Operating instructions/accessories/spare

parts
Demag DC-ProDC 1-15, DC-ProCC 1-15, DC-ProFC 1-15 chain hoist

43406245_xml.eps

100620 en GB 211 191 44 720 IS 817

 Original operating instructions
Manufacturer
Demag Cranes & Components GmbH
Forststrasse 16
40597 Düsseldorf, Germany
www.demagcranes.com
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative.

Owner

Where in use

Size

Serial number

Year of manufacture

Operating voltage

Control voltage

Frequency

Circuit diagram number

Tab. 1

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

6  "Available hoist chains", Page 105,

7 5 Chain type, hook path  "Model code", Page 19,
8  "Selection table", Page 20
9 6 Voltage, frequency  "Electric key data", Page 22
Type of enclosure, insulation  "Operating conditions", Page 26,
10 7
class  "Electric key data", Page 22
8 Ambient temperature  "Operating conditions", Page 26
11  "Selection table", Page 20,
9 Motor type, oil grade  "Electric key data", Page 22
 "Gearbox/oil change", Page 129
12
42770348.eps 10 Electric key data  "Electric key data", Page 22

Fig. 1 Example of a rating plate 11 Conformity symbol

12 Manufacturer’s address See above
Tab. 2

The metric system is used in this document and all figures

are shown with a comma as the decimal separator.

43307444_xml.eps
Fig. 2 Example: additional rating plate only for
DC-ProFC
211 191 44/100620

2
 Table of contents

1 General ....................................................................................................................................................................... 7
1.1 DC-ProDC 1-15, DC-ProCC 1-15, DC-ProFC 1-15 chain hoist .................................................................................. 7
1.2 DC-ProDC 1-15, DC-ProCC 1-15, DC-ProFC 1-15 documents .................................................................................. 7
1.3 Symbols/signal words.................................................................................................................................................. 8
1.4 Information on the operating instructions .................................................................................................................... 9
1.5 Liability and warranty................................................................................................................................................. 10
1.6 Copyright ................................................................................................................................................................... 10
1.7 Use of spare parts ..................................................................................................................................................... 10
1.8 Definition of personnel............................................................................................................................................... 10
1.9 Log book.................................................................................................................................................................... 11
1.10 After-sales service ..................................................................................................................................................... 11

2 Safety........................................................................................................................................................................ 12
2.1 General information on safety ................................................................................................................................... 12
2.2 Safety signs on the equipment .................................................................................................................................. 12
2.3 Intended use.............................................................................................................................................................. 13
2.4 Hazards that can be caused by the machine ............................................................................................................ 14
2.5 Responsibility of the owner ....................................................................................................................................... 15
2.6 Operating personnel requirements............................................................................................................................ 16
2.7 Personal protection equipment.................................................................................................................................. 16
2.8 Emergency-stop device ............................................................................................................................................. 16
2.9 Regular inspections................................................................................................................................................... 17

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

3.1 Design overview ........................................................................................................................................................ 18
3.2 Model code ................................................................................................................................................................ 19
3.3 Selection table ........................................................................................................................................................... 20
3.4 Electric key data ........................................................................................................................................................ 22
3.4.1 DC-ProDC, DC-ProCC (2 lifting speeds)................................................................................................................... 22
3.4.1.1 Hoist motor data ........................................................................................................................................................ 22
3.4.1.2 Mains connection delay fuse links and supply lines .................................................................................................. 23
3.4.2 DC-ProFC (variable lifting speed) for control via an external frequency inverter ...................................................... 23
3.4.2.1 Hoist motor data ........................................................................................................................................................ 23
3.4.2.2 Mains connection delay fuse links and supply lines .................................................................................................. 24
3.4.2.3 Voltage ranges of the brake for DC-ProFC ............................................................................................................... 24
3.5 Dimensions................................................................................................................................................................ 24
3.6 Noise emission/sound pressure level ........................................................................................................................ 24
3.7 Transport, packing, scope of delivery, storage.......................................................................................................... 25
3.8 Materials.................................................................................................................................................................... 26
3.9 Operating conditions ................................................................................................................................................. 26

4 Technical description ............................................................................................................................................. 27

4.1 Drive and brake ......................................................................................................................................................... 27
4.2 Gearbox and slipping clutch ..................................................................................................................................... 27
4.3 Chain drive ............................................................................................................................................................... 27
4.4 Electric equipment..................................................................................................................................................... 28
4.5 Central service enclosure.......................................................................................................................................... 29
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4.6 Pendant controller .................................................................................................................................................... 29

4.7 Limit switches ............................................................................................................................................................ 29
4.8 Trolley/crane connection ........................................................................................................................................... 29
3
 5 Assembly ................................................................................................................................................................. 30
5.1 General...................................................................................................................................................................... 30
5.2 Safety warnings for assembly ................................................................................................................................... 30
5.3 DC chain hoist tightening torques ............................................................................................................................. 32
5.4 Installation procedure ................................................................................................................................................ 33
5.5 Intermediate flange.................................................................................................................................................... 34
5.6 Connecting the controller .......................................................................................................................................... 36
5.6.1 General information on the pendant controller .......................................................................................................... 36
5.6.2 Installing a DSK pendant controller with a support sleeve ........................................................................................ 36
5.6.3 Installing a DST pendant controller with 2TY ............................................................................................................ 38
5.6.4 Handling the control cable ......................................................................................................................................... 40
5.7 Suspending the chain hoist ....................................................................................................................................... 40
5.7.1 Safety information for suspending the chain hoist..................................................................................................... 40
5.7.2 Supporting structure .................................................................................................................................................. 41
5.7.3 Suspension bracket ................................................................................................................................................... 41
5.7.4 Supporting roller fittings............................................................................................................................................. 42
5.7.5 Fittings ....................................................................................................................................................................... 42
5.8 Plug screw, vent valve............................................................................................................................................... 43
5.9 Mains connection ...................................................................................................................................................... 44
5.10 Circuit diagrams ........................................................................................................................................................ 45
5.10.1 General information on the circuit diagrams.............................................................................................................. 45
5.10.2 DC chain hoist with 2 lifting speeds........................................................................................................................... 46
5.10.2.1 Contactor control and control via DSK SP2 pendant controller................................................................................. 46
5.10.2.2 External frequency inverter control, by customer ...................................................................................................... 54
5.10.3 DC travelling hoist with 2 lifting and travel speeds .................................................................................................... 56
5.10.3.1 Direct control with contactor control provided by the customer ................................................................................. 56
5.10.3.2 Contactor control with contactor control provided by the customer........................................................................... 63
5.11 Control systems......................................................................................................................................................... 73
5.11.1 DC-ProDC ................................................................................................................................................................. 73
5.11.2 DC-ProCC ................................................................................................................................................................. 74
5.11.3 DC-ProFC.................................................................................................................................................................. 76
5.12 Adjusting the lower hook position.............................................................................................................................. 78

6 Putting into service for the first time..................................................................................................................... 79

6.1 Safety warnings when equipment is put into service for the first time....................................................................... 79
6.2 Inspection regulations ............................................................................................................................................... 79
6.3 Inspections before putting into service for the first time ............................................................................................ 80
6.4 Checks on entering service, handover ...................................................................................................................... 80

7 Operation ................................................................................................................................................................. 81
7.1 Safety instructions for operation................................................................................................................................ 81
7.2 Switching on .............................................................................................................................................................. 82
7.2.1 Checks when starting work ....................................................................................................................................... 82
7.2.2 Function checks ........................................................................................................................................................ 82
7.3 Operation................................................................................................................................................................... 83
7.3.1 Safety during operation ............................................................................................................................................. 83
7.3.2 Load pick-up .............................................................................................................................................................. 84
7.3.3 Moving loads ............................................................................................................................................................. 84
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7.3.4 Load distribution ........................................................................................................................................................ 85

7.3.5 Emergency-stop device operating function ............................................................................................................... 85
7.3.6 Slipping clutch operating function.............................................................................................................................. 85
7.3.7 Lifting path limiter operating function......................................................................................................................... 85
4
 7.4 Emergency stop ........................................................................................................................................................ 86
7.5 Taking the equipment out of operation...................................................................................................................... 87
7.5.1 Taking the equipment out of service when faults occur ............................................................................................ 87
7.5.2 Taking the equipment out of service at the end of the shift....................................................................................... 87
7.5.3 Taking the equipment out of service for maintenance and repairs............................................................................ 87
8 Maintenance/repair.................................................................................................................................................. 88
8.1 Safety warnings for maintenance and repair work .................................................................................................... 88
8.2 Basic maintenance requirements .............................................................................................................................. 89
8.3 Regular inspections................................................................................................................................................... 90
8.3.1 Required tests and inspections ................................................................................................................................. 90
8.3.2 Special operating conditions ..................................................................................................................................... 90
8.3.3 Measures for achieving safe working periods ........................................................................................................... 91
8.3.3.1 General...................................................................................................................................................................... 91
8.3.3.2 Calculating the actual duration of service S .............................................................................................................. 92
8.3.3.3 Example: DC-ProDC 10-1250 1/1 H5 V8/2 in 1Am................................................................................................... 93
8.3.4 GO general overhaul ................................................................................................................................................. 94
8.4 Maintenance schedule .............................................................................................................................................. 95
8.5 Maintenance work ..................................................................................................................................................... 96
8.5.1 Suspension................................................................................................................................................................ 96
8.5.2 Electric equipment cover ........................................................................................................................................... 96
8.5.3 Replacing the control fuse link .................................................................................................................................. 96
8.5.4 Removing the chain collector box ............................................................................................................................. 97
8.5.5 Operating limit switches ............................................................................................................................................ 98
8.5.5.1 DC-ProDC arrangement............................................................................................................................................ 98
8.5.5.2 DC-ProCC arrangement............................................................................................................................................ 99
8.5.5.3 Checking operating limit switches ........................................................................................................................... 100
8.5.5.4 Checking the operating limit switch actuator on DC-ProDC .................................................................................... 100
8.5.6 Rotary encoder........................................................................................................................................................ 101
8.5.7 Chain drive .............................................................................................................................................................. 101
8.5.7.1 Checking the chain sprocket ................................................................................................................................... 101
8.5.7.2 Checking the chain guide ........................................................................................................................................ 101
8.5.7.3 Checking the guide plate/chain entry plate ............................................................................................................. 102
8.5.7.4 Check hoist chain .................................................................................................................................................... 102
8.5.7.5 Chain set scope of supply ....................................................................................................................................... 105
8.5.7.6 Available hoist chains.............................................................................................................................................. 105
8.5.7.7 Replacing the chain set ........................................................................................................................................... 107
8.5.7.8 Chain guides until 03/2019 and from 04/2019......................................................................................................... 112
8.5.7.9 Lubricating the hoist chain....................................................................................................................................... 115
8.5.8 Load hook................................................................................................................................................................ 117
8.5.8.1 Checking the load hook ........................................................................................................................................... 117
8.5.8.2 Hook safety catch .................................................................................................................................................... 117
8.5.8.3 Checking the return sprocket .................................................................................................................................. 117
8.5.8.4 DC 1 - 10 hook with fittings (as of 2017) ................................................................................................................. 118
8.5.8.5 Replacing the hook with fittings for 1/1 reeving....................................................................................................... 120
8.5.8.6 Replacing bottom block with external cut-off springs, 2/1 reeving .......................................................................... 121
8.5.9 Buffer ....................................................................................................................................................................... 121
8.5.9.1 Check cut-off buffer/cut-off spring ........................................................................................................................... 121
8.5.9.2 Buffer/cut-off spring arrangement............................................................................................................................ 122
8.5.10 Brake ....................................................................................................................................................................... 124
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8.5.10.1 Check operation of the brake .................................................................................................................................. 124

8.5.10.2 Brake assignment.................................................................................................................................................... 124
8.5.10.3 Check brake wear ................................................................................................................................................... 124
5
 8.5.10.4 BK03 - BK07 brakes (not adjustable) ...................................................................................................................... 125
8.5.10.5 BC07/5, BC07/8, BC020 brakes (adjustable).......................................................................................................... 126
8.5.10.6 Checking the thickness of the brake disc for BC07/5, BC07/8, BC020................................................................... 127
8.5.11 Slipping clutch ......................................................................................................................................................... 128
8.5.11.1 Checking the slipping clutch .................................................................................................................................... 128
8.5.11.2 Adjusting the slipping clutch .................................................................................................................................... 128
8.5.12 Gearbox/oil change ................................................................................................................................................. 129
9 Malfunctions .......................................................................................................................................................... 131
9.1 Safety instructions in the event of malfunctions ...................................................................................................... 131

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

11 Accessories ........................................................................................................................................................... 133

11.1 Assemblies .............................................................................................................................................................. 133

12 Spare parts............................................................................................................................................................. 134

12.1 Parts on the DC-Pro 1-10 gearbox.......................................................................................................................... 134
12.2 Parts on the DC-Pro 15 gearbox ............................................................................................................................. 136
12.3 Brake ....................................................................................................................................................................... 137
12.4 Chain drive .............................................................................................................................................................. 138
12.5 Chain guides ........................................................................................................................................................... 140
12.6 DC 1 - 10 hook with fittings (as of 2017) ................................................................................................................. 142
12.7 Hook assembly........................................................................................................................................................ 143
12.8 DC 10 bottom block with external cut-off springs (standard) as of 10/2014............................................................ 144
12.9 DC-Pro 15 bottom block with external cut-off springs (standard)............................................................................ 145
12.10 Motor ....................................................................................................................................................................... 146
12.11 Service cover........................................................................................................................................................... 147
12.12 DC-ProDC and DC-ProCC electric equipment cover .............................................................................................. 148
12.13 DC-ProFC electric equipment cover........................................................................................................................ 149
Declaration of conformity ...................................................................................................................................................... 150
.................................................................................................................................................................................................. 151
Declaration of incorporation ................................................................................................................................................. 152
Index ........................................................................................................................................................................................ 153
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 1 General

1.1 DC-ProDC 1-15, DC-ProCC 1-15, DC-ProFC 1-15 chain hoist

You have purchased a Demag quality product.
This chain hoist was manufactured to European standards and regulations in accordance with state-of-the-art en‐
gineering principles. The EC Machinery Directive requirements are satisfied.

1.2 DC-ProDC 1-15, DC-ProCC 1-15, DC-ProFC 1-15 documents

Further documents are available for sub-assemblies/components in addition to these operating instructions. The
corresponding documents are supplied as necessary or can be ordered separately – also for special designs or if
additional options are ordered which differ from these operating instructions.

Documents 1)
Technical data/catalogues Part no. Operating instructions/component parts Part no.

DC-Pro chain hoist 203 525 44 RU 11 DK trolley 206 602 44

CF5-DC/DCM trolley 203 568 44 RU 22 DK trolley 206 603 44
U11-U34/DC/DCM/DK trolley 203 569 44 Dedrive Compact STO 211 170 44
RU/EU56 trolley 203 691 44 KBK installations 206 076 44
KBK classic (steel, powder-coated) 202 976 44 Log book Part no.
DSK pendant controller 202 836 44
KBK trailing cable 202 617 44 DC log book 214 745 44
DKUN 1-20 202 846 44 Certificates 235 309 44
Clamp-fitted buffers 203 313 44
Assembly instructions Part no.

Friction force checking device 206 973 44

Z motor external pulse generator 214 372 44
Tab. 3
211 191 44/100620

1) The documents can be ordered from the relevant Demag office. 7

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

DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.

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

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

Operating hazard for the machine.

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

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 1.4 Information on the operating instructions
These operating instructions are designed to provide the owner and operator with useful instructions for transport‐
ing, installing, commissioning, operating and maintaining our chain hoists. These operating instructions are an in‐
tegral part of the machine.
Persons entrusted with the various types of work must know and comply with the safety regulations and the oper‐
ating instructions.
The machine may only be operated by personnel who are fully familiar with the operating instructions. In particu‐
lar, they contain the "Safety" section and the relevant safety instructions in the working sections of these operat‐
ing instructions.
The operating instructions must be available to operating personnel at all times to prevent operating errors and to
ensure smooth and trouble-free operation of our products. They must be kept in the immediate vicinity.
Chain hoists with direct control (DC) or contactor control (CC) are delivered ready for operation as a complete
machine with a controller for direct control or as partly completed machinery without a controller. DC-ProDC chain
hoists for operating voltages higher than 500 V AC must not be operated with controllers for direct control.
DC-ProFC chain hoists are only supplied as partly completed machinery with a declaration of incorporation.

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

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

Partly completed machinery

These instructions inform the manufacturer of an installation with a chain hoist about:
● basic technical information,
● some typical risks,
● the assembly and operation of the chain hoist.
The information contained in this document can be used as the basis for the risk assessment and operating in‐
structions which must be compiled by the manufacturer of the equipment in compliance with the Machinery Direc‐
tive.
For operation of the equipment, the manufacturer of the equipment must provide additional operating procedure
instructions as the result of the risk assessment, as required, and inform the owner about any remaining hazards.
A declaration of incorporation is enclosed for a chain hoist supplied as partly completed machinery which is as‐
sembled with additional parts to form a machine that is ready for operation. The declaration of incorporation refers
to the scope of delivery of the partly completed or non-assembled machinery. The owner must take additional
measures to satisfy the safety requirements for the machine before the unit is put into operation.
Installation of a partly completed or non-assembled chain hoist to create machinery ready for operation must be
carried out in compliance with the information provided by the manufacturer for the machinery. Installation and
operating instructions for the chain hoist contained in this document must be observed.
A conformity inspection in accordance with the Machinery Directive must be carried out for the assembled ma‐
chine when it is ready for operation and a declaration of conformity must be produced. The information contained
in the declaration of incorporation for the chain hoist may be used for the conformity inspection.
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 1.5 Liability and warranty
All information included in these instructions has been compiled on the basis of the relevant regulations, state-of-
the-art engineering principles and our many years of experience.
These instructions must be read carefully before starting any work on and with the chain hoist, especially before
it is put into service for the first time. The manufacturer assumes no liability for any damage which results from
the following:
● non-compliance with the instructions,
● incorrect use,
● untrained personnel,
● unauthorised conversions,
● technical modifications.

Wearing parts are not subject to liability for defects.

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

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

1.7 Use of spare parts

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

1.8 Definition of personnel

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

1.9 Log book

A log book filled in with all details must be available for the hoist (according to the rules and regulations of the
German Social Accident Insurance (DGUV) in the Federal Republic of Germany). The results of the regular tests
and inspections must be entered into the log book and must be certified by the inspector. Log book part no.:
 Tab. 3, Page 7.

1.10 After-sales service

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

2.1 General information on safety

The "Safety" chapter provides an overview of all important safety aspects for optimum protection of personnel as
well as safe and trouble-free operation of the machine.
When it is placed on the market, the machine is built according to generally accepted engineering standards and
is considered to be safe to operate. It may still be a cause of danger if it is not used correctly or as intended by
suitably trained personnel.
Knowledge of the contents of the operating instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the machine safely and reliably.
Any conversions, modifications or additions to the machine are prohibited unless approved by the manufacturer in
writing.

2.2 Safety signs on the equipment

1 2 3

SKZ_BKYE_xml.eps
Fig. 3

1. Warning against dangerous electric voltage

2. Warning against hand injuries/pinching and crushing
3. Warning against hot surface

Any pictograms, signs or labels on the machine must be obeyed and

must not be removed. Pictograms, signs or labels that are damaged or
no longer legible must be replaced immediately.

43229046_xml.eps
Fig. 4 Example: load capacity plate on hook as‐
sembly
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 2.3 Intended use
The machine may only be used as intended and in compliance with the requirements for the owner and the fol‐
lowing limitations as specified in these operating instructions. Any other use may result in a danger to life and limb
and/or cause damage to the machine and/or load.
● Chain hoists are only intended for lifting, lowering and moving loads and may be used as stationary or travel‐
ling units.
● The suspension/support structure for the chain hoist must be designed to accommodate loads resulting from
operation of the chain hoist. The maximum safe working load is the load capacity specified on the capacity
plate. This must not be exceeded. The maximum permitted load capacity of the chain hoist includes the load
and any load handling attachment.
● The machine may only be installed, used, operated, maintained and removed by trained personnel when it is in
perfect working order. Personnel must meet the requirements according to  "Operating personnel require‐
ments", Page 16.
● Intended use includes compliance with the safety warnings as well as any other instructions on assembly and
disassembly, commissioning, function and operation, maintenance and fault elimination as well as compliance
with the instructions on the machine safety devices, any possible remaining hazards and protection against
hazards.
● The machine may only be used subject to the permissible technical data,  "Technical data", Page 18.
● The machine must be maintained regularly and appropriately by trained personnel in line with the specified
deadlines and checked according to  "Maintenance schedule", Page 95. Wearing parts must be replaced in
good time.
● National occupational health and safety regulations must be observed and followed.
No liability for inappropriate use
The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐
ceptable according to these operating instructions. In particular, the manufacturer assumes no liability for damage
due to inappropriate or any other prohibited use of the machine in the sense of the "Intended use" section.
No liability for structural modifications
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of de‐
livery, or the installation or use of third-party accessories, equipment or sub-assemblies that are not approved by
the manufacturer.
Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by an
expert engineer before it is handed over to the owner.
Use of the pendant controller
Powered lifting and lowering and, if applicable, cross-travel and long-travel motions are controlled by means of
the corresponding control elements on the controller. The slow speeds are intended for attaching the load, lifting it
free and depositing it. Loads can be precisely positioned at slow speeds.
Short transport times can be achieved at higher speeds. They are suitable for travelling without a load or with a
safely suspended load if no hazard can be caused by the faster motion sequences.
Inching (flick switching) must be avoided, as it causes increased wear and load sway.
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 2.4 Hazards that can be caused by the machine
The machine has been subjected to a risk assessment. The design and execution based on this analysis corre‐
sponds to state-of-the-art engineering principles. However, residual risks remain.

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

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

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

Certain work and practices are prohibited when using the machine as they can involve danger to life and limb and
result in lasting damage to the machine. Observe the safety warnings in the sections:
●  "Assembly", Page 30
●  "Putting into service for the first time", Page 79
●  "Operation", Page 81
●  "Maintenance/repair", Page 88
211 191 44/100620

14
 2.5 Responsibility of the owner
Information on safety at work refers to the regulations of the European Union that apply when the machine is
manufactured. The owner is obliged to ensure that the specified health and safety measures comply with the lat‐
est rules and regulations and to observe new regulations during the entire service life of the machine. Local indus‐
trial safety legislation and regional regulations and codes of practice applicable at the site of operation of the ma‐
chine must be observed outside the European Union.
General safety, accident prevention and environmental protection regulations that apply where the machine is in
operation must be observed and complied with in addition to the safety instructions contained in these operating
instructions.
The owner and any personnel authorised by him are responsible for correct operation of the machine and for
clearly defining responsibilities for installation, operation, maintenance and cleaning. The operating instructions
must be followed in full and without any limitations.
Special local conditions or applications can lead to situations which are not considered in these operating instruc‐
tions. In such cases, the required safety measures must be defined and implemented by the owner. Necessary
measures may also relate, for example, to the handling of hazardous materials or tools and the provision/wearing
of personal protection equipment. The operating instructions must, if required, be supplemented by the owner with
instructions relating to organisation of work, working procedures, authorised personnel, supervising and reporting
obligations, etc. For further information, see  "Safety instructions for operation", Page 81.
Furthermore, the owner must ensure that
● any further working and safety instructions resulting from the hazard assessment of the machine workplaces
are specified in operating procedures.
● personnel who work with or on the machine are provided with appropriate first-aid equipment. Personnel must
be trained in the use of the first-aid equipment.
● the operating instructions are always kept available in the immediate vicinity of the machine for installation, op‐
erating, maintenance and cleaning personnel.
● personnel are trained in accordance with the work to be performed.
● the machine is only operated when in safe and proper working order.
● safety devices are always kept freely accessible and are checked regularly.
● national regulations for the use of cranes and lifting appliances are observed.
● any specified regular checks and inspections are carried out on time and are documented.
The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these
instructions at a suitable place where they can be easily seen.
The owner is obliged to ensure that
● the rules and regulations of the German Social Accident Insurance (DGUV) are applied in the Federal Repub‐
lic of Germany.
● national occupational safety and health regulations are observed and followed.

Extract from the transfer list of the rules and regulations of German Social Accident Insurance (DGUV)
Previous no. New no. Title
BGV D6 DGUV Regulation 52 Cranes
BGV D8 DGUV Regulation 54 Winches, lifting and towing devices
BGG/GUV-G 905 DGUV Policy 309-001 Inspection of cranes
Tab. 4
211 191 44/100620

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

2.7 Personal protection equipment

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

2.8 Emergency-stop device

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

43406446_xml.eps

Fig. 5 Position of emergency stop (1)

211 191 44/100620

16
 2.9 Regular inspections
The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation
and regional regulations. This is regulated by the rules and regulations of the German Social Accident Insurance
(DGUV) in the Federal Republic of Germany, for example. These specify that
● the machine must be inspected before it is put into operation,
● the machine must be inspected regularly,
● the elapsed share of the theoretical service life must be calculated,
● a record must be kept in a log book.
The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe
new regulations at all times.
If no comparable inspection regulations or requirements apply at the machine operating location, we recommend
compliance with the above-mentioned regulations.
211 191 44/100620

17
 3 Technical data

3.1 Design overview

43213948_xml.eps

Fig. 6 Diagram showing a single-fall DC-Pro chain hoist

Item Designation Item Designation Item Designation

1 Electric equipment cover 13 Round-section steel chain Cut-off buffer for operating limit switch on
22
2 Electric sub-assembly 14 Slipping clutch DC-ProCC
4 Window 15 Dished washer pack 23 Hook assembly with load capacity plate
6 Magnet brake 16 Slipping clutch adjusting nut 24 Motor shaft
7 Brake disc with linings DC 1 - 5 two-stage helical gearbox 25 Winding head cover
8 Brake springs 17 DC 10 and DC 15 three-stage helical 26 Stator
9 Brake magnet gearbox 27 Rotor
10 Gearbox housing 18 Suspension bracket 28 Fan
11 Chain guide 19 Suspension pin 29 Fan cover
12 Chain sprocket 20 Service cover 30 Mounting points
Tab. 5
211 191 44/100620

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

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

DC-Com product range

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

Not all features of the model code can be combined.

211 191 44/100620

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

DC-ProDC, DC-ProCC (2 lifting speeds)

Load ca‐ Chain hoist Reeving Group of mecha‐ Chain size Lifting speed Standard Motor size 3) Max. weight for hook
pacity size nisms hook path path 4)
DIN EN 14492 at 50 Hz at 60 Hz H 5) 4m 5m
[kg] DC-ProDC FEM/ISO [mm] [m/min] [m/min] [m] [kg] [kg]
DC-ProCC
1 8,0/2,0 9,6/2,4 ZNK 71 A 8/2 6)
4,2x12,2 22
80 2 16,0/4,0 19,2/4,8 ZNK 71 B 8/2
5 5,3x15,2 24,0/6,0 7) 28,8/7,2 ZNK 80 B 8/2 28
1 8,0/2,0 9,6/2,4 ZNK 71 A 8/2 6)
4,2x12,2 22
100 2 16,0/4,0 19,2/4,8 ZNK 71 B 8/2
5 5,3x15,2 24,0/6,0 7) 28,8/7,2 ZNK 80 B 8/2 28
4m/M7
1 8,0/2,0 9,6/2,4 ZNK 71 A 8/2 6)
4,2x12,2 22
125 2 16,0/4,0 19,2/4,8 ZNK 71 B 8/2
5 5,3x15,2 24,0/6,0 7) 28,8/7,2 ZNK 80 B 8/2 28
2 4,2x12,2 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22
160 16,0/4,0 19,2/4,8
5 5,3x15,2 ZNK 80 B 8/2 28
24,0/6,0 7) 28,8/7,2
2 3m/M6 4,2x12,2 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22
200 5 5,3x15,2 16,0/4,0 19,2/4,8 ZNK 80 B 8/2 28
4m/M7
10 7,4x21,2 24,0/6,0 7) 28,8/7,2 ZNK 100 A 8/2 48
2 2m+ 8)/M5+ 4,2x12,2 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22
250 5 5,3x15,2 16,0/4,0 19,2/4,8 5 and 8 ZNK 80 B 8/2 - 28
1/1
10 7,4x21,2 24,0/6,0 7) 28,8/7,2 ZNK 100 A 8/2 48
5 4m/M7 5,3x15,2 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28
315 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48
10 7,4x21,2
24,0/6,0 7) 28,8/7,2 ZNK 100 B 8/2 56
5 3m/M6 5,3x15,2 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28
400 4m/M7 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48
10 7,4x21,2
3m/M6 24,0/6,0 7) 28,8/7,2 ZNK 100 B 8/2 56
5 2m+ 8)/M5+ 5,3x15,2 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28
500 4m/M7 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48
2m+ 8)/M5+ 24,0/6,0 7) 28,8/7,2 ZNK 100 B 8/2 56
6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48
630 4m/M7
12,0/3,0 14,4/3,6 ZNK 100 B 8/2 56
10 7,4x21,2
6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48
800 3m/M6
12,0/3,0 14,4/3,6 ZNK 100 B 8/2 56
2m+ 8)/M5+ 6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48
1000 2m+ 8) 9)/M5+ 12,0/3,0 14,4/3,6 56
15 4m 10)/M7 8,7x24,2 8,0/2,0 9,6/2,4 4 71 72
2/1 4m/M7 6,0/1,5 7,2/1,8 65
10 7,4x21,2 5 and 8 -
1250 1Am 11)/M4 8,0/2,0 9,6/2,4 56
1/1
15 3m 10)/M6 8,7x24,2 8,0/2,0 9,6/2,4 4 71 72
10 2/1 3m/M6 7,4x21,2 6,0/1,5 7,2/1,8 5 and 8 - 65
1600 ZNK 100 B 8/2
15 1/1 2m+ 8) 12)/M5+ 8,7x24,2 8,0/2,0 9,6/2,4 4 71 72
10 2m+ 8) 9)/M5+ 7,4x21,2 6,0/1,5 7,2/1,8 5 and 8 - 65
2000
15 4m 13)/M7 8,7x24,2 4 83 86
10 2/1 1Am 11)/M4 7,4x21,2 5 and 8 - 65
2500 4,0/1,0 4,8/1,2
3m/M6
15 8,7x24,2 4 83 86
3200 2m+ 8) 9)/M5+
211 191 44/100620

Tab. 7

3) Motor key data  "Electric key data", Page 22.

20 4) DC-ProCC units weigh approximately 3 kg more.
 DC-ProFC (variable lifting speed) for control via an external frequency inverter

Load ca‐ Chain Reeving Group of mecha‐ Chain size Lifting speed at motor speed 14) 15) Gearbox Motor size 3) Max. weight for
pacity hoist size nisms 16) 17) transmis‐ hook path 5)
sion ratio
DIN EN 14492 vsrated vsmax 4m 5m
[kg] DC-ProFC FEM/ISO [mm] [m/min] [rpm] [m/min] [rpm] i [kg] [kg]
80 14,6 26,6 25,57
100 1 14,6 26,6 25,57
4m/M7
125 14,6 26,6 25,57
4,2x12,2 ZNK 71 B 4 25
160 14,6 26,6 25,57
200 2 3m/M6 14,6 26,6 25,57
250 2m+ 8)/M5+ 14,6 26,6 25,57
5 5,3x15,2 7,1 13,0 54,24 ZNK 80 A 4 30
315 4m/M7
10 7,4x21,2 10,2 18,6 53,07 ZNK 100 A 4 50
5 3m/M6 5,3x15,2 7,1 13,0 54,24 ZNK 80 A 4 30
400 -
10 4m/M7 7,4x21,2 10,2 18,6 53,07 ZNK 100 A 4 50
1/1
5 2m+ 8)/M5+ 5,3x15,2 7,1 13,0 54,24 ZNK 80 A 4 30
500
10,2 18,6 53,07
4m/M7 5,4 9,8 100,15
630
10,2 18,6 53,07
10 7,4x21,2 5,4 9,8 100,15 50
800 3m/M6 2550 4650
10,2 18,6 53,07
2m+ 8)/M5+ 5,4 9,8 100,15
1000 2m+ 8) 9)/M5+ 10,2 18,6 53,07
15 4m 10)/M7 8,7x24,2 6,7 12,3 91,68 73 74
1Am 11)/M4 3,8 7,0 140,96 58
10 7,4x21,2 ZNK 100 A 4 -
1250 2/1 4m/M7 5,1 9,3 53,07 67
15 1/1 3m 9)/M6 8,7x24,2 6,7 12,3 91,68 73 74
10 2/1 3m/M6 7,4x21,2 5,1 9,3 53,07 - 67
1600
15 1/1 2m+ 8) 12)/M5+ 8,7x24,2 6,7 12,3 91,68 73 74
10 2m+ 8) 9)/M5+ 7,4x21,2 5,1 9,3 53,07 - 67
2000 2/1
15 4m 13)/M7 8,7x24,2 3,4 6,1 91,68 85 88
10 1Am 11)/M4 7,4x21,2 3,6 6,5 75,67 - 67
2500 2/1
15 3m 10)/M6 3,4 6,1 91,68 85 88
8,7x24,2
3200 15 2/1 2m+ 8) 9)/M5+ 3,4 6,1 91,68 85 88
Tab. 8

5) Hook paths as for DC-Pro.

6) ZNK 71 A 8/2 with 380-415 V/50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.
7) Only with operating limit switch for lifting; operating limit switch for lowering on request (the lower end position must not be approached in nor‐
mal operation).
8) 2m+ corresponds to a service life of 1900 hours at full load.
9) FEM 1Am chain drive to EN 818-7
10) FEM 2m chain drive to EN 818-7
11) FEM 1Cm chain drive to EN 818-7
12) FEM 1Bm chain drive to EN 818-7
13) FEM 3m chain drive to EN 818-7
211 191 44/100620

14) vsmin corresponds to a control ratio vsmin : vsmax of 1 : 200 (default setting 1 : 100). The optional parameter-programming set (part no.
720 905 45) is needed for the 1:200 setting.
15) vsmax, vsrated, vsmin, acceleration time and deceleration time can also be changed by programming parameters with the pendant controller
(see “DCS-Pro chain hoist operating instructions”)
16) Max. lifting speed in the partial load range/without load
17) vsmax at max. 5000 rpm in field-weakening range, consider reduced load capacity due to field weakening 21
 3.4 Electric key data

3.4.1 DC-ProDC, DC-ProCC (2 lifting speeds)

3.4.1.1 Hoist motor data

Voltage 18) Size and control type Motor size No. of PN CD nN Starts/h Min./max. currents and start-up current
Frequency poles F IN min. IN max. IA/IN max. cos φN
Imax. 19)
(Conformity)
Direct Contactor [kW] [%] [rpm] [A] [A] [A]
8 0,05 20 720 240 1,75 2,10 2,10 1,45 0,48
DC-ProDC 1 DC-ProCC 1 ZNK 71 B 8/2
2 0,18 40 2925 120 2,10 2,80 2,80 2,75 0,46
8 0,10 20 675 240 1,80 2,10 2,35 1,45 0,56
3 ~ 220-240 V DC-ProDC 2 DC-ProCC 2 ZNK 71 B 8/2
2 0,37 40 2825 120 2,40 2,80 3,20 2,75 0,63
50 Hz 8 0,18 20 665 240 2,45 2,80 2,95 1,45 0,51
DC-ProDC 5 DC-ProCC 5 ZNK 80 B 8/2
(CE) 2 0,72 40 2745 120 3,80 4,20 4,70 3,00 0,77
8 0,27 20 690 240 2,95 3,30 3,80 1,80 0,54
20) DC-ProDC 10 DC-ProCC 10 ZNK 100 A 8/2
2 1,10 40 2745 120 5,40 5,40 6,10 3,60 0,81
DC-ProDC 10 8 0,57 20 675 240 5,20 5,90 6,80 1,85 0,58
DC-ProDC 15 - ZNK 100 B 8/2
2 2,30 40 2790 120 9,50 10,70 11,00 4,15 0,77
ZNK 71 A 8/2 8 0,05 20 700 240 0,95 1,10 1,10 1,20 0,66
21)
2 0,18 40 2840 120 1,20 1,40 1,40 2,60 0,57
DC-ProDC 1 DC-ProCC 1
8 0,05 20 720 240 1,00 1,20 1,20 1,45 0,48
ZNK 71 B 8/2
2 0,18 40 2925 120 1,20 1,60 1,60 2,75 0,46
3 ~ 380-415 V 8 0,10 20 675 240 1,00 1,20 1,35 1,45 0,56
DC-ProDC 2 DC-ProCC 2 ZNK 71 B 8/2
2 0,37 40 2825 120 1,40 1,60 1,85 2,75 0,63
50 Hz
8 0,18 20 665 240 1,40 1,60 1,70 1,45 0,51
DC-ProDC 5 DC-ProCC 5 ZNK 80 B 8/2
(CE) 2 0,72 40 2745 120 2,20 2,40 2,70 3,00 0,77
8 0,27 20 690 240 1,70 1,90 2,20 1,80 0,54
DC-ProDC 10 DC-ProCC 10 ZNK 100 A 8/2
2 1,10 40 2745 120 3,10 3,10 3,50 3,60 0,81
DC-ProDC 10 DC-ProCC 10 8 0,57 20 675 240 3,00 3,40 3,90 1,85 0,58
DC-ProDC 15 DC-ProCC 15 ZNK 100 B 8/2
2 2,30 40 2790 120 5,50 6,20 6,40 4,15 0,77
8 0,05 20 720 240 0,75 0,95 1,45 0,48
DC-ProDC 1 DC-ProCC 1 ZNK 71 B 8/2
2 0,18 40 2925 120 0,90 1,25 2,75 0,46
8 0,10 20 675 240 0,80 1,10 1,45 0,56
DC-ProDC 2 DC-ProCC 2 ZNK 71 B 8/2
3 ~ 500 V 2 0,37 40 2825 120 1,10 1,45 2,75 0,63
8 0,18 20 665 240 1,20 1,35 1,45 0,51
50 Hz DC-ProDC 5 DC-ProCC 5 ZNK 80 B 8/2
2 0,72 40 2745 120 1,80 2,15 3,00 0,77
(CE) 8 0,27 20 690 240 1,35 1,75 1,80 0,54
DC-ProDC 10 DC-ProCC 10 ZNK 100 A 8/2
2 1,10 40 2745 120 2,40 2,80 3,60 0,81
DC-ProDC 10 DC-ProCC 10 8 0,57 20 675 240 2,50 3,10 1,85 0,58
DC-ProDC 15 DC-ProCC 15 ZNK 100 B 8/2
2 2,30 40 2790 120 4,60 5,10 4,15 0,77
8 0,06 20 870 240 2,10 2,50 2,50 1,45 0,47
DC-ProDC 1 DC-ProCC 1 ZNK 71 B 8/2
2 0,22 40 3525 120 2,50 3,35 3,35 2,75 0,45

3 ~ 220-240 V 8 0,11 20 825 240 2,10 2,50 2,80 1,45 0,55

DC-ProDC 2 DC-ProCC 2 ZNK 71 B 8/2
2 0,44 40 3425 120 2,90 3,30 3,85 2,75 0,62
60 Hz 8 0,22 20 815 240 2,90 3,30 3,50 1,45 0,50
DC-ProDC 5 DC-ProCC 5 ZNK 80 B 8/2
(CE/CCSAUS) 2 0,86 40 3345 120 4,60 5,00 5,60 3,00 0,76
8 0,32 20 840 240 3,55 3,90 4,60 1,80 0,53
20) DC-ProDC 10 DC-ProCC 10 ZNK 100 A 8/2
2 1,30 40 3345 120 6,50 6,40 7,30 3,60 0,80
DC-ProDC 10 8 0,68 20 825 240 6,20 7,10 8,10 1,85 0,57
- ZNK 100 B 8/2
DC-ProDC 15 2 2,80 40 3390 120 11,40 12,90 13,30 4,15 0,76
211 191 44/100620

18) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
19) I = maximum rated current for lowering motion.
max
20) DC-ProDC 10 - 15 with ZNK 100 B 8/2 with SE+GP brake module combination.

22 21) ZNK 71 A 8/2 with 380-415 V/50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.
 Voltage 18) Size and control type Motor size No. of PN CD nN Starts/h Min./max. currents and start-up current
Frequency poles F IN min. IN max. IA/IN max. cos φN
Imax. 19)
(Conformity)
Direct Contactor [kW] [%] [rpm] [A] [A] [A]
8 0,06 20 870 240 1,35 1,60 1,60 1,45 0,47
DC-ProDC 1 DC-ProCC 1 ZNK 71 B 8/2
2 0,22 40 3525 120 1,70 2,00 2,00 2,75 0,45
8 0,11 20 825 240 1,50 1,60 1,80 1,45 0,55
DC-ProDC 2 DC-ProCC 2 ZNK 71 B 8/2
3 ~ 380-400 V 2 0,44 40 3425 120 1,80 2,00 2,30 2,75 0,62
8 0,22 20 815 240 1,80 1,95 2,00 1,45 0,50
60 Hz DC-ProDC 5 DC-ProCC 5 ZNK 80 B 8/2
2 0,86 40 3345 120 1,75 2,90 3,20 3,00 0,76
(CE) 8 0,32 20 840 240 2,40 2,70 2,90 1,80 0,53
DC-ProDC 10 DC-ProCC 10 ZNK 100 A 8/2
2 1,30 40 3345 120 3,80 4,00 4,60 3,60 0,80
DC-ProDC 10 DC-ProCC 10 8 0,68 20 825 240 3,90 4,30 4,90 1,85 0,57
ZNK 100 B 8/2
DC-ProDC 15 DC-ProCC 15 2 2,80 40 3390 120 7,20 7,70 8,00 4,15 0,76
8 0,06 20 870 240 1,05 1,25 1,25 1,45 0,47
DC-ProDC 1 DC-ProCC 1 ZNK 71 B 8/2
2 0,22 40 3525 120 1,25 1,65 1,65 2,75 0,45
8 0,11 20 825 240 1,05 1,25 1,40 1,45 0,55
DC-ProDC 2 DC-ProCC 2 ZNK 71 B 8/2
3 ~ 440-480 V 2 0,44 40 3425 120 1,45 1,65 1,95 2,75 0,62
8 0,22 20 815 240 1,50 1,70 1,80 1,45 0,50
60 Hz DC-ProDC 5 DC-ProCC 5 ZNK 80 B 8/2
2 0,86 40 3345 120 2,30 2,50 2,80 3,00 0,76
(CE/CCSAUS) 8 0,32 20 840 240 1,80 1,95 2,30 1,80 0,53
DC-ProDC 10 DC-ProCC 10 ZNK 100 A 8/2
2 1,30 40 3345 120 3,25 3,20 3,70 3,60 0,80
DC-ProDC 10 DC-ProCC 10 8 0,68 20 825 240 3,10 3,50 4,00 1,85 0,57
ZNK 100 B 8/2
DC-ProDC 15 DC-ProCC 15 2 2,80 40 3390 120 5,70 6,40 6,60 4,15 0,76
Tab. 9

3.4.1.2 Mains connection delay fuse links and supply lines

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

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

DC-ProDC Frequency 50 Hz 60 Hz
DC-ProCC
Motor size [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m] [A] [mm2] [m]
1/2 ZNK 71 … 6 89 100 6 76 100
5 ZNK 80 B 8/2 1,5 31 6 6 100 1,5 26 6 1,5 75 6 100
10 94 10
ZNK 100 A 8/2 34 1,5 1,5 29 78 1,5
10
ZNK 100 B 8/2 10 38 61 13 16 2,5 45 10 43
13 2,5 26 10 22) 2,5 21
15 ZNK 100 B 8/2 16 46 73 15 1,5 36 15 52
[A] = amperage of the mains connection fuse; [mm2] = cross-section for the supply line; [m] = max. cable length
The lengths of the supply lines are calculated on the basis of: 5% voltage drop Δ U, start-up current I A and an earth-loop impedance of 200 mΩ.
Tab. 10

3.4.2 DC-ProFC (variable lifting speed) for control via an external frequency inverter

3.4.2.1 Hoist motor data

Product selection is based on the voltage ranges of the DC-ProDC. However, they only refer to the brake that is
actually installed. The motor must be fed by a frequency inverter. The rated operating point is always at
360 V / 87 Hz. The speed is approx. 2540 rpm at the rated point. The motor frequency can be further increased
up to a maximum of 150 Hz. This corresponds to a speed of approx. 5000 rpm – (important: f > 87 Hz = field-
weakening range)
211 191 44/100620

18) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
19) I = maximum rated current for lowering motion.
max
22) Tripping characteristic D 23
 Size Motor size No. of PN CDF nN Min./max. currents and start-up current
DC-ProFC poles 23)
Load capacity vsrated In 360 MK/MN cos φN
[kW] [%] [rpm] [kg] [m/min] [A]
360 V, 87 Hz, 3 ~ (CE) 24)
1-2 ZNK 71 B 4 0,73 60 2480 125 - 250 3,10 2,50 0,50
16
5 ZNK 80 A 4 0,73 60 2540 500 2,90 3,20 0,58
4 1000 6 4,50
10 - 15 ZNK 100 A 4 2,20 60 2520 1000 12 5,50 2,70 0,82
2000 6 5,50
Tab. 11

3.4.2.2 Mains connection delay fuse links and supply lines

DANGER
Danger – live components.
Danger to life and limb.
– Frequency inverter-fed chain hoists must only be operated if a protective earth conductor is connected. If
the protective earth conductor connection is damaged or interrupted, the chain hoist must be disconnected
from the power supply without delay.
– Fault-free operation with a current-operated e.l.c.b. (earth-leakage circuit breaker) is ensured with a tripping
current ≥ 30 mA, if residual-current-operated circuit breakers (type B to EN 50178, e.g. Siemens 5SZ3 ...
G00) are used.

The values for the mains connection fuse link and supply cable depend on the frequency inverter used, see also
"Dedrive Compact STO frequency inverter operating instructions"  Tab. 3, Page 7.

3.4.2.3 Voltage ranges of the brake for DC-ProFC

Voltage range 3 ~ 380-415 V 50 Hz 3 ~ 500 V 50 Hz 3 ~ 380-400 V 60 Hz 3 ~ 440-480 V 60 Hz

Brake voltage 180 V 258 V 180 V 198 V
Tab. 12

3.5 Dimensions
For further information, data and dimensions, see "Demag DC-Pro 1 - 25 chain hoist technical data"  Tab. 3,
Page 7.

3.6 Noise emission/sound pressure level

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

Chain hoist size DC 1 DC 2 DC 5 DC 10 DC 15

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

These noise emission levels were measured under maximum load. The following structural influences were not
considered in the above measurements:
● transmission of noise via steel structures,
● reflection of noise from walls, etc.
211 191 44/100620

23) 20% CDF at vsmin; 60% CDF at vsnom up to vsmax

24 24) Motors are rated to insulation class F.
 3.7 Transport, packing, scope of delivery, storage

Safety warnings

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

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

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

Scope of delivery
If special designs or additional options are ordered or the latest technical modifications are incorporated, the ac‐
tual scope of supply may differ from the data and information as well as from the illustrations described here. If
you have any questions, please contact the manufacturer.
Storage
Until they are installed, the equipment and accessories must be kept closed and may only be stored under the
following conditions:
● Do not store outdoors.
● Store in dry and dust-free places, relative air humidity: max. 60%.
● Do not expose to aggressive media.
● Protect against direct sunlight.
● Avoid mechanical vibrations.
● Storage temperature: -25 to +70 °C.
● Avoid strong temperature fluctuations (condensation).
● Oil all bare machine parts (rust protection).
● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
protection.
211 191 44/100620

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

25
 3.8 Materials
Linings
We only use asbestos-free slipping-clutch and brake linings.
Housing
The housing of the chain hoist is made of strong and light-weight die-cast aluminium. The fan cover on the motor,
the service cover and the movable chain collector box are made of particularly impact-resistant plastic material.
Surface protection and paint finish
As standard, the chain hoist is provided with corrosion protection (powder coating/paint finish) and supplied in the
following colours:

Chain hoist RAL 5009 Azure blue

Hook assembly RAL 1007 Daffodil yellow
Finish
Load hook and suspension bracket RAL 9005 Jet black
Trolley RAL 5009 Azure blue
Tab. 14

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

3.9 Operating conditions

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

The chain hoist and the trolley can be operated at:

Ambient temperature Humidity Height Type of enclo‐ Electromagnetic compatibility

sure
Resistance to interference in industrial environments
Interference emission for residential, commercial and light-
Max. 80% relative humidi‐ Up to 1000 m above sea industrial environments
-20 °C to +45 °C IP55
ty level The electromagnetic compatibility of DC-ProFC units de‐
pends on how they are integrated into the customer’s in‐
stallation.
Tab. 15

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

Special operating conditions may be agreed with the manufacturer in individual cases. Such operating conditions
may occur in the following applications, for example:
● Galvanizing plants or electroplating facilities,
● Hygiene areas,
● Low or high temperature applications.
On request, suitably optimised equipment and important information for safe, low-wear operation can be supplied
for these applications.
Reduced duty factor at increased ambient temperatures
If DC chain hoists are operated at ambient temperatures that differ from that given above, the duty factor must be
reduced:

Ambient temperature -20 °C to +45 °C >+45 °C to +50 °C >+50 °C to +55 °C >+55 °C to +60 °C
Duty factor [%] 20/40 15/35 15/25 10/20
211 191 44/100620

Tab. 16

26
 4 Technical description

4.1 Drive and brake

A robust pole-changing AC asynchronous motor is used as the hoist motor for DC-ProDC and DC-ProCC or a 4-
pole motor for DC-ProFC units. 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 mechanical brake is applied as soon as the emergency stop is actuated, regardless of the lifting speed.
● The brake cannot be adjusted for chain hoist types:
- DC-ProDC 1 - 2, DC-ProCC 1 - 15, DC-ProFC 1 - 15.
● The brake can be adjusted for chain hoist types:
- DC-ProDC 5 - 15.

4.2 Gearbox and slipping clutch

A Drives B Brakes
1 Slipping clutch 4 Brake
2 Motor 5 Gearbox
3 Chain drive
Tab. 17

The slipping clutch is arranged between the motor shaft and the gear‐
box input shaft. In connection with the limit stops on the chain, it per‐
forms the function of the emergency limit stop device for the highest
and lowest hook position and protects the Demag chain hoist against
overload. The slipping clutch also fulfils the EC Machinery Directive re‐
quirements for a load control device for load capacities as of 1000 kg.
The slipping clutch must not be approached in normal operation.
The brake arranged on the load side prevents the load from slowly
dropping when the unit is at rest.
The gearbox is maintenance-free for up to 10 years.
On DC-ProCC chain hoists, the additional electric operating limit
switches for the highest and lowest hook positions prevent the slipping
427219464_XML.eps
clutch from being approached as an emergency limit stop device during
Fig. 7 Parts in which the load is borne normal operation.

4.3 Chain drive

The special Demag chain is of high-strength ageing-resistant material with a high degree of surface hardening,
galvanised with additional surface treatment. The dimension tolerances of this chain have been precisely adapted
to the chain drive. We therefore urgently recommend that the Demag special chain be used to ensure safe opera‐
tion. The maximum service life of the chain can only be reached if the specified regular lubrications are correctly
carried out. The entire chain drive is always replaced when a chain is replaced. A chain set which can be easily
replaced is available for this purpose.
The chain set offers the following benefits:
● the optimum duration of service is ensured for the chain;
● certainty that the individual chain drive components are replaced when necessary;
● reduction in service costs by replacement and installation in one step; the motor and gearbox do not need to
be disassembled.
If special fittings are installed on the chain hoist, make sure that they are counter-balanced. Suspension of the
chain hoist at an angle results in premature wear of the chain drive.
211 191 44/100620

27
 4.4 Electric equipment
DC-ProDC for direct control
This chain hoist is designed for direct control as standard.
The positively disconnected emergency-stop contact on the pendant controller immediately opens three phases of
the main circuit so that the motor is de-energised and the brake is applied.
Further standard feature:
● A three-phase travel motor can be connected.
The equipment can be controlled by the customer’s control system or direct in the main circuit by a DSK 3 DP2 or
DST pendant controller.
The pendant controller is supplied with the control cable connected to it.
Plastic-sheathed wire cords or a support sleeve are used for strain relief of the control cable. Provide strain relief
for the pendant controller according to the DSK or DST pendant controller assembly instructions (see  "Instal‐
ling a DSK pendant controller with a support sleeve", Page 36 and  "Installing a DST pendant controller with
2TY", Page 38).
DC-ProCC with contactor control
This chain hoist is fitted with conventional contactor control for 48 V AC and is designed to be controlled via float‐
ing contacts.
The positively disconnected emergency-stop contact on the pendant controller switches the main contactor off
and opens three phases of the main circuit so that the motor is de-energised and the brake is applied.
Further standard feature:
● A trolley control system can be connected in a separate enclosure.
The equipment can be controlled by the customer’s control system or direct in the control circuit by a DSK 3 SP2
or DST pendant controller.
The pendant controller is supplied with the control cable connected to it.
DC-ProFC frequency inverter control (by the customer)
This chain hoist is designed to be used with an inverter-fed control system provided by the customer.
The electric equipment under the electric equipment cover carries the terminal strip to connect the motor and the
brake module (rectifier) to control the brake.
In addition, the chain hoist is equipped with an incremental encoder to evaluate the speed.
Chain hoists that are fitted with DC-ProFC electric equipment control board are supplied as partly completed ma‐
chinery (only with a declaration of incorporation) and must be supplemented with an electric control system suita‐
ble for the application (e.g. frequency inverter).
211 191 44/100620

28
 4.5 Central service enclosure

43214444.eps

Fig. 8

Important service work can be carried out at a central point, the service enclosure. Cable unions to the terminal
strip for power supply and the pendant controller are arranged under the impact-resistant plastic cover. The chain
is also lubricated from this point.
The plastic cover also provides mechanical protection for the components fitted under it. The functions are indica‐
ted by pictograms fitted on the outside of the service cover. The service cover of the DC 15 is made of sheet
metal and does not have any pictograms.

4.6 Pendant controller

The DSK housing is made of high-quality thermoplastic, the DST housing is made of glass fibre-reinforced poly‐
ester; they are resistant to impacts, fuels, salt water, grease, oils and alkaline solutions.
IP55 (65) enclosure for DSK and IP65 for DST.
Strong mineral acids, e.g. hydrochloric or sulphuric acid, can corrode switch housings.
Replace such switches in good time.

4.7 Limit switches

DC-ProDC chain hoist sizes 10 and 15 in combination with ZNK 100 B 8/2 motors are fitted with operating limit
switches for the lifting motion as standard. An optional operating limit switch for the lifting motion can be ordered
for all other DC-ProDC chain hoists. An intermediate flange is required between the gearbox housing and the
electric equipment cover if the unit is fitted with an operating limit switch for the lifting motion.
DC-ProCC chain hoist sizes 1 - 15 are fitted with operating limit switches for the lifting and lowering motions as
standard.
The operating limit switch is not needed in chain hoists for installation control systems supplied by the customer
which include a corresponding limit cut-off arrangement.

4.8 Trolley/crane connection

The universal box (part no. 772 167 45) is available for further trolley/crane wiring arrangements.
211 191 44/100620

29
 5 Assembly

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

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

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

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

5.2 Safety warnings for assembly

DANGER
Incorrect assembly
Danger to life and limb.
Incorrect installation can result in severe injury and/or damage to property. Therefore, this work may only be car‐
ried out by authorised, instructed personnel who are familiar with the principle of operation of the machine in
compliance with all safety regulations.
– Ensure sufficient working clearance before starting assembly work.
– Secure and fence off the working area and danger zone.
– If an elevating work platform is used for assembly, only use appropriate attachments for the lifting of per‐
sons which ensure that work is carried out in a safe and stable position.
– Only suitable, tested and calibrated tools and accessories may be used for assembly or disassembly work.
– Wear protective equipment.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any machine parts or fittings and tools that are not needed in
such a way that there is no risk of them falling.
– Fit components correctly and as intended. Comply with specified bolt tightening torques. Incorrectly fitted
components can fall and cause severe injuries.
– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐
ments must be fulfilled. The electrode holder and earth must be connected to the same assembly when
welding work is carried out. Otherwise serious damage can be caused to the hoist.
– Customer-specific regulations must be observed.
211 191 44/100620

30
 DANGER
Live components
Danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐
nel", Page 10) in compliance with the safety regulations.
Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐
tected against unauthorised or accidental restoration of the power supply by means of a padlock.

Mechanical safety
All bolted connections must be correctly tightened.
Self-locking nuts must not be replaced by other types of nut. Self-locking nuts must be replaced when they have
been tightened and untightened five times. The clamping torque of a self-locking nut must not be lower than the
loosening torque specified by EN ISO 2320.
A sufficiently secure connection can only be guaranteed by tightening to the specified tightening torque.
Bolted connections must not be lubricated as otherwise the specified tightening torque values will be too high.
Check to ensure that pin connections are correctly fitted.
All installation and assembly work must be completed in accordance with the operating instructions and the hoist
chain must be greased. Operation with defective or damaged chains results in a high risk of accidents with per‐
sonal injuries and damage to the chain hoist and is, therefore, strictly prohibited.
Any change or modification which prejudices safety must be reported to the nearest person responsible immedi‐
ately. Defects may only be eliminated by experienced technicians.
Ensure that all suspensions are freely accessible for checks and inspection work or that free access can be provi‐
ded.
The control device (e.g. pendant controller) must be marked in such a way that the direction of movement is clear
and distinct. The arrow symbol on the control elements must correspond to the direction of movement.
Electric safety
The chain hoist operating instructions must be referred to when Demag chain hoists are used.
These operating instructions only contain standard circuit diagrams. Depending on the chain hoist type, an order-
specific circuit diagram may apply.
Protective earth conductor
The protective earth conductor in insulated leads and cables must be coloured green and yellow along its entire
length.
The protective earth conductor must not be connected to retaining bolts or screws.
Protective earth junctions and connections must be protected against accidental loosening (e.g. by using serrated
lock washers to DIN 6798). It must be possible to disconnect each individual connection.
Protective earth conductors must not carry any current in normal operation.
The same number of protective earth conductor connection points must be provided as electric power infeed and
outfeed points.
The PE conductor connection must be checked for continuity and low resistance (guide value < 1 Ohm).
Mains connection switch
A mains connection switch must always be provided for the main power supply line to the machine. The mains
connection switch must be arranged to disconnect all poles of your DC-Bas chain hoist from the mains supply.
Ensure that the mains connection switch is installed in an easily accessible position in the vicinity of your machine
and that it is clearly marked.
Isolating switch
If two or more lifting appliances are fed from a common main power supply, each one should be provided with an
isolating switch. This enables you to carry out maintenance work on individual hoist units after turning off the iso‐
lating switch, without affecting operation of the rest of the system.
Power supply
The power supply line/cable to be used depends on the motor size, see the "Hoist motor data" section.
211 191 44/100620

31
 5.3 DC chain hoist tightening torques
Tightening torques [Nm] DC 1 DC 2 DC 5 DC 10 DC 15
Reeving 1/1 1/1 2/1 1/1 2/1
Motor 9,5 25,0
Counterweight 4,3 5,5 -
Fan cover 4,0
Gearbox cover 5,5 -
2-piece gearbox housing - 25
Gearbox plug screw - 15
Gearbox vent valve - 15
Brake 5,5
Operating limit switches 1,5 3,0
Control set 3,0
Electric equipment cover 9,5
Service cover 5,5 7,5 25
Limit stop 4,0 4,3
Anchorage halves - 10,5 - 25
Guide plate 5,5 25
Hook assembly 6,8 11,5 25,0 - 27,5 -
Bottom block with external cut-off springs 55,0 - 55,0
Bottom block halves - 52,0 -
Bottom block with internal cut-off springs
Guide section halves 5,5 -
Tab. 18

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

211 191 44/100620

32
 5.4 Installation procedure
1. Unpack and dispose of the packing material in an environmentally compatible way  "Transport, packing,
scope of delivery, storage", Page 25.
2. Check the delivery is complete  "Transport, packing, scope of delivery, storage", Page 25.
3. Connect the pendant controller, if necessary  "Connecting the controller", Page 36.
4. Which suspension bracket is suitable for suspension?  "Suspending the chain hoist", Page 40.
5. Connect to the power supply  "Mains connection", Page 44.
6. Set the lowest hook position, if necessary  "Adjusting the lower hook position", Page 78.
7. Lubricate the hoist chain with grease over its entire length before the equipment is put into operation for the
first time  "Lubricating the hoist chain", Page 115.

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

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

8. Carry out checks before putting the unit into operation for the first time  "Inspections before putting into
service for the first time", Page 80.

The equipment is ready for operation  "Operation", Page 81.

211 191 44/100620

33
 5.5 Intermediate flange

43426844_xml.eps

Fig. 9 1/1 reeving (A), 2/1 reeving (B)

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

Load capacity [kg] ≤ 125 ≤ 250 ≤ 500 ≤ 1000 ≤ 1250 ≤ 2500 ≤ 1600 ≤ 3200
Reeving 1/1 2/1 1/1 2/1
Motor size ZNK 71 A 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2
l [mm] 532 532 578 618 668 668 708 708

DC-ProDC
Operating limit switch - Standard without operating limit switch for lifting - Standard with operating limit switch for lifting
for lifting - Option with operating limit switch for lifting - Option without operating limit switch for lifting (The operating
limit switch is not needed in chain hoists for installation control
systems supplied by the customer which include a corresponding
limit cut-off arrangement.)
Intermediate flange - Standard without intermediate flange - Standard with intermediate - Standard with intermediate
- Option with intermediate flange flange flange
- For option with operating limit switch for lifting with intermediate - For option with operating limit
flange switch for lifting without inter‐
mediate flange
Counterweight - For option with intermediate flange with coun‐ - No counterweight
terweight fitting on the motor

DC-ProCC
Operating limit switch - Standard
for lifting + lowering
Intermediate flange - Standard

DC-ProFC
Intermediate flange - For combined rotary encoder with intermediate - For combined rotary encoder or for AG 1 - 2 incremental encoder without inter‐
flange mediate flange
211 191 44/100620

- For AG 1 - 2 incremental encoder without inter‐

mediate flange
Tab. 19

34
 Assembly

43426747_xml.eps

Fig. 10

Item DC 1 - 2 DC 5 DC 10 - 15
1 M6x90 hexagon socket bolt; 9,5 Nm M6x100 hexagon socket bolt; 9,5 Nm
2 A6,4 serrated lock washer
3 DC 5 electric equipment cover DC 10 - 15 electric equipment cover
4 4,5x1,8N O-ring
5 DC 1/2 CC seal DC 5 CC seal DC10CC seal
6 M6x25 hexagon socket bolt; 9,5 Nm DC 5 CC pin; 9,5 Nm DC10/15CC pin; 9,5 Nm
7 Intermediate flange
8 DC electric equipment cover seal
9 Cable retaining tape
10 Window
11 M5x12 hexagon socket bolt; 5,5 Nm
211 191 44/100620

12 20/3 sleeve insert; PG21 dummy insert

Tab. 20

35
 5.6 Connecting the controller

5.6.1 General information on the pendant controller

WARNING
Electric power
Danger to life and limb if the power supply is incorrectly connected.
Only connect the pendant controller according to the circuit diagram.
This connection work may only be carried out by qualified specialist personnel.

The pendant controller must be suspended approx. 1000-1200 mm above floor level.

5.6.2 Installing a DSK pendant controller with a support sleeve

Undo the three housing screws (8). Two screws are located under flexi‐
ble boot (2).
Remove housing lower section (9).
Push flexible boot (2) over support sleeve (1). Slide the support sleeve
onto connecting socket (4) until it stops and secure it by tightening clip
(3).
Insert cable (5) through clamp section (6) and clamp it tight. Carefully
lay cable conductors (7) and connect them to terminals, see  "Circuit
diagrams", Page 45.
Screw housing lower section (9) back into place. Ensure that sealing
washers are placed below bolt heads (8).

43331545.eps

Fig. 11

Strain relief with intermediate flange

43407244_xml.eps

Fig. 12
211 191 44/100620

Item Designation Item Designation Item Designation

1 Sleeve insert 3 Control cable 5 Support sleeve with round cable arranged inside
2 Flexible boot 4 Hose clamp 6 Intermediate flange
Tab. 21
36
 1. Slide support sleeve (5) over flexible boot (2) and sleeve insert (1).
2. Attach support sleeve (5) using hose clamp (4).

Strain relief without intermediate flange

42765044_xml.eps

Fig. 13

Item Designation Item Designation

1 Insert to replace inspection window 3 Hose clamp
2 Threaded sleeve 4 Support sleeve with round cable arranged inside
Tab. 22
211 191 44/100620

37
 5.6.3 Installing a DST pendant controller with 2TY

DANGER
Live components
Danger to life and limb.
Connect the control cable according to the circuit diagram.

Connection (A) and strain relief (B) on the pendant controller

● Unscrew housing screws (10) and remove housing lower sec‐
tion (13).
● Fasten protective sleeve (7) with housing cap (8) to housing upper
section (9) with two screws and cut off protective sleeve (7) as re‐
quired for the relevant cable diameter.
● Insert control cable (2) into protective sleeve (7) and through clamp
section (14) (small opening for 10–20 mm cable diameters and wide
opening for 20–26 mm cable diameters) and clamp the cable by
tightening the screws.
● Tighten hose clip (6) on protective sleeve (7). This ensures that the
cable entry is water-tight.
● Carefully bunch cable conductors (11) behind cable clip (12) and
connect them to terminals as required.
● Bolt housing lower section (13) into position when the electric con‐
nections have been made. Ensure that sealing washers are placed
below screw heads (10).

43418045_xml.eps

Fig. 14

Strain relief

42506345_xml.eps
211 191 44/100620

Fig. 15 Separating the strain relief cords

Correct Incorrect Incorrect

Tab. 23

38
 Strain relief with intermediate flange

Item Designation Item Designation

1 Cable union 4 Talurit ferrule
2 Intermediate flange 5 Strain relief cord
3 Carbine hook 6 2TY control cable
Tab. 24

● Separate vulcanised strain relief cords (5) from control cable (6).
● Shorten strain relief cords (5) by approx. 100 mm and strip the
sheath off.
● Create a loop with each strain relief cord (5) and use pliers to crimp
a Talurit ferrule (4) around the strain relief cord.
● Clip a carbine hook (3) through the loop and attach it to the eye be‐
low the chain hoist.

43407344_XML.eps

Fig. 16

Strain relief without intermediate flange

Item Designation Item Designation

1 Control cable retainer 5 M25 union
2 Carbine hook
M8 X 30 hexagon socket bolt
3 Talurit ferrule 6
Tightening torque 11 Nm
4 Insert
Tab. 25

42765145_XML.eps

Fig. 17
211 191 44/100620

39
 5.6.4 Handling the control cable

Do not allow the control cable to be wound around the

chain when lifting motions are performed.

43215644.eps

Fig. 18

5.7 Suspending the chain hoist

5.7.1 Safety information for suspending the chain hoist

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

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

DANGER
Chain hoist may fall
Danger to life and limb and risk of damage.
Do not move the chain hoist or leave it unsupervised when the suspension bracket is open.
211 191 44/100620

40
 5.7.2 Supporting structure
Hoist units that have a load capacity greater than or equal to 1000 kg must be provided with overload protection
to DIN EN 14492-2.
DC chain hoists are used with a slipping clutch which directly acts as overload protection. The slipping clutch
must be adjusted according to the load capacity of the chain hoist. For information on adjustment, see "Friction
force checking device" document  Tab. 3, Page 7.
According to DIN EN 14492-2, the force limitation factor for DC chain hoists with a load capacity ≥ 1000 kg is:
ϕDAL = 1,6
The supporting structure must be designed to accommodate the static and dynamic forces that occur when the
overload protection device is tripped.

5.7.3 Suspension bracket

42713246_xml.eps
Fig. 19

Fig. Designation Fig. Designation Item Designation Item Designation

A) Suspension bracket opened D) DC 15 1/1 reeving 1 Suspension bracket 3 Pin
B) DC 10 1/1 reeving E) DC 15 2/1 reeving 2 Retaining clip 4 Spacer tube (DC 10)
C) DC 10 2/1 reeving
Tab. 26

The chain hoist is delivered with the long suspension bracket (DC 1-10) fitted to the chain hoist. The optional
short suspension bracket (DC 1-10) can be fitted as follows for an improved C dimension.
1. Remove the retaining clip and pin on one side.
2. Attach the suspension bracket (DC 10, DC 15 according to the reeving arrangement) to the superstructure/
trolley.
3. Insert the pin through the suspension and the suspension bracket (and through additional spacer tube (4) for
DC 10) and secure with the retaining clip.
Make sure that the suspension bracket is fitted to match the reeving arrangement of the chain hoist. The chain
hoist will hang at an angle if the suspension bracket is installed incorrectly. Suspension of the chain hoist at an
angle results in premature wear of the chain drive. If special fittings are installed on the chain hoist, make sure
211 191 44/100620

that they are counter-balanced.

41
 5.7.4 Supporting roller fittings
Supporting rollers need to be fitted to trolleys for smaller flange widths in combination with the larger motors.
Supporting rollers are required for trolleys in the following cases:
● U11-U34 and EU56 trolleys with
● ZBF 80 motors up to flange width 130;
● ZBF 90 motors up to flange width 200.
● See also "DC-Pro chain hoist technical data"  Tab. 3, Page 7.

5.7.5 Fittings

The following must be considered if fittings are installed

on the motor:
● The thread depth of the M5 x 16 bolts in the motor
must equal 9 mm;
● The tightening torque of 5,9 Nm must be applied.

43480445_xml.eps

Fig. 20

Counterweight

43480446_xml.eps

Fig. 21

The weight needs to be compensated on DC-ProCC chain hoists due to the control system:
● DC-ProCC 1 - 2: 3 counterweights, see (A);
● DC-ProCC 5: 3 counterweights, see (B);
● DC-ProCC 10: no counterweights, see (C).
The following must be considered if fittings are installed on the motor:
● No additional fittings must be attached to the counterweights. Additional fittings (e.g. electric enclosure, Hart‐
ing plug, geared limit switch) must be bolted to the counterweight plate on the pendant controller side.
● The tightening torque of 8,7 Nm must be applied.
211 191 44/100620

42
 5.8 Plug screw, vent valve
Before putting the chain hoist into operation, remove plug
screw (1) (plug and O ring) and install the vent valve inclu‐
ded in the delivery. See also  "Gearbox/oil change",
Page 129

Tightening torques [Nm] DC 15

M16 plug screw 15
M16 vent valve 15
Tab. 27

42767847_XML.eps

Fig. 22
211 191 44/100620

43
 5.9 Mains connection

43406945_xml.eps

Fig. 23

Item Designation Item Designation

A) DC 1 - 5 strain relief attachment 1 Mains connection
B) DC 10 strain relief attachment 2 Recess for round cable
C) DC 15 strain relief attachment 3 Recess for flat cable
Tab. 28

The mains connection cable, the mains connection fuse links and any devices to disconnect and switch the po‐
werfeed must be available on site in order to connect the unit to the power supply. You need a 4-lead cable with a
PE protective earth conductor which complies with the table in  "Electric key data", Page 22 for the power sup‐
ply.
211 191 44/100620

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

44
 Connection to the electric supply
● First check to ensure that the voltage and frequency specified on the rating plate match your mains supply.
Ensure that the mains connection cable is not connected to the power supply and secured against accidental
restoration of the power supply.
● Remove the service cover and open the electric equipment cover to connect the supply cable.
● Finally insert the mains cable into the opening in the gearbox housing and secure it with the strain relief clamp.
Depending on the cable type (flat or round cable), the strain relief clamp must be turned to match the shape of
the cable.
● All housing parts must be securely latched to ensure the unit is sealed.
● Check continuity and low resistance (guide value < 1 Ohm) of the earth lead connection after the pow‐
er cable has been connected and before the chain hoist is put into operation.

Checking the direction of movement

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

WARNING
Incorrect direction of movement
Danger to life and limb if the direction of movement is wrong.
– 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 mains connection.

See  "Circuit diagrams", Page 45 and  "Control systems", Page 73 for connection examples.

5.10 Circuit diagrams

5.10.1 General information on the circuit diagrams

Installation Number of speeds Control method Pendant con‐ Circuit diagram See section
Hoist Crab Crane Contactor Direct (DC) troller no.
(CC)
Contactor control  "Direct control with contactor control provided
2 X See crab
by customer by the customer", Page 56
 "Contactor control and control via DSK SP2
Hoist unit 2 X DSK SP2 631 311 46
pendant controller", Page 46
 "External frequency inverter control, by cus‐
External frequency inverter (FC) by customer 631 316 46
tomer", Page 54
 "Direct control with contactor control provided
2 2 X 631 303 46
Contactor control by the customer", Page 56
Crab
by customer  "Contactor control with contactor control provi‐
2 2 X 631 300 46
ded by the customer", Page 63
Crane 2 2 2 X DST7 SP222 On request
Tab. 29

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

For further circuit diagrams with E11 - E34 travel drives, see  Tab. 3, Page 7 E11-E34 DC travel drive assembly
instructions (II).

For further information on E11 - E34 travel drives, see  Tab. 3, Page 7 E11-E34 DC travel drive assembly in‐
211 191 44/100620

structions (I).

For further information on cross-travel limit switch part no. 716 663 45, see  Tab. 3, Page 7 E11-E34 DC travel
drive assembly instructions (I).
45
 5.10.2 DC chain hoist with 2 lifting speeds

5.10.2.1 Contactor control and control via DSK SP2 pendant controller

211 191 44/100620

46 Fig. 24
211 191 44/100620

Fig. 25

47
48
Fig. 26
211 191 44/100620
211 191 44/100620

Fig. 27

49
50
Fig. 28
211 191 44/100620
211 191 44/100620

Fig. 29

51
52
Fig. 30
211 191 44/100620
211 191 44/100620

Fig. 31

53
54
5.10.2.2
1 2 3 4 5 6 7 8
NETWORK SUPPLY

Fig. 32
MOTOR Brake THERMAL CONTACT PULSE DEVICE GEARED LIMIT SWITCH
A A

: 091
: 44DIN4
L1
L2
L3
PE

Classification-No. : 141
Code Point
Norm
B EXTERNAL FREQUENCY IMVERTER B
Mains voltage ~ BY CUSTOMER
CONTROL
Brake
FROM
FREQUENCY INVERTER
U = 0 - 360V
f = 0 - 87Hz EVALUATION FREQUENCY INVERTER INTERNAL

C C
External frequency inverter control, by customer

5 6 8 1 12 10
-X1 1 2 3 PE 4 5 8 9
5 6 7 3 4
-V013 ~ ~ ~ -B015 A A B B VCC GND

16.01.2017 11:20
GE 3,0A + -
1 2 A
PULSE DEVICE PLUG B
D DC Pro FC -XM013 1 -S017 11 21 31 41 D
2-pol. 2

Observe legal Protection according to ISO 16016

-XF013 1 2 1=B\ 9 8=B DC-GGS4 12 14 22 24 32 34 42 44
2-pol.
10=GND 12=VCC
U1 V1 W1 PE 2 7
PE BD1 TB1 OPTIONAL
-M011 M 11
3AC 3 6=A\
ZNK BD2 TB2
.4 TB1 TB2 PE 4 5=A
.3 BD1 BD2 OPTIONAL
E E

CAD Drawing, no manual Changes

SIA-Date
F Date 25.04.2013 Customer Designation = 00D31 F
Drawn Völkl TERMINAL HOUSING + G1
01 Revision 01 16.01.2017 Tetter Check DC-Pro FC Order No. Dept. Format Lang. Ident No. SK DT Sheet 01
Issue Mod. Date Name Ch.Date Compiled f. Repl.from Repl.by DC_STANDARD MHR24 3 EN 63131646 N 11 1 Sh.
1 2 3 4 5 6 7 8
211 191 44/100620
211 191 44/100620

1 2 3 4 5 6 7 8

Fig. 33
FOR REQUIRED CABLE SIZE AND MAINS PROTECTION SEE OPERATING INSTRUCTIONS
A A

: 091
: 44DIN4
EXTERNAL FREQUENCY IMVERTER

Classification-No. : 141
Code Point
Norm
BY CUSTOMER
B B

=00D31 =00D31 =00D31

*
C +G1 +G1 +G1 C
DC Pro FC -V013 -B015 -S017

PULSE DEVICE
GEARED LIMIT SWITCH

16.01.2017 11:20
=00D31 -XF013
+G1
=00D31 -XM013
+G1
D D

Observe legal Protection according to ISO 16016

=00D31
THERMAL CONTACT +G1 Brake
-M011

HOIST MOTOR
E E

CAD Drawing, no manual Changes

SIA-Date
F Date 25.04.2013 Customer Designation = Connection F
Drawn Völkl Interconnection Diagram +
01 Revision 01 16.01.2017 Tetter Check DC-Pro FC Order No. Dept. Format Lang. Ident No. SK DT Sheet 01
Issue Mod. Date Name Ch.Date Compiled f. Repl.from Repl.by DC_STANDARD MHR24 3 EN 63131646 N 60 1 Sh.
1 2 3 4 5 6 7 8

55
 5.10.3 DC travelling hoist with 2 lifting and travel speeds

5.10.3.1 Direct control with contactor control provided by the customer

211 191 44/100620

56 Fig. 34
211 191 44/100620

Fig. 35

57
58
Fig. 36
211 191 44/100620
211 191 44/100620

Fig. 37

59
60
Fig. 38
211 191 44/100620
211 191 44/100620

Fig. 39

61
62
Fig. 40
211 191 44/100620
 5.10.3.2 Contactor control with contactor control provided by the customer
211 191 44/100620

Fig. 41

63
64
Fig. 42
211 191 44/100620
211 191 44/100620

Fig. 43

65
66
Fig. 44
211 191 44/100620
211 191 44/100620

Fig. 45

67
68
Fig. 46
211 191 44/100620
211 191 44/100620

Fig. 47

69
70
Fig. 48
211 191 44/100620
211 191 44/100620

Fig. 49

71
72
Fig. 50
211 191 44/100620
 5.11 Control systems

5.11.1 DC-ProDC

43407044_xml.eps

Fig. 51

Item Designation Item Designation

1 GF brake control 2a Terminal 1 - 9, 25 - 26 from top to bottom
Terminal strip X1
3 Brake 2b Terminal 10 - 18, 23 - 24 from top to bottom
Tab. 30

Terminal strip X1
Function Item 2a Signal Remark Function Item 2b Signal Remark
No. No.
1 L1 10 1U2U Speed stage V1/V2
Mains input 2 L2 11 1V
Point-to-point terminals for power‐ Speed stage V1
3 L3 feed/controller supply Cross-travel motor point- 12 1W
Earth connec‐ to-point terminals
PE PE 13 2V
tion Speed stage V2
4 1U2U Speed stage V1/V2 14 2W
5 1V Earth connection PE PE
Speed stage V1 LI. LI. SW.
6 1W Lifting limit switch 1+ 15
Hoist motor 11
control LI. LI. SW.
7 2V Lifting limit switch 2+ 16 Limit switch point-to-point ter‐
21
Speed stage V2 minals (optional); for evaluation
LI. LI. SW. by customer
8 2W Lifting limit switch 1- 17
12
LI. LI. SW.
- 9 1U2U’ Internal point-to-point terminal Lifting limit switch 2- 18
22
25 Brake ~ Floating contact, Thermal contact + 23 Sensor + Thermal contact point-to-point
Brake addition‐
see motor data for customer con‐ terminals (optional); for evalua‐
211 191 44/100620

al contact 26 Brake ~ Thermal contact - 24 Sensor -

tact load tion by customer
Tab. 31

73
 5.11.2 DC-ProCC

43480344_xml.eps

Fig. 52

Item Designation Item Designation Item Designation

Terminals 15 - 26 2 Main contactor 6 Transformer
1a
from top to bottom 3 Fast travel contactor 7 Brake module
Terminal strip X1
Terminals L1 - L3, PE, 5 - 12 4 Lifting contactor 8 Intermediate flange
1b
from top to bottom 5 Lowering contactor
Tab. 32

Terminal strip X1
Function Item 1a Signal Remark Function Item 1b Signal Remark
No. No.

See technical data for 1 L1

Control voltage 15 UCtrl V
control voltage; 2 L2
Reference potential 16 Reference Dependent on variant Mains input 3 L3 Powerfeed
Emergency
Emergency stop 17 PE PE
stop
Lifting 18 Lifting Lifting axis control sig‐ 5 1V
nals
Lowering 19 Lowering 6 1W
Speed V2 20 V2 7 2V
Lifting lim. Point-to-point terminals Hoist motor connection Point-to-point terminals
Lifting limit switch 21 terminals 8 2W (internal)
sw. (internal)
Lowering Limit switch and thermal
Lowering limit switch 22 contact; 9 1U2U
lim. sw.
Thermal contact 23 Sensor + PE PE
Right 24 Right Controller point-to-point 10 L1’
211 191 44/100620

Left 25 Left terminals Supply to crab control 11 L2’ Output to crab control
Speed V2 26 V2 Cross-travel signals 12 L3’
Tab. 33

74
 Crab control, separate enclosure fitted to the outside

43608944_xml.eps

Fig. 53

Item Designation Item Designation

1 Terminal strip X1: terminals 1 - 8, PE, 9 - 18 (from left to right) 3 Lowering contactor
2 Lifting contactor 4 Fast travel contactor
Tab. 34

Terminal strip X1 function No. Signal Remark

1 L1
Mains input 2 L2 Powerfeed
3 L3
4 1U2U
5 1V
6 1W
Cross-travel motor connection Cross-travel motor connection
7 2V
8 2W
PE PE
Reference potential 9 Reference
Right/right limit switch + 10 Right
Left/left limit switch + 11 Left
Speed 2/right fast-to-slow limit switch + 12 V2 Point-to-point terminals for
- Reference potential
Control voltage/thermal contact + 13 UVol - Limit switches
Right limit switch - 14 Right lim. sw. - - Fast-to-slow limit switches
- Thermal contact
Left limit switch - 15 Left lim. sw. - See  "Circuit diagrams", Page 45
Right fast-to-slow limit switch -/left fast-to-slow limit switch + 16 Right FA./SL. LI. SW. -
Thermal contact - 17 TB 2
211 191 44/100620

Left fast-to-slow limit switch - 18 Left FA./SL. LI. SW. -

Tab. 35

75
 5.11.3 DC-ProFC

43449246_xml.eps

Fig. 54 Example of a chain hoist with a rotary encoder fitting

Item Designation Item Designation Item Designation

A) DC-ProFC 1 - 10 with AG 1 - 2 1 Intermediate flange 4 Terminals
DC-ProDC 1 - 5 with combined rotary encoder with intermediate
B) 2 Brake module 5 Rotary encoder
flange
C) DC-ProDC 10 with combined rotary encoder and BC20 brake 3 Mounting plate 6 Brake
Tab. 36

Terminal strip X1 function No. Signal Remark

1 U
2 V Motor connection terminals
Motor connection
3 W
PE PE Earth connection terminal
4 BD 01
Brake control Control of the brake
5 BD 01
8 TB 1 Umax = 250 V
Thermal contact
9 TB 2 Imax = 6,3 A
Tab. 37
211 191 44/100620

76
 Rotary encoder AG 2 incremental encoder, Combined rotary encoder,
Part no. 720 402 45 25) Part no. 538 132 84
Type Incremental Absolute SSI Incremental
Size 58 58
Model Flange, synchro Flange, synchro
Shaft diameter 6 mm 14 mm
Shaft length 12 mm 12 mm
Shaft load, axial ≤ 70 N ≤ 10 N
Shaft load, radial
≤ 125 N ≤ 20 N
(at shaft end)
5 m cable with open end, 17-pole connector, Coninvers,
Connection
 Tab. 39, Page 77  Fig. 55, Page 77
≤ 6000 rpm (continuous duty);
Speed ≤ 12000 rpm
≤ 10000 rpm
Type of enclosure IP 65 IP 65
Operating temperature -40 °C … +80 °C -20 °C … +70 °C
Interface RS 422 (TTL) RS 422 (TTL)
Output level H > 2,5 V DC; L < 0,5 V DC - H > 2,5 V DC; L < 0,5 V DC
Supply voltage UB 5 … 30 V DC 11 … 27 V DC
Current consumption (no load), typical 50 mA 50 mA
Output voltage 5 V DC - RS 422
Output load ≤ 20 mA per channel ≤ 50 mA per channel
Output signal A, Ainv; B, Binv; N, Ninv Gray code A, Ainv; B, Binv
Phase offset with reference to a pitch
90° ± 7,5 % - 90° ± 7,5 %
length
Division marks 1024 1024/32768 (10Bit/15Bit) 1024
Pulse frequency ≤ 150 kHz - ≤ 300 kHz
Permissible cable lengths for
250 m 150 m
3000 … 6000 rpm
Tab. 38

5 m cable with open end on AG 2 incremental encoder

Function 0 V GND +UB 0 V Sens +UB Sens A /A B /B 0 /0 Sceen
Conductor WH BN GYPK RDBU GN YE GY PK BU RD C
Tab. 39

17-pole CONINVERS connector, clockwise pins, radial on the encoder;

0,14 mm2 signal cable; 0,5 mm2 supply cable
PIN Function Con‐ PIN Function Con‐
duc‐ ductor
tor
1 Clock input - WH 9 Serial programming interface RS485 BK
2 Clock input + BN 10 Serial programming interface RS485 VT
3 Data output + GN 11 Change counting direction GYPK
4 Data output - YE 12 Specified value 1 RDBU
5 Channel A GY 13 Specified value 2 WHGN
41871346_xml.eps
6 Channel Ainv PK 14
Fig. 55 PIN arrangement (looking at the con‐ 7 Channel B BU 15
necting pins)
8 Channel Binv RD 16 Supply voltage YEBN
17 GND WHGY
Tab. 40
211 191 44/100620

25) Suitable for use with Demag Dedrive Compact frequency inverters. We recommend type AG 2 for use with Demag Dedrive Compact frequen‐
cy inverters. Please use an EM ENC-02 extension module. 77
 5.12 Adjusting the lower hook position

1
2
3

43215744.eps

Fig. 56

Item Designation Item Designation

1 Buffer (limit switch option) 4 Limit stop
2 Damping plate 5 Unloaded chain fall
3 Buffer plate
Tab. 41

Ensure that the load hook touches the ground in the lower hook position when determining the hook path/lifting
height. The chain hoists are provided with a hook path of 5 m or 8 m as standard.
Secure the limit stop to the 5th chain link at the dead (unloaded) end of the chain.
● Follow the order of assembly. See also  "Buffer/cut-off spring arrangement", Page 122

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

Limit stop 4,0 4,3
Tab. 42

To reduce the hook path, proceed as follows:

1. Position the hook as shown in the diagram.
2. Stop the chain hoist by actuating the emergency stop or the mains connection switch and secure it against
switching on again.
3. Remove the chain collector box  "Removing the chain collector box", Page 97.
4. Remove the limit stop on the chain collector box end.
5. Slide the buffer/buffer plate or damping plate onto the chain until it reaches the guide plate.
6. Attach the limit stop directly behind the buffer, the buffer plate must be positioned between the buffer and the
limit stop. The unloaded chain fall behind the limit stop must consist of at least 5 chain links.
7. Place the chain in the chain collector and re-connect it to the chain hoist.
211 191 44/100620

8. Switch the chain hoist on and check adjustment of the lower hook position by moving the hook and run the
chain once through over entire adjusted hook path.

78
 6 Putting into service for the first time

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

The machine may only be handed over when its safety has been verified by means of a corresponding check
 "Checks on entering service, handover", Page 80.

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

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

6.2 Inspection regulations

WARNING
Non-compliance with operating and maintenance regulations
Danger to life and limb.
Compliance with all inspection regulations is an essential aspect of ensuring safe operation of the machine.
Required tests and inspections must be carried out.
All inspections must be arranged and documented by the owner at the specified intervals/points of time.
– Inspection according to national regulations, e.g. according to the rules and regulations of the German So‐
cial Accident Insurance (DGUV).
The owner is responsible for ensuring that power-driven chain hoists are inspected by an expert engineer
before they are first put into service and before they are put into service again after major modifications
have been carried out. This also applies to manually operated or semi-powered chain hoists that have a
load capacity of more than 1000 kg.
– Adjustment, maintenance and inspection activities and inspection deadlines including specifications con‐
cerning the replacement of parts/assemblies prescribed in the operating instructions must be observed.
– Please refer to  "Noise emission/sound pressure level", Page 24 for sound pressure level measurement
values to DIN 45 635.
This work may only be carried out by specialist personnel.
211 191 44/100620

79
 6.3 Inspections before putting into service for the first time
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 and low resistance of the PE conductor connection - X
Check emergency-stop device - X
Check direction of movement  "Mains connection", Page 44 X
Lubricate the chain along its entire length before the equipment is first put into operation.  "Available hoist chains", Page 105 X
Check chain lubrication (under arduous conditions, the chain must be lubricated more fre‐
quently)
Check cut-off buffer/cut-off spring/operating limit switch actuator  "Check cut-off buffer/cut-off spring", Page 121, X
Check cable and controller housing for damage - X
Check operation of the brake - X
Check hook and hook safety catch  "Checking the load hook", Page 117 X
Tab. 43

6.4 Checks on entering service, handover

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

By means of suitable measures carried out by the owner or on his behalf, the owner must ensure that the load
handling devices and machinery ready for operation function in complete safety before they are first put into serv‐
ice. The specified measures must allow for the static and dynamic features of the machinery.
The following checks must be carried out when the equipment enters service:
● The supporting structure must be in good condition and the load capacity of the chain hoist must be checked.
● Safety devices must be complete and effective.
● Clearances and safety distances must be maintained.
● The emergency-stop device must be checked by actuating the emergency stop.
When the unit is first put into operation, it must be checked to ensure that it is used as intended in all possible
applications, in each case with the maximum permissible load. Operation of the safety devices must be checked
(e.g. by lifting an overload). At the same time, the behaviour of the chain hoist must be checked when it is not
used correctly.
Various checks of the machine must be carried out before it is handed over:
● Check to ensure it is suitable for operation
● Acceptance inspection
The test and inspection records can be compiled as soon as safe operation of the chain hoist is ensured.
The test and inspection records (log book; observe relevant national regulations) must be handed over when the
machine is handed over.
The machine may be used as intended after it has been handed over.
211 191 44/100620

80
 7 Operation

7.1 Safety instructions for operation

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

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

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

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

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

The machine must not be put into operation or must be taken out of service immediately if any defects or irregu‐
larities relating to safe operation or function are detected.
Safety devices must not be rendered inoperative or modified contrary to their intended use.
211 191 44/100620

81
 Ensuring safe operation
Special local conditions or special applications may lead to situations which were not known when this chapter
was written. In this case, the owner must ensure safe operation or take the machine out of service until measures
for safe operation have been clarified and implemented in agreement with the manufacturer or other relevant bod‐
ies.
In the event of a stoppage (e.g. if defects regarding safe and reliable operation are detected, in emergency situa‐
tions, in the event of operating malfunctions, for repairs and maintenance work, if damage is detected or after fin‐
ishing work), the operator must carry out all prescribed safety measures or observe that they are automatically
carried out.
Work on electric equipment may only be carried out by qualified electricians.

7.2 Switching on

7.2.1 Checks when starting work

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

7.2.2 Function checks

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

Activity Section Check

Check emergency-stop device - X
Check chain lubrication (under arduous conditions, the chain must be lubricated more fre‐  "Available hoist chains", Page 105 X
quently)
Check cut-off buffer/cut-off spring/operating limit switch actuator  "Check cut-off buffer/cut-off spring", Page 121 X
Check cable and controller housing for damage - X
Check operation of the brake - X
211 191 44/100620

Check hook and hook safety catch  "Checking the load hook", Page 117 X
Tab. 44

82
 7.3 Operation

7.3.1 Safety during operation

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

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

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

Important information for operation

Observe the following during operation:
– Take the machine out of service immediately if functional defects or irregularities are detected.
– The operator is obliged to check the machine for any visible damage at least once per shift and to report any
damage immediately.
– Do not render safety devices inoperative.
– Limit stops must not be approached in normal operation, e.g. emergency limit stop devices (emergency limit
switches), emergency limiters (slipping clutch or emergency limit switch), track and limit buffers to stop
movement of the crab or crane, hook assembly or bottom block against limit stops. Continuously approach‐
ing these limit stops can result in severe damage and can even break the chain hoist chain.
– Pay attention to all regulations regarding the correct loading of chains.

– Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing, parts of the
body or hair becoming entangled.
– Adequate illumination must be available for safe operation.
Requirements for illuminating workplaces are laid down in DIN EN 12464.
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 7.3.2 Load pick-up
– The load handling attachment and load must be flexibly suspended. Rigid connections cause uncontrolled
forces to be transmitted and lead to fatigue fracture. To protect the chain from unwanted torsion when the
load turns, movement of the hook assembly/bottom block must not be restricted.
– The bottom block must not be twisted or turned over for 2/1 reeving arrangements; chain links facing the
same direction must be arranged opposite each other without being twisted.
– When attaching the load, ensure that the load or load attachment does not slip off the hook and that the load
does not fall over, fall apart, slip or roll off when it is picked up or set down.
– When the load is lifted, the hook must move to an upright position to ensure that the hook safety catch is not
subjected to a load by the load handling slings and, as a result, damaged.
– Do not use the equipment to transport persons.
– The load capacity specified on the load capacity plate indicates the maximum permissible load, which must
not be exceeded. This is the sum of the lifted load and the load handling attachment. Only approved load
handling attachments may be used. The load capacity of the load handling attachment must not be excee‐
ded.

7.3.3 Moving loads

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

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

42774544_XML.eps
Fig. 57

7.3.5 Emergency-stop device operating function

The pendant controller for direct control or contactor control is provided with an emergency-stop button.
When the emergency stop is actuated, the hoist motor is disconnected from three phases of the electric power
supply, the mechanical brake is applied and it brings any movement to standstill.
The emergency stop latches in the open position. If the emergency stop was actuated owing to incorrect function‐
ing of the self-resetting button or of the direction contactor for the long-travel motions, it cannot be ruled out that
the interrupted motion will start up again when the emergency stop is released.
The effectiveness of the emergency-stop function depends on the good operating condition of the mechanical
brake.
Unusually long braking distances may indicate excessive wear of the brake. In this case, the brake must be in‐
spected by an experienced technician without delay.

7.3.6 Slipping clutch operating function

The chain hoist is fitted with a slipping clutch, which limits the lifting capacity to the adjusted friction force. The
force in the chain fall is limited and, therefore, impermissible loads cannot be lifted. After the slipping clutch trips,
the operator must switch off the lifting motion to avoid overloading of the slipping clutch and slipping of the load.
If the slipping clutch already starts to slip at rated load, the friction force must be measured by an experienced
technician and re-adjusted, as required.
Travel against the upper/lower limit position in normal operation and tripping of the slipping clutch caused by this
is not permitted.

7.3.7 Lifting path limiter operating function

The permissible lifting path is limited by limit stops in the chain. The limit stops trigger the slipping clutch function
in the upper and lower limit positions.
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 7.4 Emergency stop

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

Every chain hoist is fitted with an emergency-stop device with which all
motions can be stopped in the event of a hazard.
The emergency-stop button is arranged in a clearly visible position on
the pendant controller. Anybody who identifies an immediate danger of
personal injury must actuate the emergency stop without delay. This al‐
so applies in the case of malfunctions and damage that occurs to parts
of the machine and equipment which makes it necessary to stop and
secure the machine immediately.
43406446_xml.eps

Fig. 58 Position of emergency stop (1)

● To actuate the emergency stop, press the button until it reaches the end stop. It then locks automatically and
the chain hoist is shut down.
● To unlock the actuated emergency stop, turn the pushbutton in the direction of the arrows (clockwise) and re‐
lease it.
Following an emergency stop, do not switch the machine on again until trained specialist personnel is satisfied
that:
● the cause which led to actuation of this function has been rectified and
● continued operation of the machine constitutes no further hazard.

Pendant controller
Demag chain hoists can be equipped with various controllers, as required. Refer to the relevant documents for
operation of the pendant controller and button assignments, see  Tab. 3, Page 7. 211 191 44/100620

86
 7.5 Taking the equipment out of operation
7.5.1 Taking the equipment out of service when faults occur
The machine must be switched off immediately if the following faults occur:
● If electric devices and cables as well as parts of the insulation are damaged.
● Brake and safety device failure.

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

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

8.1 Safety warnings for maintenance and repair work

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

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

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

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

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

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

8.2 Basic maintenance requirements

General information on maintenance/repairs

The specified inspection and maintenance intervals ( "Maintenance schedule", Page 95) apply to normal chain
hoist operating conditions. All wearing parts must be checked in the course of the annual inspection.
If routine maintenance reveals that the maintenance intervals are too long, they should be adapted to the specific
operating conditions.
Electric components
Only fuse links with the specified amperage and tripping characteristics may be used in the electric circuits. De‐
fective fuse links must not be bridged.
Pay attention to the following when working on machinery or machine equipment:
1. Wear personal protection equipment.
2. Before starting any maintenance work, switch off the mains connection switch and protect it against unau‐
thorised or accidental re-connection to the power supply by locking it with a padlock.
3. Ensure that the chain hoist is switched off, checked that it is de-energised and, in special cases, isolated.
4. Only carry out maintenance work on the chain hoist when the load has been removed.
5. Ensure that there is sufficient freedom of movement. Keep the working area clean and tidy. Loose parts or
tools left lying around can cause accidents.
6. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.
7. Observe the relevant accident prevention regulations, instructions concerning appropriate use and statutory
regulations for operation and maintenance.
8. Observe the relevant safety regulations (e.g. VDE regulations) when repairing electric equipment.
Maintenance work which is not possible from the ground may only be carried out from work stands or platforms.
The danger zone below the chain hoist must be fenced off if there is a risk of falling objects.
Instructions for maintenance work in the course of operation
If maintenance work has to be carried out on the chain hoist in the course of operation, special safety precautions
must be taken depending on the operating situation. In each individual case, the owner or the person assigned by
him must check whether the maintenance work may be carried out in the course of operation without risk of per‐
sonal injury and, taking into account the local conditions, must implement all necessary safety precautions.
Replace damaged or deformed spring clip fasteners and spring sleeves.
Defective bolted connections must be replaced.
Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly
manner.
211 191 44/100620

After finishing maintenance work

Reinstall safety devices as required by relevant regulations and check them for correct operation after finishing
maintenance work.
89
 Carry out a test run at partial load after the chain hoist has been fully re-assembled. Ensure that the chain runs
smoothly during the test run.

8.3 Regular inspections

8.3.1 Required tests and inspections

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

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

Please also note  "Measures for achieving safe working periods", Page 91 and  "Maintenance schedule",
Page 95.
Updating the log book
● All inspections must be arranged and documented in the log book by the owner.

8.3.2 Special operating conditions

CAUTION
Premature wear of the chain.
Danger of falling load.
Special operating conditions or the design of the chain hoist may make it necessary shorten the maintenance
and inspection intervals.
– If, for example, the unit always brakes heavily at the same position and with a heavy load, increased wear
may occur on the chain links that are in the area of the chain sprocket or return sprocket when the brake is
applied.
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 8.3.3 Measures for achieving safe working periods
8.3.3.1 General
The safety and health provisions of the EC Machinery Directive make it a legal requirement to eliminate special
hazards which may be caused, for example, by fatigue and ageing.
This requirement is also reflected by the rules and regulations of the German Social Accident Insurance (DGUV).
This requirement obliges the owner of serial hoist units to determine the actual duration of service of the chain
hoist on the basis of the operating hours, load spectra and/or recording factors. This is based on
FEM 9.755/06.1993 Measures for achieving safe working periods for powered serial hoist units.
The objective of this rule is to determine measures for achieving safe working periods over the entire duration of
service, although, according to the state-of-the-art, the chain hoists are designed for specific periods of operation.
Premature failure cannot, however, be ruled out.
The following items have been taken from FEM rule 9.755 with reference to the electric chain hoist:
1. 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.

4. The value determined for operating time Ti using an operating time counter must be multiplied by the type of
recording factor f = 1,1.
5. The value determined for the estimated operating hours and load spectrum must be multiplied by the type of
recording factor f = 1,2.
6. The actual duration of service S is calculated as: S = kmi x Ti x f

7. A general overhaul must be carried out when the theoretical duration of service is reached.
8. All checks and inspections and the general overhaul must be arranged by the owner of the chain hoist.
A general overhaul is defined as:
Inspection of the machinery for the purpose of detecting all defective components and/or components and parts
close to failure and the replacement of all such components and parts. Following a general overhaul, the machi‐
nery is in a condition similar to that of the same machinery in new condition as far as the principle of operation
and performance values are concerned.
For electric chain hoists classified according to FEM 9.511, the following theoretical durations of service apply
(converted into full load hours):

Group of mechanisms 1Cm 1Bm 1Am 2m 2m+ 3m 4m

Duration of service/full load hours [h] 200 400 800 1600 1900 3200 6300
Tab. 45

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.
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 8.3.3.2 Calculating the actual duration of service S
The actual duration of service S of the electric chain hoist can be determined as follows (as standard, DC-ProDC
1-15, DC-ProCC 1-15 and DC-ProFC 1-15 chain hoists are not fitted with elapsed operating time counters):
S = kmi • Ti • f
kmi : Actual load spectrum factor
Ti : Number of operating hours
f : factor depending on the type of recording
Calculating the number of hours of operation (operating time) Ti (by the owner)
The operating time can be calculated by means of an operating time counter or according to the following method:
Operating time per inspection interval:

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

Ti =
60 x lifting speed
Tab. 46

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 together 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 (e.g. 1 year) in terms of per‐
centage.
The following bar diagram shows the km load spectrum modules for the load conditions without load up to full load
in time increments of 5 and 10%. Larger shares of the time period must be correspondingly added together.
Load spectrum factor kmi can be obtained by adding together the individual km load spectrum modules.

Diagram
0,021

0,0062

0,0125

0,0008

0,0016
0,05

0,10

L B
0,042

4/4

3/4 1

1/2

1/4

0 t
5 10 5 10 5 10 5 10 40
[%]
100 43230144.eps
Fig. 59 Type of load (B), load (L), time (t), partial load (1)

Factor depending on the type of recording:

● f = 1,1
For calculating the operating hours using an operating time counter.
● f = 1,2
For estimating the operating hours and the load spectrum.
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 8.3.3.3 Example: DC-ProDC 10-1250 1/1 H5 V8/2 in 1Am

Lifting speed 8/2 m/min

No. of cycles per hour 10 cycles/h
Lifting and lowering (2+2) m/cycle = 4 m/cycle
Operating time per day 8 hours/day
Days per inspection interval 250 days/inspection interval
Tab. 47

Calculation

10 • 4 • 8 • 250
Ti =
60 • 8
Tab. 48

With estimated operating time: 166,6 hours

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

0,042

0,0125+

0,0016+

L B
0,0125

0,0008

5% x 4/4

10% x 3/4

20% x 1/2

15% x 1/4

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

Fig. 60 Type of load (B), load (L), time (t)

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

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

● With estimated operating time 0,119 x 166,6 x 1,2 = 23,8
For classification in FEM group of mechanisms 1Am (see DC-ProDC data plate) with a theoretical duration of
service of 800 hours (see table below) the hoist has a theoretical remaining duration of service of
● With estimated operating time 776,2 hours
Documentation:
Enter these values in your log book or crane log book. This entry may appear as follows:

Date Operating hours Load [%] km factor Load spec‐ Actual Theoretical Remaining use
trum factor duration of duration of
service service
From To Ti value [h] full 3/4 1/2 1/4 none kmi f S [h] D [h] Group of D - S [h]
mech.
5 10 20 15 50
3.1.- 30.12.- Estimated 166,6 0,119 1,2 23,8 800/1Am 776,2
0,05 0,042 0,025 0,002 -
Tab. 49
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93
 8.3.4 GO general overhaul
The chain hoist is designed to be used for a period of at least 10 years until the first general overhaul is carried
out. This is based on the condition that the specified group of mechanisms is not exceeded by the actual dura‐
tion of service. When the actual duration of service has reached the theoretical duration of service relevant for
the given group of mechanisms, further operation of the chain hoist is only permitted after a general overhaul
has been carried out.

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 FEM 9.755. You can
arrange to have the actual service life calculated as part of the annual inspection by our after-sales service.
The owner must arrange for a GO general overhaul to be carried out when 90% of the theoretical duration of serv‐
ice has elapsed. A GO general overhaul must be carried out by the end of the theoretical duration of service.
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,
● Slipping clutch.
The small parts (screws, washers, etc.) to be replaced when maintenance and assembly work is carried out are
not listed separately. The general overhaul carried out by the manufacturer or a specialist company authorised by
him satisfies the 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 opera‐
tion in the log book. Completion of the general overhaul must be confirmed in the log book and a further period of
utilisation in accordance with FEM 9.755 must be entered.

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 8.4 Maintenance schedule
Activity Section Before first Before start‐ During the an‐
putting into ing work nual inspec‐
operation tion
Check continuity and low resistance of the PE conductor connec‐ -
X
tion
Check emergency-stop device - X X
Check direction of movement  "Mains connection", Page 44 X
Check chain lubrication (under arduous conditions, the chain must  "Available hoist chains", Page 105
X X X
be lubricated more frequently)
Check cut-off buffer/cut-off spring/operating limit switch actuator  "Check cut-off buffer/cut-off spring",
X X X
Page 121
Check cable and controller housing for damage - X X X
Check operation of the brake - X X X
Check hook and hook safety catch  "Checking the load hook", Page 117 X X X

Estimate or calculate operating hours to determine the remaining  "Measures for achieving safe working
X
safe working period periods", Page 91
Check electric switchgear and wiring - X
Check operation of the slipping clutch  "Checking the slipping clutch",
X
Page 128
Check adjustment of the slipping clutch  "Adjusting the slipping clutch",
X
Page 128
Check brake wear  "Brake", Page 124 X
Grease brake V sealing ring X
Check suspension, suspension bracket and securing elements  "Suspension", Page 96
X
(clip, etc.)
Check fastening bolts on hook assembly/bottom block - X
Check hooks for cracks, deformation and wear  "Checking the load hook", Page 117 X
Check hook safety catch for deformation - X
Check hook bearing for wear - X
Check sprocket of chain guide, chain sprocket of bottom block,  "Chain drive", Page 101
X
chain guide, guide plate
Check that the chain is properly secured - X
Check the chain collector and suspension for external damage  "Removing the chain collector box",
(e.g. cracks, stress whitening, weld seams on metal collector Page 97
X
buckets, threads on chain collector bags, rivets, clips)
Remove DC 1-15 service cover
Check the chain for deformation, damage, cracks, pitting, reduc‐  "Check hoist chain", Page 102
tion in the thickness of the links or increase in pitch due to wear, X
elongation caused by deformation
Check securing elements (clips, bolts, etc.) for tight fit and corro‐ -
X
sion
Check and apply or add corrosion protection, as required - X
Check the electric enclosure and gearbox for leakage - X
Check trolley, crossbar and condition of buffers  "Check cut-off buffer/cut-off spring",
X
Page 121
Oil change  "Gearbox/oil change", Page 129 Every 10 years 26)
General overhaul
The general overhaul should coincide with the annual inspection. When 90% of the theoretical duration of service is
reached  "Measures for achieving safe working
periods", Page 91
Fit chain hoist-specific Demag GO set X
The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not listed separately. The checks and work speci‐
fied in the inspection and maintenance schedule must be carried out during the general overhaul.
Tab. 50
211 191 44/100620

26) For use according to FEM classification 95

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

Suspension bracket

Chain hoist DC 1/2/5 DC 10 DC 15

Suspension bracket short long short long long
Min. dimension e for sus‐
[mm] 15,3 14,4 25,2 24,3 31,5
pension bracket
Tab. 51

43218944.eps

Fig. 61

Suspension ring

Chain hoist DC 1/2/5 DC 10 DC 15

Min. dimension e for sus‐
e

pension ring turned 90°

[mm] 17,55 24,3 34,2
(chain hoist parallel to gird‐
er)
Tab. 52

42599450_XML.eps

Fig. 62

8.5.2 Electric equipment cover

The electric equipment cover must be held in place when it is opened. Do not allow the electric equipment cover
to fall against its retainer.

8.5.3 Replacing the control fuse link

The control fuse link is held in a fuse terminal on the control transformer.
The required amperage of the fuse link can be seen on the transformer data plate. 211 191 44/100620

96
 8.5.4 Removing the chain collector box

2
1

3 3

4
3 3

3
5 6

43227644.eps
Fig. 63

– Unscrew and remove service cover (1).

– Place bag (2) with the control cable on top of the chain hoist.
– Disconnect spring (3) and place it in the recess in the chain collector box.
– Remove retaining spring (4) from pin (5) and remove the pin. While doing so, hold the chain collector.
– Place chain collector box (6) on the ground.
211 191 44/100620

97
 8.5.5 Operating limit switches

8.5.5.1 DC-ProDC arrangement

43609044_xml.eps

Fig. 64

Item DC 1 - 5 DC 10
1 Switching element
2 Rubber cap
3 8,4x18x4 rubber washer 12,5x18,4 rubber washer
4 ━ 12x12 spacer sleeve
5 Actuating plate
6 6,4x18x1,6 washer 8,4x24x2 washer
7 M6x25 hexagon socket bolt; 9,5 Nm M8x35 hexagon socket bolt; 10,5 Nm
8 M6 nut
9 Control cable retainer ━
10 M8x30 hexagon socket bolt; 10,5 Nm
211 191 44/100620

Tab. 53

98
 8.5.5.2 DC-ProCC arrangement

43609144_xml.eps

Fig. 65 Example: limit switch fitting on a DC-ProCC 10

Item Designation Item Designation Item Designation

1 Chain guide intermediate plate 4 Hexagon socket bolt 5 Oval head screw
2 Upper chain entry plate  "DC chain hoist tightening torques", 6 Limit switch bracket
Page 32
3 Lower chain entry plate 7 Limit-switch cut-off
Tab. 54
211 191 44/100620

99
 8.5.5.3 Checking operating limit switches

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

If an operating limit switch is defective, the hoist motor is switched off when the 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.

A B C Checking the operating limit switch for lifting: Raise the hook as‐
sembly or bottom block until it is approximately 10 cm below the highest
hook position. Then raise it to the highest hook position at creep lifting
speed until the chain hoist automatically switches off.
● 1/1 reeving:
It must only be possible to compress the buffer or cut-off springs on
the hook assembly by a small amount after the unit has switched off.
● 2/1 reeving:
It must only be possible to compress the upper part of a bottom
block with internal cut-off springs onto the lower part by a small
amount so that approx. 20 mm of the black part of the bottom block
remains visible.
It must also only be possible to compress the springs on a bottom
42768545.eps block with external cut-off springs by a small amount after the unit
has switched off.
Fig. 66 Buffer with limit switch not actuated
(A), buffer with limit switch actuated (B), de‐
fective buffer with limit switch actuated (C).

Damage to the machine caused by frequently approaching the limit position

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

Checking the operating limit switch for lowering

The "Operating limit switch for lowering" must be checked at least once per year. Proceed as follows:
● Remove chain collector box  "Removing the chain collector box", Page 97
● Check as described above for the "Operating limit switch for lifting".
Optional geared limit switch
If an optional geared limit switch is fitted, the hoist unit must be switched off before the bottom block or hook as‐
sembly come into contact with the chain hoist guide plate. To check this function, the highest hook position must
be approached at high lifting speed (without a load). When the hoist unit has been switched off, there must be a
minimum distance of at least 20 mm between the bottom block or hook assembly and the chain hoist guide plate.

8.5.5.4 Checking the operating limit switch actuator on DC-ProDC

The operating limit switch actuator must be checked for any external damage, e.g. a bent actuator plate.
211 191 44/100620

100
 8.5.6 Rotary encoder

Item Designation
1 Rotary encoder
2 Toothed belt
3 M4x8 hexagon socket bolt
4 Mounting plate
A Bore hole to attach the spring scale
Tab. 55

The 3 M4x8 hexagon socket bolts (3) must not be firmly tightened when
toothed belt (2) is tensioned.
● Attach a spring scale to bore hole (A).
● While pulling the spring scale in the direction of the arrow with a
force of 10 N, re-attach mounting plate (4) with the 3 M4x8 hexagon
socket bolts (3) with a tightening torque of 2,5 Nm.
43642344_xml.eps
Fig. 67 Tensioning the toothed belt

8.5.7 Chain drive

8.5.7.1 Checking the chain sprocket

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

43448844_XML.eps
Fig. 68 Chain sprocket wear

8.5.7.2 Checking the chain guide

The chain drive can move easily on the drive shaft, i.e. lateral play of
approx. ±2 mm is normal. A defective chain guide must be replaced im‐
mediately:
● Open the service cover.
● Check the chain guide for any damage, e.g. ruptured guide section
halves or loose bolts.

42774644_xml.eps

Fig. 69 Example of a defective chain guide

211 191 44/100620

101
 8.5.7.3 Checking the guide plate/chain entry plate

Maximum guide plate dimensions [mm] a b c d

DC 1/2 16,0 5,5 16,8 6,8
DC 5 19,4 6,8 21,0 8,9
DC 10 26,7 9,4 28,8 12,0
a
DC 15 31,1 11,5 33,4 15,3
b
A) Tab. 56

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

d c
mensions or if cracks can be seen on the guide plate, it must be re‐
placed.
Multiple fitting and removal of the guide plate retaining bolts may dam‐
age the thread in the aluminium housing in such a way that a tight fit of
the bolts can no longer be ensured. A "Guide plate accessories" set is
available to do this (part no. 717 830 45), see also "DC 1 - 15 guide
plate accessories" document  Tab. 3, Page 7.
B)

42774745_xml.eps

Fig. 70 Load hook side (A), chain collector box

side (B)

8.5.7.4 Check hoist chain

Checking wear or deformation of the original Demag chain

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

For single-shift operation, operation according to FEM classification and for chain hoist operating conditions ac‐
cording to  "Operating conditions", Page 26, the chain should be checked once a year (see inspection and
maintenance schedule).
If routine maintenance reveals that the maintenance intervals are too long, they should be adapted to the specific
operating conditions.

Visual inspection of the chain

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

If the chain displays deformation, damage, cracks, pitting from corro‐
sion, reduction in the link thickness or increase in pitch dimension due
to wear or elongation as a result of plastic deformation, the chain must
be replaced immediately.
211 191 44/100620

43410044_XML.eps
Fig. 71 Chain wear

102
 Measuring wear or deformation of the original Demag chain
Two methods can be used to measure wear or deformation of the original Demag chain:
● Measuring with a calliper gauge:
- wear of a single chain link  Fig. 72, Page 103;
- over 11 chain links  Fig. 73, Page 103.
● Measuring with a chain gauge:
- over 11 chain links  Fig. 74, Page 104.

Measuring wear of a single chain link with a calliper gauge

42726244_xml.eps
Fig. 72

The chain link contact areas must be visually checked for traces of wear. If the chain hangs at angle when no load
is attached to it, for example, this usually indicates wear of an individual chain link.
Measure the diameter of the chain link material in the chain link contact area using a calliper gauge, if required.
For minimum link diameter values, see  "Tab. 57", Page 103.

Measuring with a calliper gauge over 11 chain links

A partial load must be suspended from the load hook when the chain is
measured over 11 chain links.
Measurements over 11 chain links can be taken in steps of 2 x 3 and 1
x 5 chain links.
The sum total of the three readings taken, i.e. a1 + a2 + a3 must not ex‐
ceed the specified limit a. Otherwise the chain must be replaced.
Demag is stamped on every 12th link of genuine Demag chains.
Do you find that, after fitting a new chain, it does not run smoothly over
the chain drive mechanism? If so, please contact our after-sales service
centre.
We strongly recommend that you use genuine Demag chains. This will
ensure that the safety and service life of the chain hoist are guaranteed.
40460845_XML.eps

Fig. 73

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

Chain designation d x t [mm] 4,2 x 12,2 5,3 x 15,2 7,4 x 21,2 8,7 x 24,2 10,5 x 28,2
Limit dimensions according to DIN 685 part 5
Measurement over the outside of 11 chain links, maximum dimension a = a 1 + a 2 +
[mm] 144,7 180,3 253 289 337,4
a3
Overall length of 1 chain link on inside, max. dimension t [mm] 12,8 15,9 22,4 25,5 29,8
Measurement of the chain link diameter, minimum dimension dm = 0,9 x d [mm] 3,8 4,8 6,7 7,8 9,45
Tab. 57
211 191 44/100620

The limit dimensions apply to all hoist chains listed in  "Available hoist chains", Page 105.

103
 Measuring with a chain gauge over 11 chain links

Fig. 74

It does not yet need to be discarded. The chain does not yet need to be replaced.
A DC/DK/PK new chain 2 The chain needs to be replaced if the measuring pin can no longer be inserted into
the 11th chain link.
B PK old chain 3 Measuring pin
1 Chain gauge, part no. 836 025 44 4 11th chain link; the chain is ready to be discarded. The chain must be replaced.
Tab. 58

A partial load must be suspended from the load hook when the chain is measured over 11 chain links.
211 191 44/100620

104
 8.5.7.5 Chain set scope of supply

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

The chain must be replaced when the permissible chain wear limit is reached (for determining the wear limit of the
chain, see  "Check hoist chain", Page 102). A chain set is always supplied when a new standard RDC/TDK
chain is ordered. The chain set includes the following parts:
● Chain,
● Chain sprocket,
● Chain guide with plate and cap,
● Chain guide plate,
● Buffers for upper and lower hook positions,
● Tube of Demag chain grease,
● Retaining ring.
The chain guide is pre-assembled, the chain is already fitted in the chain guide.

8.5.7.6 Available hoist chains

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

CAUTION
Pay attention to reduced load capacities.
For non-standard operating conditions, the special chains listed below are available for special ambient condi‐
tions.
211 191 44/100620

105
 Chain hoist Max. load capacity for reeving Dimension Stamp, Weight per Production Minimum Minimum
size Chain grade metre test force breaking elongation
1/1 2/1 force at rupture
[kg] [kg] [mm] [kg] [kN] [kN] [%]
Demag RDC/TDK standard chain
DC 1 - 2 250 - 4,2 x 12,2 0,38 13,8 22
DC 5 500 - 5,3 x 15,2 0,62 22 35
DAT
DC 10 1250 2500 7,4 x 21,2 1,20 43 70 10
RDC/TDK
DC 15 - 16 1600 3200 8,7 x 24,2 1,67 59 95
DC 25 2500 5000 10,5 x 28,2 2,49 87 138
High-strength ageing-resistant material with a high degree of surface hardening, galvanised with additional surface treatment, blue-chromated,
Properties
colour: DC 1 - 10 silver, DC 15 - 25 yellow
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication GP00H-30REN.SO-GFB grease
Demag Corrud special chain
DC 1 - 2 250 - 4,2 x 12,2 0,38 13,8 22
Application, e.g.
Galvanizing DC 5 500 - 5,3 x 15,2 0,62 22 35
DAT
plants, electro‐ DC 10 1250 2500 7,4 x 21,2 1,20 43 70 10
RDC/TDK
plating facilities, DC 15 - 16 1600 3200 8,7 x 24,2 1,67 59 95
pickling plants
DC 25 2500 5000 10,5 x 28,2 2,49 87 138
Properties Ageing-resistant, corrosion-free, "Corrud DS" micro-layer corrosion protection, black-coated, colour: black, Stabylan 2001
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication Acid-resistant chain grease, e.g. Ceplattyn BL white paste (part no. 665 023 44)
Demag HS7 special chain
DC 1 - 2 160 - 4,2 x 12,2 0,38 12,5 19,3

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

foundry, dust, DC 10 800 1600 7,4 x 21,2 RSX/DS 1,20 38,7 60 5
emery, blasting DC 15 - 16 - - - - - -
DC 25 1600 3200 10,5 x 28,2 2,49 78 121
Properties Ageing-resistant, colour: silver, with deeper surface hardening
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication Dry or with dry lubricant, e.g. Ceplattyn 300 paste (part no. 665 022 44)
Demag RS6 special chain
DC 1 - 2 125 27) - 160 28) - 4,2 x 12,2 0,38 10 16
DC 5 200 27) - 250 28) - 5,3 x 15,2 0,62 16 25
Application, e.g.
foodstuffs sec‐ DC 10 400 27) - 500 28) 800 29) - 1000 30) 7,4 x 21,2 RSA/S 1,20 32 50 15
tor
DC 15 - 16 - - - - - -
DC 25 630 27) - 800 28) 1250 29) - 1600 30) 10,5 x 28,2 2,23 50 80
Properties Non-rusting chain, not hardened, bright
Material Stainless steel AISI 316 (V4A) 1,4401
Lubrication Food-safe lubricant, e.g. 4 UH1-1500 N oil (part no. 664 028 44)
Tab. 59

Use of HS7 special chain in foundries, fettling shops or other environments with high dust levels:
● We recommend that the chain be lubricated with a dry lubricant, e.g. Cettaplyn 300 paste (part no.
665 022 44).
● The chain can also be used dry. Without any lubrication, however, greatly increased wear and louder operat‐
ing noise in the chain drive must be expected.
● The chain must not be lubricated with normal grease in environments with high dust levels, as the grease
will form clumps and any chain wear will not be visible.
211 191 44/100620

27) For max. 25 - 50 cycles per day

28) For max. 10 cycles per day
29) For max. 12 - 25 cycles per day

106 30) For max. 5 cycles per day

 8.5.7.7 Replacing the chain set

1) 2)

3) 4)

43227444.eps

Fig. 75

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

Before starting any maintenance work, switch the hoist off and secure it against reconnection to the power supply.
To replace the chain set, proceed as follows:
211 191 44/100620

1. Open and remove service cover (1).

107
 2. Place bag (2) with the control cable on the chain hoist; pull out mains cable union (3) with fitted mains cable
(4) and place to one side; if a travel drive is fitted, remove the connecting cable from the strain relief
arrangement;
3. Loosen cap (5) with a screwdriver (lever off);
4. Remove chain collector box (6) and set it down ( "Removing the chain collector box", Page 97);

1) 2)

3)

43227544.eps

Fig. 76

1. Remove guide plate (7);

211 191 44/100620

108
 2. Remove retaining ring (8) using ring pliers; either use straight or offset pliers (access through the opening in
the gearbox housing on the side of the motor or from the service enclosure);
DC-Pro 1 to 5: in the area of the power supply insert;
DC-Pro 10: Fold cover (9) of the opening in the gearbox housing to the side.
3. Remove chain guide (10) with the chain sprocket from the output shaft; to do this, slide the complete sub-
assembly in the direction of the motor until the chain sprocket is free; the worn chain set can then be
removed from the service enclosure.
Proceed in reverse order to install the new chain set.
Pay attention to the following points:

Chain hoist with geared limit switch

42792644_xml.eps

Fig. 77

A) Chain guide for DC 10 without geared limit switch B) Chain guide for DC 10 with geared limit switch
Tab. 60

The chain guide has a larger opening on chain hoists that are equipped with a geared limit switch.

See also  "Chain drive", Page 138.

Output shaft spacer rings

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

Item Designation
1 Cap
2 Retaining ring
3 Spacer ring DC-Pro 15 1 off
4 Chain guide
DC-Pro 1/2 3 off
DC-Pro 5 1 off
5 Spacer ring
DC-Pro 10 2 off
DC-Pro 15 2 off
Tab. 61

Apply Molykote or a similar lubricant to the splines of the

42776945_xml.eps
output shaft before you install the chain sprocket.
Fig. 78
211 191 44/100620

109
 Fitting the retaining ring

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

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

41058845_XML.eps

Fig. 79

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

41058846_XML.eps
Fig. 80

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

● Fit the chain anchorage before bolting the guide plates into position for DC-Pro 10 units with 2/1 reeving. Bolt
chain anchorage halves (1) together (fig. A).
● Insert the bolted chain anchorage into the opening of the gearbox housing (fig. B).
● Fit pins (2) (the pins are retained by the fitted guide plates).
211 191 44/100620

110
 Fitting the chain anchorage for 2/1 reeving on DC 15

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

Item Designation
1 Chain anchorage pin
2 Hexagon socket bolt for chain anchorage halves
3 Chain anchorage half
4 Guide plate
5 Hexagon socket bolt for guide plate
Tab. 62
42792544_xml.eps
Fig. 81

Fitting the limit stop

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

41058847_XML.eps

Fig. 82

Further procedure after replacing the chain set

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

– Fit the hook assembly/bottom block  "Load hook", Page 117

– Lubricate the chain  "Available hoist chains", Page 105,  "Lubricating the hoist chain", Page 115
– Adjust the bottom hook position, if necessary  "Adjusting the lower hook position", Page 78.
– Fit chain collector box  "Removing the chain collector box", Page 97.
– If the chain hoist is fitted with an optional geared limit switch, it must be re-adjusted each time the chain is
replaced, see "DC geared limit switch" document  Tab. 3, Page 7.
211 191 44/100620

111
 Tightening torques [Nm] DC-Pro 1/2 DC-Pro 5 DC-Pro 10 DC-Pro 15
Reeving 1/1 1/1 2/1 1/1 2/1
Service cover 5,5 7,5 25
Limit stop 4,0 4,3
Chain anchorage halves - - 10,5 - 25
Guide plate 5,5 25
Tab. 63

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

DC 1–2 chain guide until 03/2019

Item no. Designation

1 Chain guide
2 Chain entry plate
Tab. 64

43718744_xml.eps

Fig. 83

211 191 44/100620

112
 DC 1–2 chain guide from 04/2019

Item Designation
no.
1 Chain guide
2 Upper chain entry plate
3 Lower chain entry plate
Tab. 65
1

43718844_xml.eps

Fig. 84

DC 5 chain guide until 03/2019

Item Designation
no.
1 Chain guide
2 Intermediate plate
3 Chain entry plate
Tab. 66

43718944_xml.eps

Fig. 85
211 191 44/100620

113
 DC 5 chain guide from 04/2019

Item Designation
no.
1 Chain guide
2 Upper chain entry plate
3 Lower chain entry plate
1 Tab. 67

43719044_xml.eps

Fig. 86

DC 10 chain guide until 03/2019

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

43719144_xml.eps

Fig. 87
211 191 44/100620

114
 DC 10 chain guide from 04/2019

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

43719244_xml.eps

Fig. 88

8.5.7.9 Lubricating the hoist chain

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

The chain link contact areas must be re-lubricated appropriately – after being cleaned – at intervals depending on
the service and load conditions. A dry film lubricant (lubricating varnish) should be used in environments where
abrasives occur (emery, sand, etc.). For non-standard lubrication, see  "Available hoist chains", Page 105.

CAUTION
Premature wear of the chain.
Danger of falling load due to broken chain.
The chain must be lubricated along its entire length.
Even chain links which are covered, e.g. in the chain anchorage, hook assembly, limit stop or crab frame, must
be fully lubricated.
211 191 44/100620

115
 DC-Pro 1-10 chain hoist

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

42650744_XML.eps
Fig. 89

DC-Pro 15 chain hoist

Apply the lubricant with a brush.

41059444_xml.eps
Fig. 90
211 191 44/100620

116
 8.5.8 Load hook
8.5.8.1 Checking the load hook

A) B)

L2
a2
L4
a2
L4

b1
b1

h2
h2

a1 h1 a1 h1
43229246_xml.eps

Fig. 91

Chain hoist DC 1 - 10 (as of DC-Pro/Com DC-Com (old)

2017) Item B Item B
Item A
Load capacity [kg] 315 630 1250 125 250 500 1250 2500 1600 3200 125 250 500 1250 2000
Size 1-2 5 10 1 2 5 10 15 1 2 5 10
Reeving 1/1 1/1 2/1 1/1 2/1 1/1 2/1
Load hook Type V-I V-II V-III V2 V3 V4 V5 V5 V6 T010 T020 T04 V5
a1 [mm] 30 36 43 30 36 43 50 50 56 28 34 40 50
a2Nom 31) [mm] 25,6 29,6 36 25,3 30,5 36 43 43 49 22,8 25,4 33,7 43
a2max [mm] 23,5 26,7 39,6 27,8 33,5 39,6 47,3 47,3 53,9 25,08 27,94 37,07 47,3
b1 [mm] 13 19 22 13 19 22 29 29 30 16 21 27 29
Dimensions h1 [mm] 22 27,5 33,5 22 27,5 33,5 44 44 55 20 26,1 34 44
h2Nom 32) [mm] 18 21,5 26 18 21,5 27 36 36 38 16,9 21,8 27,7 36
h2min [mm] 17,1 20,4 24,7 17,1 20,4 25,7 34,2 34,2 36,1 16,055 20,71 26,315 34,2
L2 [mm] 14 14 20 22 30 36 45 45 56 20 24 28 45
L4 [mm] 84 95 115 86 109 110 159 159 187 82 94 116 159
Max. test force [kN] 8 16 25 8 16 25 50 50 65 6 13 25 50
Tab. 70

8.5.8.2 Hook safety catch

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

8.5.8.3 Checking the return sprocket

The return sprocket must be checked every month to ensure that it turns easily. To do this, any load bars attach‐
ed to the bottom block have to be removed.
Check to ensure that the bottom block moves easily during lifting and lowering motions. Abrupt movements of the
bottom block indicate wear.
211 191 44/100620

31) Permissible difference +10%

32) Permissible difference -5% 117
 8.5.8.4 DC 1 - 10 hook with fittings (as of 2017)

2
3
4

8 9

5
6
10 9 7

43702944_xml.eps

Fig. 92

Item Designation Item Designation Item Designation

1 Hoist chain 5 Chain link anchorage section 8 Hook assembly half
2 Hook assembly sleeve 6 O-ring 9 Hook assembly bolted connection
3 Ball thrust bearing 7 Load hook 10 Capacity plate
4 Supporting washer
Tab. 71

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

Pay attention to the non-standard lubrication instructions for special ambient conditions or special chains, e.g.
stainless steel chain or foodstuffs sector. See also  "Available hoist chains", Page 105.

– Thread hook assembly sleeve (2), ball thrust bearing (3) and supporting washer (4) onto hoist chain (1) in
the correct order and orientation.
– Grease the end of the chain with the enclosed grease.
– Place the last chain link of hoist chain (1) into chain link anchorage sections (5) and position them with their
tabs in the recesses of supporting washer (4).
211 191 44/100620

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

118
 – Now place hoist chain (1) with hook assembly sleeve (2), ball thrust bearing (3), supporting washer (4) and
chain link anchorage sections (5) into hook assembly half (8).
– Position load hook (7) with O-ring (6) below them.
– Fit hook assembly bolted connection (9) and tighten it to the correct tightening torque.

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

Hook assembly 11,5 25,0
Tab. 72
211 191 44/100620

119
 8.5.8.5 Replacing the hook with fittings for 1/1 reeving

1. 2.

1 2 1

3. 4.

4
43227344.eps

Fig. 93

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

1. Remove both bolts from the new hook.

Lever buffer cap (1) off with a screwdriver.
2. Remove the upper half of the hook assembly.
Slide buffer cap (1) onto the chain.
Remove chain link anchorage sections (2) from the load hook and place them around the last chain link.
Grease the last chain link in the chain link anchorage section.
211 191 44/100620

3. Insert the chain and chain link anchorage sections (2) in the new hook and fit upper half of hook assem‐
bly (3). Ensure that locating pins (4) are correctly positioned.
4. Tighten the housing bolts according to the tightening torque table.
120
 Tightening torques [Nm] DC-Pro 1 DC-Pro 2 DC-Pro 5 DC-Pro 10 DC-Pro 15
Hook assembly 6,8 11,5 25,0 27,5
Tab. 73

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

Fig. 94

The tightening torque is 55,0 Nm for DC 10 and DC 15.

8.5.9 Buffer

8.5.9.1 Check cut-off buffer/cut-off spring

1 2 3

42775146_XML.eps
Fig. 95 Examples of wear

1. Buffer wear:
Visually check the buffers in the course of the annual inspection. Check for damage, cracks and tears.
2. Missing buffer plate:
Ensure that the component parts are installed in the right order when new buffers are installed (see also
 "Buffer/cut-off spring arrangement", Page 122). A missing buffer plate, for example, will result in prema‐
ture wear of buffers.
3. Wear of external cut-off springs:
211 191 44/100620

Visually check the external cut-off springs in the course of the annual inspection. Check the sleeves of the
springs for cracks and damage. The individual windings of the spring must not cross over each other.

121
 8.5.9.2 Buffer/cut-off spring arrangement

42770450_xml.eps

Fig. 96 Cut-off buffer (1), buffer plate (2), damping plate (3), cut-off spring (4)

211 191 44/100620

122
 Product Size Reeving Lifting speed 33) Switches fitted Plate dia. d1/ Height Load side Chain collector box
range 34) dia. d2 h side
DC [m/min] [mm] [mm] Fig. Ident. no. Fig. Ident. no.
0BES G 717 534 45
1+2 V8 1BES 45/45 79,5 E 717 250 45
GGS
DC-ProDC O 717 534 45
0BES G 717 534 45
2 V16 1BES 45/45 79,5 E 717 250 45
GGS
1+2 V8 45 A 718 255 45 M
DC-ProCC 1BES 45/42 717 253 45
2 V16 80 B 718 256 45 N
0BES G 717 534 45 P
DC-ProFC 1+2 VS16 717 534 45
GGS O
0BES G 718 534 45
V8/V16 1BES 45/45 79,5 E 718 250 45 O 718 534 45
DC-ProDC GGS
0BES/1BES 45/42 130 C 718 249 45 M 718 253 45
V24
GGS O 718 534 45
DC 5 1/1
V8 45 A 718 255 45 M
DC-ProCC V16 1BES 45/42 80 B 718 256 45 N 718 253 45
V24 130 C 718 249 45 M
0BES G 718 534 45 P
DC-ProFC VS8 718 534 45
GGS O
0BES G 715 534 45
V6/V8/V12/V24
GGS
DC-ProDC O 715 534 45
V6/V8/V12 E
1BES 52/55 81,2 715 074 45
V24 2x E
V6 43 D 715 260 45
M
V8 55 A 715 254 45 715 253 45
DC-ProCC 1BES 52/55
V16 74 B 715 255 45 N
V24 125 C 715 249 45 O 715 534 45
DC 10
0BES G 715 534 45 P
DC-ProFC VS4/VS6/VS12
GGS
715 534 45
GGS 55 H 715 254 45 O
DC-ProDC V4/V6 52/55
0BES/1BES 81,2 J 715 074 45
V4 M
DC-ProCC 2/1 1BES 52/55 43 K 715 260 45 715 253 45
V6 N
0BES 52/55 81,2 J 715 074 45 P
DC-ProFC VS4/VS6 715 534 45
GGS O
GGS
1/1 V8
0BES/1BES 62/55 55 2x A 721 753 45
DC-ProDC 2x Q 721 753 45
GGS
2/1 V4
0BES/1BES 62/55 55 L 721 753 45
1/1 V8 A
DC-ProCC DC 15 1BES 62/55 55 721 753 45
2/1 V4 L
0BES 62/55 55 A 721 753 45
1/1 VS8 Q 721 753 45
GGS
DC-ProFC
0BES 62/55 55 L 721 753 45
2/1 VS4
GGS
Tab. 74
211 191 44/100620

33) Lifting speed: V = 2-stage speed at 50 Hz, VS = variable speed at vsnom.

34) 0BES = no operating limit switch, 1BES = operating limit switch fitted, GGS = geared limit switch fitted. 123
 8.5.10 Brake
8.5.10.1 Check operation of the brake
– Raise the load hook and lower it again. The load hook must only run on a short distance when the button is
released.
The load hook must stay at the same height (i.e. it must not lower without a button being actuated) when a
load is attached to it.
Significant run-on or lowering when in the idle position indicates that the brake is worn.
– Run the travelling hoist to the right/left. Braking of the travelling hoist must be clearly noticeable when the
button is released.
It must not be possible to move the travelling hoist by pulling the chains to one side.
Significant run-on or the possibility of moving it when in the idle position indicates that the brake is worn.
– Brake linings must be inspected once a year.

WARNING
Only operate the machine if it is in safe operating condition.
If inspection reveals that a brake slips, the brake must be adjusted or repaired. Do not operate the machine if the
brake slips.

8.5.10.2 Brake assignment

Load capacity Chain hoist Reeving Motor size Brake Max. brake displacement
[kg] Type Size [mm]
80 - 250 1-2 ZNK 71 B 8/2
BK03
80 - 500 5 ZNK 80 B 8/2
1/1
200 - 1000 ZNK 100 A 8/2
DC-ProCC 0,60
315 - 1250 10
BK07
1250 - 2500 2/1 ZNK 100 B 8/2
1000 - 3200 15 1/1, 2/1

80 - 250 1-2 ZNK 71 B 8/2 BK03 0,60

80 - 500 5 ZNK 80 B 8/2 BC07/5
1/1
200 - 1000 ZNK 100 A 8/2 BC07/8
DC-ProDC
315 - 1250 10 0,65
1250 - 2500 2/1 ZNK 100 B 8/2 BC020
1000 - 3200 15 1/1, 2/1

80 - 250 1-2 ZNK 71 B 4

BK03
80 - 500 5 1/1 ZNK 80 B 4
200 - 1250 DC-ProFC 0,60
10
1250 - 2500 2/1 ZNK 100 B 4 BK07
1000 - 3200 15 1/1, 2/1
Tab. 75

8.5.10.3 Check brake wear

Check brake wear depending on the year of manufacture of your chain hoist:
● The brake must be replaced immediately as soon as the maximum brake displacement is reached (see
 Tab. 75, Page 124).
● For brake displacement up to 0,5 mm, the brake can still be used until the next maintenance is due.

Tightening torques [Nm]

211 191 44/100620

Brake 5,5
Electric equipment cover 9,5
Tab. 76

124
 8.5.10.4 BK03 - BK07 brakes (not adjustable)

1 2

42777044_xml.eps
Fig. 97

The brakes are equipped with a plug inside the brake housing to enable brake wear to be measured without the
need to remove the brake. Brake wear is measured by the air gap.
Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching on
again.
● Open the electric equipment cover.
● Unscrew brake plug screw (1) from the brake.
● Check brake wear with feeler gauge (2) (see  Tab. 75, Page 124).

Assembly and maintenance

42791644_xml.eps

Fig. 98

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

In the course of the annual inspection, V sealing ring (1) of the brake must be re-greased with anti-friction
bearing grease without any solid lubricant.
211 191 44/100620

125
 8.5.10.5 BC07/5, BC07/8, BC020 brakes (adjustable)

a
43406544_xml.eps

Fig. 99

Item Designation Item Designation Item Designation Item Designation

A) BC07 front side 3 Armature plate 8 Covering tape 13 M6x12 socket head bolt
B) BC07 rear side 4 Stop plate 9 Locknut α1 Adjusting angle
C) BC020 front side 5 Friction disc 10 Socket head bolt s1 Air gap
1 Feeler gauge 6 Brake disc 11 Collared pin Bd Thickness of brake disc
2 Covering tape retainer 7 Magnet assembly 12 M6 hexagon nut t Wear indicator on collared
pin (BC020)
Tab. 77

Brake BC07/5 BC07/8 BC020

s1 min. 0,30 0,30 0,30
Brake air gap [mm]
s1 max. 0,65 0,65 0,65
Adjusting angle α1 120° 120° 120°
min. 4,7 5,4 7,5
Thickness of brake disc [mm]
new 6,2 8,4 10
Tab. 78
211 191 44/100620

Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching on
again.
● Open the electric equipment cover.
126
 ● Remove covering tape (8), clean, wash out.
● Blow out brake with compressed air.
● Check brake air gap and adjust, as required:
- Check air gap s1 using a feeler gauge (1) at three points around the circumference. Make sure that stop
plate (4) is not damaged.
- If the inspection shows that the brake air gap is less than 0,4 mm, the brake can still be used. Otherwise, it
must be adjusted to ensure sufficient volume for wear until the next maintenance is due.
- To adjust the brake air gap, uniformly and carefully tighten the brake with locknuts (9) until the air gap is
zero.
- Then loosen the three locknuts (9) by adjusting angle α1. If, after checking again, the brake air gap is still
not within the specified range, repeat the procedure.
- If it is not possible to tighten the brake until the air gap is zero after adjusting the brake air gap, remove
brake disc (6) and measure its remaining thickness, see  "Checking the thickness of the brake disc for
BC07/5, BC07/8, BC020", Page 127.

8.5.10.6 Checking the thickness of the brake disc for BC07/5, BC07/8, BC020

BC07 brake
1. Remove the three locknuts (9).
2. Pull the complete brake off the shaft of the chain hoist.
3. Completely unscrew the two M4 socket head bolts (10) on the rear, the tension of the brake springs is then
released.
4. Remove friction disc (5), covering tape retainer (2) and brake disc (6).
5. Measure the thickness of the brake disc and replace brake disc (6), as required.
6. Reassemble the brake in reverse order. Bolt the brake together on the rear with two socket head bolts (10)
until a brake air gap of 0,5+0,3 mm is created.
7. For initial assembly, socket head bolts (10) are provided with a micro-encapsulated layer to secure the
screws. When they are fitted again, a small amount of a liquid locking agent must be carefully applied in the
threaded bore hole.
8. Uniformly and carefully tighten the brake with locknuts (9) until the air gap is zero, then loosen the three lock‐
nuts (9) by adjusting angle α1.

BC020 brake
Wear of brake disc (6) on this brake can also be estimated on the basis of wear indicator "t" on each of the col‐
lared pins. Brake disc (6) must be replaced when wear indicator "t" reaches armature plate (3).
1. Remove the three locknuts (9), this releases the brake spring tension.
2. Remove magnet assembly (7), stop plate (4), armature plate (3) and brake disc (6).
3. Measure the thickness of the brake disc and replace brake disc (6), as required.
4. Re-assemble the brake in reverse order.
5. Uniformly and carefully tighten the brake with locknuts (9) until the air gap is zero, then loosen the three lock‐
nuts (9) by adjusting angle "α1".
If the BC020 brake has to be completely replaced, remove the three M6x12 socket head bolts (13) which con‐
nect the friction disc to the intermediate flange. In this case, the three M6 hexagon nuts (12) on the back of the
brake must not be loosened.
211 191 44/100620

127
 8.5.11 Slipping clutch

8.5.11.1 Checking the slipping clutch

The slipping clutch provides the function of an emergency limit stop de‐
vice and overload protection for the chain hoist.
The slipping clutch is initially adjusted in the factory. Under normal op‐
erating conditions, the slipping clutch does not need to be re-adjusted.
The slipping clutch must be checked as part of the annual inspection.
The slipping clutch may only be adjusted by authorised specialist per‐
sonnel. An increase of the tripping torque which exceeds the default
setting is not permitted.
Check operation of the slipping clutch as follows:
● The chain collector must be disconnected in order to remove the limit
stop,  "Removing the chain collector box", Page 97. Remove the
limit stop  Fig. 82, Page 111 from the section of chain which is not
under load and fit it above the hook assembly. Run the limit stop
against the guide plate at creep lifting speed. The partly optional op‐
erating limit switches must not be actuated while this is being done.
42657644_XML.eps

Fig. 100

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.
If the slipping clutch is working correctly, the following will be observed:
● the hoist motor fan is still turning while there is no lifting motion.

8.5.11.2 Adjusting the slipping clutch

The slipping clutch is adjusted to the load capacity of the chain hoist
during the final inspection in the factory. An increase of the tripping tor‐
que which exceeds the default setting is not permitted, see also
 "Suspending the chain hoist", Page 40.
For DC chain hoists that have a load capacity ≥ 1000 kg, the setting
1 meets the requirements of EN 14492-2 for slipping clutches used as
overload protection. Overload protection must be provided for load ca‐
pacities ≥ 1000 kg.
If an acceptance check of the hoist or crane installation is carried out, a
load of 110% of the rated load capacity must be lifted (without adjust‐
ment of the slipping clutch) as part of the dynamic overload test. A load
> 160% must not be lifted, (EN 14492-2 "Direct acting rated capacity
limiters").
42657745_XML.eps
Fig. 101

If, owing to the operating conditions or due to malfunctions, adjustment of the slipping clutch needs to be
checked, 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" docu‐
ment  Tab. 3, Page 7.
211 191 44/100620

128
 8.5.12 Gearbox/oil change

Fig. 102

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

Oil quantities [l] 0,35 0,50 0,90 1,3
Gearbox cover [Nm] 5,5 -
2-piece gearbox housing [Nm] - 25
Tightening torques
Oil fill opening and breather M16 [Nm] - 15
Service cover [Nm] 5,5 7,5 25
Tab. 79

Dispose of waste oil in accordance with environmental protection requirements.

Oil lubrication
Under normal operating conditions, the lubricant must be changed at least every 10 years. Under exceptional
conditions, e.g. increased ambient temperatures, we recommend that oil changes be adapted to suit these oper‐
ating conditions.
Oil grades
Demag special oil with wear-minimising additives. Contact the manufacturer for ambient temperatures lower than
-20 °C or higher than +45 °C.

CAUTION
Safe operation cannot be ensured
Malfunctions of the slipping clutch may occur if oils are used that are not approved and safe operation can then
no longer be ensured.

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

DCS-Pro DC-ProCC range
DC-Com
DC-ProFC
Frequency [Hz] 50/60 50 60
 "Parts on the DC-Pro 1-10 gearbox", Page 134
1 1 -
Standard  "Parts on the DC-Pro 15 gearbox", Page 136
Application, e.g.
- - 2 10W-30 664 020 44
Foodstuffs sector 3 3 3 180 003 98
Tab. 80
211 191 44/100620

129
 General remarks on oil changes
Drain the old oil at operating temperature. Turn the gearbox so that the oil drains. The flushing oil should have a
viscosity of 46-68 mm2/s at rated temperature. The quantity of flushing oil used should be approximately twice that
specified for lubrication. Then flush the gears by switching the hoist on and allowing the hook to run several times
over the entire length of its lifting path. Then drain the flushing oil and refill the gearbox with new oil. Please refer
to the table above for the required oil quantities.
DC 1 - 10: Remove control unit with plug-and-socket connections (2, not for DC-ProDC/CC/FC) under electric
equipment cover (3). Now remove the bolts of gearbox cover (1).
DC 15: The oil can be changed by unscrewing vent valve (4).
The air vent screw vents when the overpressure reaches approx. 0,03 - 0,05 bar. Check with the manufacturer
before using the chain hoist in a different mounting position. The air vent valve might have to be installed in a
different position.

211 191 44/100620

130
 9 Malfunctions

9.1 Safety instructions in the event of malfunctions

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

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

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

Conduct when malfunctions occur

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

Conduct after a fault is eliminated

WARNING
Check for correct assembly
Before reconnecting the power supply, ensure that
– Malfunction and cause of malfunction have been eliminated.
– All safety devices have been fitted properly and are in perfect condition and working order.
– Nobody is present in the danger zone of the equipment.
211 191 44/100620

131
 10 Disassembly/disposal

10.1 General

WARNING

Before disassembly, follow the safety instructions in  "Maintenance/repair", Page 88 of these operat‐
ing instructions.

Refer to  "Assembly", Page 30 of these operating instructions for information on removing rail sections, trolleys
and current collector trolleys. Other parts are removed in reverse order to assembly.
Unless a return or disposal agreement has been concluded, separated components must be recycled after proper
removal:
● Scrap any remaining metallic material,
● Dispose of plastic elements for recycling,
● Separate and dispose of any other components by material type.
Electric scrap, electronic components, lubricants and other auxiliary materials are subject to special disposal
regulations and may only be disposed of by certified companies.

National disposal regulations must be considered regarding environmentally friendly disposal. Further information
can be obtained from corresponding local authorities.

211 191 44/100620

132
 11 Accessories

11.1 Assemblies

43433048_xml.eps

Fig. 103

Item Description Size Part no.

DC 1/2 717 808 45
Return sprocket assembly, consisting of: DC 5 718 808 45
1 1 return sprocket, 1 pin, 1 retaining ring, 1 supporting washer, 2 thrust wash‐
ers, 2 needle-roller assemblies DC 10 715 808 45
DC 15 721 845 45
2 M25x 1,5 insert for electric equipment cover 720 292 45
3 Counterweight kit See  "Counterweight", Page 42 717 632 45
DC 1/2 (incl. DC 5 electric equipment
750 075 45
Intermediate flange  "Intermediate flange", Page 34 cover)
4
(The counterweights must be ordered separately.) DC 5 751 075 45
DC 10/15 752 075 45
DC 5 718 272 45
5 Short suspension bracket
DC 10 715 272 45
See  "Installing a DSK pendant con‐
Installation set for single-axis DSK pendant controller(no support sleeve) 720 229 45
troller with a support sleeve", Page 36
Not shown See  "Installing a DST pendant con‐
Installation set for single-axis DST pendant controller 720 230 45
troller with 2TY", Page 38
Installation set for DC Di 2TY 2/3-axes 720 231 45
DC-ProDC 1 - 2 750 076 45
Limit cut-off kit  "DC-ProDC arrangement", Page 98 DC-ProDC 5 751 076 45
Not shown
(The intermediate flange must be ordered separately.) DC-ProDC 10 752 076 45
DC-ProDC 15 722 076 45
Limit cut-off kit  "DC-ProCC arrangement", Page 99
Not shown DC-ProCC 1 - 15 720 523 45
(The intermediate flange must be ordered separately.)
Tab. 81
211 191 44/100620

133
 12 Spare parts

12.1 Parts on the DC-Pro 1-10 gearbox

211 191 44/100620

42763849_xml.eps
134 Fig. 104
 Item Part no. Qty Designation
3 Gearbox set On request

4 71897433 1 DC 1- 5 suspension set

4 71597433 1 DC 10 suspension set

5 75263133 1 DC1/2 seal set

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

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

6 71594733 1 Adjusting nut/pulse wheel DC 10
6 75269733 1 Adjusting nut/pulse wheel DC-ProDC10 BC20

7 71887133 1 180 V brake set BK03; 380-415V 50Hz; 5,5 Nm

7 71887233 1 216 V brake set BK03; 440-480V 60Hz; 5,5 Nm
7 71887333 1 DCS 1-5 104 V brake set BK03; 220-240 V 50/60 Hz; 5,5 Nm
7 71887433 1 258 V brake set BK03; 500V 50Hz; 5,5 Nm
7 71888133 1 DC 5Di 180V brake set BC07/5; 380-415 V 50 Hz; 5,5 Nm
7 71888233 1 DC 5Di 198V brake set BC07/5; 440-480 V 60 Hz; 5,5 Nm
7 71888333 1 DC 5Di 104V brake set BC07/5; 220-240 V 50/60 Hz; 5,5 Nm
7 71888433 1 DC 5Di 258V brake set BC07/5; 500 V 50 Hz; 5,5 Nm
7 71587133 1 DC10/15 180/198 V brake set BK07; 380-415V 50Hz; 440-480V 60Hz
7 71587333 1 DC/DCS10/15 brake set BK07; 220-240 V 50/60 Hz
7 71587433 1 DC10/15 258 V brake set BK07; 500-525V 50Hz; 575V 60Hz
7 71588133 1 DC10Di 180V brake set BC07/8; 380-415 V 50 Hz; 5,5 Nm
7 71588233 1 DC10Di 198V brake set BC07/8; 440-480 V 60 Hz; 5,5 Nm
7 71588333 1 DC10Di 104V brake set BC07/8; 220-240 V 50/60 Hz; 5,5 Nm
7 71588433 1 DC10Di 258V brake set BC07/8; 500 V 50 Hz; 5,5 Nm
7 71587633 1 DC10Di 180V brake set BC020; 380-415V 50Hz; 5,5 Nm
7 71587733 1 DC10Di 198V brake set BC020; 440-480V 60Hz; 5,5 Nm
7 71587833 1 DC10Di 104V brake set BC020; 220-240 V 50/60 Hz; 5,5 Nm
7 71587933 1 DC10Di 258V brake set BC020; 500V 50Hz; 5,5 Nm

8 71885633 1 Insert/connector

63 71511345 1 DC 10 cover plate kit

Gear oil see also  "Gearbox/oil change", Page 129

91 75262733 1 DC1/2DC gear oil set 0,35 litre
91 75262833 1 DC5DC gear oil set 0,5 litre
91 75262933 1 DC10DC gear oil set 0,9 litre

96 75258033 1 DC 1 DC coupling set V8

96 75258133 1 DC 2 DC coupling set V6, V8, V16
96 75258233 1 DC 5 DC coupling set V8
96 75258333 1 DC 5 DC coupling set V16, V24
96 75258433 1 DC10 DC coupling set V4, V6, V12, B
96 75258533 1 DC10 DC coupling set V24, B
96 75258633 1 DC10 DC coupling set V6, V12, A
96 75258733 1 DC10 DC coupling set V24, A
Tab. 82
211 191 44/100620

135
 12.2 Parts on the DC-Pro 15 gearbox

7 6

89

90

91 87

5, 89, 91

5, 6, 92 90

88

5, 6 6, 92 89

5
93

92

88
211 191 44/100620

88 89 86 5, 93 5
43425046_xml.eps
136 Fig. 105
 Item Part no. Qty Designation
4 72127433 1 DC16/25 suspension bracket
5 75263433 1 DC 15 seal set
6 71594733 1 Adjusting nut/pulse wheel DC 15
7 71587633 1 DC10Di 180V brake set 380-415V 50Hz; 5,5 Nm
7 71587733 1 DC10Di 198V brake set 440-480V 60Hz; 5,5 Nm
7 71587833 1 DC10Di 104V brake set 220-240 V 50/60 Hz; 5,5 Nm
7 71587933 1 DC10Di 258V brake set 500V 50Hz; 5,5 Nm
86 72160333 1 DC15 T1 gearbox housing
87 72160733 1 DC15 T2 gearbox housing
88 72191833 1 DC15 bearing set
89 72192033 1 DC 15 small parts set
90 71885633 1 Insert/connector

Gear oil see also  "Gearbox/oil change", Page 129

91 75261733 1 DC15DC gear oil set 1,3 litres

92 71519533 1 DC15 coupling half G

93 72163833 1 DC15 coupling half M
Tab. 83

12.3 Brake

42573246_xml.eps

Fig. 106

Item Part no. Qty Designation

59 26096233 1 B003 wear set BC07/5
59 26097033 1 B007 wear set BC07/8
59 26097533 1 B020 wearing set BC020
Tab. 84
211 191 44/100620

137
 12.4 Chain drive

15

19
211 191 44/100620

42764352_xml.eps
138 Fig. 107
 Item Part no. Qty Designation
11 71795033 1 DC/DCM 1/2 H 5 chain set
11 71795133 1 DC 1/2 H 8 chain set
11 75266533 1 DC1/2 H9-H12 chain set
11 75266633 1 DC1/2 H13-H15 chain set
11 75266733 1 DC1/2 H16-H18 chain set
11 75266833 1 DC1/2 H19-H25 chain set
11 75266933 1 DC1/2 H26-H35 chain set
11 71895033 1 DC/DCM 5 H 5 chain set
11 71895133 1 DC 5 H 8 chain set
11 75267033 1 DC5 H9-H12 chain set
11 75267133 1 DC5 H13-H16 chain set
11 75267233 1 DC5 H17-H20 chain set
11 75267333 1 DC5 H21-H27 chain set
11 75267433 1 DC5 H28-H35 chain set
11 75395033 1 DC10 1/1 H 5 chain set
11 75395133 1 DC10 1/1 H 8 chain set
11 75263733 1 DC 10 5 m 1/1 chain set for GGS;  "Replacing the chain set", Page 107
11 75263833 1 DC 10 8 m 1/1 chain set for GGS;  "Replacing the chain set", Page 107
11 75267533 1 DC10 1/1 H9-H10 chain set
11 75267733 1 DC10 1/1 H11-15 chain set
11 75268633 1 DC10 1/1 H16-20 chain set
11 75267833 1 DC10 1/1 H21-25 chain set
11 75267933 1 DC10 1/1 H26-30 chain set
11 75264933 1 DC15 1/1 H 4 chain set
11 75265633 1 DC15 1/1 H 5 chain set
11 75266133 1 DC15 1/1 H 6 chain set
11 75265733 1 DC15 1/1 H 8 chain set
12 71596033 1 DC10 2/1 H 5 chain set
12 71596133 1 DC10 2/1 H 8 chain set
12 75263933 1 DC 10 5 m 2/1 chain set for GGS;  "Replacing the chain set", Page 107
12 75264033 1 DC 10 8 m 2/1 chain set for GGS;  "Replacing the chain set", Page 107
12 75268033 1 DC10 2/1 H9-10 chain set
12 75268333 1 DC10 2/1 H11-15 chain set
12 75268433 1 DC10 2/1 H16-20 chain set
12 75268533 1 DC10 2/1 H21-25 chain set
12 75265033 1 DC15 2/1 H 4 chain set
12 75265833 1 DC15 2/1 H 5 chain set
12 75266233 1 DC15 2/1 H 6 chain set
12 75265933 1 DC15 2/1 H 8 chain set
15 71538845 1 DC 10 anchorage/limit stop kit DC 10; 2/1 reeving
15 72238845 1 DC 15 anchorage/limit stop kit DC 15; 2/1 reeving
16 Buffer/cut-off spring  "Buffer/cut-off spring arrangement", Page 122
17 71798633 1 DC1/2 5 m chain collector box set
17 71798733 1 DC1/2 8 m chain collector box set
17 71898633 1 DC5 5 m chain collector box set
17 71898733 1 DC5 8 m chain collector box set
17 71598633 1 DC10 1/1 5 m chain collector box set
17 71598733 1 DC10 1/1 8 m chain collector box set DC 10; 2/1 reeving; H5
17 71535045 1 Flexible chain collector 20 m DC 10; 2/1 reeving; H8
17 72118945 1 Chain collector box S DC15
17 72119045 1 Chain collector box size 1 DC15/16/25
17 72119145 1 Chain collector box size 2 DC15/16/25
17 72135045 1 Flexible chain collector DC15/16/25
18 71719945 1 Chain collector suspension kit DC1/2
18 71819945 1 Chain collector suspension kit DC5
211 191 44/100620

18 71519945 1 Chain collector suspension kit DC10

18 72219945 1 Chain collector suspension kit DC15

139
 Item Part no. Qty Designation
75115646 Single chain by the metre DC1/2; 4,2 x 12,2 mm
19 83507844 1 Pilot section for 4 x 12 mm chain
75115746 Single chain by the metre DC5; 5,3 x 15,2 mm
19 83607844 1 Pilot section for 5 x 15 mm chain
75115846 1 Single chain by the metre, DC10; 7,4 x 21,2. Important:
When the chain is replaced on DC 10 units that have 2/1 reeving,
the chain anchorages and anchorage pins must also be replaced;
include chain anchorage set 715 279 33 with the order.
19 83707844 1 Pilot section for 7 x 21 mm chain
75115446 1 Single chain by the metre DC 15/16; 8,7 x 24,2 mm. Important:
When the chain is replaced on DC 15/16 units that have 2/1 reev‐
ing, the chain anchorages and anchorage pins must also be re‐
placed – include chain anchorage set 721 820 45 with the order.
19 83737844 1 Pilot section for 9 x 24 mm chain
75115546 Single chain by the metre DC 25; 10,5 x 28,2 mm. Important:
When the chain is replaced on DC 25 units that have 2/1 reeving,
the chain anchorages and anchorage pins must also be replaced;
include chain anchorage set 721 825 45 with the order.
19 83807844 1 Pilot section for 10 x 28 mm chain
71527933 1 Chain anchorage set DC10
72182045 1 Chain anchorage set DC15/16
72182545 1 Chain anchorage set DC25
Tab. 85

12.5 Chain guides

1 DC 1–2 chain guide

Item no. Part no. Qty Designation

Chain guide set
1 75318033 1
(incl. upper and lower chain entry plate)
not shown 75115646 1 4,2 x 12,2 mm chain
Tab. 86

43718845_xml.eps

Fig. 108
211 191 44/100620

140
 1 DC 5 chain guide

Item no. Part no. Qty Designation

Chain guide set
1 75318133 1
(incl. upper and lower chain entry plate)
not shown 75115746 1 5,3 x 15,2 mm chain
Tab. 87

43719045_xml.eps

Fig. 109

1 DC 10 chain guide

Item no. Part no. Qty Designation

Chain guide set
1 75318233 1
(incl. upper and lower chain entry plate)
not shown 75115846 1 7,4 x 21,2 mm chain
Tab. 88

43719245_xml.eps

Fig. 110
211 191 44/100620

141
 12.6 DC 1 - 10 hook with fittings (as of 2017)

18, 19 18, 19

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

43702945_xml.eps

Fig. 111

Item Part no. Qty Designation

18 72340033 1 DC1/2 hook assembly set
18 72340133 1 DC 5 hook assembly set
18 72340233 1 DC 10 hook assembly set
19 75116033 1 DC1/2 hook assembly half set without hook
19 75116133 1 DC 5 hook assembly half set without hook
19 75116233 1 DC 10 hook assembly half set without hook
20 75043333 1 DC1/2 load hook set 315 kg 1Am
20 75143333 1 DC5 load hook set 630 kg 1Am
20 75243333 1 DC10 load hook set 1250 kg
21 83565933 1 Size 2 x4 hook safety catch set DC 1-2
21 83665933 1 Size 3 x4 hook safety catch set DC 5
21 83765933 1 Hook safety catch set size 4 x5 DC 10
22 75262333 1 DK5 DC1-10 load capacity plate set
Tab. 89
211 191 44/100620

142
 12.7 Hook assembly

18
19
27

18
19

18
19
22

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

Fig. 112

Item Part no. Qty Designation

18 71798033 1 DC1/2 hook assembly set 6,8 Nm
18 71898033 1 DC 5 hook assembly set 11,5 Nm
18 71598033 1 DC 10 hook assembly set 25 Nm
18 72144133 1 DC16/DK16 hook assembly DC 15; 27,5 Nm
19 71728133 1 DC1/2 hook assembly half set without hook; 6,8 Nm
19 71828133 1 DC 5 hook assembly half set without hook; 11,5 Nm
19 71528133 1 DC 10 hook assembly half set without hook; 25 Nm
19 72144533 1 DC16/DK16 1/1 hook assembly DC 15; without hook; 27,5 Nm
27 71728145 1 DC 1/2 buffer cap DC 1-2
27 71828145 1 DC 5 buffer cap DC 5
27 71528145 1 DC 10 buffer cap DC 10
27 83875344 1 2,5 T buffer cap DC 15
20 83565033 1 Load hook set no. 2 400 kg DC 1-2
20 83665033 1 Load hook set no. 3 800 kg DC 5
20 83765033 1 Load hook set no.4 DC 10
20 83865033 1 DC16/25 DK10/20 load hook DC 15; size 5
21 83565933 1 Hook safety catch set size 2 DC 1-2
21 83665933 1 Size 3 x4 hook safety catch set DC 5
21 83765933 1 Hook safety catch set size 4 x5 DC 10
21 83865633 1 Hook safety catch set size 5 x5 DC 15
22 71724033 1 DC1/2 Pro load capacity plate set DC 1-2
22 71393433 1 DK5 1/1 load capacity plate set DC 5
22 83590833 1 DK10/DC10 load capacity plate set DC 10
22 72144933 1 DC16/DK16 1/1 load capacity plate set DC 15
211 191 44/100620

Tab. 90

143
 12.8 DC 10 bottom block with external cut-off springs (standard) as of 10/2014

42764146_xml.eps

Fig. 113 A) Load side, B) Chain collector box side, 1) Limit switch actuator not included.

Item Part no. Qty Designation

71 75244033 1 DC10 2/1 bottom block set
72 75244133 1 DC10 2/1 bottom block half set 52 Nm
73 75244333 1 DC10 2/1 load hook
74 83865633 5 Hook safety catch set size 5 x5
75 75244533 1 DC10 2/1 return sprocket set
76 75242133 2 DC10 2/1 load capacity plate set 1,25t
76 75242233 2 DC10 2/1 load capacity plate set 1,6t
76 75242333 2 DC10 2/1 load capacity plate set 2,0t
76 75242433 2 DC10 2/1 load capacity plate set 2,5t
76 75242533 2 DC10 2/1 load capacity plate set 2750lbs
76 75242633 2 DC10 2/1 load capacity plate set 3500lbs
76 75242733 2 DC10 2/1 load capacity plate set 4400lbs
76 75242833 2 DC10 2/1 load capacity plate set 5500lbs
211 191 44/100620

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

77 71525545 1 DC 10V12 cut-off spring V6 lifting speed for 2/1 reeving; 50 Hz
Tab. 91

144
 12.9 DC-Pro 15 bottom block with external cut-off springs (standard)

42728046_xml.eps

Fig. 114

Item Part no. Qty Designation

21 72144233 1 DC16/DK16 2/1 bottom block set. 55 Nm; 35)
22 72144633 1 DC16/DK16 2/1 bottom block set without hook; 55 Nm; 35)
23 82903433 1 DC16 DK16 2/1 load hook Size 6
24 82907733 1 Hook safety catch set size 6
27 72175345 1 V8 cut-off spring accessories
34 72145033 1 DC16/DK16 2/1 load capacity plate
Tab. 92
211 191 44/100620

35) Buffer not for DC-Pro 15 145

 12.10 Motor

42763744_xml.eps
Fig. 115

Item Part no. Qty Designation

1 71785033 1 DC 2 fan set DC 1-2; ZNK 71; 4 Nm
1 71885033 1 DC 5 fan set DC 5; ZNK 80; 4 Nm
1 71585033 1 ZNK 100A fan set DC 10; ZNK 100A; 4 Nm
1 71585133 1 ZNK 100B fan set DC 10-15; ZNK 100B; 4 Nm
2 71784133 1 Motor set 240 V 50 Hz DC 1-2; 220-240V 50Hz; 9,5 Nm
2 71784233 1 Motor set 415 V 50 Hz DC 1-2; 380-415V 50Hz; 9,5 Nm
2 71784433 1 Motor set 525 V 50 Hz DC 1-2; 500V 50Hz; 9,5 Nm
2 71784533 1 Motor set 460 V 60 Hz DC 1-2; 440-480V 60Hz; 9,5 Nm 36)
2 71784633 1 Motor set 240 V 60 Hz DC 1-2; 220-240V 60Hz; 9,5 Nm 36)
2 71784733 1 Motor set 380 V 60 Hz DC 1-2; 380-400V 60Hz; 9,5 Nm
2 71884133 1 Motor set 240 V 50 Hz DC 5; 220-240V 50Hz; 9,5 Nm
2 71884233 1 Motor set 415 V 50 Hz DC 5; 380-415V 50Hz; 9,5 Nm
2 71884433 1 Motor set 525 V 50 Hz DC 5; 500V 50Hz; 9,5 Nm
2 71884533 1 Motor set 460 V 60 Hz DC 5; 440-480V 60Hz; 9,5 Nm 36)
2 71884633 1 Motor set 240 V 60 Hz DC 5; 220-240V 60Hz; 9,5 Nm 36)
2 71884733 1 Motor set 380 V 60 Hz DC 5; 380-400V 60Hz; 9,5 Nm
2 71584133 1 Motor set 240 V 50 Hz A DC 10; 220-240V 50Hz; 25 Nm
2 71584233 1 Motor set 415 V 50 Hz A DC 10; 380-415V 50Hz; 25 Nm
2 71584433 1 Motor set 575 V 60 Hz A DC 10; 500V 50Hz; 25 Nm
2 71584533 1 Motor set 460 V 60 Hz A DC 10; 440-480V 60Hz; 25 Nm 36)
2 71584633 1 Motor set 240 V 60 Hz A DC 10; 220-240V 60Hz; 25 Nm 36)
2 71584733 1 Motor set 380 V 60 Hz A DC 10; 380-400V 60Hz; 25 Nm
2 71584833 1 Motor set DC10/16 B 50 Hz DC 10-15; 220-240V 50Hz; 25 Nm
2 71583233 1 Motor set DC10/16 B 50 Hz DC 10-15; 380-415V 50Hz; 25 Nm
2 71583433 1 Motor set DC10/16 B 60 Hz DC 10-15; 500V 50Hz; 25 Nm
2 71583533 1 Motor set DC10/16 B 60 Hz DC 10-15; 440-480V 60Hz; 25 Nm 36)
2 71583733 1 Motor set DC10/16 B 60 Hz DC 10-15; 380-400V 60Hz; 25 Nm
2 71584933 1 Motor set DC10/16 B 60 Hz DC 10-15; 220-240V 60Hz; 25 Nm 36)
2 71784833 1 ZNK 71B4 motor set DC-ProFC: DCS 1-2; 380 V-480 V 50/60 Hz, 9,5 Nm
2 71884833 1 ZNK 80B4 motor set DC-ProFC: DCS 5; 380 V-480 V 50/60 Hz, 9,5 Nm
2 71984833 1 ZNK100A4 motor set DC-ProFC: DCS 10-15; 380 V-480 V 50/60 Hz, 25 Nm
62 26564933 1 DC1/2 winding head cover
62 71821033 1 DC 5 winding head cover
62 71521033 1 DC 10 winding head cover
211 191 44/100620

Tab. 93

146 36) Incl. thermal contact. For other voltages, please specify in the order if a thermal contact is required.
 12.11 Service cover

42764450_xml.eps

Fig. 116

Item Part no. Qty Designation

53 71792033 1 DC 1/2 service cover set 5,5 Nm
53 71892033 1 DC 5 service cover set 5,5 Nm
53 71592033 1 DC 10 service cover set 7,5 Nm
58 72027145 1 Sleeve compartment cpl.
64 72238945 1 DC 15 service cover kit
Tab. 94
211 191 44/100620

147
 12.12 DC-ProDC and DC-ProCC electric equipment cover

42763952_xml.eps

Fig. 117

Item Part no. Qty Designation

50 72019745 1 DC-DC 1-15 electric equipment set VDE; 3 Nm
50 72029745 1 DC-DC 1-15 electric equipment set CSA; 3 Nm
51 71792133 1 DC 1/2 electric equipment cover set 9,5 Nm
51 71892133 1 DC 5 electric equipment cover set 9,5 Nm
51 71592133 1 DC 10 electric equipment cover set DC 10-15; 9,5 Nm
52 26094384 1 GF brake control 0,8A
52 72030245 1 CC 48V brake control
54 71812545 1 Window DC 1-15
94 72019845 1 DC-CC 1-15 electric equipment set 230–500 V 50 Hz/48 V; VDE
94 72029845 1 DC-CC 1-15 electric equipment set 230–500 V 50 Hz/48 V; CSA
95 Intermediate flange  "Intermediate flange", Page 34,  "Assemblies", Page 133
Tab. 95
211 191 44/100620

148
 12.13 DC-ProFC electric equipment cover

42763955_xml.eps

Fig. 118 (A) DC-ProFC 1-2, (B) DC-ProFC 5, (C) DC-ProFC 10, (D) DC-ProFC 15

Item Part no. Qty Designation

Electric equipment cover and intermediate flange
see  "DC-ProDC and DC-ProCC electric equip‐
ment cover", Page 148
97 53818084 1 Right-angle plug enc. SSI&INC with 5m cable
98 72040245 1 AG2 TTL5/24 rotary encoder with 5 m cable
98 53813284 1 SSI&INC 1024' TTL encoder
99 75099145 1 Combined rotary encoder fitting kit DC FC 1/2
99 75199045 1 AG1/2 rotary encoder fitting kit DC FC 1-5
99 75199145 1 Combined rotary encoder fitting kit DC FC 5
99 75299045 1 AG1/2 rotary encoder fitting kit DC FC 10
99 75299145 1 Combined rotary encoder fitting kit DC FC 10
99 72299045 1 AG1/2 rotary encoder fitting kit DC FC 15
99 72299145 1 Combined rotary encoder fitting kit DC FC 15
100 72022245 1 DC-FC 1/2/5 electric equipment set  "DC-ProFC", Page 76
100 72021945 1 DC-FC 10 electric equipment set  "DC-ProFC", Page 76
100 72022345 1 DC-FC 15 electric equipment set  "DC-ProFC", Page 76
101 10014698 1 3 T2,5 / 285 toothed belt DC FC 1-10,  "Rotary encoder", Page 101
211 191 44/100620

101 10017198 1 3 T2,5 / 380 toothed belt DC FC 15,  "Rotary encoder", Page 101
102 71598445 1 Synchronising disc with hub DC FC 1-15; AG2
102 75098445 1 Synchronising disc with hub 2 DC FC 1-15; combined
103 26089084 1 GE 3 A brake control
Tab. 96 149
 Original Ident. number / Language
EC conformity declaration for a machine 19961144 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
1217 1/ 2

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

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

Demag DC chain hoist with trolley

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

EC Machinery Directive 2006/42/EC.

e
The safety objectives of Low Voltage Directive 2014/35/EU are achieved.
The product additionally complies with the following relevant directives/provisions:
EU EMC Directive 2014/30/EU

EN 14492-2

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

Cranes - Power driven winches and hoists -

Part 2: Power driven hoists
Safety of machinery - Electrical
equipment of machines - Part 32:
m
Requirements for hoisting machines

The relevant technical documentation according to Annex VII Part A of Directive 2006/42/EC has
been compiled and will be made available to authorised national authorities by the designated
authorised representative in response to a justified request.
Authorised representative for technical documentation:
Sa

Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany

Düsseldorf, 26.02.2019

ppa. Thomas Wiesmann i.V. Franz Schulte

Head of Plant Wetter Knowledge Centers &
Core of Lifting

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
EC conformity declaration for a machine 19961144 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
1217 2/ 2

Demag DC chain hoist with trolley

Serial no.: XXX-XXX-XXX

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

For assembly / first putting into service including function check

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

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

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

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

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

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

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

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

Company that carries out the work:

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

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

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

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

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Original Ident. number / Language
Declaration for fitting partly completed machinery 19961244 / EN
according to Machinery Directive 2006/42/EC, Annex IIB Issue Page
1217 1/ 1

Hereby we,

Demag Cranes & Components GmbH

Forststrasse 16, 40597 Düsseldorf, Germany

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

Demag DC chain hoist

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

EC Machinery Directive 2006/42/EC.

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

e
Basic requirements of the EC Machinery Directive, insofar as they are relevant for the scope of
delivery, are met by application of the following harmonised standards or C standard drafts:
EN 14492-2 Cranes - Power driven winches and hoists -

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

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

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

The special technical documentation according to Annex VII Part B of Directive 2006/42/EC has
been compiled and will be made available to authorised national authorities by the designated
authorised representative in response to a justified request.
Sa

Authorised representative for technical documentation

Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany

Düsseldorf, 26.02.2019

ppa. Thomas Wiesmann i.V. Franz Schulte

Head of Plant Wetter Knowledge Centers &
Core of Lifting

Industrial Equipment
BOTTW

Subject to change. No liability for errors or omissions

 Index

A
Actual load spectrum factor 92
Actual duration of service 92

B
Buffer 78
Buffer plate 122, 78

C
Canopy 26
Chain link anchorage section 120
Chain wear 105
Contactor control 28
Continuity of the PE conductor connection 31
Counterweight compensation 41
Cut-off spring 122
Cut-off buffer 122

D
Damping plate 78, 122

F
Factor depending on the type of recording 92

L
Load spectrum factor 92

N
Number of operating hours 92

R
Rating plate 2
Reeving 41
Retaining clip 41

S
Self-locking nuts 31
Special fittings 41
Strain relief attachment 44

T
Theoretical duration of service 94
Three-phase asynchronous motor 27

W
Wear of a single chain link 103
Wear or deformation of the chain 102
211 191 44/100620

Welding work 30, 88

153
154
211 191 44/100620
211 191 44/100620

155
The current addresses of our sales offices, subsidiaries and agencies worldwide can be
found on the homepage
www.demagcranes.com

Demag Cranes & Components GmbH

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

Fax +49 (0)2335 92-7676

www.demagcranes.com

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