Operating instructions/accessories/spare

parts
Demag DC-Pro 1 - 15 chain hoist
Demag DC-Com 1 - 10 chain hoist

43213748.eps

280823 en GB 211 273 44 720 IS 817

 Original operating instructions
Manufacturer
Demag Cranes & Components GmbH
Forststrasse 16
40597 Düsseldorf, Germany
www.demagcranes.com
Please fill in the following table before first putting the unit into service. This provides you with 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

Circuit diagram number

Tab. 1

Item Designation
1 1 Manufacturer See above
 "Model code", Page 19,
2 2 Chain hoist type
 "Selection tables", Page 20
3 Serial no., calendar week, year
3
of manufacture
4 Load capacity, group of mecha‐  "Model code", Page 19,
4
5 nisms  "Selection tables", Page 20

6  "Available hoist chains", Page 88,

7 5 Chain type, hook path  "Model code", Page 19,
8  "Selection tables", Page 20
9 6 Voltage, frequency  "Electric key data", Page 21
Type of enclosure, insulation  "Operating conditions", Page 27,
10 7
class  "Electric key data", Page 21
8 Ambient temperature  "Operating conditions", Page 27
11  "Selection tables", Page 20,
9 Motor type, oil grade  "Electric key data", Page 21
 "Gear oil change", Page 121
12
42770348.eps 10 Electric key data  "Electric key data", Page 21

Fig. 1 Example of a rating plate 11 Conformity symbol

12 Manufacturer’s address See above
Tab. 2

The metric system is used in this document and all figures are shown with a comma as the decimal separator.
211 273 44/280823

2
 Table of contents

1 General ....................................................................................................................................................................... 7
1.1 DC chain hoist ............................................................................................................................................................. 7
1.2 DC documents............................................................................................................................................................. 8
1.3 Symbols/signal words.................................................................................................................................................. 8
1.4 Information on the operating instructions .................................................................................................................... 9
1.5 Liability and warranty................................................................................................................................................. 10
1.6 Copyright ................................................................................................................................................................... 10
1.7 Use of spare parts ..................................................................................................................................................... 10
1.8 Definition of personnel............................................................................................................................................... 10
1.9 Log book.................................................................................................................................................................... 11
1.10 After-sales service ..................................................................................................................................................... 11

2 Safety........................................................................................................................................................................ 12
2.1 General information on safety ................................................................................................................................... 12
2.2 Safety signs on the equipment .................................................................................................................................. 12
2.3 Intended use.............................................................................................................................................................. 13
2.4 Hazards that can be caused by the machine ............................................................................................................ 14
2.4.1 General information on safety ................................................................................................................................... 14
2.4.2 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) ................................ 14
2.5 Responsibility of the owner ....................................................................................................................................... 15
2.6 Operating personnel requirements............................................................................................................................ 16
2.7 Personal protection equipment.................................................................................................................................. 16
2.8 Emergency-stop device ............................................................................................................................................. 17
2.9 Regular inspections................................................................................................................................................... 17

3 Technical data ......................................................................................................................................................... 18

3.1 Design overview ........................................................................................................................................................ 18
3.2 Model code ................................................................................................................................................................ 19
3.3 Selection tables ......................................................................................................................................................... 20
3.3.1 DC-Pro ...................................................................................................................................................................... 20
3.3.2 DC-Com .................................................................................................................................................................... 21
3.4 Electric key data ........................................................................................................................................................ 21
3.4.1 DC-Pro ...................................................................................................................................................................... 21
3.4.1.1 Hoist motor data ....................................................................................................................................................... 21
3.4.1.2 Mains connection delay fuse links and supply lines .................................................................................................. 23
3.4.2 DC-Com .................................................................................................................................................................... 23
3.4.2.1 Hoist motor data ........................................................................................................................................................ 23
3.4.2.2 Mains connection delay fuse links and supply lines .................................................................................................. 25
3.5 Dimensions................................................................................................................................................................ 25
3.6 Noise emission/sound pressure level ........................................................................................................................ 25
3.7 Transport, packing, scope of delivery, storage.......................................................................................................... 26
3.8 Materials.................................................................................................................................................................... 27
3.9 Operating conditions ................................................................................................................................................. 27

4 Technical description ............................................................................................................................................. 28

4.1 Drive and brake ......................................................................................................................................................... 28
4.2 Gearbox and slipping clutch ..................................................................................................................................... 28
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4.3 Chain drive ............................................................................................................................................................... 28

4.4 Electric equipment..................................................................................................................................................... 28
4.4.1 Control system .......................................................................................................................................................... 28
4.4.2 7-segment display for operating status and fault display .......................................................................................... 29 3
 4.4.3 Display of software version, operating hours, number of cycles ............................................................................... 30
4.5 Central service enclosure.......................................................................................................................................... 30
4.6 Pendant controller/control cable height adjustment .................................................................................................. 31
4.7 Controller ................................................................................................................................................................... 31

5 Assembly ................................................................................................................................................................. 32
5.1 General...................................................................................................................................................................... 32
5.2 Safety warnings for assembly ................................................................................................................................... 32
5.3 Chain hoist tightening torques................................................................................................................................... 34
5.4 Installation procedure ................................................................................................................................................ 35
5.5 Connecting the controller .......................................................................................................................................... 36
5.6 Control cable ............................................................................................................................................................. 37
5.6.1 Control cable technical data ...................................................................................................................................... 37
5.6.2 Handling the control cable ......................................................................................................................................... 37
5.6.3 Pendant controller height adjustment........................................................................................................................ 38
5.6.4 Installing the support sleeve on DSC, DSK or DST pendant controllers................................................................... 39
5.6.5 Mobile control system................................................................................................................................................ 41
5.7 Suspending the chain hoist ....................................................................................................................................... 42
5.7.1 Safety information for suspending the chain hoist..................................................................................................... 42
5.7.2 Supporting structure .................................................................................................................................................. 42
5.7.3 Suspension bracket ................................................................................................................................................... 43
5.8 Plug screw, vent valve............................................................................................................................................... 43
5.9 Mains connection ...................................................................................................................................................... 44
5.10 Circuit diagrams and control board ........................................................................................................................... 46
5.10.1 General information on the circuit diagrams.............................................................................................................. 46
5.10.2 DC 1 - 15 solo hoist circuit diagram .......................................................................................................................... 47
5.10.3 Control board............................................................................................................................................................. 52
5.11 Programming parameters with the controller ............................................................................................................ 53
5.11.1 General...................................................................................................................................................................... 53
5.11.2 Meaning of the buttons.............................................................................................................................................. 53
5.11.3 Meaning of the parameters ....................................................................................................................................... 54
5.11.4 Starting parameter-programming mode .................................................................................................................... 54
5.12 Adjusting the lower hook position.............................................................................................................................. 56

6 Putting into service for the first time..................................................................................................................... 57

6.1 Safety warnings when equipment is put into service for the first time....................................................................... 57
6.2 Inspection regulations ............................................................................................................................................... 57
6.3 Inspections before putting into service for the first time ............................................................................................ 58
6.4 Checks on entering service, handover ...................................................................................................................... 59

7 Operation ................................................................................................................................................................. 60
7.1 Safety instructions for operation................................................................................................................................ 60
7.2 Switching on .............................................................................................................................................................. 61
7.2.1 Checks before/when starting work ............................................................................................................................ 61
7.2.2 Function checks ........................................................................................................................................................ 61
7.3 Operation................................................................................................................................................................... 62
7.3.1 Safety during operation ............................................................................................................................................. 62
7.3.2 Picking up the load .................................................................................................................................................... 63
7.3.3 Moving loads ............................................................................................................................................................. 63
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7.3.4 Controlling speed with the controller ......................................................................................................................... 64

7.3.5 Moving the load with the controller............................................................................................................................ 64
7.3.6 Load distribution ........................................................................................................................................................ 65
4
 7.3.7 Emergency-stop device operating function ............................................................................................................... 65
7.3.8 Slipping clutch operating function.............................................................................................................................. 65
7.3.9 Lifting path limiter operating function......................................................................................................................... 65
7.4 Emergency stop ........................................................................................................................................................ 66
7.5 Taking the equipment out of operation...................................................................................................................... 67
7.5.1 Taking the equipment out of service when faults occur ............................................................................................ 67
7.5.2 Taking the equipment out of service at the end of the shift....................................................................................... 67
7.5.3 Taking the equipment out of service for maintenance and repairs............................................................................ 67
8 Maintenance/repair.................................................................................................................................................. 68
8.1 Safety warnings for maintenance and repair work .................................................................................................... 68
8.2 Basic maintenance requirements .............................................................................................................................. 69
8.3 Routine inspections ................................................................................................................................................... 70
8.3.1 Required tests and inspections ................................................................................................................................. 70
8.3.2 Special operating conditions ..................................................................................................................................... 70
8.3.3 Service life of the contactor ....................................................................................................................................... 70
8.3.4 Measures for achieving safe working periods in Germany ....................................................................................... 71
8.3.5 Calculating actual duration of service S according to FEM 9.755 (Germany) .......................................................... 72
8.3.6 Measures for achieving safe working periods according to ISO 12482 ................................................................... 74
8.3.7 Determining the remaining service life according to ISO 12482 .............................................................................. 75
8.3.8 General overhaul (GO) ............................................................................................................................................. 78
8.4 Maintenance schedule .............................................................................................................................................. 80
8.5 Maintenance work ..................................................................................................................................................... 81
8.5.1 Suspension................................................................................................................................................................ 81
8.5.2 Electric equipment cover ........................................................................................................................................... 81
8.5.3 Remove chain collector box ...................................................................................................................................... 82
8.5.4 Operating limit switches (standard for DC-Pro 1-15 and DC-Com 10 with 2/1 reeving) ........................................... 83
8.5.4.1 Checking operating limit switches ............................................................................................................................. 83
8.5.4.2 Checking the operating limit switch actuator ............................................................................................................. 84
8.5.5 Chain drive ................................................................................................................................................................ 84
8.5.5.1 Checking the chain sprocket ..................................................................................................................................... 84
8.5.5.2 Checking the chain guide .......................................................................................................................................... 84
8.5.5.3 Checking the guide plate/chain entry plate ............................................................................................................... 85
8.5.5.4 Check hoist chain ...................................................................................................................................................... 85
8.5.5.5 Chain set scope of supply ......................................................................................................................................... 88
8.5.5.6 Available hoist chains................................................................................................................................................ 88
8.5.5.7 Replacing the chain set ............................................................................................................................................. 90
8.5.5.8 Chain guides until 03/2019 and from 04/2019........................................................................................................... 95
8.5.5.9 Lubricating the hoist chain......................................................................................................................................... 99
8.5.6 Load hook................................................................................................................................................................ 100
8.5.6.1 Checking the load hook ........................................................................................................................................... 100
8.5.6.2 DC-Pro hook safety catch ....................................................................................................................................... 100
8.5.6.3 Checking the return sprocket .................................................................................................................................. 100
8.5.6.4 Replacing DC 1 - 15 hook assembly (from 12/2017) .............................................................................................. 101
8.5.6.5 Replacing DC 15 – 25 hook with fittings (as of 2018).............................................................................................. 102
8.5.6.6 Replacing DC-Pro hook assembly for 1/1 reeving .................................................................................................. 104
8.5.6.7 Replacing DC-Com hook assembly for 1/1 reeving ................................................................................................ 105
8.5.6.8 Replacing bottom block with external cut-off springs, 2/1 reeving .......................................................................... 106
8.5.7 Buffers/cut-off springs ............................................................................................................................................. 106
8.5.7.1 Check cut-off buffer/cut-off spring ........................................................................................................................... 106
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8.5.7.2 Buffer/cut-off spring arrangement 10/2014 until 10/2018 ........................................................................................ 107

8.5.7.3 Buffer/cut-off spring arrangement from 11/2018 until 03/2020................................................................................ 107
8.5.7.4 Buffer/cut-off spring arrangement from 04/2020 until 03/2021................................................................................ 113
5
 8.5.7.5 Buffer/cut-off spring arrangement from 04/2021 ..................................................................................................... 116
8.5.8 Brake ....................................................................................................................................................................... 118
8.5.8.1 Brake assignment.................................................................................................................................................... 118
8.5.8.2 Check brake wear ................................................................................................................................................... 119
8.5.9 Slipping clutch ......................................................................................................................................................... 120
8.5.9.1 Checking the slipping clutch .................................................................................................................................... 120
8.5.9.2 Adjusting the slipping clutch .................................................................................................................................... 121
8.5.10 Gear oil change ....................................................................................................................................................... 121
8.5.11 Replacing the contactor on the control board.......................................................................................................... 123
8.5.12 Replacing the relay on the control board................................................................................................................. 124
8.5.13 Replacing the control cable ..................................................................................................................................... 125
9 Malfunctions/warnings.......................................................................................................................................... 127
9.1 Safety instructions for malfunctions/warnings ......................................................................................................... 127
9.2 7-segment display ................................................................................................................................................... 128
9.3 Operating statuses/general messages.................................................................................................................... 129
9.4 Warning messages.................................................................................................................................................. 130
9.5 Error messages ....................................................................................................................................................... 131

10 Disassembly/disposal........................................................................................................................................... 132
10.1 General.................................................................................................................................................................... 132

11 Spare parts............................................................................................................................................................. 133

11.1 Motor ....................................................................................................................................................................... 133
11.2 Parts on the DC 1-15 gearbox................................................................................................................................. 134
11.3 Parts on the DC-Pro 15 gearbox ............................................................................................................................. 136
11.4 Chain drive .............................................................................................................................................................. 138
11.5 Chain guides ........................................................................................................................................................... 141
11.6 DC 1-15 hook assembly (from 12/2017) ................................................................................................................. 143
11.7 DC 15-25 hook assembly (from 2018) .................................................................................................................... 144
11.8 DC-Pro hook assembly until 06/2018...................................................................................................................... 145
11.9 DC-Com hook assembly until 11/2017 (replaced by DC 1-15 hook assembly from 12/2017) ................................ 146
11.10 DC 10 bottom block with external cut-off springs .................................................................................................... 147
11.11 DC-Pro 15 bottom block with external cut-off springs ............................................................................................. 148
11.12 Electric equipment cover ......................................................................................................................................... 149
11.13 Control cable, service cover .................................................................................................................................... 150
11.14 DSC–5 / DSC–7 pendant controller......................................................................................................................... 151
EC declaration of conformity for a machine ........................................................................................................................ 152
.................................................................................................................................................................................................. 153
EC declaration for the incorporation of partly completed machinery............................................................................... 154
UK declaration for the incorporation of partly completed machinery............................................................................... 155
UK declaration of conformity for a machine........................................................................................................................ 156
.................................................................................................................................................................................................. 157
Index ........................................................................................................................................................................................ 158
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 1 General

1.1 DC chain hoist

You have purchased a Demag quality product.
This chain hoist was manufactured to European standards and regulations in accordance with state-of-the-art en‐
gineering principles. The EC Machinery Directive requirements are satisfied.
High productivity, efficiency and operating reliability are the most important requirements to be met by state-of-
the-art material flow systems. Demag develops and produces innovative materials handling solutions for all indus‐
tries and companies of all sizes, from small workshops to major industrial corporations.
All inclusive: fully featured with no need for extras. Many features are already integrated into the Demag DC chain
hoist as standard that have to be ordered and bought as extras for other chain hoists. The DC chain hoist is a fully
featured, highly versatile chain hoist, which can be installed and put into service in a minimum of time.
Certified:
DC chain hoists satisfy the relevant provisions of:
● EC Machinery Directive 2006/42/EC,
● EC Low Voltage Directive 2006/95/EC and
● EC EMC Directive 2004/108/EC.
Electromagnetic compatibility is rated for interference immunity in industrial environments and for interference
emissions in commercial and industrial environments.
In addition, an optional variant of these chain hoists meets the strict CCSAUS regulations for Canada and the USA.

Safety-related functions:
Improved safety thanks to rugged and proven electronic controls in comparison with conventional controls. At
least Category 2 and Performance Level PL = c are achieved for the safety-related functions specified in
DIN EN 14492-2.
(PL = c and Cat. 1 apply for DC/CC/FC conventional controls):
● Emergency stop
● Lifting and lowering limiters
● Overload protection (as of 1 t)
for travelling hoists to EN 15011:
● Emergency stop
● Travel limiters (right/left)
and for tandem operation with two hoist units by means of tandem box:
● Interlocking of the hoist units
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 1.2 DC documents
Further documents are available for sub-assemblies/components in addition to these operating instructions. The
corresponding documents are supplied as necessary or can be ordered separately – also for special designs or if
additional options are ordered which differ from these operating instructions.

Documents 1)
Technical data/catalogues Part no. Assembly – Adjustment – Dimensions Part no.

Demag DC chain hoist 203 525 44 Crane hook adapter 211 240 44
CF5-DC/DCM trolley 203 568 44 DC-Run module 211 248 44
U11-U34/DC/DCM/DK trolley 203 569 44 DC double brake 211 217 44
RU/EU56 trolley 203 691 44 LDC-D double chain hoist 211 162 44
KBK classic (steel, powder-coated) 202 976 44 KDDC/UDDC articulated trolley 211 159 44
KBK Aluline (anodized) 203 245 44 DC electric enclosure 211 250 44
Clamp-fitted buffers 203 313 44 Limit switch 211 210 44
Operating instructions/component parts Part no. E11-E34 DC travel drive (I) 214 810 44
E11-E34 DC travel drive (II) (circuit diagrams) 211 229 44
DC-Pro/Com 1 - 15 chain hoist 211 273 44 DRC-DC radio control system 214 689 44
DC-Pro 1 - 15 chain hoist (valid until 12/2015) 214 741 44 DRC-DC radio control system quick-step instructions 211 045 44
DC-Pro 16 - 25 chain hoist 211 033 44 DC geared limit switches 211 011 44
DC-Com chain hoist (valid until 12/2015) 214 802 44 Manulift chain swivel unit 211 164 44
DCS-Pro chain hoist 214 827 44 KDC low-headroom travelling hoist 211 017 44
DC-ProCC/DC/FC 1 - 15 chain hoist 211 191 44 DC protective sleeve 211 227 44
DC-ProCC/DC/FC 16 - 25 chain hoist 211 163 44 DC Polu box 211 249 44
DC-Wind chain hoist 211 010 44 LDC-Q quadro chain hoist 211 261 44
DSM Manulift 211 309 44 Friction force checking device 206 973 44
PGS parallel grippers 214 095 44 DC 1 - 25 safety hook 211 228 44
Log book Part no. DC PWM/3ST signal converter 211 094 44
DSC-EX pendant controller 214 832 44
DC log book 214 745 44 DSE-10C pendant controller 214 998 44
Certificates 235 309 44 DC 1 - 25 tandem 211 108 44
VG11-34 EU11-34 dual-output gearbox 211 122 44
DC 1 - 15 guide plate accessories 211 095 44
Long hook path accessories 211 178 44
DSC strain relief device 211 092 44
Tab. 3

1.3 Symbols/signal words

Important safety information and instructions are marked by corresponding symbols and signal words in these in‐
structions.
Safety warnings and instructions must be followed. Exercise particular caution to ensure that accidents, injuries
and damage are avoided in such cases.
Locally applicable accident prevention regulations and general safety regulations must also be followed.
The following symbols and instructions warn against possible injuries or damage and are intended to assist you in
your work.

DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
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8 1) The documents can be ordered from the relevant Demag office.

 WARNING
This symbol indicates a possibly hazardous situation which might result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.

CAUTION
This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage.
– Follow these instructions at all times and be particularly careful and cautious.

Operating hazard for the machine.

● This symbol indicates information on appropriate use of the machine.
● This symbol indicates all warnings which, if not complied with, can result in malfunctions or damage.

1.4 Information on the operating instructions

These operating instructions are designed to provide the owner and operator with useful instructions for transport‐
ing, installing, commissioning, operating and maintaining our chain hoists. These operating instructions are an in‐
tegral part of the machine.
Persons entrusted with the various types of work must know and comply with the safety regulations and the oper‐
ating instructions.
The machine may only be operated by personnel who are fully familiar with the operating instructions. In particu‐
lar, they contain the "Safety" section and the relevant safety instructions in the working sections of these operat‐
ing instructions.
The operating instructions must be available to operating personnel at all times to prevent operating errors and to
ensure smooth and trouble-free operation of our products. They must be kept in the immediate vicinity.
Demag chain hoists are delivered ready for operation as a complete machine with a controller or as partly com‐
pleted machinery without a controller.

Complete machine
Based on Machinery Directive 2006/42/EC, the chain hoist is also designated as a machine in the sense of a
complete machine in the following.

For a chain hoist delivered ready for operation in the sense of a complete machine, we confirm conformity with
the requirements of Directive 2006/42/EC by means of the attached EC declaration of conformity.

Partly completed machinery

These instructions inform the manufacturer of equipment with a chain hoist about:
● basic technical information,
● some typical risks,
● the assembly and operation of the chain hoist.
The information contained in this document can be used as the basis for the risk assessment and operating in‐
structions which must be compiled by the manufacturer of the equipment in compliance with the Machinery Direc‐
tive.
For operation of the equipment, the manufacturer of the equipment must provide additional operating procedure
instructions as the result of the risk assessment, as required, and inform the owner about any remaining hazards.
A declaration of incorporation is enclosed for a chain hoist supplied as partly completed machinery which is as‐
sembled with additional parts to form a machine that is ready for operation. The declaration of incorporation refers
to the scope of delivery of the partly completed or non-assembled machinery. The owner must take additional
measures to satisfy the safety requirements for the machine before the unit is put into operation.
211 273 44/280823

Installation of a partly completed or non-assembled chain hoist to create machinery ready for operation must be
carried out in compliance with the information provided by the manufacturer for the machinery. Installation and
operating instructions for the chain hoist contained in this document must be observed.

9
 A conformity inspection in accordance with the Machinery Directive must be carried out for the assembled ma‐
chine when it is ready for operation and a declaration of conformity must be produced. The information contained
in the declaration of incorporation for the chain hoist may be used for the conformity inspection.

1.5 Liability and warranty

All information included in these instructions has been compiled on the basis of the relevant regulations, state-of-
the-art engineering principles and our many years of experience.
These instructions must be read carefully before starting any work on and with the chain hoist, especially before
it is put into service for the first time. The manufacturer assumes no liability for any damage which results from
the following:
● non-compliance with the instructions,
● incorrect use,
● untrained personnel,
● unauthorised conversions,
● technical modifications.

Wearing parts are not subject to liability for defects.

We reserve the right to incorporate technical modifications within the scope of improving the operating character‐
istics and further development of the product.

1.6 Copyright
These instructions are only intended to be used by people who work with or on the chain hoist.
Any and all content, texts, drawings, images and any other information are protected within the sense of copyright
law and are subject to further industrial rights. Any misuse is an offence.
No part of this documentation, in whole or in part, may be reproduced, distributed, shown in public or used in any
other way without specific prior consent. Infringements are an offence resulting in obligatory compensatory dam‐
ages. Further rights reserved.
All industrial rights reserved.

1.7 Use of spare parts

We urgently recommend that only spare parts and accessories approved by us be used. Only then can we ensure
the safety and normal service life of the equipment.
Spare parts not approved by us may cause unpredictable hazards, damage, malfunctions or complete failure of
the chain hoist.
The use of unauthorised spare parts may render null and void any claims for warranty, service, damages or liabili‐
ty against the manufacturer or his appointed personnel, dealers and representatives.

1.8 Definition of personnel

The manufacturer is the person who:
1. manufactures the equipment under his or her own name and places it on the market for the first time;
2. resells other manufacturers’ equipment under his or her own name, whereby the reseller is not considered to
be the manufacturer provided the name of the manufacturer (as in 1.) appears on the equipment;
3. imports the equipment into the country and places it on the market for the first time or
4. exports equipment to another member state of the European Union and hands it over direct to a user in that
country.
Owner
Owners (employer, company) are defined as persons who own the machine and who use it as intended or allow it
to be operated by suitable and trained persons.
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 Operating personnel/operator
Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper‐
ate the machine. This person must be trained by the owner in accordance with the tasks to be performed.
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. Personnel must be informed about required safety
equipment, protective measures, relevant regulations, codes of practice, accident prevention regulations and op‐
erating conditions and must provide verification of their competence. This person must be trained by the owner in
accordance with the tasks to be performed.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks,
such as installation, setting-up, maintenance and fault elimination. This person must be trained by the owner in
accordance with the tasks to be performed.
Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of
electric machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. This person must be
trained by the owner in accordance with the tasks to be performed.
Experienced technician
Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐
cient knowledge in the field of the machine. They must be familiar with the relevant national industrial safety regu‐
lations, codes of practice, accident prevention regulations, directives and generally accepted engineering stand‐
ards enabling them to judge the safe operating condition of machines.
Assigned expert engineer (where the rules and regulations of the German Social Accident Insurance
(DGUV) apply in the Federal Republic of Germany)
An assigned expert engineer is defined as an experienced technician specifically assigned by the manufacturer to
determine the remaining service life of the machine (S.W.P. = safe working period) and to carry out a general
overhaul of the machine.
Authorised expert engineer (where the rules and regulations of the German Social Accident Insurance
(DGUV) apply in the Federal Republic of Germany)
In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorised expert engi‐
neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers’ Mu‐
tual Insurance Association.

1.9 Log book

A log book filled in with all details must be available for the hoist (according to the rules and regulations of the
German Social Accident Insurance (DGUV) in the Federal Republic of Germany). The results of the regular tests
and inspections must be entered in the log book and must be certified by the inspector. Log book part no.:
 Tab. 3, Page 8.

1.10 After-sales service

If you have any questions about our products, need technical information or wish to place spare parts orders, etc.,
please contact our after-sales service. Please keep a note of the serial or order number (see log book, load ca‐
pacity plate on the crane). Specifying this data ensures that you receive the correct information or the required
spare parts.
The current addresses of our sales offices in Germany and our subsidiaries and agencies worldwide can be found
on our homepage at www.demagcranes.com
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 2 Safety

2.1 General information on safety

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.
When it is placed on the market, the machine is built according to generally accepted engineering standards and
is considered to be safe to operate. It may still be a cause of danger if it is not used correctly or as intended by
suitably trained personnel.
Knowledge of the contents of the operating instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the machine safely and reliably.
Any conversions, modifications or additions to the machine are prohibited unless approved by the manufacturer in
writing.

2.2 Safety signs on the equipment

Any pictograms, signs or labels on the machine must be obeyed and
must not be removed. Pictograms, signs or labels that are damaged or
no longer legible must be replaced immediately.

43229046_xml.eps
Fig. 2

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 2.3 Intended use
The machine may only be used as intended and in compliance with the requirements for the owner and the fol‐
lowing limitations as specified in these operating instructions. Any other use may result in a danger to life and limb
and/or cause damage to the machine and/or load.
● Chain hoists are only intended for lifting, lowering and moving loads and may be used as stationary or travel‐
ling units.
● The suspension/support structure for the chain hoist must be designed to accommodate loads resulting from
operation of the chain hoist. The maximum safe working load is the load capacity specified on the capacity
plate. This must not be exceeded. The maximum permitted load capacity of the chain hoist includes the load
and any load handling attachment.
● The machine may only be installed, used, operated, maintained and removed by trained personnel when it is in
perfect working order. Personnel must meet the requirements according to  "Operating personnel require‐
ments", Page 16.
● Intended use includes compliance with the safety warnings as well as any other instructions on assembly and
disassembly, commissioning, function and operation, maintenance and fault elimination as well as compliance
with the instructions on the machine safety devices, any possible remaining hazards and protection against
hazards.
● The machine may only be used subject to the permissible technical data,  "Technical data", Page 18.
● The machine must be maintained regularly and appropriately by trained personnel in line with the specified
deadlines and checked according to  "Maintenance schedule", Page 80. Wearing parts must be replaced in
good time.
● National occupational health and safety regulations must be observed and followed.
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. In particular, 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.
No liability for structural modifications
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of de‐
livery, or the installation or use of third-party accessories, equipment or sub-assemblies that are not approved by
the manufacturer.
Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by an
expert engineer before it is handed over to the owner.
Use of the controller
Powered lifting and lowering and, if applicable, cross-travel and long-travel motions are controlled by means of
the corresponding control elements on the controller. The slow speeds are intended for attaching the load, lifting it
free and depositing it. Loads can be precisely positioned at slow speeds.
Short transport times can be achieved at higher speeds. 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.
Inching (flick switching) must be avoided, as it causes increased wear and load sway.
211 273 44/280823

13
 2.4 Hazards that can be caused by the machine
2.4.1 General information on safety
The machine has been subjected to a risk assessment. The design and execution based on this analysis corre‐
sponds to state-of-the-art engineering principles. However, residual risks remain.

DANGER
Live components
Danger to life and limb.
Electric energy can cause very severe injuries. Danger of death caused by electric current if the insulation or
individual components are damaged.
– Switch the machine off and secure it against restoration of the power supply before any maintenance,
cleaning or repair work is carried out.
– Switch the power supply off before any work is carried out on the electric equipment. Check to ensure that
the components to be replaced are de-energised.
– Do not remove any safety equipment or render it inoperative by modifications.

WARNING
Crushing hazard
Body parts can be crushed when loads are lifted or lowered.
Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered.

WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
Keep out of the danger zone at all times
– Keep a sufficient safety distance.
– Never step under suspended loads.

Certain work and practices are prohibited when using the machine as they can involve danger to life and limb and
result in lasting damage to the machine. Observe the safety warnings in the sections:
●  "Assembly", Page 32
●  "Putting into service for the first time", Page 57
●  "Operation", Page 60
●  "Maintenance/repair", Page 68

2.4.2 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH)
Demag Cranes & Components GmbH is fully aware of its obligations under Regulation (EC) no. 1907/2006 of the
European Parliament and of the Council of 18 December 2006 concerning the Registration, Evaluation, Authori‐
zation and Restriction of Chemicals (REACH). Twice a year the EU publishes a candidate list of Substances of
Very High Concern (“SVHC”) for authorization. Manufacturers and EU importers have the duty to inform their EU
customers when a product contains SVHCs in a concentration above 0,1% weight by weight. Some Demag prod‐
ucts do include small quantities of SVHCs, such as lead which is typically used in brass and in certain steel mate‐
rials. These cases are exemptions, as there are currently no satisfactory alternatives available for such substan‐
ces. We are actively searching for alternatives to substitute articles including SVHCs.
For a list of SVHCs, please see https://www.demagcranes.com/en/company/reach-notice.
211 273 44/280823

14
 2.5 Responsibility of the owner
Information on safety at work refers to the regulations of the European Union that apply when the machine is
manufactured. The owner is obliged to ensure that the specified health and safety measures comply with the lat‐
est rules and regulations and to observe new regulations during the entire service life of the machine. Local indus‐
trial safety legislation and regional regulations and codes of practice applicable at the site of operation of the ma‐
chine must be observed outside the European Union.
General safety, 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 owner and any personnel authorised by him are responsible for correct operation of the machine and for
clearly defining responsibilities for installation, operation, maintenance and cleaning. The operating instructions
must be followed in full and without any limitations.
Special local conditions or applications can lead to situations which are not considered in these operating instruc‐
tions. In such cases, the required safety measures must be defined and implemented by the owner. Necessary
measures may also relate, for example, to the handling of hazardous materials or tools and the provision/wearing
of personal protection equipment. The operating instructions must, if required, be supplemented by the owner with
instructions relating to organisation of work, working procedures, authorised personnel, supervising and reporting
obligations, etc. For further information, see  "Safety instructions for operation", Page 60.
Furthermore, the owner must ensure that
● any further working and safety instructions resulting from the hazard assessment of the machine workplaces
are specified in operating procedures.
● personnel who work with or on the machine are provided with appropriate first-aid equipment. Personnel must
be trained in the use of the first-aid equipment.
● the operating instructions are always kept available in the immediate vicinity of the machine for installation, op‐
erating, maintenance and cleaning personnel.
● personnel are trained in accordance with the work to be performed.
● the machine is only operated when in safe and proper working order.
● safety devices are always kept freely accessible and are checked regularly.
● national regulations for the use of cranes and lifting appliances are observed.
● any specified regular checks and inspections are carried out on time and are documented.
The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these
instructions at a suitable place where they can be easily seen.
The owner is obliged to ensure that
● the rules and regulations of the German Social Accident Insurance (DGUV) are applied in the Federal Repub‐
lic of Germany.
● national occupational safety and health regulations are observed and followed.

Extract from the transfer list of the rules and regulations of German Social Accident Insurance (DGUV)
Previous no. New no. Title
BGV D6 DGUV Regulation 52 Cranes
BGV D8 DGUV Regulation 54 Winches, lifting and towing devices
BGG/GUV-G 905 DGUV Policy 309-001 Inspection of cranes
Tab. 4
211 273 44/280823

15
 2.6 Operating personnel requirements
Only authorised and trained specialist personnel may work on the installation. Personnel must have received in‐
struction on the installation functions and any hazards that can occur.
Every individual given the task of working on or with the equipment must have read and understood the instruc‐
tions before any work starts.
Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with
the equipment.
Age and job-specific regulations relevant at the equipment operating location must be observed for the selection
of any personnel.
Personnel are obliged to report to the owner without delay any changes to the equipment that impair safety.
For independent operation (operator) or maintenance (trained maintenance fitter) of the installation, the owner
may only employ persons
● who are at least 18 years of age,
● who are mentally and physically suitable,
● who have been instructed in the operation and maintenance of the installation and who have proven their quali‐
fication to the owner in this respect.

2.7 Personal protection equipment

When work is carried out on or with the installation, the following protective equipment is recommended to be
worn according to the owner’s hazard assessment:
● Protective clothing, closely fitting working clothes (low tear strength, no loose sleeves, no rings or any other
jewellery, etc.);
● Safety shoes to protect against falling parts and against slipping;
● Safety helmet to be worn by everybody in the danger zone.

211 273 44/280823

16
 2.8 Emergency-stop device

DSC DSC-5 DSE-10C DSM-C DRC-DC

43713744_xml.eps

Fig. 3 Position of emergency stop (1)

The machine is fitted with an emergency-stop device (1) to prevent damage and injuries. This is located on the
controller. The emergency-stop device operating function must be checked regularly.

2.9 Regular inspections

The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation
and regional regulations. This is regulated by the rules and regulations of the German Social Accident Insurance
(DGUV) in the Federal Republic of Germany, for example. These specify that
● the machine must be inspected before it is put into operation,
● the machine must be inspected regularly,
● the elapsed share of the theoretical service life must be calculated,
● a record must be kept in a log book.
The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe
new regulations at all times.
If no comparable inspection regulations or requirements for use of the machine apply at the operating location, we
recommend compliance with the above-mentioned regulations.
211 273 44/280823

17
 3 Technical data

3.1 Design overview

43213945_xml.eps

Fig. 4 Example: DC-Pro single-fall design

Item Designation Item Designation Item Designation

1 Electric equipment cover 11 Chain guide 21 Adjusting mechanism for control cable
2 Control system 12 Chain sprocket 22 Cut-off buffer for operating limit switch
3 Elapsed operating time counter 13 Round-section steel chain 23 Hook assembly with load capacity plate
4 Window 14 Slipping clutch 24 Motor shaft
5 Pulse wheel for speed monitoring 15 Dished washer pack 25 Winding head cover
6 Magnet brake 16 Slipping clutch adjusting nut 26 Stator
DC 1 - 5 two-stage helical gearbox
7 Brake disc with linings 17 DC 10 and DC 15 three-stage helical 27 Rotor
gearbox
8 Brake springs 18 Suspension bracket 28 Fan
9 Brake magnet 19 Suspension pin 29 Fan cover
10 Gearbox housing 20 Service cover 30 Mounting points
Tab. 5
211 273 44/280823

18
 3.2 Model code
E K L D DC-Pro - D 10 - 1000 X X X H5 V6/1,5 2/4 - 2000 380 - 415/ 50 24/6 200 220 - 480
Voltage range/voltage
Travel drive [V]
Max. flange width of the trolley [mm]
Travel speed [m/min]
Frequency [Hz]
Chain hoist voltage range [V]
Double chain hoist/big bag travelling hoist load hook centre distance
Double chain hoist load hook run-off position
Lifting speed [m/min]
V 2-stage= Main/creep lifting
VS Stepless = VS at nominal load up to VSmax in the partial load range
Hook path [m]
1/1, 2/1 reeving LDC-D 2x1/1; 2x2/1
KLDC-D 2/2-2; 4/2-2
Total load capacity [kg]
Size 2)
D Double chain hoist (2 chain lead-offs)
Q Quadro chain hoist (4 chain lead-offs)
DC-Pro product range DC-Pro product range
DC-Pro 2-stage chain hoist (Demag chain hoist) DC-ProCC 2-stage chain hoist for conventional contactor con‐
DCM-Pro 2-stage Manulift trol

DCS-Pro Variable-speed chain hoist DC-ProDC 2-stage chain hoist for direct control
DCMS-Pro Variable-speed Manulift DC-ProFC Variable-speed chain hoist for control by means of
DCRS-Pro Stepless rocker switch an external frequency inverter

DC-Com product range

DC-Com 2-stage chain hoist
D Articulated trolley
L Long trolley
K Low-headroom travelling hoist
U Standard-headroom monorail hoist
11 Trolley size load capacity [kg • 100]
22
34
56
R Push-travel trolley
E Travel drive
C F 5 Click-Fit (push-travel trolley)
Tab. 6

Not all features of the model code can be combined.

211 273 44/280823

2) Since 04/2006, the designation for sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1, respectively. 19
 3.3 Selection tables

3.3.1 DC-Pro

Load ca‐ Chain Reeving Group of mecha‐ Chain size Lifting speed Standard Motor size 5) Max. weight
pacity hoist size nisms hook path 4) for hook path
3)
DIN EN 14492 at 50 Hz at 60 Hz H 4m 5m 8m
[kg] DC-Pro FEM/ISO [mm] [m/min] [m/min] [m] [kg] [kg] [kg]
1 8,0/2,0 9,6/2,4 ZNK 71 A 8/2 6)
4,2x12,2 22 24
80 2 16,0/4,0 19,2/4,8 ZNK 71 B 8/2
5 5,3x15,2 24,0/6,0 7) 28,8/7,2 ZNK 80 B 8/2 28 30
1 8,0/2,0 9,6/2,4 ZNK 71 A 8/2 6)
4,2x12,2 22 24
100 2 16,0/4,0 19,2/4,8 ZNK 71 B 8/2
5 5,3x15,2 24,0/6,0 7) 28,8/7,2 ZNK 80 B 8/2 28 30
4m/M7
1 8,0/2,0 9,6/2,4 ZNK 71 A 8/2 6)
4,2x12,2 22 24
125 2 16,0/4,0 19,2/4,8 ZNK 71 B 8/2
5 5,3x15,2 24,0/6,0 7) 28,8/7,2 ZNK 80 B 8/2 28 30
2 4,2x12,2 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22 24
160 16,0/4,0 19,2/4,8
5 5,3x15,2 ZNK 80 B 8/2 28 30
24,0/6,0 7) 28,8/7,2
2 3m/M6 4,2x12,2 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22 24
200 5 5,3x15,2 16,0/4,0 19,2/4,8 ZNK 80 B 8/2 28 30
4m/M7
10 7,4x21,2 24,0/6,0 7) 28,8/7,2 ZNK 100 A 8/2 48 52
2 2m+ 8)/M5+ 4,2x12,2 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22 24
250 5 5,3x15,2 16,0/4,0 19,2/4,8 5 and 8 ZNK 80 B 8/2 - 28 30
1/1
10 7,4x21,2 24,0/6,0 7) 28,8/7,2 ZNK 100 A 8/2 48 52
5 4m/M7 5,3x15,2 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28 30
315 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48 52
10 7,4x21,2
24,0/6,0 7) 28,8/7,2 ZNK 100 B 8/2 56 60
5 3m/M6 5,3x15,2 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28 30
400 4m/M7 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48 52
10 7,4x21,2
3m/M6 24,0/6,0 7) 28,8/7,2 ZNK 100 B 8/2 56 60
5 2m+ 8)/M5+ 5,3x15,2 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28 30
500 4m/M7 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48 52
2m+ 8)/M5+ 24,0/6,0 7) 28,8/7,2 ZNK 100 B 8/2 56 60
6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48 52
630 4m/M7
12,0/3,0 14,4/3,6 ZNK 100 B 8/2 56 60
10 7,4x21,2
6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48 52
800 3m/M6
12,0/3,0 14,4/3,6 ZNK 100 B 8/2 56 60
2m+ 8)/M5+ 6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48 52
1000 2m+ 8) 9)/M5+ 12,0/3,0 14,4/3,6 56 60
15 4m 10)/M7 8,7x24,2 8,0/2,0 9,6/2,4 4 71 72 77
2/1 4m/M7 6,0/1,5 7,2/1,8 65 73
10 7,4x21,2 5 and 8 -
1250 1Am 11)/M4 8,0/2,0 9,6/2,4 56 60
1/1
15 3m 10)/M6 8,7x24,2 8,0/2,0 9,6/2,4 4 71 72 77
10 2/1 3m/M6 7,4x21,2 6,0/1,5 7,2/1,8 5 and 8 - 65 73
1600 ZNK 100 B 8/2
15 1/1 2m+ 8) 12)/M5+ 8,7x24,2 8,0/2,0 9,6/2,4 4 71 72 77
10 2m+ 8) 9)/M5+ 7,4x21,2 6,0/1,5 7,2/1,8 5 and 8 - 65 73
2000
15 4m 13)/M7 8,7x24,2 4 83 86 96
10 2/1 1Am 11)/M4 7,4x21,2 5 and 8 - 65 73
2500 4,0/1,0 4,8/1,2
3m/M6
15 8,7x24,2 4 83 86 96
3200 2m+ 8) 9)/M5+
211 273 44/280823

Tab. 7

3) Since 04/2006, the designation for sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1, respectively.
4) Larger hook paths on request.
20 5) Motor key data  "Electric key data", Page 21.
 3.3.2 DC-Com

Load ca‐ Chain Reeving Group of mecha‐ Chain size Lifting speed Standard Motor size 17) Max. weight
pacity hoist size nisms 15) hook path 16) for hook path
14)
DIN EN 14492 at 50 Hz at 60 Hz H 4m 5m 8m
[kg] DC-Com FEM/ISO [mm] [m/min] [m/min] [m] [kg] [kg] [kg]
80 4m/M7
100 1 8,0/2,0 9,6/2,4 ZNK 71 A 8/2 18)
125 3m/M6
4,2x12,2 21 22 24
160
200 2 6,0/1,5 7,2/1,8 ZNK 71 B 8/2
2m/M5
250
1/1
315 3m/M6
400 5 5,3x15,2 4,5/1,1 5,4/1,3 4, 5 and 8 ZNK 80 A 8/2 27 28 30
2m/M5
500
630 3m/M6
800 ZNK 100 A 8/2 47 48 52
2m/M5
1000
10 7,4x21,2 4,0/1,0 4,8/1,2
1250 3m/M6
1600 2/1 ZNK 100 B 8/2 63 65 73
2m/M5
2000
Tab. 8

3.4 Electric key data

3.4.1 DC-Pro

3.4.1.1 Hoist motor data

Voltage 19) Size Motor size No. of PN CDF nN Starts/h Min./max. currents and start-up current
Frequency poles
IN min. IN max. Imax. 20) IA/IN max. cos φN
(Conformity)
[kW] [%] [rpm] [A] [A] [A]
8 0,05 20 720 240 1,75 2,10 2,10 1,45 0,48
DC-Pro 1 ZNK 71 B 8/2
2 0,18 40 2925 120 2,10 2,80 2,80 2,75 0,46
8 0,09 20 675 240 1,80 2,10 2,35 1,45 0,56
DC-Pro 2 ZNK 71 B 8/2
3 ~ 220-240 V 2 0,36 40 2825 120 2,40 2,80 3,20 2,75 0,63
8 0,18 20 665 240 2,45 2,80 2,95 1,45 0,51
50 Hz DC-Pro 5 ZNK 80 B 8/2
2 0,73 40 2745 120 3,80 4,20 4,70 3,00 0,77
(CE) 8 0,27 20 690 240 2,95 3,30 3,80 1,80 0,54
DC-Pro 10 ZNK 100 A 8/2
2 1,09 40 2745 120 5,40 5,40 6,10 3,60 0,81
DC-Pro 10
ZNK 100 B 8/2 -
DC-Pro 15

6) ZNK 71 A 8/2 with 380-415 V/50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.
7) Only with operating limit switch for lifting; operating limit switch for lowering on request (the lower end position must not be approached in nor‐
mal operation).
8) 2m+ corresponds to a service life of 1900 hours at full load.
9) FEM 1Am chain drive to EN 818-7
10) FEM 2m chain drive to EN 818-7
11) FEM 1Cm chain drive to EN 818-7
12) FEM 1Bm chain drive to EN 818-7
13) FEM 3m chain drive to EN 818-7
14) Since 04/2006, the designation for sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1, respectively.
211 273 44/280823

15) Replacement gearboxes for DC-Com units delivered until 12/2013 will be supplied with higher FEM classification as of 01/2014.
16) Larger hook paths on request.
17) Motor key data  "Electric key data", Page 21.
18) ZNK 71 A 8/2 with 380-415 V/50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.
19) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
20) I
max = maximum rated current for lowering motion. 21
 Voltage 19) Size Motor size No. of PN CDF nN Starts/h Min./max. currents and start-up current
Frequency poles
IN min. IN max. Imax. 20) IA/IN max. cos φN
(Conformity)
[kW] [%] [rpm] [A] [A] [A]
ZNK 71 A 8/2 8 0,05 20 700 240 0,95 1,1 1,1 1,2 0,66
21)
2 0,18 40 2840 120 1,2 1,4 1,4 2,6 0,57
DC-Pro 1
8 0,05 20 720 240 1,00 1,20 1,20 1,45 0,48
ZNK 71 B 8/2
2 0,18 40 2925 120 1,20 1,60 1,60 2,75 0,46
3 ~ 380-415 V 8 0,09 20 675 240 1,00 1,20 1,35 1,45 0,56
DC-Pro 2 ZNK 71 B 8/2
2 0,36 40 2825 120 1,40 1,60 1,85 2,75 0,63
50 Hz
8 0,18 20 665 240 1,40 1,60 1,70 1,45 0,51
DC-Pro 5 ZNK 80 B 8/2
(CE) 2 0,73 40 2745 120 2,20 2,40 2,70 3,00 0,77
8 0,27 20 690 240 1,70 1,90 2,20 1,80 0,54
DC-Pro 10 ZNK 100 A 8/2
2 1,09 40 2745 120 3,10 3,10 3,50 3,60 0,81
DC-Pro 10 8 0,54 20 675 240 3,00 3,40 3,90 1,85 0,58
ZNK 100 B 8/2
DC-Pro 15 2 2,18 40 2790 120 5,50 6,20 6,40 4,15 0,77
8 0,05 20 720 240 0,75 0,95 0,95 1,45 0,48
DC-Pro 1 ZNK 71 B 8/2
2 0,18 40 2925 120 0,90 1,25 1,25 2,75 0,46
8 0,09 20 675 240 0,80 0,95 1,10 1,45 0,56
DC-Pro 2 ZNK 71 B 8/2
3 ~ 500-525 V 2 0,36 40 2825 120 1,10 1,25 1,45 2,75 0,63
8 0,18 20 665 240 1,20 1,30 1,35 1,45 0,51
50 Hz DC-Pro 5 ZNK 80 B 8/2
2 0,73 40 2745 120 1,80 1,90 2,15 3,00 0,77
(CE) 8 0,27 20 690 240 1,35 1,50 1,75 1,80 0,54
DC-Pro 10 ZNK 100 A 8/2
2 1,09 40 2745 120 2,40 2,50 2,80 3,60 0,81
DC-Pro 10 8 0,54 20 675 240 2,50 2,70 3,10 1,85 0,58
ZNK 100 B 8/2
DC-Pro 15 2 2,18 40 2790 120 4,60 4,90 5,10 4,15 0,77
8 0,05 20 870 240 2,1 2,5 2,5 1,45 0,47
DC-Pro 1 ZNK 71 B 8/2
2 0,22 40 3525 120 2,5 3,35 3,35 2,75 0,45
8 0,11 20 825 240 2,10 2,50 2,80 1,45 0,55
DC-Pro 2 ZNK 71 B 8/2
3 ~ 220-240 V 2 0,44 40 3425 120 2,90 3,30 3,85 2,75 0,62
8 0,22 20 815 240 2,90 3,30 3,50 1,45 0,50
60 Hz DC-Pro 5 ZNK 80 B 8/2
2 0,87 40 3345 120 4,60 5,00 5,60 3,00 0,76
(CE/CCSAUS) 8 0,33 20 840 240 3,55 3,90 4,60 1,80 0,53
DC-Pro 10 ZNK 100 A 8/2
2 1,31 40 3345 120 6,50 6,40 7,30 3,60 0,80
DC-Pro 10
ZNK 100 B 8/2 -
DC-Pro 15
8 0,05 20 870 240 1,35 1,60 1,60 1,45 0,47
DC-Pro 1 ZNK 71 B 8/2
2 0,22 40 3525 120 1,70 2,00 2,00 2,75 0,45
8 0,11 20 825 240 1,50 1,60 1,80 1,45 0,55
DC-Pro 2 ZNK 71 B 8/2
3 ~ 380-400 V 2 0,44 40 3425 120 1,80 2,00 2,30 2,75 0,62
8 0,22 20 815 240 1,80 1,95 2,00 1,45 0,50
60 Hz DC-Pro 5 ZNK 80 B 8/2
2 0,87 40 3345 120 2,70 2,90 3,20 3,00 0,76
(CE) 8 0,33 20 840 240 2,40 2,70 2,90 1,80 0,53
DC-Pro 10 ZNK 100 A 8/2
2 1,31 40 3345 120 3,80 4,00 4,60 3,60 0,80
DC-Pro 10 8 0,65 20 825 240 3,90 4,30 4,90 1,85 0,57
ZNK 100 B 8/2
DC-Pro 15 2 2,61 40 3390 120 7,20 7,70 8,00 4,15 0,76
8 0,05 20 870 240 1,05 1,25 1,25 1,45 0,47
DC-Pro 1 ZNK 71 B 8/2
2 0,22 40 3525 120 1,25 1,65 1,65 2,75 0,45
8 0,11 20 825 240 1,05 1,25 1,40 1,45 0,55
DC-Pro 2 ZNK 71 B 8/2
3 ~ 440-480 V 2 0,44 40 3425 120 1,45 1,65 1,95 2,75 0,62
8 0,22 20 815 240 1,50 1,70 1,80 1,45 0,50
60 Hz DC-Pro 5 ZNK 80 B 8/2
2 0,87 40 3345 120 2,30 2,50 2,80 3,00 0,76
(CE/CCSAUS) 8 0,33 20 840 240 1,80 1,95 2,30 1,80 0,53
DC-Pro 10 ZNK 100 A 8/2
2 1,31 40 3345 120 3,25 3,20 3,70 3,60 0,80
DC-Pro 10 8 0,65 20 825 240 3,10 3,50 4,00 1,85 0,57
ZNK 100 B 8/2
DC-Pro 15 2 2,61 40 3390 120 5,70 6,40 6,60 4,15 0,76
211 273 44/280823

19) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
22 20) I
max = maximum rated current for lowering motion.
 Voltage 19) Size Motor size No. of PN CDF nN Starts/h Min./max. currents and start-up current
Frequency poles
IN min. IN max. Imax. 20) IA/IN max. cos φN
(Conformity)
[kW] [%] [rpm] [A] [A] [A]
8 0,05 20 870 240 0,85 0,85 1,45 0,48
DC-Pro 1 ZNK 71 B 8/2
2 0,22 40 3525 120 0,90 0,9 2,75 0,46
8 0,11 20 825 240 0,90 1,00 1,45 0,65
DC-Pro 2 ZNK 71 B 8/2
3 ~ 575 V 2 0,44 40 3425 120 1,00 1,15 2,75 0,63
8 0,22 20 815 240 1,10 1,35 1,45 0,54
60 Hz DC-Pro 5 ZNK 80 B 8/2
2 0,87 40 3345 120 1,75 2,10 3,00 0,88
(CE/CCSAUS) 8 0,33 20 840 240 1,35 1,55 2,10 0,58
DC-Pro 10 ZNK 100 A 8/2
2 1,31 40 3345 120 2,40 2,70 3,80 0,87
DC-Pro 10 8 0,65 20 825 240 2,40 2,70 1,85 0,62
ZNK 100 B 8/2
DC-Pro 15 2 2,61 40 3390 120 4,40 4,50 4,15 0,83
Tab. 9

3.4.1.2 Mains connection delay fuse links and supply lines

CAUTION
For safety reasons, we recommend the use of 3-pole automatic circuit breakers/circuit breakers (to DIN EN
60898-1, tripping characteristic B or C) instead of separate fuse links. This arrangement ensures that all phases
are disconnected from the power supply in the event of a short circuit.

Size Voltage 220-240 V 380-415 V 500-525 V 220-240 V 380-400 V 440-480 V 575 V

DC-Pro Frequency 50 Hz 60 Hz
Motor size [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m]
1/2 ZNK 71 … 6 89 100 6 76 100
5 ZNK 80 B 8/2 1,5 31 6 6 100 1,5 26 6 1,5 75 6 100 100
10 94 10 6
ZNK 100 A 8/2 34 1,5 1,5 29 78 1,5 1,5
10
ZNK 100 B 8/2 10 38 10 61 16 2,5 45 10 43 78
- -
15 ZNK 100 B 8/2 16 46 10 73 16 1,5 36 16 52 10 90
[A] = amperage of the mains connection fuse; [mm2] = cross-section for the supply line; [m] = max. cable length
The lengths of the supply lines are calculated on the basis of: 5% voltage drop Δ U, start-up current I A and an earth-loop impedance of 200 mΩ.
Tab. 10

3.4.2 DC-Com

3.4.2.1 Hoist motor data

Voltage 22) Size Motor size No. of PN CDF nN Starts/h Min./max. currents and start-up current
Frequency poles
IN min. IN max. Imax. 23) IA/IN max. cos φN
(Conformity)
[kW] [%] [rpm] [A] [A] [A]
8 0,05 20 720 240 1,75 2,10 2,10 1,45 0,48
DC-Com 1 ZNK 71 B 8/2
2 0,18 40 2925 120 2,10 2,80 2,80 2,75 0,46
8 0,07 20 695 240 1,80 2,10 2,35 1,45 0,52
3 ~ 220-240 V DC-Com 2 ZNK 71 B 8/2
2 0,27 40 2880 120 2,30 2,80 3,20 2,75 0,55
50 Hz 8 0,10 20 720 240 1,90 1,90 2,15 2,50 0,46
DC-Com 5 ZNK 80 A 8/2
2 0,41 40 2910 120 3,60 4,70 5,50 4,70 0,49
(CE)
8 0,18 20 705 240 2,80 3,10 3,65 1,90 0,48
ZNK 100 A 8/2
DC-Com 10 2 0,73 40 2850 120 3,50 4,00 4,50 4,85 0,65
ZNK 100 B 8/2 -
211 273 44/280823

19) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
20) I = maximum rated current for lowering motion.
max
21) ZNK 71 A 8/2 with 380-415 V/50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.
22) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
23) I
max = maximum rated current for lowering motion. 23
 Voltage 22) Size Motor size No. of PN CDF nN Starts/h Min./max. currents and start-up current
Frequency poles
IN min. IN max. Imax. 23) IA/IN max. cos φN
(Conformity)
[kW] [%] [rpm] [A] [A] [A]
ZNK 71 A 8/2 8 0,05 20 700 240 0,95 1,1 1,1 1,2 0,66
24)
2 0,18 40 2840 120 1,2 1,4 1,4 2,6 0,57
DC-Com 1
8 0,05 20 720 240 1,00 1,20 1,20 1,45 0,48
ZNK 71 B 8/2
2 0,18 40 2925 120 1,20 1,60 1,60 2,75 0,46
3 ~ 380-415 V 8 0,07 20 695 240 1,00 1,20 1,35 1,45 0,52
DC-Com 2 ZNK 71 B 8/2
2 0,27 40 2880 120 1,30 1,60 1,85 2,75 0,55
50 Hz
8 0,10 20 720 240 1,10 1,10 1,25 2,50 0,46
DC-Com 5 ZNK 80 A 8/2
(CE) 2 0,41 40 2910 120 2,10 2,70 3,20 4,70 0,49
8 0,18 20 705 240 1,60 1,80 2,10 1,90 0,48
ZNK 100 A 8/2
2 0,73 40 2850 120 2,00 2,30 2,60 4,85 0,65
DC-Com 10
8 0,36 20 705 240 2,80 3,20 3,70 1,95 0,48
ZNK 100 B 8/2
2 1,45 40 2880 120 3,50 5,00 5,20 5,15 0,59
8 0,05 20 720 240 0,75 0,95 0,95 1,45 0,48
DC-Com 1 ZNK 71 B 8/2
2 0,18 40 2925 120 0,90 1,25 1,25 2,75 0,46
8 0,07 20 695 240 0,80 0,95 1,10 1,45 0,52
DC-Com 2 ZNK 71 B 8/2
3 ~ 500-525 V 2 0,27 40 2880 120 1,10 1,25 1,45 2,75 0,55
8 0,10 20 720 240 0,90 0,90 1,00 2,50 0,46
50 Hz DC-Com 5 ZNK 80 A 8/2
2 0,41 40 2910 120 1,70 2,15 2,55 4,70 0,49
(CE) 8 0,18 20 705 240 1,30 1,40 1,70 1,90 0,48
ZNK 100 A 8/2
2 0,73 40 2850 120 1,70 1,80 2,00 4,85 0,65
DC-Com 10
8 0,36 20 705 240 2,40 2,50 2,90 1,95 0,48
ZNK 100 B 8/2
2 1,45 40 2880 120 3,40 4,00 4,20 5,15 0,59
8 0,05 20 870 240 2,1 2,5 2,5 1,45 0,47
DC-Com 1 ZNK 71 B 8/2
2 0,22 40 3525 120 2,5 3,35 3,35 2,75 0,45
8 0,08 20 845 240 2,10 2,50 2,80 1,45 0,51
3 ~ 220-240 V DC-Com 2 ZNK 71 B 8/2
2 0,33 40 3480 120 2,70 3,30 3,85 2,75 0,54
60 Hz 8 0,12 20 870 240 2,30 2,30 2,60 2,50 0,45
DC-Com 5 ZNK 80 A 8/2
2 0,49 40 3510 120 4,40 5,60 6,60 4,70 0,48
(CE/CCSAUS)
8 0,22 20 855 240 3,35 3,75 4,40 1,90 0,47
ZNK 100 A 8/2
DC-Com 10 2 0,87 40 3450 120 4,20 4,80 5,40 4,85 0,67
ZNK 100 B 8/2 -
8 0,05 20 870 240 1,35 1,60 1,60 1,45 0,47
DC-Com 1 ZNK 71 B 8/2
2 0,22 40 3525 120 1,70 2,00 2,00 2,75 0,45
8 0,08 20 845 240 1,40 1,60 1,70 1,45 0,51
DC-Com 2 ZNK 71 B 8/2
3 ~ 380-400 V 2 0,33 40 3480 120 1,80 2,00 2,20 2,75 0,54
8 0,12 20 870 240 1,55 1,55 1,75 2,50 0,45
60 Hz DC-Com 5 ZNK 80 A 8/2
2 0,49 40 3510 120 3,00 3,50 4,10 4,70 0,48
(CE) 8 0,22 20 855 240 2,30 2,50 2,80 1,90 0,47
ZNK 100 A 8/2
2 0,87 40 3450 120 2,70 2,90 3,30 4,85 0,64
DC-Com 10
8 0,44 20 855 240 3,20 3,30 3,80 1,95 0,47
ZNK 100 B 8/2
2 1,74 40 3480 120 4,50 5,30 5,50 5,15 0,58
8 0,05 20 870 240 1,05 1,25 1,25 1,45 0,47
DC-Com 1 ZNK 71 B 8/2
2 0,22 40 3525 120 1,25 1,65 1,65 2,75 0,45
8 0,08 20 845 240 1,05 1,25 1,40 1,45 0,51
DC-Com 2 ZNK 71 B 8/2
3 ~ 440-480 V 2 0,33 40 3480 120 1,35 1,70 1,95 2,75 0,54
8 0,12 20 870 240 1,15 1,15 1,30 2,50 0,45
60 Hz DC-Com 5 ZNK 80 A 8/2
2 0,49 40 3510 120 2,20 2,80 3,30 4,70 0,48
(CE/CCSAUS) 8 0,22 20 855 240 1,65 1,85 2,20 1,90 0,47
ZNK 100 A 8/2
2 0,87 40 3450 120 2,10 2,40 2,70 4,85 0,64
DC-Com 10
8 0,44 20 855 240 2,90 3,20 3,80 1,95 0,47
ZNK 100 B 8/2
2 1,74 40 3480 120 3,60 5,20 5,40 5,15 0,58
211 273 44/280823

22) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
24 23) I
max = maximum rated current for lowering motion.
 Voltage 22) Size Motor size No. of PN CDF nN Starts/h Min./max. currents and start-up current
Frequency poles
IN min. IN max. Imax. 23) IA/IN max. cos φN
(Conformity)
[kW] [%] [rpm] [A] [A] [A]
8 0,05 20 870 240 0,85 0,85 1,45 0,48
DC-Com 1 ZNK 71 B 8/2
2 0,22 40 3525 120 0,90 0,9 2,75 0,46
8 0,08 20 845 240 0,80 0,90 1,65 0,60
DC-Com 2 ZNK 71 B 8/2
3 ~ 575 V 2 0,33 40 3480 120 1,00 1,15 2,75 0,55
8 0,12 20 870 240 0,95 1,10 2,50 0,45
60 Hz DC-Com 5 ZNK 80 A 8/2
2 0,49 40 3510 120 1,80 2,10 4,70 0,48
(CE/CCSAUS) 8 0,22 20 855 240 1,30 1,50 2,20 0,46
ZNK 100 A 8/2
2 0,87 40 3450 120 1,60 1,80 5,70 0,73
DC-Com 10
8 0,44 20 855 240 2,20 2,50 1,95 0,52
ZNK 100 B 8/2
2 1,74 40 3480 120 2,80 2,90 5,15 0,70
Tab. 11

3.4.2.2 Mains connection delay fuse links and supply lines

CAUTION
For safety reasons, we recommend the use of 3-pole automatic circuit breakers/circuit breakers (to DIN EN
60898-1, tripping characteristic B or C) instead of separate fuse links. This arrangement ensures that all phases
are disconnected from the power supply in the event of a short circuit.

Size Voltage 220-240 V 380-415 V 500-525 V 220-240 V 380-400 V 440-480 V 575 V

DC-Com Frequency 50 Hz 60 Hz
Motor size [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m]
1/2 ZNK 71 … 6 89 6 76
100
5 ZNK 80 A 8/2 1,5 67 6 100 6 100 1,5 56 6 1,5 6 100 100
10 1,5 1,5 10 1,5 6 1,5
ZNK 100 A 8/2 34 29 80
10
ZNK 100 B 8/2 - 10 38 10 61 - 16 2,5 26 10 43 59
[A] = amperage of the mains connection fuse; [mm2] = cross-section for the supply line; [m] = max. cable length
The lengths of the supply lines are calculated on the basis of: 5% voltage drop Δ U, start-up current I A and an earth-loop impedance of 200 mΩ.
Tab. 12

3.5 Dimensions
For further information, data and dimensions, see "Demag DC-Pro 1 - 25 chain hoist technical data"  Tab. 3,
Page 8.

3.6 Noise emission/sound pressure level

Sound pressure level (LpAF) to DIN 45635 at a distance of 1 m from the chain hoist is:

Type DC 1 DC 2 DC 5 DC 10 DC 15
Lifting speed up to [m/min] 8 16 12 12 8
Sound pressure level [dB (A)] 65+2 65+2 69+2 69+2 69+2
Tab. 13

These noise emission levels were measured under maximum load. The following structural influences were not
considered in the above measurements:
● transmission of noise via steel structures,
● reflections from walls, etc.
211 273 44/280823

22) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
23) I = maximum rated current for lowering motion.
max
24) ZNK 71 A 8/2 with 380-415 V/50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements. 25
 3.7 Transport, packing, scope of delivery, storage

Safety warnings

WARNING
Falling parts
Risk of injury from falling parts during transport, loading and unloading operations.
– Do not step under suspended loads. Keep a sufficient safety distance.
– Cordon off a large area around the working zone.

WARNING
Damage caused in transit
The chain hoist may be damaged or destroyed by inappropriate transport.
Attach lifting and handling equipment only at the correspondingly marked points.

Transport inspection
● Check that the delivery is complete and check it for any transport damage immediately on receipt.
● If any transport damage is visible from the outside, do not accept the delivery or only on condition. Note the
scope of damage in the shipping documents/delivery note of the forwarding company. Lodge a claim.
● Lodge a claim for any defects as soon as they are detected, since claims for damages can only be asserted
within the relevant claim notification periods.
Packing
Demag chain hoists, the accessories and the trolleys are shipped in cardboard packing.
If no agreement has been made on the return of the packing material, separate the materials according to type
and size and make them available for further use or recycling.
Environmental protection:
● Always dispose of packing materials in an environmentally compatible way and according to locally applicable
disposal regulations.
● If required, utilise the services of a recycling company.

Scope of delivery
If special designs or additional options are ordered or the latest technical modifications are incorporated, the ac‐
tual scope of supply may differ from the data and information as well as from the illustrations described here. If
you have any questions, please contact the manufacturer.
Storage
Until they are installed, the equipment and accessories must be kept closed and may only be stored under the
following conditions:
● Do not store outdoors.
● Store in dry and dust-free places, relative air humidity: max. 60%.
● Do not expose to aggressive media.
● Protect against direct sunlight.
● Avoid mechanical vibrations.
● Storage temperature: -25 to +70 °C.
● Avoid strong temperature fluctuations (condensation).
● Oil all bare machine parts (rust protection).
● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
protection.
211 273 44/280823

● If stored in a damp location, the installation parts must be packed tight and protected against corrosion (desic‐
cant).

26
 3.8 Materials
Linings
We only use asbestos-free slipping-clutch and brake linings.
Housing
The housing of the chain hoist is made of strong and light-weight die-cast aluminium. The fan cover on the motor,
the service cover and the movable chain collector box are made of particularly impact-resistant plastic material.
Surface protection and paint finish
As standard, the chain hoist is provided with corrosion protection (powder coating/paint finish) and supplied in the
following colours:

Paint finish DC-Pro DC-Com

Chain hoist RAL 5009 Azure blue RAL 5009 Azure blue
Hook assembly RAL 1007 Daffodil yellow Unpainted die-cast aluminium
Load hook and suspension RAL 9005 Jet black RAL 9005 Jet black
bracket
Trolley RAL 5009 Azure blue RAL 5009 Azure blue
Tab. 14

The DC-Pro chain hoist or trolley can be supplied with other paint finishes.

3.9 Operating conditions

CAUTION
Operating safety risk
Safe operation is only possible under the specified operating conditions. Contact the manufacturer if the operat‐
ing conditions differ from those specified  "After-sales service", Page 11

The chain hoist and the trolley can be operated at:

Ambient temperature Humidity Height Type of enclo‐ Electromagnetic compatibility

sure
Resistance to interference in industrial environments
Max. 80% relative humidi‐ Up to 1000 m above sea
-20 °C to +45 °C IP55 Interference emission for residential, commercial and light-
ty level
industrial environments
Tab. 15

Demag chain hoists operating outdoors should be provided with a cover for protection against the weather or
chain hoists, trolleys and travel drives should be kept under cover if they are not in use.

Special operating conditions may be agreed with the manufacturer in individual cases.
Such operating conditions may occur in the following applications, for example:
● Galvanizing plants or electroplating facilities,
● Hygiene areas,
● Low or high temperature applications.
On request, suitably optimised equipment and important information for safe, low-wear operation can be supplied
for these applications.

Reduced duty factor at increased ambient temperatures

If DC chain hoists are operated at ambient temperatures that differ from  Tab. 15, Page 27, the duty factor must
be reduced:

Ambient temperature -20 °C to +45 °C >+45 °C to +50 °C >+50 °C to +55 °C >+55 °C to +60 °C
211 273 44/280823

Chain hoist range Duty factor [%]

DC-Pro, DC-Com 20/40 15/35 15/25 10/20
Tab. 16

27
 4 Technical description

4.1 Drive and brake

A robust pole-changing AC asynchronous motor is used as the hoist motor. The brake is arranged on the load
side in such a way that the load is safely braked and held if the slipping clutch is tripped. The brake is released
electrically. Pressure springs ensure that the brake is applied automatically when power to the motor is switched
off or if there is a power failure. The motor is automatically switched off and, at the same time, the brake is applied
when the slipping clutch is tripped and if errors occur. In addition for DC-Pro units, the motor is automatically
switched off at the upper and lower limit positions of the lifting path
The hoist drive first decelerates by switching from fast speed (2-pole winding) to creep speed (8-pole winding).
Mechanical braking occurs when the creep lifting speed has almost been reached.
The mechanical brake is applied as soon as the emergency stop is actuated, regardless of the lifting speed.
Wear of the mechanical brake is significantly reduced by electric and regenerative braking of the motor. The
brakes of DC 1 - 5 chain hoists are maintenance-free for up to 10 years, the brakes of DC 10 and DC 15 chain
hoists for up to 5 years.

4.2 Gearbox and slipping clutch

A Drives B Brakes
A B
5 1 Slipping clutch 4 Speed sensor

1 4 2 Motor 5 Brake
3 Chain drive 6 Gearbox
Tab. 17

2 3 6 The slipping clutch is arranged between the motor shaft and the gear‐
box input shaft. In connection with the limit stops on the chain, it per‐
forms the function of the emergency limit stop device for the highest
and lowest hook position and protects the Demag chain hoist against
overload. The additional electric operating limit switches (standard for
DC-Pro 1 - 15 and DC-Com 10 with 2/1 reeving, optional for DC-
Com 1-10 with 1/1 reeving) for the highest and lowest hook positions
prevent the slipping clutch from being approached as an emergency
limit stop device during normal operation. The slipping clutch also fulfils
the EC Machinery Directive requirements for a load control device for
load capacities as of 1000 kg.
The brake arranged on the load side prevents the load from slowly
42721945_XML.eps
dropping when the unit is at rest. Monitoring of the slipping clutch and
Fig. 5 Parts in which the load is borne automatic cut-out of the drive if slip occurs increase the service life and
protect the slipping clutch against overload and incorrect use.
The gearbox and the slipping clutch are maintenance-free for up to 10 years.

4.3 Chain drive

The special Demag chain is of high-strength ageing-resistant material with a high degree of surface hardening,
galvanised with additional surface treatment. The dimension tolerances of this chain have been precisely adapted
to the chain drive. We therefore urgently recommend that the Demag special chain be used to ensure safe opera‐
tion. The maximum service life of the chain can only be reached if the specified regular lubrications are correctly
carried out. The entire chain drive is always replaced when a chain is replaced. A chain set which can be easily
replaced is available for this purpose.
The chain set offers the following benefits:
● the optimum duration of service is ensured for the chain;
● certainty that the individual chain drive components are replaced when necessary;
● reduction in service costs by replacement and installation in one step; the motor and gearbox do not need to
be disassembled.

4.4 Electric equipment

211 273 44/280823

4.4.1 Control system

The chain hoist is fitted with a 24 V contactor control system. The contactor control system is supplemented by an
electronic system with programmed functions. This electronic system detects the control commands that are
28
 triggered by the operator with the pendant controller. Permissible control commands generate switching com‐
mands for the contactors to control the hoist motor. The electronic system monitors the control sequence speci‐
fied by the operator based on the speed feedback from the drive shaft, the operating limit switch contacts and, if
applicable, from the thermal contacts in the motor. In there are any discrepancies, the chain hoist is automatically
brought to a safe status and warning or error messages are generated. The positively disconnected emergency-
stop contact on the pendant controller immediately opens the electric circuit for the contactor supply so that the
motor is de-energised and the brake is applied.
As standard, the control system features the following characteristics:
● Operating limit switches for lifting and lowering (standard for DC-Pro 1 - 15 and DC-Com 10 with 2/1 reeving,
optional for DC-Com 1 - 10 with 1/1 reeving);
● Plug-in connections for pendant controller, power supply, motor connection, brake, operating limit switches;
● Connection for the E11 – E34 trolley control system;
● 7-segment display for operating hours, operating status and error messages;
● Infrared interface for wireless transmission of service data;
● Replaceable socket-mounted contactor.
● Signal transmission in steps with 24 V tri-state signals for controlled DC chain hoists (half-wave evaluation);
Demag pendant controllers are connected via plug-in connectors for manual control. Compact DSC control units,
which are optimised for Demag DC chain hoists without electric trolleys, are used for such applications; DSC-5/
DSC-7 or DSE-10C units are used for applications with electric trolleys depending on the configuration.

Please refer to the information contained in the "DC electric accessories" document  Tab. 3, Page 8 for inte‐
grating DC chain hoists into existing installations with contactor control. A Polu box with integrated contactor
control is needed to control pole-changing AC motors (with or without a brake) of long and cross-travel units, see
"Polu box electric accessories" document  Tab. 3, Page 8.

4.4.2 7-segment display for operating status and fault display

43216145.eps
Fig. 6

The 7-segment display is arranged on the control board under the electric equipment cover, it can be read
through the window on the lower side of the chain hoist (arrow, lower side of electric equipment cover).
The following data can be read:
● Software version  Fig. 7, Page 30,
● Operating hours  Fig. 8, Page 30,
211 273 44/280823

● Operating statuses  "Operating statuses/general messages", Page 129,

● Warning messages  "Warning messages", Page 130,
● Error messages  "Error messages", Page 131.
29
 4.4.3 Display of software version, operating hours, number of cycles

Display of software version

0,8 s 0,8 s 0,8 s

0,2 s 0,2 s 0,2 s

43216445_xml.eps
Fig. 7 Example: software version 1.01

The software version is displayed every time power is switched on or after an emergency stop (from software ver‐
sion 1.01).

Display of operating hours

0,8 s 0,8 s 0,8 s

0,2 s 0,2 s 0,2 s

43216045_xml.eps
Fig. 8 Example: 123 hours of operation

The display appears after 3 seconds without any lifting motion.

If the control board has to be replaced, we recommend, if technically possible, that the details for the number of
operating hours be read off and documented in the log book. The elapsed operating time counter starts at "zero" if
a replacement control board is installed.

Display of the number of cycles of the K1 contactor

0,8 s 0,8 s 0,8 s

0,2 s 0,2 s 0,2 s
<H123>
43226445_xml.eps

Fig. 9 Example: C 15 corresponds to 15 x 100.000 = 1,5 million K1 switching cycles

The display alternates between showing this information and the number of hours of operation (not for DCS-Pro).

For preventive maintenance, see  "Service life of the contactor", Page 70

4.5 Central service enclosure

43214444_xml.eps

Fig. 10

All important service work can be carried out at a central point, the service enclosure. The relevant connectors for
power supply, pendant controller and travel drive are arranged under the impact-resistant plastic cover. The chain
211 273 44/280823

is also lubricated from this point.

In addition, any control cable length that is not required is kept under the cover.

30
 The plastic cover also provides mechanical protection for the components fitted under it. The functions are indica‐
ted by pictograms fitted on the outside of the service cover. The service cover of the DC-Pro 15 is made of sheet
metal and does not have any pictograms.

4.6 Pendant controller/control cable height adjustment

The control cable is protected by a flexible, easily bent strain relief sleeve. Its suspension height can be specifical‐
ly adapted to the requirements at the workplace at any time by means of an adjusting mechanism. To do this, it is
not necessary to cut the cable conductors or to shorten the strain relief sleeve. The length of control cable that is
not needed is stored under the service cover. The strain relief sleeve must be fixed at the required suspension
height by means of a self-locking clamp mechanism. The pendant controller can be adjusted to a different sus‐
pension height by unlocking the clamp mechanism.
The strain relief sleeve for the control cable consists of an abrasion-resistant fabric hose with flame-protection im‐
pregnation.
The control cable is reinforced by means of elastic rubber filler material in the gripping area (0,8 m) of the strain
relief sleeve.

4.7 Controller
DSC pendant controllers (lifting/lowering) must be used for manual cable-connected control of the chain hoist.
Pendant controller models DSC-5 (2 motion axes) and DSC-7 (3 motion axes) as well as DSE-10C (2 to 3 motion
axes) are also still available. The pendant controllers have the same plug-in connection for the control cable. The
control cable and pendant controller are connected by a bayonet connector.
The shock and impact-resistant housings are of made high-quality thermoplastic and are resistant to fuels, salt
water, greases, oils and alkaline solutions; IP65 enclosure. Strong mineral acids (hydrochloric or sulphuric acid,
etc.) can, however, corrode switch housings. To avoid this, they must be replaced in good time.
The rubber button caps may be subject to premature wear under aggressive operating conditions (contact with
corrosive substances or special chemicals). Replace any damaged button caps in good time.
211 273 44/280823

31
 5 Assembly

5.1 General
These operating instructions enable the owner to install, re-install or replace the DC chain hoist himself. The own‐
er must appoint a coordinator who is authorised to issue instructions before assembly work commences.
Despite detailed information, errors cannot be excluded if the equipment is installed by the customer. For this
reason, we recommend that this work be carried out by our trained specialists or by persons authorised by us.

The wiring of Demag chain hoists complies in all respects with current DIN VDE and accident prevention regula‐
tions.
Unauthorised intervention and modifications eliminate compliance with these regulations.

DANGER
Live components
Danger to life and limb.
It must be possible to switch off the power supply by means of a device to disconnect the power supply (e.g.
mains connection or isolating switch with a padlock).

The chain hoists are supplied with power from an AC power network. The voltage and frequency of the AC pow‐
er network must match the data specified on the rating plate of the chain hoist.

5.2 Safety warnings for assembly

DANGER
Incorrect assembly
Danger to life and limb.
Incorrect installation can result in severe injury and/or damage to property. Therefore, this work may only be car‐
ried out by authorised, instructed personnel who are familiar with the principle of operation of the machine in
compliance with all safety regulations.
– Ensure sufficient working clearance before starting assembly work.
– Secure and fence off the working area and danger zone.
– If an elevating work platform is used for assembly, only use appropriate attachments for the lifting of per‐
sons which ensure that work is carried out in a safe and stable position.
– Only suitable, tested and calibrated tools and accessories may be used for assembly or disassembly work.
– Wear protective equipment.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any machine parts or fittings and tools that are not needed in
such a way that there is no risk of them falling.
– Fit components correctly and as intended. Comply with specified bolt tightening torques. Incorrectly fitted
components can fall and cause severe injuries.
– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐
ments must be fulfilled. The electrode holder and earth must always be connected to the same assembly
when welding work is carried out. Otherwise serious damage can be caused to the hoist.
– Customer-specific regulations must be observed.
211 273 44/280823

32
 DANGER
Live components
Danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐
nel", Page 10) in compliance with the safety regulations.
Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐
tected against unauthorised or accidental restoration of the power supply by means of a padlock.

Mechanical safety
All bolted connections must be correctly tightened.
Self-locking nuts must not be replaced by other types of nut. Self-locking nuts must be replaced when they have
been tightened and untightened five times. The clamping torque of a self-locking nut must not be lower than the
loosening torque specified by EN ISO 2320.
A sufficiently secure connection can only be guaranteed by tightening to the specified tightening torque.
Bolted connections must not be lubricated as otherwise the pre-tensioning forces will be too high.
Check to ensure that pin connections are correctly fitted.
All installation and assembly work must be completed in accordance with the operating instructions and the hoist
chain must be greased. Operation with defective or damaged chains results in a high risk of accidents with per‐
sonal injuries and damage to the chain hoist and is, therefore, strictly prohibited.
Any change or modification which prejudices safety must be reported to the nearest person responsible immedi‐
ately. Defects may only be eliminated by experienced technicians.
Ensure that all suspensions are freely accessible for checks and inspection work or that free access can be provi‐
ded.
The control device (e.g. pendant controller) must be marked in such a way that the direction of movement is clear
and distinct. The arrow symbol on the control elements must correspond to the direction of movement.
Electric safety
The chain hoist operating instructions must be referred to when Demag chain hoists are used.
These operating instructions only contain standard circuit diagrams. Depending on the chain hoist type, an order-
specific circuit diagram may apply.
Protective earth conductor
The protective earth conductor in insulated leads and cables must be coloured green and yellow along its entire
length.
The protective earth conductor must not be connected to retaining bolts or screws.
Protective earth junctions and connections must be protected against accidental loosening (e.g. by using serrated
lock washers to DIN 6798). It must be possible to disconnect each individual connection.
Protective earth conductors must not carry any current in normal operation.
The same number of protective earth conductor connection points must be provided as electric power infeed and
outfeed points.
Continuity of the PE conductor connection must be checked.
Mains connection switch
A mains connection switch must always be provided for the main power supply line to the machine. The mains
connection switch must be arranged to disconnect all poles of your DC chain hoist from the mains supply.
Ensure that the mains connection switch is installed in an easily accessible position near your machine and that it
is clearly marked.
Isolating switch
If two or more hoists are fed from a common main power supply, each one should be provided with an isolating
switch. This enables you to carry out maintenance work on individual hoist units after turning off the isolating
switch, without affecting operation of the rest of the system.
Power supply
The power supply line/cable to be used depends on the motor size, see the "Hoist motor data" section.
211 273 44/280823

33
 5.3 Chain hoist tightening torques
Tightening torques [Nm]
Size DC 1 DC 2 DC 5 DC 10 DC-Pro 15
Reeving 1/1 1/1 2/1 1/1 2/1
Motor 9,5 25,0
Fan cover 4,0
Gearbox cover 5,5 -
2-piece gearbox housing - 25
Gearbox plug screw - 15
Gearbox vent valve - 15
Brake 5,5
Operating limit switch 1,5 3,0
Control set 3,0
Electric equipment cover 9,5
Service cover 5,5 7,5 25
Limit stop 4,0 4,3
Anchorage halves - 10,5 - 25
Guide plate 5,0 5,5 9,5 15
DC-Pro 6,8 11,5 25,0 - 27,5 -
Hook assembly
DC-Com 6,8 9,5 25,0 - -
Bottom block with external cut-off springs - 55,0 - 55,0
Control cable locking mechanism 11,0
Tab. 18

CAUTION
Loose connections
Loose connections are a danger to life and limb and a risk of damage to the machine.
Metal nuts featuring a locking element (self-locking nuts) are mainly used for Demag chain hoists.
– They must not be replaced by normal nuts.

211 273 44/280823

34
 5.4 Installation procedure
1. Unpack and dispose of the packing material in an environmentally compatible way  "Transport, packing,
scope of delivery, storage", Page 26.
2. Check the delivery is complete  "Transport, packing, scope of delivery, storage", Page 26.
3. Connect the pendant controller, if necessary  "Connecting the controller", Page 36.
4. Which suspension bracket is suitable for suspension?  "Suspending the chain hoist", Page 42.
5. Adjust the height of the pendant controller  "Pendant controller height adjustment", Page 38.
6. Connect to the power supply  "Mains connection", Page 44.
7. Lubricate the hoist chain with grease over its entire length before the equipment is put into operation for the
first time  "Lubricating the hoist chain", Page 99.

WARNING
Premature wear of the chain.
Danger of falling load due to broken chain.
The chain must be lubricated along its entire length.
Even chain links which are covered, e.g. in the chain anchorage, hook assembly, limit stop or crab frame, must
be fully lubricated.

The chain is not lubricated before it leaves the factory, but only protected against corrosion.

8. Set the lowest hook position, if necessary  "Adjusting the lower hook position", Page 56.
9. Carry out checks before putting the unit into operation for the first time  "Inspections before putting into
service for the first time", Page 58.

The equipment is ready for operation  "Operation", Page 60.

211 273 44/280823

35
 5.5 Connecting the controller

1) 2)

3) 4)

43215144.eps

Fig. 11

The pendant controller is of plug-in design. The connector on the end of the control cable is turned and locked in
the bayonet sleeve. If a connector is not locked, it can be pulled out and must be locked again by applying pres‐
sure.
Unless the chain hoist is supplied with the controller fitted, connect the DSC pendant controller with the control
cable and lock the connection with the bayonet lock as follows:
1. Lift bend protection sleeve (1) on the pendant controller off the two pins.

2. Then pull bend protection sleeve (1) off the pendant controller.
3. Slide bend protection sleeve (1) onto the control cable. Insert the control cable into the pendant controller
and turn the bayonet lock until it is locked. Ensure that
– groove (a) on the connector fitting lines up with swivel lock (b) in the pendant controller housing and
– the two pins (c) on the pendant controller housing line up with bayonet lock (d).
4. Slide bend protection sleeve (1) over the pendant controller again. Pay attention to the positioning markers.
211 273 44/280823

Press bend protection sleeve (1) firmly into place.

The pendant controller can be attached to the chain hoist or installed as a travelling unit, see  "Mobile control
system", Page 41.
36
 5.6 Control cable

5.6.1 Control cable technical data

Item Designation
1 Sleeve compartment
2 Control cable locking mechanism latch
3 Control cable locking mechanism bolt, tightening torque 11 Nm

Hook path H4 H5 H8 H11

1 Cable lengths 0,8 m - 2,8 m 0,8 m - 3,8 m 3,8 m - 6,8 m 6,8 m - 9,8 m
2 Tab. 19

The pendant controller is supplied with standard cable lengths. The

3 height can be adjusted by 2 or 3 m.
Longer control cable lengths can be provided, for example, by using a
2TY control cable and DST-C or DSE-C control pendants.
Ergonomic workplace.
● The suspension height can be adjusted by means of a
self-locking mechanism to suit individual requirements
at any time.
● Adjust the suspension height of the pendant controller
in such a way that the control elements are arranged at
42597646_XML.eps
elbow height to obtain an ergonomic operating position.
Fig. 12

5.6.2 Handling the control cable

Do not allow the control cable to be wound around the

chain when lifting motions are performed.

Optional snag protection can be used for the upper part of the control
cable.

Designation Part no.

Protective sleeve with attachment material 720 085 45
Tab. 20

43215644.eps

Fig. 13
211 273 44/280823

37
 5.6.3 Pendant controller height adjustment

1)
2)

3) 4) 5)

6)

7)

x y

43215344.eps

Fig. 14

x Control cable locking mechanism engaged

y Control cable locking mechanism released

1. Undo the screws of the service cover.

2. Open and disconnect the service cover.
3. Remove and open the bag with the control cable.
4. Take the control cable out of the bag.
5. Slide the latch of the control cable locking mechanism upwards and hold it in place. At the same time, pull
the control cable until the pendant controller reaches the correct height.
6. If the pendant controller is positioned too low, pull on the control cable sleeve behind the service cover. Slide
the latch of the control cable locking mechanism downwards and lock the retainer by a short, strong pull on
the control cable above the pendant controller.
7. Lay the remaining control cable in loops and place it in the bag. The bag must be located behind the edge of
211 273 44/280823

the chain collector box. Close the service cover (tightening torque = 5,5 Nm).

38
 5.6.4 Installing the support sleeve on DSC, DSK or DST pendant controllers
Disassembling the DSC pendant controller
● Slide the bend protection sleeve upwards on the control cable and turn the bayonet connector to disconnect
the pendant controller from the control cable, see also section  "Connecting the controller", Page 36.
● Remove the bend protection sleeve from the control cable.
● Open the service cover and electric equipment cover, loosen the screw on the sleeve compartment and thread
the control cable out of the chain hoist, see also section  "Replacing the control cable", Page 125.

Installing the support sleeve on DSC pendant controllers

2
1

4 5 6
3

43618944_xml.eps
Fig. 15

● Slide bend protection sleeve (1) and hose clip (2) onto support sleeve (3) with new control cable (4).
● Pull new control cable (4) out of support sleeve (3) by at least 5 cm on the pendant controller side. Keep the
support sleeve stretched tight.
● Slide connector fitting (5) slightly away from the connector and press connector (6) into the DSC pendant con‐
troller until you hear the connector click into place.
● Press connector fitting (5) into the DSC pendant controller.
● Keep support sleeve (3) stretched tight and slide it over the connecting sleeve of the pendant controller until it
stops against the housing and secure support sleeve (3) by tightening hose clip (2). The screw of hose clip (2)
must be located at the back as otherwise bend protection sleeve (1) cannot be correctly positioned.
● Slide bend protection sleeve (1) over the pendant controller again. Pay attention to the positioning markers.
Press bend protection sleeve (1) firmly into place.

Installing the support sleeve on DSK pendant controllers

3 6
5

6 4
43618945_xml.eps
Fig. 16

● Slide the bend protection sleeve upwards on the control cable and undo the screws of the DSK pendant con‐
troller housing.
● Loosen the hose clip on the connecting sleeve and disconnect the plug from the DSK pendant controller.
● Slide the bend protection sleeve and the hose clip onto support sleeve (3) with new control cable (4).
● Remove strain relief (7) in the DSK pendant controller.
● Pull new control cable (4) out of support sleeve (3) by at least 5 cm on the pendant controller side. Keep the
support sleeve stretched tight.
211 273 44/280823

Carefully cut connector fitting (5) with side cutters or a similar tool. Remove connector fitting (5) from control ca‐
ble (4). Ensure that the control cable is not damaged.

39
 ● Insert control cable (4) into the DSK pendant controller and connect connector (6).
● Keep support sleeve (3) stretched tight and slide it over the connecting sleeve of the pendant controller until it
stops against the housing and secure support sleeve (3) by tightening the hose clip.
● Slide the bend protection sleeve over the pendant controller again.

Installing the support sleeve on DST pendant controllers

Fig. 17

● Loosen the hose clip on the bend protection sleeve, undo the two screws for the housing cap below the bend
protection sleeve and the housing screws of the DST pendant controller.
● Open strain relief (7) in the pendant controller and disconnect the plug from the DST pendant controller.
● Cut off the end of the bend protection sleeve to match the support sleeve and slide the hose clip, the housing
cap and the bend protection sleeve onto support sleeve (3) with new control cable (4).
● Pull new control cable (4) out of support sleeve (3) by at least 5 cm on the pendant controller side. Keep the
support sleeve stretched tight.
Carefully cut connector fitting (5) with side cutters or a similar tool. Remove connector fitting (5) from control ca‐
ble (4). Ensure that the control cable is not damaged.

● Insert control cable (4) into the DST pendant controller and connect connector (6).
● Keep support sleeve (3) stretched tight and slide it until it stops against the housing of the pendant controller.
Secure the bend protection sleeve by tightening the screw of the housing cap and secure support sleeve (3) by
tightening the hose clip.
● Close the pendant controller.

Further steps for assembly

● Push seal (9) into position against sleeve compartment (8).

● Insert the new control cable into the chain hoist and connect it.
● Screw the sleeve compartment into place.
● Close the service cover and the electric equipment cover.

9
8

43618947_xml.eps
Fig. 18
211 273 44/280823

40
 5.6.5 Mobile control system

Component parts
Item Designation Comprising Part no.
1 11-pole + PE flat cable 720 139 45
1 Socket enclosure
Mounting frame
2 Connector enclosure cpl. 720 187 45
2 VC-AMS8 pin insert
Flat cable union
3
Bayonet lock
4 VC-MP-1-R-M25 bush enclosure
3 Connector adapter cpl. 720 087 45
VC-TR1/2M bush frame
5 VC-TFS8 socket insert
4 Cable collector 720 065 45
DSE-10C pendant controller 773 352 45
5 DSC-5 pendant controller 773 935 33
DSC-7 pendant controller 773 937 33
6 Control cable locking mechanism -
Tab. 21

Height-adjustable standard control cables H4, H5, H8, H11 must be

used if a cable collector is fitted.
2
3
4
6

42711245.eps

Fig. 19

X40 plug connector pin assignment

X40 Con‐ Con‐
Signal duc‐ PIN duc‐ Signal
tor tor
- - B4 B8 - -
PE PE B3 B7 - -
- - B2 B6 - -
Special F2 10 B1 B5 8 Right
Left 9 A4 A8 7 Lower
A
Control voltage
Lift 6 A3 A7 5
(24 V, STS)
Emergency stop 4 A2 A6 3 Reverse
Forwards 2 A1 A5 1 Special F1
Tab. 22

42724246.eps
211 273 44/280823

Fig. 20

41
 5.7 Suspending the chain hoist
5.7.1 Safety information for suspending the chain hoist

DANGER
Overload
Danger to life and limb if the components are overloaded.
The suspension/support structure for the chain hoist must be designed for the maximum load caused by opera‐
tion of the chain hoist when used as intended.

DANGER
Chain hoist may fall
Danger to life and limb and risk of damage.
Chain hoists that have fixed suspensions (e.g. suspension bracket, suspension ring, suspension hook) must not
be used for inclined pull of loads. The chain hoist must be suspended with an articulated arrangement. Inclined
pull must be prevented from rigid suspension arrangements.

DANGER
Chain hoist may fall
Danger to life and limb and risk of damage.
Do not move the chain hoist or leave it unsupervised when the suspension bracket is open.

5.7.2 Supporting structure

Hoist units that have a load capacity greater than or equal to 1000 kg must be provided with overload protection
to DIN EN 14492-2.
DC chain hoists are used with a slipping clutch which directly acts as overload protection. The slipping clutch
must be adjusted according to the load capacity of the chain hoist. For information on adjustment, see "Friction
force checking device" document  Tab. 3, Page 8.
According to DIN EN 14492-2, the force limitation factor for DC chain hoists with a load capacity ≥ 1000 kg is:
ϕDAL = 1,6
The supporting structure must be designed to accommodate the static and dynamic forces that occur when the
overload protection device is tripped.
211 273 44/280823

42
 5.7.3 Suspension bracket

42713246_xml.eps
Fig. 21 (A) DC 1 - 5 suspension bracket opened; (B) DC 10 1/1 reeving; (C) DC 10 2/1 reeving; (D) DC-Pro 15 1/1 reeving; (E) DC-Pro 15
2/1 reeving

Item Designation Item Designation Item Designation Item Designation

1 Suspension bracket 2 Retaining clip 3 Pin 4 Spacer tube (DC 10)
Tab. 23

The chain hoist is delivered with the long suspension bracket (DC 1-10) fitted to the chain hoist. The enclosed
short suspension bracket (DC 1-10) can be installed for an improved C dimension:
1. Remove the retaining clip and pin on one side.
2. Attach the suspension bracket (DC 10, DC 15 according to the reeving arrangement) to the superstructure/
trolley.
3. Insert the pin through the suspension and the suspension bracket (and through additional spacer tube (4) for
DC 10) and secure with the retaining clip.
Make sure that the suspension bracket is fitted to match the reeving arrangement of the chain hoist. The chain
hoist will hang at an angle if the suspension bracket is installed incorrectly. Suspension of the chain hoist at an
angle results in premature wear of the chain drive. If special fittings are installed on the chain hoist, make sure
that they are counter-balanced.

5.8 Plug screw, vent valve

1 Before putting the chain hoist into operation, remove plug

screw (1) (plug and O ring) and install the vent valve inclu‐
ded in the delivery. See also  "Gear oil change",
Page 121

Tightening torques [Nm] DC-Pro 15

M16 plug screw 15
M16 vent valve 15
Tab. 24
211 273 44/280823

42767846_XML.eps
Fig. 22 43
 5.9 Mains connection

43215445_xml.eps

Fig. 23 Only ever replace components 1, 2, 3 as a set, since parts 2 + 3 from sets until 04/2021 are not compatible with parts from sets as of
05/2021.
211 273 44/280823

44
 Item Designation Item Designation Item Designation
Strain relief attachment
A) 1 Sealing sleeve 4 Mains connection
DC 1 - 5
Strain relief attachment
B) 2 4-pole connector 5 Recess for round cable
DC 10
Strain relief attachment
C) 3 Connector enclosure 6 Recess for flat cable
DC-Pro 15
Tab. 25

The mains connection cable, the mains connection fuse links and any devices to disconnect and switch the po‐
werfeed must be available on site in order to connect the unit to the power supply. You need a 4-lead cable with a
PE protective earth conductor which complies with the table in  "Electric key data", Page 21 for the power sup‐
ply.
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 caused by undervoltage when the motor starts up.

Connection to the electric supply

● First check to ensure that the voltage and frequency specified on the rating plate match your mains supply.
Ensure that the mains connection cable is not connected to the power supply and secured against accidental
restoration of the power supply.
● Remove the service cover to connect the supply cable.
● Use the mains connection set included in the delivery for the plug connection to the mains connection cable.
● Cut sleeve (1) to match the shape of the mains cable.
● In the area marked 7 to 13 for round cable; in the area marked 18x7 to 20x8 for flat cable. The system is de‐
signed for cable conductor cross-sections of 4x1,5 mm2 or 4x2,5 mm2.
● Slide sleeve (1) onto the mains cable. Make sure sleeve (1) tightly encloses the cable for the specified enclo‐
sure requirements.
● Connect the power cable on connector (2) to terminals L1, L2, L3 and to the PE. If required, use the wire end
sleeves included in the delivery.
● Slide connector (2) into housing (3) until it latches and close housing (3) with sleeve (1).
● Then insert connector (2) into the control system until the housing (3) latches with the card bracket.
● Finally insert the mains cable into the opening in the gearbox housing and secure it with the strain relief clamp.
For DC 1 to 5 units, the strain relief clamp must be turned to match the shape of the cable depending on the
cable type (flat or round cable).

● Only ever replace components 1, 2, 3 as a set, since parts 2 + 3 from sets until 04/2021 are not com‐
patible with parts from sets as of 05/2021.
● All housing parts must be securely latched to ensure the unit is sealed.
● Check continuity of the earth lead connection after the mains cable has been connected and before
the chain hoist is put into operation.
● The mains connector must never be disconnected under load.

Phase sequence for connection to the AC power network

The chain hoist is configured for connection to clockwise R-S-T phases. The lift and lower buttons correspond to
the movements of the load hook if the R-S-T mains phases are connected to L1-L2-L3 in the specified sequence.
Then check the direction of movement as described below. If the phase sequence of the connection cable is un‐
known, connection with the correct phases is established in this way.
Checking direction of motion
The chain hoist must be connected to the power supply to check whether all phases are correctly connected. Turn
the power supply on, unlock the emergency stop and actuate the "Lift" button on the controller. The load hook
must now move upwards.

WARNING
211 273 44/280823

Incorrect direction of movement

Indirect direction of movement can result in danger to life and limb.

45
 – If the direction of movement is not correct, disconnect the power supply at the mains connection switch and
check to ensure that it is not live.
– Swap phases L2 and L3 of the supply cable at the power supply plug.

5.10 Circuit diagrams and control board

5.10.1 General information on the circuit diagrams

For further circuit diagrams, see "www.dc.demag-designer.com".

For further circuit diagrams with E11 - E34 travel drives, see  Tab. 3, Page 8 E11-E34 DC travel drive assembly
instructions (II).

For further information on E11 - E34 travel drives, see  Tab. 3, Page 8 E11-E34 DC travel drive assembly in‐
structions (I).

For further information on cross-travel limit switch part no. 716 663 45, see  Tab. 3, Page 8 E11-E34 DC travel
drive assembly instructions (I).

211 273 44/280823

46
 5.10.2 DC 1 - 15 solo hoist circuit diagram
211 273 44/280823

Fig. 24
47
48
Fig. 25
211 273 44/280823
211 273 44/280823

Fig. 26

49
50
Fig. 27
211 273 44/280823
211 273 44/280823

Fig. 28

51
 5.10.3 Control board

1 2 3

4
5

9 10 11
6

8
SN ...

SN ...
PE

12

13

14

PE

43229644.eps

Fig. 29

Item Designation Terminal strip Function

1 Plug-and-socket con‐ X8 Motor
nector
2 Plug-and-socket con‐ X6 Brake
nector
3 Relay Fast/slow
4 Relay Lifting/lowering
5 Relay Lifting/lowering
6 Contactor On/off
7 Transformer
8 Plug-and-socket con‐ X1 Power
nector
9 Fork light barrier Pulse generator
10 IR transmitter diode IR interface
211 273 44/280823

11 7-segment LED Multi-function display, e.g.: elapsed operating time counter, status indicator, error code display
12 Plug-and-socket con‐ X4 Operating limit switch or plug-in jumper
nector
13 Dummy plug X5 (Optional) trolley
52
 Item Designation Terminal strip Function
14 Plug-and-socket con‐ X3 Control cable
nector
SN... Serial number Label with:
- Serial no. "SN ..."
- Modification status "MS …"
- Calendar week/year production date "**/**"
Tab. 26

RJ45 Function assignment

connec‐
tor
1
PIN Control cable X3 (14) Trolley X5 (13)
1 Special F1 Special F1
2 Crane forwards Crane forwards
3 Crane reverse Crane reverse
4 Emergency stop Emergency stop
5 Controller supply Controller supply
6 Lift 24 V AC from chain hoist
42741844_xml.eps
7 Lower Pendant controller reference potential
Fig. 30 Pin 1 (1)
8 Travelling hoist right Travelling hoist right
9 Travelling hoist left Travelling hoist left
10 Special F2 Special F2
Tab. 27

Function assignment
PIN Lifting limit switch X4 (12)
1
Lift
2

1 3
Lower
4
Tab. 28

42741845_xml.eps
Fig. 31 Pin 1 (1)

5.11 Programming parameters with the controller

5.11.1 General
Parameters can be programmed to adapt the chain hoist to specific application requirements. The parameters
can be programmed using the controller together with the 7-segment display on the bottom of the chain hoist.

5.11.2 Meaning of the buttons

1 2 3

42742845_XML.eps
Fig. 32

1 "Lift" - Accept selection 2 "Lower" - Move to next parameter or se‐ 3 "Emergency stop" - End parameter pro‐
211 273 44/280823

lection value gramming (changes are saved)

Tab. 29

53
 5.11.3 Meaning of the parameters
From software version SW 2.10, the following parameters can be programmed:

Display of parameter no. Parameter name Display of parameter value Remark

0, 1, 6–9. -
n. Default V1/V2
2. Hoist only V2 speed
Y. V2
Default Pendant controller is locked when several buttons are
n.
actuated.
3. Lock the pendant controller
Priority is given to the first button that is pressed if the lifting
Y.
and lowering buttons are actuated together.
Time-controlled start-up n. Default Speed-dependent start-up
4.
(e.g. for tandem operation) Y. Time-controlled start-up
n. Default DC-Pro
5. Chain hoist
Y. DC-Com 2-5, ZNK 71 B 8/4, ZNK 80 A 8/4
Tab. 30

5.11.4 Starting parameter-programming mode

1 2 3

42771844_xml.eps
Fig. 33

1st step: 2nd step: 3rd step:

Actuate emergency stop. Press and hold down the "Lift" button and unlock When "P." is displayed, release the "Lift" button.
emergency stop. Wait for approx. 10 seconds.
7-segment display: 8. 7-segment display: (displays a dot) 7-segment display: P.
Tab. 31

4 5 6

42771845_xml.eps

Fig. 34
211 273 44/280823

54
 4th step: 5th step: 6th step:
"P." disappears after approx. 2 seconds. Press the Release the button. Parameter-programming mode Press the "Lower" button to scroll through the menu
"Lift" button again and hold it down until "o." (for is now active. items faster.
O.K.) is displayed. When parameter-programming mode has been acti‐ Each figure represents a parameter, see  "Mean‐
vated, figures "0." to "9." are each successively dis‐ ing of the parameters", Page 54.
played for 2 seconds.
7-segment display: o. 7-segment display: 0. → 1. ··· 9. 7-segment display:
Tab. 32

7 8 9

42771846_xml.eps

Fig. 35

7th step: 8th step: 9th step:

Press the "Lift" button to select the currently dis‐ To set a different value, press the "Lower" button Select the value again by using the "Lift" button, the
played parameter. The value selection menu for the until the required value is shown on the display. system then also returns to parameter selection
parameter opens at the same time. The currently set mode.
values are symbolically displayed with the charac‐
ters "A.", "b.", "C.", etc.
For meanings of the characters, see  "Meaning of
the parameters", Page 54.
7-segment display: A. b. C. 7-segment display: 7-segment display:
Tab. 33

10 10th step:
Press the "Emergency stop" button to return to normal operating mode. All changes are
first saved.
7-segment display:
Tab. 34

42771847_xml.eps

Fig. 36
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55
 5.12 Adjusting the lower hook position

1
2
3

43215744_xml.eps

Fig. 37

Item Designation Item Designation

1 Buffer (limit switch option) 4 Limit stop
2 Damping plate 5 Unloaded chain fall
3 Buffer plate
Tab. 35

Ensure that the load hook touches the ground in the lower hook position when determining the hook path/lifting
height. The chain hoists are provided with a hook path of 5 m or 8 m as standard.
Secure the limit stop to the 5th chain link at the dead (unloaded) end of the chain.
● Follow the order of assembly. See also  "Buffer/cut-off spring arrangement 10/2014 until 10/2018",
Page 107

Tightening torques [Nm] DC 1 DC 2 DC 5 DC 10 DC-Pro 15

Limit stop 4,0 4,3
Tab. 36

To reduce the hook path, proceed as follows:

1. Position the hook as shown in the diagram.
2. Stop the chain hoist by actuating the emergency stop or the mains connection switch and secure it against
switching on again.
3. Remove the chain collector box  "Remove chain collector box", Page 82.
4. Remove the limit stop on the chain collector box end.
5. Attach the limit stop directly behind the buffer. The unloaded chain fall behind the limit stop must consist of at
least 5 chain links.
6. Place the chain in the chain collector and re-connect it to the chain hoist.
7. Switch the chain hoist on and check adjustment of the lower hook position by moving the hook and run the
211 273 44/280823

chain once through over entire adjusted hook path.

56
 6 Putting into service for the first time

6.1 Safety warnings when equipment is put into service for the first time

The machine may only be handed over when its safety has been verified by means of a corresponding check
 "Checks on entering service, handover", Page 59.

WARNING
Safe operation of the machine is not yet ensured when it is first put into operation.
Machines may only be put into service if they have been installed/assembled according to the assembly instruc‐
tions.
– Machines may only be put into operation by qualified personnel.
– Check installation/operation of the safety devices before commissioning.
– Check to ensure that the line voltage and frequency match the details specified on the rating plate.
– Move the trolleys by hand and check that they can travel without resistance over the entire length of the
track section (if fitted).
– Ensure sufficient working clearance before starting assembly work.
– Secure and fence off the working area and danger zone.
– Wear protective equipment.
– Adequate illumination must be available for safe operation.
Requirements for illuminating workplaces are laid down in DIN EN 12464.

Only trained specialist personnel may be employed when the installation is first put into operation since:
● it may be necessary to render safety devices or features inoperative when adjustments or function checks are
carried out,
● work may need to be performed in the danger zone when the equipment is first put into operation.

6.2 Inspection regulations

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
Compliance with all inspection regulations is an essential aspect of ensuring safe operation of the machine.
Required tests and inspections must be carried out.
All inspections must be arranged and documented by the owner at the specified intervals/points of time.
– Inspection according to national regulations, e.g. according to the rules and regulations of the German So‐
cial Accident Insurance (DGUV).
The owner is responsible for ensuring that power-driven chain hoists are inspected by an expert engineer
before they are first put into service and before they are put into service again after major modifications
have been carried out. This also applies to manually operated or semi-powered chain hoists that have a
load capacity of more than 1000 kg.
– Adjustment, maintenance and inspection activities and inspection deadlines including specifications con‐
cerning the replacement of parts/assemblies prescribed in the operating instructions must be observed.
– Please refer to  "Noise emission/sound pressure level", Page 25 for sound pressure level measurement
values to DIN 45 635.
This work may only be carried out by specialist personnel.
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57
 6.3 Inspections before putting into service for the first time

WARNING
Premature wear of the chain.
Danger of falling load due to broken chain.
The chain must be lubricated along its entire length.
Even chain links which are covered, e.g. in the chain anchorage, hook assembly, limit stop or crab frame, must
be fully lubricated.

The chain is not lubricated before it leaves the factory, but only protected against corrosion.

The owner is obliged to carry out the following checks before the unit is put into operation for the first time:

Activity Section Check

Check continuity of the PE conductor connection - X
Check emergency-stop device - X
Check direction of movement  "Mains connection", Page 44 X
Check 7-segment display  "7-segment display for operating status and fault display", Page 29, X
 "Display of software version, operating hours, number of cycles",
Page 30
Check chain lubrication (if used heavily, the chain must be lubricated  "Available hoist chains", Page 88 X
more frequently)
Check operation of the lifting-motion operating limit switch  "Checking operating limit switches", Page 83 X
Check operation of the lowering-motion operating limit switch  "Checking operating limit switches", Page 83 X
Check cut-off buffer/cut-off spring/operating limit switch actuator  "Check cut-off buffer/cut-off spring", Page 106, X
 "Checking the operating limit switch actuator", Page 84
Check cable and controller housing for damage - X
Check operation of the brake - X
Check hook and hook safety catch  "Checking the load hook", Page 100 X
Tab. 37

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58
 6.4 Checks on entering service, handover

WARNING
Unauthorised operation
Danger to life and limb if the machine is operated without previous inspection.
Machines may only be put into service if they have been checked for compliance with the corresponding acci‐
dent prevention regulations.

By means of suitable measures carried out by the owner or on his behalf, the owner must ensure that the load
handling devices and machinery ready for operation function in complete safety before they are first put into serv‐
ice. The specified measures must allow for the static and dynamic features of the machinery.
The following checks must be carried out when the equipment enters service:
● The supporting structure must be in good condition and the load capacity of the chain hoist must be checked.
● Safety devices must be complete and effective.
● Clearances and safety distances must be maintained.
● The emergency-stop device must be checked by actuating the emergency stop.
When the unit is first put into operation, it must be checked to ensure that it is used as intended in all possible
applications, in each case with the maximum permissible load. Operation of the safety devices must be checked
(e.g. by lifting an overload). At the same time, the behaviour of the chain hoist must be checked when it is not
used correctly.
Various checks of the machine must be carried out before it is handed over:
● Check to ensure it is suitable for operation
● Acceptance inspection
The test and inspection records can be compiled as soon as safe operation of the chain hoist is ensured.
The test and inspection records (log book; observe relevant national regulations) must be handed over when the
machine is handed over.
The machine may be used as intended after it has been handed over.
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59
 7 Operation

7.1 Safety instructions for operation

WARNING
Incorrect operation
Risk of injury due to incorrect operation.
Incorrect operation can result in severe injury and/or damage to property. The equipment may only be operated
by authorised and instructed personnel in compliance with all accident-prevention and safety regulations. Na‐
tional regulations for the use of cranes and lifting appliances must be observed and followed.
– The owner must arrange for operating personnel to be trained.

WARNING
Crushing hazard
There is a risk of injury due to parts of the body being crushed/sheared or clothing or hair becoming
entangled when loads are lifted or lowered:
– Do not touch the chain.
– Do not reach into the upper and lower chain entry points.
– Do not reach into the area of the Manulift coupling when the quick-release coupling is connected.
– Do not reach between the load hook opening and the load handling attachment when loads are lifted.
– Ensure that nobody is present in the immediate danger zone when the load is set down.

WARNING
Risk of burns
Risk of burns from contact when the chain hoist is in operation.
Do not touch hot motor housings.

WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
Keep out of the danger zone at all times
– Keep a sufficient safety distance.
– Never step under suspended loads.
– Do not lift loads above people.
– Wear protective equipment.

WARNING
Non-compliance with operating regulations/industrial safety regulations
Danger to life and limb if relevant regulations are disregarded.
Machinery may only be operated in compliance with relevant national operating regulations, e.g. the rules and
regulations of the German Social Accident Insurance (DGUV).
– Attach a copy of the relevant operating regulations, part no. 214 748 44, at a suitable place where opera‐
tors can read them at any time (e.g. at the mains connection switch).

The machine must not be put into operation or must be taken out of service immediately if any defects or irregu‐
larities relating to safe operation or function are detected.
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Safety devices must not be rendered inoperative or modified contrary to their intended use.

60
 Ensuring safe operation
Special local conditions or special applications may lead to situations which were not known when this chapter
was written. In this case, 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 the manufacturer or other relevant bod‐
ies.
In the event of a stoppage (e.g. if defects regarding safe and reliable operation are detected, in emergency situa‐
tions, in the event of operating malfunctions, for repairs and maintenance work, if damage is detected or after fin‐
ishing work), the operator must carry out all prescribed safety measures or observe that they are automatically
carried out.
Work on electric equipment may only be carried out by qualified electricians.

7.2 Switching on

7.2.1 Checks before/when starting work

Before starting work, the operator must be satisfied that the machine is in safe and correct operating condition.
Ensure that nobody can be endangered by operation of the hoist unit before the machine is switched on or put
into operation. If the operator notices persons who can be exposed to a risk to their health or personal safety by
operation of the equipment, he must stop operation immediately and may not resume operation until the persons
are outside the danger zone.
The chain hoist must be taken out of service without delay if there are any defects which endanger safe and relia‐
ble operation. Defects relevant to safety in this sense are, for example:
● Damage to electric devices, cables or insulation,
● Delayed operation or failure of brakes and safety devices,
● Missing covers or housing parts or
● Damage to the chain or to supporting parts.
Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay.
This also applies if damage occurs to parts of machinery or equipment which makes an immediate stoppage nec‐
essary.
If the chain hoist has been stopped by an emergency stop due to safety-related defects, it must be secured
against being returned to operation until an experienced technician is satisfied that the cause of the hazard situa‐
tion has been eliminated and that operation of the machine is possible without any hazard.
Before starting work:
● Wear protective equipment.
● Ensure that nobody is present in the danger zone of the equipment.

7.2.2 Function checks

Note for operators where the rules and regulations of the German Social Accident Insurance (DGUV) ap‐
ply in the Federal Republic of Germany:
In accordance with the DGUV, the crane operator must also check operation of the emergency limit stop device
when he or she starts work. This does not apply to slipping clutches used as an emergency limit stop device
which do not need to be checked when starting work. DC chain hoists are fitted with a slipping clutch as an emer‐
gency limit stop device which does not need to be checked by the crane operator, therefore a device to by-pass
the limit switches which are approached during normal operation is not fitted.
The following main functions of the machine must be checked before work begins:

Activity Section Check

Check emergency-stop device - X
Check 7-segment display  "7-segment display for operating status and fault display", Page 29, X
 "Display of software version, operating hours, number of cycles",
Page 30
Check chain lubrication (if used heavily, the chain must be lubricated  "Available hoist chains", Page 88 X
more frequently)
Check operation of the lifting-motion operating limit switch  "Checking operating limit switches", Page 83 X
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Check cut-off buffer/cut-off spring/operating limit switch actuator  "Check cut-off buffer/cut-off spring", Page 106 X
Check cable and controller housing for damage - X

61
 Activity Section Check
Check operation of the brake - X
Check hook and hook safety catch  "Checking the load hook", Page 100 X
Tab. 38

7.3 Operation

7.3.1 Safety during operation

DANGER
Danger of broken chain and falling load
The chain can break and loads can be dropped if the emergency limit position limiter is frequently ap‐
proached.
The chain hoist slipping clutch provides the emergency limit position limiter function for chain hoists that are not
fitted with an operating limit switch or which have a defective operating limit switch. This emergency limit position
limiter may only be approached in exceptional cases, i.e. it must not be approached in normal operation. High
additional loads occur in the chain when the slipping clutch is tripped.
For this reason, the "operating limit switch for lifting" function must be checked every day.

WARNING
Overload
Danger to life and limb.
Higher loads than those specified on the load capacity plate must not be handled.
– Do not exceed the maximum permissible load capacity of the hoist.
– Only use load handling attachments which are adequately dimensioned.
– Only use load handling attachments for their intended purpose.

WARNING
Movable parts may start moving.
Danger to life and limb.
The pendant controller is designed to be suspended from its connecting cable. It may only be used as suspen‐
ded equipment. It must not be deposited in/on transport containers, workbenches, etc., or in any other way.

Important information for operation

Observe the following during operation:
– Take the machine out of service immediately if functional defects or irregularities are detected.
– The operator is obliged to check the machine for any visible damage at least once per shift and to report any
damage immediately.
– Do not render safety devices inoperative.
– Limit stops must not be approached in normal operation, e.g. emergency limit stop devices (emergency limit
switches), emergency limiters (slipping clutch or emergency limit switch), track and limit buffers to stop
movement of the trolley or crane, hook assembly or bottom block against limit stops. Continuously approach‐
ing these limit stops can result in severe damage and can even break the chain hoist chain.
– Pay attention to all regulations regarding the correct loading of chains.
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62
 – Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing, parts of the
body or hair becoming entangled.
– Adequate illumination must be available for safe operation.
Requirements for illuminating workplaces are laid down in DIN EN 12464.

7.3.2 Picking up the load

– The load handling attachment and load must be flexibly suspended. Rigid connections cause uncontrolled
forces to be transmitted and lead to fatigue fracture. To protect the chain from unwanted torsion when the
load turns, movement of the hook assembly/bottom block must not be restricted.
– The bottom block must not be twisted or turned over for 2/1 reeving arrangements; chain links facing the
same direction must be arranged opposite each other without being twisted.
– When attaching the load, ensure that the load or load attachment does not slip off the hook and that the load
does not fall over, fall apart, slip or roll off when it is picked up or set down.
– When the load is lifted, the hook must move to an upright position to ensure that the hook safety catch is not
subjected to a load by the load handling slings and, as a result, damaged.
– Do not use the equipment to transport persons.
– The load capacity specified on the load capacity plate indicates the maximum permissible load, which must
not be exceeded. This is the sum of the lifted load and the load handling attachment. Only approved load
handling attachments may be used. The load capacity of the load handling attachment must not be excee‐
ded.

7.3.3 Moving loads

– For lifting and travel motions, adopt a position that provides a clear view of the danger zone or use a second
person who can observe the danger zone.
– Push-travel hoists/trolleys/cranes may only be moved by pulling or pushing the load, bottom block or load
hook assembly. Never pull on the pendant controller.
– Push-travel loads must be guided by hand. The load must never be thrown or hurled.
– Do not handle suspended loads above persons.
– Do not pull or drag suspended loads at an angle. The chain drive mechanism may be damaged at angles of
4° or more.
– Do not pull free fixed or obstructed loads with the chain hoist.
– Do not leave suspended loads unsupervised.
– Do not allow the chain to pass over edges and do not use the chain as a load bearing sling.
– Do not allow loads to drop when the chain is not under load.
– Vibration from the load being transported (e.g. when the load is deposited on vibrating machinery) must not
be transmitted to the lifting equipment.
– Chain hoists must be suspended in such a way that they do not collide with stationary equipment and struc‐
tures, e.g. when slewing cranes are turned.
– Do not pick the load up at full speed.
– Avoid inching (e.g. giving short pulses to the motor).
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63
 7.3.4 Controlling speed with the controller

Pendant controllers are usually equipped with two-stage control buttons

for moving the load
Q ● Press the buttons until they reach the first step to activate the creep
speed (creep lifting, slow travel).
= 0% 100%
● Press the buttons until they reach the second step to activate the
fast speed (fast lifting, fast travel).

Q
= 0% 100%
43752544_xml.eps

Fig. 38

7.3.5 Moving the load with the controller

● Lifting: press the buttons to lift/lower the load.

● Cross travel: press the buttons to move the chain hoist right/left
along the crane bridge.
● Long travel: press the buttons to move the crane bridge forwards or
backwards along the runway beam.

43752644_xml.eps

Fig. 39
211 273 44/280823

64
 7.3.6 Load distribution

CAUTION
Premature wear of the chain guide and chain.
Danger of falling load.
Avoid uneven loads on the chain falls. This results in dam‐
age to the chain guide and causes the chain to break.
Blocked chains or large play between the chain and the
chain sprocket will destroy the chain guide.
– Eliminate any knots or blockages in the chain before
lifting/lowering.
– Watch the bottom block or hook with fittings during
lifting motions to avoid any knots or blockages in the
chain, for example.

42774544_XML.eps
Fig. 40

7.3.7 Emergency-stop device operating function

When the emergency stop is actuated, the hoist motor is immediately disconnected from the electric power sup‐
ply, the mechanical brake is applied and it brings any movement to standstill. Operation can only be resumed by
unlatching the emergency stop when no lifting or lowering commands are applied (off-position interlock). The ef‐
fectiveness of the emergency-stop function depends on the good operating condition of the mechanical brake.
Unusually long braking distances may indicate excessive wear of the brake. In this case, the brake must be in‐
spected by an experienced technician without delay.

7.3.8 Slipping clutch operating function

The chain hoist is fitted with a slipping clutch that is tripped if an overload occurs. The brake is then automatically
applied and the motor is switched off. Only lowering motion remains possible after the slipping clutch has tripped.
Therefore, an overload cannot be lifted from the ground. A load that is already suspended can be safely deposited
by actuating the Lower button. When the lowering motion has been completed, lifting is possible again. If the slip‐
ping clutch already trips at rated load, the friction force must be measured by an experienced technician and re-
adjusted, as required.

7.3.9 Lifting path limiter operating function

Only motion in the opposite direction remains possible after the lifting path limiter has tripped. The lifting path is
limited by limit stops at the ends of the chain. Consequently, the slipping clutch acts as an emergency limit stop
device, the brake is automatically applied and the motor is switched off. A warning message is shown on the dis‐
play if the emergency limit stop device is tripped. Operating limit switch contacts prevent travel against the emer‐
gency limit stop device; they are actuated by elastic buffers on the limit stop and switch the motion off before the
emergency limit stop device is reached.
The emergency limit stop device must not be tripped by DC-Com chain hoists that are not fitted with operating
limit switches.
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65
 7.4 Emergency stop

DSC DSC-5 DSE-10C DSM-C DRC-DC

43713744_xml.eps

Fig. 41 Position of emergency stop (1)

WARNING
Unauthorised, negligent or accidental switching-on.
Danger to life and limb.
Check to ensure that the reason for the emergency stop has been eliminated before the machine is switched on
again.
The emergency-stop device must not be used to switch the machine off in normal operation.

Every chain hoist is fitted with an emergency-stop device with which all motions can be stopped in the event of a
hazard.
The emergency-stop button is arranged in a clearly visible position on the pendant controller. Anybody who identi‐
fies an immediate danger of personal injury must actuate the emergency stop without delay. This also applies in
the case of malfunctions and damage that occurs to parts of the machine and equipment which makes it necessa‐
ry to stop and secure the machine immediately.
● To actuate the emergency stop, press the button until it reaches the end stop. It then locks automatically and
the chain hoist is shut down.
● To unlock the actuated emergency stop, turn the pushbutton in the direction of the arrows (clockwise) and re‐
lease it.
Following an emergency stop, do not switch the machine on again until trained specialist personnel is satisfied
that:
● the cause which led to actuation of this function has been rectified and
● continued operation of the machine constitutes no further hazard.

Controller
211 273 44/280823

Demag chain hoists can be equipped with various controllers, as required. Refer to the relevant documents for
operation of the pendant controller and button assignments, see  Tab. 3, Page 8.

66
 7.5 Taking the equipment out of operation
7.5.1 Taking the equipment out of service when faults occur
The machine must be switched off immediately if the following faults occur:
● If electric devices and cables as well as parts of the insulation are damaged.
● Brake and safety device failure.

7.5.2 Taking the equipment out of service at the end of the shift
The following measures must be taken when finishing work or leaving the working area:
● Position the hoist unit outside the travel area.
● Move the unloaded hoist unit into its resting position.
● Actuate the emergency stop.
● Switch the hoist unit power supply off at the mains connection or isolating switch.
The chain hoist must be disconnected from the power supply when finishing work or leaving the working area.
However, if the Demag chain hoist is continuously connected to the power supply, the following must be consid‐
ered:
● The chain hoist is not protected against unauthorised or accidental switching-on and, therefore, it is not pro‐
tected against unintended movements.
● Damage may be caused by an electric surge if lightning strikes.
● The power-supply line and the electric cabling and wiring must be checked with particular care and at shorter
intervals.
● The control system of the chain hoist consumes approx. 1,1 VA when at standstill.

7.5.3 Taking the equipment out of service for maintenance and repairs
1. Switch off the mains connection or isolating switch before starting any maintenance and repair work.
2. Secure the mains connection switch with a padlock to prevent unauthorised or accidental re-connection to
the supply.
3. Only carry out maintenance and repair work on the chain hoist when the load has been removed.
4. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.
5. Observe the relevant accident prevention regulations, instructions concerning intended use and statutory
regulations for operation and maintenance.
6. Observe relevant safety regulations (e.g. VDE regulations) when repairing electric equipment.
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67
 8 Maintenance/repair

8.1 Safety warnings for maintenance and repair work

The following sections contain a description of maintenance work that is necessary for optimum and uninterrupted
operation of the equipment.

DANGER
Live components
Danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐
nel", Page 10) in compliance with the safety regulations.
Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐
tected against unauthorised or accidental restoration of the power supply by means of a padlock.

WARNING
Risk of burns
Risk of burns from contact after the chain hoist has been in operation.
Do not touch hot motor housings. Allow the motor to cool down before performing any maintenance or repair
work.

WARNING
Inappropriate maintenance work
Danger to life and limb. Risk of material damage.
Maintenance and repair work may only be carried out by authorised, trained specialist personnel ( "Definition
of personnel", Page 10) in compliance with all safety regulations.
– Secure and fence off the working area and danger zone.
– If an elevating work platform is used for maintenance work, only use appropriate attachments for the lifting
of persons which ensure that work is carried out in a safe and stable position.
– Only suitable, tested and calibrated tools and accessories may be used for maintenance work.
– Only use approved spare parts, see also  "Use of spare parts", Page 10.
– Wear protective equipment.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any machine parts or fittings and tools that are not needed in
such a way that there is no risk of them falling.
– Fit components correctly and as intended. Comply with specified bolt tightening torques. Incorrectly fitted
components can fall and cause severe injuries.
– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐
ments must be fulfilled. The electrode holder and earth must always be connected to the same component
when welding work is carried out. Otherwise serious damage can be caused to the hoist. Trolleys must not
be welded or drilled.
– Customer-specific regulations must be observed.

CAUTION
Loose connections
Loose connections are a danger to life and limb and a risk of damage to the machine.
Metal nuts featuring a locking element (self-locking nuts) are mainly used for Demag chain hoists.
– They must not be replaced by normal nuts.
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 CAUTION
Risk of injury.
Oils and lubricants may pose a health hazard.
Contact with these media can result in serious damage to health (poisoning, allergies, skin irritation, etc.).

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

8.2 Basic maintenance requirements

General information on maintenance/repairs

The specified inspection and maintenance intervals ( "Maintenance schedule", Page 80) apply to normal chain
hoist operating conditions. All wearing parts must be checked in the course of the annual inspection.
If routine maintenance reveals that the maintenance intervals are too long, they should be adapted to the specific
operating conditions.
Electric components
Only fuse links with the specified amperage and tripping characteristics may be used in the electric circuits. De‐
fective fuse links must not be bridged.
Pay attention to the following when working on machinery or machine equipment:
1. Wear personal protection equipment.
2. Before starting any maintenance work, switch off the mains connection switch and protect it against unau‐
thorised or accidental re-connection to the power supply by locking it with a padlock.
3. Ensure that the chain hoist is switched off, checked that it is de-energised and, in special cases, isolated.
4. Only carry out maintenance work on the chain hoist when the load has been removed.
5. Ensure that there is sufficient freedom of movement. Keep the working area clean and tidy. Loose parts or
tools left lying around can cause accidents.
6. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.
7. Observe the relevant accident prevention regulations, instructions concerning appropriate use and statutory
regulations for operation and maintenance.
8. Observe the relevant safety regulations (e.g. VDE regulations) when repairing electric equipment.
9. Reinstall safety devices as required by relevant regulations and check them for correct operation after finish‐
ing maintenance work.
Maintenance work which is not possible from the ground may only be carried out from work stands or platforms.
The danger zone below the chain hoist must be fenced off if there is a risk of falling objects.
Instructions for maintenance work in the course of operation
If maintenance work has to be carried out on the chain hoist in the course of operation, special safety precautions
must be taken depending on the operating situation. In each individual case, 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 per‐
sonal injury and, taking into account the local conditions, must implement all necessary safety precautions.
Damaged or deformed spring clip fasteners and spring sleeves must be replaced.
Defective bolted connections must be replaced.
211 273 44/280823

Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly
manner.
After finishing maintenance work
69
 Safety devices must be re-installed as required by relevant regulations and checked for correct operation when
maintenance work is finished.
Carry out a test run at partial load after the chain hoist has been fully re-assembled. Ensure that the chain runs
smoothly during the test run.

8.3 Routine inspections

8.3.1 Required tests and inspections

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
Required tests and inspections must be carried out.
– An annual inspection, e.g. as specified in the rules and regulations of the German Social Accident Insur‐
ance (DGUV), must be carried out.
– Adjustment, maintenance and inspection activities and inspection deadlines including specifications con‐
cerning the replacement of parts/assemblies prescribed in the operating instructions must be observed.
This work may only be carried out by specialist personnel.

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

Please also note  "Measures for achieving safe working periods in Germany ", Page 71 as well as  "Meas‐
ures for achieving safe working periods according to ISO 12482 ", Page 74 and  "Maintenance schedule",
Page 80.
Updating the log book
● All inspections must be arranged and documented in the log book by the owner.

8.3.2 Special operating conditions

CAUTION
Premature wear of the chain.
Danger of falling load.
Special operating conditions or the design of the chain hoist may make it necessary shorten the maintenance
and inspection intervals.
– If, for example, the unit always brakes heavily at the same position and with a heavy load, increased wear
may occur on the chain links that are in the area of the chain sprocket or return sprocket when the brake is
applied.

8.3.3 Service life of the contactor

211 273 44/280823

The switchgear is subject to wear when the chain hoist is operated. Its service life has been rated for the specified
loading group. Premature wear may occur if the equipment is frequently started and stopped.

70
 Chain hoist Motor size Display value C for Unom 380 - 575 V Display value C for Unom 220 - 240 V
DC 1 80 80
ZNK 71
DC 2 80 60
DC 5 ZNK 80 60 50
DC 10 ZNK 100 A 50 20
DC 10; DC–Pro 15 ZNK 100 B 20 -
Tab. 39

Display value C specifies the expected service life of the contactor multiplied by 100000. This value was deter‐
mined under normal operating conditions. For other conditions, the service life of the contactor may be shorter or
longer,  "Display of software version, operating hours, number of cycles", Page 30.
We recommend that the contactor or the control module be replaced when the relevant display value has been
reached,  "Replacing the contactor on the control board", Page 123.

8.3.4 Measures for achieving safe working periods in Germany

The safety and health provisions of the EC Machinery Directive make it a legal requirement to eliminate special
hazards which may be caused, for example, by fatigue and ageing.
This requirement is also reflected by the rules and regulations of the German Social Accident Insurance (DGUV)
(see Regulation 54, Section 23(4) from page 39).
An owner of serial hoist units is obliged to determine the actual duration of service of the chain hoist on the basis
of the operating hours, load spectra and/or recording factors. This is based on FEM 9.755: Measures for achiev‐
ing safe working periods for powered serial hoist units (S.W.P.).
The objective of this rule is to determine measures for achieving safe working periods over the entire duration of
service, although, according to the state-of-the-art, the chain hoists are designed for specific periods of operation.
Premature failure cannot, however, be ruled out.
The following items have been taken from FEM rule 9.755 with reference to the electric chain hoist:
1. Recording the mode of operation is divided into 3 classes. The owner is responsible for recording and docu‐
menting information in the log book. The information must be documented at least once per year during the
checks to be performed (ISO/DIS 9927/1).
2. Operating time Ti (number of operating hours) can be estimated or read on an operating time counter.

3. Type of load kmi (load spectrum) must be estimated, if necessary.

4. Recording with devices (e.g. load spectrum recorder): Load spectra and the corresponding operating
hours are recorded by suitable devices. The actual duration of service S is obtained by evaluating the recor‐
ded data.
When information is recorded by devices, recording factor f = 1,0. (i.e. the value is used without any
changes, FEM 9.755, 3.1.)
5. Documentation and suitable counting devices (e.g. operating time counter): The actual load spectra
and the load spectrum factors (Km1 to Km4) as well as the relevant operating hours TI are documented by
the owner. Serial hoist units are equipped with a suitable counting device (for time or distance) to enable the
effective operating hours TI to be calculated. Serial hoist units are equipped with a lifted load limiter (overload
protection) (slipping clutch, electric overload cut-off, etc.).
The value determined for operating time Ti and documented in the log book using an operating time counter
must be multiplied by the type of recording factor f = 1,1 (FEM 9.755, 3.2 and 4.2).
6. Documentation without counting devices: The owner documents the load spectra and operating hours
according to item 5., however without suitable counting devices.
The value determined for the estimated load spectra and operating hours based on documented produc‐
tion must be multiplied by the type of recording factor f = 1,2 (FEM 9.755, 3.3 and 4.3).
7. For unknown operating hours and types of load25)26), the estimated value (according to the duty class and
age of the chain hoist) must be multiplied by the type of recording factor f = 1,5 (FEM 9.755, 6.2.1 and 6.2.2).
8. The actual duration of service S is calculated as: S = kmi x Ti x f
211 273 44/280823

25) The following assumptions are made for periods where the use or mode of operation is unknown: The operating conditions are assumed as Km
= 0,25. The annual operating time is assumed to be 250 hours (1 hour per day x 250 days per year).
26) For periods of non-use, the following assumptions are made as a precaution: The operating conditions are theoretically specified as Km =
0,125. The theoretical annual operating time is assumed to be 125 hours (0,5 hour per day x 250 days per year). 71
 9. A general overhaul must be carried out when the theoretical duration of service is reached.
10. All checks and inspections and the general overhaul must be arranged by the owner of the chain hoist.
For electric chain hoists classified according to FEM 9.511, the following theoretical durations of service apply
(converted into full load hours):

Duty class/Group of mechanisms M2/1Cm M3/1Bm M4/1Am M5/2m M5+/2m+ M6/3m M7/4m M8/5m
Duration of service/full load hours [h] 200 400 800 1600 1900 3200 6300 12500
Tab. 40

The actual duration of service is considerably increased if the chain hoist is only operated with partial loads. For a
chain hoist operated on average with half load, for example, this results in an 8-fold increase in the actual duration
of service; with operation at one quarter of the full load, a 64-fold increase.

8.3.5 Calculating actual duration of service S according to FEM 9.755 (Germany)

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 hours of service (operating time) Ti (by the owner)
The operating time can be calculated by means of an operating time counter or according to the following method:
Operating time per inspection interval:

(lifting + lowering) x cycles/h x operating time/day x days/inspection interval

Ti =
60 x lifting speed
Tab. 41

Only lifting and lowering motions are counted, long and cross-travel times are not considered.
Estimating load spectrum factor kmi (by the owner)
To simplify, each type of load can be grouped together into km load spectrum modules. The types of load are sim‐
plified and quoted as 1/4, 1/2, 3/4 load and full load.
Dead loads are added to the loads. Loads up to 20% of the rated load capacity are not considered.
The operating time for each type of load is divided up within the inspection interval (e.g. 1 year) in terms of per‐
centage.
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%. Larger shares of the time period must be correspondingly added together.
Load spectrum factor kmi can be obtained by adding together the individual km load spectrum modules.

kmi load spectrum factor diagram

0,021

0,0062

0,0125

0,0008

0,0016
0,05

0,10

L B
0,042

4/4

3/4 1

1/2

1/4

0 t
5 10 5 10 5 10 5 10 40
[%]
100 43230144_xml.eps

Fig. 42 Type of load (B), load (L), time (t), dead load (1)

B Type of load t Time

211 273 44/280823

L Load 1 Dead load

Factor depending on the type of recording

72
 Recording operating hours und load spectrum Recording factor f
Operating hours recorded using an operating time counter and the load spectrum recor‐
1,0
ded with a load spectrum recorder and documented in the log book
Value for operating time Ti determined with an operating time counter and load spectra
1,1
documented in the log book
Load spectra and operating hours documented without suitable counting devices 1,2
Estimated value for unknown operating hours and type of load
1,5
(depending on duty class and age of the chain hoist)
Tab. 42

Example: DC-Pro 10-1250 1/1 H5 V8/2 in 1Am

In the following example, f = 1,1 is assumed as the factor for the recording method.

Lifting speed 8/2 m/min

No. of cycles per hour 10 cycles
Lifting and lowering (2+2) m/cycle = 4 m/cycle
Operating time per day 8 hours
Days per inspection interval 250 days
Tab. 43

Calculation

10 • 4 • 8 • 250
Ti =
60 • 8
Tab. 44

With operating time read: Ti = 167

In the operating time as read above, the chain hoist has transported the following loads:
0,05

0,042

0,0125+

0,0016+

L B
0,0125

0,0008

5% x 4/4

10% x 3/4

20% x 1/2

15% x 1/4

50% x 0 t
5 10 20 15 50
[%]
100 43230244_xml.eps

Fig. 43 Type of load (B), load (L), time (t)

Adding the load spectrum modules km together results in load spectrum factor kmi = 0,119

Thus, the actual duration of service amounts to S [h] = kmi x Ti x f

● With operating time read 0,119 x 167 x 1,1 = 21,9

For classification in FEM group of mechanisms 1Am (see chain hoist data plate) with a theoretical duration of
service of 800 hours (see table below) the hoist has a theoretical remaining duration of service of 778,1 hours.
Documentation
Enter these values in your log book or crane log book. This entry may appear as follows:
211 273 44/280823

73
 Date Operating Type of load [%] km factor Type of load Actual Theoretical Remaining use
hours factor duration duration of
of service service
From To Ti value full 3/4 1/2 1/4 none kmi f S D [h] Group of D-S
[h] [h] mechanisms [h]
5 10 20 15 50
3.1.- 30.12.- Read 167 0,119 1,1 21,9 800/1Am 778.1
0,05 0,042 0,025 0,002 -
Tab. 45

8.3.6 Measures for achieving safe working periods according to ISO 12482

The safety and health provisions of the EC Machinery Directive make it a legal requirement to eliminate special
hazards which may be caused, for example, by fatigue and ageing.
An owner of serial hoist units is obliged to determine the actual duration of service of the chain hoist on the basis
of the operating hours, load spectra and/or recording factors.
According to ISO 12482, the group of mechanisms and operating conditions of the equipment must be regularly
checked for changes so that the remaining service life can be corrected, if necessary. ISO 12482 uses the term
"(DWP) Design Working Period", i.e. the (theoretical) total service life for which the hoist unit is rated.
The following items have been taken from ISO 12482 with reference to electric chain hoists:
1. The actual duration of service determined on the basis of operating time and load must be documented at
least once per year.
2. Operating time Ti (number of operating hours) can be estimated or read on an operating time counter.

3. Type of load kmi (load spectrum) must be estimated.

4. The value determined for operating time Ti and documented in the log book using an operating time counter
must be multiplied by the recording factor f = 1,1 (ISO 12482, 4.3).
5. The value determined for the estimated operating hours and load spectrum based on documented produc‐
tion must be multiplied by the recording factor f = 1,2 (ISO 12482, 4.3).
6. The value determined for the estimated operating hours and load spectrum based on undocumented pro‐
duction must be multiplied by the recording factor f = 1,3 (ISO 12482, 4.3).
7. For unknown operating hours and types of load, the estimated value (according to the duty class and age of
the chain hoist) must be multiplied by the recording factor f = 1,5 (ISO 12482, 4.3).
8. The actual duration of service S is calculated as: S = kmi x Ti x f

9. A general overhaul must be carried out when the theoretical duration of service is reached.
10. All checks and inspections and the general overhaul must be arranged by the owner of the chain hoist.
For electric chain hoists classified according to FEM 9.511, the following theoretical durations of service apply
(converted into full load hours):

Duty class/Group of mechanisms M2/1Cm M3/1Bm M4/1Am M5/2m M5+/2m+ M6/3m M7/4m M8/5m
Duration of service/full load hours [h] 200 400 800 1600 1900 3200 6300 12500
Tab. 46

The actual duration of service is considerably increased if the chain hoist is only operated with partial loads. For a
chain hoist operated on average with half load, for example, this results in an 8-fold increase in the actual duration
of service; with operation at one quarter of the full load, a 64-fold increase.
211 273 44/280823

74
 8.3.7 Determining the remaining service life according to ISO 12482
The remaining service life A of the electric chain hoist can be determined as follows:
A = kmi x Ti x f
kmi : Actual load spectrum factor
Ti : Number of operating hours
f : factor depending on the type of recording
Calculating/estimating the operating hours (operating time) Ti (by the owner)
The operating time can be estimated by means of an operating time counter or according to the following method:
Estimated operating time per inspection interval:

(lifting + lowering) x cycles/h x operating time/day x days/inspection interval

Ti =
60 x lifting speed
Tab. 47

Only lifting and lowering motions are counted, long and cross-travel times are not considered.
Estimating load spectrum factor kmi (by the owner)
To simplify, each type of load can be calculated using km load spectrum modules based on the load spectra in
ISO 4301-1.

kmi value for kmi value for

Calculated
Load 5% operating 10% operating kmi value
time time
4/4 full load 0,05 0,1
3/4 load 0,025 0,05
1/2 load 0,0125 0,025
1/4 load 0,0063 0,0125
Tab. 48 - based on table B1 on page 10 of ISO 12482, however, with val‐
ues for 5% and 10% for simplified calculation.

If more precise information is available on loads and operating times resulting from estimates or records relating
to use, load details can be calculated according to ISO 4301-1.

For widely differing types of use, value km should be determined more precisely with the following equation 27):

km = (b1 + g)3 * c1 + (b2 + g)3 * c2 + …

Where:

Partial load
b1 =
Load capacity

Dead load
g=
Load capacity

Number of load cycles with this load (partial load + dead load)
c1 =
Number of all load cycles with all loads
Tab. 49

The values given in the following diagram are based on the information given in ISO 4301-1.
The types of load are simplified and quoted as 1/4, 1/2, 3/4 load and full load.
Dead loads are added to the loads. Loads up to 20% of the rated load capacity are not considered.
The operating time for each type of load is divided up within the inspection interval (e.g. 1 year) in terms of per‐
centage.
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%. Larger shares of the time period must be correspondingly added together.
Load spectrum factor kmi can be obtained by adding together the individual km load spectrum modules.
211 273 44/280823

27) Foreven more detailed calculations, e.g. for different operating times with and without a load in one cycle, see Annex A and B of ISO 12482,
for example 75
 kmi load spectrum factor diagram

0,0125

0,0063

0,0125
0,05

0,10
B

0,025
L

0,025
0,5
4/4

3/4 1

1/2

1/4

0 t
5 10 5 10 5 10 5 10 40
[%]
100 43230144a_xml.eps
Fig. 44 Type of load (B), load (L), time (t), dead load (1)

Factor depending on the type of recording

Recording operating hours und load spectrum Recording factor f

Crane operating data are recorded by a special, purpose-built system,
which always operates automatically when the crane is in use. The 1,0
crane operator cannot turn the recording system off.
The crane is equipped with counter devices that record the crane oper‐
ating data. The user collects and documents operating data manually 1,1
from the counters.
The crane duty history is calculated based upon a regular process in
which the crane is working. The crane is an integral part of the process. 1,2
Process data are documented.
The crane duty history is estimated based upon general production data
1,3
of the site where the crane is working.
The crane duty history is incomplete or unknown (e.g. in the case of a
second-hand crane). The operating data for calculation of the remaining
safe working period are based on estimates or the assumption that us‐ 1,5
age corresponds to the classification (see also no. 5 in table 1 on
page 3 of ISO 12482).
Tab. 50

Example: DC-Pro 10-1250 1/1 H5 V8/2 in 1Am

In the following example, f = 1,3 is assumed as the factor for the recording method, since usage data are estima‐
ted on the basis of production data at the workplace.

Lifting speed 8/2 m/min

No. of cycles per hour 10 cycles
Lifting and lowering (2+2) m/cycle = 4 m/cycle
Operating time per day 8 hours
Days per inspection interval 250 days
Tab. 51

Calculation

10 x 4 x 8 x 250
Ti =
60 x 8
Tab. 52

With estimated operating time: Ti = 166,6

211 273 44/280823

76
 In the operating time as estimated above, the chain hoist has transported the following loads:

0,05

0,0125+
L B

0,025+

0,0063
0,125
0,05
5% x 4/4

10% x 3/4

20% x 1/2

15% x 1/4

50% x 0 t
5 10 20 15 50
[%]
100 43230244a_xml.eps

Fig. 45 Type of load (B), load (L), time (t)

Adding the load spectrum modules km together results in load spectrum factor kmi = 0,1688

Thus, the Design Working Period amounts to A [h] = kmi x Ti x f

● With estimated operating time 0,1688 x 166,6 x 1,3 = 36,56

For classification in M4 with a theoretical duration of service of 800 hours according to the M classes of
ISO 4301:2016, there is a theoretical remaining duration of service of 763,44 hours.

Documentation;
Enter these values in your log book or crane log book. This entry may appear as follows:

Date Operating Type of load [%] km factor Type of load Actual Theoretical Remaining service
hours factor duration duration of life
of serv‐ service
ice
Fro To Ti value full 3/4 1/2 1/4 none kmi f S D [h] Group D-S
m [h] [h] of mecha‐ [h]
nisms
Estimated 5 10 20 15 50
3.1.- 30.12.- 0,1688 1,3 36,56 800/1Am 763,44
166,6 0,05 0,05 0,05 0,0188 -
Tab. 53
211 273 44/280823

77
 8.3.8 General overhaul (GO)
The chain hoist is designed to be used for a period of at least 10 years until the first general overhaul is carried
out. This is based on the condition that the specified group of mechanisms is not exceeded by the actual dura‐
tion of service. When the actual duration of service has reached the theoretical duration of service relevant for
the given group of mechanisms, further operation of the chain hoist is only permitted after a general overhaul
has been carried out.

GO in Germany according to DGVU and ISO 12482 (FEM 9.755)

The theoretical duration of service D (hours at full load h) depends on the Group of Mechanisms classification of
the chain hoist. The actual duration of service should be determined every year according to ISO 12482
(FEM 9.755). You can arrange to have the actual service life calculated as part of the annual inspection by our
after-sales service.
The owner must arrange for a GO general overhaul to be carried out when 90% of the theoretical duration of serv‐
ice has elapsed – if the chain hoists are correctly classified after 8 to 10 years. A GO general overhaul must be
carried out by the end of the theoretical duration of service.
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. Following a general overhaul, the machi‐
nery 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.
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 installed gear parts,
● Gear oil and gearbox cover with seal,
● Connecting elements,
● Shaft sealing rings, bearings, plugs,
● Brake.
The small parts (screws, washers, etc.) to be replaced when maintenance and assembly work is carried out are
not listed separately.
The general overhaul carried out by the manufacturer or a specialist company authorised by him satisfies the re‐
quirement to be met for continued operation of the chain hoist.
Therefore, the provisions of the German Social Accident Insurance (DGUV) are satisfied.
The equipment may continue to be used when an expert engineer has entered the conditions for continued opera‐
tion in the log book. Completion of the general overhaul must be confirmed in the log book and a further period of
utilisation in accordance with FEM 9.755 must be entered.

General information on inspection and general overhaul according to ISO 12482

A general overhaul is a combination of repair, replacement and maintenance measures that are necessary for the
continued safe use of a crane. Some items can require that measures must be taken immediately, others can be
postponed. In this case, these measures must be planned according to the actual future use of the crane.
The need for and timing of a general overhaul are determined by a special assessment. The contents of a general
overhaul should follow the manufacturer’s instructions.
When the first general overhaul is performed, various components will have reached different stages of cumula‐
tive fatigue or wear. Depending on the type of component and stage of fatigue, the component under review will
require a particular type of general overhaul activity.
A distinction is made between the following measures according to ISO 12482:
● The component is always replaced during a general overhaul, whereby replacement can also be necessary
even if there are no physical signs.
● The component can be repaired, only some parts may need to be replaced.
● Replacement of the components is uneconomical, in this case a complete inspection is conducted during the
first general overhaul and increased shorter inspection frequency and rejection criteria are specified for the fu‐
ture.
211 273 44/280823

The manufacturer must provide maintenance instructions for the crane containing information on inspection, re‐
pair and replacement criteria for the components.

78
 Theoretical duration of service
A general overhaul must be conducted if the theoretical safe working period is found to have reached 90% when
the mandatory calculation of the remaining safe working period is performed every year. The theoretical duration
of service D (e.g. hours at full load h) depends on the classification of the chain hoist according to ISO 4301‑1/
FEM 9.755. The actual duration of service should be determined every year according to ISO 12482. You can
arrange to have the actual service life calculated as part of the annual inspection by our after-sales service.
The owner must arrange for a GO general overhaul to be carried out when 90% of the theoretical duration of serv‐
ice has elapsed. A GO general overhaul must be carried out by the end of the theoretical duration of service.
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.
Following a general overhaul, the machinery is in a condition similar to that of the same machinery in new condi‐
tion as far as the principle of operation and performance values are concerned.
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 installed gear parts,
● Gear oil and gearbox cover with seal,
● Connecting elements,
● Shaft sealing rings, bearings, plugs,
● Brake.
The small parts (screws, washers, etc.) to be replaced when maintenance and assembly work is carried out are
not listed separately.
The general overhaul carried out by the manufacturer or a specialist company authorised by him satisfies the re‐
quirement to be met for continued operation of the chain hoist.
The equipment may continue to be used when an expert engineer has entered the conditions for continued opera‐
tion in the log book. Completion of the general overhaul must be confirmed in the log book and a further period of
utilisation in accordance with ISO 12482 must be entered.
211 273 44/280823

79
 8.4 Maintenance schedule
Activity Section Before first Before During the
putting into starting annual in‐
operation work spection
Check continuity of the PE conductor connection - X
Check emergency-stop device - X X
Check direction of motion  "Mains connection", Page 44 X
Check 7-segment display  "7-segment display for operating status and
fault display", Page 29,
X X
 "Display of software version, operating
hours, number of cycles", Page 30
Check chain lubrication (if used heavily, the chain must be lubrica‐  "Available hoist chains", Page 88
X X X
ted more frequently)  "Lubricating the hoist chain", Page 99
Check operation of the lifting-motion operating limit switch  "Checking operating limit switches",
X X X
Page 83
Check operation of the lowering-motion operating limit switch  "Checking operating limit switches",
X X
Page 83
Check cut-off buffer/cut-off spring/operating limit switch actuator  "Check cut-off buffer/cut-off spring",
Page 106;  "Checking the operating limit X X X
switch actuator", Page 84
Check cable and controller housing for damage - X X X
Check operation of the brake - X X X
Check hook and hook safety catch  "Checking the load hook", Page 100 X X X
Read switching cycles C  "Service life of the contactor", Page 70 X
Read operating hours to determine the remaining duration of serv‐  "7-segment display for operating status and
ice fault display", Page 29
 "Measures for achieving safe working peri‐
X
ods in Germany ", Page 71 and/or  "Meas‐
ures for achieving safe working periods ac‐
cording to ISO 12482 ", Page 74
Check electric switchgear and wiring - X
Check operation of the slipping clutch  "Checking the slipping clutch", Page 120 X
Check adjustment of the slipping clutch  "Adjusting the slipping clutch", Page 121 Every 10 years 28)
Check brake wear  "Brake", Page 118 Every 10 years 29) 28)
Grease brake V sealing ring X
Check suspension, suspension bracket and securing elements  "Suspension", Page 81
X
(clip, etc.)
Check fastening bolts on hook assembly/bottom block - X
Check the hook for cracks, deformation and wear  "Checking the load hook", Page 100 X
Check hook safety catch for deformation - X
Check hook bearing for wear - X
Check chain sprocket of chain guide, chain sprocket of bottom  "Chain drive", Page 84
X
block, chain guide, guide plate
Check that the chain is properly secured - X
Check the chain collector and suspension for external damage  "Remove chain collector box", Page 82
(e.g. cracks, stress whitening, weld seams on metal collector
X
buckets, threads on chain collector bags, rivets, clips)
Remove DC 1-15 service cover
Check the chain for deformation, damage, cracks, pitting, reduc‐  "Check hoist chain", Page 85
tion in the thickness of the links or increase in pitch due to wear, X
elongation caused by deformation
Check securing elements (clips, bolts, etc.) for tight fit and corro‐ -
X
sion
Check and apply or add corrosion protection, as required - X
Check the electric enclosure and gearbox for leakage - X
Check trolley, crossbar and condition of buffers  "Check cut-off buffer/cut-off spring",
X
Page 106
Oil change  "Gear oil change", Page 121 Every 10 years 28)
The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not listed separately.
Tab. 54
211 273 44/280823

28) For use according to FEM classification

80 29) Every 5 years for DC 10 and DC-Pro 15
 General overhaul
The general overhaul should coincide with the annual inspection. When 90% of the theoretical duration of service is reached  "Measures for
achieving safe working periods in Germany ", Page 71; or  "Measures for
achieving safe working periods according to ISO 12482 ", Page 74
Fit chain hoist-specific Demag GO set X
The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not listed separately. The checks and work speci‐
fied in the inspection and maintenance schedule must be carried out during the general overhaul.
Tab. 55

8.5 Maintenance work

8.5.1 Suspension
If a check or inspection reveals that these components are worn beyond the specified dimensions or if cracks can
be seen in these parts, they must be replaced at once.

Suspension bracket

DC-
Chain hoist DC 1/2/5 DC 10
Pro 15
Suspension bracket short long short long long
Min. dimension e for sus‐
[mm] 15,3 14,4 25,2 24,3 31,5
pension bracket
Tab. 56

43218944.eps

Fig. 46

Suspension ring

DC-
Chain hoist DC 1/2/5 DC 10
Pro 15
e

Min. dimension e for sus‐

pension ring turned 90°
[mm] 17,55 24,3 34,2
(chain hoist parallel to gird‐
er)
Tab. 57

42599450_XML.eps

Fig. 47

8.5.2 Electric equipment cover

The electric equipment cover must be held in place when it is opened. Do not allow the electric equipment cover
to fall against its retainer.
When the electric equipment cover is closed again, ensure that the retainer does not snag and does not block the
inspection window.
211 273 44/280823

81
 8.5.3 Remove chain collector box

2
1

3 3

4
3 3

3
5 6

43227644_xml.eps
Fig. 48

– Unscrew and disconnect service cover (1).

– Place bag (2) with the control cable on top of the chain hoist.
– Disconnect spring (3) and place it in the recess in the chain collector box.
– Remove retaining spring (4) from pin (5) and remove the pin. While doing so, hold the chain collector.
– Place chain collector box (6) on the ground.
211 273 44/280823

82
 8.5.4 Operating limit switches (standard for DC-Pro 1-15 and DC-Com 10 with 2/1 reeving)
8.5.4.1 Checking operating limit switches

DANGER
Danger of broken chain and falling load
The chain can break and loads can be dropped if the emergency limit position limiter is frequently ap‐
proached.
The chain hoist slipping clutch provides the emergency limit position limiter function for chain hoists that are not
fitted with an operating limit switch or which have a defective operating limit switch. This emergency limit position
limiter may only be approached in exceptional cases, i.e. it must not be approached in normal operation. High
additional loads occur in the chain when the slipping clutch is tripped.
For this reason, the "operating limit switch for lifting" function must be checked every day.

If an operating limit switch is defective, the hoist motor is switched off when the electronic speed monitoring func‐
tion of the slipping clutch is tripped. For this reason, cut-off in the highest hook position is not a reliable indicator
for correct operation of the operating limit switch. If cut-off by the operating limit switch fails, a warning message is
output, see  "Warning messages", Page 130.

A B C Checking the operating limit switch for lifting: Raise the hook as‐
sembly or bottom block until it is approximately 10 cm below the highest
hook position. Then raise it to the highest hook position at creep lifting
speed until the chain hoist automatically switches off.
● 1/1 reeving:
It must only be possible to compress the buffer or cut-off springs on
the hook assembly by a small amount after the unit has switched off.
● 2/1 reeving:
It must only be possible to compress the upper part of a bottom
block with internal cut-off springs onto the lower part by a small
amount so that approx. 20 mm of the black part of the bottom block
remains visible.
It must also only be possible to compress the springs on a bottom
42768545.eps block with external cut-off springs by a small amount after the unit
has switched off.
Fig. 49 Buffer with limit switch not actuated
(A), buffer with limit switch actuated (B), de‐
fective buffer with limit switch actuated (C).

If the buffer or cut-off springs are strongly compressed, it may be assumed that the hoist motor will not be
switched off by the operating limit switch, but by the speed-monitoring function of the slipping clutch. This can
cause the chain to break if the limit position is frequently approached.

Checking the operating limit switch for lowering

The "Operating limit switch for lowering" must be checked at least once per year. Proceed as follows:
● Remove chain collector box  "Remove chain collector box", Page 82
● Check as described above for the "Operating limit switch for lifting".
Optional geared limit switch
If an optional geared limit switch is fitted, the hoist unit must be switched off before the bottom block or hook as‐
sembly come into contact with the chain hoist guide plate. To check this function, the highest hook position must
be approached at high lifting speed (without a load). When the hoist unit has been switched off, there must be a
minimum distance of at least 20 mm between the bottom block or hook assembly and the chain hoist guide plate.
211 273 44/280823

83
 8.5.4.2 Checking the operating limit switch actuator
Check the operating limit switch actuator for any external damage, e.g. a bent actuator plate.

8.5.5 Chain drive

8.5.5.1 Checking the chain sprocket

Since the chain sprocket is usually replaced together with the chain set,
no further check is necessary under normal conditions.
However, if you notice any uneven or harsh running in the chain drive
mechanism, this may indicate wear.
The chain guide must be removed and degreased to enable the chain
sprocket to be inspected properly.
If the chain sprocket shows signs of wear from the chain or chipping on
its sides, the chain set must be replaced without delay.

43448844_XML.eps
Fig. 50 Example: chain sprocket wear

8.5.5.2 Checking the chain guide

The picture shows a defective chain guide (type installed until 03/2019).
The chain drive can move easily on the output shaft, i.e. lateral play of
approx. ±2 mm is normal. A defective chain guide must be replaced im‐
mediately:
● Open the service cover.
● Check the chain guide for any damage, e.g. ruptured guide section
halves or loose bolts.

42774644_xml.eps

Fig. 51 Example of a defective chain guide

The figure shows the type of chain guide installed until 03/2019 on the
left (1) and the new chain guide installed from 04/2019 on the right (2).

43719344_xml.eps

Fig. 52
211 273 44/280823

84
 8.5.5.3 Checking the guide plate/chain entry plate

Maximum guide plate dimensions [mm] a b c d

DC 1/2 16,0 5,5 16,8 6,8
DC 5 19,4 6,8 21,0 8,9
DC 10 26,7 9,4 28,8 12,0
a
DC-Pro 15 31,1 11,5 33,4 15,3
b
A) Tab. 58

If a check or inspection reveals that it is worn beyond the specified di‐

d c
mensions or if cracks can be seen on the guide plate, it must be re‐
placed.
Multiple fitting and removal of the guide plate retaining bolts may dam‐
age the thread in the aluminium housing in such a way that a tight fit of
the bolts can no longer be ensured. A "Guide plate accessories" set is
available to do this (part no. 717 830 45), see also "DC 1 - 15 guide
plate accessories" document  Tab. 3, Page 8.
B)

42774745_xml.eps

Fig. 53 Load hook side (A), chain collector box

side (B)

8.5.5.4 Check hoist chain

Checking wear or deformation of the original Demag chain

In addition to selecting the correct hoist unit for the given application, owners of chain hoists are obliged by rele‐
vant regulations – such as DIN 685 part 5 – to check the round-section steel chain continuously in operation to
ensure optimum operating safety and, therefore, to avoid any accidents.

For single-shift operation, operation according to FEM classification and for chain hoist operating conditions ac‐
cording to  "Operating conditions", Page 27, the chain must be checked once per year (see inspection and
maintenance schedule).
If routine maintenance reveals that the maintenance intervals are too long, they must be adapted to the specific
operating conditions.

Visual inspection of the chain

Carry out a visual inspection of the chain before starting work.

If the chain displays deformation, damage, cracks, pitting from corro‐
sion, reduction in the link thickness or increase in pitch dimension due
to wear or elongation as a result of plastic deformation, the chain must
be replaced immediately.
211 273 44/280823

43410044_XML.eps
Fig. 54 Example: chain wear

85
 Measuring wear or deformation of the original Demag chain
Two methods can be used to measure wear or deformation of the original Demag chain:
● Measuring with a calliper gauge:
- wear of a single chain link  Fig. 55, Page 86;
- over 11 chain links  Fig. 56, Page 86.
● Measuring with a chain gauge:
- over 11 chain links  Fig. 57, Page 87.

Measuring wear of a single chain link with a calliper gauge

42726244_xml.eps
Fig. 55

The chain link contact areas must be visually checked for traces of wear. If the chain hangs at angle when no load
is attached to it, for example, this usually indicates wear of an individual chain link.
Measure the diameter of the chain link material in the chain link contact area using a calliper gauge, if required.
For minimum link diameter values, see  "Tab. 59", Page 86.

Measuring with a calliper gauge over 11 chain links

A partial load must be suspended from the load hook when the chain is
measured over 11 chain links. Measurements over 11 chain links can
be taken in steps of 2 x 3 and 1 x 5 chain links. The sum total of the
three readings taken, i.e. a1 + a2 + a3 must not exceed the specified limit
a. Otherwise the chain must be replaced.
Demag is stamped on every 12th link of genuine Demag chains. We
strongly recommend that you use genuine Demag chains. This will en‐
sure that the safety and service life of the chain hoist are guaranteed.
Do you find that, after fitting a new chain, it does not run smoothly over
the chain drive mechanism? If so, please contact our after-sales service
centre.

40460845_XML.eps

Fig. 56

Demag chain hoist DC 1/2 DC 5 DC 10 DC-Pro 15 / 16 DC-Pro 25

Chain designation d x t [mm] 4,2 x 12,2 5,3 x 15,2 7,4 x 21,2 8,7 x 24,2 10,5 x 28,2
Limit dimensions according to DIN 685 part 5
Measurement over the outside of 11 chain links,
[mm] 144,7 180,3 253 289 337,4
maximum dimension a = a 1 + a 2 + a 3
Overall length of 1 chain link measured on the inside,
[mm] 12,8 15,9 22,4 25,5 29,8
Max. dimension t
Measurement of the chain link diameter,
[mm] 3,8 4,8 6,7 7,8 9,45
minimum dimension dm = 0,9 x d
211 273 44/280823

Tab. 59

The limit dimensions apply to all hoist chains listed in  "Available hoist chains", Page 88.

86
 Measuring with a chain gauge over 11 chain links

Fig. 57

It does not yet need to be replaced. The chain does not yet need to be replaced. The
A DC/DK/PK new chain 2 chain needs to be replaced if the measuring pin can no longer be inserted into the 11th
chain link.
B PK old chain 3 Measuring pin
1 Chain gauge, part no. 836 025 44 4 11th chain link; the chain is ready to be replaced. The chain must be replaced.
Tab. 60

A partial load must be suspended from the load hook when the chain is measured over 11 chain links.
211 273 44/280823

87
 8.5.5.5 Chain set scope of supply

WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
When the chain is replaced on DC 10–25 units that have 2/1 reeving, the anchorage pins and chain anchorages
must also always be replaced. They are included in the chain sets.
If a single chain is purchased by the metre, the anchorages must be separately ordered and installed, refer to
 "Chain drive", Page 138.

The chain must be replaced when the permissible chain wear limit is reached (for determining the wear limit of the
chain, see  "Check hoist chain", Page 85). A chain set is always supplied when a new standard RDC/TDK chain
is ordered. The chain set includes the following parts:
●
● Chain,
● Chain sprocket,
● Chain guide with plate and cap,
● Chain guide plate,
● Buffers for upper and lower hook positions,
● Tube of Demag chain grease,
● Retaining ring.
Also anchorage pins and chain anchorages for 2/1 reeving
The chain guide is pre-assembled, the chain is already fitted in the chain guide.

8.5.5.6 Available hoist chains

Genuine Demag chain is a round-section steel chain tested to EN 818-7 and is subject to the regulations and test
criteria issued for round-section steel chains used in hoist applications, the inspection regulations to DIN 685
part 5 of Nov. 1981 as well as the rules and regulations of the German Social Accident Insurance (DGUV).

CAUTION
Pay attention to reduced load capacities.
For non-standard operating conditions, the special chains listed below are available for special ambient condi‐
tions.
211 273 44/280823

88
 Chain hoist Max. load capacity for reeving Dimension Stamp, Weight per Production Minimum Minimum
size Chain grade metre test force breaking elongation
1/1 2/1 force at rupture
[kg] [kg] [mm] [kg] [kN] [kN] [%]
Demag RDC/TDK standard chain
DC 1 - 2 250 - 4,2 x 12,2 0,38 13,8 22
DC 5 500 - 5,3 x 15,2 0,62 22 35
DAT
DC 10 1250 2500 7,4 x 21,2 1,20 43 70 10
RDC/TDK
DC 15 - 16 1600 3200 8,7 x 24,2 1,67 59 95
DC 25 2500 5000 10,5 x 28,2 2,49 87 138
High-strength ageing-resistant material with a high degree of surface hardening, galvanised with additional surface treatment, blue-chromated,
Properties
colour: DC 1 - 10 silver, DC 15 - 25 yellow
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication GP00H-30REN.SO-GFB grease
Demag Corrud special chain
DC 1 - 2 250 - 4,2 x 12,2 0,38 13,8 22
Application, e.g.
Galvanizing DC 5 500 - 5,3 x 15,2 0,62 22 35
DAT
plants, electro‐ DC 10 1250 2500 7,4 x 21,2 1,20 43 70 10
RDC/TDK
plating facilities, DC 15 - 16 1600 3200 8,7 x 24,2 1,67 59 95
pickling plants
DC 25 2500 5000 10,5 x 28,2 2,49 87 138
Properties Ageing-resistant, corrosion-free, "Corrud DS" micro-layer corrosion protection, black-coated, colour: black, Stabylan 2001
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication Acid-resistant chain grease, e.g. Ceplattyn BL white paste (part no. 665 023 44)
Demag HS7 special chain
DC 1 - 2 160 - 4,2 x 12,2 0,38 12,5 19,3

Application, e.g. DC 5 400 - 5,3 x 15,2 0,62 19,8 30,8

foundry, dust, DC 10 800 1600 7,4 x 21,2 RSX/DS 1,20 38,7 60 5
emery, blasting DC 15 - 16 - - - - - -
DC 25 1600 3200 10,5 x 28,2 2,49 78 121
Properties Ageing-resistant, colour: silver, with deeper surface hardening
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication Dry or with dry lubricant, e.g. Ceplattyn 300 paste (part no. 665 022 44)
Demag RS6 special chain
DC 1 - 2 125 30) - 160 31) - 4,2 x 12,2 0,38 10 16
DC 5 200 30) - 250 31) - 5,3 x 15,2 0,62 16 25
Application, e.g.
foodstuffs sec‐ DC 10 400 30) - 500 31) 800 32) - 1000 33) 7,4 x 21,2 RSA/S 1,20 32 50 15
tor
DC 15 - 16 - - - - - -
DC 25 630 30) - 800 31) 1250 32) - 1600 33) 10,5 x 28,2 2,23 50 80
Properties Non-rusting chain, not hardened, bright
Material Stainless steel AISI 316 (V4A) 1,4401
Lubrication Food-safe lubricant, e.g. Berusynth CB 180 H1 oil (part no. 678 645 39)
Tab. 61

Use of HS7 special chain in foundries, fettling shops or other environments with high dust levels:
● We recommend that the chain be lubricated with a dry lubricant, e.g. Cettaplyn 300 Paste (part no.
665 022 44).
● The chain can also be used dry. Without any lubrication, however, greatly increased wear and louder operat‐
ing noise in the chain drive must be expected.
● The chain must not be lubricated with normal grease in environments with high dust levels, as the grease
will form clumps and any chain wear will not be visible.
211 273 44/280823

30) For max. 25 - 50 cycles per day

31) For max. 10 cycles per day
32) For max. 12 - 25 cycles per day
33) For max. 5 cycles per day 89
 8.5.5.7 Replacing the chain set

1) 2)

3) 4)

43227444.eps

Fig. 58

There are different chain guide variants, the diagrams only show examples. The method to replace the chain set
is, however, largely the same. For details on the relevant chain guide type, refer to  "Chain guides until
03/2019 and from 04/2019", Page 95

WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
When the chain is replaced on DC 10–25 units that have 2/1 reeving, the anchorage pins and chain anchorages
must also always be replaced. They are included in the chain sets.
If a single chain is purchased by the metre, the anchorages must be separately ordered and installed, refer to
 "Chain drive", Page 138.
211 273 44/280823

Before starting any maintenance work, switch the hoist off and secure it against reconnection to the power supply.
To replace the chain set, proceed as follows:
– Open and remove service cover (1).
90
 – Place bag (2) with the control cable on the chain hoist; pull out mains cable union (3) with fitted mains cable
(4) and place to one side; if a travel drive is fitted, remove the connecting cable from the strain relief arrange‐
ment;
– Loosen cap (5) with a screwdriver (lever off);
– Remove chain collector box (6) and set it down ( "Remove chain collector box", Page 82);

1) 2)

3)

43227544.eps

Fig. 59

– Remove guide plate (7);

211 273 44/280823

91
 – Remove retaining ring (8) using ring pliers; either use straight or offset pliers (access through the opening in
the gearbox housing on the side of the motor or from the service enclosure);
DC 1 to 5: in the area of the power supply insert;
DC 10: fold cover (9) of the opening in the gearbox housing to the side.
– Remove chain guide (10) with the chain sprocket from the output shaft; to do this, slide the complete sub-
assembly in the direction of the motor until the chain sprocket is free; the worn chain set can then be
removed from the service enclosure.
Proceed in reverse order to install the new chain set.
Pay attention to the following points:

Chain hoist with geared limit switch

42792644_xml.eps

Fig. 60 (A) Chain guide for DC 10 without geared limit switch; (B) Chain guide for DC 10 with geared limit switch

The DC 10 chain guide has a larger opening on chain hoists that are equipped with a geared limit switch (units
made until 2012).

See also  "Chain drive", Page 138.

Output shaft spacer rings

● Ensure that the complete quantity of spacer rings is fitted on the out‐
put shaft when the chain guide is installed.

Item Designation
1 Cap
2 Retaining ring
3 Spacer ring DC-Pro 15 1 off
4 Chain guide
DC 1/2 3 off
DC 5 1 off
5 Spacer ring
DC 10 2 off
DC-Pro 15 2 off
Tab. 62

Apply Molykote or a similar lubricant to the splines of the

42776945_xml.eps
output shaft before you install the chain sprocket.
Fig. 61
211 273 44/280823

92
 Fitting the retaining ring

● The stamped burr of retaining ring (1) must face the motor. The re‐
taining ring is correctly installed if it can be easily turned on the out‐
1
put shaft after assembly.

DANGER
Danger of broken chain and falling load
An incorrectly installed chain can result in a broken
chain and falling loads.
When the chain is installed, ensure that it is introduced in
the same position and with the same alignment.
The chain must operate without any twist.

41058845_XML.eps

Fig. 62

Fitting the chain anchorage for 2/1 reeving on DC 10

41058846_XML.eps
Fig. 63

WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
When the chain is replaced on DC 10–25 units that have 2/1 reeving, the anchorage pins and chain anchorages
must also always be replaced. They are included in the chain sets.
If a single chain is purchased by the metre, the anchorages must be separately ordered and installed, refer to
 "Chain drive", Page 138.

● Fit the chain anchorage before bolting the guide plates into position for DC 10 hoists with 2/1 reeving. Bolt
chain anchorage halves (1) together (fig. A).
● Insert the bolted chain anchorage into the opening of the gearbox housing (fig. B).
● Fit pins (2) (the pins are retained by the fitted guide plates).
211 273 44/280823

93
 Fitting the chain anchorage for 2/1 reeving on DC 15

Fit the chain anchorage before bolting guide plate (4) into position for
DC-Pro 15 units with 2/1 reeving.
● When you remove the chain anchorage, only push both pins (1) far
enough out of the bore holes until the chain anchorage can be re‐
moved.
● Place the end of the chain between the two halves of chain anchor‐
age (3) and bolt them together with a tightening torque of 25 Nm.
● Insert the bolted chain anchorage into the opening of the gearbox
housing.
● Push both pins (1) completely back into the bore holes (the pins are
secured by the fitted guide plate).

Item Designation
1 Chain anchorage pin
2 Hexagon socket bolt for chain anchorage halves
3 Chain anchorage half
4 Guide plate
5 Hexagon socket bolt for guide plate
Tab. 63
42792544_xml.eps
Fig. 64

Fitting the limit stop

● Attach the limit stop to the 5th chain link at the dead (unloaded) end
of the chain; pay attention to the tightening torque, see  Tab. 64,
Page 95.
● If the chain hoist is operated with a replacement chain that is longer
than suitable for the standard capacity of the chain collector, an addi‐
tional limit stop must be fitted to the chain between the hook assem‐
bly and the buffer plate. The limit stop must be fitted in such a way
that the extra length of chain is positioned between the hook assem‐
bly and the limit stop. In this case, a geared limit switch is required
for DC 10 and DC 15 units with 2/1 reeving.

41058847_XML.eps

Fig. 65

Further procedure after replacing the chain set

If the chain has to be replaced because it has reached its wear limit, the return sprockets are usually also worn
and have to be replaced. For this reason, the condition of the return sprockets must be checked when the chain
is replaced. We recommend that the return sprocket should be replaced no later than every second time the
chain is replaced.

– Fit the hook assembly/bottom block  "Load hook", Page 100

– Lubricate the chain  "Available hoist chains", Page 88,  "Lubricating the hoist chain", Page 99
– Adjust the bottom hook position, if necessary  "Adjusting the lower hook position", Page 56.
– Fit chain collector box  "Remove chain collector box", Page 82.
– If the chain hoist is fitted with an optional geared limit switch, it must be re-adjusted each time the chain is
replaced, see "DC geared limit switch" document  Tab. 3, Page 8.
211 273 44/280823

94
 Tightening torques [Nm] DC 1/2 DC 5 DC 10 DC-Pro 15
Reeving 1/1 1/1 2/1 1/1 2/1
Service cover 5,5 7,5 25
Limit stop 4,0 4,3
Chain anchorage halves - - 10,5 - 25
Guide plate 5,0 5,5 9,5 15
Tab. 64

8.5.5.8 Chain guides until 03/2019 and from 04/2019

DC 1–2 chain guide until 03/2019

Item no. Designation

1 Chain guide
2 Chain entry plate
Tab. 65

43718744_xml.eps

Fig. 66
211 273 44/280823

95
 DC 1–2 chain guide from 04/2019

Item Designation
no.
1 Chain guide
2 Upper chain entry plate
3 Lower chain entry plate
Tab. 66
1

43718844_xml.eps

Fig. 67

DC 5 chain guide until 03/2019

Item Designation
no.
1 Chain guide
2 Intermediate plate
3 Chain entry plate
Tab. 67

43718944_xml.eps

Fig. 68
211 273 44/280823

96
 DC 5 chain guide from 04/2019

Item Designation
no.
1 Chain guide
2 Upper chain entry plate
3 Lower chain entry plate
1 Tab. 68

43719044_xml.eps

Fig. 69

DC 10 chain guide until 03/2019

Item Designation
no.
1 Chain guide
2 Intermediate plate
3 Upper chain entry plate
4 Lower chain entry plate
Tab. 69

43719144_xml.eps

Fig. 70
211 273 44/280823

97
 DC 10 chain guide from 04/2019

Item Designation
no.
1 Chain guide
1
2 Upper chain entry plate
3 Lower chain entry plate
Tab. 70

43719244_xml.eps

Fig. 71

DC 15 chain guide

Item no. Designation

1 Chain guide
2 Chain entry plate
Tab. 71

43762244_xml.eps

Fig. 72
211 273 44/280823

98
 8.5.5.9 Lubricating the hoist chain
After fitting, before a test load is lifted and before the hoist is put into operation as well as during normal opera‐
tion when no load is attached, the chain link contact areas of hoist chains must be lubricated with gear grease,
part no. 665 009 44.

The chain link contact areas must be re-lubricated appropriately – after being cleaned – at intervals depending on
the service and load conditions. A dry film lubricant (lubricating varnish) should be used in environments where
abrasives occur (emery, sand, etc.). For non-standard lubrication, see  "Available hoist chains", Page 88.

WARNING
Premature wear of the chain.
Danger of falling load due to broken chain.
The chain must be lubricated along its entire length.
Even chain links which are covered, e.g. in the chain anchorage, hook assembly, limit stop or crab frame, must
be fully lubricated.

DC 1 to 10 chain hoist

Cut off the tip of the grease tube and insert the grease tube at the lubri‐
cation point. Insert grease into the chain guide by pressing the tube
while you run the chain to its end positions to ensure complete and
even lubrication of the chain.

42650744_XML.eps
Fig. 73

DC-Pro 15 chain hoist

Apply the lubricant with a brush.

211 273 44/280823

41059444_xml.eps
Fig. 74

99
 8.5.6 Load hook
8.5.6.1 Checking the load hook

A) B)

L2
a2
L4
a2
L4

b1
b1

h2
h2

a1 h1 a1 h1
43229246_xml.eps

Fig. 75

Chain hoist DC 1 - 15 (from 12/2017) DC-Pro/Com DC-Com (old)

Item A Item B Item B
320
Load capacity [kg] 315 630 1250 1600 125 250 500 1250 2500 1600 125 250 500 1250 2000
0
Size 1-2 5 10 15 1 2 5 10 15 1 2 5 10
Reeving 1/1 1/1 2/1 1/1 2/1 1/1 2/1
Load hook Type V-I V-II V-III V-IV V2 V3 V4 V5 V5 V6 T010 T020 T04 V5
a1 [mm] 30 36 43 50 30 36 43 50 50 56 28 34 40 50
a2Nom 34) [mm] 23,5 26,7 36 43 25,3 30,5 36 43 43 49 22,8 25,4 33,7 43
a2max [mm] 25,6 29,6 39,6 47,3 27,8 33,5 39,6 47,3 47,3 53,9 25,08 27,94 37,07 47,3
b1 [mm] 13 19 22 29 13 19 22 29 29 30 16 21 27 29
Dimen‐
h1 [mm] 22 27,5 33,5 44 22 27,5 33,5 44 44 55 20 26,1 34 44
sions
h2Nom 35) [mm] 18 21,5 26 36 18 21,5 27 36 36 38 16,9 21,8 27,7 36
h2min [mm] 17,1 20,4 24,7 34,2 17,1 20,4 25,7 34,2 34,2 36,1 16,055 20,71 26,315 34,2
L2 [mm] 14 14 20 45 22 30 36 45 45 56 20 24 28 45
L4 [mm] 84 95 115 159 86 109 110 159 159 187 82 94 116 159
Max. test force [kN] 8 16 25 50 8 16 25 50 50 65 6 13 25 50
Tab. 72

8.5.6.2 DC-Pro hook safety catch

If the hook safety catch has to be replaced, turn the nut on the bolt until at least two turns of the thread can be
seen on the other side of the nut. The bolted connection must only be tightened enough to allow the hook safety
catch to move freely.

8.5.6.3 Checking the return sprocket

The return sprocket must be checked every month to ensure that it turns easily. To do this, any load bars attach‐
ed to the bottom block have to be removed.
Check to ensure that the bottom block moves easily during lifting and lowering motions. Abrupt movements of the
bottom block indicate wear.
We recommend that the return sprocket should be replaced every second time the chain is replaced.
211 273 44/280823

34) Permissible difference +10%

100 35) Permissible difference -5%
 8.5.6.4 Replacing DC 1 - 15 hook assembly (from 12/2017)

2
3
4

8 9

5
6
10 9 7

43702944_xml.eps

Fig. 76

Item Designation Item Designation Item Designation

1 Hoist chain 5 Chain link anchorage section 8 Hook assembly half
2 Hook assembly sleeve 6 O-ring 9 Hook assembly bolted connection
3 Ball thrust bearing 7 Load hook 10 Capacity plate
4 Supporting washer
Tab. 73

DANGER
Load can fall
Incorrect assembly can cause loads to be dropped.
Ensure that the parts are fitted in the right order and orientation when they are installed.

Pay attention to the non-standard lubrication instructions for special ambient conditions or special chains, e.g.
stainless steel chain or foodstuffs sector. See also  "Available hoist chains", Page 88.

– Thread hook assembly sleeve (2), ball thrust bearing (3) and supporting washer (4) onto hoist chain (1) in
the correct order and orientation.
– Grease the end of the chain with the enclosed grease.
– Place the last chain link of hoist chain (1) into chain link anchorage sections (5) and position them with their
tabs in the recesses of supporting washer (4).
211 273 44/280823

– Install O-ring (6) over the tabs at the top of load hook (7). The O-ring acts as a shock absorber.
– Fill one hook assembly half (8) with the enclosed grease.

101
 – Now place hoist chain (1) with hook assembly sleeve (2), ball thrust bearing (3), supporting washer (4) and
chain link anchorage sections (5) into hook assembly half (8).
– Position load hook (7) with O-ring (6) below them.
– Fit hook assembly bolted connection (9) and tighten it to the correct tightening torque.

Tightening torques [Nm] DC-Pro 1 DC-Pro 2 DC-Pro 5 DC-Pro 10

Hook assembly 11,5 25,0
Tab. 74

8.5.6.5 Replacing DC 15 – 25 hook with fittings (as of 2018)

43708044_xml.eps

Fig. 77

Item Designation Item Designation Item Designation

1 Hoist chain 4 Supporting washer 7 Hook assembly half
2 Hook assembly sleeve 5 Chain link anchorage section 8 Hook assembly bolted connection
3 Ball thrust bearing 6 Load hook 9 Capacity plate
Tab. 75

DANGER
Load can fall
Incorrect assembly can cause loads to be dropped.
Ensure that the parts are fitted in the right order and orientation when they are installed.

Pay attention to the non-standard lubrication instructions for special ambient conditions or special chains, e.g.
211 273 44/280823

stainless steel chain or foodstuffs sector. See also  "Available hoist chains", Page 88.

– Thread hook assembly sleeve (2), ball thrust bearing (3) and supporting washer (4) onto hoist chain (1) in
the correct order and orientation.
102
 – Grease the end of the chain with the enclosed grease.
– Place the last chain link of hoist chain (1) into chain link anchorage sections (5) and position them with their
tabs in the recesses of supporting washer (4).
– Install O-ring (6) over the tabs at the top of load hook (7). The O-ring acts as a shock absorber.
– Fill one hook assembly half (8) with the enclosed grease.
– Now place hoist chain (1) with hook assembly sleeve (2), ball thrust bearing (3), supporting washer (4) and
chain link anchorage sections (5) into hook assembly half (8).
– Position load hook (7) with O-ring (6) below them.
– Fit hook assembly bolted connection (9) and tighten it to the correct tightening torque.

Tightening torques [Nm] DC -Pro 15 DC Pro 16 DC Pro 25

Hook assembly 51
Tab. 76
211 273 44/280823

103
 8.5.6.6 Replacing DC-Pro hook assembly for 1/1 reeving

1. 2.

1 2 1

3. 4.

4
43227344.eps

Fig. 78

WARNING
Premature wear of the chain.
Danger of falling load due to broken chain.
The chain must be lubricated along its entire length.
Even chain links which are covered, e.g. in the chain anchorage, hook assembly, limit stop or crab frame, must
be fully lubricated.

1. Remove both bolts from the new hook.

Lever buffer cap (1) off with a screwdriver.
2. Remove the upper half of the hook assembly.
Slide buffer cap (1) onto the chain.
Remove chain link anchorage sections (2) from the load hook and place them around the last chain link.
211 273 44/280823

Grease the last chain link in the chain link anchorage section.

104
 3. Insert the chain and chain link anchorage sections (2) in the new hook and fit upper half of hook assem‐
bly (3). Ensure that locating pins (4) are correctly positioned.
4. Tighten the housing bolts according to the tightening torque table.

Tightening torques [Nm] DC-Pro 1 DC-Pro 2 DC-Pro 5 DC-Pro 10 DC-Pro 15

Hook assembly 6,8 11,5 25,0 27,5
Tab. 77

8.5.6.7 Replacing DC-Com hook assembly for 1/1 reeving

42768245_xml.eps

Fig. 79

– Remove the existing hook.

Remove both bolts (4) from the new hook.
Remove the upper half of the hook assembly.

DANGER
Load can fall
Incorrect assembly can cause loads to be dropped.
During assembly, ensure:
– that chain link sections (1) are positioned with their collar in bearing (2). Grease the bearing and bearing
seat.
– that retaining pin (3) is correctly fitted when the hook with fittings is assembled.

– Tighten housing bolts (4) according to the tightening torque table.

Tightening torques [Nm] DC-Com 1 DC-Com 2 DC-Com 5 DC-Com 10

211 273 44/280823

Hook assembly 6,8 9,5 25,0

Tab. 78

105
 8.5.6.8 Replacing bottom block with external cut-off springs, 2/1 reeving

43217444_xml.eps

Fig. 80

Tightening torques [Nm] DC 10/DC-Pro 15

Bottom block with external cut-off springs 55,0
Tab. 79

8.5.7 Buffers/cut-off springs

8.5.7.1 Check cut-off buffer/cut-off spring

1 2 3

42775146_XML.eps
Fig. 81 Examples of wear

1. Buffer wear:
Visually check the buffers in the course of the annual inspection. Check for damage, cracks and tears.
2. Missing buffer plate:
Ensure that the component parts are installed in the right order when new buffers are installed (see also
 "Buffer/cut-off spring arrangement 10/2014 until 10/2018", Page 107). A missing buffer plate, for example,
will result in premature wear of buffers.
3. Wear of external cut-off springs:
Visually check the external cut-off springs in the course of the annual inspection. Check the sleeves of the
springs for cracks and damage. The individual windings of the spring must not cross over each other.
211 273 44/280823

106
 8.5.7.2 Buffer/cut-off spring arrangement 10/2014 until 10/2018

42770450_xml.eps

Fig. 82 Cut-off buffer (1), buffer plate (2), damping plate (3), cut-off spring (4)

The cut-off springs must be replaced on 60 Hz chain hoists that have operating limit switches:
● V8 spring ➔ V16 spring;
● V6 spring ➔ V12 spring.

Product range Size Reeving Lifting speed Switches Plate dia. d1/ Height Load hook side Chain collector box
36)36)36)36) 37)37)37)37) fitted dia. d2 h side
38)38)38)38)
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
1+2 V8 45 A 718 255 45 M
DC-Pro/DC-ProCC 1BES 45/42
2 V16 80 B 718 256 45 N
717 253 45
1+2 V8 M M
DCM-Pro 1BES 717 253 45
2 V16 N N
1 V8
0BES F 717 534 45 O 717 534 45
2 V6
DC-Com 1/1
1 V8
1BES
2 V6
45/42 45 A 718 255 45
1 VS30
DCS-Pro 1BES M 717 253 45
2 VS16
DCMS-Pro; 1 VS30
1BES M 717 253 45
DCRS-Pro 2 VS16
211 273 44/280823

36) LDC:buffers as for DC; KLDC: buffers as for KDC; KDC-ProDC: no buffers, since they are always fitted with GGS geared limit switches.
37) Lifting
speed: V = 2-stage speed at 50 Hz, VS = variable speed at vsnom.
38) 0BES = no operating limit switch, 1BES = operating limit switch fitted, GGS = geared limit switch fitted. 107
 Product range Size Reeving Lifting speed Switches Plate dia. d1/ Height Load hook side Chain collector box
36)36)36)36) 37)37)37)37) fitted dia. d2 h side
38)38)38)38)
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
0BES G 717 534 45 P
DC-ProFC 1+2 VS16
GGS
0BES G 717 534 45
1+2 V8 1BES 45/45 79,5 E 717 250 45
717 534 45
GGS O
DC-ProDC
0BES G 717 534 45
2 V16 1BES 45/45 79,5 E 717 250 45
GGS
DC-Pro; DC-ProCC V8 45 A 718 255 45 M
V16 1BES 45/42 80 B 718 256 45 N
DC-Pro; DC-ProCC
V24 130 C 718 249 45 M 718 253 45
V16 N 718 253 45 N
DCM-Pro 1BES
V24 45/42 130 C 718 249 45 M
1/1
0BES F 718 534 45 O 718 534 45
DC-Com V4,5
1BES
45/42 45 A 718 255 45 M 751 253 45
DCS-Pro VS8 1BES
DC 5
0BES G 718 534 45 P
DC-ProFC VS8
GGS
0BES 55 G 718 534 45 718 534 45
O
V8/V16 1BES 45/45 79,5 E 718 250 45
DC-ProDC GGS
0BES/1BES 45/42 130 C 718 249 45 M 718 253 45
V24
GGS O 718 534 45
KDC-Pro/KDCS-Pro V8/VS8 45 A 718 255 45 M
KDC-Pro V16 80 B 718 256 45 N
1BES 45/42 718 253 45
KDC-Com V4,5 45 A 718 255 45 M
KDC-Pro/KDCS-Pro 2/1 V4/VS4 80 B 718 256 45 N

211 273 44/280823

36) LDC:buffers as for DC; KLDC: buffers as for KDC; KDC-ProDC: no buffers, since they are always fitted with GGS geared limit switches.
37) Lifting
speed: V = 2-stage speed at 50 Hz, VS = variable speed at vsnom.
108 38) 0BES = no operating limit switch, 1BES = operating limit switch fitted, GGS = geared limit switch fitted.
 Product range Size Reeving Lifting speed Switches Plate dia. d1/ Height Load hook side Chain collector box
36)36)36)36) 37)37)37)37) fitted dia. d2 h side
38)38)38)38)
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
V6 43 D 715 260 45
M
V8 55 A 715 254 45 715 253 45
DC-Pro/DC-ProCC 1BES 52/55
V12 74 B 715 255 45 N
V24 125 C 715 249 45
O 715 534 45
0BES F 715 53445
DC-Com V4
1BES 52/55 43 D 715 260 45
M 715 253 45
DCS-Pro VS4/VS6/VS12 1BES 52/55 55 A 715 254 45
0BES G 715 534 45 P
DC-ProFC VS4/VS6/VS12
1/1 GGS
0BES G 715 534 45
V6/V8/V12/V24 715 534 45
GGS O
DC-ProDC
V6/V8/V12 E
81,2 715 074 45
V24 2x E
V6 43 D 715 260 45
KDC-Pro DC 10 M 715 253 45
V12 55 A 715 254 45
KDC-Com V4
43 D 715 260 45 M
KDCS-Pro VS6/VS12 1BES
52/55
DC-Pro; DC-ProCC; 55 715 254 45 M
V4
DC-Com K 7152 253 45
DC-Pro; DC-ProCC V6 74 715 255 45 N
VS4 55 H 715 254 45 M
DCS-Pro
VS6 74 I 715 255 45 N
2/1 0BES 81,2 J 715 074 45 P
DC-ProFC VS4/VS6 715 534 45
GGS O
GGS 55 H 715 254 45
DC-ProDC V4/V6 O 715 534 45
0BES/1BES 81,2 J 715 074 45
KDC-Pro; KDCS-Pro V6/VS6 74 I 715 255 45 N
715 253 45
KDC-Com V4 H 715 254 45 M
1/1 V8 1BES 62/55 A
DC-Pro; DC-ProCC
2/1 V4 55 L
721 753 45
DCS-Pro
A Q 721 753 45
1/1 VS8 0BES
DC-ProFC
GGS
DCS-Pro VS4 1BES
DC15 62/55 55 L 721 753 45
2/1 0BES
DC-ProFC VS4
GGS
GGS
1/1 V8 2xQ 721 753 45
0BES/1BES 62/55 55 2xA 721 753 45
DC-ProDC
GGS
2/1 V4
0BES/1BES 62/55 55 L 721 753 45
Tab. 80
211 273 44/280823

36) LDC:buffers as for DC; KLDC: buffers as for KDC; KDC-ProDC: no buffers, since they are always fitted with GGS geared limit switches.
37) Lifting
speed: V = 2-stage speed at 50 Hz, VS = variable speed at vsnom.
38) 0BES = no operating limit switch, 1BES = operating limit switch fitted, GGS = geared limit switch fitted. 109
 8.5.7.3 Buffer/cut-off spring arrangement from 11/2018 until 03/2020

A, B, C, F G H, I, J, K L M N O P Q
D, E

1
d1

2
4
3

h
d2

43716544_xml.eps

Fig. 83 Cut-off buffer (1), buffer plate (2), damping plate (3), cut-off spring (4)

The cut-off springs must be replaced on 60 Hz chain hoists that have operating limit switches:
● V8 spring ➔ V16 spring;
● V6 spring ➔ V12 spring.

Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
1+2 V8 45 A 718 255 45 M
DC-Pro/DC-ProCC 1BES 45/42
2 V16 80 B 718 256 45 N
751 253 45
1+2 V8 M M
DCM-Pro 1BES 751 253 45
2 V16 N N
1 V8
0BES F 717 534 45 O 717 534 45
2 V6
DC-Com 1/1
1 V8
1BES
2 V6
45/42 45 A 718 255 45
1 VS30
DCS-Pro 1BES M 751 253 45
2 VS16
DCMS-Pro; 1 VS30
1BES M 751 253 45
DCRS-Pro 2 VS16
211 273 44/280823

110
 Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
0BES G 717 534 45 P
DC-ProFC 1+2 VS16
GGS
0BES G 717 534 45
1+2 V8 1BES 45/45 79,5 E 717 250 45
717 534 45
GGS O
DC-ProDC
0BES G 717 534 45
2 V16 1BES 45/45 79,5 E 717 250 45
GGS
DC-Pro; DC-ProCC V8 45 A 718 255 45 M
V16 1BES 45/42 80 B 718 256 45 N
DC-Pro; DC-ProCC
V24 130 C 718 249 45 M 751 253 45
V16 N 751 253 45 N
DCM-Pro 1BES
V24 45/42 130 C 718 249 45 M
1/1
0BES F 718 534 45 O 718 534 45
DC-Com V4,5
1BES
45/42 45 A 718 255 45 M 751 253 45
DCS-Pro VS8 1BES
DC 5
0BES G 718 534 45 P
DC-ProFC VS8
GGS
0BES 55 G 718 534 45 718 534 45
O
V8/V16 1BES 45/45 79,5 E 718 250 45
DC-ProDC GGS
0BES/1BES 45/42 130 C 718 249 45 M 751 253 45
V24
GGS O 718 534 45
KDC-Pro/KDCS-Pro V8/VS8 45 A 718 255 45 M
KDC-Pro V16 80 B 718 256 45 N
1BES 45/42 751 253 45
KDC-Com V4,5 45 A 718 255 45 M
KDC-Pro/KDCS-Pro 2/1 V4/VS4 80 B 718 256 45 N
211 273 44/280823

111
 Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
V6 43 D 715 260 45
M 752 253
V8 55 A 715 254 45
DC-Pro/DC-ProCC 1BES 52/55 4539)39)39)
V12 74 B 715 255 45 N
V24 125 C 715 249 45
O 715 534 45
0BES F 715 53445
DC-Com V4
1BES 52/55 43 D 715 260 45
M 752 253 45
DCS-Pro VS4/VS6/VS12 1BES 52/55 55 A 715 254 45
0BES G 715 534 45 P
DC-ProFC VS4/VS6/VS12
1/1 GGS
0BES G 715 534 45
V6/V8/V12/V24 715 534 45
GGS O
DC-ProDC
V6/V8/V12 E
81,2 715 074 45
V24 2x E
V6 43 D 715 260 45
KDC-Pro DC 10 M 752 253 45
V12 55 A 715 254 45
KDC-Com V4
43 D 715 260 45 M
KDCS-Pro VS6/VS12 1BES
52/55
DC-Pro; DC-ProCC; 55 715 254 45 M
V4
DC-Com K 752 253 45
DC-Pro; DC-ProCC V6 74 715 255 45 N
VS4 55 H 715 254 45 M
DCS-Pro
VS6 74 I 715 255 45 N
2/1 0BES 81,2 J 715 074 45 P
DC-ProFC VS4/VS6 715 534 45
GGS O
GGS 55 H 715 254 45
DC-ProDC V4/V6 O 715 534 45
0BES/1BES 81,2 J 715 074 45
KDC-Pro; KDCS-Pro V6/VS6 74 I 715 255 45 N
752 253 45
KDC-Com V4 H 715 254 45 M
1/1 V8 1BES 62/55 A
DC-Pro; DC-ProCC
2/1 V4 55 L
721 753 45
DCS-Pro
A Q 721 753 45
1/1 VS8 0BES
DC-ProFC
GGS
DCS-Pro VS4 1BES
DC15 62/55 55 L 721 753 45
2/1 0BES
DC-ProFC VS4
GGS
GGS
1/1 V8 2xQ 721 753 45
0BES/1BES 62/55 55 2xA 721 753 45
DC-ProDC
GGS
2/1 V4
0BES/1BES 62/55 55 L 721 753 45
Tab. 81
211 273 44/280823

112 39) DC 10 changed to new buffers in 11/2018

 8.5.7.4 Buffer/cut-off spring arrangement from 04/2020 until 03/2021

A, B, C, F G H, I, J, K L M N O P Q R
D, E

1
d1

2
4
3

h
d2

43716545_xml.eps

Fig. 84 Cut-off buffer (1), buffer plate (2), damping plate (3), cut-off spring (4)

The cut-off springs must be replaced on 60 Hz chain hoists that have operating limit switches:
● V8 spring ➔ V16 spring;
● V6 spring ➔ V12 spring.

Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
1+2 V8 45 A 718 255 45 M
DC-Pro/DC-ProCC 1BES 45/42
2 V16 80 B 718 256 45 N
751 253 45
1+2 V8 M
DCM-Pro 1BES R 718 260 45
2 V16 N
1 V8
0BES F 717 534 45 O 717 534 45
2 V6
DC-Com 1/1
1 V8
1BES
2 V6
45/42 45 A 718 255 45
1 VS30
DCS-Pro 1BES M 751 253 45
2 VS16
DCMS-Pro; 1 VS30
1BES R 718 260 45
DCRS-Pro 2 VS16
211 273 44/280823

113
 Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
0BES G 717 534 45 P
DC-ProFC 1+2 VS16
GGS
0BES G 717 534 45
1+2 V8 1BES 45/45 79,5 E 717 250 45
717 534 45
GGS O
DC-ProDC
0BES G 717 534 45
2 V16 1BES 45/45 79,5 E 717 250 45
GGS
DC-Pro; DC-ProCC V8 45 A 718 255 45 M
V16 1BES 45/42 80 B 718 256 45 N
DC-Pro; DC-ProCC
V24 130 C 718 249 45 M 751 253 45
V16 N
DCM-Pro 1BES R 718 260 45
V24 45/42 130 M
1/1
0BES F 718 534 45 O 718 534 45
DC-Com V4,5
1BES
45/42 45 A 718 255 45 M 751 253 45
DCS-Pro VS8 1BES
DC 5
0BES G 718 534 45 P
DC-ProFC VS8
GGS
0BES 55 G 718 534 45 718 534 45
O
V8/V16 1BES 45/45 79,5 E 718 250 45
DC-ProDC GGS
0BES/1BES 45/42 130 C 718 249 45 M 751 253 45
V24
GGS O 718 534 45
KDC-Pro/KDCS-Pro V8/VS8 45 A 718 255 45 M
KDC-Pro V16 80 B 718 256 45 N
1BES 45/42 751 253 45
KDC-Com V4,5 45 A 718 255 45 M
KDC-Pro/KDCS-Pro 2/1 V4/VS4 80 B 718 256 45 N

211 273 44/280823

114
 Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
V6 43 D 715 260 45
M 752 253
V8 55 A 715 254 45
DC-Pro/DC-ProCC 1BES 52/55 4539)
V12 74 B 715 255 45 N
V24 125 C 715 249 45
O 715 534 45
0BES F 715 53445
DC-Com V4
1BES 52/55 43 D 715 260 45
M 752 253 45
DCS-Pro VS4/VS6/VS12 1BES 52/55 55 A 715 254 45
0BES G 715 534 45 P
DC-ProFC VS4/VS6/VS12
1/1 GGS
0BES G 715 534 45
V6/V8/V12/V24 715 534 45
GGS O
DC-ProDC
V6/V8/V12 E
81,2 715 074 45
V24 2x E
V6 43 D 715 260 45
KDC-Pro DC 10 M 752 253 45
V12 55 A 715 254 45
KDC-Com V4
43 D 715 260 45 M
KDCS-Pro VS6/VS12 1BES
52/55
DC-Pro; DC-ProCC; 55 715 254 45 M
V4
DC-Com K 752 253 45
DC-Pro; DC-ProCC V6 74 715 255 45 N
VS4 55 H 715 254 45 M
DCS-Pro
VS6 74 I 715 255 45 N
2/1 0BES 81,2 J 715 074 45 P
DC-ProFC VS4/VS6 715 534 45
GGS O
GGS 55 H 715 254 45
DC-ProDC V4/V6 O 715 534 45
0BES/1BES 81,2 J 715 074 45
KDC-Pro; KDCS-Pro V6/VS6 74 I 715 255 45 N
752 253 45
KDC-Com V4 H 715 254 45 M
1/1 V8 1BES 62/55 A
DC-Pro; DC-ProCC
2/1 V4 55 L
721 753 45
DCS-Pro
A Q 721 753 45
1/1 VS8 0BES
DC-ProFC
GGS
DCS-Pro VS4 1BES
DC15 62/55 55 L 721 753 45
2/1 0BES
DC-ProFC VS4
GGS
GGS
1/1 V8 2xQ 721 753 45
0BES/1BES 62/55 55 2xA 721 753 45
DC-ProDC
GGS
2/1 V4
0BES/1BES 62/55 55 L 721 753 45
Tab. 82
211 273 44/280823

115
 8.5.7.5 Buffer/cut-off spring arrangement from 04/2021

A, B, C, F G H, I, J, K L M N O P Q R
D, E

1
d1

2
4
3

h
d2

43716545_xml.eps

Fig. 85 Cut-off buffer (1), buffer plate (2), damping plate (3), cut-off spring (4)

The cut-off springs must be replaced on 60 Hz chain hoists that have operating limit switches:
● V8 spring ➔ V16 spring;
● V6 spring ➔ V12 spring.

Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
1+2 V8 45 A 718 255 45 M
DC-Pro/DC-ProCC 1BES 45/42
2 V16 80 B 718 256 45 N
751 253 45
1+2 V8 M
DCM-Pro 1BES R 718 260 45
2 V16 N
1 V8
DC-Com 1/1 1BES
2 V6
45/42 45 A 718 255 45
1 VS30
DCS-Pro 1BES M 751 253 45
2 VS16
DCMS-Pro; 1 VS30
1BES R 718 260 45
DCRS-Pro 2 VS16
211 273 44/280823

116
 Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
0BES G 717 534 45 P
DC-ProFC 1+2 VS16
GGS
0BES G 717 534 45
1+2 V8 1BES 45/45 79,5 E 717 250 45
717 534 45
GGS O
DC-ProDC
0BES G 717 534 45
2 V16 1BES 45/45 79,5 E 717 250 45
GGS
DC-Pro; DC-ProCC V8 45 A 718 255 45 M
V16 1BES 45/42 80 B 718 256 45 N
DC-Pro; DC-ProCC
V24 130 C 718 249 45 M 751 253 45
V16 N
DCM-Pro 1BES R 718 260 45
1/1 V24 45/42 130 M
DC-Com 1BES
45/42 45 A 718 255 45 M 751 253 45
DCS-Pro VS8 1BES
DC 5 0BES G 718 534 45 P
DC-ProFC VS8
GGS
0BES 55 G 718 534 45 718 534 45
O
V8/V16 1BES 45/45 79,5 E 718 250 45
DC-ProDC GGS
0BES/1BES 45/42 130 C 718 249 45 M 751 253 45
V24
GGS O 718 534 45
KDC-Pro/KDCS-Pro V8/VS8 45 A 718 255 45 M
KDC-Pro V16 80 B 718 256 45 N
1BES 45/42 751 253 45
KDC-Com V4,5 45 A 718 255 45 M
KDC-Pro/KDCS-Pro 2/1 V4/VS4 80 B 718 256 45 N
211 273 44/280823

117
 Product range 36) Size Reeving Lifting speed 37) Switches Plate dia. d1/ Height Load hook side Chain collector box
fitted 38) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
V6 43 D 715 260 45
M 752 253
V8 55 A 715 254 45
DC-Pro/DC-ProCC 1BES 52/55 4539)
V12 74 B 715 255 45 N
V24 125 C 715 249 45 O 715 534 45
DC-Com 1BES 52/55 43 D 715 260 45
M 752 253 45
DCS-Pro VS4/VS6/VS12 1BES 52/55 55 A 715 254 45
0BES G 715 534 45 P
DC-ProFC VS4/VS6/VS12
GGS
1/1
0BES G 715 534 45
V6/V8/V12/V24 715 534 45
GGS O
DC-ProDC
V6/V8/V12 E
81,2 715 074 45
V24 2x E
V6 43 D 715 260 45
KDC-Pro M 752 253 45
DC 10 V12 55 A 715 254 45
KDC-Com V4
43 D 715 260 45 M
KDCS-Pro VS6/VS12 1BES
52/55
DC-Pro; DC-ProCC; 55 715 254 45 M
V4
DC-Com K 752 253 45
DC-Pro; DC-ProCC V6 74 715 255 45 N
VS4 55 H 715 254 45 M
DCS-Pro
VS6 74 I 715 255 45 N
2/1 0BES 81,2 J 715 074 45 P
DC-ProFC VS4/VS6 715 534 45
GGS O
GGS 55 H 715 254 45
DC-ProDC V4/V6 O 715 534 45
0BES/1BES 81,2 J 715 074 45
KDC-Pro; KDCS-Pro V6/VS6 74 I 715 255 45 N
752 253 45
KDC-Com V4 H 715 254 45 M
1/1 V8 1BES 62/55 A
DC-Pro; DC-ProCC
2/1 V4 55 L
721 753 45
DCS-Pro
A LQ 721 753 45
1/1 VS8 0BES
DC-ProFC
GGS
DCS-Pro VS4 1BES
DC15 62/55 55 L 721 753 45
2/1 0BES
DC-ProFC VS4
GGS
GGS
1/1 V8 2xQ 721 753 45
0BES/1BES 62/55 55 2xA 721 753 45
DC-ProDC
GGS
2/1 V4
0BES/1BES 62/55 55 L 721 753 45
Tab. 83

8.5.8 Brake

8.5.8.1 Brake assignment

Max. brake displace‐

Load capacity Chain hoist Reeving Motor size Brake Brake torque
ment
DC-Pro/DCS-
[kg] [mm] [Nm]
Pro
80 - 125 1
ZNK 71 B 8/2
80 - 250 2 BK03 3,8
80 - 500 5 1/1 ZNK 80 B 8/2
200 - 1000 ZNK 100 A 8/2 0,6
211 273 44/280823

315 - 1250 10
BK07 12
1250 - 2500 2/1 ZNK 100 B 8/2
1000 - 3200 15 1/1, 2/1
Tab. 84
118
 Max. brake displace‐
Load capacity Chain hoist Reeving Motor size Brake Brake torque
ment
[kg] DC-Com [mm] [Nm]
80 - 125 1
ZNK 71 B 8/2
160 - 250 2 BK03 3,8
1/1
315 - 500 5 ZNK 80 A 8/2 0,6
630 - 1000 ZNK 100 A 8/2
10 BK07 12
1250 - 2000 2/1 ZNK 100 B 8/2
Tab. 85

8.5.8.2 Check brake wear

1 2

42777044_xml.eps
Fig. 86

Check brake wear depending on the year of manufacture of your chain hoist.
Since 04/2009, brakes no longer need to be removed to measure brake wear. Brake wear is measured by the air
gap.
● Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching on
again.
● Open the electric equipment cover.
● Unscrew brake plug screw (1) from the brake.
● Check brake wear with feeler gauge (2) (see  "Brake assignment", Page 118).
● The brake must be replaced immediately as soon as the maximum brake displacement is reached (see
 "Brake assignment", Page 118).
● For brake displacement up to 0,5 mm, the brake can still be used until the next maintenance is due.
211 273 44/280823

119
 Assembly and maintenance

42791644_xml.eps

Fig. 87

When the brake is installed, make sure that the area of V sealing ring (1) on the brake base is lightly greased.
Ensure that no grease penetrates inside the brake. The continuous sealing lip must be in full contact with the
back of the brake.

In the course of the annual inspection, V sealing ring (1) of the brake must be re-greased with anti-friction
bearing grease without any solid lubricant.

Tightening torques [Nm] DC 1/2/5/10/15

Brake 5,5
Electric equipment cover 9,5
Tab. 86

8.5.9 Slipping clutch

8.5.9.1 Checking the slipping clutch

The slipping clutch provides the function of an emergency limit stop de‐
vice and overload protection for the chain hoist.
The slipping clutch is initially adjusted in the factory. Under normal op‐
erating conditions, the slipping clutch does not need to be re-adjusted.
The slipping clutch is maintenance-free for up to 10 years. The slipping
clutch must be checked as part of the annual inspection.
The slipping clutch may only be adjusted by authorised specialist per‐
sonnel. An increase of the tripping torque which exceeds the default
setting is not permitted.
Check operation of the slipping clutch as follows:
● The chain collector must be disconnected in order to remove the limit
stop,  "Remove chain collector box", Page 82. Remove the limit
stop  Fig. 65, Page 94 from the section of chain which is not under
load and fit it above the hook assembly. Run the limit stop against
the guide plate at creep lifting speed. The operating limit switches
42657644_XML.eps must not be actuated while this is being done.
Fig. 88

If the slipping clutch is working correctly, the following will be observed:

● the hoist motor fan is still turning while there is no lifting motion;
● The 7-segment display shows the SLIP LIFTING V1 warning message,  "Warning messages", Page 130.

When the slipping clutch function has been checked, the limit stop must be fitted again to the section of chain
which is not under load.
211 273 44/280823

120
 8.5.9.2 Adjusting the slipping clutch

The slipping clutch is adjusted to the load capacity of the chain hoist
during the final inspection in the factory. An increase of the tripping tor‐
que which exceeds the default setting is not permitted, see also
 "Suspending the chain hoist", Page 42.
For DC chain hoists that have a load capacity ≥ 1000 kg, the setting
1 meets the requirements of EN 14492-2 for slipping clutches used as
overload protection. Overload protection must be provided for load ca‐
pacities ≥ 1000 kg.
If an acceptance check of the hoist or crane installation is carried out, a
load of 110% of the rated load capacity must be lifted (without adjust‐
ment of the slipping clutch) as part of the dynamic overload test. A load
> 160% must not be lifted, (EN 14492-2 "Direct acting rated capacity
limiters").
42657745_XML.eps
Fig. 89

The slipping clutch is protected against overload by slip monitoring, which means that it does not have to re-ad‐
justed until a general overhaul is carried out. A friction force checking device,  part no. 836 708 44, must be
used if adjustment needs to be checked owing to the operating conditions or due to malfunctions. Inspection and
adjustment may only be carried out by an experienced technician in compliance with the "Friction force checking
device" document  Tab. 3, Page 8.

8.5.10 Gear oil change

Fig. 90

Chain hoist size DC 1/2 DC 5 DC 10 DC-Pro 15

Oil quantities [l] 0,35 0,50 0,90 1,3
Gearbox cover [Nm] 5,5 -
2-piece gearbox housing [Nm] - 25
Tightening torques
Oil fill opening and breather M16 [Nm] - 15
Service cover [Nm] 5,5 7,5 25
Tab. 87

Dispose of waste oil in accordance with environmental protection requirements.

Oil lubrication
211 273 44/280823

Under normal operating conditions, the lubricant must be changed at least every 10 years. Under exceptional
conditions, e.g. increased ambient temperatures, we recommend that oil changes be adapted to suit these oper‐
ating conditions.

121
 Oil grade
Shell Donax TD 10W-30 universal gear oil with wear-minimising additives, range of viscosity 10W-30. Contact the
manufacturer for ambient temperatures lower than -20 °C or higher than + 45 °C.

CAUTION
Safe operation cannot be ensured
Malfunctions of the slipping clutch may occur if oils are used that are not approved and safe operation can then
no longer be ensured.
For oil part no. depending on the year of manufacture of the chain hoist, see  "Parts on the DC 1-15 gearbox",
Page 134.

Product range DC-Pro DC-ProDC Viscosity Part no.

DCS-Pro DC-ProCC range
DC-Com
DC-ProFC
Frequency [Hz] 50/60 50 60
 "Parts on the DC 1-15 gearbox", Page 134,
1 1 -
Standard  "Parts on the DC-Pro 15 gearbox", Page 136
Application, e.g.
- - 2 10W-30 664 020 44
Foodstuffs sector 3 3 3 180 003 98
Tab. 88

Instructions for gear oil change

– Drain the old oil at operating temperature.
– Turn the gearbox so that the oil drains.
– Flush with flushing oil. The flushing oil should have a viscosity of 46-68 mm2/s at rated temperature. The
quantity of flushing oil used should be approximately twice that specified for lubrication.
– Then flush the gears with this quantity of flushing oil by switching the hoist on and allowing the hook to run
several times over the entire length of its lifting path.
– Then drain the flushing oil and refill the gearbox with new oil. Please refer to the table above for the required
oil quantities.
DC 1 - 10: Remove the control unit with plug-and-socket connections (2) under electric equipment cover (3). Re‐
move the bolts of gearbox cover (1).
DC 15: First remove vent valve (4). 211 273 44/280823

122
 8.5.11 Replacing the contactor on the control board

2 3

C
B
B
A

42776847_XML.eps
Fig. 91

1. Unclip the contactor retaining mechanism by pressing locking tab (A) with your thumb. This carefully bends
locking tab (A) away from the contactor.
2. Then turn contactor (B) using your other hand until the mechanism no longer holds it.
3. Then unclip second locking tab (A) on the opposite side (as described in step 1 above).
4. Using your other hand, remove contactor (B) by pulling it away from the board.
The replacement contactor can only be inserted into the socket in one position. Push the contactor into contactor
211 273 44/280823

socket (C) until both locking tabs (A) click into position.

123
 8.5.12 Replacing the relay on the control board

1 2
D

B C

3 4

D D

C
C

43613744_XML.eps
Fig. 92 (A) Control board; (B) Contactor; (C) Relay; (D) Spring clip; (E) Screwdriver

1. Use screwdriver (E) to lever one side of spring clip (D) out of its retaining bracket.
2. Then unclip spring clip (D) on the other side.
3. Lift spring clip (D) up and off relays (C).
4. Relays (C) can now be removed from their bases.
If relays have to be replaced, please note the following:
● The contact pins of the new relays must not be bent.
● When new relays have been fitted on the control board, the spring clip must be installed from above. The tabs
of the spring clip must clip back into the correct position on the relay base. The spring clip must sit “tight”,
there must be no play between the top edge of the relays and the spring clip.

211 273 44/280823

124
 8.5.13 Replacing the control cable

43227844.eps

Fig. 93

1. Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching
on again.
211 273 44/280823

Open and disconnect the service cover.

2. Remove and open bag (1) with the control cable.
3. Take the control cable out of the bag.
125
 4. Turn and disconnect bayonet lock (2) and remove the control cable plug connector.
5. Unscrew electric equipment cover.
6. Loosen screw (3) on the control cable locking mechanism and remove the locking mechanism. Remove the
control cable.
Install the new control cable in reverse order.
It must be ensured that
● the groove on the connector fitting lines up with the swivel lock in the electric enclosure and
● that the two pins on the electric enclosure line up with the bayonet lock.

Assemble the pendant controller  "Connecting the controller", Page 36.

Adjust the height of the pendant controller  "Pendant controller height adjustment", Page 38.

Tightening torques [Nm] DC 1 DC 2 DC 5 DC 10 DC-Pro 15

Electric equipment cover 9,5
Service cover 5,5 7,5 25
Control cable locking mechanism 11,0
Tab. 89

211 273 44/280823

126
 9 Malfunctions/warnings

9.1 Safety instructions for malfunctions/warnings

WARNING
Incorrect fault elimination
Danger to life and limb. Risk of damage to the machine.
Faults may only be eliminated by authorised, trained specialist personnel ( "Definition of personnel", Page 10)
in compliance with the safety regulations.

DANGER
Live components
Danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐
nel", Page 10) in compliance with the safety regulations.
Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐
tected against unauthorised or accidental restoration of the power supply by means of a padlock.

WARNING
Risk of burns
Risk of burns from contact after the chain hoist has been in operation.
Do not touch hot motor housings. Allow the motor to cool down before eliminating the fault.

Conduct when malfunctions occur

1. Bring the machine to an immediate standstill by actuating the emergency stop without delay if malfunctions
occur that result in an immediate danger of personal injury, damage and/or an operating hazard.
2. Switch the chain hoist off at the mains connection or isolating switch and secure it against switching on
again.
3. Inform the person responsible at the operating location about the malfunction.
4. Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per‐
sonnel.

Conduct after a fault is eliminated

WARNING
Check for correct assembly
Before reconnecting the power supply, ensure that
– Malfunction and cause of malfunction have been eliminated.
– All safety devices have been fitted properly and are in perfect condition and working order.
– Nobody is present in the danger zone of the equipment.
211 273 44/280823

127
 9.2 7-segment display
The 7-segment display is located on the underside of the chain hoist behind a window.

Warning messages start with a lightning symbol.

Movement in the opposite direction is possible, the warning message
does not need to be acknowledged using the emergency stop.
43226544.eps
Fig. 94

Error messages start with an "E" for error.

Before any further movement is possible, the error message must be
acknowledged using the emergency stop.
43226644.eps
Fig. 95

Safety function failure

If a safety function fails, the equipment must not be operated until it is repaired.
Malfunctions
The chain hoist can only function when it is correctly connected to the power supply. Therefore, if a malfunction
occurs, first check cables, strain relief and power supply connections. Malfunctions can also be caused by incor‐
rect transmission of commands from the controller. Therefore, check the pendant controller and the control cable
for damage and the plug-in connector on the controller and in the service enclosure for correct fit.
The symbols are shown one after the other.
● Please contact our after-sales service if the cause of the fault cannot be eliminated with the given measures.

211 273 44/280823

128
 9.3 Operating statuses/general messages
1 2 3 4 5

6 7 8 9

10 11 12

432160A30_xml.eps

Fig. 96

Item Display Malfunction/event Possible cause Remark

1 No lifting, no lowering. No power supply (display is dark) Check mains connection and fuse link; check connection
cable for interruption; check mains connector in the service
enclosure. Check PE phase for correct connection.
2 No lifting, no lowering. Emergency stop actuated. Unlock emergency stop by turning it.
Connecting cables not connected or defective. Check and replace connections, as required.
Plug connections not connected or defective. Check and replace plug connections, as required.
3 No lifting, no lowering. When the voltage is switched on or the emergency- Release button and actuate it again.
stop is unlocked, a button is already actuated.
Control cable interrupted. Check connections of the control cable on the controller
and in the service enclosure. Check control cable for con‐
tinuity.
4 - - Operating status: Lifting V1
5 - - Operating status: Lowering V1
6 - - Operating status: Lifting V2
7 - - Operating status: Lowering V2
8 - - Operating status: Lifting start-up
9 - - Operating status: Lowering start-up
10 Upper limit position Upper limit switch actuated. Limit position reached. Lower.
reached. No lifting.
11 Lower limit position Lower limit switch actuated. Limit position reached. Lift.
reached. No lowering.
12 Button lock
No travel "Left" and "Right" buttons actuated simultaneously. Release buttons and press only one.
Invalid controller signals. Strong electric interference.
Tab. 90
211 273 44/280823

129
 9.4 Warning messages
In general, all warning messages are generated by comparison of the actual and theoretical speed. There may be
various causes for differences in speed:
● incorrectly adjusted slipping clutch;
● a binding brake or
● a dirty or defective speed sensor.
These causes can result in frequent warning messages. Various measures must be taken to eliminate the
warning messages:
- clean the speed sensor with compressed air (e.g. dirt accumulation on the photo cell);
- check and, if necessary, adjust the slipping clutch;
- check and, if necessary, adjust the brake air gap.

1 2 3 4 5

6 7 8 9

432160B19_xml.eps
Fig. 97 Display examples

Item Dis‐ Malfunction/event Possible cause Remark

play
1 .1. SLIP LIFTING start-up: No A mains phase is missing or the motor is blocked. Check mains connection and fuse link; check connection
lifting. cable for interruption; check mains connector in the service
No lifting with load. enclosure.
Chain hoist overloaded or undervoltage. Reduce load to the permissible load capacity. Ensure ap‐
propriate supply voltage.
2 .2. SLIP LIFTING V1: Cut-out Limit switch contact is no longer actuated. (-.) is displayed when the limit switches function correctly.
in the upper limit position. The slipping clutch acts as an emergency limit stop device
if there is a malfunction.
Connection and operation of the limit switch contact must
be inspected by an experienced technician.
3 .3. SLIP LIFTING V2: Cut-out Limit switch contact is no longer actuated. (-.) is displayed when the limit switches function correctly.
in the upper limit position. The slipping clutch acts as an emergency limit stop device
Fast lifting with load is if there is a malfunction.
switched off. Connection and operation of the limit switch contact must
be inspected by an experienced technician.
Chain hoist overloaded. Reduce load to the permissible load capacity.
4 .4. Defective internal data Defective control system. Replace control system.
memory.
6 .6. No speed information. Hardware monitoring malfunction. Repeat lifting process; if the load does not move, have the
brake and control system checked by an experienced tech‐
nician.
7 .7. SLIP LOWERING start-up: A mains phase is missing or the motor is blocked. Check mains connection and fuse link; check connection
No lowering. cable for interruption; check mains connector in the service
enclosure.
8 .8. SLIP LOWERING V1: Low‐ Chain blocked. Check chain entry point, replace chain, if required.
ering is switched off, lower Limit switch contact is no longer actuated. (-.) is displayed when the limit switches function correctly.
limit position is not The slipping clutch acts as an emergency limit stop device
reached. Cut-out in the if there is a malfunction.
lower limit position. Connection and operation of the limit switch contact must
be inspected by an experienced technician.
9 .9. SLIP LOWERING V2: Low‐ Chain blocked. Check chain entry point, replace chain, if required.
ering is switched off, lower Limit switch contact is no longer actuated. (-.) is displayed when the limit switches function correctly.
limit position is not The slipping clutch acts as an emergency limit stop device
reached. Cut-out in the if there is a malfunction.
lower limit position. Connection and operation of the limit switch contact must
be inspected by an experienced technician.
211 273 44/280823

Tab. 91

130
 9.5 Error messages
1 2 3 4 5

6 7 8 9

432160E19_xml.eps
Fig. 98 Display examples

Item Display Malfunction/event Possible cause Remark

1 E.1. Chain hoist is blocked. Hardware error of control system. Check error message by actuating and unlocking the emer‐
gency stop.
Then actuate Lowering. If necessary, remove suspended
load.
One phase is missing. Check the phases.
Defective electronic monitoring Replace hoist control system.
Defective “On/off” contactor Replace contactor,  "Replacing the contactor on the con‐
Contact wear trol board", Page 123

2 E.2. Chain hoist is blocked. Drive blocked. Check error message by actuating and unlocking the emer‐
gency stop.
Then actuate Lowering. If necessary, remove suspended
load.
Brake blocked. Check and, if necessary, replace the brake.
Speed measurement failure. Replace hoist control system.
3 E.3. Hoist unit: Overspeed or Lowering speed too high. Reduce load to the permissible load capacity. Check mains
load cannot be held. Low‐ connection and fuse link; check connection cable for inter‐
ering with load is switched ruption; check mains connector in the service enclosure.
off.
5 E.5. Chain hoist is blocked. Hardware error of control system. Check error message by actuating and unlocking the emer‐
gency stop.
Then actuate Lowering. If necessary, remove suspended
load.
K1 contactor sticking. Check and, if necessary, replace the K1 contactor.
Defective electronic monitoring. Replace hoist control system.
6 E.6. Chain hoist is blocked. Hardware error of control system. Check error message by actuating and unlocking the emer‐
gency stop.
Then actuate Lowering. If necessary, remove suspended
load.
Defective electronic monitoring. Replace hoist control system.
7 E.7. Hoist unit: incorrect direc‐ Direction of hoist unit cannot be switched. Check error message by actuating and unlocking the emer‐
tion of rotation; chain hoist gency stop.
is blocked. Then actuate Lowering. If necessary, remove suspended
load.
8 E.8. Lifting is switched off. Brake defective or slipping clutch incorrectly adjus‐ Check brake and slipping clutch.
ted. If there is no fault, replace electronics.
9 E.9.9. Chain hoist is blocked. Emergency-stop circuit of control system defective. Check error message by actuating and unlocking the emer‐
gency stop.
Then actuate Lowering. If necessary, remove suspended
load.
Replace hoist control system.
Tab. 92

Hardware faults are displayed with two characters by software version 1.60 and higher.
211 273 44/280823

131
 10 Disassembly/disposal

10.1 General

WARNING

Before disassembly, follow the safety instructions in  "Maintenance/repair", Page 68 of these operat‐
ing instructions.

Refer to  "Assembly", Page 32 of these operating instructions for information on removing rail sections, trolleys
and current collector trolleys. 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
regulations 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.

211 273 44/280823

132
 11 Spare parts

11.1 Motor

42763744_xml.eps
Fig. 99

Item no. Part no. Qty Designation

1 71785033 1 DC 2 fan set DC 1-2; ZNK 71
1 71885033 1 DC 5 fan set DC 5; ZNK 80
1 71585033 1 ZNK 100A fan set DC 10; ZNK 100A
1 71585133 1 ZNK 100B fan set DC 10-15; ZNK 100B
2 71784133 1 Motor set 240 V 50 Hz DC 1-2; 220-240 V 50 Hz
2 71784233 1 Motor set 415 V 50 Hz DC 1-2; 380-415 V 50 Hz
2 71784433 1 Motor set 525 V 50 Hz DC 1-2; 500-525 V 50 Hz; 575 V 60 Hz 40)
2 71784533 1 Motor set 460 V 60 Hz DC 1-2; 440-480 V 60 Hz 40)
2 71784633 1 Motor set 240 V 60 Hz DC 1-2; 220-240 V 60 Hz 40)
2 71784733 1 Motor set 380 V 60 Hz DC 1-2; 380-400 V 60 Hz
2 71884133 1 Motor set 240 V 50 Hz DC-Pro 5; 220-240 V 50 Hz
2 71884233 1 Motor set 415 V 50 Hz DC-Pro 5; 380-415 V 50 Hz
2 71884433 1 Motor set 525 V 50 Hz DC-Pro 5; 500-525 V 50 Hz; 575 V 60 Hz 40)
2 71884533 1 Motor set 460 V 60 Hz DC-Pro 5; 440-480 V 60 Hz 40)
2 71884633 1 Motor set 240 V 60 Hz DC-Pro 5; 220-240 V 60 Hz 40)
2 71884733 1 Motor set 380 V 60 Hz DC-Pro 5; 380-400 V 60 Hz
2 71867133 1 Motor set DC5 240 V 50 Hz 8/2 DC-Com 5; 220-240 V 50 Hz
2 71867233 1 Motor set DC5 415 V 50 Hz 8/2 DC-Com 5; 380-415 V 50 Hz
2 71867333 1 Motor set DC5 575V60Hz 8/2 DC-Com 5; 500-525 V 50 Hz; 575 V 60 Hz 40)
2 71867433 1 Motor set DC5 480 V 60 Hz 8/2 DC-Com 5; 440-480 V 60 Hz 40)
2 71867533 1 Motor set DC5 240 V 60 Hz 8/2 DC-Com 5; 220-240 V 60 Hz 40)
2 71867633 1 Motor set DC5 380 V 60 Hz 8/2 DC-Com 5; 380-400 V 60 Hz
2 71584133 1 Motor set 240 V 50 Hz A DC 10; 220-240 V 50 Hz
2 71584233 1 Motor set 415 V 50 Hz A DC 10; 380-415 V 50 Hz
2 71584433 1 Motor set 575 V 60 Hz A DC 10; 500-525 V 50 Hz; 575 V 60 Hz 40)
2 71584533 1 Motor set 460 V 60 Hz A DC 10; 440-480 V 60 Hz 40)
2 71584633 1 Motor set 240 V 60 Hz A DC 10; 220-240 V 60 Hz 40)
2 71584733 1 Motor set 380 V 60 Hz A DC 10; 380-400 V 60 Hz
2 71583233 1 Motor set DC10/16 B 50 Hz DC 10-15; 380-415 V 50 Hz
2 71583433 1 Motor set DC10/16 B 60 Hz DC 10-15; 500-525 V 50 Hz; 575 V 60 Hz 40)
2 71583533 1 Motor set DC10/16 B 60 Hz DC 10-15; 440-480 V 60 Hz 40)
2 71583733 1 Motor set DC10/16 B 60 Hz DC 10-15; 380-400 V 60 Hz
62 26564933 1 DC1/2 winding head cover
62 71821033 1 DC 5 winding head cover
211 273 44/280823

62 71521033 1 DC 10 winding head cover

Tab. 93

40) Incl. thermal contact. For other voltages, please specify in the order if a thermal contact is required. 133
 11.2 Parts on the DC 1-15 gearbox

211 273 44/280823

42763849_xml.eps
134 Fig. 100
 Item no. Part no. Qty Designation Material
3 71771533 1 DC-PRO 1V8/2 gearbox set DC-Pro 1; V8/2
3 71790533 1 DC-PRO 2V8/2 gearbox set DC-Pro 2; V8/2
3 71790633 1 DC-PRO 2V16/4 gearbox set DC-Pro 2; V16/4
3 71890833 1 DC-PRO 5V8/2 gearbox set DC-Pro 5; V8/2
3 71890933 1 DC-PRO 5V16/4 gearbox set DC-Pro 5; V16/4
3 71800933 1 DC5V3 gearbox set DC-Pro 5; V24/6
3 71590533 1 DC-PRO10V6/1,5 gearbox set DC-Pro 10; 1/1 reeving; V6/1,5
3 71590833 1 DC-PRO 10V8/2 gearbox set DC-Pro 10; 1/1 reeving; V8/2
3 71590633 1 DC-PRO10V12/3 gearbox set DC-Pro 10; 1/1 reeving; V12/3
3 71500933 1 DC-Pro10V24 gearbox DC-Pro 10; 1/1 reeving; V24/6
3 71590933 1 DC-PRO 10V4/1 gearbox set DC-Pro 10; 2/1 reeving; V4/1
3 71590733 1 DC-PRO10V6/1,5 gearbox set DC-Pro 10; 2/1 reeving; V6/1,5

3 71771533 1 DC-PRO 1 V8/2 gearbox set DC-Com 1; V8/2 manufactured from 2007
3 71774033 1 DC-Com 2 gearbox set DC-Com 2; V6/1,5 manufactured from 2007
3 71890433 1 DC-Com 5 gearbox set DC-Com 5; V4,5/1,1 manufactured from 2007
3 71570533 1 DC-COM 10 V4/1 gearbox set DC-Com 10; 1/1 reeving; V4/1
3 71570733 1 DC-COM 10 V4/1 gearbox set DC-Com 10; 2/1 reeving; V4/1

4 71897433 1 DC 1- 5 suspension set

4 71597433 1 DC 10 suspension set

5 75263133 1 DC1/2 seal set

5 75263233 1 DC 5 seal set
5 75263333 1 DC 10 seal set

6 71894733 1 Adjusting nut/pulse wheel DC 1-5

6 71594733 1 Adjusting nut/pulse wheel DC 10

7 71887133 1 180 V brake set DC 1-5; 380-415 V 50 Hz

7 71887233 1 216 V brake set DC 1-5; 440-480 V 60 Hz
7 71887333 1 DCS 1-5 104 V brake set DC 1-5; 220-240 V 50/60 Hz
7 71887433 1 258 V brake set DC 1-5; 500-525 V 50 Hz; 575 V 60 Hz
7 71587133 1 DC10/15 180/198 V brake set DC 10-15; 380-415 V 50 Hz; 440-480 V 60 Hz
7 71587333 1 DC/DCS10/15 brake set DC 10-15; 220-240 V 50/60 Hz
7 71587433 1 DC10/15 258 V brake set DC 10-15; 500-525 V 50 Hz; 575 V 60 Hz

8 71885633 1 Insert/connector

63 71511345 1 DC 10 cover plate kit

91 75260433 1 DC-Com1/2 gear oil set DC-Com 1-2 manufactured from 2004 to 2006; 0,35 litre Omala
91 75260533 1 DC-Com5 gear oil set DC-Com 5 manufactured from 2004 to 2006; 0,5 litre Omala
91 75260133 1 DC1/2 gear oil set 0,35 litre Donax
91 75260233 1 DC5 gear oil set 0,5 litre Donax
91 75260333 1 DC10 gear oil set 0,9 litre Donax

96 On request Coupling set

Tab. 94
211 273 44/280823

135
 11.3 Parts on the DC-Pro 15 gearbox

7 6

89

90

91 87

5, 89, 91

5, 6, 92 90

88

5, 6 6, 92 89

5
93

92

88
211 273 44/280823

88 89 86 5, 93 5
43425046_xml.eps
136 Fig. 101
 Item no. Part no. Qty Designation Material
4 72127433 1 DC16/25 suspension bracket
5 75263433 1 DC 15 seal set
6 71594733 1 Adjusting nut/pulse wheel DC 15
7 71587133 1 DC10/15 180/198 V brake set 380-415 V 50 Hz; 440-480 V 60 Hz
7 71587333 1 DC/DCS10/15 brake set 220-240 V 50/60 Hz
7 71587433 1 DC10/15 258 V brake set 500-525 V 50 Hz; 575 V 60 Hz
86 72160333 1 DC15 T1 gearbox housing
87 72160733 1 DC15 T2 gearbox housing
88 72191833 1 DC15 bearing set
89 72192033 1 DC 15 small parts set
90 71885633 1 Insert/connector
91 75261233 1 DC15 gear oil set 1,3 litres Donax
92 71519533 1 DC15 coupling half G
93 72163833 1 DC15 coupling half M
Tab. 95
211 273 44/280823

137
 11.4 Chain drive

15

19
17, 17a
211 273 44/280823

42764353_xml.eps
138 Fig. 102
 Item no. Part no. Qty Designation
11 71795033 1 DC/DCM 1/2 H 5 chain set
11 71795133 1 DC 1/2 H 8 chain set
11 75266533 1 DC1/2 H9-H12 chain set
11 75266633 1 DC1/2 H13-H15 chain set
11 75266733 1 DC1/2 H16-H18 chain set
11 75266833 1 DC1/2 H19-H25 chain set
11 75266933 1 DC1/2 H26-H35 chain set
11 71895033 1 DC/DCM 5 H 5 chain set
11 71895133 1 DC 5 H 8 chain set
11 75267033 1 DC5 H9-H12 chain set
11 75267133 1 DC5 H13-H16 chain set
11 75267233 1 DC5 H17-H20 chain set
11 75267333 1 DC5 H21-H27 chain set
11 75267433 1 DC5 H28-H35 chain set
11 75395033 1 DC10 1/1 H 5 chain set
11 75395133 1 DC10 1/1 H 8 chain set
11 75263733 1 DC 10 5 m 1/1 chain set for geared limit switch;  "Replacing the chain set", Page 90
11 75263833 1 DC 10 8 m 1/1 chain set for geared limit switch;  "Replacing the chain set", Page 90
11 75267533 1 DC10 1/1 H9-H10 chain set
11 75267733 1 DC10 1/1 H11-15 chain set
11 75268633 1 DC10 1/1 H16-20 chain set
11 75267833 1 DC10 1/1 H21-25 chain set
11 75267933 1 DC10 1/1 H26-30 chain set
11 75264933 1 DC15 1/1 H 4 chain set
11 75265633 1 DC15 1/1 H 5 chain set
11 75266133 1 DC15 1/1 H 6 chain set
11 75265733 1 DC15 1/1 H 8 chain set
12 71596033 1 DC10 2/1 H 5 chain set
12 71596133 1 DC10 2/1 H 8 chain set
12 75263933 1 DC 10 5 m 2/1 chain set for geared limit switch;  "Replacing the chain set", Page 90
12 75264033 1 DC 10 8 m 2/1 chain set for geared limit switch;  "Replacing the chain set", Page 90
12 75268033 1 DC10 2/1 H9-10 chain set
12 75268333 1 DC10 2/1 H11-15 chain set
12 75268433 1 DC10 2/1 H16-20 chain set
12 75268533 1 DC10 2/1 H21-25 chain set
12 75265033 1 DC15 2/1 H 4 chain set
12 75265833 1 DC15 2/1 H 5 chain set
12 75266233 1 DC15 2/1 H 6 chain set
12 75265933 1 DC15 2/1 H 8 chain set
13 71888033 1 Limit switch set DC 1-5
14 71588033 1 Limit switch set DC 10-15;  "DC 10 bottom block with external cut-off springs",
Page 147
15 71538845 1 DC 10 anchorage/limit stop kit DC 10; 2/1 reeving
15 72238845 1 DC 15 anchorage/limit stop kit DC 15; 2/1 reeving
16 Buffer/cut-off spring Part numbers  "Check cut-off buffer/cut-off spring", Page 106
17 71798633 1 DC1/2 5 m chain collector box set
17 71798733 1 DC1/2 8 m chain collector box set
17 71898633 1 DC5 5 m chain collector box set
17 71898733 1 DC5 8 m chain collector box set
17 71598633 1 DC10 1/1 5 m chain collector box set
17 71598733 1 DC10 1/1 8 m chain collector box set DC 10; 2/1 reeving; H5
17a41) 71535045 1 Flexible chain collector 20 m DC 10; 2/1 reeving; H8
17a41) 72119045 1 Chain collector kit DC16/25 for chain lengths 10 - 16 m
17a41) 72119145 1 Solo chain collector DC15/16/25 for chain lengths 18 - 26 m
17a41) 72135045 1 Flexible chain collector DC15/16 for chain lengths 27 - 40 m
211 273 44/280823

18 71719945 1 DC1/2 chain collector suspension kit

18 71819945 1 DC5 chain collector suspension kit

41) Suspension (18) is not included with chain collector 17a and must be ordered additionally. 139
 Item no. Part no. Qty Designation
18 71519945 1 DC10 chain collector suspension kit
18 72219945 1 DC15 chain collector suspension kit
75115646 Single chain by the metre DC1/2; 4,2 x 12,2 mm
19 83507844 1 Pilot section for 4 x 12 mm chain
75115746 Single chain by the metre DC5; 5,3 x 15,2 mm
19 83607844 1 Pilot section for 5 x 15 mm chain
75115846 Single chain by the metre, DC 10; 7,4 x 21,2 mm; Important:
When the chain is replaced on DC 10 units that have 2/1 reeving,
the chain anchorages and anchorage pins must also be replaced;
include chain anchorage set 715 279 33 with the order.
19 83707844 1 Pilot section for 7 x 21 mm chain
75115446 Single chain by the metre DC 15/16; 8,7 x 24,2 mm; Important:
When the chain is replaced on DC 15/16 units that have 2/1 reev‐
ing, the chain anchorages and anchorage pins must also be re‐
placed – include chain anchorage set 721 820 45 with the order.
71527933 1 Chain anchorage set DC10
72182045 1 Chain anchorage set DC15/16
Tab. 96

211 273 44/280823

140
 11.5 Chain guides
1 DC 1–2 chain guide

Item no. Part no. Qty Designation

Chain guide set
1 75318033 1
(incl. upper and lower chain entry plate)
not shown 75115646 1 4,2 x 12,2 mm chain
Tab. 97

43718845_xml.eps

Fig. 103

1 DC 5 chain guide

Item no. Part no. Qty Designation

Chain guide set
1 75318133 1
(incl. upper and lower chain entry plate)
not shown 75115746 1 5,3 x 15,2 mm chain
Tab. 98

43719045_xml.eps

Fig. 104
211 273 44/280823

141
 1 DC 10 chain guide

Item no. Part no. Qty Designation

Chain guide set
1 75318233 1
(incl. upper and lower chain entry plate)
not shown 75115846 1 7,4 x 21,2 mm chain
Tab. 99

43719245_xml.eps

Fig. 105

1 DC 15 chain guide

Item no. Part no. Qty Designation

Chain guide
1 721 660 33 1
(incl. chain entry plate and retaining ring)
Tab. 100

43762244a_xml.eps

Fig. 106
211 273 44/280823

142
 11.6 DC 1-15 hook assembly (from 12/2017)

18, 19 18, 19

18
19 18, 19
22
18, 19 20
18, 21

43702945_xml.eps

Fig. 107

Item no. Part no. Qty Designation

18 72340033 1 DC1/2 hook assembly set
18 72340133 1 DC 5 hook assembly set
18 72340233 1 DC 10 hook assembly set
18 72144133 1 DC 15 hook assembly set
19 75116033 1 DC1/2 hook assembly half set without hook
19 75116133 1 DC 5 hook assembly half set without hook
19 75116233 1 DC 10 hook assembly half set without hook
19 75259333 1 DC 15 hook assembly half set without hook
20 75043333 1 DC1/2 load hook set 315 kg 1Am
20 75143333 1 DC5 load hook set 630 kg 1Am
20 75243333 1 DC10 load hook set 1250 kg
20 72143333 1 DC15 load hook set 1600 kg
21 83565933 1 Hook safety catch set size 2 x 3 DC 1-2
21 83665933 1 Hook safety catch set size 3 x 3 DC 5
21 83765933 1 Hook safety catch set size 4 x 5 DC 10
21 83865633 1 Hook safety catch set size 5 x 3 DC 15
22 75262333 1 Load capacity plate set DK5, DC1-15
Tab. 101
211 273 44/280823

143
 11.7 DC 15-25 hook assembly (from 2018)

18, 19 18, 19

18
19
22 18, 19

18, 19 20
18, 21

18

43708045_xml.eps

Fig. 108

Item no. Part no. Qty Designation

18 72243033 1 DC 15/16 hook assembly set
18 72143033 1 DC 25 hook assembly set
19 75259333 1 DC 15/16 hook assembly half set without hook
19 75259433 1 DC 25 hook assembly half set without hook
20 72143333 1 DC 15 – 25 load hook set
21 83865633 1 DC 15 - 25 hook safety catch set Size 5 x 5
22 71391933 1 Neutral load capacity plate set
Tab. 102
211 273 44/280823

144
 11.8 DC-Pro hook assembly until 06/2018

18
19
27

18
19

18
19
22

18, 19 18, 20 18, 21 42764044_xml.eps

Fig. 109 (replaced by DC 1 – 10 hook assembly from 2017)

Item no. Part no. Qty Designation

18 71798033 1 DC1/2 hook assembly set
18 71898033 1 DC 5 hook assembly set
18 71598033 1 DC 10 hook assembly set
18 72144133 1 DC16/DK16 hook assembly DC 15
19 71728133 1 DC1/2 hook assembly half set without hook
19 71828133 1 DC 5 hook assembly half set without hook
19 71528133 1 DC 10 hook assembly half set without hook
19 72144533 1 DC16/DK16 1/1 hook assembly DC 15; without hook
27 71728145 1 DC 1/2 buffer cap DC 1-2
27 71828145 1 DC 5 buffer cap DC 5
27 71528145 1 DC 10 buffer cap DC 10
27 83875344 1 2,5 T buffer cap DC 15
20 83565033 1 Load hook set no. 2 400 kg DC 1-2
20 83665033 1 Load hook set no. 3 800 kg DC 5
20 83765033 1 Load hook set no.4 DC 10
20 83865033 1 DC16/25 DK10/20 load hook DC 15; size 5
21 83565933 1 Hook safety catch set size 2 DC 1-2
21 83665933 1 Size 3 x4 hook safety catch set DC 5
21 83765933 1 Hook safety catch set size 4 x5 DC 10
21 83865633 1 Hook safety catch set size 5 x5 DC 15
22 71724033 1 DC1/2 Pro load capacity plate set DC 1-2
22 71393433 1 DK5 1/1 load capacity plate set DC 5
22 83590833 1 DK10/DC10 load capacity plate set DC 10
22 72144933 1 DC16/DK16 1/1 load capacity plate set DC 15
211 273 44/280823

Tab. 103

145
 11.9 DC-Com hook assembly until 11/2017 (replaced by DC 1-15 hook assembly
from 12/2017)

M 1:4

18 18

18 18, 21 42764045_xml.eps

Fig. 110

Item no. Part no. Qty Designation

18 71778033 1 DC-Com 2 hook assembly set
18 71878033 1 DC-Com 5 hook assembly set
18 71578033 1 DC-Com10 hook assembly set
21 71851633 1 DC1-5 hook safety catch set
21 71551633 1 DC10 T04 hook safety catch set
Tab. 104
211 273 44/280823

146
 11.10 DC 10 bottom block with external cut-off springs

42764146_xml.eps

Fig. 111 A) Load side, B) Chain collector box side, 1) Limit switch actuator not included.

Item no. Part no. Qty Designation

71 75244033 1 DC10 2/1 bottom block set
72 75244133 1 DC10 2/1 bottom block half set
73 75244333 1 DC10 2/1 load hook
74 83865633 5 Hook safety catch set size 5 x5
75 75244533 1 DC10 2/1 return sprocket set
76 75242133 2 DC10 2/1 load capacity plate set 1,25 t
76 75242233 2 DC10 2/1 load capacity plate set 1,6 t
76 75242333 2 DC10 2/1 load capacity plate set 2,0 t
76 75242433 2 DC10 2/1 load capacity plate set 2,5 t
76 75242533 2 DC10 2/1 load capacity plate set 2750lbs
76 75242633 2 DC10 2/1 load capacity plate set 3500lbs
76 75242733 2 DC10 2/1 load capacity plate set 4400lbs
76 75242833 2 DC10 2/1 load capacity plate set 5500lbs
211 273 44/280823

77 71525445 1 DC 10V 8 cut-off spring V4 lifting speed for 2/1 reeving; 50 Hz

77 71525545 1 DC 10V12 cut-off spring V6 lifting speed for 2/1 reeving; 50 Hz
Tab. 105

147
 11.11 DC-Pro 15 bottom block with external cut-off springs

23, 24
27

24
23
34
24

23
24

22
24

21
22
24
42728048_xml.eps

Fig. 112

Item no. Part no. Qty Designation

21 82907733 1 Hook safety catch set size 6
22 82903433 1 DC16 DK16 2/1 load hook Size 6
23 72144633 1 DC16/DK16 2/1 bottom block set without hook; 42)
24 72144233 1 DC16/DK16 2/1 bottom block set. 42)

27 72175345 1 V8 cut-off spring accessories

34 72145033 1 DC16/DK16 2/1 load capacity plate
Tab. 106
211 273 44/280823

148 42) Buffer not for DC-Pro 15

 11.12 Electric equipment cover

M 1:6,66
50, 52 50

54

51 50, 53 51, 54 51 42763945_xml.eps

Fig. 113

Item no. Part no. Qty Designation

50 77326033 1 DC1-15 230 V control set 220-240 V 50/60 Hz
50 77306033 1 DC1-15 400 V control set 380-415 V 50 Hz; 380-400 V 60 Hz
50 77336033 1 DC1-15 575 V control set 500-525 V 50 Hz; 575 V 60 Hz
50 77316033 1 DC1-15 460 V control set 440-480 V 60 Hz
51 71792133 1 DC 1/2 electric equipment cover set DC 1/2
51 71892133 1 DC 5 electric equipment cover set DC 5
51 71592133 1 DC 10 electric equipment cover set DC 10-15
52 71582533 1 Contactor set DC 1-15
53 47928533 3 DC 1-15 board relay DC 1-15, 10 A 24 V DC
54 71812545 1 Window DC 1-15
Tab. 107
211 273 44/280823

149
 11.13 Control cable, service cover

42764449_xml.eps
Fig. 114

Item no. Part no. Qty Designation

53 71792033 1 DC 1/2 service cover set
53 71892033 1 DC 5 service cover set
53 71592033 1 DC 10 service cover set
54 71881033 1 5 m control cable set
54 71880933 1 8 m control cable set can be used for 8 and 10-pole design
54 72003745 1 11 m DC control cable
56 77330033 1 DSC pendant controller
57 71880433 1 DSC/DSC-S emergency-stop set/
rubber cap
58 72027145 1 Sleeve compartment cpl.
64 72238945 1 DC 15 service cover kit
211 273 44/280823

65 75371033 1 DSC bending+impact protection

Tab. 108

150
 11.14 DSC–5 / DSC–7 pendant controller

6
1 2

3,4 5

3,4

6
3

43713844_xml.eps

Fig. 115

Item no. Part no. Qty Designation

1 77393533 1 DSC–5 pendant controller
2 77393733 1 DSC–7 pendant controller
3 77395233 1 DSC–5 Emergency-stop set/rubber cap
4 77395333 1 DSC–7 Emergency-stop set/rubber cap
5 77393633 1 DSC–5/DSC–7 PCB
6 75371033 1 DSC bending+impact protection
Tab. 109
211 273 44/280823

151
 Original Ident. number / Language
EC conformity declaration for a machine 19961144 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
0117 1/ 2

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

declare that the electrically driven hoist / trolley for lifting and moving loads

Demag DC chain hoist with trolley

Serial no.: XXX-XXX-XXX
ready for service - as a series product or manufactured to order - with a cable-connected control
pendant/wireless control unit after completion of assembly/being put into service including
function check and load test prior to being put into service to be confirmed on page 2
complies with all relevant requirements of

EC Machinery Directive 2006/42/EC.

e
The safety objectives of Low Voltage Directive 2014/35/EU are achieved.

The product additionally complies with the following relevant directives/provisions:

EU EMC Directive 2014/30/EU

EN 14492-2

EN 60204-32
pl
Applied harmonised standards and/or C standard drafts, in particular:

Cranes - Power driven winches and hoists -

Part 2: Power driven hoists
Safety of machinery - Electrical equipment of machines -
Part 32: Requirements for hoisting machines
m
Authorised representative for technical documentation:
Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany

Düsseldorf, 14.08.2023
Sa

ppa. Thomas Wiesmann i.V. Oliver Moll

Senior Director Director
Supply CTO Wetter Hoist Platforms

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
EC conformity declaration for a machine 19961144 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
0117 2/ 2

Demag DC chain hoist with trolley

Serial no.: XXX-XXX-XXX

-----------------------------------------------------------------------------------------------------------

For assembly / first putting into service including function check

...................................., date ................................................

Company that carries out the work: ................................................

Function in the company: ................................................

Name: ................................................

e
Signature: ................................................

------------------------------------------------------------------------------------------------------------

pl
For the load test in the scope of the acceptance test

...................................., date

Company that carries out the work:

................................................

................................................
m
Function in the company: ................................................

Name: ................................................

Signature: ................................................
Sa

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
Declaration for fitting partly completed machinery 19961244 / EN
according to Machinery Directive 2006/42/EC, Annex IIB Issue Page
0919 1/ 1

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

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
Serial no.: XXX-XXX-XXX
supplied as partly completed machinery is intended to be incorporated into machinery and its
initial bringing into service is prohibited until the machinery* into which this partly completed
machinery is to be incorporated has been declared in conformity with all relevant provisions of

EC Machinery Directive 2006/42/EC.

(* insofar as this machinery is subject to the scope of application)

e
Basic requirements of the EC Machinery Directive, insofar as they are relevant for the scope of
delivery, are met by application of the following harmonised standards or C standard drafts

EN 14492-2

EN 60204-32
pl Cranes - Power driven winches and hoists -
Part 2: Power driven hoists
Safety of machinery - Electrical equipment of machines -
Part 32: Requirements for hoisting machines

The safety objectives of Low Voltage Directive 2014/35/ЕU are achieved

m
The product additionally complies with the following relevant directives/provisions:
EU EMC Directive 2014/30/EU

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
Sa

authorised representative in response to a justified request.

Authorised representative for technical documentation
Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany

Düsseldorf, 14.08.2023

ppa. Thomas Wiesmann i.V. Oliver Moll

Senior Director Director
Supply CTO Wetter Hoist Platforms

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Original UK Declaration of Incorporation Ident. number / Language
of partly completed Machinery 19940244 / EN
acc. to Supply of Machinery (Safety) Regulations 2008, Issue Page
Annex II, sub. B 0721 1/ 1

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

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
Serial no.: XXX-XXX-XXX
supplied as partly completed machinery is intended to be incorporated into machinery and its
initial bringing into service is prohibited until the machinery* into which this partly completed
machinery is to be incorporated has been declared in conformity with all relevant provisions of

Supply of Machinery (Safety) Regulations 2008 No. 1597.

e
(* insofar as this machinery is subject to the scope of application)

Basic requirements of the Supply of Machinery (Safety) Regulations, insofar as they are relevant
for the scope of delivery, are met by application of the following designated standards or C
standard draftspl
- regarding 2008 No. 1597:

- regarding 2016 No. 1101:

EN 14492-2:2006+A1:2009

EN 60204-32:2008
m
The safety objectives of Electrical Equipment (Safety) Regulations 2016 No. 1101 are achieved.

The product additionally complies with the following relevant statutory instruments/provisions:
Electromagnetic Compatibility Regulations 2016 No. 1091

The special technical documentation according to Annex VII, sub. B of Supply of Machinery
Sa

(Safety) Regulations 2008 No. 1597 has been compiled and will be made available to authorised
national authorities by the designated authorised person in response to a justified request.
Person authorised to compile the technical file:
Paul Bartlett, Beaumont Road, Banbury, OX16 1QZ, United Kingdom

Düsseldorf, 21.09.2021

ppa. Thomas Wiesmann i.V. Oliver Moll

Senior Director Director
Supply CTO Wetter Hoist Platforms

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
UK Declaration of Conformity of the Machinery 19940144 / EN
acc. to Supply of Machinery (Safety) Regulations 2008, Issue Page
Annex II, sub. A 0721 1/ 2

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

declare that the electrically driven hoist / trolley for lifting and moving loads

Demag DC chain hoist with trolley

Serial no.: XXX-XXX-XXX
ready for service - as a series product or manufactured to order - with a cable-connected control
pendant/wireless control unit after completion of assembly/being put into service including
function check and load test prior to being put into service to be confirmed on page 2
complies with all relevant requirements of

Supply of Machinery (Safety) Regulations 2008 No. 1597.

e
The safety objectives of Electrical Equipment (Safety) Regulations 2016 No. 1101 are achieved.

The product additionally complies with the following relevant statutory instruments/provisions:
Electromagnetic Compatibility Regulations 2016 No. 1091
pl
Applied designated standards and/or C standard drafts, in particular
- regarding 2008 No. 1597:

- regarding 2016 No. 1101:

EN 14492-2:2006+A1:2009

EN 60204-32:2008
m
Person authorised to compile the technical file:
Paul Bartlett, Beaumont Road, Banbury, OX16 1QZ, United Kingdom

Düsseldorf, 21.09.2021
Sa

ppa. Thomas Wiesmann i.V. Oliver Moll

Senior Director Director
Supply CTO Wetter Hoist Platforms

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
UK Declaration of Conformity of the Machinery 19940144 / EN
acc. to Supply of Machinery (Safety) Regulations 2008, Issue Page
Annex II, sub. A 0721 2/ 2

Demag DC chain hoist with trolley

Serial no.: XXX-XXX-XXX

-----------------------------------------------------------------------------------------------------------

For assembly / first putting into service including function check

...................................., date ................................................

Company that carries out the work: ................................................

Function in the company: ................................................

Name: ................................................

e
Signature: ................................................

------------------------------------------------------------------------------------------------------------

pl
For the load test in the scope of the acceptance test

...................................., date

Company that carries out the work:

................................................

................................................
m
Function in the company: ................................................

Name: ................................................

Signature: ................................................
Sa

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Index

A Load spectrum factor 75

Actual load spectrum factor 72, 75
N
AC asynchronous motor 28
Number of operating hours 72, 75
B
O
Bayonet connector 31
Bayonet lock 36, 126 Oil grade 122
Bend protection sleeve 36 Operating limit switches 29
Buffer 56
Buffer plate 107, 110, 113, 116, 56 P
Phase sequence 45
C
Cable collector 41 R
Calculating hours of service 72 R-S-T network 45
Calculating the actual duration of service 72 Rating plate 2
Canopy 27 Recording factor 74, 76, 72
Chain link anchorage section 104 Recording method 72
Chain wear 88 Recording with devices 71
Contactor control 29 Reeving 43
Continuity of the PE conductor connection 33 Retaining clip 43
Control cable locking mechanism 38
Control cable snag protection 37 S
Counterweight compensation 43
Safe working periods according to ISO 12482 74
Cut-off spring 107, 110, 113, 116
Cut-off buffer 107, 110, 113, 116 Safe working periods in Germany 71
Self-locking nuts 33
D Special fittings 43
Starting frequency 70
Damping plate 56, 107, 110, 113, 116 Strain relief attachment 45
Design Working Periods 74 Strain relief sleeve 31
Design Working Period 74, 75 Switching cycles 30
Determining Design Working Period 75 Swivel lock 126
Documentation 73, 77 S.W.P. = safe working period 71
Documentation without counting devices 71
T
E
Tri-state signals 29
Elapsed operating time counter 30
Estimating load spectrum factor 72 W

F Wear of a single chain link 86

Wear or deformation of the chain 85
Factor depending on the type of recording 72, 75, 76 Welding work 68, 32
FEM 9.755 71 Window 29

G
General overhaul 78
General overhaul according to ISO 12482 78
GO in Deutschland according to DGVU and FEM 9.755 78

I
211 273 44/280823

Infrared interface 29
ISO 12482 74

L
158
211 273 44/280823

159
The current addresses of our sales offices, subsidiaries and agencies worldwide can be
found on the homepage
www.demagcranes.com

Demag Cranes & Components GmbH

PO Box 67 · 58286 Wetter (Germany)
Phone +49 (0)2335 92-0
Printed in Germany

Fax +49 (0)2335 92-7676

www.demagcranes.com

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