitable for the dimensions of the load to be handled. the belt is tightened by pulling the free end so that the part to be handled cannot drop out. the tongs must be lowered until the jaws are automatically locked in the open position so that they can be lifted off. The tongs need not be operated manually. The jaws close and the load is gripped when the tongs are lifted. It must not be used for handling loads which have sharp edges or coarse surfaces. 46 The belt sling must uniformly support the load with its whole width. It must not be used for handling loads with tempera‐ tures higher than 50 °C. the open tongs are set down on the load to be handled. When using pantograph-type tongs which hold the load by contact pressure (rubber-lined jaws). – Fig. Locking and unlocking (for opening and closing) is effected by the tongs’ dead weight.3. When depositing loads. The clamping jaws must have full contact with the load or grip it from below. 214 741 44/210610 75 . This automatically unlocks the tongs.g. the sur‐ faces of the loads to be handled must be free from oil and grease. The angle between legs must not exceed 120°. After the handling cycle has been finished. the loop can be loosened and the belt sling be opened by lifting the closing eye.7. To this effect. The tongs must never be used for handling bar stock and compressible goods.

The hook throat must remain horizontal even under load. – Fig. Loads must never be handled with the tip of the hook.Open hook CAUTION Load falling down In order to ensure the safe use of the open hook please note the following: – In order to avoid that the load slips off. negligent or accidental restarting. Check to ensure that the reason for the emergency stop has been eliminated before the machine is restarted. the loads to be picked up may only be supported by the horizontal part of the hook throat. Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay. Every chain hoist features an emergency-stop device with which all motions can be stopped in the event of a hazard.4 Emergency stop Fig. 49 Position of the emergency stop device (1) WARNING Unauthorised. Danger to life and limb. 48 – 7. 76 214 741 44/210610 . The emergency-stop is arranged in a clearly visible position on the control pendant. This also applies in the case of damage occurring to parts of the machine and equipment which makes immediate stoppage and securing of the installation necessary. The emergency-stop device must not be used to switch off the machine in normal operation.

1 Taking out of service Taking out of service in the case of faults The machine 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 the insulation. ● Switch off the hoist unit power supply at the mains connection or isolator switch. ● Actuate the emergency stop. 7. do not switch the machine on again until you are satisfied that: ● the cause which led to actuation of this function has been rectified and ● continued operation of the machine constitutes no further hazard. 2.5. Switch off the mains connection or isolator switch before commencing maintenance and repair work. instructions concerning appropriate use and statutory regulations for operation and maintenance. Following an emergency stop. 7. 3.3 Taking the unit out of service for maintenance and repairs 1.2 Taking the hoist out of service on finishing work The following measures must be taken when finishing work or leaving the working area: ● Position the hoist unit outside the travel area. Page 7.5.5. Observe the relevant safety regulations when repairing electrical equipment. It then locks automatically and the chain hoist is shut down. 3.5 7. 214 741 44/210610 77 . turn the knob in the direction of the arrow (clockwise) and release. 4. ● To unlock the actuated emergency-stop. Secure the mains connection switch with a padlock to prevent unauthorised or accidental reconnection to the supply. 5. ● Brake and safety device failure. 7. Observe the relevant accident prevention regulations. Stop all moving parts and ensure that they cannot start moving while maintenance work is being performed. Control pendant Depending on the requirements the Demag chain hoist can be equipped with different control pendants. Only carry out maintenance work on the chain hoist when the load has been removed. see ⇒ Tab.● To actuate the emergency-stop. The oper‐ ation of the control pendant and the assigment of buttons can be seen in the corresponding brochures. 6. ● Drive the unloaded hoist unit into the resting position. press until it reaches the end stop.

tested and calibrated tools and accessories may be used for maintenance and repair work. Maintenance and repair work may only be carried out by authorized. Customer-specific regulations must be observed. Work on electrical equipment may only be carried out by qualified specialist personnel (⇒ "Definition of personnel". The mains connection or isolator switch must be secured against unauthorized or accidental reconnection by means of a padlock. The electrode holder and earth must be connected to the same assembly when welding work is carried out. the electrical supply must be switched off. Page 10 ) in compliance with the safety instructions. Let motor cool down before starting maintenance and repair work. Do not touch the hot motor housing. Only suitable. – CAUTION Loose connections Loose connections mean danger for life and limb or risk of machine damage. Only use approved spare parts. Wear protective equipment! Caution on open sharp-edged parts! Risk of injury! Ensure order and cleanliness at the workplace.8 Maintenance / repair 8. Tighten screws with the prescribed tightening torque. Appropriately fit component parts. Trolleys must not be welded or drilled. Danger of material damage. – Self-locking nuts must not be replaced by other types of nut. WARNING Inappropriate maintenance Danger to life and limb. see also ⇒ "Use of spare parts". Before starting work. Welding work may only be carried out by persons having a special qualification. instructed personnel (⇒ "Definition of per‐ sonnel". When using a working platform for maintenace and repair work.1 Safety Instructions for maintenance / repair In the following sections maintenance work is described which is necessary for optimum and trouble-free operation of the device. DANGER Live components Danger to life and limb. Page 9. Machine parts or fittings that are not required must be stored so that they cannot fall down. – – – – – – – – – Secure working and danger zone. only systems designed for passenger trans‐ port should be used that provide for a stable position and work without any risk. WARNING Risk of burning There is a risk of burning when touching the chain hoist after operation. Page 10 ) in compliance with the safety instructions. 214 741 44/210610 78 . Metal nuts featuring a locking element (self-locking nuts) are mainly used for Demag chain hoists. The requirements of DIN regarding welding work must be complied with. Otherwise serious damage may be caused to the hoist. Inappropriately fixed component parts may fall down and result in severe injuries.

6. Ensure that the chain hoist is switched off.). If routine maintenance reveals that the intervals are too long. If there is a risk of objects falling down. Page 84) apply to normal operating conditions of the chain hoist. Released oils and lubricants must immediately be absorbed by means of sawdust or oil absorbent and disposed of in an environmentally sound way. Components and tools being loose or lying around may cause accidents. Wear personal protection equipment. special safety precautions are necessary. 8. 79 . 5. 4. Ensure order and cleanliness at the workplace. checked for being de-energized and. 3. switch off the mains connection switch and protect it against unauthorized or accidental restarting by locking it with a padlock. depending on the operating situation. Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly manner. Defective fuse links must not be bridged. all wearing parts are checked. In the course of the annual inspection. Electrical components In the circuits. skin irritation etc. Before starting maintenance work. taking into account the local conditions.CAUTION Risk of injury! Oils and lubricants may be dangerous to health. isolated. implement all necessary safety precautions. 214 741 44/210610 Replace damaged or deformed spring clip fasteners and split sleeves. Observe the relevant safety regulations when repairing electrical equipment. the owner or the person assigned by him must check whether the maintenance work may be carried out in the course of operation without risk of personal injury and. Contact with these media may lead to serious damage to health (poisoning. Instructions for repair work in the course of operation If maintenance work on the chain hoist must be carried out in the course of operation. 7. 2. Maintenance work which is not possible from the floor may only be carried out from work stands or platforms. Ensure appropriate clearance for working. In each individual case. Observe the relevant accident prevention regulations and statutory regulations for operation and maintenance. only fuse links with specified amperage and tripping characteristics may be used. When working on machines or machine equipment the following must be observed: 1. they should be adapted to the specific operating conditions. the danger zone below the chain hoist must be made safe.2 Basic information on maintenance General information on maintenance/repair The specified inspection and maintenance intervals (⇒ "Inspection and maintenance schedule". in special cases. allergy. Stop all moving parts and ensure that they cannot start moving while maintenance work is being performed. Defective bolted connections must be replaced. CAUTION Risk of injury! Leaking oils and lubricants are hazard sources due to increased slippery. Only carry out maintenance work on the chain hoist when the load has been removed. 8.

3. In the case of extreme switching frequencies. 8. including those parts which cannot normally be seen. Adjustment. Under other operating conditions the service life of the contactor may be shorter or longer. number of cycles.After maintenance work After having finished maintenance work refit safety devices as prescribed and check for functioning. The routine inspection must be carried out in accordance with BGV D6 and ZH 1/27 "Principles for the inspection of cranes" in Germany. corrosion or other safety devices. Cranes and equipment must be inspected by a specialist at least once a year. This work may only be carried out by specialists. Defective parts and components and parts close to failure must be replaced. 50 Motor size ZNK 71 ZNK 80 ZNK 100 A ZNK 100 B Display value C at Unom 380 .". During the test run take care for smooth running of the chain. specified in German accident prevention regulations UVV/BGV D8 § 23 (2) and BGV D6 (1) must be carried out. After the chain hoist has been assembled completely.3. maintenance and inspection activities and inspection deadlines including specifications concern‐ ing replacement of parts/assemblies prescribed in the operating instructions must be observed.575 V 80 80 60 50 20 Display value C at Unom 220 . DC-Pro chain hoist 1 2 5 10 10 / 15 Tab.W. Page 84. by fatigue and ageing.3 8. we recommend that the contactor or control module be replaced.1 Measures for achieving safe working periods S. General The safety and health provisions of the EC Machine Directive make it a legal requirement to eliminate special hazards which may be caused. wear. The results of the inspection must be entered into a test and inspection booklet. premature wear is possible. – – An annual inspection as e.3. 80 214 741 44/210610 .3 8.3. 8.240 V 80 60 50 20 - The display value C specifies the expected service life of the contactor multiplied by 100 000. for example.3. Routine inspections mainly consist of visual inspections and function checks which should include a check to determine the condition of components and equipment regarding damage. All inspections must be arranged and documented by the owner. carry out a test run at partial load. When the corresponding display value is reached. Load carrying means must be inspected along their entire length.P. Prescribed tests and inspections must be carried out. Page 33.g. operating hours.1 Routine inspections Prescribed inspections WARNING Non-compliance with operating and maintenance instructions Danger to life and limb. operating statuses".P. ⇒ "Software version. Please also note ⇒ "Measures for achieving safe working periods S. ⇒ "Replacing the contactor on the control card". 8.W. Page 80 and ⇒ "Inspection and maintenance schedule". This value has been determined at normal operating conditions.2 Service life of the contactor The switchgear is subject to wear during operation of the chain hoist. Page 117. Its service life has been rated for the specified loading group. It may be necessary to dismantle the unit in order to inspect wearing parts.

The actual duration of service determined on the basis of operating time and load must be documented at least once per year. according to the state-of-the-art. 3. The objective of this rule is to determine measures for achieving safe working periods over the entire duration of service.755 with reference to the electric chain hoist: 1. The value determined for the estimated operating hours and load spectrum must be multiplied by the type of recording factor f = 1. For electric chain hoists classified according to FEM 9. For a chain hoist operated on average with half load. the following theoretical durations of service apply (con‐ verted into full load hours): Group of mechanisms Duration of service / full load hours [h] Tab. 2. 6. All checks and inspections and the general overhaul must be arranged by the owner of the hoist unit. 5.1993 Measures for achieving safe working periods for powered serial hoist units (S. for example. a 64-fold increase. 4.755/06. 51 1Cm 200 1Bm 400 1Am 800 2m 1600 2m+ 1900 3m 3200 4m 6300 The actual duration of service is considerably increased if the chain hoist is only operated with partial load.This requirement is also reflected in the third supplement to German accident prevention regulations UVV/BGV D8 (VBG 8) of 1. 7.3.). The operating time Ti (number of operating hours) can be estimated or read on an elapsed time indicator. be ruled out.W. The value determined for operating time Ti using an elapsed time indicator must be multiplied by the type of recording factor f = 1. The load kmi (load spectrum) must be estimated.2. although.3. this results in an 8-fold increase in the actual duration of service.1. The actual duration of service S is calculated as: S = kmi • Ti • f A general overhaul must be carried out when the theoretical duration of service is reached.P. however.1996. Premature failure cannot. This is based on FEM 9. the hoist units are designed for specific periods of operation. 8. A general overhaul is defined as: Inspection of the machinery for the purpose of detecting all defective components and/or components and parts close to failure and the replacement of all such components and parts.2 Calculating the actual duration of service S The actual duration of service S of the electric chain hoist can be determined as follows: S = kmi • Ti • f kmi : Actual load spectrum factor Ti : Number of operating hours f : Factor depending on the type of recording Calculating the number of operating hours (operating time) Ti (by the owner) 214 741 44/210610 The operating time can be calculated by means of an elapsed time indicator or according to the following method: Operating time per inspection interval: 81 . load spectra and/or recording factors. The following items have been taken from FEM rule 9. Following a general overhaul.4. with operation at one quarter of the full load. the machinery is in a condition similar to that of the same machinery in new condition as far as the principle of operation and performance values are concerned. This requirement obliges the owner of serial hoist units to determine the actual duration of service of the chain hoist on the basis of the operating hours.511. 8.

2 For estimating the operating hours and the load spectrum 8. Larger shares of the time period must be correspondingly added together. Dead loads are added to the loads.g. 52 (lifting + lowering) x cycles/h x operating time/day x days/inspection interval 60 x hoist speed Only lifting and lowering movements are counted.3 Example: DC-Pro 10-1250 1/1 H5 V8/2 in 1Am Hoist speed No. each type of load can be grouped together into km load spectrum modules. 3/4 load and full load. 1 year) in terms of percentage.3. 50 B L Load Load t 1 Time Dead load Factor depending on the type of recording ● f = 1.1 For calculating the operating hours using an elapsed time indicator (included in the DC-Pro standard scope of delivery) ● f = 1. Estimating the load spectrum factor kmi (by the owner) To simplify estimation. Loads up to 20% of the rated load capacity are not taken into consideration. of cycles per hour Lifting and lowering Operating time per day Days per inspection interval Tab. The types of load are simplified and quoted as 1/4. The operating time for each type of load is divided up within the inspection interval (e. 1/2. 53 8/2 m/min 10 cycles/h (2+2) m/cycle = 4 m/cycle 8 h/day 250 days/inspection interval Calculation Ti = Tab. Load spectrum factor kmi can be obtained by adding together the individual km load spectrum modules.Ti = Tab.3. long and cross travel times are not taken into consideration. The following bar diagram shows the km load spectrum modules for the load conditions without load up to full load in time increments of 5 and 10%. 54 10 • 4 • 8 • 250 60 • 8 214 741 44/210610 82 With operating time read: 167 . Diagram Fig.

002 15 0.1 = 21.025 20 0. the actual duration of service amounts to S [h] = kmi x Ti x f = ● with operating time read 0.9 ● with operating time estimated 0. This entry may appear as follows: Date Operating hours Load spectrum module km [%] Load spec‐ trum factor kmi 0. 800/1Am 800/1Am Remaining use D-S [h] 778.2 214 741 44/210610 83 .30.042 10 0.2 = 23.1 hours ● with operating time estimated 776.1 1. the chain hoist has transported the following loads: Fig.8 For classification in FEM group of mechanisms 1Am (see DC-Pro data plate) with a theoretical duration of service of 800 hours (see table below) the hoist has a theoretical remaining duration of service of ● with operating time read 778.6 full 5 0.119 • 166.119 Thus.12.8 Theor.05 5 0. duration of service D [h]/Group of mech. duration of service S [h] 21.025 1/4 15 0.6 In the operating time as read / estimated above.05 3/4 10 0.119 f Act.9 23.With operating time estimated: 166.3.12.1.Tab.119 x 167 x 1.6 • 1.042 1/2 20 0.002 Without 50 50 - 3.1.- 1. 51 B Load L t Load Time Adding the load spectrum modules km together results in the load spectrum factor kmi = 0.2 hours Documentation: Enter these values in your test and inspection booklet or crane installation test and inspection booklet.1 776.2 from to Ti value [h] read 167 estimated 166. 55 30.119 0.

● Gear oil and gearbox cover with seal. ⇒ „Software version.3. bearings. Page 103 ⇒ „Checking the load hook“. etc. further operation of the chain hoist is only permissible after a general overhaul. number of cycles. Page 33 ⇒ „Available hoist chains“. operating hours. 8.755. Page 80 X X Check chain lubrication (under arduous conditions. the chain must be lubricated more frequently) Check function of operating limit switch for lifting Check function of operating limit switch for lowering Check switch-off buffer / switch-off spring / operating limit switch actuator X X X X X X X X X X X X X X X X X X X X Check control cable and control pendant housing for damage Check function of the quick-release coupling (Manulift) for accommodating the load handling attachment Check operation of the brake Check hook and hook safety catch X 214 741 44/210610 X Read the switching cycles C X 84 . Page 33. operating statuses“. washers. The general overhaul carried out by the manufacturer or an authorized specialist company fulfills the condition for continued operation of the chain hoist. Page 88 ⇒ „Checking the quick-release cou‐ pling“. The small parts (screws. During the annual inspection by our after-sales service. The theoretical duration of service D (hours at full load h) depends on the group of mechanisms classification of the chain hoist. Thus the relevant accident prevention regulations and the BGV D8 (VBG 8) are complied with.8. Page 87 ⇒ „Checking the operating limit switches“. Page 100 ⇒ „Service life of the contactor“.4 General overhaul GO The chain hoists are designed for a period of use of at least 10 years until the first general overhaul is carried out. ● Shaft sealing rings. plugs. A general overhaul must be carried out no later than when the end of the theoretical duration of service is reached. When the actual duration of service has reached the theoretical duration of service valid for the group of mechanisms. Further utilization is approved when an expert engineer has entered the conditions for further utilization into the test and inspection booklet. Page 54 ⇒ „7-segment display for operating status and error display“. Page 93 ⇒ „Checking the operating limit switches“.) to be replaced during maintenance and assembly work are not listed sep‐ arately.755 must be entered. This is based on the condition that the specified group of mechanisms is not exceeded by the actual duration of service. Page 87 ⇒ „Checking the switch-off buffer / switch-off spring“. During the general overhaul the following parts must be replaced in addition to the checks and work specified in the inspection and maintenance schedule: ● Gearbox housing with joined gearing parts. ● Brake.4 Inspection and maintenance schedule Action Section Before first putting into operation X X X X Before start‐ ing work In the course of annual in‐ spection Check continuity of the PE conductor connection Check emergency stop device Check direction of movement Check 7-segment display ⇒ „Line connection“. Page 109 ⇒ „Checking the operating limit switch actuator“. Completion of the general overhaul must be confirmed in the test and inspection booklet and a further period of utilization in accordance with FEM 9. ● Connecting elements. The actual duration of service is to be determined annually in accordance with FEM 9. you may have the actual service life determined. Upon expiration of 90% of the theoretical duration of service – if the chain hoists are correctly classified after 8 to 10 years – the owner must arrange for a general overhaul GO to be carried out.

Page 115 ⇒ „Adjusting the slipping clutch“. Page 80 ⇒ „Checking the slipping clutch“.) for tight fit and corrosion Check and apply or supplement corrosion protection. deformation and wear Check hook safety catch for deformation Check hook bearing for wear Check rubber lip seal in the bottom block X X X X X X X Check the load and chain anchorage in the control unit (Manulift) incl. Page 115 ⇒ „Brake“. Page 33 ⇒ „Measures for achieving safe working periods S. fastening screws Check the cylindical pins fitted in the quick-release coupling (Manulift) for wear and fracture Check sprocket of chain guide. chain sprocket of bottom block.P. etc. chain guide. suspension bracket and securing ele‐ ments (clip. Page 116 Every 10 years 45) Every 10 years 45) Every 10 years 46) 45) Check electrical switchgear and wiring Check operation of the slipping clutch Check setting of the slipping clutch Check brake wear. cracks.) Check fastening screws on hook assembly / bottom block Check hooks for cracks. Page 86 ⇒ „Checking the load hook“. etc. Page 102 ⇒ „Manulift“.. bolts. guide plate Check that the chain and chain collector box are properly secured Check the chain for deformation. During the general overhaul. crossbar and status of buffers Change oil General overhaul The general overhaul should coincide with the annual inspection X X X X X X X X X On reaching 90% of the theoretical duration of service ⇒ „Measures for achieving safe working periods S. Page 109 ⇒ „Gearbox / oil change“. washers . pitting. reeving 2/1“.) to be replaced during maintenance and assembly work are not listed separately.Action Section Before first putting into operation Before start‐ ing work In the course of annual in‐ spection X X X Read operating hours for determining the remaining duration of service ⇒ „7-segment display for operating status and error display“.P. Page 90 ⇒ „Checking the switch-off buffer / switch-off spring“. elongation caused by deformation Check securing elements (clips. Page 80 X Fit chain hoist-specific Demag GO set The small parts (screws. Page 100 ⇒ „Replacing the bottom block (standard for DC 10) with internal switch-off springs.“. 56 214 741 44/210610 45) For 46) DC-Pro use in accordance with the FEM classification 10 and DC-Pro 15 every 5 years 85 .. Page 103 ⇒ „Chain drive“. Page 103 ⇒ „Checking the quick-release cou‐ pling“. Page 113 ⇒ „Suspension“.“. damage. reduction in the thickness of the links or increase in pitch due to wear. Page 89 ⇒ „Checking the hoist chain“.W. as re‐ quired Check electrical enclosure and gearbox for leakage Check trolley.W. the checks and work specified in the inspection and maintenance schedule must be carried out. grease V sealing ring Check suspension. Tab.

52 Suspension ring Chain hoist Min. dimension e suspen‐ sion ring turned 90° (chain hoist parallel to gird‐ er) Tab.55 DC 10 24.4 DC 10 short 25.3 long 14. they must be replaced at once. 53 8. 58 [mm] DC 1/ 2 / 5 17. Do not let the electrical equipment cover fall into the fall pro‐ tection.5 8.1 Maintenance work Suspension If a check or inspection reveals that the dimensions are lower or higher than those specified due to wear or if cracks can be seen in these parts.5 Fig.8.3 DC 15 34. dimension e suspen‐ sion bracket Tab.2 Electrical equipment cover Hold the electrical equipment cover while opening it.5. When closing the electrical equipment cover.2 Fig. make sure that the fall protection does not cover the window or is jammed. Suspension bracket Chain hoist Suspension bracket Min. 86 214 741 44/210610 .5. 57 [mm] DC 1/ 2 / 5 short 15.2 long 24.3 DC 15 long 31.

hold the chain collector. 87 .4. Operating limit switches Checking the operating limit switches DANGER Broken chains and load drop Frequent approaches of the emergency limit stop device may result in broken chains or load drops.5.1 214 741 44/210610 Unscrew and disengage the service cover (1).4 8.3 Dismantling the chain collector box Fig.5. Disengage the spring (3) and place it in the recess in the chain collector box. 54 – – – – – 8. Deposit the chain collector box (6) on the ground. While doing so.5. Place the bag (2) with control cable on the top of the chain hoist.8. Remove securing spring (4) from the pin (5) and pull out pin.

● 1/1 reeving: After switching off the buffer or switch-off spring on the hook assembly may be compressed only to a small extent. Proceed as follows: ● Remove chain collector box ⇒ "Dismantling the chain collector box". After the hoist has been switched off.g. high additional loads are exerted on the chain. Fig. For checking the highest hook position must be approached at high lifting speed (without load).For chain hoists without operating limit switch or with defective operating limit switch.. ● 2/1 reeving: When a bottom block with internal switch-off springs is used. When the buffer or switch-off spring are excessively compressed. it must not be approached in normal operation. a warning is displayed. When the slipping clutch is tripped. the hoist unit must be switched off. Therefore the function "Operating limit switch for lifting" must be checked every day. defective buffer limit switch being actuated (C). the hoist motor is switched off by the triggering of the electronic speed monitoring device of the slipping clutch. Optional geared limit switch When the optional geared limit switch is used. 55 Buffer with limit switch not being actu‐ ated (A).e. 8. Page 124. the upper part may also be shifted onto the lower part only to a small extent so that approx. Page 87 ● For further check procedure. This emergency limit stop device may only be ap‐ proached in exceptional cases. the slipping clutch of the chain hoist perfoms the function of the emergency limit stop device. it may be assumed that the hoist motor is not switched off by the operating limit switch but by the speed monitoring device of the slipping clutch. Checking the operating limit switch for lowering The function of the "Operating limit switch for lowering" must be checked at least once per year. buffer with limit switch being actuated (B).4. e. see ⇒ "Warning messages". 88 214 741 44/210610 . the springs may also be compressed only to a small extent when switching off. When a bottom block with external switch-off springs is used. i. Then lift at creep speed up to the highest hook position until the chain hoist is automatically switched off.5. 10 cm below the highest hook position. 20 mm of the black part of the bottom block remain visible. When switching off by the operating limit switch fails. If the operating limit switch is defective. bent actuator plate. Checking the operating limit switch for lifting: Lift the hook assembly or bottom block up to approx. the minimum distance to the guide plate of the chain hoist must be 20 mm.2 Checking the operating limit switch actuator The operating limit switch actuator must be checked for external damage. proceed as described above under "Operating limit switch for lifting". This may result in broken chains when the end position is approached frequently. before the bottom block or the hook assembly touch the guide plate of the chain hoist. The fact that the hoist unit is switched off in the highest hook position does not indicate that the operating limit switch functions correctly.

59 a 16. see also brochure "Guide plate accessories DC 1 . For this purpose a set "Guide plate ac‐ cessories" is available (part no.5 8.5. 8. 56 Example for defective chain guide 8.e.1 Chain drive Checking the sprocket wheel Since the sprocket wheel is replaced together with the chain set. 57 214 741 44/210610 89 .7 31.9 12.4 d 6. However.4 11. i.g. 3. Fig. if you find that the chain does not run smoothly over the sprocket wheel.8 8. Page 7. A defective chain guide must be replaced im‐ mediately. 717 830 45). a lateral play of approx. halves burst open or loose fit of the screws. Fig.8 9.8 33.5. Multiple fitting and removal of the guide plate retaining bolts may damage the thread in the aluminium housing in such a way that a tight fit of the bolts can no longer be ensured.5 c 16.5.0 28. it must be replaced at once.0 15. e.5.2 Checking the chain guide The chain drive can move easily on the drive shaft. this may indicate wear.0 19.5. ● Open the service cover.5.15" ⇒ Tab.5.3 Checking the guide plate Maximum dimensions of the guide plate [mm] DC 1 / 2 DC 5 DC 10 DC 15 Tab.4 26.5 6.3 If a check or inspection reveals that the dimensions specified are excee‐ ded due to wear or if cracks can be seen on the guide plate.8 21.8. ±2 mm is normal. at normal conditions no further check is necessary.1 b 5. ● Check the chain guide for damage.

If routine maintenance reveals that the intervals are too long. Measuring with a calliper gauge Measurements on 11 chain links may be taken in steps of 2 x 3 and 1 x 5 chain links. they should be adapted to the specific operating conditions. a1 + a2 + a3 must not exceed limit a. Fig. owners of hoist units are obliged by DIN 685 part 5 regulations to constantly check the round section steel chain in order to ensure optimum operating safety and. 59 214 741 44/210610 90 . Otherwise the chain must be replaced. to avoid serious accidents. We urgently recommend you use genuine Demag chains. Measuring wear or deformation of the original Demag chain A partial load must be suspended from the load hook when measuring the chain for wear or deformation. i. 1.5. for example. as required. Page 30.5. The sum total of the 3 readings taken. 60". If the chain hangs at angle while it is unloaded. Page 91. it does not run smoothly over the sprocket? Please contact our after-sales service centre. This measurement can be taken in two different ways. values of the wire diameter see⇒ "Tab. Do you find that. This will ensure that the safety and service life of the chain hoist is guaranteed. the chain should be checked once a year (see inspection and maintenance schedule).8. therefore. 58 The chain link contact areas must be visually checked for traces of wear. 2. Measuring with a calliper gauge Measuring with a chain gauge Wear of individual link Fig. Demag is stamped on every 12th link of original Demag chains. For single-shift operation.e.4 Checking the hoist chain Checking the discarding status of the original Demag chain In addition to selecting the correct hoist unit. operation in accordance with FEM specification and for operating conditions of the chain hoist in accordance with ⇒ "Operating conditions". Min. Measure the wire diameter of the chain in the chain link contact area by means of a calliper gauge. on fitting a new chain. this usually indicates wear of an individual chain link.

dimension t Measurement of the chain link diameter.4 x 21.8 mm DC-Pro 5 5. Measuring pin 11. max. when the meas‐ 2 3 uring pin can no longer move into the 11th chain link.9 mm 4.8 mm Measuring with a chain gauge Fig.2 253 mm 22.3 mm 15.2 289 mm 25. th chain link.5 mm 7. 60 DC-Pro 1 / 2 4.Demag chain hoist Chain designation d x t Limit dimensions according to DIN 685 part 5 Measurement over 11 chain links outside.2 180.7 mm 12. dimension = a 1 + a 2 + a 3 Overall length of 1 chain link measured on the inside. The discarding status has been reached.9 x d Tab.3 x 15. It is not yet necessary to replace the chain.8 mm 3.4 mm 6.2 144. 60 A B 1 DC / DK / PK new chain PK old chain The discarding status has not yet been reached.540 Designation Chain gauge Tab.2 x 12.: 836 025 44 214 741 44/210610 91 .8 mm DC-Pro 10 7. dimension dm = 0. It is necessary to replace the chain. The chain must be replaced.7 mm DC-Pro 15 8. Weight [kg] 0.7 x 24. min. 61 Part no. max.

Page 90.5. ● Buffers for upper and lower hook position. ● Sprocket wheel. ● Chain guide with plate and cap. the chain is already fitted in the chain guide. The chain guide is pre-assembled. ● Retaining ring. ● Chain guide plate. The chain set includes the following parts: ● Chain. When a new RDC standard chain is ordered. ● Demag chain grease tube. 92 214 741 44/210610 . a chain set is always supplied.5.5 Scope of supply chain set On reaching the permissible limit of chain wear the chain set must be replaced (for determining the wear limit of the chain ⇒ "Checking the hoist chain".8.

for max.7 x 24.2 5.38 0. 10 cycles per day = 500 kg For max.3 x 15.500 47) 800 . blue chromated.20 10 16 32 16 25 50 15 125 .8.2 x 12.5.5 19. 1981 as well as BGV D8 (VBG 8) and BGV D6 (VBG 9).62 1.2 5. Chain hoist size Dimension Stamp.5.1000 48) - Non-rusting chain. 62 4.1 Dry or with dry lubricant.1 Grease GP00H-30REN. part 5. foundry. colour: silver Ni-Mo special chain steel acc.2 5.7 19.3. with deeper hardening surface Ni-Mo special chain steel acc.20 1. Stabylan 2001 Ni-Mo special chain steel acc. 12-25 cycles per day = 800 kg 93 . to EN 818-7.2 RSA / S DC 1 / 2 DC 5 DC 10 DC 15 4.20 12.20 13.67 [kN] 13.g. galvanised with additional surface treat‐ ment.2 5. load capacity for reev‐ ing 1/1 [kg] 250 500 1250 1600 2/1 [kg] 2500 3200 [mm] Demag RDC standard chain DC 1 / 2 DC 5 DC 10 DC 15 Properties Material Lubrication Demag Corrud special chain Application e. to EN 818-7.62 1.2 x 12.38 0. CAUTION Pay attention to reduced capacity. part 5. blasting Properties Material Lubrication Demag RS6 special chain DC 1 / 2 Application e.8 22 43 59 High strength.3.3 x 15.2 x 12.2 7. galvanizing.250 400 . 5 cycles per day = 1000 kg.3 x 15.g. chain quality Weight per meter Production test force Minimum breaking force [kN] 22 35 70 95 10 Minimum breaking elonga‐ tion [%] Max. part 5.38 0.4 x 21. ageing-resistant material with a high degree of surface hardening.38 0.62 1. 25-50 cycles per day = 400 kg max.g.2 DAT / RDC [kg] 0. e. Paraliq chain spray 214 741 44/210610 47) For 48) For max.6 Available hoist chains The original Demag chain is a round section steel chain tested to EN 818-7 which is subject to the directives for round section steel chains in hoisting operation of the Main Association of Industrial Employers' Mutual Insurance Societies. Klüber UNIMOLY C220 0.g.160 200 . corrosion-free.2 7.3.3 30. the special chains listed in the following are available for special ambient conditions.8 60 5 160 400 800 1600 - Ageing-resistant. bright Stainless steel AISI 316 (V4A) 1.2 7. Central Department for Accident Prevention and to the test criteria for round section steel chains in hoisting operation and to the inspection regulations according to DIN 685 part 5 Nov.g. foodstuffs sector DC 5 DC 10 DC 15 Properties Material Lubrication Tab. blue chromated. colour black.4 x 21.4 x 21.4401 Edible lubricant.2 x 12.2 8.4 x 21.2 DAT / RDC 4. e. emery. dust.1 Acid-resistant chain grease 0. micro-layer corrosion protection „Corrud DS“ coated black.2 7.3 x 15. electro‐ plating facilities Properties Material Lubrication Demag HS7 special chain Application e.62 1.SO-GFB 0.8 22 43 22 35 70 10 250 500 1250 2500 - Ageing-resistant.8 38. to EN 818-7. Deviating from the standard operating conditions for which RDC chains are used. not hardened.2 RSX / DS DC 1 / 2 DC 5 DC 10 DC 15 4.

4. proceed as follows: 1.5. Loosen cap (5) with a screw driver (lever off). Remove and deposit the chain collector box (6) (⇒ "Dismantling the chain collector box".5. pull out and deposit mains cable union (3) with fitted mains cable (4). remove the connection cable from the strain relief. if a travel drive is fitted. To replace the chain set. 94 214 741 44/210610 .7 Replacing the chain set Fig. Open and disengage the service cover (1). 2. 3. Place bag with control cable on chain hoist (2). Page 87).8. 61 Before starting maintenance work take the hoist out of service and secure against restarting.

Remove the retaining ring (8) using Seeger ring pliers. 2. either use offset or straight pliers (access through the opening in the gearbox housing on the side of the motor or from the service enclosure). proceed accordingly in reverse order. DC-Pro 10 : Fold the cover of the opening in the gearbox housing (9) to the side. slide the complete assembly in the direction of the motor until the sprocket wheel is free. Remove the guide plate (7). to do this. 62 1. 214 741 44/210610 The following points must be noted: 95 . 3.Fig. then remove the worn chain set from the service enclosure. DC-Pro 1 to 5: In the area of the power supply insert. For fitting the new chain set. Remove the chain guide (10) with sprocket wheel from the output shaft.

64 3 1 2 2 DC-Pro 15 1 Fig. the complete number of spacer rings must be fitted on the output shaft. 65 96 . 63 A) Tab. lubricate the splining of the output shaft with Molykote or similar. DANGER Broken chains and load drop An incorrectly fitted chain may lead to broken chains or load drops. Fitting the retaining ring ● The stamped burr of the retaining ring (1) must face the motor. Item 1 2 3 4 Designation Cap Retaining ring Spacer ring Chain guide DC-Pro 1 / 2 5 Spacer ring DC-Pro 5 DC-Pro 10 DC-Pro 15 Tab. the chain guide has a larger bore hole. it must be ensured that the chain is introduced in the same position and orientation. Page 132 Spacer rings for the output shaft ● When fitting the chain guide. When fitting the chain. 63 Chain guide for DC 10 without geared limit switch B) Chain guide for DC 10 with geared limit switch When the chain hoist is equipped with a geared limit switch. See also ⇒ "Chain drive". 64 Before you slide on the chain sprocket. 214 741 44/210610 Fig.Chain hoist with geared limit switch Fig. The chain must operate without any twist. Correct fit of the retaining ring is ensured when it can be easily turned on the output shaft after assembly.

● Put the chain end between the two chain anchorage halves (3) and bolt them together with a tightening torque of 25 Nm. Item 1 2 3 4 5 Tab. B). 2/1 reeving Fig. ● Completely push back the two pins (1) into the bore holes (the pins are secured by the fitted guide plate). socket head screw of chain anchorage halves Chain anchorage half Guide plate Hex. Bolt the chain anchorage halves (1) together (Fig. A). 67 214 741 44/210610 97 . 65 Designation Chain anchorage pin Hex. ● When removing the chain anchorage push the two pins (1) out of the bore holes only to such an extent that the chain anchorage can be removed. 66 ● Fit the chain anchorage before bolting the guide plates into position for DC-Pro 10 with 2/1 reeving. socket head screw of guide plate Fig.Fitting the chain anchorage for DC 10. ● Insert the bolted chain anchorage into the opening of the gearbox housing. Fitting the chain anchorage for DC 15. ● Fit the pins (2) (the pins are secured by the fitted guide plates). 2/1 reeving Fit the chain anchorage before bolting the guide plate (4) into position for DC-Pro 15 with 2/1 reeving. ● Insert the bolted chain anchorage into the opening of the gearbox housing (Fig.

5 25 25 DC-Pro 10 2/1 1/1 25 DC-Pro 15 2/1 Tightening torques [Nm] Reeving Service cover Limit stop Chain anchorage halves Guide plate Tab.3 10. in the chain anchorage. see brochure "DC geared limit switch" ⇒ Tab. because it has reached the wear limit. Deviating lubrication see ⇒ "Available hoist chains". Fit chain collector box ⇒ "Dismantling the chain collector box".g. The chain link contact areas must be relubricated appropriately – after being cleaned – at intervals depending on the service and load conditions. The limit stop must fitted so that the excess length of the chain lies between the hook assembly and the limit stop.). an additional limit stop must be fitted to the chain between the hook assembly and the buffer plate. sand. Page 98 Adjust the lower hook position as required ⇒ "Setting the lower hook position". Therefore the condition of the return sprockets must be checked when replacing the chain. Even chain links being covered e. hook assembly. 68 Furher procedure after having replaced the chain set If the chain must be replaced. before lifting a test load and putting the hoist into operation as well as during normal operation when being unloaded. A dry film lubricant should be used in environments where abrasives occur (emery. 214 741 44/210610 98 . In this case a geared limit switch is required for the DC 10 and the DC 15 with 2/1 reeving.5. ● If the chain hoist is operated with a chain that is longer than suitable for the standard capacity of the chain collector box.0 5. Fig. limit stop or crab frame must com‐ pletely be lubricated. Page 100 Lubricate the chain ⇒ "Available hoist chains". part no. 3. 66 8. Page 67. The chain must be lubricated along its entire length.5. Page 7. Page 87. We recommend replacing the return sprocket every second time the chain is replaced at the latest. the chain link contact areas must be lubricated with a gear grease. – – – – – Fit the hook assembly/bottom block ⇒ "Load hook".5 DC-Pro 5 1/1 7. 665 009 44. Page 93! CAUTION Premature wear of the chain! Danger of load drop due to broken chains. the return sprockets are ususally also worn and must be replaced. etc. it must be readjusted after having replaced the chain. ⇒ "Lubricating the hoist chain". DC-Pro 1 / 2 1/1 5. If an optional geared limit switch is fitted to the chain hoist.5 4.Fitting the limit stop ● Fix limit stop to the 5th link at the dead (unloaded) end of the chain paying attention to the tightening torque.5 4.8 Lubricating the hoist chain After fitting. Page 93.

Fig. 70 214 741 44/210610 99 . 69 DC-Pro 15 chain hoist Apply the lubricant with a brush. To ensure complete and even lubrication of the chain. Fig. move the chain into its end positions while you fill the grease into the chain guide by pressing on the tube.DC-Pro 1-10 chain hoist Cut off the tip of the grease tube and insert the grease tube at the lubri‐ cation point.

test force Max.5.7 48.5 26 24.2 Checking the return sprocket The return sprocket must be checked for smooth turnability every month.8. hook force Tab.3 250 2 1/1 500 5 V3 36 30.3 24 154 38 50 100 a2max 27.1 22 86 19. 67 [kN] [kN] 49) [kg] DC-Pro 125 1 V2 30 25.6.5.8 65 130 V4 43 36 39.5 20.7 36 110 31.5 33.8 8 16 8. 100 49) Permissible 50) Permissible deviation +10% deviation -5% 214 741 44/210610 .8 50 100 3200 2/1 V6 56 49 53.5. Jerky movements of the bottom block indicate wear.8 25 50 V5 50 39 42. 71 Max.9 29 44 34 32.1 Load hook Checking the load hook SWL Chain hoist Reeving Load hook Type a1 a2nom b1 Dimensions [mm] h1 h2nom 50) h2min L2 L4 d1 Fig. Check whether the bottom block moves correctly when lifting and lowering.42 30 109 23.5 21. For this purpose it may be necessary to remove fixed crossbars from the bottom block.1 56 187 49.07 29 44 34 32.8 16 32 1250 10 2500 2/1 1600 15 1/1 V5 50 43.6.83 13 22 18 17.9 30 55 38 36.6 22 33.6 8.55 19 27.3 45 159 41.

5.8. DC-Pro 1 DC-Pro 2 DC-Pro 5 11.5 DC-Pro 10 25. Tighten the housing bolts according to the tightening torque table.5 6.6. reeving 1/1 Fig.3 Replacing the hook assembly. 3. Pay attention to the correct position of the locking nose (4). 4. 2.0 DC-Pro 15 27. 72 1. 68 214 741 44/210610 101 . Deposit the new hook and remove the two bolts Lift off buffer cap (1) with a screw driver. Remove the chain link sections (2) from the load hook and put them around the last chain link. Remove the upper half of the hook assembly. Slide the buffer cap (1) onto the chain. Insert the chain and chain link sections (2) in the new hook and put the upper half of the hook assembly (3) on it.8 Tightening torques [Nm] Hook assembly Tab.

5 Tightening torques [Nm] Bottom block with internal switch-off springs Tab. 09/2009 the bottom block is provided with rubber lips (1) in the area of the chain entry.6.0 5. Check the correct fit of the four switch-off springs (3) in the new bottom block halves (4). Fit the new guide halves (1) and tighten the screws (5) with 5. 102 214 741 44/210610 Fig. 8. Loosen the clamping screws (2) of the bottom block and remove the bottom block.8. Assemble the bottom block and tighten the screws (2) with 52 Nm. 09/2009 From approx. reeving 2/1 Fig. Introduce the chain into the new bottom block in the same position and orientation (chain must operate without any twist). During the annual inspection the rubber lip must be checked for wear and correct fit. Perform function check (run against operating limit switches and check 7-segment display). 3. DC-Pro 10 Bottom block halves Guide halves 52. 2. 74 . 73 1. 5. Remove the guide halves (1) (four M 6 screws).5 Nm. 4. 69 Bottom block from approx. 6.5. 7. Apply load capacity plate.4 Replacing the bottom block (standard for DC 10) with internal switch-off springs.

option for DC 10) with external switch-off springs.0 8.5. 70 DC-Pro 10 / DC-Pro 15 55. To do this.8. The diameter of the cylindrical pins must not be lower than 5.5.7 8. The diameter is increased due to wear. reeving 2/1 Fig. 71 Designation Coupling pin Socket for load handling attach‐ ment Unlocking sleeve Control unit Pressure spring Item 6 7 8 9 10 Designation Cylindrical pin Swivel lock Top cover Emergency stop Actuating rockers The quick-release coupling must be checked daily for correct functioning and smooth operation. The diameter of the quick-release coupling for plugging in load handling attachments is 20 mm. slacken the 2 connecting screws on the unlocking sleeve (3). 214 741 44/210610 Fig.7. The swivel lock (7) fitted in the load handling attachment must be checked for tight fit and wear every three months. 76 103 . It must not be larger than 26 mm at any point.5 Replacing the bottom block (standard for DC 15. 75 Tightening torques [Nm] Bottom block with external switch-off springs Tab.6. The cylindrical pins (6) fitted to the quick-release coupling must be checked for wear every three months.1 Manulift Checking the quick-release coupling Item 1 2 3 4 5 Tab.5.4 mm at any point.

72 Designation Chain collector box side Load side DCM-Pro 1 / 2 4. Fig. Page 94. Page 105. . ● Remove helical cable from control unit ⇒ "Replacing the helical cable". Page 87. ● Remove the two limit stops (1).2 Replacing the chain Item A B 1 2 Tab. ● Loosen chain anchorage on the control unit ⇒ "Fitting the chain to the control unit". ● Fit the free chain end to the control unit ⇒ "Fitting the chain to the control unit".3 Limit stop Screw for chain retainer halves Tightening torques [Nm] ● Dismantle the chain collector box ⇒ "Dismantling the chain collector box".0 5-6 DCM-Pro 5 4.7.8. ● Replace chain set ⇒ "Replacing the chain set".Fix limit stop to the 5th link on the chain collector box side. Page 105. Page 120.Fix limit stop to the 17th link on the load side. 77 104 214 741 44/210610 .5. ● Fit both limit stops: . Page 98. ● Lubricate new chain before putting it into operation ⇒ "Lubricating the hoist chain".

3 Fitting the chain to the control unit From year of manufacture 04/2009 the chain swivel unit is fitted as standard Fig. 73 Designation Top cover screw Helical cable Top cover Chain anchorage Item 5 6 7 8 Designation Chain anchorage screw Pin Chain link section Bearing Item 9 10 11 12 Designation Retaining pin Chain swivel unit Chain Swivel unit screw 105 .8.5.7. 78 Item 1 2 214 741 44/210610 3 4 Tab.

Close swivel unit halves (10) and tighten screws (12) with the correct tightening torque: Chain 4. DANGER Load drop Incorrect assembly may result in load drops. 79 1. During assembly it must be ensured 1. Insert pin (6) in the chain anchorage (4) and bolt the two chain anchorage halves (4) together with a tightening torque of 5 . Slide top cover (3) over the pin (6) and tighten the top cover screws (1) with a tightening torque of 3 Nm. 7. 4. Chain 5.5 Nm.2 x 12. Open the chain anchorage (4) and remove the chain link sections and the chain.8 Nm. with a screwdriver). DANGER Load drop Incorrect assembly may result in load drops. Until year of manufacture 03/2009 Fig. Pull the new chain through cap (2) before fitting. 6. 214 741 44/210610 . 5. Grease the bearing and bearing seat.Deposit the Manulift so that the chain and helical cable are unloaded.2 ⇒ 6. Push helical cable (2) to the side and loosen the screws (1) of the top cover (3). 2. Assembly: 3. that retaining pin (9) is correctly fitted when the swivel unit is assembled. Disassembly: 1. That the chain link sections (7) are positioned in bearing (8) with their collar. Insert retaining pin (9) in chain (11) and put the swivel unit half (10) around pin (6). Fit bearing (8) and the chain link sections (7) on pin (6) in the correct sequence.g. During assembly it must be ensured 1.6 Nm. Loosen screw (5) of the chain anchorage (4). Slide top cover (3) off the chain anchorage (4) and secure it against slipping. slide cap (2) upwards and secure against dropping (e. 106 Loosen cap screws (1).2 ⇒ 9.3 x 15.

2. 3.

Before loosening the hexagon socket screw (3), set the control unit down. Open the chain retainer halves (5) until the last link of the chain (4) can be removed. Place the last link of the chain between chain link sections (6) before fitting.

DANGER Load drop due to incorrect fitting The chain link sections (6) must be inserted turned by 90° to the chain retainer halves.
Tightening torques [Nm] Screw for chain retainer halves (Manulift) Tab. 74 DC-Pro 1 / 2 / 5 5-6

8.5.7.4

Replacing the switching elements

Fig. 80

1.

Loosen the four cover screws (2) and remove housing cover (1). Tighten diagonal pairs of cover screws when re-fitting the cover. No gap must remain between the cover and the lower part of the housing (3) when the cover screws are tightened.

2. 3.

Disconnect the electrical connections (4). After removing the four switching element screws (5), disconnect cores and remove switching element (6). The switching element can only be fitted in one position determined by a rib on the housing.

DANGER Live components Only connect the helical cable in accordance with the circuit diagram. Pay attention to core identification.

214 741 44/210610

107

8.5.7.5

Replacing the gearbox

Fig. 81

1. 2. 3. 4.

Loosen cap screws (1), slide cap (2) upwards and secure against dropping (e.g. with a screwdriver). Loosen the four screws (4) and lift off upper part of housing (3). After removing the bearing block screws (5), pull upwards the complete gear mechanism with rocker switches (6). Turn the shaft (10) by 90° in relation to the bearing block (7) and remove it. Fit the shaft (10) with the bevel gear (8) into the bearing block (7) as illustrated. Ensure that the bevel gears mesh properly with their counterpart gears.

5.

Pull the bevel gear (8) off the shaft (10). When fitting the bevel gear (8) to the shaft, ensure that it is pushed on until it comes up against the stop. Pay attention to the correct position in relation to the lever (9).

6. 8.5.7.6

The emergency-stop button (11) must not be pressed when the two halves of the housing are fitted together.

Load handling attachments Load handling attachments must be checked depending on their frequency of use: ● The smooth locking and unlocking operation of the tongs locking mechanism must be checked daily. Keep the mechanism clean (but do not oil).
214 741 44/210610

● Regularly check the smooth operation of the pantograph hinges. Clean and oil the hinges as necessary. Affected parts must be replaced immediately if cracks, deformation, wear of hinge pins (hinge play approx. 1,5 mm) and jaws are detected. ● Belt slings must be checked once a week if they are regularly used, or before being used again if they have not been used for a long period. During these checks, the fabric should be examined for brittleness, damage by 108

chemicals or stretching, and for deformation caused by heat; the general condition of the end fittings should also be checked. 8.5.8 8.5.8.1 Buffers Checking the switch-off buffer / switch-off spring

Fig. 82

1. 2.

Buffer wear: In the course of annual inspection visually check the buffers. Check for damage and cracks. Missing buffer plate: When fitting new buffers, pay attention to the correct fitting sequence of the component parts ( see also ⇒ "Buffer design", Page 110), e.g. a missing buffer plate leads to premature wear of the buffers.

3.

Wear of external switch-off spring: In the course of annual inspection visually check the external switch-off springs. Check the sleeves of the springs for damage and cracks. The individual windings of the springs must not be shifted above each other.

214 741 44/210610

109

75 110 214 741 44/210610 .10 without operating limit switch DC-Pro 1 .5.8.10 DC-Com 1 .10 DC-Com 1 .10 with operating limit switch DC-Pro 1 .10 DC-Pro 15 Tab. 83 1 Buffers 2 3 Buffer plate Switch-off spring Load side A C E G J Chain collector box side B D F H K Chain hoist range DC-Pro 1 .2 Buffer design Buffer variants Fig.8.

6/2.2/1.6/2.6/2.6/2.2 9.4/3.5 12.0/3.5 8.8 9.0 12.8/7.8 14.2 9.4 7.8 28.6/2.0/3.0 6.0/3.4 14.0/6.8/7.4/3.6 7.0 24.0/1.2/1.2/4.0/2.4 19.8 14.0 16.2 7.0/2.0/2.0/4.0/1.4/3.2/1.0/2.4 7.8/7.0/3.8 28.0/2.0 8.0/4.6/2.0/3.0 24.5 8.0 24.0 24.2/4.0/2.8 Chain collec‐ tor box side B D H B D H B D H B D H B D H B D H B D H B D H B D H B D B D B D K D B K D K D K B K 4m 5m H5 H8 H5 H8 H5 H8 H5 H8 H5 H8 H5 8m - H8 H5 H8 H5 H8 H5 H8 H5 H8 H5 H8 H5 H8 H8 S S S S S H8 H5 H8 H8 H8 - Flex H8 Flex Flex Flex - A 2xJ .0/3.0 24.4/3.6/2.2/1.8 28.8 14.0/1.6 28.2/4.0/6.6/2.4 19.0 8.0 16.0 12.2 9.0/6.6 9.0/6.0 8.0/4.0 16.0/2.8/1.0 6.0/2.0/2.8 9.0 630 10 800 6.8 28.51) 2xJ .0 24. Page 110 Load hook side A C G A C G A C G A C G A C G A C G A C G A C G A C G A C A C A C 2xJ 51) Chain collector box size at hook path at 50 Hz [kg] 80 DC-Pro 1 2 5 1 100 2 5 1 125 2 5 2 160 5 2 200 5 10 2 250 5 10 5 315 10 5 400 10 5 500 1/1 [m/min] 8. 111 .0 8.8/7.0/2.0 24.0/4.4 19.4 7.2/4.8/7.0/1.4/3.0 8. 83.5 1000 15 1250 10 15 1600 2000 2500 3200 Tab.2 9.6 28.4 14.0 6. 76 10 15 10 15 10 15 15 2/1 1/1 2/1 1/1 12.0/6.8/7.0 6.0/1.0/2.0/1.6 28.4 19.0/6.6/2.0 8.0 8.0 24.4 19.2/4.0/4.2 9.6 7.0/1.4 9.2 5 and 8 4 ZNK 100 B 8/2 Motor size Buffer / switch-off springs see figure ⇒ Fig.51) J .0/2.5 12.0 8.6/2.0 4.8 28.4 19.0 12.51) J 214 741 44/210610 51) Integrated in the bottom block.0 16.4/3. Under certain ambient conditions DK bottom block with external switch-off springs.0/2.8/7.6/2.8/7.0 24.6/2.0 8.0/6.2/1.0/6.2/1.2 9.0 16.Buffer arrangement DC Pro SWL Chain hoist Reeving Hoist speed Hook path H [m] ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 71 B 8/2 5 and 8 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 4 5 and 8 4 5 and 8 4 5 and 8 4 2/1 4.4 14.8 28.6/2.5 at 60 Hz [m/min] 9.0 8.2/4.0 16.2 9.2 9.0/6.0 6.8/7.0/4.

3 m Buffer arrangement DC-Pro.4/3.0/2. 78 5 1/1 6.8 2.8/7.5 7.2 9.0/1.0 16.8 and 4.0/2.0 8.8 m H8 4.2/4.4 19.Buffer arrangement DCM Pro SWL Chain hoist DCMPro 1 80 2 5 1 125 2 5 200 250 Tab.6/2.4 19. hoist speeds until 03/2007 (no longer available) SWL Chain hoist DCMPro 5 1/1 Reeving Hoist speed at 50 Hz [kg] 200 250 Tab.6/2.0 8.2/4.2/4.0 14.3 ZNK 80 A 8/2 Motor size Buffer / switch-off springs see figure Load hook side Chain collector box side Chain collector box size at hook path 2. 79 [m/min] 12.8 and 4.6 5 and 8 ZNK 80 A 8/2 A B [m/min] at 60 Hz [m/min] Hook path H [m] ZNK 71 B 8/2 Motor size Buffer / switch-off springs see figure Load hook side C Chain collector box side D H5 H8 Chain collector box size at hook path 5m 8m Buffer arrangement DCM-Pro.8/7.8 28.0 16.8 28.4 19.0/2.0 at 60 Hz [m/min] 14.0 16.8 12.6 Hook path H [m] 2.0 24.0 8.2 9.3 Hook path H [m] ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 Motor size Buffer / switch-off springs see figure Load hook side A C G A C G A C A C Chain collector box side B D F B D F B D B D Chain collector box size at hook path 2.0 24.0/3.0/4.3 m H8 C D 112 214 741 44/210610 . 77 2 5 2 5 1/1 Reeving Hoist speed at 50 Hz [kg] [m/min] 8.4 19.4/3.0/6.6/2. hoist speeds until 03/2007 (no longer available) SWL Chain hoist DC-Pro Reeving Hoist speed at 50 Hz [kg] 160 200 250 315 400 500 Tab.0 16.2/4.0/4.6/2.0/4.0/2.0/3.0/6.0 at 60 Hz [m/min] 9.8 9.8 m H5 H8 H5 H5 H8 H5 H5 H8 H5 H8 4.0/4.2/1.

depending on the size. the brake must be immediately replaced.2500 1000 . the brakes have gradually been equipped with plugs in the brake housing. brake displacement [mm] 8.3200 Tab.250 80 .1250 1250 . the brake can still be used until the next maintenance is due. 80. Page 113). ● For brake displacements up to 0.1 Brake Brake assignment SWL [kg] 80 . Page 113).9. 84 Since 04/2009.5.9 8. ● Check brake wear using a feeler gauge (2) (see ⇒ Tab. brake displacement is reached (see ⇒ Tab.6 BK03 Reeving Motor size Brake Max.500 200 . Disconnect chain hoist from power supply (mains connection switch) and secure against restarting. ● Open the electrical equipment cover.1000 315 .125 80 .5. 214 741 44/210610 ● Unscrew screw plug (1) from the brake.9.5 mm.8.5. so that the brake does not have to be dismantled for checking brake wear. 80. 80 15 10 2/1 1/1.2 Check brake wear Check brake wear depending on the year of manufacture of your chain hoist: ● When the max. Brake wear is checked via the air gap. 113 . From year of manufacture 04/2009 Fig. 2/1 ZNK 100 B 8/2 Chain hoist DC-Pro 1 2 5 1/1 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 BK07 0.

Ensure that no grease penetrates into the inside of the brake. The continuous sealing lip must be in full contact on the brake rear side. ● Use both measured values to calculate the difference. 007 177 84). ● Open the electrical equipment cover.Until year of manufacture 03/2009 Fig. Measure brake wear with calliper gauge as follows: ● Measure the distance from brake rear side to brake disk with depth gauge or calliper gauge when the brake is not actuated. 214 741 44/210610 114 . ● Disconnect brake connector. press the brake disk against the springs until it stops. 85 Disconnect chain hoist from power supply (mains connection switch) and secure against restarting. In the course of the annual inspection the V sealing ring (1) of the brake must be re-greased (grease part no. make sure that the area of the V sealing ring (1) on the brake base is slightly greased. 86 During assembly of the brake. to do this. Assembly and maintenance Fig. this difference is the brake displacement. ● Dismantle brake. ● Measure the distance from brake rear side to brake disk with depth gauge or calliper gauge when the brake is actuated.

If owing to the operating conditions or malfunctions. the following will be observed: ● the hoist motor fan is still turning while there is no lifting motion. In the course of the annual inspection. Over‐ load protections are prescribed for load capacities ≥ 1000 kg. Under normal operating conditions. the setting needs to be checked. Page 48.Tightening torques [Nm] Brake Electrical equipment cover Tab.1 Slipping clutch Checking the slipping clutch The slipping clutch performs the function of an emergency limit stop de‐ vice and protects the chain hoist against overloads. 3. a load of 110% of the load capacity must be lifted within the dynamic overload test (without any change in the setting of the slipping clutch). ⇒ part no. An increase of the tripping torque which exceeds the factory setting is not permitted. must be used. 87 When the slipping clutch function has been checked. ● The 7-segment display shows the SLIP LIFTING V1 warning.10 8. 836 708 44. Page 87. 68. the slipping clutch does not need to be adjusted. Run the limit stop against the guide plate at creep speed.2 Adjusting the slipping clutch During the final inspection in the factory. A load > 160% must not be lifted. the chain collector box must be dis‐ connected. An increase of the tripping torque which exceeds the factory setting is not permitted. Fig. Inspection and adjustment may only be carried out by an experienced technician in compliance with the brochure "Friction force checking device" ⇒ Tab. ⇒ "Warning messages". The operating limit switches must not be actuated while this is being done.10. Adjustment of the slipping clutch may only be carried out by authorized specialists. 8. Remove the limit stop ⇒ Fig.5 8.5 9. 81 DC-Pro 1 / 2 / 5 / 10 / 15 5. the slipping clutch must be checked. the limit stop must be fitted again to the section of chain which is not under load. 214 741 44/210610 115 . the friction force checking device. Page 7. The slipping clutch is initially set in the factory. Fig. If the slipping clutch is functioning correctly. Check the slipping clutch function as follows: ● In order to remove the limit stop. During the acceptance test of the hoist or crane installation. ⇒ "Dismantling the chain collector box".10.5. For DC-Pro chain hoists ≥ 1000 kg the setting complies with the require‐ ments of EN 14492-2 for slipping clutches as overload protection. The slipping clutch is maintenance-free for up to 10 years. the slipping clutch is set to the load capacity of the chain hoist.5.5. Page 124. (EN 14492-2 "Directly acting overload protections"). Page 98 from the chain fall which is not under load and fit it above the hook assembly. see also ⇒ "Suspending the chain hoist". 88 The slipping clutch is protected against overload by slip monitoring so that re-setting is only necessary during the general overhaul.

malfunctions of the slipping clutch may occur.35 DC-Pro 1 / 2 DC-Pro 5 0. Then drain the flushing oil and refill the gearbox with new oil. Under exceptional con‐ ditions. The flushing oil should have a viscosity of 46-68 mm2/s at rated temperature.11 Gearbox / oil change Fig.5. the lubricant must be changed at least every 10 years.5 DC-Pro 10 0. we recommend that oil changes be adapted to suit these conditions. 82 [Nm] [Nm] [Nm] [Nm] 5. Part no. DC 1-10 Remove the control unit with the plug-and-socket connections (2) under the electrical equipment cover set (3). For higher or lower ambient temperatures than -20 °C to + 45 °C.90 DC-Pro 10 DC-Pro 15 1.5 7. increased ambient temperatures.3 DC-Pro 15 25 15 25 Dispose of waste oil in accordance with environmental protection requirements.5 [l] DC-Pro 1 / 2 0.50 DC-Pro 5 5. contact the manufacturer. range of viscosity 10W-30.8. see Spare parts. If oils are used that are not approved. Turn the gearbox in such a way that the oil is drained. Then flush the gears by switching the hoist on and allowing the hook to run several times over the entire length of its path. For the required oil quantities please refer to the table above. The quantity of flushing oil used should be approximately twice that specified for lubrication. General on oil change Drain the old oil at operating temperature. Now remove the screws of the gearbox cover (1). 89 Chain hoist Oil quantities Tightening torques Gearbox cover Gearbox housing 2-piece Oil fill opening and breather M16 Service cover Tab. Oil quality Universal gear oil Shell Donax TD 10W-30 with wear-minimising additives. 116 . e. Oil lubrication Under normal operating conditions.g. 214 741 44/210610 DC 15 The oil can be changed by unscrewing the vent valve (4).

214 741 44/210610 117 . 3. 90 1. 5. Press contactor onto the contactor socket until both locking arms latch into place. 2.5. 4.8. 6. Pull off the contactor. Contactor socket without contactor Lower side of the contactor The spare contactor can only be inserted in the socket in one position.12 Replacing the contactor on the control card Fig. Carefully unlock the locking arms on both sides of the contactor using a screwdriver.

13 8. 91 .13.1 Replacing cables Replacing the control cable 118 214 741 44/210610 Fig.8.5.5.

Fitting the control pendant ⇒ "Connecting the control pendant". Remove and open the bag (1) with the control cable. It must be ensured that ● the groove of the connector holder matches the swivel lock in the enclosure and ● that the two pins on the enclosure match the bayonet lock. 3. Page 46. Unscrew electrical equipment cover. 1. Open and disengage the service cover. Work on the electrical equipment may only be carried out by a qualified electrician or by trained personnel. Loosen bayonet lock (2) by turning and remove control cable plug connection. 6. Loosen the screw (3) on the control cable lock and remove the lock. Tightening torques [Nm] Electrical equipment cover Service cover Control cable lock Tab. Take the control cable out of the pocket. Fit the new control cable in reverse order. 83 5.0 DC-Pro 1 DC-Pro 2 DC-Pro 5 9. 4.5 25 DC-Pro 10 DC-Pro 15 214 741 44/210610 119 . 2.5 11. Remove the control cable. Height adjustment of the control pendant ⇒ "Height adjustment of the control pendant". 5.5 7.DANGER Live components Danger to life and limb. Disconnect chain hoist from power supply (mains connection switch) and secure against restarting. Page 51.

92 214 741 44/210610 120 .5.13.8.2 Replacing the helical cable Fig.

All further steps as ⇒ "Replacing the control cable".to the 17th chain link for a hook path of 2.0 DC-Pro 1 DC-Pro 2 9.3 m. seal by tightening the flanged cable entry sleeve with rubber seal.5 5. First fit helical cable inlet (8) to centering rib of housing and ensure helical cable is correctly arranged. remove helical cable (7).8 m.DANGER Live components Danger to life and limb. 5. Loosen bayonet lock by turning and remove control cable plug connection. Loosen cap screws (4). Disconnect helical cable.0 11. with a screwdriver). Page 118 – – – – Open and disengage the service cover. When fitting the new cable. 4. slide cap (5) upwards and secure against dropping (e. 84 4. Loosen flanged cable entry sleeve (6).5 4. . 1. Loosen the screw on the control cable lock and remove the lock. Tightening torques [Nm] Electrical equipment cover Service cover Limit stop Control cable lock Tab. 2. Work on the electrical equipment may only be carried out by a qualified electrician or by trained personnel.to the 21st chain link for a hook path of 4. screws and pipe clamps from the adapter ring. Undo the four screws (2) to remove cover (1). Disconnect electrical connections (4). Disconnect chain hoist from power supply (mains connection switch) and secure against restarting. Tighten diagonal pairs of screws when re-fitting the cover. It must be ensured that ● the groove of the connector holder matches the swivel lock in the enclosure and ● that the two pins on the enclosure match the bayonet lock. ● Depending on the hook path the limit stop (9) must be fitted: .g. 3. Unscrew electrical equipment cover. Fit the new helical cable in reverse order.3 DC-Pro 5 214 741 44/210610 121 . Remove the control cable.

Before starting work. What to do after the fault has been eliminated WARNING Check appropriate assembly. Page 10 ) in compli‐ ance with the safety instructions. Danger of machine damage. Before restarting make sure that – – – the fault and the cause of the fault have been eliminated. 122 214 741 44/210610 . all safety devices have been fitted properly and are in perfect working order. 4. Do not touch the hot motor housing. DANGER Live components Danger to life and limb. Page 10 ) in compliance with the safety instructions. Work on electrical equipment may only be carried out by qualified specialist personnel(⇒ "Definition of personnel". Let motor cool down. before eliminating the fault. no persons are in the danger zone of the unit. The mains connection or isolator switch must be secured against unauthorized or accidental reconnection by means of a padlock. Faults may only be eliminated by qualified instructed personnel(⇒ "Definition of personnel".9 Faults / Warnings 9.1 Safety instructions for faults / warnings WARNING Inappropriate fault elimination Danger to life and limb. Inform the responsible person on site about the fault. In the case of faults which constitute an immediate danger for persons and property and/or operating safety. Switch off the chain hoist on the mains connection switch or isolator switch and secure it against restarting. WARNING Risk of burning There is a risk of burning when touching the chain hoist after operation. the machine must immediately be shut down by means of the emergency stop device. 2. What to do in case of faults 1. the electrical supply must be switched off. 3. Have the fault and the cause of the fault determined and eleminated by authorized specialist personnel.

94 Before a new movement can be started. 85 Possible cause Emergency stop actuated. a button is already actuated. No lifting. no lowering Remarks Two phases of the mains connection cable must be changed. Failed safety functions If a safety function has failed. Fig. strain relief and power supply connections. no lowering No lifting. Bimetal contact open. Check connections of the control cable on the pendant and in the service enclosure. check the control pendant and the control cable for damage and the plug-in connector on the pendant and in the service enclosure for correct fit. Check dummy plug for trolley connection. Emergency-stop cable inter‐ rupted. 214 741 44/210610 123 .2 7-segment display The 7-segment display is located on the bottom side of the chain hoist behind a window. Warning messages Warning messages start with the lightning symbol. ● Please contact our after-sales service if the cause of the fault cannot be eliminated with the given measures. In the event of a failure. Tab. First disconnect unit from the power supply. therefore first check cables.3 General messages Possible cause No power supply (display dark) Fig. Fig. no lowering Tab. 86 Possible cause Incorrect direction of motor rotation. check mains connector in the service enclosure.9. the warning message does not have to be acknowledged by means of the emergency stop. 87 Check connections of the control cable on the pendant and in the service enclosure. Control cable interrupted. Check control cable for continuity. Therefore. When the power supply is switched on or the emergen‐ Release button and actuate it again! cy-stop is unlocked. 97 Upper or lower end position is reached. Malfunctions may also be caused by incorrect trans‐ mission of commands from the control pendant. the error message must be ac‐ knowledged by means of the emergency stop. 96 No lifting. no lowering Tab. Error messages Error messages start with an Error. Fig. The symbols are shown one after the other. Faults The chain hoist can only function when it is correctly connected to the power supply. Fig. Check PE phase for correct connection. check connection ca‐ ble for interruption. Remarks Check mains connection and fuse link. 9. 93 Movement in the opposite direction is possible. Check motor connector X8 for continuity between terminal 4 and 8. 95 No lifting. Remarks Unlock emergency-stop switch by turning it. operation may only be continued after repair.

if required. lower end position is not reached. Fig.) is displayed when the limit switches function correctly. In the case of an error. Switch-off in the lower end position Fig. In the case of an error.9. check connection ca‐ ble for interruption. Remarks Replace control system. Fast lifting with load is switched off. Reduce load to the permissible load capacity. 104 SLIP LOWERING V1: Lowering is switched off. Ensure appro‐ priate mains voltage. Operating limit switch con‐ tact is no longer actuated. Remarks Check mains connection and fuse link. 95 214 741 44/210610 Remarks Check chain running in. Tab. Operating limit switch con‐ tact is no longer actuated. 105 SLIP LOWERING V2: Lowering is switched off. check mains connector in the service enclosure. 90 Possible cause Control system defective. Tab. Tab. Reduce load to the permissible load capacity. replace chain. the slipping clutch acts as an emergen‐ cy-stop device: Connection and functioning of the operating limit switch contact must be inspected by an experienced technician. Remarks Repeat lifting process. 94 Possible cause Chain blocked. lower end position is not reached. 92 Fig. the slipping clutch acts as an emergen‐ cy-stop device: Connection and functioning of the operating limit switch contact must be inspected by an experienced technician. Fig. Possible cause A mains phase is missing or the motor is blocked. Remarks Check chain running in. 88 Possible cause Operating limit switch con‐ tact is no longer actuated. Switch-off in the lower end position 124 . if load does not move. (-.) is displayed when the limit switches function correctly. check mains connector in the service enclosure. Tab. Tab. Tab. 103 SLIP LOWERING start-up: No lowering Tab. check connection ca‐ ble for interruption. the slipping clutch acts as an emergen‐ cy-stop device: Connection and functioning of the operating limit switch contact must be inspected by an experienced technician. have the brake and control system checked by an experienced technician. Fig. Remarks (-. In the case of an error. 99 SLIP LIFTING V1: Switch-off in the upper end position.4 Warning messages Possible cause A mains phase is missing or the motor is blocked.) is displayed when the limit switches function correctly. No lift‐ ing with load. Fig. Tab. Fig. the slipping clutch acts as an emergen‐ cy-stop device: Connection and functioning of the operating limit switch contact must be inspected by an experienced technician. replace chain. Possible cause Hardware monitoring faulted. Chain hoist overloaded. 89 Possible cause Operating limit switch con‐ tact is no longer actuated. (-. 101 Internal data memory defective. if required. 100 SLIP LIFTING V2: Switch-off in the up‐ per end position. Remarks (-. 102 No speed information. 98 SLIP LIFTING start-up: No lifting. In the case of an error. 91 Fig. Chain hoist overloaded or undervoltage.) is displayed when the limit switches function correctly. 93 Possible cause Chain blocked. Remarks Check mains connection and fuse link.

Chain hoist is blocked. Check mains connection and fuse link. Fig. Remarks Check error message by actuating and unlocking the emer‐ gency stop. Chain hoist is blocked. Replace hoist control system. check mains connector in the service enclosure. Then actuate Lowering. check connection cable for inter‐ ruption. If necessary. Remarks Check error message by actuating and unlocking the emer‐ gency stop. Then actuate Lowering. Replace hoist control system.5 Error messages Possible cause Drive blocked. Tab. Tab. Remarks Check error message by actuating and unlocking the emer‐ gency stop. 106 Hoist unit: Speed error or drive is ob‐ structed. Speed measurement failed. 108 Hoist unit: Monitoring electronics defec‐ tive. Possible cause Hardware error of control system. tive. Chain hoist is blocked. Fig. If necessary. Monitoring electronics defec‐ Replace hoist control system. Monitoring electronics defec‐ Replace hoist control system. tive. Fig. Then actuate Lowering. 214 741 44/210610 125 . remove suspended load. Tab. Remarks Check error message by actuating and unlocking the emer‐ gency stop. Lowering with load is switched off. 107 Hoist unit: Overspeed or load cannot be held. If necessary. 109 Hoist unit: Monitoring electronics defec‐ tive. 98 Possible cause Hardware error of control system. Fig. remove suspended load. 100 Fig. 97 Remarks Reduce load to the permissible load capacity. If necessary. remove suspended load. 96 Possible cause Lowering speed too high. Chain hoist is blocked.9. Tab. 110 Hoist unit: Motor runs in wrong direction. remove suspended load. 99 Possible cause Direction cannot be switch‐ ed. Tab. Then actuate Lowering.

10

Disassembly / Disposal

10.1

General

WARNING Before disassembly, follow the safety instructions in ⇒ "Maintenance / repair", Page 78 of these operating in‐ structions.

For information on removing track sections, trolleys and current collector trolleys refer to chapter ⇒ "Assembly", Page 43 of these operating instructions. Other parts are removed in reverse order to assembly. Unless a return or disposal agreement has been concluded, separated components must be recycled after proper removal: ● Scrap any remaining metallic material, ● Dispose of plastic elements for recycling, ● Separate and dispose of any other components by material type. Electric scrap, electronic components, lubricants and other auxiliary materials are subject to special disposal reg‐ ulations and may only be disposed of by certified companies. National disposal regulations must be considered regarding environmentally friendly disposal. Further information can be obtained from corresponding local authorities.

126

214 741 44/210610

11

Accessories

11.1

Components

Fig. 111 Item 1 Description Bottom block with switch-off springs (e.g. for hot applications) consisting of: bottom block, switch-off springs, grooved pins with round head, capacity plates Size DC-Pro 10 2/1 Part no.: 715 431 45 717 808 45 718 808 45 715 808 45 721 845 45 717 250 45 718 250 45 715 250 45 718 249 45 715 249 45 717 306 45 718 306 45 721 753 45 773 509 44 773 511 44 773 513 44 773 514 44

2

DC-Pro 1 / 2 Return sprocket assembly: DC-Pro 5 1 return sprocket, 1 pin, 1 retaining ring, 1 supporting washer, 2 thrust washers, 2 DC-Pro 10 needle-roller assemblies DC-Pro 15 Switch-off spring (e.g. for hot applications) consisting of: 2 switch-off sleeves, 1 pressure spring (for DC 10, 2/1 reeving: 2x part no.) Switch-off spring (e.g. for hot applications) consisting of: 2 switch-off sleeves, 1 pressure spring V6,0/1,5 V12,0/3,0 V24,0/6,0 DC-Pro 1 / 2 DC-Pro 5 DC-Pro 10 DC-Pro 5 DC-Pro 10 DCM-Pro 1 / 2 DCM-Pro 5 DC-Pro 15 DCM-Pro 1 / 2 H2,8 DCM-Pro 5 H2,8 DCM-Pro 1 / 2 H4,3 DCM-Pro 5 H4,3

3

4

Swivel unit - swivel joint for Manulift (since 04/2009 in the Manulift as standard), consisting of: 1 swivel unit, 1 pin Switch-off spring (standard) consisting of:: 2 switch-off sleeves, 1 pressure spring for V1 (for V2: 2x part no.) Assembly for converting DC-Pro to Manulift DCM-Pro, consisting of: Manulift handle, helical cable, helical cable clamp, swivel unit, load hook, 2 x link sections, buffer plate, 2 x buffers

5

No fig.

Tab. 101

214 741 44/210610

127

12 Spare parts
Spare parts for DC 15 are being prepared. Please contact our customer service department.

12.1 Overview

1/1 reeving

2/1 reeving

128

42764249.eps

214740ET.indd/210610

9.480 V.480 V.5 Nm 220 V . 60 Hz.12.indd/210610 129 .415 V. 50 Hz / 575 V. 50 Hz / 575 V. 60 Hz. 25 Nm 380 V . 9. 9.5 Nm 440 V .5 Nm 500 V .5 Nm 380 V . 25 Nm 380 V . 25 Nm 500 V .415 V.525 V.400 V. 71785033 71885033 71585033 71585133 71784133 71784233 71784433 71784533 71784633 71784733 71884133 71884233 71884433 71884533 71884633 71884733 71584133 71584233 71584433 71584533 71584633 71584733 71583233 71583433 71583533 71583733 Qty.480 V.525 V. 25 Nm 380 V . 50 Hz. 60 Hz. 9. 60 Hz. 60 Hz. 60 Hz.5 Nm 220 V . 50 Hz.240 V. 60 Hz. 9. 50 Hz.tbl 214740ET. 25 Nm 440 V . 25 Nm 21474011. 60 Hz. ZNK 80 4 Nm 4 Nm Material Standard 220 V . 9.400 V. 60 Hz.eps Item 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Part no. ZNK 71 4 Nm.415 V. 60 Hz.400 V.2 Motor 42763744.5 Nm 440 V .525 V.400 V.5 Nm 380 V .5 Nm 380 V . 50 Hz. 50 Hz / 575 V. 9. 9.5 Nm 220 V .240 V.5 Nm 500 V . 60 Hz.240 V.480 V. 25 Nm 220 V . 9.240 V. 50 Hz. 25 Nm 500 V .240 V.415 V. 25 Nm 440 V .5 Nm 380 V .240 V.525 V. 50 Hz / 575 V. 50 Hz. 60 Hz. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation DC Pro 1/2 Fan set DC 2 DC-Pro 5 Fan set DC 5 DC-Pro 10 Fan set ZNK 100A Fan set ZNK 100B DC Pro 1/2 Motor set 240V50Hz Motor set 415V50Hz Motor set 525V50Hz Motor set 460V60Hz Motor set 240V60Hz Motor set 380V60Hz DC-Pro 5 Motor set 240V50Hz Motor set 415V50Hz Motor set 525V50Hz Motor set 460V60Hz Motor set 240V60Hz Motor set 380V60Hz DC-Pro 10 Motor set 240V50Hz A Motor set 415V50Hz A Motor set 575V60Hz A Motor set 460V60Hz A Motor set 240V60Hz A Motor set 380V60Hz A Motor set DC10/16 B 50Hz Motor set DC10/16 B 60Hz Motor set DC10/16 B 60Hz Motor set DC10/16 B 60Hz 4 Nm. 9. 9. 9. 50 Hz.5 Nm 220 V . 25 Nm 380 V . 60 Hz. 60 Hz. 60 Hz.

12.eps 214740ET.indd/210610 .3 Parts on gearbox 130 42763845.

V16/4 DC-Pro 5. V24/6 DC-Pro 10. V8/2 DC-Pro 2. 5. 1/1 reeving.5 Nm. 5. 1/1 reeving.1/1 reeving.5 Nm.5 Nm 21474012.Item 3 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 5 5 5 6 6 7 7 7 7 7 7 7 7 8 Part no. 5. 60 Hz.5 Nm 440 V .240 V. V24/6 DC-Pro 10. 1/1 reeving. V6/1.5 Year of manufacture 2004 until 03/2007 Gearbox set DC-PRO5 V6/1. 0.indd/210610 131 . V8/2 DC-Pro 2.525 V. V12/3 DC-Pro 10. 5.5 Nm 440 V . 50 Hz / 575 V. V12/3 Material Standard 380 V .415 V.5 DC-Pro 5.5 Nm 500 V . 5. 5.5 Nm 500 V . V8/2 DC-Pro 10. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation Gearbox set DC-PRO 1 V8/2 Gearbox set DC-PRO 2 V8/2 Gearbox set DC-PRO 2 V16/4 Gearbox set DC-PRO 5 V8/2 Gearbox set DC-PRO 5 V16/4 Gearbox set DC5 V3 Gearbox set DC-PRO10V6/1.5 Nm 220 V .tbl 214740ET. V4/1 DC-Pro 10. 2/1 reeving. 50/60 Hz.5 Nm 380 V .5 Nm. 60 Hz. 5.5 DC-Pro 10. V8/2 DC-Pro 5.2/1 reeving.5 Gearbox set DC-PRO 5 V12/3 Suspension set DC 1. V6/1. 50 Hz. 50 Hz / 575 V.5 Gearbox set DC-PRO 10 V8/2 Gearbox set DC-PRO10 V12/3 Gearbox DC-Pro10 V24 Gearbox set DC-PRO 10 V4/1 Gearbox set DC-PRO10V6/1.415 V.35 litres.5 litres 5.5 Suspension set DC10 Gear oil/seal Pro 2 Gear oil/seal Pro 5 Gear oil/seal DC10 Adjusting nut/pulse wheel Adjusting nut/pulse wheel DC Pro 1/2/5 Brake set 180V Brake set 216V Brake set DCS 1-5 104V Brake set 258V DC-Pro 10 Brake set DC10 180V Brake set DC 10 216V Brake set DC/DCS10 Brake set DC10 258V Insert/plug 5. 60 Hz. 0. 0.9 litres DC1/2/5 DC10 DC-Pro 1.5 DC-Pro 5.480 V. DC-Pro 1 / 2 5. V16/4 DC-Pro 5. V6/1.525 V.240 V. 60 Hz.5 Nm 220 V . 5.480 V. 71771533 71790533 71790633 71890833 71890933 71800933 71590533 71590833 71590633 71500933 71590933 71590733 71890533 71890633 71897433 71597433 71791933 71891933 71591933 71894733 71594733 71887133 71887233 71887333 71887433 71587133 71587233 71587333 71587433 71885633 Qty. 50 Hz. 50/60 Hz.

4 Chain drive 1/1 reeving 2/1 reeving 132 42764348.eps 214740ET.indd/210610 .12.

3 Nm 7.5. for GGS 1) DC 10 2/1. for GGS 1) DC 10 2/1.4 Nm.indd/210610 1) See section 8.4 Nm DC 10 2/1.4 Nm.3 Nm 4. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation Chain set DC/DCM 1/2 H 5 Chain set DC 1/2 H 8 Chain set DC/DCM 5 H 5 Chain set DC 5 H 8 Chain set DC10 1/1 H 5 Chain set DC10 1/1 H 8 Chain set DC 10 5m 1/1 Chain set DC 10 8m 1/1 Chain set DC10 2/1 H 5 Chain set DC10 2/1 H 8 Chain set DC 10 5m 2/1 Chain set DC 10 8m 2/1 Limit switch set Limit switch set Chain anchorage 2/1 set Buffer set DC 1/2 Buffer set DC5 Buffer set DC10 Chain collector set DC1/2 5m Chain collector set DC1/2 8m Chain collector set DC5 5m Chain collector set DC5 8m Chain collector DC10 1/1 5m Chain collector DC10 1/1 8m Chain collector flexible 20 m 4. 3 Nm DC 10 2/1 Material Standard # DC 10 2/1 H5 DC 10 2/1 H8 21474015. 3 Nm DC 10.tbl 214740ET. for GGS 1) DC 1 2/5.Item 11 11 11 11 11 11 11 11 12 12 12 12 13 14 15 16 16 16 17 17 17 17 17 17 17 Part no.4 Nm 7. 7.4 Nm 7.4 Nm.5. 71795033 71795133 71895033 71895133 71595033 71595133 75263733 75263833 71596033 71596133 75263933 75264033 71888033 71588033 71527933 71795333 71895333 71595333 71798633 71798733 71898633 71898733 71598633 71598733 71535045 Qty. 7. for GGS 1) 7. 7. 7.7 133 .4 Nm DC 10 2/1.0 Nm 4.0 Nm 4.4 Nm.

tbl 134 214740ET.8 Nm 11.5 Nm 25 Nm 6. w/o hook DC Pro 1/2 DC-Pro 5 DC-Pro 10 DC Pro 1/2 DC-Pro 5 DC-Pro 10 Material Standard 21474016. 4 Hook safety catch set S.indd/210610 . 2 Hook safety catch set S. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation Load hook assembly set DC1/2 Load hook assembly set DC 5 Hook assembly set DC10 Hook assembly half set DC1/2 Hook assembly half set DC5 Hook assembly half set DC10 Load hook set no. w/o hook 11. 71798033 71898033 71598033 71728133 71828133 71528133 83565033 83665033 83765033 83565933 83665933 83765933 71724033 71393433 71528033 Qty.5 Hook assembly 42764044. 2 400kg Load hook set no. 3 800kg Load hook set no.12. 3 x4 Hook safety catch set S.8 Nm. 4 x5 Load capacity plate set DC1/2 Pro Load capacity plate set DK5 1/1 Load capacity plate set DC10 1/1 6. w/o hook 25 Nm.5 Nm.eps Item 18 18 18 19 19 19 20 20 20 21 21 21 22 22 22 Part no.

12.6 Bottom block with internal switch-off springs (standard)

42764145.eps

Item 23 24 25 26

Part no. 71598533 71544233 83865633 75262033

Qty. 1 1 1 1

Designation Bottom block set DC 2/1 Bottom block half set DC10 2/1 Hook safety catch set S. 5 x5 Load capacity plate set DC10 2/1

Material

Standard

21474017.tbl

214740ET.indd/210610

135

12.7 Bottom block with external switch-off springs (option)

42778044.eps

Item 28 29 30 31 32

Part no. 83785233 83865033 83865633 83592833

Qty. 1 1 1 1

Designation Bottom block with switch-off spring Bottom block half set DK10 Load hook DC16/25 DK10/20 Hook safety catch set S. 5 x5 Capacity plate DK10 1) 6.8 Nm

Material

Standard

21474019.tbl

136

1) See chapter 11

214740ET.indd/210610

12.8 Electrical cover

42763945.eps

Item # # # # # # # # 50 50 50 50 50 50 50 50 51 51 51 52

Part no. 77222033 77202033 77232033 77212033 77226033 77206133 77236033 77216033 71792133 71892133 71592133 71582533

Qty. 1 1 1 1 1 1 1 1 1 1 1 1

Designation DC-Pro 1 - 5 Control set DC1-5, 230V Control set DC1-5, 400V Control set DC1-5, 575V Control set DC1-5, 460V DC-Pro 10 Control set Control set Control set Control set DC10, DC10, DC10, DC10, 230V 400V 575V 460V

Material 220 V - 240 V, 50/60 Hz; 3 Nm 380 V - 415 V, 50 Hz / 380 V - 400 V, 60 Hz; 3 Nm 500 V - 525 V, 50 Hz / 575 V, 60 Hz; 3 Nm 440 V - 480 V, 60 Hz; 3 Nm 220 V - 240 V, 50/60 Hz; 3 Nm 380 V - 415 V, 50 Hz / 380 V - 400 V, 60 Hz; 3 Nm 500 V - 525 V, 50 Hz / 575 V, 60 Hz; 3 Nm 440 V - 480 V, 60 Hz; 3 Nm 9.5 Nm 9.5 Nm 9.5 Nm DC-Pro 10

Standard

Electrical cover set DC 2 Electrical cover set DC 5 Electrical cover set DC10 Contactor set

21474013.tbl

214740ET.indd/210610

137

9 Manulift 138 42509045.indd/210610 .eps 214740ET.12.

2 Emergency stop button set Bearing DSM 5 Haousing set DSM 5 Switching element CBDN 3OE Switching element set Cap set Load bearing element 125/250 Unlocking half Helical cable cpl. H 4. (part no. 35 .indd/210610 1) See chapter 11 139 . 2800 Helical cable cpl. H 2.36. 38 . 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation Control cable mounting set DCM Twist adapter Cap DSM 5 set Helical cable entry Bracket chain 4.3 Nm. H 2.Item 33 34 35 36 37 37 38 39 40 41 42 43 44 45 46 46 47 47 48 49 49 49 49 Part no.1m Chain set DC 1/ 2 5m Chain set 3.8 DCM 5.3 cpl. (part no.3 21474018.3x15. H 4. 35 .1m Chain set DC 5 5m 1) Material Standard # # 4. 33.45) DCM 1 / 2.45) cpl.3 Nm. H 4.3 DCM 5.36.2x12.tbl 214740ET. 33. 71831533 77206833 77203933 77207333 77201133 77204733 77207533 77200133 77207933 77345233 77202333 77207633 77201833 77345733 77345933 77345033 77345533 83566544 71794833 71795033 71894833 71895033 Qty.2 Bracket chain 5.8 4. H 2.8 DCM 1 / 2. 38 . 4300 Control unit DSM-C 1/2 Control unit DSM-C 5 Load hook DKDSM5 250KG Chain set 3.

1 1 1 1 1 1 1 1 1 Designation Service cover set DC 2 Service cover set DC 5 Service cover set DC10 Control cable set 5m Control cable set 8m DC control cable 11m DSC control pendant Emergency stop set / rubber cap DSC-S Bag.12.eps Item 53 53 53 54 54 54 56 57 58 Part no.indd/210610 140 . control cable.tbl 214740ET. service cover 42764446.10 Control pendant.5 Nm 7.5 Nm 5.5 Nm 11 Nm 11 Nm 11 Nm Material Standard 21474014. hose 5. 71792033 71892033 71592033 71881033 71880933 72003745 77330033 71880433 72004145 Qty.

78 Winding protection control cable 50 Window 33 L Length adjustment belt sling 37 Load spectrum factor 82 N 141 . 110 C Cable collector 52 Canopy 30 Chain link section 101 Chain wear 92 Closing eye 37 Contactor control 32 Continuity of the PE conductor connection 44 Control cable stop 51 Counterweight compensation 49 Coupling pin 37 Curve radii for trolleys 40 D Discarding status of the chain 90 E Emergency limit switch 32 F Factor depending on the type of recording 81 Fahrwerkpuffer 41 Flange width 41 G Gripping hook 37 I Infrared interface 32 K KBK crane construction kit 42 KBK track 42 214 741 44/210610 Number of operating hours 81 O Oil change 116 Oil lubrication 116 Oil quality 116 Optional suspension 38 P Pantograph tongs 37 Parallel gripper 37 Phase sequence 55 Q Quick-release coupling 36 R R-S-T network 55 Reeving 49 Retaining clip 49 Rolling resistance 42 S Self-locking nut 44 Special fittings 49 Strain relief attachment 54 Strain relief hose 35 Stromzuführung 40 Supporting rollers 41 Suspension bracket 38 Switch-off spring 110 Switching cycles 34 Switching frequency 80 Swivel lock 36. 46.Index A Actual duration of service 81 Actual load spectrum factor 81 Actuator plate 67 AC asynchronous motor 31 B Bayonet lock 35. 119 Belt sling 37 Bend protection sleeve 46 Buffer 67 Buffer plate 67. 119 T Theoretical duration of service 84 Tracks 40 Tri-state signals 32 Type plate 2 W Wear of individual link 90 Welding work 43. 37.

number / Language 19961044 / EN Issue Page 0110 1/ 1 Hereby we.as a series product or manufactured to order . 58286 Wetter Wetter.08. D. Schulte Engineering/Development HT/AT The safety objectives of Low Voltage Directive 2006/95/EC are achieved. Demag Cranes & Components GmbH. The product additionally complies with the following relevant directives/provisions: EC EMC Directive 2004/108/EC Cranes . Annex IIA Ident.Original EC conformity declaration for a machine according to Directive 2006/42/EC. Applied harmonised standards. 58300 Wetter declare that the electrically driven hoist for lifting loads Demag DC chain hoist Model code: Serial no.2010 ppa. 24. Dr.with a cable-connected control pendant/wireless control unit complies with all relevant requirements of EC Machinery Directive 2006/42/EC. Demag Cranes & Components GmbH Ruhrstraße 28.Part 32: Requirements for hoisting machines Industrial Cranes Segment Subject to change. No liability for errors or omissions . Harkort Wetter Factory Manager Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH.Power driven winches and hoists Part 2: Power driven hoists Safety of machinery .: nnnnnnnn ready for service .Electrical equipment of machines . 58286 Wetter m pl e ppa. in particular EN 14492-2 EN 60204-32 The relevant technical documentation according to Annex VII Part A of Directive 2006/42/EC has been compiled and will be made available to authorised national authorities by the designated authorised representative in response to a justified request. Sa Authorised representative for technical documentation Hans-Jörg Böttcher.

Power driven winches and hoists Part 2: Power driven hoists EN 60204-32 Safety of machinery .2010 The special technical documentation according to Annex VII Part B of Directive 2006/42/EC has been compiled and will be made available to authorised national authorities by the designated authorised representative in response to a justified request. are met by application ofthe following harmonised standards or C standard drafts: EN 14492-2 Cranes . Demag Cranes & Components GmbH Ruhrstraße 28. 58300 Wetter declare that the electrically driven hoist / hoist with trolley for lifting loads / lifting and moving loads Demag DC chain hoist/Demag DC chain hoist with trolley Model code: Serial no. insofar as they are relevant for the scope of delivery. D. Dr.08. Schulte Engineering/Development HT/AT EC Machinery Directive 2006/42/EC.: nnnnnnnn supplied as partly completed machinery is intended to be incorporated into machinery and that it must not be put into serviceuntil the machinery* into which this partly completed machinery is to be incorporated has been declared in conformity with all relevant provisions of Basic requirements of the EC Machinery Directive. Annex IIB Ident.Electrical equipment of machines . 58286 Wetter ppa. (* insofar as this machinery is subject to the scope of application) Industrial Cranes Segment Subject to change. Demag Cranes & Components GmbH.Part 32: Requirements for hoisting machines The safety objectives of Low Voltage Directive 2006/95/EC are achieved The product additionally complies with the following relevant directives/provisions: EC EMC Directive 2004/108/EC Sa Wetter. 24. 58286 Wetter m pl e ppa. number / Language 19961244 / EN Issue Page 0110 1/ 1 Hereby we.Original Declaration for fitting partly completed machinery according to Machinery Directive 2006/42/EC. Authorised representative for technical documentation Hans-Jörg Böttcher. No liability for errors or omissions . Harkort Wetter Factory Manager Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH.

The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found on the Demag Cranes & Components homepage at www. Not liable for errors or omissions.demagcranes. Printed in Germany . 58286 Wetter (Germany) Subject to change.com/Contact Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH.