Operating and

Maintenance Instructions

CHAIN HOIST DC-II

07 June 2024 21157444

 Internal reference: X856513 / en-US / A / DOC2559317 / A

Contact information After-sales service

Contact the manufacturer’s local representative or If you have any questions about the product, need
Demag Cranes & Components GmbH technical information, or wish to place spare parts
Forststraße 16 orders, contact our after-sales service. Keep a note
40597 Düsseldorf of the serial or order number. Specifying this data
GERMANY ensures that you receive the correct information or
www.demagcranes.com the required spare parts.
The current addresses of the sales offices in
Germany and the subsidiaries and agencies
worldwide can be found on the Demag Cranes &
Components GmbH homepage at
www.demagcranes.com.

Customer and order form

Table 1.

Customer name

Customer application

Order number

Contract number

DDS ID

IS classification number
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

This document and the information contained herein, is the exclusive property of Demag Cranes & Components and represents a non-public, confidential and proprietary trade secret that
may not be reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Demag Cranes & Components
GmbH. Copyright 2024 © Demag Cranes & Components GmbH. All rights reserved.

2
Product owner form
Fill in the following form before first putting the unit into service. This provides you with important information if
you ever have to contact the manufacturer or his representative.

Owner

Where in use

Crane type

Year of manufacture

Load capacity

Crane serial number

Chain hoist model code

Chain hoist serial number

Drawing number

Operating voltage

Control voltage

Frequency

Wiring diagram number

Contactor control/direct control

Supplier

Assembled by

Signature Date

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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 OPERATING AND MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS

TABLE OF CONTENTS
1 Introduction......................................................................................................................................... 10
1.1 About this information........................................................................................................................10
1.1.1 How to use this information..................................................................................................... 10
1.1.2 Copyright notice...................................................................................................................... 10
1.1.3 Definition of terms................................................................................................................... 10
1.1.4 Definition of personnel............................................................................................................ 12
1.1.5 Symbols and conventions....................................................................................................... 13
1.1.6 Related information................................................................................................................. 15
1.2 About this product.............................................................................................................................. 16
1.2.1 Intended use........................................................................................................................... 16
1.2.2 Conditions of warranty............................................................................................................ 16
1.2.3 Product identification...............................................................................................................17
1.2.4 Standards and directives.........................................................................................................18
1.2.5 Log book................................................................................................................................. 18

2 Health, safety and the environment (HSE)........................................................................................ 20

2.1 Safety messages and signals.............................................................................................................20
2.1.1 Signal words........................................................................................................................... 20
2.1.2 Hazard symbols...................................................................................................................... 20
2.1.3 Mandatory action symbols.......................................................................................................22
2.1.4 Prohibited action symbols....................................................................................................... 22
2.1.5 Product safety labels...............................................................................................................22
2.1.6 Safety label locations.............................................................................................................. 23
2.2 Responsibilities of the owner.............................................................................................................23
2.2.1 Preventing work-related hazards.............................................................................................23
2.2.2 Preventive maintenance..........................................................................................................23
2.2.3 Personal protective equipment................................................................................................ 24
2.2.3.1 Fall protection..................................................................................................................... 25
2.2.4 Working at heights.................................................................................................................. 25
2.2.5 Incident reporting.................................................................................................................... 26
2.3 Conditions for product use................................................................................................................ 26
2.3.1 Operating conditions............................................................................................................... 26
2.3.2 Prohibited use......................................................................................................................... 27
2.3.3 Changes to the product........................................................................................................... 27
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2.4 Emergency stop.................................................................................................................................. 28

2.5 Using the emergency stop button......................................................................................................30
2.6 Main isolation switch.......................................................................................................................... 31
2.7 Lockout-tagout-tryout procedure.......................................................................................................31
2.8 Fire safety............................................................................................................................................ 32
2.9 Emissions............................................................................................................................................ 33
2.9.1 Measured sound levels........................................................................................................... 33
2.10 Personnel requirements..................................................................................................................... 33
2.11 Environmental information.................................................................................................................34
2.11.1 Product life-cycle stages......................................................................................................... 34
2.11.2 Handling waste material.......................................................................................................... 34
2.11.3 Disposing of electronic products securely............................................................................... 35
2.11.4 Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals
(REACH).................................................................................................................................35

3 Product description............................................................................................................................ 37
3.1 Main parts of the chain hoist..............................................................................................................37

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TABLE OF CONTENTS OPERATING AND MAINTENANCE INSTRUCTIONS

3.2 Product code....................................................................................................................................... 38

3.2.1 Demag product code...............................................................................................................38
3.3 Technical data..................................................................................................................................... 38
3.3.1 Product range for DC-Com II...................................................................................................38
3.3.2 Product range for DC-Pro II.....................................................................................................39
3.3.3 Hoist classification...................................................................................................................39
3.3.4 Chain hoist motor data............................................................................................................ 39
3.3.5 Mains connection circuit breaker and supply lines...................................................................40
3.4 Dimensions..........................................................................................................................................40
3.5 Materials and coating..........................................................................................................................40
3.6 Drive and brake................................................................................................................................... 41
3.7 Gearbox and slipping clutch.............................................................................................................. 41
3.8 Chain drive.......................................................................................................................................... 42
3.9 Electric equipment.............................................................................................................................. 42
3.9.1 Control system........................................................................................................................ 42
3.9.2 7-segment display for operating status and fault display......................................................... 43
3.9.3 Display of software version, operating hours, number of cycles.............................................. 43
3.10 Central service enclosure...................................................................................................................44
3.11 Pendant controller.............................................................................................................................. 44

4 Installation........................................................................................................................................... 46
4.1 Safety during installation................................................................................................................... 46
4.1.1 Responsibilities of installation personnel................................................................................. 47
4.2 Installation preparation.......................................................................................................................48
4.2.1 Installation environment requirements.....................................................................................48
4.2.2 Tool requirements for installation.............................................................................................48
4.2.3 Preparing for installation..........................................................................................................48
4.2.4 Evaluating the weight of the hoist............................................................................................49
4.2.5 Lifting equipment.....................................................................................................................49
4.2.6 Lifting points on the hoist.........................................................................................................49
4.2.7 Before lifting............................................................................................................................ 50
4.3 Installation procedure.........................................................................................................................50
4.4 Connecting the pendant controller to the control cable.................................................................. 52
4.5 Suspending the chain hoist................................................................................................................53

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4.5.1 Supporting structure................................................................................................................54
4.5.2 Attaching the chain hoist to the supporting structure or the trolley...........................................55
4.6 Electrical connections........................................................................................................................ 56
4.6.1 Safety during electrical work................................................................................................... 56
4.6.2 Circuit diagrams...................................................................................................................... 56
4.6.3 Control board.......................................................................................................................... 57
4.6.4 Control cable...........................................................................................................................59
4.6.5 Adjusting the suspension height of the pendant controller.......................................................59
4.6.6 Installing the support sleeve on DSC, DSK or DST pendant controllers.................................. 61
4.6.6.1 Disassembling the DSC pendant controller......................................................................... 61
4.6.6.2 Installing the support sleeve on DSC pendant controllers....................................................62
4.6.6.3 Installing the support sleeve on DSK pendant controllers....................................................62
4.6.6.4 Installing the support sleeve on DST pendant controllers.................................................... 63
4.6.6.5 Installing the sleeve compartment on the rubber sleeve cable............................................ 64
4.6.7 Mobile control system............................................................................................................. 64
4.6.8 Mains connection.................................................................................................................... 66
4.6.8.1 Connecting the chain hoist to the electric supply.................................................................67
4.6.8.2 Phase sequence for connection to the AC power network...................................................67
4.6.8.3 Checking directions of motion............................................................................................. 67

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 OPERATING AND MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS

4.7 Programming parameters with the pendant controller.................................................................... 68

4.7.1 Chain hoist parameters........................................................................................................... 68
4.7.2 Using parameter-programming mode, travel drive E22-C/E...WD........................................... 69
4.8 Adjusting the lower hook position.....................................................................................................71

5 Commissioning................................................................................................................................... 73
5.1 Safety during commissioning............................................................................................................ 73
5.1.1 Responsibilities of commissioning personnel.......................................................................... 73
5.2 Commissioning preparation...............................................................................................................74
5.2.1 Commissioning environment requirements..............................................................................74
5.2.2 Commissioning tool requirements........................................................................................... 74
5.2.3 Preparing for commissioning...................................................................................................74
5.3 Commissioning instructions.............................................................................................................. 74
5.3.1 Commissioning inspections.....................................................................................................74
5.3.2 Checks before first use............................................................................................................75
5.4 Finishing commissioning................................................................................................................... 75

6 Operation.............................................................................................................................................77
6.1 Safety during operation...................................................................................................................... 77
6.1.1 Operating environment............................................................................................................77
6.1.2 Responsibilities of the operator............................................................................................... 77
6.2 Checks before operating.................................................................................................................... 78
6.2.1 Checking the hoist before every working shift......................................................................... 78
6.2.2 Checking the operation with the emergency stop button pressed down.................................. 79
6.2.3 Checking the operation with the controller enabled................................................................. 79
6.3 Starting the equipment....................................................................................................................... 80
6.3.1 Setting up the controller.......................................................................................................... 80
6.3.2 Operational checks................................................................................................................. 80
6.4 Safe load handling practices..............................................................................................................81
6.4.1 Load evaluation.......................................................................................................................81
6.4.2 Attaching the load................................................................................................................... 82
6.4.2.1 Lockable hook.....................................................................................................................82
6.4.3 Handling a load....................................................................................................................... 82
6.4.4 Load balancing........................................................................................................................83
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

6.4.5 Shock loading......................................................................................................................... 84

6.4.6 Load swing..............................................................................................................................85
6.4.6.1 Preventing load swing......................................................................................................... 85
6.5 Controlling the equipment..................................................................................................................86
6.5.1 Picking up the load..................................................................................................................86
6.5.2 Moving loads...........................................................................................................................87
6.6 Controlling load movements.............................................................................................................. 87
6.6.1 Moving the manual push trolley...............................................................................................87
6.6.2 Controlling speed with the controller........................................................................................88
6.6.3 Moving the load with the controller.......................................................................................... 88
6.6.4 Lifting a load with push button control..................................................................................... 89
6.6.5 Lowering a load with push button control................................................................................ 89
6.6.6 Combining the movements......................................................................................................90
6.6.7 Detaching a load..................................................................................................................... 90
6.7 Slipping clutch operation................................................................................................................... 90
6.8 Hoisting limit switch operation.......................................................................................................... 90
6.9 Shutting down the equipment............................................................................................................ 91

7 Maintenance........................................................................................................................................ 92

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TABLE OF CONTENTS OPERATING AND MAINTENANCE INSTRUCTIONS

7.1 Safety during maintenance.................................................................................................................92

7.2 Maintenance preparation....................................................................................................................93
7.2.1 Maintenance environment....................................................................................................... 93
7.2.2 Preparing for maintenance...................................................................................................... 93
7.3 About maintenance.............................................................................................................................93
7.3.1 Maintenance intervals............................................................................................................. 93
7.3.2 Service personnel................................................................................................................... 94
7.3.3 Measures for achieving safe working periods in Germany.......................................................94
7.3.3.1 Calculating actual duration of service S according to FEM 9.755 (Germany)...................... 95
7.3.3.2 Example of duration of service S according to FEM 9.755 (Germany) for chain hoist
size 10 1250 kg 1/1 H5 V8/2 in 1Am................................................................................... 97
7.3.4 Measures for achieving safe working periods according to ISO 12482....................................98
7.3.4.1 Determining the remaining service life according to ISO 12482...........................................99
7.3.4.2 Example for determining the remaining service life according to ISO 12482 for chain
hoist size 10 1250 kg 1/1 H5 V8/2 in 1Am......................................................................... 101
7.3.5 GO general overhaul.............................................................................................................102
7.3.5.1 General overhaul in Germany according to DGVU and ISO 12482 (FEM 9.755)...............102
7.3.5.2 General information on inspection and general overhaul according to ISO 12482.............103
7.3.5.3 Theoretical duration of service.......................................................................................... 103
7.4 Basic maintenance requirements.................................................................................................... 104
7.4.1 Electric components..............................................................................................................104
7.4.2 Working on machinery or machine equipment.......................................................................104
7.4.3 Instructions for maintenance work in the course of operation................................................ 105
7.4.4 After finishing maintenance work...........................................................................................105
7.5 Maintenance schedule...................................................................................................................... 105
7.5.1 Routine inspections...............................................................................................................107
7.5.1.1 Required tests and inspections......................................................................................... 107
7.5.1.2 Special operating conditions..............................................................................................107
7.5.1.3 Service life of the contactor............................................................................................... 108
7.6 Maintaining the suspension............................................................................................................. 108
7.7 Maintaining the electric equipment cover....................................................................................... 109
7.8 Removing the chain collector box................................................................................................... 109
7.9 Maintaining the limit switches..........................................................................................................110
7.9.1 Checking the operating limit switches....................................................................................110
7.9.2 Checking the operating limit switch for lifting..........................................................................111
7.9.3 Checking the operating limit switch for lowering.....................................................................111

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
7.9.4 Optional geared limit switch...................................................................................................112
7.9.5 Checking the operating limit switch actuator..........................................................................112
7.10 Maintaining the chain drive.............................................................................................................. 112
7.10.1 Checking the chain sprocket..................................................................................................112
7.10.2 Checking the chain guide...................................................................................................... 112
7.10.3 Checking the guide plate or the chain entry plate.................................................................. 113
7.10.4 Checking the chain wear....................................................................................................... 113
7.10.4.1 Inspecting the chain visually.............................................................................................. 113
7.10.4.2 Measuring chain wear or deformation................................................................................114
7.10.4.3 Measuring wear of a single chain link with a caliper gauge................................................114
7.10.4.4 Measuring wear over 11 chain links with a caliper gauge...................................................114
7.10.4.5 Measuring wear over 11 chain links with a chain gauge.................................................... 116
7.10.5 Chain set scope of supply..................................................................................................... 116
7.10.6 Available chains.................................................................................................................... 118
7.10.7 Replacing the chain set......................................................................................................... 119
7.10.7.1 Chain hoist with geared limit switch...................................................................................122
7.10.7.2 Fitting the retaining ring.....................................................................................................123
7.10.7.3 Fitting the chain anchorage for 2/1 reeving in DC-II 10......................................................124
7.10.7.4 Fitting the limit stop........................................................................................................... 125

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 OPERATING AND MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS

7.10.7.5 Steps after replacing the chain set.................................................................................... 125

7.10.8 Chain guides......................................................................................................................... 126
7.10.9 Lubricating the chain............................................................................................................. 127
7.10.9.1 Lubricating the chain with a grease tube........................................................................... 127
7.10.9.2 Lubrication intervals of the chain....................................................................................... 128
7.11 Load hook..........................................................................................................................................130
7.11.1 Load hook dimensions and wear...........................................................................................130
7.11.2 DC-Pro II hook safety latch................................................................................................... 130
7.11.3 Checking the return sprocket in the hook block..................................................................... 130
7.11.4 Replacing DC-II 1–DC-II 10 hook assembly.......................................................................... 131
7.11.5 Replacing the bottom block with external cut-off springs, 2/1 reeving....................................132
7.12 Buffers and cut-off springs.............................................................................................................. 134
7.12.1 Checking the cut-off buffers and cut-off springs.....................................................................134
7.12.2 Buffer and cut-off spring arrangement................................................................................... 135
7.13 Brake..................................................................................................................................................137
7.13.1 Maintaining the brake............................................................................................................137
7.13.2 Checking the brake wear.......................................................................................................138
7.13.3 Replacing the brake.............................................................................................................. 139
7.14 Slipping clutch.................................................................................................................................. 142
7.14.1 Checking the slipping clutch..................................................................................................142
7.14.2 Adjusting the slipping clutch.................................................................................................. 142
7.15 Maintaining the gearbox................................................................................................................... 145
7.15.1 Gear oil................................................................................................................................. 145
7.15.2 Changing the gear oil............................................................................................................ 145
7.16 Replacing the contactor on the control board................................................................................ 147
7.17 Replacing the relay on the control board........................................................................................ 148
7.18 Replacing the control cable..............................................................................................................149
7.19 Finishing maintenance..................................................................................................................... 151

8 Troubleshooting................................................................................................................................ 152
8.1 Safety during troubleshooting......................................................................................................... 152
8.2 7-segment display.............................................................................................................................153
8.2.1 Troubleshooting when the display indicates malfunction....................................................... 153
8.3 Operating statuses and general messages.....................................................................................153
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

8.4 Warning messages............................................................................................................................154

8.5 Error messages................................................................................................................................. 155

9 Transportation, storage and dismantling........................................................................................ 157

9.1 Transporting the product..................................................................................................................157
9.2 Transport inspection.........................................................................................................................157
9.3 Packaging.......................................................................................................................................... 157
9.4 Storing the product...........................................................................................................................157
9.5 Returning the product to use........................................................................................................... 158
9.6 Dismantling the product................................................................................................................... 158

APPENDIX I: Recommended tightening torques........................................................................................ 159

APPENDIX II: DC-II 1–DC-II 10 solo hoist circuit diagram.......................................................................... 160

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 TABLE OF CONTENTS
OPERATING AND MAINTENANCE INSTRUCTIONS

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION

1 Introduction

1.1 About this information

This information offers guidance to enable safe and efficient operation of the product.

Taking the time to read this information helps you to prevent damage to the product, and, most
importantly, personnel that are situated close to it. The product is safe when used correctly.
However, there are many potential hazards that are associated with incorrect operation and
these hazards can be avoided when you know how to recognize and anticipate them.

This information also makes you aware of your responsibilities regarding the product and help
you to ensure that it is kept in a safe operating condition throughout its lifetime.

This information is not intended as a substitute for proper training but provides
recommendations and methods for safe and efficient operation and maintenance. The owner of
the product must ensure that operators are properly trained before operation and, always,
comply with all of the applicable and prevailing safety and other standards, rules, and
regulations.

1.1.1 How to use this information

Every person that is exposed to the equipment of the manufacturer must, before operating,
servicing and maintaining such products, read and understand the contents of this information
and strictly adhere and conform their conduct with and to the information, recommendations,
and warnings that are provided in this document.

NOTE Keep these instructions in a safe, accessible location for future reference by personnel
operating the equipment or exposed to the operating equipment.

WARNING! IGNORING INSTRUCTIONS HAZARD

Failure to follow the given instructions can cause death, serious injury, or property
damage.
Read and understand this information before operating, servicing, and maintaining the
product.

The manufacturer makes absolutely no warranty whatsoever regarding the contents of this
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

document, express or implied, whether arising by operation of law or otherwise, including, but
not limited to, any implied warranties of merchantability or fitness for a particular purpose.

1.1.2 Copyright notice

This document and the information contained herein, is the exclusive property of Demag Cranes
& Components GmbH and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any
manner whatsoever without the express written consent of Demag Cranes & Components
GmbH. Demag Cranes & Components GmbH © 2024. All rights reserved.

1.1.3 Definition of terms

All brand names, product names and trademarks that are used in this document are registered
trademarks of their respective owners.

The following terms and definitions may have been used in this document:

ANSI American National Standards Institute

Authorized personnel Persons who the owner authorizes and who have the
necessary training to carry out operation or service actions.

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1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS

cCSAus CSA means "Canadian Standards Association". CSA is an

independent organization for the testing and certification of
products. The CSA standard guarantees high quality and
safety and grants access to the North American market.
The subscripted c and the subscripted us means for use in
both the USA and Canada.
CE marking The CE marking indicates that the product complies with
the appropriate CE regulations.
Check A visual and functional assessment (not a test) of the
product without dismantling.
Controller A pendant controller or another type of controller that the
operator uses to give commands to the product.
Dynamic braking A method of controlling speed by using the motor as a
generator, with the energy being dissipated in resistors.
Electric panel The electric panel controls the power to the motors.
Expert A person with extensive knowledge about the current
subject matter.
Floor-operated hoist A hoist which an operator controls by using a radio
controller or a pendant controller which is suspended from
the hoist.
Hoist Drive mechanism for lifting and lowering the load.
Inching Making small movements of the product by repeatedly and
momentarily pressing the direction control.
Inspection Checking the product looking for defects and checking the
operation of the controls and limiting and indicating devices
without loading the product. This inspection is more than a
check but does not normally require any part of the product
to be dismantled other than for removal or opening of
covers, housings, or enclosures.
ISO International Organization for Standardization
Main isolation switch The main isolation switch is a power switch that the
operator should use to turn on or switch off the power to the
product.
Operating and Maintenance Principal means by which the manufacturer provides
Instructions information or instructions concerning the product which are

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
relevant to the owner, operator, and maintenance personnel
of the product.
Operator Person operating the hoist for handling loads.
Qualified personnel A person with the necessary qualification to perform
required activities as listed in the operating and
maintenance instructions of the product. The necessary
qualification is based on theoretical and practical knowledge
of the product. The person with the necessary qualification
must be in a position to assess the safety of the installation
together with the application. Persons with the authority to
undertake certain maintenance work on the product include
service engineers of the manufacturer and trained fitters
with a corresponding certification.
Radio-controlled hoist A hoist which an operator controls by using an operating
station which is not attached to the hoist (for example, radio
control).
Regenerative braking A method of controlling speed in which the electrical energy
generated by the motor is fed back into the power system.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION

Rated capacity Load that the product is designed to lift for a given operating
condition (for example, configuration, position of the load).
Secondary brake Some chain hoists can have two similar brakes, one of
which is redundant or a "secondary brake."
Standby hoist A hoist which is used only occasionally or intermittently.
Trolley The trolley supports the hoisting machinery, and moves
along the main girder (bridge) or runway.
UKCA (UK Conformity The marking indicates that the product complies with the
Assessed) appropriate UK regulations.

1.1.4 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.

Operating personnel or operator

Operating personnel or machine operators are defined as persons assigned by the owner of the
machine to operate 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 that
are assigned to them and on the possible hazards resulting from inappropriate conduct.
Personnel must be informed about the required protective devices, protective measures,
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

relevant regulations, codes of practice, accident prevention regulations and operating 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 that are 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.

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1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS

Experienced technician
Experienced technicians are defined as persons who, owing to their technical training and
experience, have sufficient knowledge in the field of the machine. They must be familiar with the
relevant national industrial safety regulations, codes of practice, accident prevention
regulations, directives, and accepted engineering standards 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 safe working period (S.W.P.) and to carry out a
general overhaul of the machine.

Authorized 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
authorized expert engineer for the inspection of machines is defined as an expert engineer
authorized by the Industrial Employers’ Mutual Insurance Association.

1.1.5 Symbols and conventions

Familiarize yourself with the following symbols and conventions that are used in this document.

Symbol Description

Indicates that the product is slowing down or is moving at its

slowest speed

Indicates that the product is accelerating or moving at its highest

speed

NOTE Indicates items which require special attention by the reader.

There is no obvious risk of injury that is associated with notes.

Indicates fast steady movement

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Indicates slow steady movement

Indicates rapidly accelerating movement

Indicates slowly accelerating movement

Time-related task

Stop movement

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 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION

Symbol Description

Product conforms to the ATEX directive

Product conforms to the ATEX directive

Measurement inspection

Visual inspection

Tools needed

Operational inspection

Grease brush lubrication needed

Oil can lubrication needed

Grease gun lubrication needed

Noise check
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Ground symbol

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1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS

1.1.6 Related information

For this product, there is technical information available for different purposes and audiences.
Contact your supplier if you require any information listed here.

Operating and Maintenance Describes the responsibilities of the owner. Includes the
Instructions functionality, usage, and maintenance of the product.
Mechanical drawings Describes the mechanical design information.
Electrical drawings Describes the electrical design information and item lists.
Certificates Describes that the equipment is in conformity with directives
and manufactured according to standards. Includes also
testing results.
Log Book Consists of records of the usage and service history.
Spare Parts Catalog Includes part numbers for all parts supplied.
NOTE Store documents in a safe, dry place where they can be easily located when required.

Additional documents are available for sub-assemblies and components. 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 instructions. Additional documents can be
ordered from the relevant Demag office.

Table 1. Additional documents

Documents Part no.

Technical data or catalogs

KBK Aluline Crane Construction Kit, Classic/Ergo System; Project

203 813 44
Engineering and Components

Technical Data and Fitting Instructions KP-A10 and KP-T16 Clamp-fitted

203 313 44
Buffers

Technical Data DC-II Chain Hoist 203 825 44

Technical Data, Project Engineering and Components for KBK Crane

202 976 44
Construction Kit, Classic/Ergo System
Log book

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Inspection and Test Log Book 211 745 44
Assembly, adjustment, and dimension documents

Assembly Instructions for Chain Hoist Trolley U3.5, U11, U34, EU11, and
203 896 44
EU34

Assembly Instructions for Click-fit Trolley CF5 203 892 44

Assembly Instructions for Friction Force Checking Device 206 973 44

Assembly Instructions for Travel Drive E11–E34 1/2WD 211 711 44

Assembly Instructions, Technical Data and Component Parts DSE–

214 998 44
10C/CS multi-button Pendant Switches
Quick installation guides

Quick installation E11-E34 Control Board Replacement 211 715 44

15
 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION

1.2 About this product

1.2.1 Intended use

The machine may only be used as intended and in compliance with the requirements for the
owner and the following limitations as specified in these operating instructions. Any other use
may result in a danger to life and limband/or cause damage to the machine and load.

• Chain hoists are only intended for lifting, lowering, and moving loads and may be used as
stationary or traveling units.
• The suspension or 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 that is 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 "Responsibility of the owner".
• Intended use includes compliance with the safety warnings and 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. For more
information, see "Product description".
• The machine must be maintained regularly and appropriately by trained personnel in line with
the specified deadlines and checked according to "Maintenance schedule". Wearing parts
must be replaced in good time.
• National occupational health and safety regulations must be observed and followed.

Use of the pendant controller

Powered lifting and lowering and, if applicable, cross-travel and long-travel motions are
controlled by 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 traveling without
a load or with a safely suspended load if no hazard can be caused by the faster motion
sequences.

NOTE Inching (flick switching) must be avoided, as it causes increased wear and load sway.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

For more information on the required ambient conditions, see "Operating conditions". Contact
the manufacturer or manufacturer's representative if there is doubt.

1.2.2 Conditions of warranty

The terms under which seller's equipment and/or services are warranted are defined pursuant
to the warranty set forth in the contract between seller and customer for seller's products and/or
services and, if not so set forth, the warranty for seller's products and/or services is seller's
standard warranty in effect at the time of sale, a copy of which is available from seller upon
request. THE FOREGOING REPRESENTS THE SOLE AND EXCLUSIVE WARRANTY GIVEN
BY SELLER AND IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT
LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.

Seller provides no warranties for products manufactured or services provided by parties other
than seller ("Third Party Products"). Modifying any seller product or incorporating any Third
Party Product into any seller product or service without the seller's approval invalidates

16
1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS

warranty. Seller does not accept, shall not have any responsibility and disclaims any liability for
accidents, injury or physical or property damage arising as a consequence of such unauthorized
modifications and/or incorporation of Third Party Products.

Further, e.g. each of the following invalidates any warranty of seller and relieves seller from any
responsibility and liability for accidents, injury or physical or property damage: failure to operate
and/or maintain products in accordance with the applicable manuals, instructions, guides,
recommendations etc., regardless of their form, concerning the maintenance and operation of
products that may be communicated from time to time; side-pulling of load; shock loading;
excessive jogging; eccentric loading; overloading; accidental occurrence; improper repair;
improper handling or storage of products; chemical exposure; abnormal operating conditions
not identified to seller in writing prior to seller's issuance of a quotation; or any other cause that
in seller's sole discretion is not attributable to defects in material and workmanship. The
applicable manuals, instructions, guidelines, recommendations etc. may include, for example,
Installation and Commissioning Instructions, Owner's Manuals, Operator's Manuals, Operating
and Maintenance Instructions, User's Guides.

UNLESS OTHERWISE REQUIRED BY MANDATORY LAW, SELLER DISCLAIMS ALL

WARRANTIES RELATING TO THE CONTENTS OF THIS DOCUMENT, EXPRESS OR
IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE.

1.2.3 Product identification

1 XXXXXXXXXXXXXXXXXXXXX 1
XXXXXXXXXXXXXXXXXXXX
2 Type / Typ:
XXXXXXXXXXXXXXX
2 Type /Typ:
Serial no.: Year of manu. XXXXXXXXXXXXXXXXXXXX
3 Fabrik Nr.: XXXXXXXX Baujahr 02/2015
3 Serial no:
XXXXXXXX
Year of manu :
01/2022
Fabrik-Nr: Baujahr:
SWL.:
125 kg FEM/ISO: 4m / M7 SWL:
4 Tragfahigkeit:
4 Tragfahigkeit:
1t DIN EN 14492:
ISO/FEM:
A5 Dh2
M5 / 2m
Chain: Hook path.:
4.2x12.2RDC/TDK 5.0 m
Kette: Hakenweg: Chain: Hook path.:
7.4x21.2TDK 5m
5 3 ~ 380 - 415V / 50 Hz Uc: 24V 5 Kette: Hakenweg:

IP: 55 Iso-KI./ISN.cl.: F
7 ~3 380-415V / 50Hz Uc: 24V IP55 0:1
6 Temp.: -20 - +45ºC 6 Wkl/Th.Cl.: F
11
Motor: ZNK 71 A 8/2 0:1 9 Temp.: -20-+45ºC
UK
cos ED%
CA
8 m/min KW YA φ 1/min CDF% c/h
7 Motor: ZNC 100 B 8/2
cos ED%
8.0 0.18 160 0.46 2925 40 120 m/min KW YA 1 /min c/h
φ CDF%

10 2.0 0.06 140 0.48 720 20 240 8 12

3
2.30
0.58
6.4
3.5
0.76
0.55
2845
695
40
20
120
240

11 9 12

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
049687 212112
XXXXX XXXXXXXX XXXXX XXXXXXXXXXX
12 10 XXXXXXXX
XXXXX XXXXXXXX XXXXX

Item Designation Section

1 Manufacturer -

"Product code"
2 Chain hoist type
"Product range"

Serial no., calendar week and year of

3 -
manufacture

"Product code"
4 Load capacity and group of mechanisms
"Product range"

"Available hoist chain"

5 Load capacity and group of mechanisms "Product code"
"Product range"

17
 OPERATING AND MAINTENANCE INSTRUCTIONS 1 INTRODUCTION

Item Designation Section

6 Voltage and frequency "Chain hoist motor data"

"Operating conditions"
7 Type of enclosure and insulation class
"Chain hoist motor data"

8 Ambient temperature "Operating conditions"

"Product range"
9 Motor type and oil grade "Chain hoist motor data"
"Changing the gear oli"

"Chain hoist motor data"

10 Electric key data "Mains connection delay fuse links
and supply lines"

11 Conformity symbol -

12 Manufacturer’s address -

1.2.4 Standards and directives

This product has been designed and manufactured to conform to the following standards and
directives:

• Machinery Directive 2006/42/EC

• Electromagnetic Compatibility Directive 2014/30/EU
• Low Voltage Directive 2014/35/EU
• Restriction of the use of certain Hazardous Substances in Electrical and Electronic Equipment
Directive 2011/65/EU
• UK Statutory instrument Supply of Machinery (Safety) Regulations 2008 No. 1597
• UK Statutory instrument Electromagnetic Compatibility Regulations 2016 No. 1091
• UK Statutory instrument Electrical Equipment (Safety) Regulations 2016 No. 1101
• UK Statutory instrument Restriction of the Use of Certain Hazardous Substances in Electrical
and Electronic Equipment Regulations 2012 No. 3032
• Structure and mechanisms: ISO, FEM and EN, or CMAA
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

• Electrification: IEC and EN, or NEC

• Hook forging: DIN (if not otherwise specified)
• Product also fulfills the requirements of the following standards (if applicable): CSA, UL.
The declaration of conformity and other certificates are included in the delivery package.

NOTE The manufacturer reserves the right to modify the design and material specifications
without prior notice.

1.2.5 Log book

The crane log book is supplied in the interest of accident prevention. It is an integral part of the
equipment and shall be kept up‑to‑date and with equipment at all times. Do not remove or
discard any parts of the log book for any reason. The log book records the complete
maintenance history of the equipment and it must be transferred to the new owner when
ownership of the equipment changes.

The log book consists of the following items:

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1 INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS

• Product reference data: details of the product, its ownership, and persons who are qualified to
work with it.
• Faults that have been noticed in daily inspections, together with corrective actions.
• Records of inspections and lubrication.
• Records of repairs.
• Records of condition monitoring unit or hour counter.
• Calculations of design working period and remaining lifetime.
According to the ISO 12482 standard, the crane owner should keep records of the crane use,
so that the usage can be compared to the suppliers design principles and design limits. Records
should be kept of maintenance, inspections, repairs, modifications and exceptional occurrences,
for example, overloads, extreme climatic conditions, and collisions.

Where complete records are not available for the history of the crane, it shall be inspected in
accordance with annex A of ISO 9927‑1, and any requirements as a result of that inspection
shall be carried out before further use of the crane.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

19
 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

2 Health, safety and the environment (HSE)

2.1 Safety messages and signals

This section includes explanations of the safety symbols, signs, signals, and labels used on the
product and in the documentation.

2.1.1 Signal words

The following signal words and symbols are used to identify safety messages in these
instructions.

Indicates an imminently hazardous situation that, if not avoided, will cause death or serious
injury.

Indicates a potentially hazardous situation that, if not avoided, can cause death or serious injury.

Indicates a potentially hazardous situation that, if not avoided, can cause damage to property or
environment.

2.1.2 Hazard symbols

Hazard symbols are used to indicate the type of the hazard and the potential consequences.
Hazard symbols are indicated by a yellow triangle with black symbols and a black triangle band
that is surrounded by a yellow border. All personnel working on or in proximity of the machine
must understand and follow the information that is given in all hazard symbols.

General hazard symbol

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

The general hazard symbol identifies important safety messages in these instructions. When
you see this symbol, carefully read and understand the message that follows, and inform other
users when necessary.

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2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS
(HSE)

Mechanical hazard symbols

Falling load hazard Hand entanglement Slipping hazard Falling hazard

hazard

Crushing hazard

Electrical hazard symbols

Electrical hazard

Material hazard symbols

Harmful substance Ignition hazard

hazard

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Thermal hazard symbols

Hot surface hazard

Noise hazard symbols

Noise hazard

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 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

Radiation hazard symbols

Strong magnetic field

hazard

2.1.3 Mandatory action symbols

Mandatory action symbols specify actions to be taken to avoid a hazard. Mandatory actions are
indicated by white symbols on a blue background. All personnel working on or in proximity of
the machine must understand and follow the information that is given in all mandatory action
symbols.

Wear approved safety Wear approved Wear approved safety Switch off and lock-
gloves hearing protectors harness out equipment

Read manual

2.1.4 Prohibited action symbols

Prohibited action symbols indicate actions that are prohibited in order to avoid a hazard.
Prohibited actions are indicated by a red circle with a red diagonal line across the circle. The
action that is prohibited is always in black. All personnel working on or in proximity of the
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

machine must understand and follow the information that is given in all prohibited action
symbols.

Do not smoke Do not modify Do not touch Pacemaker not

allowed

2.1.5 Product safety labels

The product safety labels communicate the following:

• Level of risk that is based on the signal word Danger, Warning, or Notice
• Type of hazard, such as cutting parts, hanging load, hot surface, live parts
• Consequence of hazard, such as cutting, injection, crushing, burn, electric shock
• How to avoid the hazard

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2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS
(HSE)

NOTE Always keep safety labels visible. Check the condition of safety labels daily. Before
operating the machine, replace safety labels and instructions that are damaged, have
come loose, or that do not meet the legibility requirements for safe viewing distance.

2.1.6 Safety label locations

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.

2.2 Responsibilities of the owner

2.2.1 Preventing work-related hazards

The owner of the product must ensure that the operators have a sufficient knowledge of the
work-related hazards and of the ways to avoid the hazards.

The operator must always perform a local risk assessment before every work phase or shift.
The assessment ensures that the operator stops and thinks about what to do before starting to
work.

• Identify potential hazards that could affect you, your colleagues, the environment, your
product, or work method while you are performing the task

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
• Assess the risks and implement the actions that are needed to eliminate or reduce the risks
Only competent persons are allowed to carry out operation and other tasks. The responsibility
of the owner is to:

• Provide training and orientation

• Validate training methods
• Verify competence and skills
• Monitor and evaluate user performance regularly
2.2.2 Preventive maintenance
Scheduled inspections and preventive maintenance are essential for keeping the product in
safe working condition. Here are some general guidelines for preventive maintenance.

• It is the product owner's responsibility to organize proper regular inspections maintenance

to ensure long-term safety, reliability, durability, operability, and warranty for the product.
• Owner must keep a record (log book) of all maintenance activities and usage relating to the
product.
• Different maintenance actions must be carried out at different intervals and by different
persons who are qualified and authorized to perform these checks.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

• Daily checks and minor lubrication must be carried out by operators or maintenance
personnel. These checks are important for catching small faults before they become major
faults.
• Maintenance actions, excluding the daily actions that are performed by operators, must be
done by service personnel who are authorized by the owner of the product.
• Owner shall ensure that replacement parts and materials meet the specifications that are
defined by the product manufacturer.
• Keep this information in a safe, accessible location during the whole lifetime of the product.

WARNING! MACHINE MALFUNCTION HAZARD

Failure to regularly and properly maintain the product can cause death, serious injury,
or property damage.
Do not allow the product to be used if it is not in proper condition or if it has not been
maintained correctly.
Contact a service agent that is authorized by the manufacturer or manufacturer's
representative immediately in case of doubt.

RISK OF PROPERTY DAMAGE

Only use genuine spare parts, materials, and lubricants that are approved by the
NOTICE product manufacturer or manufacturer's representative. For more information, see the
product spare part catalog.

2.2.3 Personal protective equipment

NOTE This section proposes personal protective equipment to ensure the operator's safety.
Follow the local regulations and requirements of the working environment. Use only
approved and accepted personal protective equipment.

For safety, the operator or others near the product are required to wear personal protective
equipment (PPE). Various types of PPE are available as listed below and must be selected
according to the requirements of the working environment.

• Hard hat
• Eye-protector
• Hearing protectors
• Safety shoes
• Respirator
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

• Safety gloves
• Protective clothing
• Safety harness when working at heights
• High-visibility clothing
Do not wear loose clothing or jewelry that can get caught on controls or pulled into moving parts
of the product.

Tie back long hair. Long hair can get entangled.

Select the appropriate clothing for each task, for example:

• Wear fire-resistant clothing when welding, flame cutting, or using an angle grinder
• Tear-resistant clothing must resist damage from sharp edges in the steel structure
• Wear anti-static clothing when working on electrical circuits so that components do not get
damaged by a discharge of static electricity

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2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS
(HSE)

• When working with lubricants, clothing must prevent direct skin contact with the lubricant
• Choose the clothing with consideration to the temperature at the working site
• For work on explosion-proof products, clothing and equipment must be suitable for the
hazardous area.

2.2.3.1 Fall protection

While personnel are doing installation, inspection, or maintenance work at heights, they must
follow fall protection procedures as required by local regulations. Fall prevention practices and
fall protection equipment aim at protecting personnel working on or around the equipment from
exposure to falls.

If the equipment does not have a service platform or guardrail, personnel must use a properly
fitted safety harness. The safety harness is attached to the dedicated fixing points on a building
or equipment in order to prevent falls.

If the product does not have dedicated fixing points for fall protection, it is the owner's
responsibility to make sure that suitable and secure fixing points are available or provide an
appropriate manlift.

If ladders must be used, personnel must practice setting and securing the ladders before using
them for actual work.

Fall protection system has four components:

• Safety harness: Safety harness helps to prevent employees to get hurt in a fall.
• Lanyard belt: Lanyard belt is connected to the anchor point and is attached to the safety
harness. Lanyard belts are shock absorbing, which means that they slow down and eventually
stop a fall.
• Snap hook: Snap hooks connect the D-ring to the safety harness. Snap hooks must be
double locking. The basic rule is: connect only one snap hook to one D-ring.
• Anchorage point: Anchorage point is the point to which personal fall protection equipment is
attached. The point must be capable of supporting at least 2,268 kg (5,000 lb) per employee.
If there is any doubt about the strength of the attachment point, find an alternative point that
can support the worker.

A typical fall protection program may include:

• Documented and established site policies and procedures

• Conducting site assessments for fall hazards

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
• Selection of the proper fall protection system and equipment
• Training on fall protection procedures and the proper use of fall protection systems
• Inspection and proper maintenance of fall protection equipment
• Measures to prevent falling objects
• Rescue plans
If necessary, contact your supplier or service organization for assistance with designing your fall
protection program.

2.2.4 Working at heights

Maintenance and inspection work, repairs and on call services at heights must be carried out in
a safe working environment.

If the equipment does not have a service platform, all control points for maintenance must be
accessed in a safe manner by using aerial work platforms.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

WARNING! FALLING HAZARD

Lifting personnel with an aerial work platform includes a risk of falling from heights,
which can cause death or serious personal injury.
Each person on the aerial work platform must always wear a safety harness and be
attached to the platform.

The following requirements and safety precautions must be observed when using an aerial work
platform:
• All control points for maintenance must be safely reached from the aerial work platform.
• The service area must be free of obstacles and suitable for the use of the aerial work platform.
• The operating and safety instructions for the aerial work platform must be followed.
• The fall protection procedures must be followed.
• Unintended movements of the equipment must be prevented by necessary means, for
example, by using lockout-tagout-tryout procedures.

2.2.5 Incident reporting

Product safety issues that you must report are events in which the manufacturer's product has
been involved in an accident or near-miss incident. Contact your local manufacturer's
representative immediately to report any safety-related feedback, such as unauthorized
modifications, missing instructions and safety labels, neglected maintenance, or misuse.

Reporting is mandatory to ensure safe working conditions for employees, to provide information
for the risk assessment process, and to initiate product and work procedure improvements.

2.3 Conditions for product use

2.3.1 Operating conditions

WARNING
MACHINE MALFUNCTION HAZARD
Safe operation is only possible under the specified operating conditions. Using the
product outside the specified operating conditions can lead to death, serious injury, or
property damage.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Do not use the product outside the specified operating conditions. If you plan to use the
product in operating conditions that differ from the specified operating conditions,
contact the manufacturer. For more information, see "After-sales service."

The chain hoist and the trolley can be operated as described in following table.

Ambient
Humidity Height Type of enclosure Electromagnetic compatibility
temperature
Resistance to interference in industrial
Max. 90% relative Up to 2000 m
-20°C...+45°C IP55 environments. Interference emission for residential,
humidity above sea level
commercial, and light industrial environments.

NOTE 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.

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2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS
(HSE)

• Galvanizing plants or electroplating facilities

• Hygiene areas
• Low or high temperature applications
On request, suitably optimized equipment and important information for safe, low-wear
operation can be supplied for these applications.

Reduced duty factor at increased ambient temperatures

If chain hoists are operated at ambient temperatures that differ from mentioned in preceding
table, the duty factor must be reduced:

More than More than More than

Ambient temperature -20°C...+45°C
+45°C...+50°C +50°C...+55°C +55°C...+60°C
Chain hoist range Duty factor [%]
DC-Pro II, DC-Com II 20/40 15/35 15/25 10/20

2.3.2 Prohibited use

WARNING
MACHINE MALFUNCTION HAZARD
Using the machine outside the limits of its duty class or operating conditions can cause
malfunction of the machine and can cause death, serious injury, or property damage.
Do not use the machine outside the limits of the specified duty class or operating
conditions.

Prohibited use of the product includes, but is not limited to:

• Neglecting safety messages of the indicating devices

• Using the product for lifting or transporting people
• Lifting unbalanced or manually attached load against the operating instructions
• Attempting to lift a load which is fastened to the ground or to a base
• Pulling or dragging a load sideways
• Colliding the load against an obstacle
• Standing under a load

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
• Moving unexpectedly into the operating range of the product
• Using the hoist as an earth reference for welding
In case of doubt, contact the manufacturer or the manufacturer’s representative.

2.3.3 Changes to the product

WARNING
MACHINE MALFUNCTION HAZARD
Unauthorized changes or modifications to the product can cause death, severe injury,
or property damage.
Always contact the manufacturer to get advance written approval for any product
change or modification.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

All modifications and corrections that are not authorized in the product manuals or which may
affect the maintenance, operation, safety, and availability of the product need to be approved in
writing by the manufacturer before implementation. Approval requires risk assessment
considering any new risks that the changes and modifications may bring.

Changes and modifications without proper risk assessment, elimination, or reduction of risk and
without appropriate safety measures may lead to death, serious personal injuries, or damage to
property or environment. Unauthorized modifications will also void the warranty.

If a modification or correction as described above has been implemented without the

manufacturer's permission, its effect on warranty liability will be considered case-by-case. Thus,
the warranty application may be rejected altogether. Should you consider a modification or
alteration necessary, you must contact the organization that manufactured and designed the
product. No modification is permitted unless you first obtain the written approval of the
manufacturer.

2.4 Emergency stop

WARNING
UNCONTROLLED MOVEMENT HAZARD
Using the emergency stop can cause the machine to move or operate in an
uncontrolled manner. This can cause death, serious injury, or property damage.
Only use the emergency stop button in an emergency situation.

In case of machine malfunction or other emergency situations, you can press the emergency
stop button to stop all motions immediately. In normal operation, do not use the emergency stop
button. Instead, use the direction controls. Routine use of the emergency stop button increases
wear on the product and can cause the load to swing.

NOTE Do not operate the machine unless you know the location of the emergency stop button.

NOTE There can also be a stop function button on the radio controller of the product. For such
products, use the stop function button instead of emergency stop button. For more
information, see the instructions of the radio controller.

There are two main types of emergency stop buttons:

• Emergency stop button with a twist-release mechanism which latches in the activated
position.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

• Emergency stop button with a push-pull mechanism which remains pressed in.
To reset the latching-type of an emergency stop button, twist the button in the direction of an
arrow in the mushroom head. The rotating movement releases the latch and allows the button
to spring out to the normal reset position.

Figure 1. Emergency stop button with twist-release mechanism

To reset the push-pull type of emergency stop button (without a rotation arrow on the button
head), pull the button manually outwards to the normal reset position.

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2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS
(HSE)

Figure 2. Emergency stop button with push-pull mechanism

You can restart the machine and operate the controls only after the emergency stop button is
reset to the normal reset position.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

2.5 Using the emergency stop button

WARNING
UNCONTROLLED MOVEMENT HAZARD
Using the emergency stop can cause the machine to move or operate in an
uncontrolled manner. This can cause death, serious injury, or property damage.
Only use the emergency stop button in an emergency situation.

WARNING
UNEXPECTED MOVEMENT HAZARD
Releasing the emergency stop button before the reason for the emergency stop is
eliminated can cause unexpected movements. Unexpected movements can cause
death, serious injury, or property damage.
Always eliminate the danger before you release the emergency stop button.

In case of machine malfunction or other emergency situations, you can press the emergency
stop button to stop all motions immediately. In normal operation, do not use the emergency stop
button. Instead, use the direction controls in normal operation. Routine use of the emergency
stop button increases wear on the product and can cause the load to swing.

NOTE Do not operate the machine unless you know the location of the emergency stop button.

NOTE There can also be a stop function button on the radio controller of the product. For such
products, use the stop function button instead of the emergency stop button. For more
information, see the instructions of the radio controller.

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

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

1 1 1

1. Emergency stop button or a stop function button

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2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS
(HSE)

All motions can be stopped with the emergency stop button (1) in the event of a hazard.
Anybody who identifies an immediate danger of personal injury or serious malfunctions must
actuate the emergency stop without delay.

1. To actuate the emergency stop, press the emergency stop button (1) until it reaches the end
stop.
The emergency stop button locks automatically, and the chain hoist is shut down.
2. To release the emergency stop button, turn the emergency stop button (1) in the direction of
the arrows (clockwise).
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.
• Operation of the machine constitutes no further hazard.
2.6 Main isolation switch
You can only operate the product when power is turned on. The owner must identify and
document the location and function of the main isolation switch and communicate this
information to all operators.

NOTE You must know the location and functionality of main isolation switch before you operate
the product.

WARNING! ELECTRIC SHOCK HAZARD

Even though the power supply is disconnected, there may still be voltage present in
some parts of the machine. This can result in exposure to electric shocks, which can
cause death or serious injury.
Familiarize yourself with functionality of the main isolation switch.

WARNING! SWINGING LOAD HAZARD

Turning off the main isolation switch causes sudden loss of power. The sudden loss of
power could cause the load to swing, which can cause death, serious injury, or property
damage.
Avoid turning off the main isolation switch during load movement.

2.7 Lockout-tagout-tryout procedure

Before installation, inspection, and maintenance, the power sources must be de-energized,

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
isolated, locked out, and tagged out. Lockout-tagout-tryout procedures are primarily intended to
protect personnel by preventing accidental starting of the machinery or exposure to electric
shocks.

Follow the lockout-tagout-tryout procedures in accordance with the local regulations and the
documented site lockout-tagout-tryout policy. The owner must ensure that the operators are fully
aware of the applicable lockout-tagout-tryout practices.

The following items are normally included in the documented lockout-tagout-tryout policy:

• Communication requirements: who to inform before using lockout-tagout

• When the use of lockout-tagout is permitted
• Identification of each of the switches, controls, valves, and other energy isolating devices
present at the site. Role of each device should also be explained.
• Lockout-tagout sequences to be followed before, during, and after maintenance
• Safety and operational considerations regarding other products on the same runway or on
adjacent runways

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 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

WARNING
STORED ENERGY HAZARD
When the product is switched off, there may still be stored energy in the electrical,
hydraulic, or pneumatic systems, rotating parts, linearly moving parts, or in the load.
Unintended release of energy can cause death, serious injury, or property damage.
Prevent the unintended release of energy by following the approved lockout-tagout-
tryout procedures.

WARNING
MACHINE MALFUNCTION HAZARD
Operating the product while it is under installation or maintenance can cause death,
serious injury, or property damage.
Never attempt to operate a control, switch, valve, or other device when it is locked out
or tagged out.

To lock out, tag out, and try out the product:

1. Turn off the product and disconnect power.

2. Place a personal lock and tag on controls to prevent their use until you remove the lock.
3. While performing the work, always keep the key to the lock with you.
4. If more than one person locks out the same machine, use individual locks and approved
multi-lock devices.
5. Verify the absence of voltage with approved voltage test equipment.
6. Verify the isolation of other forms of energy with an approved method.
7. Attempt to operate the product using normal controls. If properly isolated or immobilized,
no equipment or system starts nor any part activates or moves.
8. Release energy (pneumatic or hydraulic pressure or other stored energy) that may cause
danger during the work in a safe way.
9. After completing the work, remove all locks and tags.

2.8 Fire safety

WARNING
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

FIRE AND EXPLOSION HAZARD

Ignition sources like smoking, open flames, welding work, and sparks, together with
combustible materials, such as fuel, can cause fire and, if not avoided, can cause death
or serious injury.
Ignition sources are prohibited near the machine.
During maintenance, follow appropriate fire prevention and protection measures,
including but not limited to trained personnel, proper fire extinguishing equipment, and
agents.
Before starting any maintenance or repairs that require ignition sources, such as
welding or flame cutting, carry out a proper risk assessment to control the risk.

• Smoking and open fire are prohibited near the product.

• Access to all fire-fighting equipment must be granted at all times, especially during
maintenance and repair works.
• All fire-fighting equipment must be inspected and serviced regularly, according to local
regulations.
• Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately.

32
2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS
(HSE)

• Know the various types of fires and the appropriate fire-fighting methods. Various fires must
not be extinguished with water. In most cases special extinguishing agents, dry powders or
deoxygenating agents are required.
• All personnel must be trained regularly in fire-fighting methods, in cooperation with local
authorities and rescue organizations. If there is a fire, the fire alarm must be activated and all
available personnel must help with fire-fighting according to the predetermined fire plan of the
workplace.
• For explosion-proof products, the owner decides whether work can be performed safely.
Usually the owner issues a specific work permit, that is required for welding and other spark-
emitting work that causes dangers to arise. The permit applies also to associated tools such
as electric drills.

2.9 Emissions

2.9.1 Measured sound levels

Hoists generate some audible noise during operation. The total sound pressure level that is
experienced in the operating area is a combination of the individual noise sources around the
operator. The main sources of noise from the hoist arise from its components, vibrating
structures, and reflective surfaces.

Hoist components which generate noise:

• Hoisting machinery
• Trolley, bridge, or other moving structures associated with the hoist.
Sound pressure level (LpAF) to DIN 45635 at a distance of one meter from the chain hoist is:

Chain hoist DC-II 1-250 DC-II 2-250 DC-II 5-500 DC-II 10-1000
Lifting speed up to [m/min] 8 8 8 6
Sound pressure level [dB (A)] 65+ 65+ 68+ 68+

These noise emission levels were measured under maximum load. The following structural
influences were not considered in the preceding measurements:

• transmission of noise through steel structures,

• reflections from walls, and son on.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
2.10 Personnel requirements

WARNING
SPECIALIST SKILLS REQUIRED
Incompetent operation and maintenance procedures can cause death or serious injury.
Operation and maintenance procedures require professional skills and special training
regarding the tasks and working methods.
Do not operate the machine or do any maintenance tasks without proper training.
Always follow the instructions.
Use appropriate personal protective equipment, depending on the task.

To avoid hazardous situations and dangerous consequences, leave all operation and
maintenance work to professionals. Tasks mentioned here below are examples of tasks which
are allowed only for trained personnel. More details on the risks related to the tasks and
instructions for carrying out these tasks safely can be found in the chapters where the
procedures are instructed. Tasks that require special technical skills and training include, but are
not limited to:

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 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

1. Hydraulic system maintenance

2. Pneumatic system maintenance
3. Electric system maintenance
4. Battery maintenance
5. Tire maintenance

2.11 Environmental information

Environmental impacts have been taken into account in designing and manufacturing this
product. To prevent environmental risks during use, follow the instructions and local regulations
for disposal of waste material. Proper use and maintenance improve the environmental
performance of this product.

2.11.1 Product life-cycle stages

Product life-cycle stages include:

• Production of materials and components

• Equipment manufacturing and assembly
• Use phase, including maintenance and modernization
• Dismantling and recycling of waste materials
• Deliveries between each stage
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Figure 3. Product life-cycle stages

2.11.2 Handling waste material

Handle and dispose of the waste material from installation, maintenance, or dismantling
according to local regulations. From the sustainability point of view, the preferred waste
handling methods are reuse, recycle as material, energy recovery and, as a final resort, safe
disposal.

As waste regulations and types of recovery and disposal methods vary regionally, no common,
detailed guidance can be given. The following list provides proposals for adequate waste
handling methods.

NOTE Always use licensed recycling companies.

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2 HEALTH, SAFETY AND THE ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS
(HSE)

Table 2. Waste handling methods

Material Waste handling method

Metals Recycle the metals.

Electronics and Some electrical parts may be treated as hazardous waste.

electromechanical
components Collect and recycle the electronics and electromechanical components
separately.
Batteries Batteries and other energy storage components may contain hazardous
substances.

Collect these items separately and recycle according to local

regulations.

Plastics Recycle plastic as material, use it for energy recovery, or deliver it to a

landfill site.

Chemicals Never spill chemicals, such as oil, grease, and other liquids, onto the
ground, soil, or sewage. Store waste oil and grease in containers that
are indicated for the purpose.

More detailed information on chemical handling as waste can be found

in the chemical's safety data sheet that is available from the
manufacturer of the chemical.
Packing materials Reuse or recycle packing materials, such as plastics, wood, and
cardboard.

Rubber Recycle rubber according to local regulations.

Whenever possible, return the used rubber tires to the tire supplier for
recycling.

2.11.3 Disposing of electronic products securely

When disposing of electronic products, remove securely the data stored (for example,
parameters and settings) in the product. If stored data cannot be removed, dispose of the
product securely to prevent potential disclosure of data contained in the product.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
The following are examples of disposal methods. They are related to electronic components
with capability of storing data long-term (such as hard drives, magnetic backup tapes, memory
cards, and portable storage devices). The disposal must include one of the following:

• Strong confidence erasure by using industry-standard methods for permanently wiping data
from a component. For example, depending on a device, writing the entire surface full of
random data.
• Physical destruction by using industry-standard methods for physically destroying the
component. For example, shredding or crushing the component, or in case of magnetic
storage (non-solid state hard drives, magnetic backup tapes) degaussing with powerful
magnets.

2.11.4 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, Authorization and Restriction of Chemicals (REACH), and under the
UK REACH in the United Kingdom. Twice a year the EU publishes a Candidate list of
Substances of Very High Concern (“SVHC”) for Authorization. Producers and EU importers/UK

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 OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY AND THE ENVIRONMENT (HSE)

importers have the duty to inform their EU/UK customers when a product contains SVHCs in a
concentration above 0.1 % weight by weight. Some Demag products do include small quantities
of SVHCs, such as lead which is typically used in brass and in certain electric components.
These cases are exemptions, as there are currently no satisfactory alternatives available for
such substances. 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.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS

3 Product description

3.1 Main parts of the chain hoist

6
7 8 9
4 5 13
3 12
1 2
10 11

14
29 16 15
17
28
18
27

26 22 21 19
24 23
25
20

1. Electric equipment cover 16. Slipping clutch DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

2. Control system 17. Round-section steel chain

3. Service cover 18. Cut-off buffer for operating limit switch
4. Gearbox housing 19. Adjusting mechanism for control cable
5. Two-stage helical gearbox with sizes 1–5, 20. Hook assembly
three-stage helical gearbox with size 10 21. Gearbox cover (cut)
6. Chain guide 22. Light barrier, 7-segment display (with
7. Chain sprocket elapsed operating time counter)
8. Suspension pin 23. Pulse wheel for speed monitoring
9. Suspension bracket 24. Chain bucket
10. Stator 25. Window
11. Rotor 26. Brake disc with linings
12. Fan cover 27. Brake magnet
13. Fan 28. Counterweight (cut)
14. Mounting points 29. Brake springs
15. Motor shaft

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 OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION

3.2 Product code

3.2.1 Demag product code

Hoist type Structural Frame size Load Reeving Hook path Hoist speed Supply Hook lead Hoist hook Trolley type Trolley Max. flange Drive type
and feature design capacity V/Hz off [opt.] distance speed
code [opt.] [opt.]
DC-Pro II K 10 1000 1/1 8 V12/3 400/50 2/4- 2000 U11 24/6 200 E11
(DES74) (DES01) (GE09) (LOA01) (DES27) (DIM02) (SPD03/ (ELE01/ (GE57) (SPD06/ (DIM39) (TM02)
SPD02) ELE03) SPD05)
1-11 13-15 17-18 20-24 26-31 33-36 37-42 44-49 51-54 55-58 60-62 64-69 71-73 75-82
Positions 12, 16, 19, 25, 32, 43, 50, 59, 63, 70, and 74 are empty.

Pos. Feature Feature Available properties

code
1-11 (DES74) Hoist type DC-Pro II 1-10, DC-Com II 1-10
13-15 (DES01) Struct. design K Low-headroom monorail hoist Standard-headroom monorail hoist
[opt.]
17-18 (GE09) Frame size (FS) 1 Frame size (= FS) 1 5 Frame size (= FS) 5
2 Frame size (= FS) 2 10 Frame size (= FS) 10
20-24 (LOA01) Load capacity FS LOA01 value [kg] FS LOA01 value [kg]
1 125 5 500
2 250 10 1000
26-31 (DES27) Reeving 1/1 Reeving 2/1 Reeving
33-36 (DIM02) Hook path 5.5 Hook path (height of lift) 5.5 m 8 Hook path (height of lift) 8 m
37-42 (SPD03/ Hoist speed V6/1.5 hoist (lifting) speed V6/1.5 [m/min.] V12/3 hoist (lifting) speed V12/3 [m/min.]
SPD02)
44-49 (ELE01/ Supply V/Hz 400/50 supply V/Hz
ELE03)
51-54 (DIM78/ Hook lead off 2/4- hook lead off (hook run-off position)
DIM79) [opt.]
55-58 (DIM77) Hoist-hook Hoist-hook distance 2000 [mm]
distance [opt.]
60-62 (GE57) Trolley type CF5 Click-fit 5, load capacity up to 550 kg U22 trolley size load, load capacity up to 2200 kg
U11 trolley size, load capacity up to 1100 kg U34 trolley size, load capacity up to 3400 kg
64-69 (SPD06/ Trolley speed 14/3.5 trolley speed 14/3.5 [m/min.] 24/6 trolley speed 24/6 [m/min.]
SPD05)
71-73 (DIM39) Max. flange 200 Max. flange width of the trolley [mm]
75-82 (TM02) Drive type E11-2WD travel drive: E11 with two-wheel drive E22-C1WD travel drive: E22-C with one-wheel drive and contactor
control
E34-2WD travel drive: E34 with two-wheel drive E22-C2WD: E22-C with two-wheel drive and contactor control
Positions 12, 16, 19, 25, 32, 43, 50, 59, 63, 70, and 74 are empty.

3.3 Technical data

3.3.1 Product range for DC-Com II

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Max. weight for hook

Load capacity Frame size Reeving Hoist classification Chain size Lifting speed Motor size1) path
(DIM116)/
(LOA01) (GE09) (DES27) (DIM01) (RR11) (SPD03) (HM18) (DIM02)
(DIM117)
DIN EN 14492 / ISO 4301 at 50 Hz 4m
[kg] FEM/ISO A/Dh class [mm] [m/min] [kg]
125 1 1/1 M6/3m A7/Dh2 4.2x12.2 8.0/2.0 ZNC 63 B 8/2 21
250 2 1/1 M5/2m A6/Dh2 4.2x12.2 6.0/1.5 ZNC 63 B 8/2 21
500 5 1/1 M5/2m A5/Dh2 5.3x15.2 4.0/1.0 ZNC 80 B 8/2 31
1000 10 1/1 M5/2m A5/Dh2 7.4x21.2 4.0/1.0 ZNC 100 A 8/2 52
The standard hook path is 4 m. Other hook paths from 3 m, also longer than 4 m, are possible.
1) Motor key data. For more information, see "Electric key data" or the motor data tables.

The hoist type DC-ComA II is available in several stock hoist sizes, with very short lead time
and attractive prices. Option range is limited. Technically the DC-ComA II is like the DC-Com II.

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3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS

3.3.2 Product range for DC-Pro II

Max. weight for hook

Load capacity Frame size Reeving Hoist classification Chain size Lifting speed Motor size1) path
(DIM116)/
(LOA01) (GE09) (DES27) (DIM01) (RR11) (SPD03) (HM18) (DIM02)
(DIM117)
DIN EN 14492 / ISO 4301 at 50 Hz 5m
[kg] FEM/ISO A/Dh class [mm] [m/min] [kg]
125 1 1/1 M7/4m A7.83)/Dh2 4.2x12.2 8.0/2.0 ZNC 63 B 8/2 21
250 2 1/1 M5+/2m+2) A6.0/Dh2 4.2x12.2 8.0/2.0 ZNC 63 B 8/2 21
500 5 1/1 M5+/2m+2) A6.0/Dh2 5.3x15.2 8.0/2.0 ZNC 80 B 8/2 32
1000 10 1/1 M5+/2m+2) A5.64)/Dh2 7.4x21.2 6.0/1.5 ZNC 100 A 8/2 53
The standard hook path is 5 m. Optionally, hook paths of 3–180 m are available.
1) Motor key data. For more information, see "Electric key data" or the motor data tables.
2) 2m+ corresponds to a service life of 1900 hours at full load.
3) The first digit refers to the A-class A7. The second digit is an additional load cycle value as a percentage. For example, ".8" is 80%.
A7.8 means A7 with 500,000 cycles and additional 80%, in total 900,000 cycles.
4) The first digit refers to the A-class A5. The second digit is an additional load cycle value as a percentage. For example, ".6" is 60%.
A5.6 means A5 with 125,00 cycles and additional 60%, in total 200,000 cycles.

3.3.3 Hoist classification

The added A and Dh classes are based on EN 14492-2 and ISO 4301. A DC-II chain hoist is
designed load cycle-based and not time-based with full load working hours. Load cycle-based is
much more demanding regarding the design of the product than just time-based.

The first digit after A refers to the A-class. The second digit means an additional load cycle
value as a percentage.

• A5.5 means A5 with 125.000 cycles and additional 50%, in total 187.500 cycles.
• A4.3 means A4 with 63.000 cycles and additional 30%, in total 81.000 cycles.

A-class Load cycles

A5 125,000

A6 250,000

A7 500,000

A8 1,000,000

Dh class Hook path per load cycle DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Dh2 2.5 m (1.25 m up and 1.25 m down)

Dh3 5.0 m (2.5 m up and 2.5 m down)

3.3.4 Chain hoist motor data

Poles PN CDF nN Starts/h IN Istart/IN cosφN Voltage1) Frequency Conformity

Frame size Motor size
[pcs] [kW] [%] [rpm] [A] [A] [V] [Hz]
8 0.09 20 650 240 1.20 1.32 0.76 3 ~ 380–415 50 CE
DC-Pro II 1/2 ZNC 63 B 8/2
2 0.36 40 2820 120 1.60 4.64 0.67 3 ~ 380–415 50 CE
8 0.18 20 665 240 1.60 2.35 0.51 3 ~ 380–415 50 CE
DC-Pro II 5 ZNC 80 B 8/2
2 0.72 40 2745 120 2.40 7.20 0.77 3 ~ 380–415 50 CE
8 0.45 20 695 240 3.10 6.51 0.50 3 ~ 380–415 50 CE
DC-Pro II 10 ZNC 100 A 8/2
2 1.80 40 2790 120 4.90 20.10 0.80 3 ~ 380–415 50 CE
8 0.57 20 700 240 3.90 7.41 0.50 3 ~ 380–415 50 CE
DC-Pro II 10 ZNC 100 B 8/2
2 2.30 40 2845 120 5.60 25.76 0.82 3 ~ 380–415 50 CE
1) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION

3.3.5 Mains connection circuit breaker and supply lines

WARNING
ELECTRIC SHOCK HAZARD
In case of a short circuit, all phases must be disconnected from the power supply.
Otherwise, an electric shock can occur, which could lead to death, serious injury, or
damage to the equipment.
To make sure that all phases are disconnected, always use a 3-pole automatic circuit
breaker in the power supply (EN 60898-1, tripping characteristic B).

Frame size Motor size [A] [mm2] [m] [V] [Hz]

1/2 ZNC 63 B 8/2 3 1.5 100 380–415 50

5 ZNC 80 B 8/2 4 1.5 100 380–415 50
ZNC 100 A 8/2 10 1.5 54 380–415 50
10
ZNC 100 B 8/2 10 1.5 36 380–415 50
[A] = amperage of the mains circuit breaker (EN 60898-1, tripping characteristic B)
Minimum values have been specified here. Larger circuit breakers up to 10 A with 1.5 mm² supply lines or 13 A with 2.5 mm²
supply lines can also be used.
[mm2] = cross-section of the supply line
[m] = max. cable length in meters
The lengths of the supply lines are calculated based on 5% voltage drop, start-up current, and an earth-loop impedance of
200 mOhm.

3.4 Dimensions
NOTE For more information, see the technical data document for the product.

3.5 Materials and coating

Slipping clutch and brake linings are free of asbestos. As standard, the chain hoist is provided
with corrosion protection (powder coating or paint finish).

Standard housing materials

Part Material
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Chain hoist housing and motor Die-cast aluminum

Fan cover of the motor Plastic, partially impact-resistant

Service cover Plastic, partially impact-resistant

Chain collector box Plastic, partially impact-resistant

The chain hoist or the trolley can be supplied with other than standard paint finishes.

Standard paint finish

Component Color code Color

Chain hoist body and motor RAL 7021 Dark gray

Electric cover and fan RAL 5009 Azure blue

Hook assembly RAL 1007 Daffodil yellow

Load hook and suspension bracket RAL 9005 Jet black

Trolley RAL 5009 Azure blue

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3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS

3.6 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 the chain hoist 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 when the emergency stop is actuated, regardless of the lifting
speed. Wear of the mechanical brake is reduced by electric and regenerative braking of the
motor. The brakes of DC-II 1–DC-II 5 chain hoists are maintenance-free for up to 10 years, and
the brakes of DC-II 10 chain hoists for up to 5 years.

3.7 Gearbox and slipping clutch

3
B
A
2

1 4

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Figure 4. Parts in which the load is borne

A = Motor torque

B = Brake torque

1. Motor 4. Gearbox
2. Slipping clutch 5. Chain drive
3. Brake

The slipping clutch is arranged between the motor shaft and the gearbox input shaft. In
connection with the limit stops on the chain, it performs the function of the emergency limit stop
device for the highest and lowest hook position and protects the chain hoist against overload.
The additional electric operating limit switches 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 fulfills the EC Machinery Directive requirements for a load
control device for load capacities as of 1000 kg.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION

The brake that is arranged on the load side prevents the load from slowly dropping when the
unit is at rest. Monitoring of the slipping clutch and 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 ten years.

3.8 Chain drive

The special Demag chain is of high-strength ageing-resistant material with a high degree of
surface hardening, galvanized with another surface treatment. The dimension tolerances of this
chain have been precisely adapted to the chain drive. Therefore urgently recommend that the
Demag special chain be used to ensure safe operation. 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:

• 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. Motor and gearbox do
not need to be disassembled.

3.9 Electric equipment

3.9.1 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 triggered by the operator with the pendant controller.
Permissible control commands generate switching commands for the contactors to control the
hoist motor.

The electronic system monitors the control sequence that is specified 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 electrical circuit for the contactor supply so that the motor is de-energized and the brake is
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

applied.

As standard, the control system features the following characteristics:

• Operating limit switches for lifting and lowering.

• 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 24V tri-state signals for controlled chain hoists (half-wave
evaluation).

Pendant controllers are connected through plug-in connectors for manual control. Compact
DSC control units, which are optimized for 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.

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3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS

NOTE For more information, see "Electric accessories" document for integrating 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, for more information, see "Polu box electric accessories"
document.

3.9.2 7-segment display for operating status and fault display

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 (For more information, see "Display of software version".)

• Operating hours (For more information, see "Display of operating hours".)
• Operating statuses (For more information, see "Operating statuses and general messages".)
• Warning messages (For more information, see "Warning messages".)
• Error messages (For more information, see "Error messages".)
3.9.3 Display of software version, operating hours, number of cycles
Display of software version

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
0.8 s 0.8 s 0.8 s

0.2 s 0.2 s 0.2 s

Figure 5. Example: software version 1.01

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

Display of operating hours

0.8 s 0.8 s 0.8 s

0.2 s 0.2 s 0.2 s

Figure 6. Example: 123 hours of operation

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 OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION

The display appears after 3 s 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>

Figure 7. 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 inverter hoists). For more information, see "Service life of the contactor" on preventive
maintenance.

3.10 Central service enclosure

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 is also lubricated from this point.

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

The plastic cover also provides mechanical protection for the components that are fitted under
it. The functions are indicated by pictograms that are fitted on the outside of the service cover.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

3.11 Pendant controller

WARNING
STRONG MAGNETIC FIELD HAZARD
Magnets on the pendant controller can impact the functioning of pacemakers,
implanted heart defibrillators, and hearing aids, which can lead to death, or personal
injury.
If you wear any of these devices, follow the precautions that are associated with
magnetic forces.

DSC pendant controllers (lifting or lowering) must be used for manual cable-connected control
of the chain hoist. Pendant controller models DSC-5 (two motion axes), DSC-7 (three motion
axes), and 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.

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3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS

The shock and impact-resistant housings are of made high-quality thermoplastic and are
resistant to fuels, salt water, greases, oils, and alkaline solutions with IP65 enclosure. Strong
mineral acids (hydrochloric or sulphuric acid) can, however, corrode switch housings. To avoid
corrosion, 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.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

4 Installation

4.1 Safety during installation

WARNING
SPECIALIST SKILLS REQUIRED
Incompetent installation can be unsafe, or cause unsafe and unreliable operation of the
product that can cause death, serious injury, or property damage.
Only personnel who are authorized and properly trained may install the product. Local
regulations and the instructions and warnings that are provided in product
documentation must be obeyed.

WARNING
MACHINE MALFUNCTION HAZARD
Using a defective machine can cause death, serious injury, or property damage.
Any defects or abnormalities that are detected during installation must be investigated
and corrected in accordance with the instructions relevant for the component.

The owner of the product must make sure that these safety-related requirements
are fulfilled
• Installation personnel must be professionally competent, qualified, and are provided with
adequate instructions and training.
• Ensure that the test loading, test drive, and commissioning have been executed properly.
Check that the handover log has been completed properly.
• Ensure that components, electrical connections, and steel structures of the product have been
inspected and certified as defect-free.
• Check with your supplier that you have received all the relevant documents for the product
delivery. Check that the documents correspond to the product you have received.
• Ensure that tools and equipment are available for installation, in accordance with the sales
contract. Lifting equipment, manlift, and test loads may be required. In high places, safety
equipment must be used to make sure that objects do not fall.
• Ensure that sufficient time has been reserved for installation and testing.
• Prevent access to the area from unauthorized persons and bystanders. Ensure that the
secured area is spacious enough to prevent injuries that could occur if components or tools
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

fall.
• Secure the area so that installation personnel are not at risk from movements of machines,
automatic doors, or other cranes at the installation site.
• Before you allow the product to be used for normal operation, ensure that all safety devices
have been restored to their full operational status. Safety devices may have been bypassed
for test purposes. Never bypass a safety device for normal operation.
• Ensure that the runway is designed for the load of the product and that the runway rails meet
the requirements and tolerances. Runway must be equipped with suitable end stops.
• Ensure that the operating environment and space that is reserved for the product is suitable
for all functions of the product.
• Items that are not properly secured to the product, such as tools or detached components,
could move or fall accidentally. When dismantling the product, lower the components to the
ground at the earliest practical opportunity.
• If welding must be done at the site, make sure that suitable fire extinguishers are available.
Do not use product structure or components for grounding. Hook must be isolated before any
welding may be performed on it or equipment that is attached to it.
• After installation and before commissioning, check that the supplied parts conform to the
drawings, instructions, parts lists, and structural measurements. Discuss any non-
conformance with the supplier immediately.

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

Installation personnel must make sure that these safety-related requirements are
fulfilled
• Use fall protection procedures.
• Obey local safety regulations.
• Make sure that you have all the appropriate personal protective equipment. Use them when
required.
• Follow lockout-tagout-tryout procedure.
• Ensure that there is no possibility for personnel or body parts to be struck, crushed, or
compressed by moving machinery:
•Make sure that installation area is secured from the movements of machines, automatic
doors, or other cranes at the installation site.
•Ensure that products cannot start accidentally or move during installation.
• To reduce the risks, maintain sufficient space in the area.
• To prevent entrapment, shield moving parts with guards.
• Make sure that there are no hazards from loose items. Items that are not attached to the
product, such as tools or detached components, could move or fall accidentally. Use proper
safety equipment to make sure that objects do not fall when you work in high places.
• Check that the supply voltage and frequency match the requirements of the product. Check
that the installed busbars are suitable for the product.
• Ensure that the operating environment and space that is reserved for the product is suitable
for all functions of the product.
• If welding must be done at the site, make sure that suitable fire extinguishers are available.
Do not use product structure or components for grounding. Hook must be isolated before any
welding may be performed on it or equipment that is attached to it.
• Check for any electrical hazards in and around the operating area and take appropriate steps
to minimize them. Only properly trained personnel may perform electrical work on the product
and they must use safe working methods.
• Do not connect power supply before you have ensured that there are correct voltages,
phases, and current ratings available for each component.

4.1.1 Responsibilities of installation personnel

WARNING
MACHINE MALFUNCTION HAZARD
Locally sourced substitute parts may not meet the required specification and could

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
present safety hazards that can cause death, serious injury, or property damage.
Do not substitute parts (for example, missing items) with locally sourced items without
approval. Contact the manufacturer if there are doubts.

NOTE Usually at least two people are needed to complete the installation safely. Some tasks
can be done by one person but some are easier with two or more people. Make sure it is
clearly agreed who does which task and that nothing is overlooked. All personnel must
be properly trained for the tasks they perform and know how to install the product safely
before installation at site.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

• Personnel must be aware of any risk of accident that is posed by the site.
• Personnel must familiarize themselves with the signs and warnings on the product.
• Personnel must familiarize themselves with use and safety instructions of needed tools, like
manlifts and lifting equipment.
• Personnel must obey the local regulations.
• Personnel must be fit for the work.
• Do not work when you are under the influence of alcohol or drugs. Alcohol and drugs can
impair judgment and cause a hazard.
• not work when you are under medication that may cause a hazard to you or others. If
Do
you are unsure, consult your doctor or pharmacist. Comply with local regulations about
working under the influence of medication.
• Do not work when you suffer from any illness or injury that can impair your ability to
properly do the required tasks.

4.2 Installation preparation

4.2.1 Installation environment requirements

• Installation site must be sufficiently spacious and clear to permit the construction of the
product. Floors must be level and the site should present no avoidable hazards to the
installation personnel.
• Prevent unauthorized persons and bystanders from walking on or below the work site. To
prevent injuries from possible falling components or tools, ensure that the secured area is
spacious enough.
• Ensure that there is no possibility for personnel or body parts to be struck, crushed, or
compressed by moving machinery:
• Secure the area so that installation personnel are not at risk from the movements of
machines, automatic doors, or adjacent cranes at the installation site.
• Ensure that products cannot start accidentally or move during installation.
• To reduce the risks, maintain sufficient space in the area.
• Adequate lighting must be available according to local regulations. For example, EN 12464.
4.2.2 Tool requirements for installation
Tools that are required during the installation work:

• Suitable lifting equipment that is able to lift the total weight of the product assembly.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

• General tools such as screwdrivers, cutters, and hacksaws.

• Torque wrench to tighten fasteners to the specified torque.
• Painting equipment may be required to paint or touch up the product.
• If it is necessary to terminate the cables during installation, you need a suitable heat gun to
shrink the heat-shrink sleeves.
• It is useful to have a range of electric or compressed air power tools available. These tools
can include drills and powered wrenches for tightening fasteners. If you use compressed air,
follow the correct procedures and be aware of the safety risks.
• Some lubricants such as cutting oil can be useful in installation. Handle and store lubricants
according to applicable safety guidelines.

4.2.3 Preparing for installation

1. Familiarize yourself with the installation instructions delivered with the hoist before you start
the work.
2. To remove the hoist from the packaging, first remove the temporary transport supports.
3. Make sure that all components match the order and are undamaged. If the delivery is
damaged or incomplete, contact manufacturer or representative of the manufacturer
immediately for instructions.

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

4. If the hoist has been stored for a long time or has been transported by sea, do the following
checks.
4.1 Make sure that the motors are dry.
4.2 Check that brake lining is undamaged.
4.3 Make sure that parts are lubricated.
4.4 Make sure that electronic devices are charged.

For more information, see chapter “Returning the product to use” in "Operating and
Maintenance Instructions".
5. Move the hoist to the installation location.

4.2.4 Evaluating the weight of the hoist

WARNING
FALLING LOAD HAZARD
Lifting a load that exceeds the rated capacity of the lifting equipment and lifting
accessories can cause the load to fall, which can cause death, serious injury, or
property damage.
Never attempt to lift a load that is heavier than the rated capacity of the machine.
Never use an overload device to determine whether the load can be lifted.

Overloading can damage the lifting equipment.

NOTICE Never attempt to lift a load until you are satisfied that it weighs less than the maximum
permitted load of the lifting equipment.

It is important that you know the weight of the hoist before lifting so that you can select an
appropriate lifting equipment and prevent overloading. The weight of the hoist can often be
found from the packing list, the technical documents, or the data plate.

4.2.5 Lifting equipment

WARNING
FALLING LOAD HAZARD
If the lifting equipment fails, the load could fall, which can cause death, serious injury,

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
or property damage.
Do not use a lifting equipment that does not clearly show the rated capacity or is not
approved by authorities. Lifting equipment must be suitable for the purpose and
undamaged. Carefully inspect lifting equipment before using them.

Always follow instructions that are provided by the lifting equipment manufacturer and
NOTICE the local authorities. The manufacturer of the hoist is not responsible for lifting
equipment by other manufacturers.

Typically, the hoist is lifted by using an auxiliary hoist and some kind of a lifting accessory. The
most common lifting accessories are chains, wire rope slings, and lifting belts. Each lifting
accessory must be clearly marked with the rated capacity and must be approved by authorities.

4.2.6 Lifting points on the hoist

Lift the hoist from the suspension bracket.

If lifting points are available on the hoist, they are marked with a sticker.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

NOTE Before lifting the hoist, read the instructions in "Evaluating the weight of the hoist",
"Lifting equipment", and "Before lifting".

4.2.7 Before lifting

WARNING
FALLING LOAD HAZARD
Using lifting equipment contrary to instructions poses several risks, which can cause in
death, serious injury, or property damage.
Use lifting equipment and lifting accessories in accordance with the instructions of the
manufacturer.

WARNING
FALLING LOAD HAZARD
Lifting an improperly attached load can cause the load to fall, which can cause death,
serious injury, or property damage.
Do not move the load until you have confirmation that it is properly attached.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

WARNING
FALLING LOAD HAZARD
An unbalanced load can drop, which can cause death, serious injury, or property
damage.
Place all slings and harnesses so that the pulling force is distributed evenly. If the load
is unbalanced, do not try to support it with your hands. Lower the load down and adjust
the lifting points until the load is balanced.

Check that the load is balanced and safely fastened at the lifting points. The load must not be
able to slide, slip, or detach itself when suspended.

NOTE When you begin to lift, check that the load is properly balanced before lifting it high off
the floor. If the load is not balanced, lower it down and adjust the lifting point.

4.3 Installation procedure

1. Unpack the product, and check that the delivery is complete.
For more information, see "Transportation, storage and dismantling".

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

2. Dispose of the packing material in an environmentally compatible way.

For more information, see "Transportation, storage and dismantling".
3. Connect the pendant controller.
For more information, see "Connecting the controller".
4. Check that the hoist is equipped with a suitable suspension bracket.
For more information, see "Suspension of the chain hoist".
5. Adjust the height of the pendant controller.
For more information, see "Pendant controller height adjustment".
6. Connect to the power supply.
For more information, see "Mains connection".
7. Lubricate the chain with grease over its entire length before the equipment is put into
operation for the first time. For more information, see "Lubricating the chain".

WARNING! FALLING LOAD HAZARD

Premature wear can lead to failure of the chain and a dropping load. Failure of the chain
and a dropping load can cause death, serious injury, or property damage.
Lubricate the chain along its entire length. Covered chain links which are, for example,
in the chain anchorage, hook assembly, limit stop, and the crab frame, must also be
fully lubricated.

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

8. Set the lowest hook position.

For more information, see "Adjusting the lower hook position".
9. Carry out the commissioning of the product.
For more information, see "Commissioning".

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

4.4 Connecting the pendant controller to the control cable

If the chain hoist is not supplied with the pendant controller fitted, connect the DSC pendant
controller to the control cable and lock the connection with the bayonet lock.

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 pressure.

The pendant controller can also be installed as a traveling unit. For more information, see
"Mobile control system".

1. Lift the bend protection sleeve (1) on the

pendant controller off the two pins.
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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

2. Pull the bend protection sleeve (1) off the

pendant controller.

3. Slide the bend protection sleeve (1)

upwards on the control cable, insert the
control cable into the pendant controller, d
and turn the bayonet lock until it locks.
•
Check that the groove (a) on the
connector fitting lines up with the swivel
lock (b) in the pendant controller housing. a

•
Check that the two pins (c) on the
pendant controller housing line up with
the bayonet lock (d). c b

4. Slide the bend protection sleeve (1) over

the pendant controller again, and press the
bend protection sleeve (1) firmly into place.
Pay attention to the positioning markers.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

4.5 Suspending the chain hoist

WARNING
OVERLOAD HAZARD
Overloaded components can cause malfunctions, which can cause serious injury,
death, or damage to the equipment.
The suspension or supporting structure of the chain hoist must be designed for the
maximum load that is caused by the operation of the chain hoist when the chain hoist is
used as intended.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

WARNING
FALLING HAZARD
The chain hoist may fall, which can cause death, serious injury, or damage to the
equipment.
Do not use chain hoists that have a fixed suspension, such as a suspension bracket or
suspension hook, for inclined pull of loads.
The chain hoist must be suspended with an articulated arrangement. Inclined pull must
be prevented from rigid suspension arrangements.

WARNING
FALLING HAZARD
The chain hoist may fall, which can cause serious injury, death, or damage to the
equipment.
Do not move the chain hoist or leave it unattended when the suspension bracket is
open.

4.5.1 Supporting structure

According to DIN EN 14492-2, the force limitation factor is ϕDAL = 1,6 for chain hoists with a
rated capacity that is greater than or equal to 1000 kg1 ston. The supporting structure must be
designed to accommodate the static and dynamic forces that occur when the overload
protection device is tripped.

According to DIN EN 14492-2, chain hoists with a rated capacity that is greater than or equal to
1000 kg1 ston must be equipped with overload protection. This chain hoist is delivered with a
slipping clutch that acts directly as an overload protection.

The slipping clutch must be adjusted according to the rated capacity of the chain hoist. For
more information, see "Adjustment of the slipping clutch".
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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

4.5.2 Attaching the chain hoist to the supporting structure or the trolley

WARNING
MACHINE MALFUNCTION HAZARD
If the suspension bracket is installed incorrectly, the chain hoist hangs at an angle.
Suspending the chain hoist at an angle results in premature wear of the chain drive.
Make sure that the suspension bracket is fitted to match the chain reeving arrangement
of the chain hoist.
If special fittings are installed on the chain hoist, make sure that they are counter-
balanced.

1 2 3

1. Suspension bracket for DC-II 1–DC-II 5 3. Suspension bracket for DC-II 10 2/1
2. Suspension bracket for DC-II 10 1/1 reeving
reeving

The chain hoist is delivered with the long suspension bracket fitted to the chain hoist. The
enclosed short suspension bracket can be installed for an improved C-dimension.

1. Remove the retaining clip (2) and pin (3) on

one side of the suspension bracket (1). 2 1
For frame size DC-II 10, also remove the
spacer tube (4). 4

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
3

2. Attach the suspension bracket to the supporting structure or the trolley.

3. Insert the pin through the suspension points on the hoist and the suspension bracket.
For frame size DC-II 10, also insert the pin through the spacer tube.
4. Secure the pin with the retaining clip.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

4.6 Electrical connections

4.6.1 Safety during electrical work

WARNING
SPECIALIST SKILLS REQUIRED
Incompetent electrical work can be unsafe, or cause unsafe and unreliable operation of
the product that can result in death, serious injury, or property damage.
Electrical work must be carried out by authorized service personnel or an experienced
service technician who is authorized by the manufacturer or representative of the
manufacturer. Electrical connections must be made according to wiring diagrams
provided with the product.

WARNING
ELECTRIC SHOCK HAZARD
If the power supply to the product is on when electrical work is done, there is a risk of
electric shock that can cause death, serious injury, or property damage.
Before doing electrical work, make sure that the power supply to the product is off and
obey local regulations for lockout-tagout-tryout procedure.

4.6.2 Circuit diagrams

NOTE The circuit diagrams for the chain hoist are shown in "APPENDIX: DC-II 1–DC-II 10 solo
hoist circuit diagram."

For more information on circuit diagrams with E11–E34 travel drives, see E11–E34 DC travel
drive assembly instructions (II).

For more information on E11–E34 travel drives, see E11–E34 DC travel drive assembly
instructions (I).

For more information on cross-travel limit switch part no. 716 663 45, see E11–E34 DC travel
drive assembly instructions (I).
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

NOTE For more information on circuit diagrams, see "www.dc.demag-designer.com."

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

4.6.3 Control board

1 2 3 4 5

11

10 12

13
9
9

14

8 7 6

Terminal
Item Designation Function
strip

1 Plug-and-socket connector X8 Motor

2 Plug-and-socket connector X6 Brake

3 Relay Fast or slow

4 Relay Lifting or lowering

5 Relay Lifting or lowering

6 Transformer

Label with:

7 Serial number • Serial no. "SN..."

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
• Modification status "MS…"
• Calendar week/year production date "**/**"
8 Flat connector Grounding, PE

9 Plug-and-socket connector X1 Power

10 Contactor On or off

11 Dummy plug X5 (Optional) trolley

12 Plug-and-socket connector X4 Operating limit switch or plug-in jumper

13 Plug-and-socket connector X3 Control cable

14 Plug pin X1.4 X1 Grounding, PE

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

RJ45 connector

1. Pin 1

Function
Pin
Control cable X3 Trolley X5

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

7 Lower Pendant controller reference potential

8 Traveling hoist right Traveling hoist right

9 Traveling hoist left Traveling hoist left

10 Special F2 Special F2

Limit switch connector

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

1. Pin 1

Function
Pin
Lifting limit switch X4

1
Lift
2

3
Lower
4

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

4.6.4 Control cable

The control cable is protected by a flexible strain relief sleeve. If you need to adjust the
suspension height of the pendant controller, you can unlock the self-locking clamp mechanism
on the strain relief sleeve, and move the pendant controller to the preferred height. The part of
the control cable that is not needed is stored under the service cover.

The strain relief sleeve for the control cable consists of an abrasion-resistant fabric hose with
flame-protection impregnation. The control cable is reinforced by elastic rubber filler material in
the gripping area (0.8 m) of the strain relief sleeve.

Figure 8. Control cable assembly

1. Sleeve compartment 3. Control cable locking mechanism bolt,

2. Control cable locking mechanism latch tightening torque 11 Nm

Hook path H4 H5 H8 H11

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Cable length [m] 0.8–2.8 0.8–3.8 3.8–6.8 6.8–9.8

The pendant controller is supplied with standard cable lengths. The length can be adjusted by 2
or 3 m, depending on the hook path. Longer control cable lengths can be provided, for example,
by using a 2TY control cable and DST-C or DSE-C control pendants.

4.6.5 Adjusting the suspension height of the pendant controller

To obtain an ergonomic operating position, you can adjust the suspension height of the pendant
controller, for example, in such a way that the control elements are arranged at elbow height.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

1. Unscrew 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.

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

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.

“x” “y”

x = Control cable locking mechanism engaged

y = Control cable locking mechanism released

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 the chain collector box.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

8. Close the service cover.

Tighten the screws to the torque of 5.5 Nm.

4.6.6 Installing the support sleeve on DSC, DSK or DST pendant controllers

4.6.6.1 Disassembling the DSC pendant controller

1. Slide the bend protection sleeve upwards on the control cable and turn the bayonet
connector to disconnect the pendant controller from the control cable. For more information,
see "Connecting the controller".
2. Remove the bend protection sleeve from the control cable.

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3. 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. For more information, see
"Replacing the control cable".

4.6.6.2 Installing the support sleeve on DSC pendant controllers

1
2
3
4 3 1
5
6

1. Slide the bend protection sleeve (1) and the hose clip (3) onto the support sleeve (2) with
the new control cable (4).
2. Pull the new control cable (4) out of support sleeve (2) by at least 50 mm on the pendant
controller side.
Keep the support sleeve stretched tight.
3. Slide the connector fitting (5) slightly away from the connector (6).
4. Press the connector (6) into the DSC pendant controller until you hear the connector click
into place.
5. Press the connector fitting (5) into the DSC pendant controller.
6. Keep the support sleeve (2) stretched tight and slide it over the connecting sleeve of the
pendant controller until it stops against the housing.
7. Secure the support sleeve (2) by tightening the hose clip (3).
The screw of the hose clip (3) must be located at the back. Otherwise, the bend protection
sleeve (1) cannot be correctly positioned.
8. Slide the bend protection sleeve (1) over the pendant controller again.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Pay attention to the positioning markers.

9. Press the bend protection sleeve (1) firmly into place.

4.6.6.3 Installing the support sleeve on DSK pendant controllers

5 3
6
6 4

Figure 9.

1. Slide the bend protection sleeve upwards on the control cable and undo the screws of the
DSK pendant controller housing.

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

2. Loosen the hose clip on the connecting sleeve and disconnect the plug from the DSK
pendant controller.
3. Slide the bend protection sleeve and the hose clip onto support sleeve (3) with new control
cable (4).
4. Remove strain relief (7) in the DSK pendant controller.
5. 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.

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

6. Insert control cable (4) into the DSK pendant controller and connect connector (6).
7. 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.
8. Slide the bend protection sleeve over the pendant controller again.

4.6.6.4 Installing the support sleeve on DST pendant controllers

5 3

6
6 4

Figure 10.

1. 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.
2. Open strain relief (7) in the pendant controller and disconnect the plug from the DST

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
pendant controller.
3. 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).
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.

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

5. Insert control cable (4) into the DST pendant controller and connect connector (6).
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.
7. Close the pendant controller.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

4.6.6.5 Installing the sleeve compartment on the rubber sleeve cable

1. Push the seal (1) into position against sleeve compartment (2).
2. Connect the new control cable to the chain hoist.
3. Attach the sleeve compartment to the chain hoist with the screw (3).
4. Close the service cover and the electric equipment cover.

4.6.7 Mobile control system

4 1

5
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Figure 11.

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

Component parts

Item Designation Comprising Part no.

1 11-pole + PE flat cable 720 139 45

Socket enclosure

Mounting frame
2 Connector enclosure cpl. 720 187 45
VC-AMS8 pin insert

Flat cable union

Bayonet lock

VC-MP-1-R-M25 bush
3 Connector adapter cpl. enclosure 720 087 45
VC-TR1/2M bush frame

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 -

NOTE Height-adjustable standard control cables H4, H5, H8, H11 must be used if a cable
collector is fitted.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
A

Figure 12. X40 plug connector

X40 plug connector pin assignment

Signal Conductor PIN Conductor Signal

- - B4 B8 - -

PE PE B3 B7 - -

- - B2 B6 - -

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

X40 plug connector pin assignment

Signal Conductor PIN Conductor Signal

Special F2 10 B1 B5 8 Right

Left 9 A4 A8 7 Lower

Control voltage
Lift 6 A3 A7 5
(24 V, STS)

Emergency stop 4 A2 A6 3 Reverse

Forwards 2 A1 A5 1 Special F1

4.6.8 Mains connection

1 2 3
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

4 5

Figure 13.

1. Sealing sleeve 4. Mains connection

2. 4-pole connector 5. Recess for cable
3. Connector enclosure

The mains connection cable, the mains connection fuse links, and any devices to disconnect
and switch the power feed must be available on site to connect the unit to the power supply. You
need a 4-lead cable with a PE protective earth conductor which complies with the electric key
data for the power supply. For more information, see "Electric key data".

The length of the supply cable that is specified for a given cross-section must not be exceeded
to avoid excessive voltage drop and malfunctions caused by undervoltage when the motor
starts up.

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

4.6.8.1 Connecting the chain hoist to the electric supply

1. Check that the voltage and the frequency that are specified on the rating plate match your
mains supply.
2. Check that the power supply to the hoist is protected with correct size fuses.
3. Ensure that the mains connection cable is not connected to the power supply, and is
secured against accidental restoration of the power supply.
For more information, see "Logout-tagout-tryout procedure".
4. Remove the service cover.
5. Use the mains connection set included in the delivery for the plug connection to the mains
connection cable.
6. Cut the sleeve (1) to match the shape of the mains cable.
For the round cable, cut the sleeve within the area that is marked 7–13 on the sleeve. For
the flat cable, cut the sleeve within the area that is marked 18x7 to 20x8. The system is
designed for cable cross-sections of 4x1.5 mm2 or 4x2.5 mm2.
7. Slide the sleeve (1) onto the mains cable.
Make sure that the sleeve (1) tightly encloses the cable for the specified enclosure
requirements.
8. Connect the power supply cable on connector (2) to terminals L1, L2, L3 and to the PE.
If necessary, use the wire end sleeves included in the delivery.
9. Slide the connector (2) into the housing (3) until it latches.
10. Close the housing (3) with the sleeve (1).
11. Insert the connector (2) into the control system until the housing (3) latches with the card
bracket.
12. Insert the mains cable into the opening in the gearbox housing and secure it with the strain
relief clamp.
For DC-II 1–DC-II 5 units, the strain relief clamp must be turned to match the shape of the
cable (flat or round cable).

NOTE • Replace components 1, 2, and 3 as a set, since parts 2 and 3 from sets until 04/2021 are
not compatible with parts from sets as of 05/2021.
• All housing parts must be securely latched to make sure that the unit is sealed.
• Check the continuity of the earth lead connection after the mains cable has been

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
connected and before the chain hoist is put into operation.
• The mains connector must never be disconnected under load.
4.6.8.2 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 unknown, connection with
the correct phases is established in this way.

4.6.8.3 Checking directions of motion

The chain hoist must be connected to the power supply to check whether all phases are
correctly connected. Turn on the power supply, unlock the emergency stop, and actuate the
"Lift" button on the controller. The load hook must now move upwards.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

WARNING! INCORRECT DIRECTION OF MOVEMENT

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

4.7 Programming parameters with the pendant controller

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

4.7.1 Chain hoist parameters

In software version SW 2.10, the following parameters can be programmed.

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

0. -

1. -

n. Default V1/V2
2. Hoist only V2 speed
Y. V2

Default Pendant controller is locked when

n.
several buttons are actuated.

3. Lock the pendant controller Priority is given to the first button that is
Y. pressed if the lifting and lowering buttons are
actuated together.

Time-controlled start-up (for n. Default Speed-dependent start-up

4. example, for tandem
operation) Y. Time-controlled start-up

Y. DC-Com 2-5, ZNK 71 B 8/4, ZNK 80 A 8/4

5. Chain hoist
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

n. Default DC-Pro

6. -

7. -

8. -

9. -

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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

4.7.2 Using parameter-programming mode, travel drive E22-C/E...WD

1. Emergency stop 3. Lower button

2. Lift button

1. Press the emergency stop (1).

7-segment displays 8.

2. Press and hold the lift button (2) and

unlock emergency stop (1). Wait for
approximately 10 seconds.
7-segment display displays a dot.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
3. When "P." is displayed, release the lift
button (2).
"P." disappears after approximately 2
seconds.

4. Press and hold the lift button (2) until "o." is

displayed.

5. Release the lift button (2).

When parameter-programming mode has
been activated, figures 0–9 are
successively displayed for 2 seconds each.
Parameter-programming mode is active.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

6. To scroll through the menu items faster,

press the lower button (3).
Each figure represents a parameter. For
more information, see "Chain hoist
parameters".

7. To select the displayed parameter, press

the lift button (2).
For more information, see "Chain hoist
parameters".
The value selection menu for the
parameter opens. The values are displayed
symbolically with the characters "A.", "b.",
"C."

8. To set a different value, press the lower

button (3) until the required value is shown
on the display.

9. To select the value, press the lift button (2).

The system returns to the parameter
selection mode. The 7-segment display is
empty.

10. To return to normal operation, press the

emergency stop (1).
All changes are saved. The 7-segment
display is empty.
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4 INSTALLATION OPERATING AND MAINTENANCE INSTRUCTIONS

4.8 Adjusting the lower hook position

Figure 14. Limit stop

1. Buffer 3. Unloaded chain fall

2. Limit stop

When determining the hook path or the lifting height, ensure that the load hook touches the
ground in the lower hook position. The chain hoists are provided with a hook path of 5 m or 8 m
as standard.

Frame size Tightening torque of the limit stop [Nm]

DC-II 1–DC-II 5 2.9

DC-II 10 4.3

1. Lower the hook on the floor.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

2. To stop the chain hoist, actuate the emergency stop or the mains connection switch, and
secure it against switching on again.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 4 INSTALLATION

3. Remove the chain collector box.

For more information, see "Removing the chain collector box".
4. Remove the limit stop on the chain collector box end.

5. Attach the limit stop directly behind the buffer.

NOTE The unloaded chain fall behind the limit stop must consist of at least five chain links. For
more information, see "Buffer and cut-off spring arrangement".

6. Place the chain in the chain collector box.

7. Reconnect the chain collector box to the chain hoist.
8. Switch on the chain hoist.
9. To check the adjustment of the lower hook position, move the hook and run the chain over
the entire adjusted hook path.
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5 COMMISSIONING OPERATING AND MAINTENANCE INSTRUCTIONS

5 Commissioning

5.1 Safety during commissioning

WARNING
SPECIALIST SKILLS REQUIRED
Incompetent commissioning can be unsafe, or cause unsafe and unreliable operation of
the product that can cause death, serious injury, or property damage.
Only personnel who are authorized and properly trained may commission the product.
Local regulations and the instructions and warnings that are provided in product
documentation must be obeyed.

WARNING
MACHINE MALFUNCTION HAZARD
Using a defective machine can cause death, serious injury, or property damage.
If you notice any abnormalities or defects during commissioning, investigate and repair
the products according to instructions. Defective products may not be taken into use.

NOTE Local regulation may demand other commissioning tests to be performed before the
products can be taken into use. Make sure that all local requirements are fulfilled in
commissioning.

• Obey local safety regulations.

• Make sure that you have all the appropriate personal protective equipment. Use them when
required.
• Follow the fall protection procedures.
• Prevent access to the area from unauthorized persons and bystanders.
• Ensure that the secured area is spacious enough to prevent injuries that could occur if
components or tools fall.
• Follow lockout-tagout-tryout procedure.
• Inform personnel who work in close the area about the commissioning and tests.
• Use hand lines that are securely attached to the building structure to lift and lower materials
and tools. When you work in high places, use safety equipment to make sure that objects do
not fall.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
• Make sure that personnel or body parts cannot be struck, crushed, or compressed by the
product when it moves:
• To prevent entrapment, use guards to shield parts that move.
• Be prepared in case the equipment moves in the wrong direction during tests.
• Verify that installation of mechanical and electrical equipment is completed according to the
SAT (site acceptance test) check list.

5.1.1 Responsibilities of commissioning personnel

• Personnel must know how to use basic controls correctly and safely for the purpose of
functional tests.
• If you use a manlift, familiarize yourself with its operating and safety instructions.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 5 COMMISSIONING

5.2 Commissioning preparation

5.2.1 Commissioning environment requirements

• Mark the operating area where you carry out the commissioning tasks, such as test loading.
• Identify possible collision hazards of the crane to structures, obstacles, equipment, or
personnel. Take proper actions to limit collision hazards.
• Adequate lighting must be available according to local regulations. For example, EN 12464.

5.2.2 Commissioning tool requirements

• Normally no electrical fault-finding is required but a multimeter may be required during
functional tests.
• Tightening fasteners to the specified torque requires a torque wrench.
5.2.3 Preparing for commissioning
1. Before commissioning, check that the supplied parts conform to the drawings, instructions,
parts lists, and structural measurements. Discuss any non-conformance with the supplier
immediately.
2. Check that there are no hazards from loose items. Items that are not attached to the
product, such as tools or detached components, could move or fall accidentally.
3. Check that no permanent or temporary obstructions are in the way of the product when it is
operated.
4. Prepare for the load test. Find out how much load is required in local regulation. Normally
the load that is required varies between 90%–130% of the rated capacity.

5.3 Commissioning instructions

5.3.1 Commissioning inspections

WARNING
FALLING LOAD HAZARD
Premature wear can lead to failure of the chain and a dropping load. Failure of the chain
and a dropping load can cause death, serious injury, or property damage.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

The chain must be lubricated along its entire length. Covered chain links, for example,
in the chain anchorage, the hook assembly, the limit stop, and the frame of a low
headroom trolley, must also be fully lubricated.

NOTE 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 the emergency stop button. - x
Check the direction of movement. "Mains connection" x
"7-segment display for operating status and fault display"
Check the 7-segment display. "Display of software version, operating hours, number of x
cycles"
Check chain lubrication. (In arduous conditions, the chain
"Available chains" x
must be lubricated more frequently.)

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5 COMMISSIONING OPERATING AND MAINTENANCE INSTRUCTIONS

Activity Section Check

Check the operation of the lifting-motion operating limit
"Checking the operating limit switches" x
switch.
Check the operation of the lowering-motion operating limit
"Checking the operating limit switches" x
switch.

Check the cut-off buffer, the cut-off spring, and the "Checking the cut-off buffers and cut-off springs"
x
operating limit switch actuator. "Checking the operating limit switch actuator"
Check the cable and the controller housing for damage. - x
Check the operation of the brake. - x
Check the hook and the hook safety latch. "Load hook dimensions and wear" x

5.3.2 Checks before first use

WARNING
IGNORING INSTRUCTIONS HAZARD
Failure to follow the given instructions can cause death, serious injury, or property
damage.
Machines may only be put into service if they have been checked for compliance with
the corresponding accident prevention regulations. Do the inspections as instructed in
"Commissioning inspections" and all the relevant checks before you put the product
into operation.

With 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 service. 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 button 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

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
in all possible applications, in each case with the maximum permissible load. Operation of the
safety devices must be checked, for example, by lifting an overload. At the same time, the
behavior 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 when safe operation of the chain hoist is
ensured.

The test and inspection records must be handed over when the machine is handed over.

The machine may be used as intended after it has been handed over.

5.4 Finishing commissioning

NOTE Local regulations may demand other commissioning testing to be performed before the
product can be taken into use. Make sure that all the local requirements are fulfilled.

NOTE All optional features must be tested before using the product.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 5 COMMISSIONING

1. Make sure that any safety devices that have been bypassed for testing purposes are
restored to full operational status. Never bypass a safety device for normal operation.
2. Turn off all controllers and main isolation switches that are on the ground level.
3. Check visually that the hoist or any other part has not damaged in any way during testing.
4. Make sure that tools and materials that are used during installation are removed from the
hoist and the runway.
5. Ensure that the hoist operator and supervision personnel are aware of the need for user
training.
The authorized service organization of the hoist manufacturer can arrange user training by
separate agreement.
6. Check the documents delivered with the hoist.
Ensure that entries in the documents are properly recorded and that the reference data in
the documentation matches that on the type data plates.
7. Compile a commissioning log for the hoist. Store the log with the other documentation for
the hoist.
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6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS

6 Operation

6.1 Safety during operation

DANGER
CRUSHING HAZARD
Persons within the operating area of the machine could become crushed by a falling
load or moving machinery. This will cause death or serious injury.
Before starting and while operating the machine, make sure that there are no
unauthorized persons on the machine or in the operating area.

• Do not deliberately use limit switches to stop the movement. Always stop the movement with
the controller.
• If the controller has a hoist or crane selection switch, be sure to select the correct hoist or
crane before operating.
• If the crane malfunctions during use, push the emergency stop button and contact the
supervisor.

6.1.1 Operating environment

Operate the product only in operating conditions that the product is designed for. For more
information, see "Operating conditions".

6.1.2 Responsibilities of the operator

WARNING
IGNORING INSTRUCTIONS HAZARD
Failure to follow the given instructions can cause death, serious injury, or property
damage.
Read and understand this information before operating, servicing, and maintaining the
machine.

Hoists are used for various purposes. They can be used to handle different types of loads, and
many different operators use them in different ways. The hoists are often operated also by non-
dedicated operators as part of work routines.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Because the manufacturer of the hoist has no direct involvement or control over the hoist
operation and application, following the safety practices is the responsibility of the owner and
the operating personnel. Only authorized and qualified personnel, who can demonstrate that
they have read and understood the instructions, are permitted to work with the hoist. The
qualified personnel must also understand the proper operation and maintenance of the product.

Operators must
• Operators must be trained by the owner of the product or a qualified designee. Operators
must be competent for the task.
• Operators must learn how to operate the product safely, before they start to work with the
product.
• Operators must know all the controls and they must be able to use them correctly and safely.
• Operators must learn how to control the movements of the hook and load.
• Operators must be aware of any risk of accident that is posed by the operating site.
• Operators must familiarize themselves with the labels and warnings on the product.
• Operators must use the instructions to familiarize themselves with the product and the product
controls.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION

• Operators must learn the hand signals for directing the product movements.
• Operators must be familiar with proper rigging procedures.
• Operators must carry out daily inspections.
• Operators must follow local regulations.
Operators must not
• Operators must not operate the product when under the influence of alcohol or drugs. Alcohol
and drugs can impair judgment and cause a hazard.
• Operators must not operate the product when under medication that may cause a hazard to
the operator or others. If unsure, consult your doctor or pharmacist. Always comply with local
regulations regarding working under the influence of medication.
• Operators must not operate the product while they suffer from any illness or injury that may
impair their ability to properly use the product.

6.2 Checks before operating

WARNING
MACHINE MALFUNCTION HAZARD
Operating a machine that is defective or in an abnormal condition can cause death,
serious injury, or property damage.
If you notice any abnormalities or defects during the operational checks, report them
immediately to the supervisor and remove the machine from use. Operation may only
continue when safe operation of the machine is ensured.

6.2.1 Checking the hoist before every working shift

Before every working shift, check the general condition of the equipment and the working
environment.
1. Check the operating environment
Check the operating environment visually to make sure that there are no (new) hazards that
can prevent the safe use of the product.
2. Check the condition of the hoist
Check the general condition of the hoist.
3. Perform visual checks
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Check the hoist visually to see that there are no oil leaks from the hoist or other equipment.
4. Check the operation of the emergency stop button
Check that the emergency stop button can be pressed down and that it stays in that
position.

NOTE Never operate the product if it is locked or tagged out.

5. Check the chain

•
Check the chain visually for any deformations, damage, or twisting.
• Check the chain for cleanness and correct lubrication. For lubrication instructions, see
chapter Lubrication.
6. Check the hook
•
Inspect the hook for nicks, gouges, and twisting. Also inspect the hook for deformation of
the throat opening and wear on the saddle or load bearing point.
•
Check that the hook rotates freely.

7. Check the pendant cable and the retaining wire

Check the condition of the pendant cable and its retaining wire. The pendant cable and the
retaining wire may not be damaged, and no wires may come out of them.
8. Check warning signs

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6 OPERATION OPERATING AND MAINTENANCE INSTRUCTIONS

Check that all warning signs are in place. Check that the warning signs are in good
condition and can be read easily.

6.2.2 Checking the operation with the emergency stop button pressed
down

WARNING! UNCONTROLLED MOVEMENT HAZARD

If the emergency stop button is faulty, the product might move unexpectedly during the
following checks. Unexpected movements during checks could cause serious injury or
death.
Do not stand in the danger zone.

1. Turn on the main isolation switch.

The product becomes operational (energized).
2. With the emergency stop button pressed down, check that the equipment does not move
when you press the direction control push buttons.
If the equipment does not move, it verifies that the emergency stop button works properly.
3. Check for smooth mechanical operation of each push button, joystick, or isolator on the
controller.

6.2.3 Checking the operation with the controller enabled

Before every working shift, all of these checks must be done with the emergency stop button
released and with the power to the hoist switched on.

WARNING! UNCONTROLLED MOVEMENT HAZARD

Releasing the emergency stop button and operating the product when it is unsafe could
cause serious injury or death.
Never release the emergency stop button and operate the product until you are sure
that it is safe to do so.

1. Check the warning devices

Before starting to use the equipment, check that all warning devices (such as indicator
lights, LEDs, displays, gongs, bells, alarm horns, alarm sirens, and beacon lights) work

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
correctly.
2. Set up the controller
Set up the controller. For instructions, see chapter Setting up the controller.
3. Check the operating directions
Check that all movements correspond to directions that are given in the controller labels.
Start the checking with the low speed.
4. Check the brakes
Check that the brakes operate in all directions and that the speed increases as it should do
in relation to the control.
5. Check the noises
Listen for unusual noises.
6. Check the mechanical limit switch operation
Check the upper and lower mechanical limit switches.
1. Check the condition of the rubber part on top of the hook. The rubber parts activate the
mechanical upper and lower limit switches on the hoist. If a rubber part is damaged or
not in place, the limit switch does not function correctly.
2. Check the correct operation of the limit switches by raising and lowering the hook at
low speed. When doing the check, drive the chain from one end to the other.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 6 OPERATION

7. Check the geared limit switch operation (if equipped)

If the hoist is equipped with a rotating geared limit switch, check the operation of the limit
switch. The cutting points (upper and lower limits) of the geared limit switch must be
adjusted before starting to operate the hoist.
1. First check the operation of the limit switch. For instructions, see chapter Testing the
hoist without load.
2. After checking the operation of the limit switch, adjust the upper and lower limits. For
instructions, see chapter Adjusting the rotating geared limit switch. If the limit switches
cannot be adjusted, the rotating geared limit switch must be replaced.
8. Check the hook safety latch
Check to ensure that the hook safety latch is in place on the hook. Check that the hook
safety latch is in good condition and that it closes automatically.

6.3 Starting the equipment

6.3.1 Setting up the controller

WARNING! UNCONTROLLED MOVEMENT HAZARD
Releasing the emergency stop button and driving the hoist when it is unsafe can cause
serious injury or death.
Never release the emergency stop button and drive the product until you are sure that it
is safe to do so.

1. Make sure that the main isolation switch is in the position ON.
The hoist becomes operational (energized) only after connection between the product and
controller has been established.
2. If applicable, use the key switch to turn on the controller.
3. To prepare the controller for operation, release the emergency stop button.
To release the emergency stop button, turn it clockwise. If the emergency stop button is a
push-pull type button, release it by lifting the button up to the raised position.
4. Energize the product by pressing the start push button (if equipped).

The controller is ready for the operational checks.

6.3.2 Operational checks

The operator must check operation of the emergency limit stop device when the operator starts
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

work. The previous does not apply to a slipping clutch as an emergency limit stop device which
does not need to be checked when starting work. Chain hoists are fitted with a slipping clutch as
an emergency limit stop device which does not need to be checked by the crane operator.
Therefore, a device to bypass 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 the emergency stop button. - x
"7-segment display for operating status and fault display"
Check the 7-segment display. "Display of software version, operating hours, number of x
cycles"
Check chain lubrication. (In arduous conditions, the chain
"Available chains" x
must be lubricated more frequently.)
Check the operation of the lifting-motion operating limit
"Checking the operating limit switches" x
switch.
Check the cut-off buffer, the cut-off spring, and the
"Checking the cut-off buffers and cut-off springs" x
operating limit switch actuator.

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Activity Section Check

Check the cable and the controller housing for damage. - x
Activity Section Check - x
Check the hook and the hook safety latch. "Load hook dimensions and wear" x

6.4 Safe load handling practices

WARNING
FALLING LOAD HAZARD
Knots or blockages in the chain can cause the chain to break and the load to fall.
Falling loads can cause death, serious injury, or property damage.
Prevent knots and blockages in slack chain before lifting a load.
To prevent the chain from slackening, do not place the hook on a surface.
Do not let the hook in 2-fall chain hoists rotate between the chains.
Remove knots, blockages, and slack chain in both 1-fall and 2-fall chain hoists before
attaching a load.

6.4.1 Load evaluation

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
WARNING
FALLING LOAD HAZARD
Lifting a load that exceeds the rated capacity of the machine and lifting accessories can
cause the load to fall, which can cause death, serious injury, or property damage.
Never attempt to lift a load that is heavier than the rated capacity of the machine.
Never use an overload device to determine whether the load can be lifted.

To prevent overloading, determine the weight of the load before lifting. Lift the load only when
you are sure that the weight of the load does not exceed the rated capacity of the product and
accessories. Do not use the overload device of the product to determine if the load can be lifted.

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6.4.2 Attaching the load

WARNING
FALLING LOAD HAZARD
Improper attachment of the load can cause death, serious injury, or property damage.
Always follow instructions provided by the lifting device manufacturer when using non-
fixed load-lifting attachments.
Never use the ropes, chains, or belts of the product as a sling to attach to the load.

The load is usually attached to the product with some kind of non-fixed load-lifting attachment.
The most common non-fixed load-lifting attachments are chains, wire rope slings, and lifting
belts. The operator must select a non-fixed load-lifting attachment that is designed for the load.

6.4.2.1 Lockable hook

With lockable hook block, it is possible to lock the hook forging in steps of 90 degrees. Lockable
hook helps to prevent load handling problems that are cause by load rotation.

6.4.3 Handling a load

Correct load handling allows you to move loads quickly and safely.

WARNING
PERSONAL INJURY HAZARD
Lifting or transporting people can cause death or serious injury.
Never use the machine for lifting or transporting people.

WARNING
COLLISION HAZARD
Failure to follow safe load handling practices can cause death, serious injury, or
property damage.
Handle the load safely at all times. Ensure that the hook, the load, or the machine and
its moving parts do not collide with objects or people.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

1. To avoid damage to the hook, position lifting accessories on the load bearing surface of the
hook. That is, the lowest point of the hook. Forces on ramshorn hooks must be equal on
both load bearing surfaces.
2. Ensure that the hook safety latches are closed. Check that the hook safety latch is not
subjected to any force by the load.
3. Check that the weight of the load is on the center line of the hook forging so that the load
does not bend the hook shank.
4. Check that the load is balanced and safely fastened at the lifting points.
The load must not be able to slide, slip, or detach itself when suspended.
5. Ensure that the hoist is positioned directly above the load so that there are no side-pulling
forces.
6. Ensure that you have a clear view from the operating position. Remove any visual
obstructions.
7. Drive carefully and reduce the speed when approaching the safety limits.

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• Avoid short, jerky motions. Unnecessary short starts cause the hoisting motor to overheat
quickly.
• Do not switch the controller back and forth unnecessarily because it causes wear.
• Do not swing the load intentionally.
• Do not use the mechanical limit switches as operational end stops by always driving the
hook up to the highest or down to the lowest position.
• To avoid damage to the rubber part that activates the mechanical upper and lower limit
switches, do not drive the hook up to the upper limit and leave it at that position for a
longer time.

Incorrect handling of the load could damage the product or load.

Never drag a load or pull it from the side.
NOTICE Never try to lift a load with the tip of the hook.
Never add any load to a hook that is already loaded.
Never twist the load chains.

Inattention could cause the load to collide with an obstacle or fall from the lifting device,
which can damage the load or work site.
NOTICE Observe the load at all times while it is in motion.
Never leave a load hanging on the lifting device unattended.

Using the mechanical limit switches as operational end stops could damage the
product or load and lead to dangerous situations or accidents.
NOTICE Do not always drive the hook up to the highest or down to the lowest position. It is not
recommended to use the mechanical limit switches as operational end stops.

Leaving the hook at the upper limit damages the rubber part that activates the
NOTICE mechanical upper and lower limit switches.
Do not drive the hook up to the upper limit and leave it at that position for a longer time.

6.4.4 Load balancing

WARNING
PERSONAL INJURY HAZARD

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Trying to balance an unbalanced load with your hands can cause death or serious
injury.
Never try to balance an unbalanced load with your hands.
Lower the load and adjust the lifting point.

When you start to lift a load, check that is it properly balanced before lifting it high off the
ground. If the load is not balanced, lower it down and adjust the lifting point.

The hook, slings, and harnesses must be positioned so that the pulling force of the product lies
on the center of gravity of the load.

Lifting centrally balanced loads

The center of gravity is usually in line with the center of the load.

As long as the contents of the container cannot move around, the balance of the load stays the
same.

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Lifting off-center balanced loads

The center of gravity of an off-center balanced load is usually towards the heavier end of the
load.

As long as the contents of the container cannot move around, the balance of the load stays the
same.

6.4.5 Shock loading

The products and accessories are designed to take up the weight of loads gradually and
steadily. They are not designed to withstand sudden increases or decreases in the apparent
weight of the load. Shock loading can occur in any situation where the load on the hoist
suddenly increases or decreases.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Shock loading can occur in many different ways. Here are some examples:

• Change in load balance can suddenly pull on the lifting medium, such as chain or rope.
• If the load is unstable, it can exert sudden force on the lifting medium. Contents of containers
should be securely fastened so that they cannot move around during lifting.
• Sudden loss of the load can cause the trolley or hoist to jump and lead to derailment.
WARNING! MACHINE MALFUNCTION HAZARD
Using defective products can cause death or serious injury.
After a shock load, do not use the products until an experienced service technician
authorized by the manufacturer or manufacturer's representative has determined that
the products can be safely used.

Shock loading can damage the product or the load.

NOTICE Avoid shock loading.

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6.4.6 Load swing

The operator must use the correct techniques to properly control the load and prevent
uncontrolled movements such as load swing or rotation. If the load tends to rotate or swing, a
third person can guide the load with a tag line, if it is safe.

WARNING! CRUSHING HAZARD

Your hands or body could get crushed between the load and an obstacle or wall, which
can cause death or serious injury.
Guiding or steadying suspended loads directly with your hands is prohibited. Use a tag
line to guide the load or a more suitable lifting device.

Sudden changes in speed or direction of the trolley or bridge movements cause load swing.
When starting up or accelerating, the load lags behind the bridge or trolley. When stopping or
decelerating, the load tends to swing ahead and pull on the equipment. If the equipment moves
at high speed and then decelerates quickly, this can result in violent load swing. The load
swings further on a long lifting medium than on a short one.

6.4.6.1 Preventing load swing

WARNING
CRUSHING HAZARD
Your hands or body could get crushed between the load and an obstacle or wall, which
can cause death or serious injury.
A swinging load moves with considerable force. Never try to stop a swinging load with
your hands.

You can prevent or minimize load swing in several ways:

• Accelerate and decelerate as gently as possible.
• Move the equipment at a speed appropriate for the load. Higher speeds increase the
likelihood of load swing.
• Transport the load close to the hoisting machinery, so that the lifting medium is short.
• Stop the equipment before you change direction.
To prevent load swing, you can take advantage of the pull of the load when you bring it to a
stop:

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
1. Anticipate the swing of the load and stop the equipment just before the setting point of the
load.

2. When the load is directly over the setting point, accelerate the equipment so that it catches
up with the load.

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3. Stop over the setting point. You can stop both the load and the equipment simultaneously
over the setting point.

NOTE You may have to repeat these actions several times to completely eliminate the load
swing.

6.5 Controlling the equipment

6.5.1 Picking up the load

• The load handling attachment and load must be flexibly suspended. Rigid connections cause
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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 or 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 latch 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 that is 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 exceeded.

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6.5.2 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, or 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 over the 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 (for example, 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 structures, for example, when slewing cranes are turned.
• Do not pick up the load at full speed.
• Avoid inching (for example, giving short pulses to the motor).
6.6 Controlling load movements

6.6.1 Moving the manual push trolley

1. Move the trolley by pushing on the load or hook. Do not on push on the chain or pendant
cable.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

NOTE Never leave an unattended load hanging from the hook.

WARNING! CRUSHING HAZARD

Never pull on the load or chain. Pulling on the load or chain could cause a crushing
hazard. You can get trapped and crushed, for example, between a wall and the moving
load, which could cause serious injury or death.
Only move the trolley by pushing on the load or hook.

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WARNING! ENTANGLEMENT HAZARD

Safety gloves or other clothes may get entangled with the load or chain, which could
cause serious injury.
Be careful when handling the movements by hand.

6.6.2 Controlling speed with the controller

Pendant controllers are usually equipped with two-stage control buttons for moving the load.

1. To activate the creep speed (creep lifting,

slow travel), press a button until the button
reaches the first step.

0% 100%

2. To activate the fast speed (fast lifting, fast

travel), press a button until the button
reaches the second step.

0% 100%

WARNING! CRUSHING HAZARD

If acceleration and deceleration are not taken into account, there is a risk that the
movement does not start and stop like intended. This can result in, for example, being
crushed by the load which can cause death or serious injury.
Take into account the starting and stopping distances before you make movements.

6.6.3 Moving the load with the controller

1. For lifting or lowering, press the buttons to
lift or lower the load.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

2. For moving the trolley, press the buttons to

move the chain hoist right or left along the
crane bridge.

3. For moving the bridge, press the buttons to

move the crane bridge forwards or
backwards along the runway beam.

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6.6.4 Lifting a load with push button control

Attach the load securely to the lifting device and position the hoisting machinery directly above
the load. If the controller has a hoist or crane selection switch, be sure to select the correct hoist
or crane.

WARNING
FALLING LOAD HAZARD
Improperly attached load could fall which could cause death, serious injury, or property
damage.
Before lifting, ensure that the load is properly attached.

WARNING
HAND ENTANGLEMENT HAZARD
Catching or trapping your hands could cause death or serious injury.
Never touch the lifting device, ropes, chains, belts, or lifting accessory during lifting.

Limit switches are safety devices. Do not use them for controlling movements. Always
NOTICE stop the movement with the controller.

Do not attempt to lift a load that is fastened to the ground or to a base which prevents it
NOTICE from being lifted.

1. Make sure that everything is ready for lifting.

2. If an alarm horn button is available, press it to warn people nearby that a load will be moved.
3. Press the up push button to slowly remove slack from the hook or lifting accessory before
you lift the load from the ground.
4. Continue to press the up push button until the load is off the ground.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
5. Press the up push button further to lift the load at a higher speed.
6. Release the up push button gradually to stop lifting.
To avoid collisions with objects, do not lift the load higher than needed.

6.6.5 Lowering a load with push button control

WARNING
CRUSHING HAZARD
Lowering load could cause death or serious injury to persons working or moving under
the load.
Make sure that nobody is underneath or nearby the load.

NOTICE To avoid damage to the product, do not allow the lifting device to hit the landed load.

1. Make sure that the landing area is clear of people and obstacles.
2. If an alarm horn button is available, press it to warn people nearby that a load will be moved.
3. Press the down push button to lower the load.

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4. To decrease the lowering speed, gradually release the down push button when the load
approaches the ground.
Take into account the possible preset deceleration ramp.
5. Fully release the down push button when there is slack in the lifting accessory but before
the lifting device hits the load.

6.6.6 Combining the movements

It is possible to combine trolley traversing, lifting, and lowering movements but there are
limitations to the combined movements:

• Before starting to combine movements, ensure that you understand how the crane behaves in
each direction individually. Different cranes have different driving characteristics.
• To reduce load swing, do not combine vertical movements (lifting or lowering) with horizontal
movements (trolley traversing).
• Do not attempt to coordinate more movements than you can safely and confidently control. To
safely control simultaneous actions, requires good observation, concentration, and
coordination skills.

WARNING
PERSONAL INJURY HAZARD
Failing to observe the movement of the crane and load could cause serious injury or
death.
Do not allow anything to divert your attention from the load and the movement of the
crane.

NOTICE Lowering the load during trolley movements accelerates load swing.

6.6.7 Detaching a load

1. Detach the load from the hook by hand.
Never try to use the product movements to detach the load from the hook. The safety latch
on the hook should prevent this.

6.7 Slipping clutch operation

The chain hoist is equipped with a slipping clutch that activates automatically when an overload
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

occurs. If an attached load is heavier than the rated hoist capacity, the slipping clutch limits the
torque, which the motor of the chain hoist can apply to the lifting gear, and prevents lifting the
load.

If the slipping clutch activates already at the rated capacity of the chain hoist, the friction force
must be measured and readjusted, if needed. A qualified service technician must do the
measurement and possible readjustment of the friction force. For more information, see chapter
Adjusting the slipping clutch.

Frequency converter driven chain hoists can detect the activation of the slipping clutch by
comparing the motor frequency and the speed that is measured at the pulse wheel. If they differ
too much, the motor of the chain hoist is switched off.

6.8 Hoisting limit switch operation

When the mechanical limit switch is activated, it is only possible to move the hook in the
opposite direction. The limit stops at both ends of the chain limit the lifting height. The brake
activates automatically, and the power to the motor is turned off. Springs and buffers activate
the contact points and stop the hook motion.

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6.9 Shutting down the equipment

WARNING
MACHINE MALFUNCTION HAZARD
Operating a defective product can cause death or serious injury.
Remove the product from service immediately if it is defective.

After every working shift, do the following procedure and checks to ensure that the product is
left in safe condition.

1. Check that there is no load on the hook or the lifting device.

2. Stop the hook in a position where it does not present a hazard to people or traffic.
Preferably leave the hook above head height, but not at the upper limit.
3. If applicable, park the product in an approved parking area.
4. Engage the emergency stop button.
5. Turn off all controls on the controller.
6. From the main isolation switch, turn off all power to the product.
7. If applicable, close the mechanical brakes, such as rail clamps and storm locks.
8. Check the product for any visible damage.
9. Report all observed defects and abnormalities in equipment or operation to the supervisor
and to the next operator.

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7 Maintenance

7.1 Safety during maintenance

WARNING
SPECIALIST SKILLS REQUIRED
Incompetent maintenance work can be unsafe, or cause unsafe and unreliable
operation of the product that can cause death, serious injury, or property damage.
Installation must be carried out only by authorized service personnel or an experienced
service technician who is authorized by the manufacturer or representative of the
manufacturer.

WARNING
ELECTRIC SHOCK HAZARD
Even if the main isolation switch is off, electrical components can have stored electrical
energy. Contact with the electrical energy can cause death, serious injury, or property
damage.
Verify that there is no voltage with approved voltage test equipment and follow the
component-specific waiting times.

WARNING
MACHINE MALFUNCTION HAZARD
Unsuitable spare parts, materials, and lubricants can result in malfunctions that can
cause death, serious injury, or property damage.
Use only original spare parts, materials, and lubricants that are approved by the
manufacturer or representative of the manufacturer.
Do not modify the product without permission of the manufacturer. Any modifications
to the product structures or performance values can be made only after they are
approved by the product manufacturer.

NOTE Some maintenance tasks require two people.

These instructions are general guidelines for safety:

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

• Observe local safety regulations.

• Make sure that you have all the appropriate personal protective equipment. Use them when
required.
• Follow the fall protection procedures.
• Prevent access to the area from unauthorized persons and bystanders.
• Ensure that the secured area is spacious enough to prevent injuries that could occur if
components or tools fall.
• Follow lockout-tagout-tryout procedure.
• Use hand lines that are securely attached to the building structure to lift and lower materials
and tools. When you work in high places, use safety equipment to make sure that objects do
not fall.
• Ensure that safety devices work properly so that they provide protection against human error.
• Beware of hot components. Some components, such as motors, can become hot in use.
Check that components are cool before you perform maintenance.
• not disassemble components further than instructed.
Do

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7.2 Maintenance preparation

7.2.1 Maintenance environment

• Prevent unauthorized persons and bystanders from walking on or below the work site. To
prevent injuries from possible falling components or tools, ensure that the secured area is
spacious enough.
• Ensure that there is no possibility for personnel or body parts to be struck, crushed, or
compressed by moving machinery:
•Secure the area so that maintenance personnel are not at risk from the movements of
machines, automatic doors, or adjacent cranes at the installation site.
•Ensure that products cannot start accidentally or move during maintenance.
• To reduce the risks, maintain sufficient space in the area.
• To prevent entrapment, shield parts that move with guards.
• Be prepared in case the equipment moves in the wrong direction during tests.
• When an aerial work platform is in use, there must be an additional person to observe the
environment and ensure safety during maintenance and inspection activities.
• Adequate lighting must be available according to local regulations. For example, EN 12464.
7.2.2 Preparing for maintenance
1. Familiarize yourself with the product and its user instructions.
2. Find out the location of the main isolation switch and the emergency stop buttons.
3. Choose a safe working location. Move the product to a location where it causes the least
disturbance and where you can access it easily.
4. Inform that the product is under maintenance and that it is not in operation.
5. Make sure that there is no load on the hook. If there is any chance that you open the
hoisting brake during maintenance, lower the hook on the floor.
6. If applicable, check the parameters of the condition monitoring unit before you switch off the
power supply.

WARNING! UNEXPECTED MOVEMENT HAZARD

Unexpected movement when you are on the service platform or manlift can cause death
or severe injury.
When you enter the service platform or use a manlift to check the parameters, take

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
precautions. Take the radio controller with you or make sure that the pendant controller
is held by service personnel.

7. Turn off all controllers and main isolation switches before you start maintenance work.
8. Lock out and tag out the product power source if necessary, in accordance with local
regulations. For more information, see "Lockout-tagout-tryout procedure".
9. To make sure that power is disconnected, measure between the phases and between each
phase to ground.

7.3 About maintenance

7.3.1 Maintenance intervals

The owner or operator of a product has the responsibility to carry out proper and regular
inspections to ensure the safe operation of the product. The periodic inspections must be
carried out according to the instructions of the manufacturer. The owner of the product must
keep a record of the performed inspections and their related findings.

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Inspection intervals that provided in the instructions are general guidelines. Depending on the
use of the product, the required inspection intervals can also be shorter than instructed here.

If the working environment or product use changes, the inspection and maintenance intervals
must be revised. Products that are used under harsh conditions may require shorter inspection
and maintenance intervals. For a tailored service agreement, consult the manufacturer or
representative of the manufacturer.

Periodic inspections must be done according to local regulations.

WARNING! MACHINE MALFUNCTION HAZARD

Defects or abnormalities can result in malfunctions that can cause death, serious injury,
or property damage.
Correct any defects and abnormalities that are detected during the periodic inspections
according to instructions.

7.3.2 Service personnel

Only authorized service personnel or an experienced service technician that is authorized by
the manufacturer or the manufacturer’s representative may perform the detailed maintenance
inspections. The inspections must be performed according to the inspection and maintenance
plan that is provided by the manufacturer. The service personnel that maintain the products
must be authorized by the original manufacturer or the manufacturer’s representative.

The owner or operator of the product must perform the daily checks and, if necessary, daily
lubrication. The service personnel that are authorized by the owner may also lubricate the
product at necessary intervals.

NOTE Mechanical and electrical maintenance work requires special skills and tools to ensure
safe and reliable operation of the product. Maintenance work must be carried out only by
authorized service personnel or an experienced service technician who is authorized by
the product manufacturer or the manufacturer’s representative.

7.3.3 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 aging.

This requirement is also reflected by the rules and regulations of the German Social Accident
Insurance (DGUV), for more information, see "Regulation 54, section 23 (4)".
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

An owner of serial hoist units is obliged to determine the actual duration of service of the chain
hoist based on the operating hours, load spectra and/or recording factors. This is based on
FEM 9.755: Measures for achieving safe working periods for motorized 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 regarding the electric chain hoist:
1. Recording the mode of operation is divided into three classes. The owner responsible for
recording and documenting information in the log book. The information must be
documented at least once for each 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. Load kmi (load spectrum) must be estimated, if necessary.

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4. Recording with devices (for example, 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 recorded data.

When information is recorded by devices, recording factor f = 1.0. (that is, the value is
used without any changes, FEM 9.755, 3.1.)
5. Documentation and suitable counting devices (for example, operating time counter):
The actual load spectra and the load spectrum factors (Km1 to Km4) and 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, and so on).

The value that is 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 production 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 loads1)2), 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. 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.

1) 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 for each day x 250 days for each year).

2) 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 for each day x 250 days per year).

For electric chain hoists classified according to FEM 9.511, the following theoretical durations of

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
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 and full load
200 400 800 1600 1900 3200 6300 12500
hours [h]

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.

7.3.3.1 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 x Ti x f

kmi: Actual load spectrum factor

Ti: Number of operating hours

f: factor depending on the type of recording

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

Calculating the number of hours of operation (operating time) Ti (by the owner)
The operating time can be calculated by an operating time counter or according to the following
method:

Operating time for each inspection interval:

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

Ti =
60 x lifting speed

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 estimation, each type of load can be grouped into km load spectrum modules. 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 (for example,
one year) in terms of percentage.

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%–10%. Larger shares of the time period must be
correspondingly added. Load spectrum factor kmi can be obtained by adding 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

0.042

L B
4/4

3/4
1
1/2

1/4

0 t
5 10 5 10 5 10 5 10 40
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

[%]
100

B = Loading

L = Load

t = Time

1. Dead load

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

Factor depending on the type of recording

Recording
Recording operating hours and load spectrum
factor [f]

Operating hours recorded using an operating time counter and the load
spectrum recorded with a load spectrum recorder and documented in the log 1.0
book.

Value for operating time Ti determined with an operating time counter and
1.1
load spectra documented in the log book.

Load spectra and operating hours documented without suitable counting

1.2
devices.

Estimated value for unknown operating hours and loading (depending on duty
1.5
class and age of the chain hoist)

7.3.3.2 Example of duration of service S according to FEM 9.755 (Germany) for

chain hoist size 10 1250 kg 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

Calculation

10 x 4 x 8 x 250
Ti =
60 x 8

With operating time read: Ti = 167

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
In the operating time as read above, the chain hoist has transported the following loads:
0.0125+

0.0016+
0.05
0.042

0.0125

0.0008

L B
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

B = Loading

L = Load

t = Time

Adding the load spectrum modules km together results in load spectrum factor kmi = 0.119

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

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 ofservice of 800 hours (see following table) 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:

Actual Theoretica
Operating Load Remaining
Date Load [%] km factor duration l duration
hours factor use
of service of service
Ti value S D [h] Group D–S
of
From To full 3/4 1/2 1/4 none kmi f
[h] [h] mechanism [h]
s
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 -

7.3.4 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 aging.

An owner of serial hoist units is obliged to determine the actual duration of service of the chain
hoist based on 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", that is, 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. Load kmi (load spectrum) must be estimated.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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 production 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 production must be multiplied by the recording factor f = 1.3
(ISO 12482, 4.3).
7. For unknown operating hours and loads, 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):

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

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

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.

7.3.4.1 Determining the remaining service life according to ISO 12482

The remaining service life A of the electric chain hoist can be determined as follows:

S = kmi x Ti x f

kmi: Actual load spectrum factor

Ti: Number of operating hours

f: factor depending on the type of recording

Calculating or estimating the operating hours (operating time) Ti (by the owner)
The operating time can be estimated by 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

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.

Table 3. Based on table B1 on page 10 of ISO 12482, however, with values for 5% and 10% for simplified
calculation

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Load kmi value for 5% kmi value for 10% Calculated kmi value
operating time operating time
4/4 full load 0.05 0.1 -

¾ load 0.025 0.05 -

½ load 0.0125 0.025 -

¼ load 0.0063 0.0125 -

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*:

*For even more detailed calculations, for example, for different operating times with and without
a load in one cycle, see Annex A and B of ISO 12482.

km = (b1 + g)3 x c1 + (b2 + g)3 x c2 + ...

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

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

The values that are 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 (for example,
one year) in terms of percentage.

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.

Load spectrum factor km can be obtained by adding together the individual km load spectrum
modules.

kmi load spectrum factor diagram

0.025

0.0125

0.0063

0.0125
0.05

0.10

0.025

L B
0.5

4/4

3/4
1
1/2
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

1/4

0 t
5 10 5 10 5 10 5 10 40
[%]
100

B = Loading

L = Load

t = Time

1. Dead load

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

Factor depending on the type of recording

Recording
Recording operating hours and load spectrum
factor [f]

Crane operating data are recorded by a special, purpose-built system, which

always operates automatically when the crane is in use. The crane operator 1.0
does not have a possibility to switch off the recording system.

The crane is provided with counters that record the crane operating data. The
1.1
user collects and documents operating data manually from the counters.

The crane duty history is calculated based on a regular process in which the
crane is working. The crane is an integral part of the process. Process data 1.2
are documented.

The crane duty history is estimated based on general production data of the
1.3
site where the crane is working.

The crane duty history is incomplete or unknown (for example, 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 usage 1.5
corresponds to the classification (see also no. 5 in table 1 on page 3 of ISO
12482).

7.3.4.2 Example for determining the remaining service life according to ISO 12482
for chain hoist size 10 1250 kg 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 estimated based on 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

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Calculation

10 x 4 x 8 x 250
Ti =
60 x 8

With estimated operating time: Ti = 166.6

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

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

0.0125+
0.05

0.025+

0.0063
L B

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

B = Loading

L = Load

t = Time

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 read 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:

Loadin Actual Theoretica

Operating Remaining
Date Load [%] km factor g duration l duration
hours service life
factor of service of service
Ti value S D [h] Group D–S
of
From To full 3/4 1/2 1/4 none kmi f
[h] [h] mechanism [h]
s
5 10 20 15 50
3.1.- 30.12.- Read 166.6 0.1688 1.3 36.56 800/1Am 763.44
0.05 0.05 0.05 0.0188 -
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

7.3.5 GO general overhaul

The chain hoist is designed to be used for at least ten 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 duration of service. When the actual
NOTICE 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.

7.3.5.1 General overhaul 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 that is
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 service 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.

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

A general overhaul is defined as:

Inspection of the machinery for 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
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, and so on) 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 that is authorized
by him satisfies the requirement 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 operation in the log book. Completion of the general overhaul must be confirmed
in the log book and a further period of utilization in accordance with FEM 9.755 must be
entered.

7.3.5.2 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 have reached different

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
stages of cumulative 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 must 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 future.

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

7.3.5.3 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 (for example, hours at full load h) depends on

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

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 that is 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 service 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 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 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, and so on) 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 authorized by
him satisfies the requirement 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 operation in the log book. Completion of the general overhaul must be confirmed
in the log book and a further period of utilization in accordance with ISO 12482 must be entered.

7.4 Basic maintenance requirements

The specified inspection and maintenance intervals apply to normal chain hoist operating
conditions. For more information, see "Maintenance schedule". All wearing parts must be
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

checked during the annual inspection.

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

7.4.1 Electric components

Only fuse links with the specified amperage and tripping characteristics may be used in the
electric circuits. Defective fuse links must not be bridged.

7.4.2 Working on machinery or machine equipment

Pay attention to the following when working on machinery or machine equipment.
1. Wear personal protective equipment.
2. Before starting any maintenance work, switch off the mains connection switch and protect it
against unauthorized or accidental reconnection to the power supply by locking it with a
padlock.
3. Ensure that the chain hoist is switched off, checked that it is de-energized and, in special
cases, isolated.

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

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 operating 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 (for example, VDE regulations) when repairing
electric equipment.
9. Reinstall safety devices as required by relevant regulations and check them for correct
operation after finishing 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.

7.4.3 Instructions for maintenance work in the course of operation

If maintenance work has to be carried out on the chain hoist in operation, special safety
precautions must be taken depending on the operating situation. In each individual case, the
owner or the person who is assigned by him must check whether the maintenance work may be
carried out during operation without risk of personal 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.

Make sure that operating and auxiliary materials and replaced parts are disposed of in an
environmentally friendly manner.

7.4.4 After finishing maintenance work

Safety devices must be reinstalled as required by relevant regulations and checked for correct
operation when maintenance work is finished.

NOTE Carry out a test run at partial load after the chain hoist has been fully reassembled. Make
sure that the chain runs smoothly during the test run.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
7.5 Maintenance schedule
Before first During the
Before
Activity Section putting into annual
starting work
operation inspection
Check continuity of the PE conductor
– X
connection.
Check emergency stop button. – X X
Check directions of motion. "Mains connection" X
"7-segment display for operating status
and fault display" and "Display of
Check 7-segment display. X X
software version, operating hours,
number of cycles"
Check chain lubrication (under arduous
"Available chains" and "Lubricating the
conditions, the chain must be lubricated more X X X
chain"
frequently).
Check operation of the lifting-motion
"Checking the operating limit switches" X X X
operating limit switch.
Check operation of the lowering-motion
"Checking the operating limit switches" X X
operating limit switch.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

Before first During the

Before
Activity Section putting into annual
starting work
operation inspection
"Checking the cut-off buffers and cut-
Check cut-off buffer and cut-off spring or
off springs" and "Checking the X X X
operating limit switch actuator.
operating limit switch actuator"
Check cable and controller housing for
– X X X
damage.
Check operation of the brake. – X X X
Check hook and hook safety latch. "Load hook dimensions and wear" X X X
Read switching cycles C "Service life of the contactor" X
"7-segment display for operating status
and fault display", "Measures for
Read operating hours to determine the achieving safe working periods in
X
remaining duration of service. Germany" and/or "Measures for
achieving safe working periods
according to ISO 12482''
Check electric switchgear and wiring. - X
Check operation of the slipping clutch. "Checking the slipping clutch" X
Check adjustment of the slipping clutch. "Adjustment of the slipping clutch" Every 10 years 3)
Check brake wear. Every 10 years 2) 3)
''Brake''
Grease brake V seal ring. X
Check suspension, suspension bracket, and
''Maintaining the suspension'' X
securing elements (clip and so on).
Check fastening bolts on hook assembly or
- X
bottom block.
Check the hook for cracks, deformation and
"Load hook dimensions and wear" X
wear.
Check hook safety latch for deformation. - X
Check hook bearing for wear. - X
Check chain sprocket of chain guide, chain
sprocket of bottom block, chain guide, guide ''Chain drive'' X
plate.
Check that the chain is properly secured. - X
Check the chain collector and suspension for
external damage (for example, cracks, stress
whitening, weld seams on metal
"Removing the chain collector box" X
collectorbuckets, threads on chain collector
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

bags, rivets and clips), Remove the service

cover.
Check the chain for deformation, damage,
cracks, pitting, reduction in the thickness of the
"Checking the chain wear" X
links or increase in pitch due to wear,
elongation caused by deformation.
Check securing elements (clips, bolts and so
- X
on) for tight fit and corrosion.
Check and apply or add corrosion protection,
- X
as required.
Check the electric enclosure and gearbox for
- X
leakage.
"Checking the cut-off buffers and cut-
Check trolley, crossbar and condition of buffers. X
off springs"
Oil change "Changing the gear oil" Every 10 years 3)
The small parts (screws, washers and so on) to be replaced when maintenance and assembly work is carried out are not listed
separately.
1) Every ten years for DC-Pro II used according to FEM classification; during the annual inspection for DC-Com II.
2) Every 5 years for DC-II 10
3) For use according to FEM classification

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

General overhaul
The general overhaul should coincide with the annual When 90% of the theoretical duration of service is reached. For more
inspection. information, see "Measures for achieving safe working periods in Germany"
and/or "Measures for achieving safe working periods according to ISO 12482''.
Fit chain hoist-specific 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 specified in the inspection and maintenance schedule must be carried out during the general overhaul.

7.5.1 Routine inspections

7.5.1.1 Required tests and inspections

WARNING
MACHINE MALFUNCTION HAZARD
Failure to maintain the product regularly and properly can cause death, serious injury,
or property damage.
Required tests and inspections must be done every 12 months. Only personnel who are
authorized and properly trained may do the required tests and inspections.
Always follow the instructions when you inspect, adjust, and maintain the product. For
more information, see "Maintenance schedule."

The product must be inspected by an experienced service technician at least once a year.
Regular inspections mainly consist of visual inspections and inspections of functions.
Inspections should include an inspection to determine the condition of components and
equipment regarding damage, wear, corrosion, or other alterations. An inspection to determine
the integrity and efficiency of safety devices should also be included.

Regular inspections must be carried out in accordance with national regulations.

It may be necessary to remove parts 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.

For more information, see "Measures for achieving safe working periods in Germany",

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
"Measures for achieving safe working periods according to ISO 12482'', and "Maintenance
schedule."

NOTICE All inspections must be arranged and documented in the log book by the owner.

7.5.1.2 Special operating conditions

WARNING
FALLING LOAD HAZARD
Premature wear of the chain can lead to failure of the chain and a dropping load. Failure
of the chain and a dropping load can cause death, serious injury, or property damage.
Special operating conditions can shorten the required maintenance and inspection
intervals of the product. If, for example, the chain hoist always brakes heavily at the
same position and with a heavy load, the wear on the chain links may increase. The
increased wear occurs on the chain links that are in the area of the chain sprocket or
return sprocket when the brake is applied.

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7.5.1.3 Service life of the contactor

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

Display value C for Display value C for

Chain hoist size Motor size
Unom 380–575 V Unom 220–240 V

DC-II 1 80 80
ZNC 63 B 8/2
DC-II 2 80 60

DC-II 5 ZNC 80 B 8/2 60 50

ZNC 100 A 8/2 50 20

DC-II 10
ZNC 100 B 8/2 20 –

Display value C specifies the expected service life of the contactor that is multiplied by 100000.
This value was determined under normal operating conditions. For other conditions, the service
life of the contactor can be shorter or longer. For more information, see "Display of software
version, operating hours, number of cycles".

We recommend that the contactor or the control module be replaced when the relevant display
value has been reached. For more information, see "Replacing the contactor on the control
board".

7.6 Maintaining the 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
e
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Chain hoist DC-II 1–DC-II 5 DC-II 10

Suspension bracket short long short long

Min. dimension e for

[mm] 21.5 21.5 28 27
suspension bracket

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Suspension ring

e
Chain hoist DC-II 1–DC-II 5 DC-II 10

Min. dimension e for

suspension ring turned 90° [mm] 19.5 27
(chain hoist parallel to girder)

7.7 Maintaining the 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.

7.8 Removing the chain collector box

1. To remove the service cover (2), remove the screw (1).

1 2

2. Place the bag (3) with the control cable on DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
top of the chain hoist. 3

3. Disconnect the spring (4).

Place the spring in the recess in the chain collector box.

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4. To remove the pin (6), remove the retaining spring (5) from the pin.
When you remove the pin, hold the chain collector box (7).

5 6 7

5. Place the chain collector box (7) on the ground.

7.9 Maintaining the limit switches

7.9.1 Checking the operating limit switches

DANGER
FALLING LOAD HAZARD
If the emergency limit position limiter is frequently approached, this action will lead to
failure of the chain and a dropping load. Failure of the chain and a dropping load will
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

cause death, serious injury, or property damage.

The slipping clutch provides the emergency limit position limiter function for chain
hoists that do not have an operating limit switch or have a defective operating limit
switch. The emergency limit position limiter may only be approached in exceptional
cases. The emergency limit position limiter must not be approached not in normal
operation. High extra loads occur in the chain when the slipping clutch is tripped.
The operating limit switch for lifting function must be checked every day. For more
information, see "Checking the operating limit switch for lifting."

If an operating limit switch is defective, the hoisting motor is switched off when the electronic
speed monitoring function 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, for more information, see
"Warning messages".

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7.9.2 Checking the operating limit switch for lifting

A B C

A = Not compressed

B = Compressed with slow lifting speed reaching end stop

C = Compressed with full lifting speed reaching end stop

1. Raise the hook assembly or the bottom block until it is approximately 10 cm below the
highest hook position.
2. Raise the hook assembly or the bottom block at creep lifting speed until the chain hoist
automatically switches off.
•
1/1 reeving:
It must only be possible to compress the buffer or the 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 block with external cut-

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
off springs by a small amount after the unit has switched off.

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

7.9.3 Checking the operating limit switch for lowering

The "Operating limit switch for lowering" must be checked at least once for each year. Proceed
as follows:
1. Remove chain collector box. For more information, see "Remove chain collector box".
2. Check as described in preceding section for the "Operating limit switch for lifting".

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7.9.4 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 assembly come into contact with the chain hoist guide plate.
To check the function of optional geared limit switch:

1. Without a load, lift the hook with high lifting speed to approach highest hook position.
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.

7.9.5 Checking the operating limit switch actuator

Check the operating limit switch actuator for any external damage, for example, a bent actuator
plate.

7.10 Maintaining the chain drive

7.10.1 Checking the chain sprocket

Figure 15. Examples: chain sprocket wear (left) and return sprocket wear (right)

Since the chain sprocket is replaced together with the chain set, no further inspection is
necessary under normal conditions. However, if you notice any uneven or harsh running in the
chain drive mechanism, such findings can indicate wear.

1. Remove the chain guide and degrease it, to inspect the chain sprocket properly.
2. If the chain sprocket shows signs of wear from the chain or chipping on its sides, replace
immediately.
Replace the chain, the chain sprocket, and the chain guide.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

7.10.2 Checking the chain guide

The chain drive can move easily on the output shaft, that is, lateral play of approx. ±2 mm is
normal. A defective chain guide must be replaced immediately:
1. Open the service cover.
2. Check the chain guide for any damage, for example, ruptured guide section halves or loose
bolts.

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7.10.3 Checking the guide plate or the chain entry plate

1. Measure the guide plate.
If the guide plate is worn more than the
specified dimensions or if there are visible a
cracks, replace the guide plate. b

A
Dimension a b c d

c
d
Frame size [mm] [mm] [mm] [mm]
DC-II 1
16.0 5.5 16.8 6.8
DC-II 2
DC-II 5 19.4 6.8 21.0 8.9
DC-II 10 26.7 9.4 28.8 12.0

A = Load hook side

B
B = Chain collector box side

NOTE Attaching and removing the bolts that

attach the guide plate can damage the
threads in the aluminum housing.

If the threads are damaged, tight fit of the

bolts can no longer be ensured. For this
purpose, a set of guide plate accessories
(part no. 717 830 45) is available.

7.10.4 Checking the chain wear

In addition to selecting the correct hoist unit for the given application, owners of chain
hoists are obliged by relevant regulations, such as DIN 685 part 5 to check the round-
NOTICE 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 according to "Operating conditions", the chain must be checked once for
each year (see inspection and maintenance schedule).

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
If routine maintenance reveals that the maintenance intervals are too long, they must be
adapted to the specific operating conditions.

7.10.4.1 Inspecting the chain visually

Figure 16. Example: chain wear

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

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If the chain displays deformation, damage, cracks, pitting from corrosion, 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.

7.10.4.2 Measuring chain wear or deformation

Two methods can be used to measure wear or deformation of the original chain:
•Measuring with a caliper gauge:
•
Wear of a single chain link. For more information, see ''Measuring wear of a single chain
link with a caliper gauge''.
•
Over 11 chain links. For more information, see ''Measuring wear over 11 chain links with a
caliper gauge''.
•Measuring with a chain gauge:
•
Over 11 chain links. For more information, see ''Measuring wear over 11 chain links with a
chain gauge''.

7.10.4.3 Measuring wear of a single chain link with a caliper gauge

1. The chain link contact areas must be visually checked for traces of wear.
If the chain, hangs at an angle when no load is attached to it, for example, this usually
indicates wear of an individual chain link.
2. Measure the diameter of the chain link material in the chain link contact area using a caliper
gauge, if necessary.
For minimum link diameter values, see table from ''Measuring wear over 11 chain links with
a caliper gauge''.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

7.10.4.4 Measuring wear over 11 chain links with a caliper gauge

1. Attach a partial load to the load hook.
2. Take the measurements in steps of 2 x 3
and 1 x 5 chain links.
The total of the three readings taken, that
is, a1 + a2 + a3 must not exceed the
a1

specified limit a. Otherwise the chain must

be replaced. d1 + d2
t

dm =
a2

2
a3
d1

d2

NOTE Demag is stamped on every 12th link of genuine Demag chains. We strongly recommend
that you use genuine Demag chains to ensure that the safety and the service life of the
chain hoist are guaranteed.

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If the chain does not run smoothly over the chain drive mechanism after fitting a new chain,
contact after-sales service.

DC-II 1
Chain hoist DC-II 5 DC-II 10
DC-II 2
Chain designation (d x t) [mm] 4.2 x 12.2 5.3 x 15.2 7.4 x 21.2
Limit dimensions according to DIN 685 part 5
Measurement over the outside of 11 chain links,
[mm] 144.7 180.3 253
maximum dimension a = a1 + a2 + a3
Overall length of 1 chain link measured on the
[mm] 12.8 15.9 22.4
inside, max. dimension t
Measurement of the chain link diameter,
[mm] 3.8 4.8 6.7
minimum dimension dm = 0.9 x d

NOTE The limit dimensions apply to all chains listed in "Available chains."

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7.10.4.5 Measuring wear over 11 chain links with a chain gauge

A B
10x28
10.5x28.2

8.7x24.2
7x21
7.4x21.2

1
5x15
5.3x15.2
4x12 3
4.2x12.2
3.6x10.6

A = DC/DK/PK new chain

B = PK old chain

1. Chain gauge, part no. 836 025 44 3. Measuring pin

2. The chain must not yet be discarded. The 4. 11th chain link: the chain is ready to be
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

chain only needs to be replaced if the discarded. The chain must be replaced.
measuring pin can no longer be inserted
into the 11th chain link.

NOTE A partial load must be suspended from the load hook when the chain is measured over
11 chain links.

7.10.5 Chain set scope of supply

WARNING
FALLING LOAD HAZARD
If a lifted load is dropped, the falling load can cause death, serious injury, or property
damage.
When the chain is replaced in DC-II 10 units that have 2/1 reeving, the chain anchorage
must also always be replaced. The relevant parts are included in the chain sets. If a
single chain is purchased by the meter, the chain anchorage must be separately
ordered and installed. For more information, see "Spare part manual."

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The chain must be replaced when the permissible chain wear limit is reached. For more
information, see "Checking the chain wear". A chain set is always supplied when a new
standard RDC/TDK chain is ordered. The chain set includes the listed parts.
• Chain sprocket
• Chain guide with plate and cap
• Chain guide plate
• Buffers for upper and lower hook positions
• Tube of chain grease
• Retaining ring
• Chain anchorage — for 2/1 reeving only
The chain guide is preassembled. The chain is already fitted in the chain guide.

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7.10.6 Available chains

Genuine chain is a round-section steel chain. The chain is 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 chain is also subject to the inspection regulations to DIN 685 part 5 of Nov. 1981 and the
rules and regulations of the German Social Accident Insurance (DGUV).

NOTE Pay attention to reduced load capacities. For non-standard operating conditions, the
following listed special chains are available for special ambient conditions.

Max. load capacity for reeving Minimum Minimum

Stamp, Weight per Production
Dimension breaking elongation at
Chain hoist size 1/1 1/2 Chain grade meter test force
force rupture
[kg] [kg] [mm] [kg] [kN] [kN] [%]
Demag DAT standard chain, high-strength
DC-II 1
250 - 4.2 x 12.2 0.38 13.8 22
DC-II 2 DAT
10
DC-II 5 500 - 5.3 x 15.2 RDC/TDK 0.62 22 35
DC-II 10 1250 2500 7.4 x 21.2 1.20 43 70
Properties High-strength ageing-resistant material with a high degree of surface hardening, galvanized with extra surface treatment, color: DC-II1-10 golden.
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication GP00H-30REN.SO-GFB grease
Chain DAT (Corrud), with high corrosion protection, high-strength
DC-II 1 125
- 4.2 x 12.2 0.38 13.8 22
Application, for example, DC-II 2 250 DAT
Galvanizing, electro plating 10
DC-II 5 500 - 5.3 x 15.2 RDC/TDK 0.62 22 35
facilities, pickling plants
DC-II 10 1250 2500 7.4 x 21.2 1.20 43 70
Properties Ageing-resistant, corrosion-free, "Corrud DS" micro-layer corrosion protection, black-coated, color: black, Stabylan 2001
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication Acid-resistant chain grease, for example, Ceplattyn BL white paste (part no. 665 023 44)
Chain HS7, with deeper surface hardening
DC-II 1
160 - 4.2 x 12.2 0.38 12.5 19.3
DC-II 2
Application, for example,
RSX/DS 5
foundry, dust, emery, blasting DC-II 5 400 - 5.3 x 15.2 0.62 19.8 30.8
DC-II 10 800 1600 7.4 x 21.2 1.20 38.7 60
Properties Ageing-resistant, color: silver, with deeper surface hardening
Material Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication Dry or with dry lubricant, for example, Ceplattyn 300 paste (part no. 665 022 44)
Chain RS6, stainless steel, not hardened
DC-II 1
DC-II 2 1251)–1602) - 4.2 x 12.2 0.38 10 16
Application, for example,
RSA/S 15
foodstuffs sector DC-II 5 2001)–2502) - 5.3 x 15.2 0.62 16 25
DC-II 10 4001)–5002) 8003)–10004) 7.4 x 21.2 1.20 32 50
Properties Non-rusting chain, not hardened, bright
Material Stainless steel AISI 316 (V4A) 1.4401
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Lubrication Food-safe lubricant, e.g. Berusynth CB 180 H1 oil (part no. 678 645 39)
1) For max. 25–50 cycles per day
2) For max. 10 cycles per day
3) For max. 12–25 cycles per day
4) For max. 5 cycles per day

NOTE Use of HS7 special chain in foundries, fettling shops, or other environments with high
dust levels: It is recommended to lubricate the chain with a dry lubricant, for example,
Ceplattyn 300 Paste (part no. 665 022 44).

The chain can also be used dry. Without any lubrication, however, greatly increased wear
and louder operating noise in the chain drive must be expected. The chain must not be
lubricated with normal grease in environments with high dust levels. Grease will form
clumps and chain wear will not be visible.

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7.10.7 Replacing the chain set

WARNING
FALLING LOAD HAZARD
If a lifted load is dropped, the falling load can cause death, serious injury, or property
damage.
When the chain is replaced in DC-II 10 units that have 2/1 reeving, the chain anchorage
must also always be replaced. The relevant parts are included in the chain sets. If a
single chain is purchased by the meter, the chain anchorage must be separately
ordered and installed. For more information, see "Spare part manual."

There are different chain guide variants. The images only show examples. The method
NOTICE to replace the chain set is, however, largely the same regardless of the variant. For
more information on the different chain guide variants, see "Chain guides."

Before starting any maintenance work, switch off the chain hoist and secure it against
reconnection to the power supply. To replace the chain set, follow the instructions.

1. To remove the service cover (2), remove the screw (1).

1 2

2. Place the bag (3) with the control cable on

top of the chain hoist. 3
Pull out the mains cable union with fitted
mains cable, and place to one side. If a

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
travel drive is fitted, remove the connecting
cable from the strain relief arrangement.

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3. Remove the chain collector box (7). Place

the chain collector box down. For more
information, see "Removing the chain
collector box."

4. Remove the guide plate (7).

With 2/1 reeving, also remove the oval
chain anchorage pin.

5. Loosen the cap (5) with a screwdriver.

The letters A and B in the image refer to different designs of different chain hoist sizes.

A B
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

6. Remove the retaining ring (1) using ring pliers.

Use either straight or offset pliers. Access through the opening in the gearbox housing on
the side of the motor or from the service enclosure.

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7. Remove the chain guide (10) with the chain

sprocket from the output shaft.
To remove the chain guide, slide the
complete subassembly in the direction of
the motor until the chain sprocket is free.
Then, the worn chain set can be removed
from the service enclosure.

10

Proceed in reverse order to install the new chain set. The correct tightening torques for the
installation are in the table at the end of this section.

NOTE When you install a new chain set, the orientation of the chain welds does not matter.

For more information, see the listed sections.

• Chain hoist with geared limit switch

• Fitting the retaining ring

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
• Fitting the chain anchorage for 2/1 reeving in DC-II 10
• Fitting the limit stop
• Steps after replacing the chain set
DC-II 1
Tightening torques [Nm] DC-II 5 DC-II 10
DC-II 2

Reeving 1/1 1/1 2/1

Service cover 10.0

Limit stop 2.9 4.3

Guide plate 6.0 10.0

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7.10.7.1 Chain hoist with geared limit switch

Figure 17. Chain guide for DC-II 10 without geared limit switch
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Figure 18. Chain guide for DC-II 10 with geared limit switch

The chain guide for DC-II 10 has a larger opening on chain hoists that are equipped with a
geared limit switch. For more information, see "Spare part manual."

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7.10.7.2 Fitting the retaining ring

DANGER
FALLING LOAD HAZARD
An incorrectly installed chain will result in a broken chain and a falling load. A broken
chain and a falling load will cause death, serious injury, or property damage.
When the chain is installed, make sure that it is introduced in the same position and
with the same alignment. The chain must operate without any twist.

1. The stamped burr of the retaining ring (1) must face the motor.
The retaining ring is correctly installed, if the retaining ring can be easily turned on the
output shaft after assembly.

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7.10.7.3 Fitting the chain anchorage for 2/1 reeving in DC-II 10

WARNING
FALLING LOAD HAZARD
If a lifted load is dropped, the falling load can cause death, serious injury, or property
damage.
When the chain is replaced in DC-II 10 units that have 2/1 reeving, the chain anchorage
must also always be replaced. The relevant parts are included in the chain sets. If a
single chain is purchased by the meter, the chain anchorage must be separately
ordered and installed. For more information, see "Spare part manual."

NOTE Fit the chain anchorage before you fit the guide plate.

1. Insert the chain (2) into the opening of the

gearbox housing.

2. Insert the oval pin (1) into the hole through

a chain link. 1
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

The chain anchorage is now fitted. The chain anchorage is properly fixed when the chain guide
is in place.

To remove the chain anchorage, you follow the instructions in reverse order. You push the oval
pin out from the side of the hoisting motor.

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7.10.7.4 Fitting the limit stop

1. Attach the limit stop to the fifth chain link at the dead (unloaded) end of the chain.

NOTE Pay attention to the tightening torque. For more information, see "Recommended
tightening torques."

NOTE If the chain hoist is operated with a replacement chain that is longer than suitable for the
standard capacity of the chain collector, you must fit an extra limit stop to the chain. The
extra limit stop is fitted between the hook assembly and the buffer plate.

NOTE The limit stop must be fitted so that the extra length of chain is positioned between the
hook assembly and the limit stop. In this case, a geared limit switch is required for DC-II
10 units with 2/1 reeving.

7.10.7.5 Steps after replacing the chain set

If the chain has to be replaced because it has reached its wear limit, the return
sprockets are also worn and have to be replaced. For this reason, the condition of the

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
NOTICE 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.

1. Fit the hook assembly and bottom block, for more information, see "Load hook."
2. Lubricate the chain. For more information, see "Available chains" and "Lubricating the
chain."
3. Adjust the bottom hook position, if necessary, for more information, see "Adjusting the lower
hook position."
4. Fit the chain collector box, for more information, see "Removing the chain collector box."
5. If the chain hoist has an optional geared limit switch, re-adjust the geared limit switch.

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7.10.8 Chain guides

Figure 19. DC-II 1–DC-II 2 chain guide

1. Chain guide 3. Lower chain entry plate

2. Upper chain entry plate

Figure 20. DC-II 5 chain guide

1. Chain guide 3. Lower chain entry plate

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

2. Upper chain entry plate

Figure 21. DC-II 10 chain guide

1. Chain guide 3. Lower chain entry plate

2. Upper chain entry plate

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7.10.9 Lubricating the chain

WARNING
MOVING MACHINERY HAZARD
Contact with moving parts of the chain hoist, such as the chain or hook, can cause
serious injury or death.
When you operate the chain hoist, watch out for any moving components.

WARNING
IRRITATING SUBSTANCE HAZARD
The machine contains several chemical substances, which can cause skin irritation and
allergies. Risk of injury when in prolonged contact with skin.
When you handle lubricants and oils, avoid direct contact with the skin. Use safety
gloves. Immediately wash skin that comes in contact with chemical substances.

Lubricate the contact surfaces between the chain links after fitting the chain, before
NOTICE taking the chain hoist into use. Lubricate the chain only when no load is attached. Use
grease, part no. 665 009 44.

1. Lubricate the chain carefully before the first

run, during the commissioning of the chain
hoist.
To extend the lifetime of the chain, continue
to lubricate the chain regularly. The
lubrication interval varies from a minimum
of one week to one year, depending on the
usage.

In environments with abrasives, for

example, sand, preferably use a dry film
lubricant (lubricating varnish). For more
information about non-standard lubrication,

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
see "Available chains."

7.10.9.1 Lubricating the chain with a grease tube

The target of the lubrication of the chain is to have enough lubricant between the chain links.
The lubricant must be applied on the contact surfaces between the chain links. Make sure that
you add the new layer of lubrication always on a clean surface.

1. Drive the hook down until the chain collector box is empty.
If a load is attached to the hook, remove the load.
2. Cut off the tip of the grease tube.
3. Insert the grease tube at the lubrication point.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

4. Lubricate the chain.

Start applying the lubricant on the chain
from the top, close to the chain hoist. Then
proceed from top to bottom of the chain.

Apply a substantial amount of lubricant

over the full length of the chain. Make sure
that the chain is lubricated all over its
surface and links, especially on all contact
areas between the chain links.

5. After lubrication, drive the hook up and down three to four times over the full length of the
chain.
The lubricant spreads evenly throughout the chain.

NOTE Do not attach any load to the hook.

Type Trade name and number Quantity

RENOLIT special chain grease

Grease (standard lubricant)
55395066
As required
Oil (optional food industry
67864539 - Berusynth CB 180 H1
lubricant)

WARNING! SLIPPING HAZARD

Lubricants or oils on the floor can cause slipping, which can cause serious injury.
If there is lubricant or oil on the floor after lubrication, clean the area immediately. Use
sawdust or an absorbent to absorb the lubricant or oil, if needed. Dispose of the
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

cleaned lubricant or oil in accordance with environmental protection requirements.

7.10.9.2 Lubrication intervals of the chain

Defining the required maintenance interval for the chain depends on the use of the product, and
must be determined case-by-case. To fully optimize the lifetime of the components, define the
exact maintenance interval for each hoist application individually.
The following conditions are examples of operating conditions that have an influence on the
required chain maintenance:

• Environment (clean or dusty, cold or hot, indoor or outdoor use)

• Use of the chain hoist (light or full loads, high process cycles, or low maintenance use)
• Construction of the chain hoist (number of chain sprockets)
Evaluate the condition of the chain visually. Combine the visual checks with regular
measurements. For more information, see chapter Inspecting the chain wear.
The following table describes the suggested lubrication intervals of the chain. The data is based
on use of the chain hoist as an industrial indoor application. It is assumed that the chain hoist is
operated under conditions where there are no external particles and where the hoist is in
continuous use with full load.

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

Chain lubrication intervals

Nbr of 1 2 3 4
sprockets

Falls 1-fall 2-falls 1-fall LH 2) 2-fall LH 2)

Hoist type

Grease 12000 6000 4000 3000

[cycles] 1)
1) Cycle = One work cycle, from pick-up to release of the load.

2) LH = Low headroom hoist.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

7.11 Load hook

7.11.1 Load hook dimensions and wear

a2
L4

b1
h2

a1 h1

Chain hoist DC-II 1–DC-II 10 DC-II 1–DC-II 10 DC-II 1–DC-II 10

Hook type Standard hook Self-locking hook Stainless steel hook
Load Capacity [kg] 315 630 1250 2600 4000 400 630 1300
Size 1–2 5 10 2 5 10 10 1–2 5 10
Reeving 1/1 1/1 2/1 1/1
BKT-7/8-10 BKT-13/8-1 CWHF 40 CWHF 50 CWHF 70
Load hook Type V-I V-II V-III
0
a1 [mm] 30 36 43 45 70 23 23 36
a2Nom1) [mm] 23.5 26.7 36 37 55 20 20 30
a2Max [mm] 25.6 29.6 39.6 - - - - -
b1 [mm] 13 19 22 24 37 16 16 22
Dimension h1 [mm] 22 27.5 33.5 30 48.5 18.5 18.5 27.6
h2Nom2) [mm] 18 21.5 26 26 39 15.3 15.3 24
h2min [mm] 17.1 20.4 24.7 - - - - -
L2 [mm] 14 14 20 47 77 21 21 29.8
L4 [mm] 84 95 115 111 160 83 83 123
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

Max. test force [kN] 8 16 25 - - - - -

1) Permissible difference +10%
2) Permissible difference -5%

7.11.2 DC-Pro II hook safety latch

If the hook safety latch must 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 joint must only be tightened enough
to allow the hook safety latch to move freely.

7.11.3 Checking the return sprocket in the hook block

The return sprocket must be checked every month to ensure that it turns easily.
1. Remove any load bars attached to the bottom block.
2. 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 that the
chain is replaced.

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7.11.4 Replacing DC-II 1–DC-II 10 hook assembly

DANGER
FALLING LOAD HAZARD
Incorrect assembling of the hook assembly will cause loads to drop. A dropping load
will cause death, serious injury, or property damage.
Make sure that you install the parts in the right order and orientation.

NOTE Pay attention to the non-standard lubrication instructions for special ambient conditions
or special chains, for example, stainless steel chain or foodstuffs sector. For more
information, see "Available chains."

8
3 9
4

9
10

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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

1. Lubricate the ball thrust bearing (3).

2. Thread the hook assembly sleeve (2), the ball thrust bearing (3), and the supporting washer
(4) onto the chain (1).
Pay attention to the correct order of installation and the correct orientation of the parts.
3. Grease the end of the chain with the enclosed grease.
4. Place the last chain link of the chain (1) between the chain link anchorage sections (5).
Place the chain link anchorage sections with their tabs in the recesses of supporting washer
(4).

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

5. Install the O-ring (6) over the tabs at the top of the load hook (7). The O-ring acts as a shock
absorber.
6. Fill one hook assembly half (8) with the enclosed grease.
7. Place the chain (1) with the hook assembly sleeve (2), the ball thrust bearing (3), the
supporting washer (4), and the chain link anchorage sections (5) into the hook assembly
half (8).
8. Position the load hook (7) with the O-ring (6) under parts 1, 2, 3, 4, and 5.
9. Fit the hook assembly bolted joint (9). Tighten the bolted joint to the correct tightening
torque.

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

Hook assembly 11.5 25.0

7.11.5 Replacing the bottom block with external cut-off springs, 2/1 reeving

DANGER
FALLING LOAD HAZARD
Incorrect assembling of the hook assembly will cause loads to drop. A dropping load
will cause death, serious injury, or property damage.
Make sure that you install the parts in the right order and orientation.

WARNING
FALLING LOAD HAZARD
A twisted chain can get stuck in the bottom block. A twisted chain stuck in the bottom
block can overload the hoist and the chain. This situation can lead to failure of the
chain and a dropping load. Failure of the chain and a dropping load can cause death,
serious injury, or property damage.
Make sure that the chain between the hook and the hoist is not twisted.
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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

NOTE For instructions on removing and installing the chain, see "Replacing the chain."

8
7 10
9

5 6
3 4

11
2

1. Hook 7. Cut-off spring

2. Ball thrust bearing 8. Chain
3. Nut 9. Hook assembly cover
4. Rated capacity plate 10. Bolt
5. Bearing 11. Hook retaining ring
6. Return sprocket

1. Lubricate the ball thrust bearing (2).

2. Assemble the hook (1) with the thrust ball
bearing (2) and the assembled hook 8 6
retaining ring (11). Place the assembled
parts into the lower cavity of one of the 9 5

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
hook assembly covers (9).
Pay attention to the correct order of
installation and the correct orientation of 1
the parts.
11 2

3. Assemble the return sprocket (6) and the bearings (5). Place the assembled parts with the
chain (8) into the upper cavity of one of the hook assembly covers (9).
Pay attention to the correct order of installation and the correct orientation of the parts. The
cut-off spring (7) must be on the side on which the chain goes into the chain guide. If the
cut-off spring is on the wrong side, the cut-off function does not work.

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4. Assemble the hook assembly covers (9)

with two bolts (10) and two nuts (3).
9
Tighten to the correct tightening torque.

10

Tightening torques [Nm] DC-II 10

Bottom block with external cut-off springs 52.0

7.12 Buffers and cut-off springs

7.12.1 Checking the cut-off buffers and cut-off springs

1. Visually check the buffers during the annual inspection. Check for damage, cracks, and
tears.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

2. Make sure that the component parts are installed in the right order when new buffers are
installed.
For more information, see "Buffer and cut-off spring arrangement." A missing buffer plate,
for example, will result in premature wear of buffers.
3. Visually check the external cut-off springs during 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.

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

7.12.2 Buffer and cut-off spring arrangement

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

ød1
2 4
3
ød2
h

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
1. Cut-off buffer 3. Damping plate
2. Buffer plate 4. Cut-off spring

NOTE 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

Plate
Switch Height Chain collector
Lifting speed 2) dia. d1/
h
Load hook side
box side
Product range 1) Size Reeving equipme dia. d2
nt 3)
[m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
1+2 V8 45 A 718 225 45 M
DC-Pro II/DC-ProCC 1BES 45/42
2 V16 80 B 718 256 45 N
1/1 751 253 45
1+2 V8 - - M
DCM-Pro 1BES R 718 260 45
2 V16 - - N

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Plate
Switch Height Chain collector
Lifting speed 2) dia. d1/
h
Load hook side
box side
Product range 1) Size Reeving equipme dia. d2
nt 3)
[m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
1 V8 - -
0BES F 717 534 45 O 717 534 45
2 V6 - -
DC-Com II
1 V8
2 V6
1/1 1BES 45/42 45 A 718 255 45
1 VS30
DCS-Pro M 751 253 45
2 VS16

DCMS-Pro/DCRS- 1 VS30 - -
1BES R 718 260 45
Pro 2 VS16 - -
0BES - - G 717 534 45 P
DC-ProFC 1+2 VS16
GGS - - - -
0BGS - - G 717 534 45
1+2 V8 1BES 45/45 79.5 E 717 250 45
1/1 717 534 45
GGS - - - - O
DC-ProDC
0BES - - G 717 534 45
2 V16 1BES 45/45 79.5 E 717 250 45
GGS - - - -
DC-Pro II/DC-ProCC V8 45 A 718 255 45 M
V16 1BES 45/42 80 B 718 256 45 N
DC-Pro II/DC-ProCC
V24 130 C 718 249 45 M 751 253 45
V16 - - N
DCM-Pro 5 1/1 1BES R 718 260 45
V24 45/42 130 M
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
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
5 1/1
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

GGS - - - -
DC-ProDC
0BES/
45/42 130 C 718 249 45 M 751 253 45
V24 1BES
GGS - - - - O 718 534 45
DC-Pro II K/
V8/VS8 45 A 718 255 45 M
DCS-Pro II K
1/1
DC-Pro II K V16 80 B 718 256 45 N
5 1BES 45/42 751 253 45
DC-Com II K V4,5 45 A 718 255 45 M
DC-Pro II K/
2/1 V4/VS4 80 B 718 256 45 N
DCS-Pro II K
V6 43 D 715 260 45
M
V8 55 A 715 254 45 752 253 45
DC-Pro II/DC-ProCC 1BES 52/55
V12 74 B 715 255 45 N
10 1/1 V24 125 C 715 249 45
O 715 534 45
0BES - - F 715 534 45
DC-Com II 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

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

Plate
Switch Height Chain collector
Lifting speed 2) dia. d1/
h
Load hook side
box side
Product range 1) Size Reeving equipme dia. d2
nt 3)
[m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
0BES - - G 715 534 45 P
DC-ProFC VS4/VS6/VS12
GGS - - - -
0BES - - G 715 534 45
10 1/1 V6/V8/V12/V24 715 534 45
GGS - - - - O
DC-ProDC
V6/V8/V12 1BES E 715 074 45
52/55 81.2
V24 1BES 2xE 715 074 45
V6 43 D 715 260 45
DC-Pro II K 52/55 M 752 253 45
V12 55 A 715 254 45
10 1/1
DC-Com II K V4
52/55 43 D 715 260 45 M
DCS-Pro II K VS6/VS12
DC-Pro II, DC- 1BES
V4 55 715 254 45 M
ProCC, DC-Com II K 752 253 45
DC-Pro II/DC-ProCC V6 74 715 255 45 N
52/55
VS4 55 H 715 254 45 M
DCS-Pro
VS6 74 I 715 255 45 N
0BES 81.2 J 715 074 45 P
DC-ProFC VS4/VS6 715 534 45
10 2/1 GGS - - - - O
GGS - 55 H 715 254 45
DC-ProDC V4/V6 0BES/ O 715 534 45
81.2 J 715 074 45
1BES
DC-Pro II K/ 62/55
V6/VS6 74 I 715 255 45 N
DCS-Pro II K 1BES 752 253 45
DC-Com II K V4 55 H 715 254 45 M
1/1 V8 A
DC-Pro II/DC-ProCC
2/1 V4 1BES L
62/55 55 721 753 45
DCS-Pro VS8
A
1/1 0BES
DC-ProFC 16 VS8 Q 721 753 45
GGS - - - -
DCS-Pro VS4 1BES
62/55 55 L 721 753 45

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
2/1 0BES
DC-ProFC VS4
GGS - - - -
GGS - - - -
1/1 V8 0BES/
62/55 55 2xA 721 753 45
1BES
DC-ProDC 16 2xQ 721 753 45
GGS - - - -
2/1 V4 0BES/
62/55 55 L 721 753 45
1BES
1) LDC: Buffers as for DC, KLDC: Buffers as for KDC, KLDC-ProDC: No buffers, since always fitted with geared limit switch.
2) Lifting speed: V = 2-stage speed for 50 Hz, VS = Variable speed at vsnenn.
3) 0BES = No operating limit switch, 1BES = Fitted with operating limit switch, GGS = Fitted with geared limit switch.

7.13 Brake

7.13.1 Maintaining the brake

NOTICE During the annual inspection, the V seal ring of the brake must be greased.

1. If a load is attached to the hook, remove it.

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2. Disconnect the chain hoist from the main power supply network.
3. Open the electric equipment cover.
4. Detach the brake. For more information, see "Replacing the brake."
Take notes or a photograph of the orientation of the brake. You must install the brake in the
same orientation.
5. Apply anti-friction grease without any solid
lubricant to the V seal ring (1).
Make sure that the area of V seal ring (1)
on the brake base is lightly greased.
1

6. Install the brake in the same orientation as before detaching the brake. For more
information, see "Replacing the brake."

NOTE Make sure that no grease penetrates inside the brake.

7. Inspect that the lip of the V seal ring (1) is in full contact with the back of the brake.
8. Install the electric equipment cover.
Tighten the screws of the electric equipment cover to the correct tightening torque. For more
information, see "Recommended tightening torques."

7.13.2 Checking the brake wear

1. If a load is attached to the hook, remove the load.
2. Disconnect the chain hoist from the main power supply network.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

3. Open the electric equipment cover.

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

4. Locate the brake check hole (1) in the

brake assembly.

5. Measure the depth of the brake check hole

gap with a caliper.

6. Compare the measured brake wear value with the maximum value for brake wear.
You can find the value on the brake.

NOTE Do not exceed the maximum value for brake wear.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
7. If the brake has worn more than the maximum value for brake wear, replace the brake.

7.13.3 Replacing the brake

1. If a load is attached to the hook, remove it.
2. Disconnect the chain hoist from the main power supply network.
3. Open the electric equipment cover.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

4. Check that the brake data of the

replacement brake matches with the data
of the original brake.
You can find the brake data on the brake.

5. Unplug the brake cable from the control

board.

6. Remove the screws (1) that hold the brake

in place.
Take notes or a photograph of the
orientation of the brake. You must install a
new brake in the same orientation.
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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

7. Remove the brake carefully.

8. Install the new brake on the shaft in the

same orientation as the removed brake.
Attach the brake with the three screws.

9. Plug in the brake cable.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

10. Install the electric equipment cover.

Tighten the screws of the electric equipment cover to the correct tightening torque. For more
information, see "Recommended tightening torques."
11. Turn on the power to the chain hoist.
12. Check that the brake works normally.
1. First test the brake without any load.
2. Test the brake with a dynamic test load of 110% (EUR) or 125% (US) of the rated
capacity. Size of the dynamic test load depends on the country regulations.
3. In the European countries, test the brake also with a static test load of 125% of the
rated capacity.

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7.14 Slipping clutch

7.14.1 Checking the slipping clutch

The slipping clutch provides the function of an
emergency limit stop device and overload
protection for the chain hoist. The slipping
clutch is initially adjusted in the factory. Under
normal operating conditions, the slipping
clutch does not need to be readjusted. The
slipping clutch is maintenance-free for up to
ten years. The slipping clutch must be
checked as part of the annual inspection. The
slipping clutch may only be adjusted by
authorized specialist personnel. An increase
of the tripping torque which exceeds the
default setting is not permitted.

Check operation of the slipping clutch as

follows:

1. Disconnect the chain collector to remove the limit stop, for more information, see "Removing
the chain collector box".
2. Remove the limit stop from the section of chain which is not under load and fit it above the
hook assembly.
3. Run the limit stop against the guide plate at creep lifting speed.
Do not actuate the operating limit switches while this is being done.
If the slipping clutch is working correctly, the following will be observed:
• Hoist motor fan is still turning while there is no lifting motion;
• 7-segment display shows the SLIP LIFTING V1 warning message, for more information,
see "Warning messages".
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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.

7.14.2 Adjusting the slipping clutch

WARNING
MOVING MACHINERY HAZARD
When you adjust the slipping clutch, the motor must not run. Contact with the moving
parts of the motor can lead to death, serious injury, or property damage.
Always turn off the power to the chain hoist before starting to work with the clutch
adjustment tools.

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

WARNING
MOVING MACHINERY HAZARD
When you adjust the slipping clutch, make sure that you do not touch any of the
moving components. Touching the moving components during the adjustment of the
slipping clutch can cause death or serious injury.
Always turn off the power to the chain hoist before starting to adjust the slipping clutch.

Overload protection must be provided for chain hoists with a rated capacity of 1000 kg or more.
All DC-II chain hoists have the overload protection. The setting that is made in the factory
installation meets the requirements of EN 14492-2 (direct acting rated capacity limiters) for
slipping clutches that are used as overload protection.

In an acceptance test of the chain hoist installation, a load of 110% of the rated capacity must
be lifted without adjusting the slipping clutch. A load of 160% of the rated capacity or more must
not be lifted.

The slipping clutch is protected against overload by slip monitoring, which means that it does
not have to be readjusted until a general overhaul is carried out. If the adjustment must be
checked because of the operating conditions or malfunctions, a friction force checking device
(part no. 836 708 44) must be used. Inspection and adjustment may only be carried out by an
experienced technician in compliance with the "Friction force checking device" document.

If adjusting the slipping clutch is necessary, follow these instructions:

1. Turn off the power to the chain hoist.

2. Remove the electric equipment cover.
3. To adjust the slipping clutch, turn the adjusting screw at the center of the brake with an
adjustment tool.

NOTE Use a T-handle key (1) or an Allen wrench (2) as an adjustment tool. For more
information, see steps 5 and 6.

1 2 3

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

NOTE If the whole brake hub turns when you turn the adjustment tool in the adjusting screw,
use a slotted screwdriver (3) to prevent rotation.

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4. To tighten the slipping clutch and to

increase torque, turn the adjustment tool
clockwise in the adjusting screw.

NOTE Make sure that you do not over-tighten the

adjusting screw. Over-tightening the
adjusting screw can damage the springs of
the slipping clutch.

NOTE If the whole brake hub turns when you turn

the adjustment tool, use a slotted
screwdriver to prevent rotation.

Place the screwdriver on the left-hand side

of the adjustment tool. Place the tip of the
screwdriver in one of the splines of the
brake. Press the screwdriver against the
adjustment tool while you turn the
adjustment tool.

5. To loosen the clutch and to decrease

torque, turn the adjustment tool
counterclockwise in the adjusting screw.

NOTE If the whole brake hub turns when you turn

the adjustment tool, use a slotted
screwdriver to prevent rotation.

Place the screwdriver on the right-hand

side of the adjustment tool. Place the tip of
the screwdriver in one of the splines of the
brake. Press the screwdriver against the
adjustment tool while you turn the
adjustment tool.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

6. Test the slipping clutch.

6.1 Turn on the power to the chain hoist.
6.2 Test the slipping clutch again with the friction force checking device.
7. Turn off the power to the chain hoist.
8. Install the electric equipment cover.
Tighten the screws of electric equipment cover to the correct tightening torque. For more
information, see "Recommended tightening torques."

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7.15 Maintaining the gearbox

7.15.1 Gear oil

DC-II 1
Chain hoist size DC-II 5 DC-II 10
DC-II 2
Oil quantities [I] 0.3 0.35 0.90
Gearbox cover [Nm] 10.0
Tightening torques Drain plug [Nm] 35.0
Service cover [Nm] 10.0

NOTE Dispose of waste oil in accordance with environmental protection requirements.

Oil lubrication

Under normal operating conditions, the lubricant must be changed at least every ten years.
Under exceptional conditions, for example, increased ambient temperatures, we recommend
that oil changes are adapted to suit these operating conditions.

Oil grade

Shell Donax TD 10W-30 universal gear oil with wear-minimizing additives, range of viscosity
10W-30.

WARNING! MACHINE MALFUNCTION HAZARD

If oils that are not approved are used, malfunctions of the slipping clutch can occur.
Malfunctions of the slipping clutch can cause death, serious injury, or property damage.
Only use oils that are approved.

DC-Pro II
Product range
DC-Com II Viscosity range Part no.

Frequency [Hz] 50/60

1 - *
Application, for Standard
- 10W-30 664 020 44
example

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Foodstuffs sector 3 - 180 003 98

* For more information, see "Spare part manual."

Numbers 1, 2, and 3 refer to the oil type that is, for example, "O:1" in the data plate.

7.15.2 Changing the gear oil

WARNING
IRRITATING SUBSTANCE HAZARD
The machine contains several chemical substances, which can cause skin irritation and
allergies. Risk of injury when in prolonged contact with skin.
When you handle lubricants and oils, avoid direct contact with the skin. Use safety
gloves. Immediately wash skin that comes in contact with chemical substances.

NOTICE Dispose of waste oil in accordance with environmental protection requirements.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

1. If a load is attached to the hook, remove the load.

2. Disconnect the chain hoist from the main power supply network.
3. Open the electric equipment cover and the service cover.
4. Remove the chain collector box. For more information, see "Removing the chain collector
box."
5. Unplug the brake cable from the control
board. Remove the brake (1). For more 4
information, see "Replacing the brake."
Also remove the V seal ring (2), the pulse
wheel (3), and the control board (4).

3
2

6. Remove the drain plug (1).

NOTE Place a container under the gearbox for

collecting the old oil before you drain the
old oil.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

7. To drain the oil, turn the gearbox on its side so that the hole of the drain plug is down. Drain
old oil at operating temperature.
8. Fill the gearbox with flushing oil when the gearbox is back in upright position.
The flushing oil must have a viscosity of 46–68 mm2/s at rated temperature. The quantity of
flushing oil is twice that specified for lubrication. For more information on the required oil
quantities, see "Gear oil."
9. Install the parts removed in steps 4–6.
10. Switch on the chain hoist and run the hook the length of the hook path several times.
11. Disconnect power to the chain hoist and drain the flushing oil as described in steps 2–7.
12. Refill the gearbox with new oil. For more information on the required oil quantities, see
"Gear oil."
13. Install the parts removed in steps 4–6.
14. Install the electric equipment cover and the service cover.

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

7.16 Replacing the contactor on the control board

1. Locking tab
1
2. Contactor
2

1. Unclip the contactor retaining mechanism

by pressing the locking tab (1) with your
thumb. Carefully bend the locking tab (1)
away from the contactor.

2. Turn the contactor (2) using your other

hand until the contactor retaining
2
mechanism no longer holds the contactor.

3. Unclip the second locking tab (1) on the

opposite side as described in step 1.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

4. Using your other hand, remove the

contactor (2) by pulling it away from the
control board.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

5. You can insert the replacement contactor

into the socket in one position only. Push
the contactor into the contactor socket (3)
until both locking tabs (1) click into position.
1 3

7.17 Replacing the relay on the control board

2
1. Control board
4
2. Contactor
3
3. Relay
4. Spring clip
1

1. Use a screwdriver (5) to lever one side of

the spring clip (4) out of its retaining
bracket.

2. Unclip the spring clip (4) on the other side.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

3. Lift the spring clip (4) up and off the relays

(3).

4. Remove the relays (3) from their bases.

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

3
3

NOTE If relays must be replaced, note the following:

• 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.

7.18 Replacing the control cable

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

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

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 OPERATING AND MAINTENANCE INSTRUCTIONS 7 MAINTENANCE

3. Take the control cable out of the bag.

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

5. Unscrew the electric equipment cover, and let the cover hang down on the suspension
wires. Do not remove the suspension wires.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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

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7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS

Install the new control cable in reverse order. Make sure that:
• The groove on the connector fitting lines up with the swivel lock in the electric enclosure
and
• The two pins on the electric enclosure line up with the bayonet lock.

Assemble the pendant controller. For more information, see "Connecting the controller."

Adjust the height of the pendant controller. For more information, see "Pendant controller
height adjustment."
7. Reassemble the electric equipment cover and the service cover in reverse order.

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

Electric equipment cover 10.0

Service cover 10.0

Control cable locking mechanism 10.5

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
7.19 Finishing maintenance
Make sure that you leave the site in a safe condition.
1. Make sure that the work area is clean.
2. Remove all locks and tags from switches.
3. Restore safety devices to operational status. If you have bypassed safety devices for test
purposes, restore them to full operational status before you allow the product to be used for
normal operation.
4. Test that the product functions normally.
5. Inform the site responsible that you have finished the work.

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 OPERATING AND MAINTENANCE INSTRUCTIONS 8 TROUBLESHOOTING

8 Troubleshooting

8.1 Safety during troubleshooting

DANGER
ELECTRIC SHOCK HAZARD
Incompetent electrical work will be unsafe or cause unsafe and unreliable operation of
the product that will result in death, serious injury, or property damage.
Work on electric equipment must be done by qualified specialist personnel in
compliance with the safety regulations. For more information, see "Definition of
personnel."
Switch off the electric power supply before starting work. Lock out and tag out the
power source. For more information, see "Lockout-tagout-tryout procedure."

WARNING
MACHINE MALFUNCTION HAZARD
Incompetent troubleshooting can be unsafe or cause unsafe and unreliable operation of
the product that can cause death, serious injury, or property damage.
Troubleshooting must be done by authorized, trained specialist personnel in
compliance with the safety regulations. For more information, see "Definition of
personnel."

WARNING
BURN HAZARD
The chain hoist has hot surfaces when the chain hoist has been in operation. Hot
surfaces can cause serious injury.
Do not touch hot motor housings. If you must touch a motor, allow the motor to cool
down before eliminating the fault.

Conduct when malfunctions occur

1. If malfunctions occur that result in an immediate danger of personal injury, damage, or an
operating hazard, stop the machine immediately. Actuate the emergency stop without
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

delay.
2. Switch off the chain hoist at the mains connection or the isolating switch, and secure it
against switching on again.
3. Inform the person responsible at the operating location about the malfunction.
4. Have the faults and causes of faults determined and rectified by authorized specialist
personnel. After a short circuit, experts must ensure that the built-in electrical components
do not have any contact welds or other faults. Continued operation without checking is not
permitted.

Conduct after a fault is eliminated

WARNING
MACHINE MALFUNCTION HAZARD
Improperly fitted safety devices can cause death, serious injury, or property damage.
Make sure that the malfuction and the cause of malfunction are eliminated before you
reconnect the power supply. Make sure that all safety devices are fitted properly and
that they are in perfect condition and working order.
Make sure that nobody is present in the danger zone of the equipment.

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8 TROUBLESHOOTING OPERATING AND MAINTENANCE INSTRUCTIONS

8.2 7-segment display

NOTE The symbols are shown one after the other.
•Contact after-sales service if the cause of the fault cannot be eliminated with the given
measures.

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.

Error messages start with an "E" for error. Before any further movement is possible, the error
message must be acknowledged using the emergency stop.

Safety function failure

If a safety function fails, the equipment must not be operated until it is repaired.

8.2.1 Troubleshooting when the display indicates malfunction

The chain hoist can only function when it is correctly connected to the power supply.
Malfunctions can also be caused by incorrect transmission of commands from the controller.
Therefore, if a malfunction occurs check the following.
1. Check cables, strain relief, and power supply connections.
2. 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.

8.3 Operating statuses and general messages

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Malfunction or
Display Possible cause Solution
event

Check mains connection and fuse link; check

No lifting, no connection cable for interruption; check mains
No power supply (display is dark)
lowering connector in the service enclosure. Check PE
phase for correct connection.

Emergency stop actuated. Unlock emergency stop by turning it.

Connecting cables that are not
No lifting, no Check and replace connections, as required.
connected or defective.
lowering
Plug connections that are not
Check and replace plug connections, as required.
connected or defective.
When the voltage is switched on or the
emergency stop is unlocked, a button is Release button and actuate it again.
No lifting, no already actuated.
lowering Check connections of the control cable on the
Control cable interrupted. controller and in the service enclosure. Check
control cable for continuity.

– – Operating status: Lifting V1

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 OPERATING AND MAINTENANCE INSTRUCTIONS 8 TROUBLESHOOTING

Malfunction or
Display Possible cause Solution
event

– – Operating status: Lowering V1

– – Operating status: Lifting V2

– – Operating status: Lowering V2

– – Operating status: Lifting start-up

– – Operating status: Lowering start-up

Upper limit position

Upper limit switch actuated. Limit position reached. Lower.
reached, no lifting

Lower limit position

Lower limit switch actuated. Limit position reached. Lift.
reached, no lowering

Button lock
"Left" and "Right" buttons that are
Release buttons and press only one.
No travel actuated simultaneously.
Invalid controller signals. Strong electric interference.

8.4 Warning messages

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

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;

• binding brake or
• dirty or defective speed sensor.
These causes may result in frequent warning messages. Various measures must be taken to
eliminate the warning messages:

• clean the speed sensor with compressed air (for example, dirt accumulation on the photo
cell);
• check and, if necessary, adjust the slipping clutch;
• check and, if necessary, adjust the brake air gap.

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8 TROUBLESHOOTING OPERATING AND MAINTENANCE INSTRUCTIONS

Display Malfunction or event Possible cause Solution

Check mains connection and fuse link;
A mains phase is missing or the check connection cable for interruption;
SLIP LIFTING start-up: No motor is blocked. check mains connector in the service
lifting. No lifting with load. enclosure.
Chain hoist that is overloaded or Reduce load to the permissible load
undervoltage. capacity. Ensure appropriate supply voltage.
(-.) is displayed when the limit switches
function correctly. The slipping clutch acts as
SLIP LIFTING V1: Cut-out in Limit switch contact is no longer an emergency limit stop device if there is a
the upper limit position. actuated. malfunction. Connection and operation of the
limit switch contact must be inspected by an
experienced technician.
(-.) is displayed when the limit switches
function correctly. The slipping clutch acts as
SLIP LIFTING V2: Cut-out in Limit switch contact is no longer an emergency limit stop device if there is a
the upper limit position. Fast actuated. malfunction. Connection and operation of the
lifting with load is switched limit switch contact must be inspected by an
off. experienced technician.
Reduce load to the permissible load
Chain hoist overloaded.
capacity.

Defective internal data

Defective control system. Replace control system.
memory.

Repeat lifting process; if the load does not

move, have the brake and control system
No speed information. Hardware monitoring malfunction.
that is checked by an experienced
technician.

Check mains connection and fuse link;

SLIP LOWERING start-up: A mains phase is missing or the check connection cable for interruption;
No lowering. motor is blocked. check mains connector in the service
enclosure.

Check chain entry point, replace chain, if

Chain blocked.
necessary.
SLIP LOWERING V1:
Lowering is switched off, (-.) is displayed when the limit switches
lower limit position is not function correctly. The slipping clutch acts as
reached. Cut-out in the lower Limit switch contact is no longer an emergency limit stop device if there is a
limit position. actuated. malfunction. Connection and operation of the
limit switch contact must be inspected by an
experienced technician.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Check chain entry point, replace chain, if
Chain blocked.
necessary.
SLIP LOWERING V2:
Lowering is switched off, (-.) is displayed when the limit switches
lower limit position is not function correctly. The slipping clutch acts as
reached. Cut-out in the lower Limit switch contact is no longer an emergency limit stop device if there is a
limit position. actuated. malfunction. Connection and operation of the
limit switch contact must be inspected by an
experienced technician.

8.5 Error messages

Display Malfunction or event Possible cause Solution
Check error message by actuating and
unlocking the emergency stop.
Hardware error of control system.
Then actuate Lowering. If necessary,
remove suspended load.
Chain hoist is blocked.
One phase is missing. Check the phases.
Defective electronic monitoring Replace hoist control system.
Defective “On/off” contactor Replace contactor, see "Replacing the
Contact wear contactor on the control board".

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 OPERATING AND MAINTENANCE INSTRUCTIONS 8 TROUBLESHOOTING

Display Malfunction or event Possible cause Solution

Check error message by actuating and
unlocking the emergency stop. Then actuate
Drive blocked
Lowering. If necessary, remove suspended
Chain hoist is blocked. load.
Brake blocked Check and, if necessary, replace the brake.
Speed measurement failure. Replace hoist control system.
Reduce load to the permissible load
Hoist unit: Overspeed or load capacity. Check mains connection and fuse
cannot be held. Lowering Lowering speed too high. link; check connection cable for interruption;
with load is switched off. check mains connector in the service
enclosure.
Check error message by actuating and
unlocking the emergency stop. Then actuate
Hardware error of control system.
Lowering. If necessary, remove suspended
load.
Chain hoist is blocked.
Check and, if necessary, replace the K1
K1 contactor sticking.
contactor.
Defective electronic monitoring. Replace hoist control system.
Check error message by actuating and
unlocking the emergency stop. Then actuate
Hardware error of control system.
Chain hoist is blocked. Lowering. If necessary, remove suspended
load.
Defective electronic monitoring. Replace hoist control system.

Check error message by actuating and

Hoist unit: incorrect direction
Direction of hoist unit cannot be unlocking the emergency stop. Then actuate
of rotation; chain hoist is
switched. Lowering. If necessary, remove suspended
blocked.
load.

Check brake and slipping clutch.

Brake defective or slipping clutch
Lifting is switched off.
that is incorrectly adjusted. If there is no fault, replace electronics.

Check error message by actuating and

unlocking the emergency stop. Then actuate
Emergency stop circuit of control Lowering. If necessary, remove suspended
Chain hoist is blocked.
system defective. load.
Replace hoist control system.

NOTE Hardware faults are displayed with two characters by software version 1.60 and higher.
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9 TRANSPORTATION, STORAGE AND OPERATING AND MAINTENANCE INSTRUCTIONS
DISMANTLING

9 Transportation, storage and dismantling

9.1 Transporting the product

When transporting the product or its components, take the following precautions:

• Load and transport the product with caution and using appropriate methods, making proper
preparations and taking appropriate caution.
• Do not load or transport products if your alertness or working ability is impaired, for example,
by medication, illness, or injury.
• Fasten the load securely for transportation.
• During loading and transportation, do not tip the product or turn it upside down. This could
cause lubricants to leak.

NOTE If transported improperly, essential parts of the product can become damaged. Defects
or faults which are due to improper transportation are not covered by the product
warranty.

9.2 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 and delivery note of the
forwarding company. Lodge a claim.
• Lodge a claim for any defects when they are detected, since claims for damages can only be
asserted within the relevant claim notification periods.

Scope of delivery
If special designs or other options are ordered or the latest technical modifications are
incorporated, the actual scope of supply may differ from the data, information and from the
illustrations described here. If you have any questions, please contact the manufacturer.

9.3 Packaging
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.

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
NOTE Always dispose of packing materials in an environmentally compatible way and
according to locally applicable disposal regulations. If necessary, utilize the services of a
recycling company.

9.4 Storing the product

Until installation, 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°C...+70°C.
• Avoid strong temperature fluctuations (condensation).

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 OPERATING AND MAINTENANCE INSTRUCTIONS 9 TRANSPORTATION, STORAGE AND DISMANTLING

• Oil all bare machine parts (rust protection).

• Check the general condition of all parts of the packing at regular intervals. If necessary,
refresh or renew rust protection.
• If stored in a damp location, the installation parts must be packed tight and protected against
corrosion (desiccant).

NOTE If stored improperly, essential parts of the product can become damaged. Defects or
faults which are due to improper storage are not covered by the product warranty.

NOTE The product must not be stored for more than one year. If the product is stored for more
than one year, the product must be connected to a power supply for at least one hour
within one year. After the product has been connected to a power supply for at least one
hour, the product can be stored for another year.

9.5 Returning the product to use

Store the product correctly. For more information, see "Storing the product."

When taking the product into use after a long period, proper commissioning must be done
according to chapter "Commissioning".

9.6 Dismantling the product

If the product must be dismantled, follow these safety instructions:

• Follow the safety precautions for dismantling the product. For example, when working at
heights, follow the fall protection procedures. Only experienced service personnel are
permitted to dismantle the product.
• Owner shall nominate a person responsible for the dismantling process. This person shall
give instructions and monitor the process.
• All controls must be placed in the OFF position, safety switches must be opened, and the
main isolator switch must be turned off. The product must be electrically isolated before
dismantling starts.
• Make sure that all personnel involved are aware that the product will be dismantled before
dismantling starts.
• Owner must prevent unauthorized persons and bystanders from walking on or below the work
site. Ensure that the secured area is spacious enough to prevent injuries which could occur as
a result of falling components or tools.
• Only use safe tools and machinery for dismantling.
• Make sure that removed fastenings and components will not fall.
DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.

• Pay attention to the environmental conditions. For example, do not disassemble the product if
the prevailing weather could compromise safety.
• Disassembly sequence is completed in the reverse order to the assembly sequence. Refer to
installation and assembly instructions for correct sequence.
• After the product has been dismantled, the owner or person responsible for dismantling can
return the working area back to normal use.

If you need more detailed dismantling instructions, contact the manufacturer of the product.

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APPENDIX I: RECOMMENDED TIGHTENING OPERATING AND MAINTENANCE INSTRUCTIONS
TORQUES

APPENDIX I: Recommended tightening torques

WARNING
FALLING LOAD HAZARD
Improper attachment and loose connections can cause death, serious injury, or
property damage.
Mainly metal nuts with a locking element, self-locking nuts, are used for chain hoists.
Do not replace self-locking nuts with normal nuts.

Tightening torques
[Nm]
Size DC-II 1 DC-II 2 DC-II 5 DC-II 10
Reeving 1/1 1/1 2/1
Motor 9.5 25.0
Fan cover 6.0
Gearbox cover 10
Drain plug in gearbox 35
Brake 3.9 5.5
Operating limit switches 1.5 3.0
Control set (Ejot screw) 1.0
Control set (metric screw) 6.0
Encoder 3.0
Electric equipment cover 10.0
Suspension wires of electric equipment cover 6.0
Service cover 10.0
Limit stop 2.9 4.3
Guide plate 6.0 10
Hook assembly 11.5 25.0 -
Bottom block - 52.0
Control cable locking mechanism 10.5
Chain guide 4.5–5.0 8.0
Pin-fixing screw - 3.0

DOC2559317A 07 June 2024 Copyright © 2024 Demag Cranes & Components GmbH. All rights reserved.
Strain relief 6.0

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 OPERATING AND MAINTENANCE INSTRUCTIONS APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST CIRCUIT
DIAGRAM

APPENDIX II: DC-II 1–DC-II 10 solo hoist circuit diagram

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APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST OPERATING AND MAINTENANCE INSTRUCTIONS
CIRCUIT DIAGRAM

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 OPERATING AND MAINTENANCE INSTRUCTIONS APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST CIRCUIT
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DIAGRAM

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APPENDIX II: DC-II 1–DC-II 10 SOLO HOIST OPERATING AND MAINTENANCE INSTRUCTIONS
CIRCUIT DIAGRAM

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DIAGRAM

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 Document ID: DOC2559317A en-US
ORIGINAL INSTRUCTIONS
07 June 2024

DEMAG CRANES & COMPONENTS GMBH

Standort Wetter
Ruhrstraße 28
58300 Wetter
E info@demagcranes.com
T +49 2335 92-0
F +49 2335 92-7676
www.demagcranes.com