Tecle DEMAG

Operating instructions / Accessories / Component partsDemag DC-Pro 1 - 15 chain hoist Demag Manulift DCM-Pro 1 - 5 chain hoist 43213744.eps 210610 en GB 214 741 44 720 IS 817 Original operating instructions Manufacturer Demag Cranes & Components GmbH P.O. Box 67 58286 Wetter Phone: +49 (0) 2335 92-0 Telefax +49 (0) 2335 92-7676 www.demagcranes.com E-mail: [email protected] Please fill in the following table before first putting the unit into service. This provides you with a definitive documentation of your Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative. Owner Where in use Size Serial number Year of manufacture Operating voltage Control voltage Frequency Wiring diagram number Tab. 1 Item 1 2 3 4 5 6 7 8 9 10 Fig. 1 Example type plate 11 12 Tab. 2 Designation Manufacturer Chain hoist type Serial no., calendar week, year of manufacture SWL, group of mechanism Chain type, hook path Voltage, frequency Type of enclosure, insulation class Ambient temperature Motor type Electrical key values Conformity symbol Manufacturer address see above ⇒ "Mounting code", Page 19, ⇒ "Selection table", Page 20 ⇒ "Available hoist chains", Page 93, ⇒ "Mounting code", Page 19, ⇒ "Selection table", Page 20 ⇒ "Hoist motor data ", Page 22 ⇒ "Operating conditions", Page 30, ⇒ "Hoist motor data ", Page 22 ⇒ "Operating conditions", Page 30 ⇒ "Selection table", Page 20, ⇒ "Hoist motor data ", Page 22 ⇒ "Hoist motor data ", Page 22 see above ⇒ "Mounting code", Page 19, ⇒ "Selection table", Page 20 2 214 741 44/210610 Table of contents 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 3.6 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.8 3.9 4 4.1 4.2 4.3 4.4 214 741 44/210610 General........................................................................................................................................................................ 7 DC-Pro chain hoist ...................................................................................................................................................... 7 DC-Pro documentation ................................................................................................................................................ 7 Symbols / signal words................................................................................................................................................ 7 Information on the operating instructions .................................................................................................................... 8 Liability and warranty................................................................................................................................................... 9 Copyright ..................................................................................................................................................................... 9 Use of spare parts ....................................................................................................................................................... 9 Definition of personnel............................................................................................................................................... 10 Test and inspection booklet....................................................................................................................................... 11 Customer service ...................................................................................................................................................... 11 Safety ........................................................................................................................................................................ 12 General...................................................................................................................................................................... 12 Safety signs on the equipment .................................................................................................................................. 12 Intended use.............................................................................................................................................................. 12 Hazards which may be caused by the machine ........................................................................................................ 13 Responsibility of the owner ....................................................................................................................................... 14 Operating personnel requirements ............................................................................................................................ 14 Personal protection equipment.................................................................................................................................. 15 Emergency stop device ............................................................................................................................................. 15 Regular inspections ................................................................................................................................................... 15 Technical data ........................................................................................................................................................... 18 Design overview ........................................................................................................................................................ 18 Mounting code ........................................................................................................................................................... 19 Selection table ........................................................................................................................................................... 20 Electrical key values .................................................................................................................................................. 22 Hoist motor data ....................................................................................................................................................... 22 Mains connection delay fuse links ............................................................................................................................. 24 Supply lines ............................................................................................................................................................... 25 Hook dimensions C ................................................................................................................................................... 26 Noise emission / sound pressure level ...................................................................................................................... 28 Transport, packing and storage................................................................................................................................. 28 Safety instructions ..................................................................................................................................................... 28 Scope of delivery ....................................................................................................................................................... 28 Transport inspection .................................................................................................................................................. 28 Packing...................................................................................................................................................................... 28 Storage ..................................................................................................................................................................... 29 Surface protection and painting................................................................................................................................. 29 Operating conditions ................................................................................................................................................. 30 Technical description................................................................................................................................................. 31 Drive and brake ......................................................................................................................................................... 31 Gearbox and slipping clutch ..................................................................................................................................... 31 Chain drive ............................................................................................................................................................... 32 Housing .................................................................................................................................................................... 32 Electrical equipment .................................................................................................................................................. 32 Control ....................................................................................................................................................................... 32 7-segment display for operating status and error display.......................................................................................... 33 Software version, operating hours, number of cycles, operating statuses ................................................................ 33 4.5 4.5.1 4.5.2 4.5.3 3 ........3 7................................................................................................................................................................................................... 65 Setting the lower hook position .............................................................................. 62 Setting parameters with the control pendant . 68 Inspection regulations ................................................................................................................ 71 Operation............4 5.......................... 50 Handling the control cable ........................................1 7........... 35 Control pendant .................................................................................................................................................................................................. 56 Circuit diagram DC-Pro 1 .....................................................................................................................6 4............. 71 Inspections when starting work .............................................. 38 Trolley.................. 77 ........................................................................2 5......................................................................................5 5...... 64 Meaning of keys ............................................................................................ 77 Taking out of service in the case of faults ......................................................... 59 Circuit diagram with E 11 ................................................... 64 Starting parameter setting mode .........................11......11.....10................................................................. 49 Control cable ....................................................................................2 7.. 76 Taking out of service ....................................................5....................... 40 Assembly ....................................................................1 5........................................... vent valve .....2 5........11 5 5........6...........................................................................................................................................................3 5............................................................................2 5................. 72 Manulift ... 48 Screw plug................1 Central service enclosure ........................15 solo hoist ......................................................................... 50 Techncal data of the control cable .............5 solo hoist ..................................................................................................................................................................................................................................................................................................2 5..................................................................2...................................................................................................................7 5...................................11.................................................7 4............................8 5.......8.................................................................. 45 Connecting the control pendant .................... 62 Control board................................................E 34 travel drive .................................................... 43 General.......................................................................................................................................................................................... 35 Manulift DCM with quick-release coupling ....................3........................ 52 Line connection ....................2................8 4.........................................................4 7.. 68 Safety instructions when first putting the unit into service ..........2 6................................................................................................................. 48 Supporting structure ................................................................................................................................................ 72 214 741 44/210610 General...................................................................................5 4 7.............................3 6....................................................................................................................................8........................................12 6 6....... 64 Meaning of parameters .............4 5...................1 5........................................................................................2 5...................... 64 General............................................................................................................................................................................................................................................... 67 Putting the unit into service for the first time .............................................................................................................................................................................. 50 Height adjustment of the control pendant................... 43 Safety instructions for assembly................................................................................................3..................3 5............................................................................1 7.................................................................................. 56 Circuit diagram DCM-Pro 1 ................................. handing over ......................................4 5............................................................2 7........9 4..................... 69 Inspections when first putting into service....... 69 Operation......................................................3 5.................. 70 Safety instructions for operation ............................................................................................9 5............................................................................................. 71 Functional tests ........................10............. 45 Assembly procedure.................1 5..............1 5.............. 75 Emergency stop ......1 5................2 7.........................................................................................10..............................................................................................4......................................................................................................................................... 68 Inspections prior to putting into service for the first time ...................................................................................................................................................................................................................................................................1 6................ 43 Tightening torques DC-Pro chain hoist ............................................... 36 Suspension...................................................11 5.......................................................................................................... 34 Control pendant height adjustment / control cable ....................11................6 5..............................................................................................4 7 7.........................................................................1 7......................................................10 4.................................................................................................10 5.... 51 Mobile control system..................................................................4 5.................................................. 70 Switching on .3 5..............................8......... 54 Circuit diagrams and control cards .................10........................................... 46 Suspending the chain hoist ..........................................................................................8.............................................6................................ 48 Suspension bracket ........................................................................................................................................................................ ............................................................................ 113 Slipping clutch ..............10 8............................... option for DC 10) with external switch-off springs.............10.........3................................2 8...............................3 8..........................................................................................................................3 8...................................8 8.....................2 8................................................... 77 Taking the unit out of service for maintenance and repairs...................................................................7.............................................................................................................................................................................4 8.......................................................................3..........................5....12 8........................... 101 Replacing the bottom block (standard for DC 10) with internal switch-off springs....................................................................... 94 Lubricating the hoist chain. 78 Safety Instructions for maintenance / repair .................5.............5............ 82 General overhaul GO ..................3 8...............................................................................................5......................................................................4......5.......................................................................................................................................5.........2 8.......................................2 8................ 79 Routine inspections ..........3 8............................................................. 87 Checking the operating limit switch actuator ....................... 102 Replacing the bottom block (standard for DC 15................ 115 Gearbox / oil change .................5 8......................... 92 Available hoist chains .........2 8.............................5.......11 8.................................5...............................................7...................................8..........5........... 116 Replacing the contactor on the control card ..........3 8......................................5...5..................................................... 81 Example: DC-Pro 10-1250 1/1 H5 V8/2 in 1Am ...........1 8..............9............2 8........................................................................ reeving 2/1.............................4 8..........................3 8............. 80 Service life of the contactor ...................................5....................................................................................................................... 103 Replacing the chain ................. 84 Inspection and maintenance schedule ..5.... 86 Electrical equipment cover ...................................................................................................................... 104 Fitting the chain to the control unit ............................................................................. 103 Checking the quick-release coupling...............3 8 8..................................................................... 93 Replacing the chain set ............................. 115 Adjusting the slipping clutch ...... 80 General..................5............................ 113 Brake assignment.......... 86 Suspension..........................................6 8.............................................................................3..........................................8 8................................................................................5........................................6 8..............................................................................................1 8....... 109 Buffer design ......5 8................. 117 Replacing cables .............................................................5............................................. 90 Scope of supply chain set ..................................... 84 Maintenance work ...........................................................................2 8..............................................................................3.....................1 8...........................9 8.........................................5.............................................W................................................. 118 Replacing the control cable ......................5..5..........5............................................5..............................................................................................5...5.......................2 8................. 100 Checking the load hook .................................................................................................................................................................................................................................. 100 Checking the return sprocket ........5................................................6.....3.......................................................................................................................................5..... 80 Prescribed inspections ......5.....................................................3......................... 78 Basic information on maintenance ........ reeving 1/1.................................1 8........................ 89 Checking the guide plate .. 86 Dismantling the chain collector box .........................................................5..........................5................................ 103 Manulift ..................7........ 109 Checking the switch-off buffer / switch-off spring .......................................5............................9.................................................................................3...................................2 7............................... reeving 2/1 .................4 8.....................6................................................................................................. 98 Load hook.......6 8......2 8... 88 Chain drive ...................2 8............................6.........................................................1 8...............................................................7 8.....................................................1 Taking the hoist out of service on finishing work ...........................................5...........4 8........................................ 80 Measures for achieving safe working periods S..........................5.......................................... 113 Check brake wear .....3.......................................1 8.............................................................................................. 115 Checking the slipping clutch ............3..............................................5... 89 Checking the chain guide ................................................................................................................................................................................................................................ 105 Replacing the switching elements ..................5...1 8...1 8.............5..............5.........................7...................7..........................................7...................4 8....................................... 77 Maintenance / repair........................................................... 89 Checking the sprocket wheel ....................... 110 Brake .........................................8.............................................P.......................................... 89 Checking the hoist chain .............. 107 Replacing the gearbox ....................................................................5 8.......................................................5..................... ....................1 8.......................................................... 80 Calculating the actual duration of service S ...................3.........5.........................................................................................................5 8.... 108 Load handling attachments ...............................5 8............1 8...5........................................5............................................................7...........13................................................................6.............5.2 8................5..............................................................................5...............................................................................10...................................................................................5...............................................................................................5.........................................5......................................... 118 214 741 44/210610 5 ..............................................................5............5..............................5............................................ 87 Operating limit switches .....................................................5.........................................................13 8............4......................5.................................5..................... 108 Buffers ...7 8.................................................................. 87 Checking the operating limit switches .......................... 100 Replacing the hook assembly.........4 8..............................................1 8.6............3 8................. .....2 9 9................................................................................... 125 Disassembly / Disposal .....................................................................................................................................1 11 11................................................................................................... service cover ..............................................................................6 12.....1 12 12.............5.................................................................................................................... 123 General messages ................................................................1 9................................................................................................................................................................................................................................................................... 127 Components ............. 141 6 214 741 44/210610 .................... 138 Control pendant................................................................................................. 128 Overview ........................................................................................................................1 12................. 123 Warning messages......................................................................................................................... 127 Spare parts .........................................8............................. 122 7-segment display ............................................................................................................................................. 124 Error messages ....................................................7 12................................. 136 Electrical equipment cover ............................................................................................................................................................................................ 130 Chain drive .....10 Replacing the helical cable......................................2 12........................................................................................................................ 129 Parts on gearbox ........................ 120 Faults / Warnings ................................................................................................................................................................................................. 135 Bottom block with external switch-off springs (option) ......................................................2 9..... control cable........ 140 Index........................................................................................................................................................................................................................................................4 9....................................................................................................................................... 126 General...................................................................13........................................................................................................................................ 126 Accessories ................... 122 Safety instructions for faults / warnings ........................5 12..................................................................................... 137 Manulift ...................8 12............................................5 10 10...................................................................................................................................... 128 Motor ................. 134 Bottom block with internal switch-off springs (standard) .............................9 12.......3 9....................................................4 12............................................3 12........................................... 132 Hook assembly ............................................................... Dimensions Friction force checking device DC PWM/3ST signal converter DSC-EX control pendant DSE10-C control pendant DC protective sleeve DC tandem box VG11-34 EU11-34 dual-output gearbox DSC strain relief Test and inspection booklet Tab.3 214 741 44/210610 Symbols / signal words Important safety information and instructions are marked by corresponding symbols and signal words.15 chain hoist DC-Pro 16 . powder-coated) KBK Aluline (anodized) KBK 0 + 25 trailing cable power supply KBK 0 + 25 power supply lines Clamp-fitted buffers DC-Pro 1 . The requirements of the EC directive are complied with. 1) The documents can be ordered from the relevant Demag office. 7 .2 DC-Pro documentation Further documents are available for sub-assemblies/components in addition to these operating instructions. 3 DC test and inspection booklet Certificates Part no. Documents1) Demag DC-Pro 1 . even if special designs or additional options deviating from these operating instructions are ordered.1 General 1.: 203 525 44 203 571 44 203 568 44 203 569 44 203 698 44 203 691 44 203 656 44 203 682 44 202 976 44 203 245 44 202 487 44 202 386 44 203 313 44 214 741 44 211 033 44 214 802 44 214 827 44 211 068 44 211 010 44 214 095 44 214 810 44 211 017 44 211 159 44 214 689 44 211 045 44 211 011 44 206 973 44 211 094 44 214 832 44 214 998 44 203 673 44 211 108 44 211 122 44 211 092 44 214 745 44 235 309 44 1.25 chain hoist Demag DCS-Pro 1 .10 chain hoist Demag DC-Com chain hoist CF5-DC/DCM trolley U11-DC/DCM/DK trolley E11-E34 DC travel drive (circuit diagrams) Technical data / Catalogues RU/EU56 trolley Electrical accessories DC Electrical accessories POLU box KBK classic (steel.Setting . 1. the corresponding documents are supplied or can be ordered separately. This chain hoist was manufactured to European standards and regulations in accordance with state-of-the-art en‐ gineering principles.1 DC-Pro chain hoist You have purchased a Demag quality product. If re‐ quired.25 chain hoist Operating instructions / Compo‐ nent parts DC-Com chain hoist DCS-Pro chain hoist DC-Di chain hoist DC-Wind chain hoist PGS parallel grippers E11-E34 DC travel drive KDC chain hoist KDDC/UDDC articulated trolley DRC-DC radio remote control DRC-DC quick-step instructions DC geared limit switch Assembly . the chain hoist will in the following also be designated as machine in the sense of a complete machine. The relevant local accident prevention regulations for the application and general safety instructions must also be complied with. this includes the "Safety" chapter and the relevant safety instructions in the working sections of these operating instructions. They must be kept available in the immediate vicinity. In particular.The safety instructions must be followed. – Follow these instructions at all times and be particularly careful and cautious. Persons entrusted with this work must know and comply with the safety regulations and the operating instructions. putting into service. 8 214 741 44/210610 . – 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. injuries and damage are avoided in such cases. Exercise particular caution to ensure that accidents. if not complied with. For a chain hoist delivered ready for operation in the sense of a complete machine. ● This symbol in the operating instructions indicates all warnings which. The operating instructions must be available to the operating personnel at all times in order to prevent operating errors and to ensure smooth and trouble-free operation of our products.4 Information on the operating instructions These operating instructions are designed to provide the owner and operator with useful instructions for transpor‐ tation. The following symbols and instructions warn against possible personal injuries or damage to property and are in‐ tended to assist you in your work. we confirm conformity with the requirements of Directive 2006/42/EC by means of the attached EC declaration of conformity. DANGER This symbol indicates an immediate hazard which can result in serious injury or death. Operating hazard for the machine ● This symbol indicates information on the appropriate use of the machine. WARNING This symbol indicates a possibly hazardous situation which might result in serious injury or death. may result in mal‐ functions or damage. Demag chain hoists are supplied ready for operation as complete machine with a control pendant or as incomplete machine without control pendant. The machine may only be operated by personnel who are fully familiar with the operating instructions. operation and maintenance of our chain hoists. Complete machine Based on Machinery Directive 2006/42/EC. These operating instructions are an integral part of the machine. – Follow these instructions at all times and be particularly careful and cautious. 1. The information contained herein may serve as basis for the risk analysis and the operating instructions which must be prepared by the manufacturer of the installation in compliance with the Machinery Directve. texts. ● the assembly and operation of the chain hoist.7 Use of spare parts We urgently recommend that only spare parts and accessories approved by us be used. Wearing parts are not subject to liability for defects.6 Copyright These operating instructions are only intended to be used by people who work with or on the chain hoist. Before putting into operation the owner must take additional measures. 9 . Infringements are an offence resulting in obligatory compensatory damages. Only then can we ensure the safety and normal service life of the installation. We reserve the right to incorporate technical modifications within the scope of improving the operating characteristics and further development of the product. 1. 1.5 Liability and warranty All information included in these operating instructions has been compiled on the basis of the relevant regulations. and inform the owner about remaining hazards. These operating instructions must be read carefully before starting any work on and with the chain hoist. No part of this documentation. Any misuse is an offence. The declaration of incorporation refers to the scope of delivery of the incomplete or non-assembled machine. state-of-the-art engineering principles and our many years of experience.Incomplete machine These instructions inform the manufacturer of an installation with a chain hoist on: ● basic technical notes. may be reproduced. ● inappropriate use. Any and all content. especially before it is put into service for the first time. All industrial rights reserved. ● technical modifications. ● untrained personnel. the manufacturer of the installation must provide additional operating instructions as the result of the risk analysis. ● unauthorized conversions. 214 741 44/210610 1. Further rights reserved. For a chain hoist as incomplete machine which is assembled with additional parts to form a machine that is ready for operation. shown in public or used in any other way without specific prior consent. the information contained in the declaration of incorporation for the chain hoist may be used. The manufacturer does not assume any liability for damage resulting from the following: ● non-compliance with the operating instructions. a declaration of incorporation will be enclosed. as required. in order to meet the safety requirements for the machine. distributed. in whole or in part. drawings. For the operation of the installation. For the conformity inspection. A conformity inspection in accordance with the Machinery Directive must be carried out for the assembled machine which is ready for operation and a declaration of conformity must be produced. images and any other information are protected within the sense of copyright law and are subject to further industrial rights. ● some typical risks. The information for assembly and op‐ eration of the chain hoist contained in these instructions must be complied with. Assembly of an incomplete or non-assembled chain hoist resulting in a machine ready for operation must be carried out in compliance with the information of the manufacturer for the machine. codes of practice. maintenance and fault elimination. codes of practice and regulations. 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. malfunctions or complete failure of the chain hoist.W. Assigned expert engineer (in the Federal Republic of Germany according to BGV D8. if the name of the manufacturer (under 1. directives and generally accepted engineering standards enabling them to judge the safe operating condition of machines. 3. 4. resells equipment of others under his name. 10 214 741 44/210610 . = safe working period) and to carry out a general overhaul of machines. The person must be trained by the owner in accordance with the tasks to be performed. have sufficient knowledge in the field of the machine. 1. The person must be trained by the owner in accordance with the tasks to be performed. damages or liability against the manufacturer or his appointed personnel.P. § 23. 2. dealers and representatives null and void. however the reseller shall not be considered as manufacturer. accident prevention regulations. protective measures. accident prevention regulations and operating conditions and must provide verification of their competence. codes of practice. service.P. imports equipment to Germany and places it on the market for the first time or exports equipment into another member state of the European Union and makes it directly available to a user. Qualified electrician Qualified electricians are defined as persons who.) appears on the equipment. The person must be trained by the owner in accordance with the tasks to be performed. owing to their technical training and experience. relevant regulations. manufactures equipment under his name and places it on the market for the first time. Experienced technician Experienced technicians are defined as persons who. setting-up. Operating personnel/operator Operating personnel or machine operators are defined as persons entrusted by the owner of the machine with operation of the equipment. Owner Owners (employer. knowledge and experience of electrical installations as well as knowledge of the relevant valid standards. company) are defined as persons who own the machine and who use it appropriately or allow it to be operated by suitable and trained persons. are able to assess the tasks given to them and to identify and eliminate potential hazards. Specialist personnel Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks such as installation. for determining the S.8 Definition of personnel Manufacturer The manufacturer is the person who 1.) An assigned expert engineer is defined as an experienced technician specifically assigned by the manufacturer to determine the remaining duration of service (S. The person must be trained by the owner in accordance with the tasks to be performed. The use of unauthorized spare parts may render any claims for guarantee. They must be familiar with the relevant national industrial safety regulations. damage. Personnel must be informed about the required pro‐ tective devices.W. owing to their technical training.Spare parts not approved by us may cause unpredictable hazards. : ⇒ Tab.9 Test and inspection booklet A test and inspection booklet filled in with all details must be available for the hoist (in the Federal Repblic of Germany according to BGV D6. 3.com 214 741 44/210610 11 .demagcranes. § 28 in Germany) In addition to the expert engineers of the Technical Supervisory and Inspection Board. 1. Please keep the serial or order number (see test and inspection booklet. 1.741268 www. The results of the regular tests and inspections must be entered into the test and inspection booklet and must be certified by the inspector. Test and inspection booklet ident. Specifying this data ensures that you receive the correct information or the required spare parts. § 28). Page 7.10 Customer service Our after-sales service will provide you with technical information on our products.Authorized expert engineer (according to BGV D6. load capacity plate on the crane) for any correspondence or spare part orders. etc. no. Demag Cranes & Components GmbH Telephone +49 (0)180 / 5 . an authorized expert engineer for the inspection of machines is defined as an expert engineer authorized by the Industrial Employers’ Mutual Insurance Association. ● The suspension/support structure for the chain hoist must be designed for loads caused by operation of the chain hoist. maintenance and fault elimination as well as compli‐ ance with the instructions on the machine safety devices. Pictograms. 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. function and operation. ● Appropriate use includes compliance with the safety instructions as well as any other instructions on assembly and disassembly. it may cause hazards if it is used inappropriately by personnel which have not been trained specially. ● The machine may only be installed. used.3 Intended use The machine may only be used as intended and in compliance with the requirements for the owner resulting from these operating instructions and the following limitations. The personnel must meet the requirements according to ⇒ "Operating personnel requirements". 214 741 44/210610 No liability for inappropriate use The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐ ceptable according to these operating instructions. therefore. The maximum safe working load is the load capacity specified on the capacity plate. This must not be exceeded. ⇒ "Technical data". Wear parts must be ex‐ changed in good time.1 General The "Safety" chapter provides an overview of all important safety aspects for optimum protection of personnel as well as for safe and reliable operation of the machine. 12 No liability in the case of structural modifications . 2 2. any possible remaining hazards and protection against hazards. ● The machine may only be used in compliance with the permissible technical data. operated. ● The machine must be maintained appropriately at the specified regular intervals and inspected according to ⇒ "Inspection and maintenance schedule". In particular. to operate the machine safely and reliably. 43229044.2 Safety signs on the equipment Any pictograms. ● Chain hoists are only intended for lifting. Page 14. Page 84 by specially trained personnel. However. At the time of placing it on the market the machine has been built according to the state-of-the-art and is considered as safe to operate. commissioning. Modifications of any kind and additions to or conversions of the machine must not be carried out without the written consent of Demag. Knowledge of the contents of the operating instructions are one of the requirements necessary to protect personnel from hazards and to avoid malfunctions and. signs or labels on the machine must be obeyed and must not be removed. The maximum permitted load of the chain hoist includes the load and the load handling attachment.2 Safety 2. 2. Page 18.eps Fig. lowering and moving loads and may be used as stationary or travelling units. signs or labels that are damaged or no lon‐ ger legible must be replaced immediately. maintained and removed by trained personnel when in perfect working order. ● The accident prevention regulations UVV/BGV D8 §23 (2) and/or BGV D6 (1) must be complied with. Any other use may result in a danger to life and limb and/ or cause damage to the machine and/or the load. switch off the machine and secure against restarting. an inspection must be carried out by an expert engineer before handing it over to the owner. special meas‐ ures must be taken by the owner in agreement with Demag. or the installation or use of accessories. cross-travel and long-travel motions are controlled by means of the corresponding control elements on the control unit. Page 68 13 . Keep a sufficient safety distance. Persons must keep out of the danger zone. as it causes increased wear and load sway. The design and execution based on this analysis corresponds to state-of-the-art engineering principles. 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. Loads can be precisely positioned at slow speeds. If the insulation or individual components are damaged. DC-Pro chain hoists are designed for operation at temperatures of -20 °C up to +45 °C. it must be ensured that no persons are in the immediate danger zone.4 Hazards which may be caused by the machine The machine has been subject to a risk analysis. Short transport times can be achieved at higher speeds. Switch off the power supply when carrying out any work on the electrical installation. there is danger to life caused by electrical current. Page 43 ● ⇒ "Putting the unit into service for the first time". – – – WARNING Crushing hazard The lifting or lowering of loads may cause crushing hazards for parts of the body. Depending on the type and scope of the machine. 2. lifting it free and depositing it. if applicable. Do not remove safety equipment or render it inoperative by modifications. The slow speeds are intended for attaching the load. Electrical energy may cause serious injuries. This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of delivery. Check the components to be replaced for being de-energized. Please note the safety instructions in the chapters: ● ⇒ "Assembly". – – 214 741 44/210610 Before carrying out maintenance. WARNING Suspended load! Falling parts! There is danger to life and limb. when lifted loads fall down. DANGER Live components Danger to life and limb. cleaning or repair work. Nevertheless there are residual risks! The machine is operated at high electrical voltage. Certain work and practices are prohibited when using the machine as they may involve danger to life and limb and result in lasting damage to the machine. Inching must be avoided. At extreme temperatures and in aggressive atmophere or under conditions deviating from the section "Operating conditions". Use of the control pendant Powered lifting and lowering and.The manufacturer is not liable for unauthorized structural modifications which have not been agreed with him. Do not walk under the suspended load. equipment or sub-assemblies of other manufacturers that are not approved by the manufacturer. When lifting or lowering loads. ● the operating instructions are always kept available in the immediate vicinity of the machine for installation. Persons under the influence of drugs. if required. The operating instructions must be followed in full and without any limitations. Page 70. Furthermore. The personnel must be trained in the use of the first-aid equipment. ● the national regulations for the operation of cranes and lifting applinces are observed. the required safety measures must be defined and implemented by the owner. 2. for example. alcohol or medicines which affect their reactions must not work on or with the machine. etc. ● the specified regular checks and inspections are carried out on time and are documented. The operating instructions must. Personnel are obliged to report to the owner without delay any changes to the machine that impair safety. to the handling of hazardous materials or tools and the provision/wearing of personal protection equipment. ● the personnel are trained in accordance with the work to be performed. to instruct users and to apply these instructions at a suitable place in a readily legible manner. Every individual given the task of working on or with the machine must have read and understood the operating instructions before any work is started. op‐ erating. ● the safety devices are always kept freely accessible and are checked regularly. The personnel must have received instruction on the machine functions and any hazards that may occur. the owner must ensure that ● any further working and safety instructions resulting from risk assessment of the machine workplaces are specified in operating procedures. the owner may only employ persons ● who are at least 18 years of age. working procedures. Necessary measures may also relate. 14 . be supplemented by the owner with instructions relating to the organization of work. maintenance and cleaning. operation. ● personnel who work with or on the machine are provided with appropriate first-aid equipment. The owner is urged to develop procedures and guidelines to cover malfunction situations. authorized personnel. In such cases. General safety. Age and job-specific regulations relevant at the place where the machine is operated must be observed for the selection of any personnel. Page 70 ● ⇒ "Maintenance / repair".● ⇒ "Operation". maintenance and cleaning personnel. 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 is obliged to ensure that the specified industrial safety measures comply with the latest rules and regulations and to observe new regulations during the entire service life of the machine. For further information please refer to ⇒ "Safety instructions for operation". The owner and any personnel authorised by him are responsible for correct operation of the machine and for clearly defining responsibilities for installation. ● the machine is only operated when in safe and proper working order. Local industrial safety legislation and regional regulations and codes of practice must be observed outside the European Union. supervising and reporting obligations. Special local conditions or applications can lead to situations which are not considered in these operating instruc‐ tions. Page 78 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 man‐ ufactured. 214 741 44/210610 For independent operation (machine operator) or maintenance (trained maintenance fitter) of the DC-Pro chain hoist.6 Operating personnel requirements Only authorised and trained personnel may operate the machine. ). for example.9 Regular inspections The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation and regional regulations. 2.8 Emergency stop device Fig. no loose sleeves.● who are mentally and physically suitable. ● Safety shoes to protect against heavy falling parts and against slipping. lifting and towing devices (BGV D8) and the accident prevention regulations for cranes (BGV D6). 2. closely-fitting working clothes (low tear strength.7 Personal protection equipment When work is carried out on or with the machine. This is located on the control unit. ● who have been instructed in the operation and maintenance of chain hoists and who have proven their qualification to the owner in this respect. In Germany. this is specified by the accident prevention regulations for winches. 3 Position of the emergency stop device (1) To prevent damage and injuries. the machine is fitted with an emergency-stop device (1). The emergency-stop operating function must be checked regularly. ● the elapsed share of the theoretical safe working period must be calculated. the following must always be worn: ● Protective equipment. ● the machine must be inspected regularly. no rings or any other jewellery. These specify that ● the machine must be inspected before it is put into operation. ● a record of tests and inspections must be kept. 15 214 741 44/210610 . ● Safety helmet for all persons in the danger zone. 2. etc. we recommend compliance with the above-mentioned regulations. If no comparable inspection regulations or requirements apply at the place where the machine is operated.The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe new regulations at all times. 16 214 741 44/210610 . 214 741 44/210610 17 . 4 Single-fall design Item 1 2 3 4 5 6 7 8 9 10 Tab.3 Technical data 3.5 two-stage helical gearbox DC 10 and DC 15 three-stage helical gearbox Suspension bracket Suspension bolt Service cover Item 21 22 23 24 25 26 27 28 29 30 Designation Adjusting mechanism for control cable Switch-off buffer for operating limit switch Hook assembly with capacity plate Motor shaft Winding head cap Stator Rotor Fan Fan cover Mounting points 18 .1 Design overview Fig. 4 214 741 44/210610 Designation Electrical equipment cover Control Operation hours counter Window Pulse wheel for speed monitoring Magnet brake Brake disk with linings Brake springs Brake magnet Gearbox housing Item 11 12 13 14 15 16 17 18 19 20 Designation Chain guide Sprocket Round section steel chain Slipping clutch Dished washer pack Slipping clutch adjusting nut DC 1 . 3. 5 Push-travel trolley Travel drive Click-Fit (push-travel trolley) 2-stage chain hoist (Demag chain hoist) 2-stage Manulift Variable speed chain hoist Variable speed Manulift Rocker switch stepless DC-Com 2-stage chain hoist basic version DC-ProDi DC-ProFi 2-stage chain hoist for direct control Variable speed chain hoist for control by means of an external frequency inverter 2-stage = Main / creep lifting Stepless = VS at nominal load up to VSmax in the partial load range Articulated curve-running trolley Long monorail hoist Low headroom hoist Standard-headroom monorail hoist 11 Trolley size load capacity [kg • 100] Not all features of the mounting code can be combined.415 / 50 24/6 200 220 .2 Mounting code E K L D DC-Pro 10 2000 2/1 H5 V6/1. 214 741 44/210610 2) The designations of sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 since 04/2006.480 Voltage range / Voltage travel drive[V] Max. flange width of trolley [mm] Travel speed [m/min] Frequency [ Hz ] Voltage range chain hoist [V] Hoist speed [m/min] V VS Hook path [m] Reeving Load capacity [kg] Size 2) DC-Pro DCM-Pro DCS-Pro DCMS-Pro DCRS-Pro D L K U 22 34 56 R E C F 5 Tab. 19 .5 380 . 4/3.5 1250 10 15 1600 2000 2500 3200 Tab.0/4.8/7.0/6.4x21.6/2.0/2.0/2.4x21.6/2.8/7.6/2.0 24.2 9.8/7. hook paths on request.8 28.0/2.0/1.2 9.4x21.4 19.8 14. 6) ZNK 71 A 8/2 with 380-415 V / 50 Hz only for initial delivery.0/1.8 28.2 7.0/2.0/2.0 7) 8.6 7.2 9.4 19.4x21.0/2.8 9. for replacement requirements.2/1.2 5.4/3.0 8.2/4.3x15.6/2.0/3.0 16.8/7.2 9.0/2.4x21.0 16.6 9.2 7.2 8.6/2.2 4.2/1.2x12.2 5.5 12.0/4.7 x 24. Page 22.4 19.2 7.4/3.2 3m/M6 2m+ 8) / M5+ 15 4m 9) / M7 2/1 1/1 2/1 1/1 2m+ 4m / M7 1Am 10) / M4 3m 11) / M6 3m/M6 8) 12) 7) 7) Standard hook path4) H [m] Motor size 5) 4m [kg] ZNK 71 A 8/2 6) ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 A 8/2 6) Max.0/1.8/7.0 6.4 7.8 9.4/3.0/1.7 x 24.8 [kg] 80 DC-Pro 1 2 5 1 100 2 5 1 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 A 8/2 6) ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 71 B 8/2 5 and 8 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 4 5 and 8 4 5 and 8 4 5 and 8 4 5 and 8 4 ZNK 100 B 8/2 125 2 5 2 160 5 2 200 5 10 2 250 5 10 5 315 10 5 400 10 5 500 630 10 800 4m / M7 12.2 7.4x21.6 7.2 5.0 7) 8.2 8.3x15.0/4.4 14.8 28.0 24.3x15.6/2.4 19.0 16.2x12.0 7) 8.0 7) 6.0 4.0/4. the motor is replaced by the ZNK 71 B 8/2 motor.2 5.2 3) The 20 designations of sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 since 04/2006.6 28.0 16.0/4.4x21.3x15.2 Chain size Hoist speed at 50 Hz [m/min] 8.2 7.2 4m / M7 5.6/2.2 4.2/4.2 7.2 7.0/3.4 19.0 6.0/3. weight at hook path 5m [kg] 22 28 22 28 22 28 22 28 22 28 48 22 28 48 28 48 56 28 48 56 28 48 56 48 56 48 56 48 56 103 103 105 65 56 105 65 105 65 105 65 105 8m [kg] 24 30 24 30 24 30 24 30 24 30 52 24 30 52 30 52 60 30 52 60 30 52 60 52 60 52 60 52 60 110 73 60 110 73 110 73 110 73 110 at 60 Hz [m/min] 9.0/2.2 8.0 7) 8.0/1.7 x 24.2 7.0/6.3.7 x 24.6/2.2 7. 5) Motor data ⇒ "Hoist motor data ".2/4.2 4.4 7.5 7.2 9.6/2.5 8.3x15.2 8.6/2.2 5.8 14.4x21.0 1000 8.2x12.0/2.0/6.0/2.0 7) 8.0 12.2/4.2x12.0 12.0 24.0 6.4 9.6 28.0 7) 8.4 7.0/2.8 28.2/1.2x12.6/2.3x15.0/6.0 16.6/2.0 12.2 9.0/6.7 x 24.4 14.5 12.0/2.2/4.2/1.0 16.0/6.2/4.2 3m/M6 4m / M7 2m+ 8) / M5+ 1/1 4m / M7 4.0/1.0 24.2 4.3x15.4x21. 6 10 15 10 15 10 15 103 103 103 / M5+ 2m+ 8) 12) / M5+ 4m 13) / M7 2/1 1Am 10) / M4 3m 9) / M6 2m+ 8) 11) / M5+ 4.0 24.4 19.0/3.8 14.2 8.0/6.0/2. 4) Larger 214 741 44/210610 .0/6.2/1.0/1.5 8.4 14.8/7.0/6.8/1.8/7.2/1.0 6.2 9.8/7.3 SWL Selection table Size 3) Chain hoist Reeving Group of mecha‐ nisms DIN EN 14492 FEM / ISO [mm] 4.6 28.2 5.4/3.0 8.2x12.0/3.0 24.2 5.4/3.6/2.0 24.0/4.0 8.3x15.2 3m/M6 4m / M7 3m/M6 2m+ 8) / M5+ 4m / M7 2m+ 8) / M5+ 5.0 6.8/7.2 9.0/3.8 28.8 28.3x15.0 24.0 24. the motor is replaced by the ZNK 71 B 8/2 motor.0 / M5+ 4m / M7 Hoist speeds until 03/2007 (no longer available) SWL Size Chain hoist [kg] 160 200 250 315 400 500 Tab.0/2. 8) 2m+ corresponds to 1900 hours operation at full load. weight at hook path 2. weight at hook path 5m [kg] 8m [kg] 7) Only with operating limit switch for lifting. 17) 2m+ corresponds to 1900 hours operation at full load.8/7. for replacement requirements.4 19.0 8.8 Hook path H [m] Motor size 14) Max.0/1.0/3. 9) Chain drive FEM 2m+ according to EN 818-7 10) Chain drive FEM 1Cm according to EN 818-7 11) Chain drive FEM 1Am according to EN 818-7 12) Chain drive FEM 1Bm according to EN 818-7 13) Chain drive FEM 3m according to EN 818-7 14) Motor data ⇒ "Hoist motor data ".0 24.2/4. operating limit switch for lowering on request (the lower end position must not be approached in normal operation).2/4.0/4.6/2. 214 741 44/210610 21 . operating limit switch for lowering on request (the lower end position must not be approached in normal operation).0 16.0/4.6/2.8 9.2 9.0 16.2 9.6/2.4/3.8 m [kg] 28 4.8 4m / M7 12.0 16.SWL Size Manulift Reeving Group of mecha‐ nisms DIN EN 14492 FEM / ISO Hoist speed at 50 Hz [m/min] 8.6 5 and 8 ZNK 80 A 8/2 19) 28 30 DC-Pro Reeving Group of mecha‐ nisms DIN EN 14492 FEM / ISO Hoist speed at 50 Hz [m/min] at 60 Hz [m/min] Standard hook path18) H [m] Motor size 14) Max.6 Hook path H [m] 2.8 28.4/3.8 28.0 at 60 Hz [m/min] 14. 7 3m/M6 4m / M7 2m+ 17) 8.0/6.0/2.0/6. 16) Only with operating limit switch for lifting. 9 DCM-Pro 5 1/1 Reeving Group of mecha‐ nisms DIN EN 14492 FEM / ISO 4m / M7 Hoist speed at 50 Hz [m/min] 12.4 19.5 7.6/2.0 16) 125 2 5 2 5 2 5 2.4 19. 19) ZNK 80 A 8/2 only for initial delivery.8/7.8 m [kg] 4.0/4.0 16) 8.8 and 4.0/2.2/4. 15) ZNK 71 A 8/2 with 380-415 V / 50 Hz only for initial delivery.0 16.3 m [kg] 30 5 1/1 2m+ 17) / M5+ 6.0 14.0 at 60 Hz [m/min] 9.2/4.3 ZNK 80 A 8/2 19) Motor size 14) Max. the motor is replaced by th ZNK 80 B 8/2 motor.3 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 200 250 Tab.2/1.0/2.4 19.0/4.3 m [kg] 24 30 24 30 24 30 24 30 [kg] DCM-Pro 1 ZNK 71 A 8/2 15) 80 22 28 22 28 22 28 22 28 2 5 1 4m / M7 1/1 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 A 8/2 15) 24. for replacement requirements.0/3. Page 22. weight at hook path 2. 8 SWL Size Manulift [kg] 200 250 Tab. 18) Larger hook paths on request.8 and 4. 56 0.80 3.15 1.80 2.80 1.27 1.20 2. Motors are designed in compliance with insulation class F.35 2.77 0.4 3.77 Starts/h IN min. 3 ~ (CE) 21) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 Tab.45 2.90 0.75 1.50 4.75 0.50 2.77 0.80 6.18 0.27 1. currents and starting current IN max.90 1.95 1.30 1.10 3.4. of poles PN [kW] 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 0.30 CD F [%] 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 nN rpm 720 2925 675 2825 665 2745 690 2745 675 2790 675 2790 700 2840 720 2925 675 2825 665 2745 690 2745 675 2790 675 2790 720 2925 675 2825 665 2745 690 2745 675 2790 675 2790 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 0. the motor is replaced by the ZNK 71 B 8/2 motor.80 2. cos φN 220-240 V.10 1.63 0.90 1.40 1.90 6.05 0.81 0.95 1.20 1.10 0.00 1.45 2.77 0.60 2.27 1.51 0.58 0.10 5.70 3.80 2.85 4.50 0.15 0.95 1.51 0.77 0.72 0.10 1.30 0.50 4.75 1.54 0.20 1.81 0.80 3.00 1.58 0.57 2.70 4.10 3.10 1.10 0. [A] 2.30 0.60 1.90 2.85 4.20 3.10 3.57 2.20 1.80 3.80 2.85 4.10 0.18 0.46 0.95 4.46 0.18 0.60 1.1 Electrical key values Hoist motor data Size Motor size No.00 1.45 2.10 5.60 1.80 3.85 1.48 0.60 1. [A] 1.45 2.20 3.10 2.54 0.10 1.46 0.40 2.20 3.56 0.57 2.70 2.70 4.20 0. 50 Hz.37 0. tolerance of the voltage range must not exceed ± 10%.10 1.05 0.35 3.35 1.85 4.00 1.45 3.56 0.60 0.48 0.51 0.37 0. 10 ZNK 100 B 8/2 20) I 22 21) The max = maximum rated current for lowering operation.40 0.75 1.90 3.57 2.20 1.57 2.45 2.05 0.40 3.40 2. 3 ~ (CE) 21) ZNK 71 A 8/2 22) DC-Pro 1 ZNK 71 B 8/2 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 500-525 V. 3 ~ (CE) 21) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 380-415 V.10 1.77 0. 50 Hz.66 0.80 4.15 1.25 1.75 1.00 1.45 3. for replacement requirements.81 IA/IN max. / max.72 0.45 2.10 1.30 0.40 Min.60 1.75 2. 50 Hz.45 3.18 0.70 2.75 2.57 0.25 0.63 0.00 5.15 1.37 0.48 0.45 1.75 1.18 0.10 2.60 1.05 0.40 1.35 2.58 0.70 3.80 2.58 0.20 2.15 1.57 2.10 0.30 0.72 0.40 2.45 3.77 0.60 2.20 1.25 1. 22) ZNK 214 741 44/210610 .18 0.95 1.10 0.40 6.10 2.50 3.20 1.40 1.54 0.40 6.00 5.60 1.30 5.18 0.10 0.30 0.50 2.95 5.80 1.20 1.40 Imax 20) [A] 2.75 1.63 0.50 3.40 1.90 6. 71 A 8/2 with 380-415 V / 50 Hz only for initial delivery.3. 45 3.88 0. of poles PN [kW] CD F [%] 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 nN rpm 870 3525 825 3425 815 3345 840 3345 825 3390 825 3390 870 3525 825 3425 815 3345 840 3345 825 3390 825 3390 870 3525 825 3425 815 3345 840 3345 825 3390 825 3390 870 3525 825 3425 815 3345 840 3345 825 3390 825 3390 Starts/h IN min.10 1.30 1.70 2. / max.15 1.22 0.35 2.60 4.86 0.80 3.00 4.57 0.46 0.76 0.44 0. 60 Hz.76 0.60 2.75 1.70 2.10 1.90 4.90 8.60 0.15 1.86 0.20 3.55 2.06 0.55 6.62 0.20 3.68 2.90 0.65 1.45 2.11 0.80 3.50 1. [A] 2.80 0.85 4.00 3.22 0.11 0.50 6.60 1.50 3.65 0.44 0.57 0.76 0.95 3.50 5.22 0.68 2.00 6.57 0.40 1.44 0.30 3.30 2.45 2.75 1.50 2.30 0.80 0.45 2.06 0.00 1.25 1.00 4.68 2.40 4.10 3.30 7.60 1.45 3.30 5.25 1.45 2.76 0.35 2.40 1.85 4.87 0.00 1. 3 ~ (CSA) 24) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 214 741 44/210610 DC-Pro 15 Tab.47 0.90 6.45 0.68 2.90 8.20 2.45 0.10 5.65 1. Motors are designed in compliance with insulation class F.Size Motor size No.86 0.30 3.50 1.80 0.10 2.75 1.00 1.45 3.30 7.65 1.32 1.80 3.05 1. 3 ~ (CE) 24) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 1.25 3.55 0.50 0.10 5.80 0.45 0.00 2.80 0.80 0.00 3.58 0.25 1.75 1.44 0.70 4.90 4.30 0.47 0.80 2.47 0.85 3.40 3.32 1.15 1.15 1.40 0.55 0.48 0.80 IA/IN max.86 0.62 0.70 4.68 2.80 1.80 2.35 2. tolerance of the voltage range must not exceed ± 10%.60 7.50 2.00 1.70 1.60 2.32 1.40 3.80 1.50 0.20 1.06 0.60 0.45 2.70 1.90 2.40 2.53 0.60 3.95 1.68 2.50 0.90 7. 3 ~ (CE/CSA) 24) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 0.75 1.85 4.11 0.35 2.40 4.80 - 380-400 V.30 0.62 0.57 0.68 2.15 1. 11 23) I ZNK 100 B 8/2 24) The max = maximum rated current for lowering operation.85 0.70 3.50 6. 23 . cos φN 220-240 V.90 1.40 2.70 4.15 0.55 0.05 1.70 4.63 0.70 2. 60 Hz.75 2.06 0. currents and starting current IN max.22 0.60 4.76 0.75 1.75 1.50 1.80 2.50 3.11 0.68 2.83 0.90 7.80 0.22 0.90 1.22 0.22 0.60 2.80 3.50 2.45 2.76 0. 3 ~ (CE/CSA) 24) DC-Pro 1 DC-Pro 2 DC-Pro 5 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 DC-Pro 10 ZNK 100 B 8/2 DC-Pro 15 ZNK 100 B 8/2 575 V.00 1.30 1.45 1.80 0.85 4.15 1.75 1.22 0.80 3.00 1.45 2.32 1.80 1.85 4.53 0.70 4.75 1.45 3.62 0.00 1.50 3.85 0.50 Min. [A] 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 240 120 1.62 0.35 1.80 3.76 0.00 1.40 Imax 23) [A] 2.60 4.00 1.25 1.90 2.95 2.00 6.54 0.53 0.83 440-480 V.30 0.10 2.85 4.45 2.80 0. 60 Hz. 60 Hz. 13 Motor size ZNK 71 A 8/2 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2 10 10 16 10 10 6 6 6 10 16 15 10 15 10 6 6 6 6 [A] 220-240 V 380-415 V 50 Hz [A] [A] [A] [A] 500-525 V 220-240 V 380-400 V 60 Hz [A] [A] 440-480 V 575 V CAUTION For safety reasons we recommend using 3-pole automatic circuit breakers / circuit breakers ( acc.55 1.10 4.30 2.50 Min.10 4.10 4.67 CD F [%] 20 40 20 40 20 40 20 40 20 40 20 40 20 40 nN rpm 710 2880 710 2880 710 2880 860 3480 860 3480 860 3480 860 3480 240 120 240 120 240 120 240 120 240 120 240 120 26) Starts/h IN min. 3 ~ (CE) 26) ZNK 80 A 8/2 380-415 V. tolerance of the voltage range must not exceed ± 10%.2 Mains connection delay fuse links Voltage Frequency Size DC-Pro 1 DC-Pro 2 DC-Pro 5 DC-Pro 10 DC-Pro 15 Tab.00 1.50 3.00 4.25 2.56 0.17 0.20 2.05 2. 60 Hz.14 0.35 3.10 4.56 0. Mains connection fuse link for hoist speeds until 03/2007 (no longer available) Voltage Frequency Size DC-Pro 5 DCM-Pro 5 Tab. 60 Hz.14 0.40 1.17 0.91 1.60 3.90 1. 3 ~ (CE/CSA) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 575 V. 12 ZNK 80 A 8/2 240 120 3.40 1.50 5. 3 ~ (CSA) DC-Pro 5 DCM-Pro 5 Tab. cos φN 220-240 V. of poles PN [kW] DC-Pro 5 DCM-Pro 5 8 2 8 2 8 2 8 2 8 2 8 2 8 2 0.35 0.00 0.47 0.45 3.35 2. 50 Hz.35 2.14 0.48 0.17 0. to DIN EN 60898-1. [A] 2.Hoist speeds until 03/2007 (no longer available) Size Motor size No. tripping characteristics B or C) instead of individual fuses.57 0. .10 1.30 2. 3 ~ (CE/CSA) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 380-400 V.40 0.10 4.65 IA/IN max.90 1. Motors are designed in compliance with insulation class F.67 0. 3 ~ (CE) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 220-240 V.10 4.56 0. 3 ~ (CE) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 440-480 V. 50 Hz.67 0.56 0.00 1. / max.17 0.67 0.57 0.20 5. [A] 2.90 Imax 25) [A] 2.47 0. 3 ~ (CE) 26) DC-Pro 5 DCM-Pro 5 ZNK 80 A 8/2 500-525 V.50 1.15 1.15 2.70 3.56 0.15 2.48 0.35 2. 60 Hz.46 0.90 2.40 5.4.70 6.48 0. 60 Hz. currents and starting current IN max.50 3.35 2.56 0.10 4.00 1. Thus all poles are disconnected from the energy source in the case of a short circuit.10 1.00 7. 14 Motor size ZNK 80 A 8/2 [A] 10 220-240 V 380-415 V 50 Hz [A] 6 [A] 6 [A] 10 [A] 6 500-525 V 220-240 V 380-400 V 60 Hz [A] 6 [A] 6 214 741 44/210610 440-480 V 575 V 24 25) I 26) The max = maximum rated current for lowering operation.47 0.00 2.35 2.80 4.35 2.57 0. 50 Hz.95 1. 5 26 29 2.4.3 Supply lines Supply lines 27) for 5% voltage drop ΔU and start-up current IA Voltage Frequency Size DC-Pro 1 DC-Pro 2 DC-Pro 5 DC-Pro 10 DC-Pro 15 Tab.5 500-525 V 220-240 V 380-400 V [m] 100 440-480 V [mm2] 1.5 [m] 100 575 V [mm2] 1.5 94 38 46 1. 16 Motor size ZNK 80 A 8/2 [mm2] 1.5 76 1. 25 .5 100 [mm2] [m] 220-240 V 380-415 V 50 Hz [mm2] [m] [mm2] [m] [mm2] [m] [mm2] 500-525 V 220-240 V 380-400 V [m] 440-480 V [mm2] [m] 575 V [mm2] [m] 60 Hz Supply lines for hoist speeds until 03/2007 (no longer available) Voltage Frequency Size DC-Pro 5 DCM-Pro 5 Tab.5 31 34 1.5 89 1.5 [m] 100 [mm2] 1.3. 15 Motor size ZNK 71 A 8/2 ZNK 71 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2 1.5 75 78 45 36 1.5 [m] 100 60 Hz 214 741 44/210610 27) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.5 [m] 100 [mm2] 1.5 78 90 100 1.5 61 73 100 1.5 100 1.5 43 52 1.5 100 1.5 1.5 [m] 51 220-240 V 380-415 V 50 Hz [mm2] 1.5 [m] 43 [mm2] 1. 29) For higher hoist speeds a larger chain collector may be required.3 m DC-Pro 5 DCM-Pro 5 2. Page 110 214 741 44/210610 . 17 ZNK 100 B 8/2 ZNK 100 B 8/2 ZNK 100 B 8/2 1/1 ZNK 80 … ZNK 71 … 326 656 726 378 708 778 472 564 493 582 582 632 395 425 335 746 816 505 597 580 - - - 435 526 615 465 615 665 - 688 H9 663 H4 663 H16 783 H8 783 H26 863 H13 863 28) The 26 C dimension is increased by 42 mm for chain hoists with v = 16/4 or v = 12/3.8 m DCM-Pro 5 4.8 m DCM-Pro 1/2 4. see ⇒ "Buffer design".5 Hook dimensions C DC-Pro chain hoist and DCM-Pro Manulift with suspension bracket 43214045.3. 5 A B Size DC-Pro with short suspension bracket DC-Pro with long suspension bracket Reeving Motor size C28) C D C129) DCM-Pro Manulift with short suspension bracket DCM-Pro Manulift with long suspension bracket Long suspension bracket C28) C129) Chain collector box size S 364 694 764 416 1 2 H5 373 H8 403 Short suspension bracket Chain collector box H5 H8 365 DC-Pro 1 / 2 DCM-Pro 1/2 2.3 m ZNK 100 A 8/2 DC-Pro 10 2/1 1/1 DC-Pro 15 2/1 Tab. the C dimension is increased by 111 mm for DC 5 chain hoists with v=24/6.eps Fig. the C dimension is increased by 131 mm for DC 10 chain hoists with v=24/6. 3 m ZNK 100 A 8/2 DC-Pro 10 2/1 ZNK 100 B 8/2 ZNK 100 B 8/2 1/1 ZNK 80 … ZNK 71 … U 11 CF 5 U 11 CF 5 U 11 CF 5 U 11 CF 5 U 11 CF 5 U 11 CF 5 U 11 U 22 U 11 U 22 U 22 U 34 U 22 U 34 RU 56 ZNK 100 B 8/2 2/1 416 406 746 776 716 844 468 458 798 846 868 896 557 569 557 569 661 644 660 752 768 H9 727 H9 743 H4 727 H4 743 H16 847 H16 863 H8 847 H8 863 H26 972 H26 943 H13 972 H13 943 - 1/1 DC-Pro 15 U 22 U 34 RU 56 Tab. 6 E F Size CF 5 trolley transverse to girder CF 5 trolley parallel to girder Reeving Motor size Trolley C31) S G H U 11.3m DC-Pro 5 DCM-Pro 5 2. U 34 trolley parallel to girder Parallel to girder 30) C31) H5 425 415 425 415 425 415 487 477 487 477 487 477 578 590 667 679 679 H8 455 445 455 445 455 445 517 507 517 507 517 507 667 679 667 679 729 410 400 740 770 710 838 462 452 792 840 862 890 581 593 581 593 685 676 692 784 800 H9 759 H9 775 H4 759 H4 775 H16 879 H16 895 H8 879 H8 895 H26 1004 H26 975 H13 1004 H13 975 S 1 C132) Chain collector box size 2 H5 419 409 419 409 419 409 481 471 481 471 481 471 602 614 691 703 703 H8 449 439 449 439 449 439 511 501 511 501 511 501 691 703 691 703 753 C132) Transverse to girder 30) Chain collector box size 1 2 DC-Pro 1 / 2 DCM-Pro 1/2 2.DC-Pro chain hoist with trolley 43214245. see ⇒ "Buffer design". 18 214 741 44/210610 C and C1 decrease when the short suspension bracket is used: for DC-Pro 1-5 by 38 mm and for DC-Pro 10 by 33 mm. U22.8 m DCM-Pro 5 4. Page 110 30) Dimensions 27 . see also ⇒ "Suspension". the C dimension is increased by 111 mm for DC 5 chain hoists with v=24/6. 32) For higher hoist speeds a larger chain collector may be required. Page 38. U22.8m DCM-Pro 1/2 4. the C dimension is increased by 131 mm for DC 10 chain hoists with v=24/6. U 34 trolley transverse to girder U 11. 31) The C dimension is increased by 42 mm for chain hoists with v = 16/4 or v = 12/3.eps Fig. 7. ● reflection of noise from walls. etc. Environmental protection: ● Always dispose of packing material in an environmentally sound way and according to the locally applicable disposal regulations.7. If no agreement on the return of the packing material has been made. a recycling company must be charged with the disposal. packing and storage Safety instructions WARNING Falling parts During transport and loading or unloading there is a danger of injury due to parts falling down.7. to DIN 45635 (LpAF) at a distance of 1 m from the chain hoist is: Type Hoist speed up to Sound pressure level Tab.2 Scope of delivery If special designs or additional options are ordered or latest technical modifications are incorporated. Do not walk under the suspended load. 3. – – WARNING Transport damage The chain hoist may be damaged or destroyed by inappropriate transport. please contact the manufacturer.1 Transport.3 Transport inspection ● Check the delivery for completeness and transport damage immediately upon receipt. do not accept the delivery or only under reserve.7. 214 741 44/210610 28 . the actual scope of supply may deviate from the data and information as well as from the illustrations described here. Keep a sufficient safety distance.6 Noise emission / sound pressure level The sound pressure level acc. separate the material according to type and size and make it available for further use or recycling. since claims for damages may only be asserted within the valid time for complaints. Structural influences such as ● transmission of noise via steel structures. 3. 3. Spaciously close off the working area. Bring your claim to attention. If you have any questions. ● In the case of transport damage visible from the outside. Note scope of damage in shipping documents / delivery note of the forwarding company. the accessories and the trolleys are shipped in cardboard packing. Sling lifting and handling equipment only at the correspondingly marked points. 19 [m/min] [dB (A)] DC-Pro 1 8 65+2 DC-Pro 2 16 65+2 DC-Pro 5 12 69+2 DC-Pro 10 12 69+2 DC-Pro 15 8 69+2 These noise emission levels were measured under maximum load. ● Claim any defects not immediately detected immediately on detecting the defects. ● If required. were not allowed for in the above measurements. 3.7 3.3.4 Packing Demag chain hoists. 7. ● Do not expose it to aggressive media.5 Storage Keep the equipment and accessories locked and stored only under the following conditions: ● Do not store it outdoors. 60%. ● Protect it against solar radiation. 3. ● Avoid mechanical vibrations. ● Storage temperature: -25 to +70 °C. 214 741 44/210610 29 . ● Avoid strong temperature fluctuations (condensed water). refresh or renew preser‐ vation. If required. 20 RAL 5009 RAL 1007 RAL 9005 RAL 5009 Azure blue Daffodil yellow Jet black Azure blue Other colours are possible. ● Store in dry and dust-free places. the chain hoist is supplied with corrosion protection (powder coating/paint finish) in the following colours: Colours Chain hoist Hook assembly Load hook and suspension bracket Trolley Tab. ● Oil all blank machine parts (rust protection). ● Check the general condition of all parts of the packing at regular intervals. ● If stored in damp locations.8 Surface protection and painting As standard. the equipment must be packed tight and protected against corrosion (desiccant). relative air humidity: max.3. for example: ● galvanizing or electroplating plants.).for very high mechanical demands on the buffers.for extreme ambient conditions (hot atmospheres. Page 30. ● hygiene areas. 21. low-wear operation may be supplied for these applications. Reduced duty factor at increased ambient temperature If the DC chain hoist is operated at ambient temperatures deviating from ⇒ Tab. IP55. Chain hoists. commercial and light-industrial environ‐ ments. Page 11 The chain hoist and the trolley can be operated at: Ambient temperature: Humidity: Height: Type of enclosure: Electromagnetic compatibility: -20 °C to +45 °C. Special operating conditions may be agreed with the manufacturer in individual cases. etc. etc.). 80 % relative humidity. ● DC 15 hook assembly / standard aluminium bottom block with external switch-off springs. frequent contact with sharp edges. trolley and travel drive should be kept under shelter if they are not used for a considerable length of time. ● low-temperature or hot applications. Such operating conditions may occur for the following applications. e. the duty factor must be reduced: Ambient temperature Chain hoist range DC-Pro DCM-Pro DC-Com 1 DC-Com 2-10 Tab. 21 Demag chain hoists operating outdoors should be provided with a canopy against the weather.Use of switch-off springs (optional) . Resistance to interference in industrial environments.for extreme ambient conditions (hot atmospheres. max. On request. . suitable optimised equipment and important information for safe. foundries. Under certain ambient conditions. foundries. galvanizing plants. ● DC1-10 reeving 2/1 DK10 aluminium bottom block with external switch-off springs (optional) . Interference emissions for residential.g. Tab. galvanizing plants. application of cut-off springs is required: ● DC1-10 reeving 1/1 hook assembly . 22 20 / 40 15 / 25 15 / 35 15 / 25 -20 °C to +45 °C > +45 °C to +50 °C > +50 °C to +55 °C > +55 °C to +60 °C Duty factor [%] 15 / 25 15 / 25 10 / 20 10 / 20 30 214 741 44/210610 .3.9 CAUTION Operating conditions Operating safety at risk Safe operation is only possible at the specified operating conditions. up to 1000 m above sea level. In the case of other operating conditions please contact the manufacturer ⇒ "Customer service". When the emergency-stop button is actuated.4 Technical description 4.2 Gearbox and slipping clutch A 1 2 3 Driving Slipping clutch Motor Chain drive B 4 5 6 Brakes Speed detection Brake Gearbox Tab.5 chain hoists is maintenance-free for up to 10 years. mechanical braking is immediately performed independent of the lifting speed.1 Drive and brake A robust pole-changing AC asynchronous motor is used as hoist motor. The additional electrical operating limit switches for the highest and lowest hook position prevent the slipping clutch from being approached as an emergency limit stop device during normal operation. The brake arranged on the load side prevents load sinking when the unit is at rest. 7 Parts in which the load is borne The slipping clutch is arranged between the motor shaft and the gearbox input shaft. The gearbox and the slipping clutch are maintenance-free for up to 10 years. The brake is arranged on the load side so that after an eventual tripping of the slipping clutch. Monitoring the slipping clutch and automatically switching off the drive in the event of slip increase the service life and protect the slipping clutch against overload and incorrect use. The bake is released elec‐ trically. it performs the function of the emergency limit stop device for the highest and lowest hook position and protects the Demag chain hoist against overload. The slipping clutch also fulfills the EC directive requirements for a load control device from a load capacity of 1000 kg on. First the hoist drive decelerates by switching from the fast speed (2-pole winding) to the creep lifitng speed (8-pole winding). Mechanical braking is performed when the creep lifting speed is almost reached. the load is safely braked and held. The motor is automatically switched off and at the same time the brake is applied in the upper and lower end positions of the lifting path. The brake for DC 1 . when the slipping clutch is tripped and in the event of error statuses. 23 Fig. Electrical or regenerative braking of the motor considerably recudes wear of the mechanical brake. In connection with the end stops on the chain. Pressure springs ensure automatic brake application when the motor current is switched off or in the event of a power failure. the brake for DC 10 and DC 15 chain hoists for up to 5 years. 4. 214 741 44/210610 31 . operating status and error messages. 3. the service cover and the movable chain collector box are of particularly impact-resistant plastic material. the chain hoist is automatically brought to a safe status and warning or error messages are generated. In the event of any discrepancies. ● reliable decision for replacing the individual chain drive components. the DSE-10C for applications with electric trolleys. The chain set offers the following benefits: ● the optimum duration of service is ensured for the chain. The electronic system monitors the control sequence specified by the operator based on the speed feedback from the drive shaft. it is not necessary to dismantle the motor or the gearbox. For Demag DC chain hoists without electric trolleys. When a chain is replaced. 4. ● Infrared interface for wireless transmission of service data. motor connection. galvanised with additional surface treatment. if the specified regular lubrications are appropriately carried out. ● Replaceable contactor with socket for DC-Pro 10 and DC-Pro 15. For integrating the DC chain hoist in existing installations with contactor control.4. ● Plug-type connections for control pendant. ● Connection for the E 11 . The contactor control system is supplemented by an electronic system with programmed functions. the control system features the following characteristics: ● Emergency limit switch for lifting and lowering. if applicable. see brochure "Elec‐ trical accessories Polu box "⇒ Tab. For manual control. 32 214 741 44/210610 . As standard. Page 7. Demag control pendants are connected via plug-in connectors. from the thermal contacts of the motor. For this purpose a chain set that can easily be replaced is available. always the entire chain drive is replaced. ● Signal transmission in steps with 24 V tri-state signals for controlled DC chain hoists (half-wave evaluation). the operating limit switch contacts and. the compact DSC optimised for this application is used. This electronic system detects the control commands that are tripped by the operator with the control pendant.5 4. The fan cover on the motor. Page 7.E 34 trolley control system. operating limit switches. The dimension tolerances of this chain have been precisely adapted to the chain drive. For controlling pole-changing AC motors (with or without brake) of cross and long travel units the Polu box with integrated contactor control is required. brake.3 Chain drive The special Demag chain is of high strength ageing-resistant material with a high degree of surface hardening.4 Housing The housing of the chain hoist is of strong light-weight die-cast aluminium.1 Electrical equipment Control The chain hoist is provided with a 24-V contactor control system. The maximum service life of the chain can only be reached. ● reduction in service costs by replacement in one installation process. ● 7-segment display for operating hours. please note the information in the brochure "DC electrical accessories" ⇒ Tab. power supply. Permissible control commands generate switching commands for the contactors to control the hoist motor.5. 3. 4. We therefore urgently recommend that the Demag special chain be used to ensure safe operation. The positively disconnected emergency stop contact of the control pendant immediately opens the circuit for the contactor supply so that the motor is de-energized and the brake is applied. 01 214 741 44/210610 33 . power is switched on or after an emergency-stop. 4.5.eps Fig. 12.5.01). Page 34. 10. Page 124. ● Warning messages ⇒ "Warning messages". 9 Every time. operating hours. ● Error messages ⇒ "Error messages". lower side of electrical equipment cover).4. number of cycles. it can be read through the window on the lower side of the chain hoist (arrow.3 Software version. ● Operating hours ⇒ Fig. operating statuses Display of the software version Fig. The following data can be read: ● Software version ⇒ Fig.2 7-segment display for operating status and error display 43216145. Example: Software version 1. 9. 8 The 7-segment display is arranged on the control card under the electrical equipment cover. Page 33. the software version is displayed (from software version 1. ● Operating statuses ⇒ Fig. Page 34. Page 125. 5 m K1 switching cycles For preventive maintenance see ⇒ "Service life of the contactor". 11 Alternatively displayed with the operating hours. 13 214 741 44/210610 . C 5 corresponds to 5 x 100. 12 4.eps Fig.000 K1 switching cycles Example: C 15 corresponds to 15 x 100.eps 34 Fig. 2 Function Emerg. Page 80 Display of operating statuses No.000 = 1. 24 4 6 8 LOWERING start-up LOWERING V1 LOWERING V2 43216046.000 = 500.Display of the operating hours Fig.6 Central service enclosure 43214444. without any lifting motion (example for 123 operating hours) Display of the number of cycles of the K1 contactor Fig. 10 The display appears after 3 sec. 1 Function Flashing: READY FOR OPERA‐ TION LIFTING start-up LIFTING V1 LIFTING V2 No. stop pressed 3 5 7 Tab. 214 741 44/210610 35 . the DSC control pendants (lifting/lowering) or the DSE-10C (2 to 3 axes) are to be used. The control cable and the control pendant are connected by means of a bayonet lock. it is not necessary to cut the cable conductors or to shorten the strain relief hose. The relevant connectors for power supply. The control cable is reinforced by means of rubber-elastic filler material in the gripping area (0. The service cover of the DC-Pro 15 is made of sheet metal without any pictograms. The control pendant can be adjusted to a different suspension height by unlocking the clamp mechanism. however. hydrochloric or sulphuric) acids may. The strain relief hose is fixed at the selected suspension height by means of a self-locking clamp mechanism. any control cable length that is not required is kept under the cover. The functions are described by pictograms fitted on the outside of the service cover. the chain is also lubricated.7 Control pendant height adjustment / control cable The control cable is protected by a flexible. To do this. oils and alcaline solutions. To avoid this. salt water. The rubber button caps may be subject to premature wear under aggressive operating conditions (contact with corrosive substances or special chemicals).All important service work can be carried out at a central point.8 Control pendant For manual cable-connected control of the chain hoist. the service enclosure. corrode pendant switch housings. The shock and impact-resistant DSC and DSE-10C housings of high quality thermoplastic are resistant to fuels. Strong mineral (e. The plastic cover also provides mechanical protection for the components fitted under it. Its suspension height can be specifically adapted to the requirements at the workplace at any time by means of an adjusting mechanism. The strain relief hose for the control pendant consists of an abrasion-resistant fabric hose with flame-protection impregnation. The control cable that is not required is accommodated under the service cover. In addition. Replace any damaged button caps in good time. Both control pendants feature the same plug-in connection for the control cable. type of enclosure IP 65. easily bent strain relief hose.g. From this point. they must be replaced in good time. 4. control pendant and travel drive are arranged under the impact-resistant plastic cover. 4. greases.8 m) of the strain relief hose. ● Fast lifting or lowering is obtained by pressing the rocker down completely.eps Fig. Convenient operation is mainly due to: The spade handle for guiding. Page 7. when no load is applied. 43214544.4. The handle can thus conveniently be gripped with the left or right hand. The rocker is actuated with the thumb without the fist having to be opened. ● Mechanical interlocking of the switching elements prevents movement in opposite directions being switched on simultaneously. The shock and impact-resistant housing of high quality thermoplastic is resistant to fuels. The integrated quick-release coupling allows the load handling attachments to be removed and replaced within seconds. For further possible applications see Technical data Demag DC-Pro chain hoist ⇒ Tab. Type of enclosure IP 65. positioning and moving the load horizontally. 2 switching stages are available: ● Slow lifting or lowering is obtained by pressing the rocker until a stop is felt. oils. The R/H and L/H rockers (lifting and lowering) which both have the same functions. salt water. 3. The swivel lock of the load handling attachment must not be removed. Power is supplied to the DSM-C control unit through a wear-resistant helical cable. The lifting and lowering movements are marked by arrow symbols.9 Manulift DCM with quick-release coupling The Manulift DCM is equipped with the DSM-C control unit. 14 36 214 741 44/210610 . greases and alkaline solutions. The rigid link between the DSM-C control unit and the load handling attachment provides a direct connection between the operator’s hand and the load. Serial load hook 1 CAUTION Swivel lock Removing the swivel lock (1) means danger to life and limb. Page 7 and "Technical data Demag DC-Pro chain hoist" ⇒ Tab. 214 741 44/210610 37 . belt sling width 45 mm. 3. 3. max. dia. Page 7. to be gripped 430 mm Coupling pin E 1 2 3 Pantograph tongs Swivel lock Length adjustment Closing eye For further information see brochure "PGS parallel gripper" ⇒ Tab.Accessories Fig. 15 A B C D Gripping hook Pantograph tongs Belt sling. 5 214 741 44/210610 Suspension hook. It is not necessary to dismantle existing trolleys. for suspension parallel to track girder 718 278 45 715 278 45 721 278 45 718 910 45 715 910 45 721 910 45 721 870 45 92 124 170 92 124 170 B 18 22 35 22 36 44. The suspension bracket facilitates installation. The short suspension bracket is included for an optimum C dimension.4.10 Suspension Standard suspension Fig.5 Dimensions [mm] H 62. Page 38 38 .4 20. Page 39.5 105 147 104 152 193 h 19. 17 Item 1 2 3 4 No fig. 26. 16 DC-Pro 1-10 chain hoists are supplied with a long suspension bracket as standard. For the DC-Pro 15 only one suspension bracket is available. Chain hoists with short or long suspension brackets can be combined with the trolleys from ⇒ Tab.5 27 38 D 31 53 84 25 36 40 d 8. 25 Designation Size DC 1-5 DC 10 DC 15 DC 1-5 DC 10 DC 15 DC 15 Part no.: L Suspension ring. 16. since the chain hoist can be directly suspended from the trolley.4 18. folding Suspension bracket for KBK III Contour as (5) in ⇒ Fig. Tab. Optional suspension Fig. 1250 1/1 with U / EU 22 DC 36) DC 10 . 16. 16. Page 38 34) up 214 741 44/210610 39 .Assigment of standard suspensions Chain hoist SWL [kg] Reeving Trolley size Trolley SWL [kg] RU 3 450 450 RU 6 700 850 RU / EU 11 DK RU / EU 22 DK RU / EU 36 DK RU / EU 55 DK CF 5 U / EU 11 DC U / EU 22 DC U / EU 34 DC RU /EU 56 DC KBK 100 Trolley I II III Articulated frame (dou‐ ble trolley) I II III 100 Load bar I II III 100 Crab frame I II III Tab.200 kg 38) DC 10 with RU / EU 56 on request 39) up to 500 kg 40) Suspension bracket for KBK III = contour as (5) in ⇒ Fig.2500 2/1 with U / EU 34 DC 37) up to 2.5 16 30 1+2 1 1+2 1 1+2 DC 1 80250 DC 2 160500 1/1 DC 5 3151250 12502500 2/1 10001600 1/1 20003200 2/1 DC 10 DC 15 See ⇒ Fig. 26 100 300 600 1300 400 1200 2600 200 600 1400-2200 2600 200 600 1200/2400 3300 3 3 40) 40) 80125 Flange width [mm] 60-90 58-143 144-300 58-143 144-300 58-300 58-143 144-300 82-300 106-300 106-186 187-300 50-91 58-200 201-310 82-200 201-310 82-310 98-200 201-310 30 55 30 40 1 15 22 30 22 16 Flange thickness [mm] 12 20 18 20 18 Crossbar diameter [mm] 21 30 35 30 38 34 45 51 56 70 82. Page 38 1+2 1 1+2 1+2 33) 1 33) 1+2 1 1 1350 2600 3600 5500 550 1100 2200 2200 3400 5600 3+4 3+4 5 5 34) 5 1+2 1+2 3+4 35) 1 1 3+4 36) 5 3 38) 3 38) 5 37) 5 2 2 2 3+4 39) 3 1 1 1 3 3 40) 3 1 1 1 3 40) 33) up to 400 kg to 2500 kg 35) DC 10 . see ⇒ Tab.4. For further information on the trolleys and the power supply. The load capacity of Demag chain hoists must not exceed the load capacity of the trolley. joint flanges. The curve radii should be as large as possible in order to ensure good travel characteristics. etc. Curve radii in mm Trolley size SWL Push travel Flange width41) [kg] CF 5 U 11 DC U 22 DC U 34 DC RU 56 DC Tab. clamping plates.g. Contact the manufacturer or his representative for frequent curve travel operation (e. 3.11 Trolley Fig. 40 flange width 500 mm (except CF 5) travel rollers optional 43) From flange width 106 mm 42) Steel 214 741 44/210610 . Demag clamp-fitted buffers). Page 7. Hoist travel on I beam tracks must in no way be obstructed by protruding suspension bolts.g. 27 EU 11 DC EU 22 DC EU 34 DC EU 56 DC 550 1100 2200 2200 3400 5600 [mm] 50-91 58-310 82-200 201-310 82-310 98-310 2000 43) 2000 Rmin [mm] 800 1000 [mm] 58-310 82-200 201-310 82-310 98-310 2500 43) 3000 Runway girder Electric travel Flange width41) Rmin [mm] 2000 Plastic Plastic42) Spheroidal graphite cast iron Spheroidal graphite cast iron Travel wheel material 41) Max. I beam track The use of I beams with parallel or sloping flanges according to DIN 1025 as tracks is possible. Curve radii for trolleys The specified curve radii apply for normal applications. automatic installations). 18 WARNING Overload There is danger to life and limb due to a possible excessive load of the trolley. I beam tracks should be bent with the utmost care in order to obtain a clean. Resilient buffers should be mounted at travel wheel axle level at the ends of tracks in order to prevent the trolley from derailing (e. regular curve. screw heads. SWL [kg] 80 to 200 200 250 Chain hoist size DC-Pro 44) 1-5 10 2-5 10 5 Reeving V14/3 Trolley Travel drive Possible cross-travel speeds in approx.. 214 741 44/210610 44) If DC-Pro 10 is combined with EU 56 DC. m/min V12/4 Trolley EU 56 DC EU 56 DC Travel drive ZBF 80 A 12/4 ZBF 80 A 12/4 ZBF 80 A 12/4 ZBF 80 A 12/4 Trolley U 11 DC U 11 DC EU 56 DC U 11 DC U 11 DC EU 56 DC U 11 DC U 11 DC EU 56 DC U 11 DC U 11 DC EU 56 DC U 11 DC U 11 DC EU 56 DC V24/6 Travel drive E 11 DC E 11 DC ZBF 71 A 8/2 E 11 DC E 11 DC ZBF 71 A 8/2 E 11 DC E 11 DC ZBF 71 A 8/2 E 11 DC E 11 DC ZBF 71 A 8/2 E 11 DC E 11 DC ZBF 71 A 8/2 Trolley EU 56 DC EU 56 DC EU 56 DC EU 56 DC V40/10 Travel drive ZBF 80 A 8/2 ZBF 80 A 8/2 ZBF 80 A 8/2 ZBF 80 A 8/2 - 315 10 5 1/1 EU 56 DC EU 56 DC - 400 10 5 10 10 10 15 10 2/1 1/1 2/1 1/1 10 15 10 15 10 15 10 15 15 2/1 U 34 DC E 34 DC 500 630 800 1000 1250 EU 56 DC ZBF 80 A 12/4 1600 2000 2500 3200 Tab. . ● If several trolleys are operated on one girder. 28 U 22 DC EU 56 DC E 22 DC ZBF 71 A 8/2 EU 56 DC ZBF 80 A 8/2 EU 56 DC ZBF 71 A 8/2 For further possible applications see Technical data Demag DC-Pro chain hoist. 41 .. we recommend the use of trolley buffers to dampen any collisions between the trolleys. ● If the EU 56 DC travel drive is used with small flange widths it is necessary to fit supporting rollers to the trolleys. a special crossbar is required. for terminal boxes or limit switches. 3. e. For further information on the trolleys and the power supply. 19 When selecting a track.g. They feature in particular quiet running characteristics. track switches and turntables. a low rolling resistance and a low deadweight. butt straps. we suggest you specify our KBK crane construction kit track section of special design. KBK profile sections can also be used for more complex installations including curved sections. see ⇒ Tab. clamping plates. screw heads. Page 7.KBK track Fig. Special fittings on the KBK profile sections. avoid any obstruction by sus‐ pension bolts. 42 214 741 44/210610 . The cold-rolled track sections feature a smooth running surface and offer the advantage of simple power supply by means of trailing cables or integrated conductor lines. Otherwise serious damage may be caused to the hoist. The owner must appoint a coordinator who is authorized to issue instructions before assembly work commences. tested and calibrated tools and accessories may be used for assembly or disassembly work. – DANGER Live components 214 741 44/210610 Danger to life and limb. Secure working and danger zone. Appropriately fit component parts. only systems designed for passenger transport should be used that provide for a stable position and work without any risk. – – – – – – – – – Before starting work ensure that sufficient working clearance is available.5 Assembly 5. The electrode holder and earth must be connected to the same assembly when welding work is carried out. Wear protective equipment! Caution on open sharp-edged parts! Risk of injury! Ensure order and cleanliness at the workplace. The chain hoists are supplied with power from an AC power network. Welding work may only be carried out by persons having a special qualification. The requirements of DIN regarding welding work must be complied with. we recommend this work be carried out by our trained specialists or by persons authorized by us. mistakes when assembling by the customer cannot be excluded. Despite detailed information. Only suitable. For this reason. It must be possible to switch off powerfeed by means of a device for disconnecting the powerfeed (e. Customer-specific regulations must be observed. Work on electrical equipment may only be carried out by qualified specialist personnel(⇒ "Definition of personnel".2 DANGER Safety instructions for assembly Inappropriate assembly Danger to life and limb. DANGER Live components Danger to life and limb. The wiring of the Demag chain hoist complies in all respects with current DIN VDE and accident prevention regu‐ lations. Inappropriately fixed component parts may fall down and result in severe injuries. 5.g. Page 10 ) in compliance with the safety instructions. Unauthorized intervention and modifications result in eliminating compliance with these regulations.1 General These assembly instructions enable the owner to fit and/or refit or replace the DC-Pro himself. 43 . Machine parts or fittings that are not required must be stored so that they cannot fall down. When using a working platform for assembly. Therefore only authorized and trained personnel who is familiar with the operating principle of the machine may carry out this work in com‐ pliance with all safety regulations. Tighten screws with the prescribed tightening torque. Inappropriate assembly may result in serious personal injury and / or material damage. mains connection or isolator switch with padlock). The voltage and frequency of the AC power network must match the data specified on the rating plate of the chain hoist. Any change or modification which prejudices safety must immediately be reported to the nearest person responsible. All assembly work must be completed in accordance with the operating instructions and the hoist chain must be greased. Earth junctions and connections must be protected against self-loosening (e.g. without affecting operation of the rest of the system. Isolator switch If two or more hoists are fed from a common main supply line. Check that pin connections are properly secured. by using serrated lock washers to DIN 6798). This makes it possible to carry out maintenance work on individual hoists. Continuity of the PE conductor connection must be checked. The protective earth conductor must not be connected to mounting bolts or screws.Before starting work. Operation with defective or damaged chains results in a high risk of accident for persons and the chain hoist and is therefore prohibited. Only by tightening to the specific tightening torque can a sufficiently secure connection be guaranteed. Mechanical safety All bolted connections must be correctly tightened. This switch must be arranged to disconnect all poles of the DC-Pro chain hoist from the mains supply. These operating instructions only contain standard circuit diagrams. The control device (e.g. The arrow symbol on the control elements must correspond to the direction of movement. Power supply system The power supply line / cable to be used depends on the motor size. Depending on the type of chain hoist an orderspecific circuit diagram may apply. each one should be provided with an isolator switch. the electrical supply must be switched off. It must be possible to disconnect each individual connection. The clamping torque of a self-locking nut must not be lower than the screw-off torque specified by EN ISO 2320. The mains connection or isolator switch must be secured against unauthorized or accidental reconnection by means of a padlock. Ensure that the switch is installed in an easily accessible position near your machine and clearly marked. Electrical safety The chain hoist operating instructions must be referred to when Demag chain hoists are used. Protective earth conductor The protective earth conductor in insulated leads and cables must be coloured green and yellow along its entire length. control pendant) must be marked in such a way that the direction of movement is clear and distinct. Repairs may only be carried out by experienced technicians. 44 214 741 44/210610 . Self-locking nuts must be replaced when they have been tightened and untightened five times. Self-locking nuts must not be replaced by other types of nut. Bolted connections must not be lubricated as otherwise the specified tightening torque values will be too high. Mains connection switch A mains connection switch must always be provided for the main power supply line of the machine. see section "Hoist motor data". Protective earth conductors must not carry any current in operation The same number of protective earth connection points must be provided as electrical power infeed and outfeed points. Ensure that all suspension fittings are freely accessible for checks and inspections or that free access can be pro‐ vided. 0 5.5 3. 9. Adjust lower hook position as required ⇒ "Setting the lower hook position". 5.5 1. 7. Connect to power supply ⇒ "Line connection". 2.5 5.5 25. Carry out inspections prior to putting the hoist into service for the first time ⇒ "Inspections prior to putting into service for the first time". Which suspension bracket is suitable for suspension? ⇒ "Suspending the chain hoist".0 6.8 4. Unpack and dispose of packing material in an environmentally compatible way ⇒ "Transport. Page 28. as required ⇒ "Connecting the control pendant". – Self-locking nuts must not be replaced by other types of nut.3 Tightening torques DC-Pro chain hoist Tightening torques [Nm] Reeving Motor Fan cover Gearbox cover Gearbox housing 2-piece Gearbox screw plug Gearbox vent valve Brake Operating limit switches Control set Electrical equipment cover Service cover Limit stop Anchorage halves Guide plate Hook assembly Bottom block with external switch-off springs Bottom block with internal switch-off springs Screw for chain retainer halves (Manulift) Control cable lock Tab.5. Page 69.5 5. Page 48.5 11.0 DC-Pro 15 1/1 2/1 CAUTION Loose connections Loose connections mean danger for life and limb or risk of machine damage.0 9. 5.5 3.0 52. ⇒ "Operation". 6.5 4. Page 67.0 25 25 5. The unit is ready for operation. Check for completeness ⇒ "Transport inspection". Page 70.0 DC-Pro 1 DC-Pro 2 1/1 9. 29 Bottom block halves Guide halves 5-6 11.4 Assembly procedure 1. Page 54. Page 51.5 4. Page 28. Metal nuts featuring a locking element (self-locking nuts) are mainly used for Demag chain hoists. packing and storage".5 25 55.0 25 15 15 DC-Pro 5 DC-Pro 10 1/1 2/1 25.0 55.5 7.5 27.3 10. 8. 4. Page 46. 214 741 44/210610 45 .0 5. Connect control pendant. Adjust control pendant height ⇒ "Height adjustment of the control pendant". 3. proceed as follows: 1.. it can be pulled out and must be locked again by pressure. Plug the control cable into the control pendant and turn the bayonet lock until it is locked. Slide the bend protection sleeve (1) onto the control cable. see ⇒ "Mobile control system".eps Fig. If a connector is not locked. Slide the bend protection sleeve (1) over the control pendant again. 2. Then pull the bend protection sleeve (1) off the control pendant. Pay attention to the positioning help. 46 214 741 44/210610 . 4. Unless the chain hoist is supplied with fitted control pendant. Lift the bend protection sleeve (1) on the control pendant off the two pins. Press the bend protection sleeve (1) firmly onto the control pendant.that the two pins (c) on the control pendant housing match the bayonet lock (d). connect the DSC control pendant with the control cable and lock the connection with the bayonet lock. 3. The control pendant can be fitted on the chain hoist as a stationary unit or installed as a travelling unit.the groove (a) of the connector holder matches the swivel lock (b) in the control pendant housing and .5. 20 The control pendant is of plug-in design. Page 52. Ensure that . The connector at the end of the control cable is locked in the bayonet sleeve and can be turned.5 Connecting the control pendant 43215144. 214 741 44/210610 47 . 21 Fig. 3.2 Suspension bracket Fig. 30 Designation Suspension bracket openend DC-Pro 10. 1/1 reeving DC-Pro 10. According to DIN EN 14492-2.6 The static and dynamic forces which occur when the overload protection is tripped must be taken into account when designing the supporting structure.6. 5.6 5. The slipping clutch must be adjusted to the load capacity of the chain hoist.1 DANGER Suspending the chain hoist Supporting structure Overload There is a danger to life and limb due to overloading the supporting structure. According to DIN EN 14492-2. Page 7.5. 2/1 reeving Item 1 2 3 4 Designation Suspension bracket Retaining clip Pin 214 741 44/210610 Spacer tube (DC-Pro 10) 48 . the force limitation factor for DC-Pro chain hoists with a load capacity ≥ 1000 kg is: ϕDAL = 1. The supporting structure must be designed for the maximum load of the chain hoist when being used appropriately. Information on the adjustment see brochure "Friction force checking device" ⇒ Tab. hoist units with a load capacity ≥ 1000 kg must be equipped with an overload pro‐ tection. 1/1 reeving DC-Pro 15.6. 2/1 reeving DC-Pro 15. DC-Pro chain hoists are equipped with a slipping clutch which directly acts as overload protection. A) B) C) D) E) Tab. make sure that an appropriate counterweight compensation is taken into account. Suspension of the chain hoist at an angle results in premature wear of the chain drive. Page 116 Tightening torques [Nm] Screw plug M16 Vent valve M16 Tab. Fitting: 1. The chain hoist is delivered with the long suspension bracket (DC-Pro 1-10) completely fitted to the chain hoist. The enclosed short suspension bracket (DC-Pro 1-10) can be fitted for an optimum C dimension. the chain hoist is suspended at an angle. Remove the retaining clip and pin on one side. The suspension / supporting structure for the chain hoist must be designed for the loads. vent valve Before putting the chain hoist into operation. 31 DC-Pro 15 15 15 Fig. Suspend the suspension bracket (DC 10. Make sure that the suspension bracket is fitted in accordance with the reeving arrangement of the chain hoist. In the case of special fittings on the chain hoist. 3. 22 214 741 44/210610 49 . 5. remove the screw plug (1) (plug and O ring) and screw in the vent valve included in the supply. – DANGER Falling down of the chain hoist There is danger to life and limb or of material damage.WARNING Overload There is a danger to life and limb due to overloading the components. 2.7 Screw plug. Slide the pin through the suspension and the suspension bracket (for DC 10 additional spacer tube (4)) and secure with the retaining clip again. See also ⇒ "Gearbox / oil change". If the suspension bracket is fitted inappropriately. Do not move the chain hoist or leave it unsupervised when the suspension bracket is open. DC 15 according to the reeving) in the superstructure / trolley. 24 50 214 741 44/210610 . The adjust‐ able height variation is 2 or 3 m.8 5.3. 32 The control pendant is supplied with standard cable lengths. 42597646_XML.8 m Tightening torque [Nm] 11 H11 6.2. 23 ● To ensure an ergonomic position for operation of the control pendant. A winding protection for the upper area of the control cable can be used as an option. Ergonomic workplace! ● The suspension height can be adjusted by means of a self-locking mechanism at any time to suit individual re‐ quirements.8 m . Designation Protective sleeve with fitting material Tab. adjust the suspension height in such a way that the operating elements are arranged at elbow height.9.8 m H8 3.8 m .5. 33 Part no.8 m Hook path Cable lengths Tab.8.6.8 m H5 0. with a 2TY control cable and DST-C or DSE-C control pendants.8 m .2 Handling the control cable Do not allow the control cable to be wound around the chain when lifting motions are performed.8.eps Fig.1 Control cable Techncal data of the control cable Item 1 2 3 Designation Hose pocket Operating buttons of the control cable stop Screw of the control cable stop H4 0.: 720 085 45 Fig. Longer control cable lengths are provided. for example. 5.8 m . 5. Take the control cable out of the pocket. Slide the operating button of the control cable stop downwards and fix the stop by a short. At the same time. Close the service cover (tightening torque 5. 4. 3. 5. The pocket must be behind the edge of the chain collector box. 214 741 44/210610 7. If the position is too low. Lay the remaining control cable in loops and store it in the pocket. 25 x y 1. 6. strong pull on the control cable above the control pendant. Remove and open the pocket with the control cable. Slide the operating button of the control cable stop upwards and hold it. pull the control cable until the correct height has been reached for the control pendant.3 Height adjustment of the control pendant Fig. Control cable stop fixed Control cable stop loose Undo the screws of the service cover. 2. pull on the control cable hose hanging behind the service cover.8. Open and disengage the service cover.5 Nm). 51 . 4 Mobile control system Component parts Item 1 Designation Flat cable 11-pole + PE Socket enclosure 2 Connector enclosure cpl. Fitting frame Pin insert VC-AMS8 Flat cable union Bayonet lock 3 Connector adapter cpl.5. Bush enclosure VC-MP-1-R-M25 Bush frame VC-TR1/2M Socket insert VC-TFS8 4 5 6 Tab. Fig. H8. H5. 35 Con‐ duc‐ tor PE 8 4 3 2 1 B4 B3 B2 B1 A4 A3 A2 A1 PIN B8 B7 B6 B5 A8 A7 A6 A5 Con‐ duc‐ tor 11 10 7 9 6 5 Signal Reference potential (24 V) Right Lowering Control voltage (24 V. H11 are used. 27 . STS) Backward Special 1 (F1/F2) 52 214 741 44/210610 Fig.: 720 139 45 For use of the cable collector. 34 Cable collector DSE10-C control pendant Control cable lock 720 065 45 773 352 45 720 087 45 720 187 45 comprising Part no.8. the height-adjustable standard control ca‐ bles H4. 26 X40 plug connector connections Signal PE Special 2 (horn) Left Lifting Emergency stop Forward Tab. 214 741 44/210610 53 . 9 Line connection Fig.5 Strain relief attachment DC-Pro 10 Strain relief attachment DC-Pro 15 Item 1 2 3 Designation Seal.5. 36 . sleeve Connector 4-pole Connector enclosure Item 4 5 6 Designation Line connection Recess for round cable Recess for flat cable 214 741 44/210610 54 Tab. 28 Item A) B) C) Designation Strain relief attachment DC-Pro 1 . WARNING Incorrect direction of movement There is a danger to life and limb due to an incorrect direction of movement. Switch on the power supply. L2. Change over leads L2 and L3 of the supply cable on the mains connection switch. The load hook must now move upwards. this is the way to establish the connection with the correct phases. For DCPro 1 to 5 units. ● Use the mains connection set included in the scope of delivery to produce the plug-and-socket connection for the mains connection cable. for a flat cable in the marking area of 18 x 7 to 20 x 8.5 mm2 or 4x2. ● Cut the sleeve (1) to suit the geometry of the mains cable. ● For a round cable in the marking area of 7 to 13. Cable cross-sections 4x1. ● Slide the connector (2) into the enclosure (3) until it latches and close the enclosure (3) with the sleeve (1). the chain hoist must be switched. ● Remove the service cover to connect the supply cable. Checking the direction of movement To check whether all phases are correctly connected. ● All enclosure parts must be securely latched to ensure the unit is sealed. Page 22 is required. If required. the lifting and lowering buttons correspond to the movements of the load hook. Phase sequence for connection to the AC power network The chain hoist is configured for connection to a R-S-T network turning clockwise. use the wire end sleeves included in the delivery. Please note that the length of the supply cable specified for a given cross section must not be exceeded in order to avoid excessive voltage drop and malfunctions during start-up of the motor caused by undervoltage. L3 and to the PE. ● The mains connector must never be disconnected under load. 214 741 44/210610 55 . If the phase sequence of the connection cable is unknown. ● After connection of the mains cable and before putting the chain hoist into operation. Make electrical connection ● First check whether the voltage and frequency specified on the capacity plate match your mains supply. the mains connection cable. unlock the emergency stop and actuate the pushbutton for "Lifting" on the control pendant. a 4-lead cable with an earth lead (PE). ● Finally. check the continuity of the earth lead connection. the mains connection fuse links and the devices for disconnecting and switching the powerfeed must be available on site. switch off the power supply on the mains connection switch and check that the unit is deenergized. ● Connect the mains cable on the connector (2) to terminals L1.To connect the chain hoist to the power supply. For connection of the mains phases R-S-T to L1-L2-L3 in the specified sequence.5 mm2 are taken into account. the strain relief clamp must be turned to suit the cable contour depending on the cable type (flat or round cable). which complies with the table in ⇒ "Hoist motor data ". Then check the movement directions as described in the following. Make sure the sleeve (1) tightly encloses the cable to comply with the type of enclosure. Ensure that the mains connection cable is at zero voltage and secured against accidental restoration of the power supply. – – If the direction of movement is incorrect. For power supply. insert the mains cable into the union on the gearbox housing and fix it with the strain relief clamp. ● Then place the connector (2) into the control system until the enclosure (3) latches with the board bracket. ● Slide the sleeve (1) onto the mains cable. 5. 29 214 741 44/210610 .1 Circuit diagrams and control cards Circuit diagram DC-Pro 1 .15 solo hoist 56 Fig.10 5.10. 214 741 44/210610 Fig. 30 57 . 58 214 741 44/210610 Fig. 31 . 32 59 .2 Circuit diagram DCM-Pro 1 .10.5 solo hoist 214 741 44/210610 Fig.5. 33 .60 214 741 44/210610 Fig. 34 61 .214 741 44/210610 Fig. E 34 DC travel drive.3 Circuit diagram with E 11 . 3.5.E 34 travel drive see ⇒ Tab. 3. Page 7 Technical data E 11 . For further information on the E 11 . Page 7 Assembly in‐ structions E 11 .4 Control board Fig.E 34 travel drive see ⇒ Tab. 35 Item 1 2 3 4 5 Designation Plug-and-socket con‐ nector Plug-and-socket con‐ nector Relay Relay Relay Terminal strip X8 X6 Function Motor 214 741 44/210610 Brake Slow / Fast Lifting / Lowering Lifting / Lowering (from 2009) 62 .10. For further information on the cross-travel limit switch. 3. 5.E 34 travel drive For further circuit diagrams with E 11 .E 34 DC travel drive. see ⇒ Tab. 716 663 45. part no.10. Page 7 Assembly instructions E 11 .E 34 DC travel drive. status indicator. 36 Pin 1 (1) 7 8 9 10 Tab. 37 Pin 1 (1) 214 741 44/210610 63 . error code display X4 X5 X3 Lifting limit switch Trolley (optional) Control cable RJ45 connec‐ tor PIN 1 2 3 4 5 6 Fig. 37 Designation Contactor Transformer Plug-and-socket con‐ nector Fork light barrier IR transmitter diode 7-segment LED Plug-and-socket con‐ nector Dummy plug Plug-and-socket con‐ nector Serial number Terminal strip Function On / Off X1 Line Pulse generator IR interface Multi-function display..g. 38 Control cable X3 (14) Special F1 Crane forward Crane backward Emergency stop Supply control pendant Lifting Lowering Trolley right Trolley left Special F2 Function assignment Trolley X5 (13) Special F1 Crane forward Crane backward Emergency stop Supply control pendant 24 V AC from chain hoist Reference potential control pendant Trolley right Trolley left Special F2 Function assignment PIN 1 2 3 4 Tab. 39 Lifting limit switch X4 (12) Lift (BN) Lift (BK) Lower (BN) Lower (BK) Fig. e.Item 6 7 8 9 10 11 12 13 14 SN..: Elapsed operating time counter. Tab. 2 Meaning of keys Fig.11. the pushbutton actu‐ ated first has priority.5. n. 41 64 214 741 44/210610 . 40 "Lifting" .3 Meaning of parameters From software version SW 2.g. for tandem operation) n.11 5. Y.Move to next parame‐ ter or selection value 3 "Emergency stop" . 5.Accept selection 2 "Lowering" . the following parameters can be programmed: Display of parameter no. 0 1 2 Parameter name Hoist only V2 speed n. 38 1 Tab. Factory setting V1/V2 V2 Factory setting Control pendant is interlocked when several pushbuttons are actuated. The parameters are set by means of the control pendant in connection with the 7-segment display on the bottom side of the chain hoist. Time-controlled start-up (e. Factory setting Speed-dependent start-up Time-controlled start-up Display of parameter value Remarks 4 5 6 7 8 9 Tab. 3 Interlocking of the control pendant Y. If “Lifting” and “Lowering” are actu‐ ated together.11.10. Y.11.1 Setting parameters with the control pendant General It is possible to set parameters in order to adapt the chain hoist to specific applications.End parameter programming (changes are saved) 5. 2 seconds. 6th step: Press the "Lower" key to move faster through the menu items. 40 4th step: "P. 7-segment display: (display spot) 3rd step: When "P. Each figure represents a parameter. Page 64.4 Starting parameter setting mode Fig. 2nd step: Press and hold down the "Lift" key and unlock the emergency stop. each." (for O. Fig.5." are displayed successively for 2 seconds." extinguishes after approx. Wait for approx. 42 7-segment display: P. 10 sec‐ onds. The parameter programming mode is actice now.11. Tab. 5th step: Release key. 39 1st step: Actuate “Emergency stop”. figures "0. 7-segment display: 7-segment display: o." is displayed." to "9. 7-segment display: 0. → 1. 43 214 741 44/210610 65 . When the parameter programming mode has been activated.K. release the "Lift" key. 7-segment display: (display dark) Tab. ··· 9. see ⇒ "Meaning of parameters". Press the "Lift" key and hold down again until "o.) is displayed. see ⇒ "Meaning of parameters". the unit switches back to normal oper‐ ation." etc. For the meaning of the characters. C. the value until the required value is shown in the display. All changes are first saved. b.". The currently set values are symbolically displayed with the characters "A.". 7-segment display: A. "b. Page 64. 7-segment display: Tab. 7-segment display: 10th step: When the "Emergency stop" key has been actuated. At the same time. the system then also returns to parameter se‐ lection mode. 42 66 214 741 44/210610 .Fig. 45 Fig. "C. Tab. 44 7-segment display: 9th step: The value is selected by means of the "Lift" key. 41 7th step: 8th step: Actuate the "Lift" key to select the currently dis‐ To set a different value. selection menu of the parameter is opened. actuate the "Lower" key played parameter. 214 741 44/210610 Move the hook as shown in the figure. 3. The unloaded chain fall behind the limit stop must consist of at least 5 chain links.3 DC-Pro 15 To reduce the hook path. 5. Stop the chain hoist by actuating the emergency stop or the mains connection switch and secure it against switching on again. 6. Page 87. Switch on the chain hoist and check the setting of the bottom hook position by moving the hook and run the hook path setting once through its entire length. Place the chain into the collector box and refit to the chain hoist. ● Pay attention to assembly sequence! See also ⇒ "Buffer design". Fix the actuating plate directly behind the buffer. Detach the limit stop on the chain collector side. 46 Designation Buffer (limit switch option) Actuator plate Buffer plate Item 4 5 Designation Limit stop Unloaded chain fall For determining the hook path / lifting height. it must be taken into account that in the bottom hook position the load hook rests on the floor. 67 . proceed as follows: 1. 43 Item 1 2 3 Tab. Dismantle the chain collector box ⇒ "Dismantling the chain collector box".0 DC-Pro 2 DC-Pro 5 DC-Pro 10 4.12 Setting the lower hook position Fig. As standard. 7. Page 110 Tightening torques [Nm] Limit stop Tab. 4. 47 DC-Pro 1 4.5. 2. the chain hoists are provided with a hook path of 5 m or 8 m. Fix limit stop to the 5th link at the dead (unloaded) end of the chain. 1 Safety instructions when first putting the unit into service The machine may only be handed over. handing over". 6. 68 214 741 44/210610 . hoists and towing devices in Germany. Before putting into operation check that the safety equipment is fitted / functioning. All inspections must be arranged at the specified time intervals / points of time and documented by the owner. For the values for noise emission measurement according to DIN 45635 please refer to ⇒ "Noise emission / sound pressure level". – – Adjustment.2 Inspection regulations WARNING Non-compliance with operating and maintenance instructions Danger to life and limb. This also applies to manually operated or semi-powered chain hoists with a load capacity of more than 1000 kg. – Inspection in accordance with relevant national regulations. Check that the mains voltage and frequency match the data specified on the rating plate.g. Before starting work ensure that sufficient working clearance is available. Page 69. Secure working and danger zone. WARNING When first putting into service. UVV/BGV D6 for cranes. when assembly has been completed according to the assemly instructions. maintenance and inspection activities and inspection deadlines including specifications concern‐ ing replacement of parts/assemblies prescribed in the operating instructions must be observed. Wear protective equipment! Only trained specialist personnel must be employed for first putting into service since: ● it may be necessary to render safety devices or features inoperative when carrying out adjustments or function checks. The owner is responsible for ensuring that powered chain hoists are inspected by an expert engineer prior to first putting into service and after major modifications have been carried out. if its safety has been verified by a corresponding inspection ⇒ "Inspections when first putting into service. – – – – – – – Putting into service may be carried out by specialist personnel. e. Page 28 This work may only be carried out by specialists. UVV/BGV D8 for winches. ● work may need to be performed in the danger zone when first putting into service. Move the trolleys by hand and check that they can be moved without resistance by hand over the entire length of the track section (if existing). before putting into service again. Machines may only be put into service. Compliance with all inspection regualtions is an integral part of securing the safe operation of the machine. Prescribed tests and inspections must be carried out.6 Putting the unit into service for the first time 6. only. safe operation of the machine is not yet guaranteed. operating statuses".3 Inspections prior to putting into service for the first time Before putting into service for the first time. ● Safety devices must be completely fitted and effective. Machines may only be put into service. all possibilities of intended use must be checked at the corresponding maximum permissible load.4 Inspections when first putting into service. operating hours. number of cycles.6. 48 X X X 6. ⇒ "Checking the operating limit switch actuator". 214 741 44/210610 When handing over the machine. After the machine has been handed over. At the same time the behaviour of the chain hoist in the case of misuse must be checked. Page 87 ⇒ "Checking the operating limit switches". the test and inspection records (test and inspection booklet. ● The emergency stop device must be checked by actuating the emergency stop. it may be used as intended. The following checks must be carried out when first putting into service: ● The proper condition of the supporting structure and the load capacity of the chain hoist. by lifting an overload). the owner ensures that the load handling attachments and machinery ready for operation function in complete safety before first being put into service. Page 54 ⇒ "7-segment display for operating status and error display". Page 109. Page 33. Page 93 ⇒ "Checking the operating limit switches". when they have been inspected according to the accident prevention regulations. observe the relevant country-specific regulations) are handed over.g. different inspections of the machine must be arranged for: ● Inspection for suitability for operation ● Acceptance test As soon as the safe operating status of the chain hoist is ensured. Page 88 ⇒ "Checking the load hook". Page 87 ⇒ "Checking the switch-off buffer / switch-off spring". Page 100 Inspec‐ tion X X X X Check chain lubrication (under arduous conditions. the owner is obliged to carry out the following inspections: Action Check continuity of the PE conductor connection Check emergency stop device Check direction of movement Check 7-segment display Section ⇒ "Line connection". ● Clearances and safety distances must be complied with. the chain must be lubricated more frequently) Check function of operating limit switch for lifting Check function of operating limit switch for lowering Check switch-off buffer / switch-off spring / operating limit switch actuator X X X X Check control cable and control pendant housing for damage Check operation of the brake Check hook and hook safety catch Tab. Page 33 ⇒ "Available hoist chains". 69 . The specified measures must allow for the static and dynamic features of the machinery. handing over WARNING Impermissible operation There is danger to life and limb when the machine is operated without previous inspection. the test and inspection records can be prepared. By means of suitable measures carried out by the owner or on his behalf. Before handing over. When putting into service for the first time. ⇒ "Software version. The functioning of the safety devices must be checked (e. Do not reach into the coupling area when changing the quick-release coupling of the Manulift. e. 206 093 44. at the mains connection switch). WARNING Suspended load! Falling parts! There is danger to life and limb. Do not reach between hook throat and load handling attachment when lifting loads. apply a copy of the relevant operating regulations.g. Do not reach into the upper or lower chain entry point. . National regulations for the use of crane and lifting equipment must be observed and complied with. no. The unit may only be operated by authorized. – – – – – WARNING Risk of burning There is a risk of burning when touching the chain hoist during operation. – – – – WARNING Non-compliance with operating regulations / regulations regarding industrial safety There is a danger to life and limb due to the non-compliance with valid standards. Safety devices must not be rendered inoperative or modified in contradiction to their intended use.1 Safety instructions for operation WARNING Inappropriate operation There is a risk of injury in the case of inappropriate operation. Keep a sufficient safety distance. It is not allowed to lift loads above persons. – If required. Inappropriate operation may result in serious personal injury and / or material damage. Persons must keep out of the danger zone. 70 214 741 44/210610 The machine must not be put into operation or must be taken out of service immediately if any defects or irregularities relating to operating safety and reliability or function are detected. when lifted loads fall down.7 Operation 7. Machines may only be operated in compliance with the country-specific operating regulations. The customer must arrange for the training of the operating personnel. Do not touch the hot motor housing. Persons must not stay in the immediate danger zone when depositing the load. Do not walk under the suspended load. – WARNING Crushing hazard When lifting or lowering loads there is a risk of injury due to parts of the body being crushed or clothing or hair becoming entangled. ident. Wear protective equipment! Do not touch the chain. at a suitable place where operators can read them at any time (e. Cranes BGV D6 (VBG 9) in Germany.g. instructed personnel in compliance with all accident prevention and safety regulations. Work on electrical equipment may only be carried out by qualified electricians. Before starting work: ● Wear protective equipment! ● Check that no persons are in the danger zone of the unit. This also applies in the case of damage occurring to parts of the machine and equipment which makes immediate stop‐ page necessary.2. Defects relevant to safety in this sense are.2.2 7. Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay. he must stop operation immediately and may not resume operation until the persons are outside the danger zone. This does not apply to slipping clutches used as an emergency-stop device which need not be checked when starting work (BGV D06. the operator must carry out all prescribed safety measures or observe that they are automatically carried out.2 Functional tests Instructions for users within the scope of application of the BGV D06 accident prevention regulations: In accordance with BGV D06. the crane operator must also check functioning of the emergency stop device when starting work.1 Switching on Inspections when starting work Before starting work. In this case. the operator must be satisfied that the machine is in safe and correct operating condition. When the chain hoist has been stopped as a consequence of safety-relevant defects by an emergency stop.g. ● Missing covers or housing parts or ● Damage to the chain or to supporting parts. in the event of operating malfunctions. 7. for example: ● Damage to electrical devices. the owner must ensure safe operation or take the machine out of service until measures for safe operation have been clarified and implemented in agreement with Demag or other responsible bodies. §30). for repairs and maintenance purposes. the chain hoist must be taken out of service without delay. it must be secured against putting into operation again until an experienced technician is satisfied that the cause of the hazard situation has been eliminated and that operation of the machine is possible without any hazard. DC chain hoists are fitted with a slipping clutch as an emergency-stop device which needs not be checked by the crane operator. ● Delayed functioning or failure of brakes and safety devices. cables or insulation. In the event of a stoppage (e. Before starting work the main functions of the machine must be checked: 214 741 44/210610 71 . if damage is detected or after finishing work). 7.Ensuring safe operation Special local conditions or special applications can lead to situations which were not known when this chapter was written. If the operator notices persons who may be exposed to a risk to health or personal safety by operation of the installation. if defects regarding safe and reliable operation are detected. Ensure that nobody is endangered by operation of the hoist before switching it on or putting it into operation. in emergency situations. therefore a device for by-passing the limit switches which are approached during normal operation is not fitted. In the event of defects which endanger safe and reliable operation. operating hours. – – – WARNING Moving parts may start moving.3. 214 741 44/210610 . Danger to life and limb. Please note the maximum permissible load capacities of the hoist. Page 87 ⇒ "Checking the switch-off buffer / switch-off spring". i. Use the load handling attachments as intended. Page 100 Inspec‐ tion X X Check chain lubrication (under arduous conditions. Page 33. ⇒ "Software version. Use load handling attachments which are sufficiently dimensioned. Important information on operation Please follow the instructions below during operation: Safety during operation – – 72 Take the machine out of service immediately if functional defects or irregularities are detected.e.3 7. Page 93 ⇒ "Checking the operating limit switches".Action Check emergency stop device Check 7-segment display Section ⇒ "7-segment display for operating status and error display". This emergency limit stop device may only be ap‐ proached in exceptional cases. it must not be approached in normal operation. number of cycles. Higher loads than those specified on the load capacity plate must not be handled. The control pendant is designed for suspension from the connection cable. WARNING Overload Danger to life and limb. Therefore the function "Operating limit switch for lifting" must be checked every day. Page 33 ⇒ "Available hoist chains". For chain hoists without operating limit switch or with defective operating limit switch. Page 109 ⇒ "Checking the load hook". the slipping clutch of the chain hoist perfoms the function of the emergency limit stop device. operating statuses". The operator is obliged to check the machine for visible damage at least once per shift and to report damage immediately.. or in any other way. 49 X X X X X X 7. the chain must be lubricated more frequently) Check function of operating limit switch for lifting Check switch-off buffer / switch-off spring / operating limit switch actuator Check control cable and control pendant housing for damage Check operation of the brake Check hook and hook safety catch Tab. work benches etc. When the slipping clutch is tripped. high additional loads are exerted on the chain. It may only be used as suspended equipment.1 DANGER Operation General Broken chains and load drop Frequent approaches of the emergency limit stop device may result in broken chains or load drops. It must not be deposited in / on transport containers. The load must never be thrown. track and end buffers for stopping motion of the trolley or crane. parts of the body or hair becoming entangled. Hoists / trolleys / cranes with push travel may only be moved by pulling or pushing on the load. When attaching the load. Do not allow loads to drop when the chain is in a slack condition. when the load is deposited on vibrating machinery) must not be transmitted to the crane. Do not pull or drag suspended loads at an angle. Do not leave suspended loads unsupervised. Pay attention to regulations pertaining to the correct loading of chains. Do not snatch the load at full speed. – – Load pick-up – The load handling attachment and load must be flexibly suspended. when slewing pivoting cranes. chain links facing the same direction must be arranged opposite each other without being twisted. fall apart. – – – – – Moving the load – – – – – – – – – – – – – 214 741 44/210610 During lifting and travelling motions the operator must take a position which provides a free view on the danger zone or a second person must be available who has a view on the danger zone. The load specified on the capacity plate indicates the highest permissible load which must not be exceeded. as a result. At an angle higher than 4° the chain drive may get damaged. move‐ ment of the hook assembly/bottom block must not be restricted. Limits must not be approached in normal operation. e.g. Never pull on the control pendant.g. Continuous approaches of these limits may result in severe damage on the chain hoist up to chain breakage. Vibration from the load being transported (e. slip or roll off when being picked up and deposited.– – Do not render safety devices inoperative. Do not allow the chain to pass over edges or to be used as a load bearing sling. ensure that loads or the load handling attachment do not slip out of the hook or that loads do not fall over. e. emergency limit stop devices (slipping clutch or emergency limit switch). Only approved load handling attachments may be used.g. Rigid connections cause uncontrolled forces and lead to fatigue fracture. Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing. The load capacity of the load handling attachment must not be exceeded. The bottom block must not be twisted or turned over for 2/1 reeving arrangements. Avoid inching operation. Hand-moved loads must be guided by hand. the hook must move to an upright position so that the safety catch is not loaded by the load handling slings and. Transporting persons is not permitted. To protect the chain from impermissible torsion when the load turns. bottom block or load hook assembly. emergency stop devices (emergency limit switches). Do not pull free fixed or obstructed loads with the chain hoist. hook assemblies or bottom block against end stops. When the load is lifted. 73 . Chain hoists must be suspended in such a way that they do not collide with stationary equipment and structures. It is the sum total of lifting load and load handling attachment. Do not handle suspended loads above persons. may be damaged. The effectiveness of the emergency stop function depends on the proper condition of the mechanical brake. The lifting path is limited by limit stops on the ends of the chain. Functioning of the lifting path limiter After the lifting path limiter has been tripped.e. they are actuated by elastic buffers on the limit stop and switch off the motion before the emergency stop device is reached. As a consequence. If the slipping clutch switches off already at rated load. A load already suspended can be safely deposited by actuating the lowering button. Operating limit switch contacts prevent travelling against the emergency stop device. In this case. Blocked chains or excessive play between chain and chain sprocket destroys the chain guide. Fig. 44 CAUTION Premature wear of the chain guide and chain Danger of load drop Avoid unequal loading of the chain falls. the hoist motor is disconnected immediately from the electrical power supply. The load must always be transmitted to the Manulift in the centre below the quick-release coupling.Load distribution WARNING Load drop The continuous transmission of bending moments leads to breakage of the load carrying element and load drop. Functioning of the slipping clutch The chain hoist is fitted with a slipping clutch that is tripped in the event of overload. the mechanical brake is applied and stops the movement. if no lifting or lowering commands are applied (off-position constraint). the slipping force must be measured by an experienced technician and readjusted. only the opposite motion is still possible. the brake must be inspected by an experienced technician without delay. i. impermissible wear on the brake may be the cause. the brake is automatically applied and the motor is switched off. lifting is possible again. the slipping clutch becomes effective as an emergency stop device. 214 741 44/210610 74 . It is therefore not possible to lift an overload from the ground. Furthermore no bending moments must be transmitted to the Manulift. After the slipping clutch has been tripped only lowering is possible. 45 Functioning of the emergency stop device When the emergency stop is actuated. When the lowering motion has been completed. Resuming operation by unlatching the emergency stop is only possible. If an unusually long braking distance is noted. This results in chain breakage and damage of the chain guide. as required. The brake is then automatically applied and the motor is switched off. the switch must hang vertically even with suspended load. Tripping of the emergency stop device causes a warning message on the display. Fig. – Eliminate any knots or blockage of the chains before lifting / lowering. 2 Manulift Belt sling CAUTION Load falling down In order to ensure the safe use of the belt sling please note the following: – – – Fig. The angle between legs must not exceed 120°. discs). It must not be used for handling loads which have sharp edges or coarse surfaces. Pantograph tongs CAUTION Load falling off In order to ensure the safe use of the pantograph tongs please note the following: – – – – Loads must always be gripped in the centre. The permissible jaw capacity is indicated by a coloured mark. To this effect. After the handling cycle has been finished. When using pantograph-type tongs which hold the load by contact pressure (rubber-lined jaws). The clamping jaws must have full contact with the load or grip it from below. – Fig. the sur‐ faces of the loads to be handled must be free from oil and grease. The sling must not come into contact with chemicals. The tongs must never be used for handling bar stock and compressible goods.g.3.7. The jaw capacity of the tongs must be suitable for the dimensions of the load to be handled. This automatically unlocks the tongs. The tongs need not be operated manually. 214 741 44/210610 75 . the tongs must be lowered until the jaws are automatically locked in the open position so that they can be lifted off. and dry. 47 For gripping. The jaws close and the load is gripped when the tongs are lifted. – – The belt sling is used for handling asymmetrical or large-area parts (e. the loop can be loosened and the belt sling be opened by lifting the closing eye. When depositing loads. 46 The belt sling must uniformly support the load with its whole width. the open tongs are set down on the load to be handled. the belt is tightened by pulling the free end so that the part to be handled cannot drop out. It must not be used for handling loads with tempera‐ tures higher than 50 °C. Locking and unlocking (for opening and closing) is effected by the tongs’ dead weight. – Fig. The emergency-stop is arranged in a clearly visible position on the control pendant. The hook throat must remain horizontal even under load. 49 Position of the emergency stop device (1) WARNING Unauthorised. Danger to life and limb. Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay. negligent or accidental restarting.4 Emergency stop Fig. Every chain hoist features an emergency-stop device with which all motions can be stopped in the event of a hazard.Open hook CAUTION Load falling down In order to ensure the safe use of the open hook please note the following: – In order to avoid that the load slips off. Check to ensure that the reason for the emergency stop has been eliminated before the machine is restarted. This also applies in the case of damage occurring to parts of the machine and equipment which makes immediate stoppage and securing of the installation necessary. the loads to be picked up may only be supported by the horizontal part of the hook throat. Loads must never be handled with the tip of the hook. The emergency-stop device must not be used to switch off the machine in normal operation. 76 214 741 44/210610 . 48 – 7. 5. Page 7. Control pendant Depending on the requirements the Demag chain hoist can be equipped with different control pendants. ● Brake and safety device failure. turn the knob in the direction of the arrow (clockwise) and release. Following an emergency stop. Switch off the mains connection or isolator switch before commencing maintenance and repair work.5 7.3 Taking the unit out of service for maintenance and repairs 1. The oper‐ ation of the control pendant and the assigment of buttons can be seen in the corresponding brochures. instructions concerning appropriate use and statutory regulations for operation and maintenance. Observe the relevant accident prevention regulations. 7. 2. Secure the mains connection switch with a padlock to prevent unauthorised or accidental reconnection to the supply. ● To unlock the actuated emergency-stop. ● Switch off the hoist unit power supply at the mains connection or isolator switch. It then locks automatically and the chain hoist is shut down. 214 741 44/210610 77 . do not switch the machine on again until you are satisfied that: ● the cause which led to actuation of this function has been rectified and ● continued operation of the machine constitutes no further hazard. Only carry out maintenance work on the chain hoist when the load has been removed.1 Taking out of service Taking out of service in the case of faults The machine must be switched off immediately in the event of the following faults: ● In the event of damage to electrical devices and cables as well as parts of the insulation. 3.5. 3. Stop all moving parts and ensure that they cannot start moving while maintenance work is being performed. ● Drive the unloaded hoist unit into the resting position.2 Taking the hoist out of service on finishing work The following measures must be taken when finishing work or leaving the working area: ● Position the hoist unit outside the travel area. press until it reaches the end stop. see ⇒ Tab. 4.● To actuate the emergency-stop. ● Actuate the emergency stop. Observe the relevant safety regulations when repairing electrical equipment. 7. 7. 5. 6.5. – – – – – – – – – Secure working and danger zone. Do not touch the hot motor housing. Page 10 ) in compliance with the safety instructions. Work on electrical equipment may only be carried out by qualified specialist personnel (⇒ "Definition of personnel". The electrode holder and earth must be connected to the same assembly when welding work is carried out. Maintenance and repair work may only be carried out by authorized. The mains connection or isolator switch must be secured against unauthorized or accidental reconnection by means of a padlock. When using a working platform for maintenace and repair work. Only use approved spare parts. Customer-specific regulations must be observed. Metal nuts featuring a locking element (self-locking nuts) are mainly used for Demag chain hoists. Page 10 ) in compliance with the safety instructions. WARNING Risk of burning There is a risk of burning when touching the chain hoist after operation. tested and calibrated tools and accessories may be used for maintenance and repair work. The requirements of DIN regarding welding work must be complied with. see also ⇒ "Use of spare parts". Tighten screws with the prescribed tightening torque. – CAUTION Loose connections Loose connections mean danger for life and limb or risk of machine damage. instructed personnel (⇒ "Definition of per‐ sonnel". Machine parts or fittings that are not required must be stored so that they cannot fall down. Before starting work. Page 9. Let motor cool down before starting maintenance and repair work. Danger of material damage. the electrical supply must be switched off.1 Safety Instructions for maintenance / repair In the following sections maintenance work is described which is necessary for optimum and trouble-free operation of the device. Inappropriately fixed component parts may fall down and result in severe injuries. only systems designed for passenger trans‐ port should be used that provide for a stable position and work without any risk.8 Maintenance / repair 8. Trolleys must not be welded or drilled. WARNING Inappropriate maintenance Danger to life and limb. Otherwise serious damage may be caused to the hoist. – Self-locking nuts must not be replaced by other types of nut. Appropriately fit component parts. Welding work may only be carried out by persons having a special qualification. DANGER Live components Danger to life and limb. 214 741 44/210610 78 . Only suitable. Wear protective equipment! Caution on open sharp-edged parts! Risk of injury! Ensure order and cleanliness at the workplace. 8. switch off the mains connection switch and protect it against unauthorized or accidental restarting by locking it with a padlock. 3. Components and tools being loose or lying around may cause accidents. Maintenance work which is not possible from the floor may only be carried out from work stands or platforms. Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly manner. they should be adapted to the specific operating conditions. 6. Ensure appropriate clearance for working. When working on machines or machine equipment the following must be observed: 1. Only carry out maintenance 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 performed. Ensure that the chain hoist is switched off. In the course of the annual inspection. Ensure order and cleanliness at the workplace. allergy. In each individual case. 214 741 44/210610 Replace damaged or deformed spring clip fasteners and split sleeves. Contact with these media may lead to serious damage to health (poisoning. 8. Defective fuse links must not be bridged. isolated. depending on the operating situation. in special cases. checked for being de-energized and. special safety precautions are necessary. 2. 7. the owner or the person assigned by him must check whether the maintenance work may be carried out in the course of operation without risk of personal injury and. skin irritation etc.CAUTION Risk of injury! Oils and lubricants may be dangerous to health. Defective bolted connections must be replaced. all wearing parts are checked. only fuse links with specified amperage and tripping characteristics may be used. taking into account the local conditions.). 5. Before starting maintenance work. 79 . If there is a risk of objects falling down. If routine maintenance reveals that the intervals are too long. Instructions for repair work in the course of operation If maintenance work on the chain hoist must be carried out in the course of operation.2 Basic information on maintenance General information on maintenance/repair The specified inspection and maintenance intervals (⇒ "Inspection and maintenance schedule". CAUTION Risk of injury! Leaking oils and lubricants are hazard sources due to increased slippery. the danger zone below the chain hoist must be made safe. Observe the relevant accident prevention regulations and statutory regulations for operation and maintenance. Page 84) apply to normal operating conditions of the chain hoist. Released oils and lubricants must immediately be absorbed by means of sawdust or oil absorbent and disposed of in an environmentally sound way. Electrical components In the circuits. Observe the relevant safety regulations when repairing electrical equipment. implement all necessary safety precautions. Wear personal protection equipment. by fatigue and ageing. After the chain hoist has been assembled completely. Load carrying means must be inspected along their entire length.3.W.3.W. operating statuses". The routine inspection must be carried out in accordance with BGV D6 and ZH 1/27 "Principles for the inspection of cranes" in Germany.2 Service life of the contactor The switchgear is subject to wear during operation of the chain hoist.P.3 8. Page 80 and ⇒ "Inspection and maintenance schedule". – – An annual inspection as e. carry out a test run at partial load. Adjustment. This value has been determined at normal operating conditions. Under other operating conditions the service life of the contactor may be shorter or longer.3. 80 214 741 44/210610 . 8. Page 117.g.After maintenance work After having finished maintenance work refit safety devices as prescribed and check for functioning. premature wear is possible. maintenance and inspection activities and inspection deadlines including specifications concern‐ ing replacement of parts/assemblies prescribed in the operating instructions must be observed. All inspections must be arranged and documented by the owner. It may be necessary to dismantle the unit in order to inspect wearing parts. specified in German accident prevention regulations UVV/BGV D8 § 23 (2) and BGV D6 (1) must be carried out.240 V 80 60 50 20 - The display value C specifies the expected service life of the contactor multiplied by 100 000. Page 33. ⇒ "Software version. for example. Cranes and equipment must be inspected by a specialist at least once a year. operating hours. Please also note ⇒ "Measures for achieving safe working periods S. including those parts which cannot normally be seen. Routine inspections mainly consist of visual inspections and function checks which should include a check to determine the condition of components and equipment regarding damage.3.3 8. General The safety and health provisions of the EC Machine Directive make it a legal requirement to eliminate special hazards which may be caused. ⇒ "Replacing the contactor on the control card".1 Measures for achieving safe working periods S.1 Routine inspections Prescribed inspections WARNING Non-compliance with operating and maintenance instructions Danger to life and limb. 8. In the case of extreme switching frequencies. The results of the inspection must be entered into a test and inspection booklet. DC-Pro chain hoist 1 2 5 10 10 / 15 Tab. Defective parts and components and parts close to failure must be replaced. During the test run take care for smooth running of the chain. corrosion or other safety devices. Its service life has been rated for the specified loading group. Page 84. 8.P. wear. we recommend that the contactor or control module be replaced.3.". 50 Motor size ZNK 71 ZNK 80 ZNK 100 A ZNK 100 B Display value C at Unom 380 .575 V 80 80 60 50 20 Display value C at Unom 220 . Prescribed tests and inspections must be carried out. number of cycles. This work may only be carried out by specialists. When the corresponding display value is reached. a 64-fold increase. the hoist units are designed for specific periods of operation. 6. 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. Following a general overhaul.2 Calculating the actual duration of service S The actual duration of service S of the electric chain hoist can be determined as follows: S = kmi • Ti • f kmi : Actual load spectrum factor Ti : Number of operating hours f : Factor depending on the type of recording Calculating the number of operating hours (operating time) Ti (by the owner) 214 741 44/210610 The operating time can be calculated by means of an elapsed time indicator or according to the following method: Operating time per inspection interval: 81 .1. 51 1Cm 200 1Bm 400 1Am 800 2m 1600 2m+ 1900 3m 3200 4m 6300 The actual duration of service is considerably increased if the chain hoist is only operated with partial load.P.755 with reference to the electric chain hoist: 1. for example. This is based on FEM 9. The objective of this rule is to determine measures for achieving safe working periods over the entire duration of service. For electric chain hoists classified according to FEM 9. 7.1996. All checks and inspections and the general overhaul must be arranged by the owner of the hoist unit. the machinery is in a condition similar to that of the same machinery in new condition as far as the principle of operation and performance values are concerned.This requirement is also reflected in the third supplement to German accident prevention regulations UVV/BGV D8 (VBG 8) of 1. The value determined for operating time Ti using an elapsed time indicator must be multiplied by the type of recording factor f = 1. with operation at one quarter of the full load. Premature failure cannot.3. the following theoretical durations of service apply (con‐ verted into full load hours): Group of mechanisms Duration of service / full load hours [h] Tab. The load kmi (load spectrum) must be estimated. load spectra and/or recording factors. although.1993 Measures for achieving safe working periods for powered serial hoist units (S.2. this results in an 8-fold increase in the actual duration of service.4.W. 4. however.511. be ruled out. The following items have been taken from FEM rule 9. 3. For a chain hoist operated on average with half load. 8. A general overhaul is defined as: Inspection of the machinery for the purpose of detecting all defective components and/or components and parts close to failure and the replacement of all such components and parts. The actual duration of service determined on the basis of operating time and load must be documented at least once per year.3. The value determined for the estimated operating hours and load spectrum must be multiplied by the type of recording factor f = 1.755/06. according to the state-of-the-art. The actual duration of service S is calculated as: S = kmi • Ti • f A general overhaul must be carried out when the theoretical duration of service is reached.). 8. 2. The operating time Ti (number of operating hours) can be estimated or read on an elapsed time indicator. 5. Dead loads are added to the loads. Estimating the load spectrum factor kmi (by the owner) To simplify estimation.Ti = Tab. 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%.3.g. Load spectrum factor kmi can be obtained by adding together the individual km load spectrum modules. 53 8/2 m/min 10 cycles/h (2+2) m/cycle = 4 m/cycle 8 h/day 250 days/inspection interval Calculation Ti = Tab. 54 10 • 4 • 8 • 250 60 • 8 214 741 44/210610 82 With operating time read: 167 . 1/2.2 For estimating the operating hours and the load spectrum 8. The types of load are simplified and quoted as 1/4. 3/4 load and full load. Diagram Fig. 52 (lifting + lowering) x cycles/h x operating time/day x days/inspection interval 60 x hoist speed Only lifting and lowering movements are counted. 1 year) in terms of percentage. The operating time for each type of load is divided up within the inspection interval (e.1 For calculating the operating hours using an elapsed time indicator (included in the DC-Pro standard scope of delivery) ● f = 1.3 Example: DC-Pro 10-1250 1/1 H5 V8/2 in 1Am Hoist speed No. Loads up to 20% of the rated load capacity are not taken into consideration. of cycles per hour Lifting and lowering Operating time per day Days per inspection interval Tab. 50 B L Load Load t 1 Time Dead load Factor depending on the type of recording ● f = 1. Larger shares of the time period must be correspondingly added together. each type of load can be grouped together into km load spectrum modules.3. long and cross travel times are not taken into consideration. 6 full 5 0.6 • 1.025 20 0.119 • 166.119 f Act.025 1/4 15 0.- 1.30.2 = 23.05 3/4 10 0.002 Without 50 50 - 3.2 214 741 44/210610 83 .1.042 1/2 20 0.119 Thus. 51 B Load L t Load Time Adding the load spectrum modules km together results in the load spectrum factor kmi = 0.1 hours ● with operating time estimated 776.12.3.1 1.9 ● with operating time estimated 0.042 10 0.8 Theor.2 hours Documentation: Enter these values in your test and inspection booklet or crane installation test and inspection booklet.6 In the operating time as read / estimated above.With operating time estimated: 166.Tab.05 5 0.12.119 0. duration of service S [h] 21. duration of service D [h]/Group of mech.8 For classification in FEM group of mechanisms 1Am (see DC-Pro data plate) with a theoretical duration of service of 800 hours (see table below) the hoist has a theoretical remaining duration of service of ● with operating time read 778.119 x 167 x 1.9 23.002 15 0.2 from to Ti value [h] read 167 estimated 166. the chain hoist has transported the following loads: Fig. 800/1Am 800/1Am Remaining use D-S [h] 778. This entry may appear as follows: Date Operating hours Load spectrum module km [%] Load spec‐ trum factor kmi 0. the actual duration of service amounts to S [h] = kmi x Ti x f = ● with operating time read 0.1. 55 30.1 = 21.1 776. 8.755. When the actual duration of service has reached the theoretical duration of service valid for the group of mechanisms.755 must be entered.8. ⇒ „Software version. This is based on the condition that the specified group of mechanisms is not exceeded by the actual duration of service. Page 109 ⇒ „Checking the operating limit switch actuator“.4 General overhaul GO The chain hoists are designed for a period of use of at least 10 years until the first general overhaul is carried out. Page 33. Page 87 ⇒ „Checking the operating limit switches“. The general overhaul carried out by the manufacturer or an authorized specialist company fulfills the condition for continued operation of the chain hoist. A general overhaul must be carried out no later than when the end of the theoretical duration of service is reached. plugs. Page 100 ⇒ „Service life of the contactor“. bearings. Page 54 ⇒ „7-segment display for operating status and error display“. ● Gear oil and gearbox cover with seal. Page 103 ⇒ „Checking the load hook“. During the general overhaul the following parts must be replaced in addition to the checks and work specified in the inspection and maintenance schedule: ● Gearbox housing with joined gearing parts. Page 88 ⇒ „Checking the quick-release cou‐ pling“. you may have the actual service life determined. The theoretical duration of service D (hours at full load h) depends on the group of mechanisms classification of the chain hoist. Page 80 X X Check chain lubrication (under arduous conditions. Page 87 ⇒ „Checking the switch-off buffer / switch-off spring“. Page 93 ⇒ „Checking the operating limit switches“. etc. The actual duration of service is to be determined annually in accordance with FEM 9. operating hours. Page 33 ⇒ „Available hoist chains“. Further utilization is approved when an expert engineer has entered the conditions for further utilization into the test and inspection booklet. During the annual inspection by our after-sales service. ● Connecting elements. ● Brake.) to be replaced during maintenance and assembly work are not listed sep‐ arately.4 Inspection and maintenance schedule Action Section Before first putting into operation X X X X Before start‐ ing work In the course of annual in‐ spection Check continuity of the PE conductor connection Check emergency stop device Check direction of movement Check 7-segment display ⇒ „Line connection“. Upon expiration of 90% of the theoretical duration of service – if the chain hoists are correctly classified after 8 to 10 years – the owner must arrange for a general overhaul GO to be carried out. the chain must be lubricated more frequently) Check function of operating limit switch for lifting Check function of operating limit switch for lowering Check switch-off buffer / switch-off spring / operating limit switch actuator X X X X X X X X X X X X X X X X X X X X Check control cable and control pendant housing for damage Check function of the quick-release coupling (Manulift) for accommodating the load handling attachment Check operation of the brake Check hook and hook safety catch X 214 741 44/210610 X Read the switching cycles C X 84 . further operation of the chain hoist is only permissible after a general overhaul. Completion of the general overhaul must be confirmed in the test and inspection booklet and a further period of utilization in accordance with FEM 9. ● Shaft sealing rings. washers. number of cycles. Thus the relevant accident prevention regulations and the BGV D8 (VBG 8) are complied with. operating statuses“.3. The small parts (screws. the checks and work specified in the inspection and maintenance schedule must be carried out.P. crossbar and status of buffers Change oil General overhaul The general overhaul should coincide with the annual inspection X X X X X X X X X On reaching 90% of the theoretical duration of service ⇒ „Measures for achieving safe working periods S. reeving 2/1“.) to be replaced during maintenance and assembly work are not listed separately. fastening screws Check the cylindical pins fitted in the quick-release coupling (Manulift) for wear and fracture Check sprocket of chain guide. washers . suspension bracket and securing ele‐ ments (clip. etc.. etc. deformation and wear Check hook safety catch for deformation Check hook bearing for wear Check rubber lip seal in the bottom block X X X X X X X Check the load and chain anchorage in the control unit (Manulift) incl. Page 102 ⇒ „Manulift“. Page 86 ⇒ „Checking the load hook“. bolts. Page 116 Every 10 years 45) Every 10 years 45) Every 10 years 46) 45) Check electrical switchgear and wiring Check operation of the slipping clutch Check setting of the slipping clutch Check brake wear. Page 80 X Fit chain hoist-specific Demag GO set The small parts (screws. as re‐ quired Check electrical enclosure and gearbox for leakage Check trolley.P. chain guide. Page 103 ⇒ „Chain drive“. chain sprocket of bottom block. reduction in the thickness of the links or increase in pitch due to wear.W.. Page 33 ⇒ „Measures for achieving safe working periods S. During the general overhaul.) for tight fit and corrosion Check and apply or supplement corrosion protection. 56 214 741 44/210610 45) For 46) DC-Pro use in accordance with the FEM classification 10 and DC-Pro 15 every 5 years 85 . cracks. elongation caused by deformation Check securing elements (clips. Page 80 ⇒ „Checking the slipping clutch“. Page 100 ⇒ „Replacing the bottom block (standard for DC 10) with internal switch-off springs. Tab.) Check fastening screws on hook assembly / bottom block Check hooks for cracks. Page 115 ⇒ „Adjusting the slipping clutch“. grease V sealing ring Check suspension.“. Page 103 ⇒ „Checking the quick-release cou‐ pling“. Page 113 ⇒ „Suspension“. Page 115 ⇒ „Brake“. Page 89 ⇒ „Checking the hoist chain“.W. Page 90 ⇒ „Checking the switch-off buffer / switch-off spring“. pitting. damage.“. Page 109 ⇒ „Gearbox / oil change“. guide plate Check that the chain and chain collector box are properly secured Check the chain for deformation.Action Section Before first putting into operation Before start‐ ing work In the course of annual in‐ spection X X X Read operating hours for determining the remaining duration of service ⇒ „7-segment display for operating status and error display“. 1 Maintenance work Suspension If a check or inspection reveals that the dimensions are lower or higher than those specified due to wear or if cracks can be seen in these parts. they must be replaced at once.3 long 14.3 DC 15 34.5 Fig. Suspension bracket Chain hoist Suspension bracket Min.3 DC 15 long 31. dimension e suspen‐ sion bracket Tab.2 Electrical equipment cover Hold the electrical equipment cover while opening it. When closing the electrical equipment cover.5.8. make sure that the fall protection does not cover the window or is jammed.5.55 DC 10 24. 52 Suspension ring Chain hoist Min. 58 [mm] DC 1/ 2 / 5 17.2 long 24. 86 214 741 44/210610 . 57 [mm] DC 1/ 2 / 5 short 15. Do not let the electrical equipment cover fall into the fall pro‐ tection.2 Fig.4 DC 10 short 25. 53 8. dimension e suspen‐ sion ring turned 90° (chain hoist parallel to gird‐ er) Tab.5 8. 5. Deposit the chain collector box (6) on the ground. hold the chain collector.1 214 741 44/210610 Unscrew and disengage the service cover (1). Place the bag (2) with control cable on the top of the chain hoist. Disengage the spring (3) and place it in the recess in the chain collector box.4 8.4. 87 . 54 – – – – – 8.3 Dismantling the chain collector box Fig.5.8.5. Operating limit switches Checking the operating limit switches DANGER Broken chains and load drop Frequent approaches of the emergency limit stop device may result in broken chains or load drops. While doing so. Remove securing spring (4) from the pin (5) and pull out pin. Page 124. 8. Fig. When the buffer or switch-off spring are excessively compressed.5. Therefore the function "Operating limit switch for lifting" must be checked every day. Then lift at creep speed up to the highest hook position until the chain hoist is automatically switched off. before the bottom block or the hook assembly touch the guide plate of the chain hoist. The fact that the hoist unit is switched off in the highest hook position does not indicate that the operating limit switch functions correctly.g.For chain hoists without operating limit switch or with defective operating limit switch. it may be assumed that the hoist motor is not switched off by the operating limit switch but by the speed monitoring device of the slipping clutch. This emergency limit stop device may only be ap‐ proached in exceptional cases. a warning is displayed. 55 Buffer with limit switch not being actu‐ ated (A). the hoist unit must be switched off. If the operating limit switch is defective. 88 214 741 44/210610 .2 Checking the operating limit switch actuator The operating limit switch actuator must be checked for external damage. the upper part may also be shifted onto the lower part only to a small extent so that approx. proceed as described above under "Operating limit switch for lifting". Proceed as follows: ● Remove chain collector box ⇒ "Dismantling the chain collector box". the minimum distance to the guide plate of the chain hoist must be 20 mm. 10 cm below the highest hook position. 20 mm of the black part of the bottom block remain visible. the springs may also be compressed only to a small extent when switching off. ● 2/1 reeving: When a bottom block with internal switch-off springs is used. it must not be approached in normal operation. see ⇒ "Warning messages". Checking the operating limit switch for lowering The function of the "Operating limit switch for lowering" must be checked at least once per year. Optional geared limit switch When the optional geared limit switch is used. i. the slipping clutch of the chain hoist perfoms the function of the emergency limit stop device.. Checking the operating limit switch for lifting: Lift the hook assembly or bottom block up to approx. e.e. buffer with limit switch being actuated (B). ● 1/1 reeving: After switching off the buffer or switch-off spring on the hook assembly may be compressed only to a small extent. For checking the highest hook position must be approached at high lifting speed (without load). Page 87 ● For further check procedure.4. When the slipping clutch is tripped. the hoist motor is switched off by the triggering of the electronic speed monitoring device of the slipping clutch. high additional loads are exerted on the chain. After the hoist has been switched off. When switching off by the operating limit switch fails. bent actuator plate. When a bottom block with external switch-off springs is used. This may result in broken chains when the end position is approached frequently. defective buffer limit switch being actuated (C). 5 6. e. it must be replaced at once.4 26.8 33. 8. at normal conditions no further check is necessary.3 Checking the guide plate Maximum dimensions of the guide plate [mm] DC 1 / 2 DC 5 DC 10 DC 15 Tab. see also brochure "Guide plate accessories DC 1 . ● Open the service cover.1 b 5.2 Checking the chain guide The chain drive can move easily on the drive shaft.5 c 16. Multiple fitting and removal of the guide plate retaining bolts may damage the thread in the aluminium housing in such a way that a tight fit of the bolts can no longer be ensured. 3. this may indicate wear.5.8. Page 7. a lateral play of approx. Fig.5.15" ⇒ Tab.4 11.3 If a check or inspection reveals that the dimensions specified are excee‐ ded due to wear or if cracks can be seen on the guide plate. 59 a 16. 717 830 45). if you find that the chain does not run smoothly over the sprocket wheel.0 28. 57 214 741 44/210610 89 .5.5. A defective chain guide must be replaced im‐ mediately.5.8 9.5 8. halves burst open or loose fit of the screws. ±2 mm is normal.9 12. However.g.8 8. 56 Example for defective chain guide 8. For this purpose a set "Guide plate ac‐ cessories" is available (part no.5.1 Chain drive Checking the sprocket wheel Since the sprocket wheel is replaced together with the chain set.0 19.8 21. Fig.0 15.7 31. ● Check the chain guide for damage.5.4 d 6.e. i. Page 30. If routine maintenance reveals that the intervals are too long.5. This will ensure that the safety and service life of the chain hoist is guaranteed. 60". 2. Min. Page 91. This measurement can be taken in two different ways. therefore. 59 214 741 44/210610 90 . Otherwise the chain must be replaced.4 Checking the hoist chain Checking the discarding status of the original Demag chain In addition to selecting the correct hoist unit. to avoid serious accidents. For single-shift operation. this usually indicates wear of an individual chain link. values of the wire diameter see⇒ "Tab. 58 The chain link contact areas must be visually checked for traces of wear. on fitting a new chain.8. The sum total of the 3 readings taken. Measure the wire diameter of the chain in the chain link contact area by means of a calliper gauge. the chain should be checked once a year (see inspection and maintenance schedule). Do you find that.e. it does not run smoothly over the sprocket? Please contact our after-sales service centre. i. Measuring with a calliper gauge Measurements on 11 chain links may be taken in steps of 2 x 3 and 1 x 5 chain links. We urgently recommend you use genuine Demag chains. for example. If the chain hangs at angle while it is unloaded. Fig. operation in accordance with FEM specification and for operating conditions of the chain hoist in accordance with ⇒ "Operating conditions". Measuring with a calliper gauge Measuring with a chain gauge Wear of individual link Fig. 1. a1 + a2 + a3 must not exceed limit a.5. owners of hoist units are obliged by DIN 685 part 5 regulations to constantly check the round section steel chain in order to ensure optimum operating safety and. as required. Measuring wear or deformation of the original Demag chain A partial load must be suspended from the load hook when measuring the chain for wear or deformation. Demag is stamped on every 12th link of original Demag chains. they should be adapted to the specific operating conditions. max. when the meas‐ 2 3 uring pin can no longer move into the 11th chain link.8 mm DC-Pro 10 7.2 144. dimension dm = 0.7 mm DC-Pro 15 8. min.8 mm DC-Pro 5 5.2 180. 61 Part no. The chain must be replaced.4 x 21.9 x d Tab.3 x 15. max.8 mm 3. The discarding status has been reached.7 mm 12. Measuring pin 11.5 mm 7.540 Designation Chain gauge Tab. It is necessary to replace the chain.7 x 24. dimension = a 1 + a 2 + a 3 Overall length of 1 chain link measured on the inside.4 mm 6. 60 DC-Pro 1 / 2 4.: 836 025 44 214 741 44/210610 91 .Demag chain hoist Chain designation d x t Limit dimensions according to DIN 685 part 5 Measurement over 11 chain links outside. 60 A B 1 DC / DK / PK new chain PK old chain The discarding status has not yet been reached.9 mm 4.2 289 mm 25. Weight [kg] 0.3 mm 15.2 x 12.2 253 mm 22.8 mm Measuring with a chain gauge Fig. dimension t Measurement of the chain link diameter. th chain link. It is not yet necessary to replace the chain. When a new RDC standard chain is ordered.5.8.5. Page 90. ● Chain guide with plate and cap. ● Demag chain grease tube. ● Retaining ring. the chain is already fitted in the chain guide. ● Sprocket wheel. The chain set includes the following parts: ● Chain. The chain guide is pre-assembled. 92 214 741 44/210610 . ● Chain guide plate. a chain set is always supplied. ● Buffers for upper and lower hook position.5 Scope of supply chain set On reaching the permissible limit of chain wear the chain set must be replaced (for determining the wear limit of the chain ⇒ "Checking the hoist chain". 2 x 12. blue chromated. CAUTION Pay attention to reduced capacity. bright Stainless steel AISI 316 (V4A) 1. foodstuffs sector DC 5 DC 10 DC 15 Properties Material Lubrication Tab. corrosion-free.4 x 21.62 1.2 x 12. e.2 7. the special chains listed in the following are available for special ambient conditions.3 x 15. 1981 as well as BGV D8 (VBG 8) and BGV D6 (VBG 9).2 5.62 1.38 0.2 5.500 47) 800 . to EN 818-7.2 DAT / RDC 4. Paraliq chain spray 214 741 44/210610 47) For 48) For max.2 7.2 8.3. galvanizing.8 38.160 200 .2 RSX / DS DC 1 / 2 DC 5 DC 10 DC 15 4.38 0. chain quality Weight per meter Production test force Minimum breaking force [kN] 22 35 70 95 10 Minimum breaking elonga‐ tion [%] Max. Central Department for Accident Prevention and to the test criteria for round section steel chains in hoisting operation and to the inspection regulations according to DIN 685 part 5 Nov.2 x 12.g.2 5. blasting Properties Material Lubrication Demag RS6 special chain DC 1 / 2 Application e. part 5.3.3 x 15.5. ageing-resistant material with a high degree of surface hardening.3 x 15. 25-50 cycles per day = 400 kg max. dust.38 0. 62 4. colour: silver Ni-Mo special chain steel acc.1 Grease GP00H-30REN. part 5.4 x 21.20 13.4 x 21.g. 12-25 cycles per day = 800 kg 93 . Deviating from the standard operating conditions for which RDC chains are used.62 1.67 [kN] 13.8 60 5 160 400 800 1600 - Ageing-resistant.2 x 12. 5 cycles per day = 1000 kg.5.2 RSA / S DC 1 / 2 DC 5 DC 10 DC 15 4.3 30.3. for max.6 Available hoist chains The original Demag chain is a round section steel chain tested to EN 818-7 which is subject to the directives for round section steel chains in hoisting operation of the Main Association of Industrial Employers' Mutual Insurance Societies. foundry.7 x 24.g.8.2 7. blue chromated.20 10 16 32 16 25 50 15 125 . Klüber UNIMOLY C220 0. not hardened. colour black.5 19.8 22 43 22 35 70 10 250 500 1250 2500 - Ageing-resistant.2 7. e.4401 Edible lubricant.g.1000 48) - Non-rusting chain.4 x 21. emery. to EN 818-7.2 DAT / RDC [kg] 0.2 5. 10 cycles per day = 500 kg For max. Stabylan 2001 Ni-Mo special chain steel acc.1 Acid-resistant chain grease 0. galvanised with additional surface treat‐ ment.20 12.20 1.62 1. with deeper hardening surface Ni-Mo special chain steel acc.7 19. micro-layer corrosion protection „Corrud DS“ coated black.g. to EN 818-7. load capacity for reev‐ ing 1/1 [kg] 250 500 1250 1600 2/1 [kg] 2500 3200 [mm] Demag RDC standard chain DC 1 / 2 DC 5 DC 10 DC 15 Properties Material Lubrication Demag Corrud special chain Application e. electro‐ plating facilities Properties Material Lubrication Demag HS7 special chain Application e.SO-GFB 0.8 22 43 59 High strength. part 5.38 0.250 400 .3 x 15. Chain hoist size Dimension Stamp.1 Dry or with dry lubricant. 2. 4. pull out and deposit mains cable union (3) with fitted mains cable (4). To replace the chain set.8. 3. Place bag with control cable on chain hoist (2). Remove and deposit the chain collector box (6) (⇒ "Dismantling the chain collector box". 94 214 741 44/210610 . Page 87). remove the connection cable from the strain relief. 61 Before starting maintenance work take the hoist out of service and secure against restarting. Open and disengage the service cover (1).5. if a travel drive is fitted.7 Replacing the chain set Fig. Loosen cap (5) with a screw driver (lever off).5. proceed as follows: 1. to do this. DC-Pro 1 to 5: In the area of the power supply insert. 2. Remove the guide plate (7). then remove the worn chain set from the service enclosure.Fig. Remove the chain guide (10) with sprocket wheel from the output shaft. slide the complete assembly in the direction of the motor until the sprocket wheel is free. 3. 214 741 44/210610 The following points must be noted: 95 . Remove the retaining ring (8) using Seeger ring pliers. DC-Pro 10 : Fold the cover of the opening in the gearbox housing (9) to the side. proceed accordingly in reverse order. 62 1. For fitting the new chain set. either use offset or straight pliers (access through the opening in the gearbox housing on the side of the motor or from the service enclosure). it must be ensured that the chain is introduced in the same position and orientation. 214 741 44/210610 Fig. When fitting the chain.Chain hoist with geared limit switch Fig. Page 132 Spacer rings for the output shaft ● When fitting the chain guide. Correct fit of the retaining ring is ensured when it can be easily turned on the output shaft after assembly. 65 96 . 64 3 1 2 2 DC-Pro 15 1 Fig. 64 Before you slide on the chain sprocket. the chain guide has a larger bore hole. lubricate the splining of the output shaft with Molykote or similar. the complete number of spacer rings must be fitted on the output shaft. 63 Chain guide for DC 10 without geared limit switch B) Chain guide for DC 10 with geared limit switch When the chain hoist is equipped with a geared limit switch. Item 1 2 3 4 Designation Cap Retaining ring Spacer ring Chain guide DC-Pro 1 / 2 5 Spacer ring DC-Pro 5 DC-Pro 10 DC-Pro 15 Tab. DANGER Broken chains and load drop An incorrectly fitted chain may lead to broken chains or load drops. See also ⇒ "Chain drive". Fitting the retaining ring ● The stamped burr of the retaining ring (1) must face the motor. The chain must operate without any twist. 63 A) Tab. socket head screw of guide plate Fig. socket head screw of chain anchorage halves Chain anchorage half Guide plate Hex. ● Insert the bolted chain anchorage into the opening of the gearbox housing. 65 Designation Chain anchorage pin Hex. ● Completely push back the two pins (1) into the bore holes (the pins are secured by the fitted guide plate). 2/1 reeving Fit the chain anchorage before bolting the guide plate (4) into position for DC-Pro 15 with 2/1 reeving. 2/1 reeving Fig. Fitting the chain anchorage for DC 15. ● Put the chain end between the two chain anchorage halves (3) and bolt them together with a tightening torque of 25 Nm. ● When removing the chain anchorage push the two pins (1) out of the bore holes only to such an extent that the chain anchorage can be removed. B).Fitting the chain anchorage for DC 10. A). 66 ● Fit the chain anchorage before bolting the guide plates into position for DC-Pro 10 with 2/1 reeving. ● Insert the bolted chain anchorage into the opening of the gearbox housing (Fig. Item 1 2 3 4 5 Tab. 67 214 741 44/210610 97 . Bolt the chain anchorage halves (1) together (Fig. ● Fit the pins (2) (the pins are secured by the fitted guide plates). A dry film lubricant should be used in environments where abrasives occur (emery. sand. Deviating lubrication see ⇒ "Available hoist chains".5 4. Fit chain collector box ⇒ "Dismantling the chain collector box". DC-Pro 1 / 2 1/1 5.0 5. in the chain anchorage.Fitting the limit stop ● Fix limit stop to the 5th link at the dead (unloaded) end of the chain paying attention to the tightening torque. The chain link contact areas must be relubricated appropriately – after being cleaned – at intervals depending on the service and load conditions. The chain must be lubricated along its entire length. Page 67.5. Page 93! CAUTION Premature wear of the chain! Danger of load drop due to broken chains.8 Lubricating the hoist chain After fitting. Fig. 3. ● If the chain hoist is operated with a chain that is longer than suitable for the standard capacity of the chain collector box. see brochure "DC geared limit switch" ⇒ Tab. it must be readjusted after having replaced the chain. the chain link contact areas must be lubricated with a gear grease.3 10. The limit stop must fitted so that the excess length of the chain lies between the hook assembly and the limit stop. 665 009 44. We recommend replacing the return sprocket every second time the chain is replaced at the latest. 66 8.5 DC-Pro 5 1/1 7. – – – – – Fit the hook assembly/bottom block ⇒ "Load hook". If an optional geared limit switch is fitted to the chain hoist. Therefore the condition of the return sprockets must be checked when replacing the chain. Page 98 Adjust the lower hook position as required ⇒ "Setting the lower hook position". part no. before lifting a test load and putting the hoist into operation as well as during normal operation when being unloaded. 68 Furher procedure after having replaced the chain set If the chain must be replaced.5 4. Page 87. Even chain links being covered e. Page 93. ⇒ "Lubricating the hoist chain". hook assembly. limit stop or crab frame must com‐ pletely be lubricated. In this case a geared limit switch is required for the DC 10 and the DC 15 with 2/1 reeving.5.5 25 25 DC-Pro 10 2/1 1/1 25 DC-Pro 15 2/1 Tightening torques [Nm] Reeving Service cover Limit stop Chain anchorage halves Guide plate Tab. an additional limit stop must be fitted to the chain between the hook assembly and the buffer plate. the return sprockets are ususally also worn and must be replaced. Page 100 Lubricate the chain ⇒ "Available hoist chains".g. etc. because it has reached the wear limit. 214 741 44/210610 98 .). Page 7. DC-Pro 1-10 chain hoist Cut off the tip of the grease tube and insert the grease tube at the lubri‐ cation point. To ensure complete and even lubrication of the chain. Fig. 69 DC-Pro 15 chain hoist Apply the lubricant with a brush. move the chain into its end positions while you fill the grease into the chain guide by pressing on the tube. Fig. 70 214 741 44/210610 99 . 83 13 22 18 17.5.07 29 44 34 32.6 22 33.5.5 20.7 48.5 21.2 Checking the return sprocket The return sprocket must be checked for smooth turnability every month. 100 49) Permissible 50) Permissible deviation +10% deviation -5% 214 741 44/210610 .7 36 110 31.55 19 27.42 30 109 23.3 45 159 41. hook force Tab.3 250 2 1/1 500 5 V3 36 30.8 8 16 8. For this purpose it may be necessary to remove fixed crossbars from the bottom block.6 8. test force Max.8 16 32 1250 10 2500 2/1 1600 15 1/1 V5 50 43.1 Load hook Checking the load hook SWL Chain hoist Reeving Load hook Type a1 a2nom b1 Dimensions [mm] h1 h2nom 50) h2min L2 L4 d1 Fig.9 30 55 38 36. 67 [kN] [kN] 49) [kg] DC-Pro 125 1 V2 30 25.8 50 100 3200 2/1 V6 56 49 53. 71 Max.3 24 154 38 50 100 a2max 27.6.9 29 44 34 32.8.5 26 24.6. Jerky movements of the bottom block indicate wear.5 33.8 65 130 V4 43 36 39. Check whether the bottom block moves correctly when lifting and lowering.8 25 50 V5 50 39 42.1 56 187 49.1 22 86 19.5. 6.5. Slide the buffer cap (1) onto the chain.8. 3. Pay attention to the correct position of the locking nose (4).8 Tightening torques [Nm] Hook assembly Tab.5 DC-Pro 10 25. Remove the upper half of the hook assembly.3 Replacing the hook assembly. DC-Pro 1 DC-Pro 2 DC-Pro 5 11. Remove the chain link sections (2) from the load hook and put them around the last chain link. 72 1. Insert the chain and chain link sections (2) in the new hook and put the upper half of the hook assembly (3) on it. Deposit the new hook and remove the two bolts Lift off buffer cap (1) with a screw driver. reeving 1/1 Fig. 68 214 741 44/210610 101 . 2.0 DC-Pro 15 27. Tighten the housing bolts according to the tightening torque table. 4.5 6. 09/2009 the bottom block is provided with rubber lips (1) in the area of the chain entry. Apply load capacity plate. 4. 3. 5. Introduce the chain into the new bottom block in the same position and orientation (chain must operate without any twist). reeving 2/1 Fig. During the annual inspection the rubber lip must be checked for wear and correct fit.6. 74 .5 Nm. 102 214 741 44/210610 Fig. 8.5. 09/2009 From approx. Loosen the clamping screws (2) of the bottom block and remove the bottom block. Perform function check (run against operating limit switches and check 7-segment display). 2. 73 1. Assemble the bottom block and tighten the screws (2) with 52 Nm. 6. DC-Pro 10 Bottom block halves Guide halves 52. 69 Bottom block from approx.5 Tightening torques [Nm] Bottom block with internal switch-off springs Tab. 7. Check the correct fit of the four switch-off springs (3) in the new bottom block halves (4). Fit the new guide halves (1) and tighten the screws (5) with 5. Remove the guide halves (1) (four M 6 screws).8.4 Replacing the bottom block (standard for DC 10) with internal switch-off springs.0 5. The diameter of the cylindrical pins must not be lower than 5. option for DC 10) with external switch-off springs. The diameter of the quick-release coupling for plugging in load handling attachments is 20 mm. 75 Tightening torques [Nm] Bottom block with external switch-off springs Tab. reeving 2/1 Fig.0 8. It must not be larger than 26 mm at any point. 76 103 . slacken the 2 connecting screws on the unlocking sleeve (3).7. 214 741 44/210610 Fig. 71 Designation Coupling pin Socket for load handling attach‐ ment Unlocking sleeve Control unit Pressure spring Item 6 7 8 9 10 Designation Cylindrical pin Swivel lock Top cover Emergency stop Actuating rockers The quick-release coupling must be checked daily for correct functioning and smooth operation. 70 DC-Pro 10 / DC-Pro 15 55.7 8.5.5. The diameter is increased due to wear.1 Manulift Checking the quick-release coupling Item 1 2 3 4 5 Tab.6.8. The swivel lock (7) fitted in the load handling attachment must be checked for tight fit and wear every three months.4 mm at any point. To do this. The cylindrical pins (6) fitted to the quick-release coupling must be checked for wear every three months.5 Replacing the bottom block (standard for DC 15.5. ● Fit both limit stops: .Fix limit stop to the 5th link on the chain collector box side.0 5-6 DCM-Pro 5 4. 72 Designation Chain collector box side Load side DCM-Pro 1 / 2 4.7. ● Remove the two limit stops (1). Page 120. Page 105.8. ● Lubricate new chain before putting it into operation ⇒ "Lubricating the hoist chain". Page 98. Page 105. ● Fit the free chain end to the control unit ⇒ "Fitting the chain to the control unit". ● Remove helical cable from control unit ⇒ "Replacing the helical cable". ● Loosen chain anchorage on the control unit ⇒ "Fitting the chain to the control unit". Page 94.2 Replacing the chain Item A B 1 2 Tab.3 Limit stop Screw for chain retainer halves Tightening torques [Nm] ● Dismantle the chain collector box ⇒ "Dismantling the chain collector box".Fix limit stop to the 17th link on the load side.5. Page 87. . ● Replace chain set ⇒ "Replacing the chain set". 77 104 214 741 44/210610 . Fig. 73 Designation Top cover screw Helical cable Top cover Chain anchorage Item 5 6 7 8 Designation Chain anchorage screw Pin Chain link section Bearing Item 9 10 11 12 Designation Retaining pin Chain swivel unit Chain Swivel unit screw 105 .7.5. 78 Item 1 2 214 741 44/210610 3 4 Tab.3 Fitting the chain to the control unit From year of manufacture 04/2009 the chain swivel unit is fitted as standard Fig.8. 8 Nm. 106 Loosen cap screws (1).Deposit the Manulift so that the chain and helical cable are unloaded. Chain 5. 2. DANGER Load drop Incorrect assembly may result in load drops. DANGER Load drop Incorrect assembly may result in load drops. Open the chain anchorage (4) and remove the chain link sections and the chain.2 x 12. slide cap (2) upwards and secure against dropping (e. Assembly: 3. 7.g. Disassembly: 1. that retaining pin (9) is correctly fitted when the swivel unit is assembled. Close swivel unit halves (10) and tighten screws (12) with the correct tightening torque: Chain 4. 4. Fit bearing (8) and the chain link sections (7) on pin (6) in the correct sequence. Slide top cover (3) off the chain anchorage (4) and secure it against slipping. 5.5 Nm.2 ⇒ 6. 6.3 x 15. During assembly it must be ensured 1. That the chain link sections (7) are positioned in bearing (8) with their collar. Loosen screw (5) of the chain anchorage (4). Until year of manufacture 03/2009 Fig. Insert retaining pin (9) in chain (11) and put the swivel unit half (10) around pin (6). Pull the new chain through cap (2) before fitting. Slide top cover (3) over the pin (6) and tighten the top cover screws (1) with a tightening torque of 3 Nm. Insert pin (6) in the chain anchorage (4) and bolt the two chain anchorage halves (4) together with a tightening torque of 5 . Push helical cable (2) to the side and loosen the screws (1) of the top cover (3). Grease the bearing and bearing seat. 79 1. During assembly it must be ensured 1. with a screwdriver).6 Nm.2 ⇒ 9. 214 741 44/210610 . 2. 3. Before loosening the hexagon socket screw (3), set the control unit down. Open the chain retainer halves (5) until the last link of the chain (4) can be removed. Place the last link of the chain between chain link sections (6) before fitting. DANGER Load drop due to incorrect fitting The chain link sections (6) must be inserted turned by 90° to the chain retainer halves. Tightening torques [Nm] Screw for chain retainer halves (Manulift) Tab. 74 DC-Pro 1 / 2 / 5 5-6 8.5.7.4 Replacing the switching elements Fig. 80 1. Loosen the four cover screws (2) and remove housing cover (1). Tighten diagonal pairs of cover screws when re-fitting the cover. No gap must remain between the cover and the lower part of the housing (3) when the cover screws are tightened. 2. 3. Disconnect the electrical connections (4). After removing the four switching element screws (5), disconnect cores and remove switching element (6). The switching element can only be fitted in one position determined by a rib on the housing. DANGER Live components Only connect the helical cable in accordance with the circuit diagram. Pay attention to core identification. 214 741 44/210610 107 8.5.7.5 Replacing the gearbox Fig. 81 1. 2. 3. 4. Loosen cap screws (1), slide cap (2) upwards and secure against dropping (e.g. with a screwdriver). Loosen the four screws (4) and lift off upper part of housing (3). After removing the bearing block screws (5), pull upwards the complete gear mechanism with rocker switches (6). Turn the shaft (10) by 90° in relation to the bearing block (7) and remove it. Fit the shaft (10) with the bevel gear (8) into the bearing block (7) as illustrated. Ensure that the bevel gears mesh properly with their counterpart gears. 5. Pull the bevel gear (8) off the shaft (10). When fitting the bevel gear (8) to the shaft, ensure that it is pushed on until it comes up against the stop. Pay attention to the correct position in relation to the lever (9). 6. 8.5.7.6 The emergency-stop button (11) must not be pressed when the two halves of the housing are fitted together. Load handling attachments Load handling attachments must be checked depending on their frequency of use: ● The smooth locking and unlocking operation of the tongs locking mechanism must be checked daily. Keep the mechanism clean (but do not oil). 214 741 44/210610 ● Regularly check the smooth operation of the pantograph hinges. Clean and oil the hinges as necessary. Affected parts must be replaced immediately if cracks, deformation, wear of hinge pins (hinge play approx. 1,5 mm) and jaws are detected. ● Belt slings must be checked once a week if they are regularly used, or before being used again if they have not been used for a long period. During these checks, the fabric should be examined for brittleness, damage by 108 chemicals or stretching, and for deformation caused by heat; the general condition of the end fittings should also be checked. 8.5.8 8.5.8.1 Buffers Checking the switch-off buffer / switch-off spring Fig. 82 1. 2. Buffer wear: In the course of annual inspection visually check the buffers. Check for damage and cracks. Missing buffer plate: When fitting new buffers, pay attention to the correct fitting sequence of the component parts ( see also ⇒ "Buffer design", Page 110), e.g. a missing buffer plate leads to premature wear of the buffers. 3. Wear of external switch-off spring: In the course of annual inspection visually check the external switch-off springs. Check the sleeves of the springs for damage and cracks. The individual windings of the springs must not be shifted above each other. 214 741 44/210610 109 5.10 DC-Com 1 .10 without operating limit switch DC-Pro 1 .10 DC-Com 1 .8. 83 1 Buffers 2 3 Buffer plate Switch-off spring Load side A C E G J Chain collector box side B D F H K Chain hoist range DC-Pro 1 .10 DC-Pro 15 Tab. 75 110 214 741 44/210610 .10 with operating limit switch DC-Pro 1 .2 Buffer design Buffer variants Fig.8. 0 8.0/2.6/2.6 7. 83.2 9.2/4.0 24.8 14.8/7.0 24.0 6.0 6.51) 2xJ .5 at 60 Hz [m/min] 9.6/2.8/7.4/3.8 14.2 9.0 24.0/4.5 8.6/2.0 6.4 14.8 9.6/2.6 28.0/2.0 16.0/2.2/1.0 8.2 9. Page 110 Load hook side A C G A C G A C G A C G A C G A C G A C G A C G A C G A C A C A C 2xJ 51) Chain collector box size at hook path at 50 Hz [kg] 80 DC-Pro 1 2 5 1 100 2 5 1 125 2 5 2 160 5 2 200 5 10 2 250 5 10 5 315 10 5 400 10 5 500 1/1 [m/min] 8.Buffer arrangement DC Pro SWL Chain hoist Reeving Hoist speed Hook path H [m] ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 71 B 8/2 5 and 8 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 ZNK 100 B 8/2 ZNK 100 A 8/2 4 5 and 8 4 5 and 8 4 5 and 8 4 2/1 4.6/2.8 28.0/1.8/7.0/3.6/2.51) J 214 741 44/210610 51) Integrated in the bottom block.2 9.8 28.0 16.0/4.0 12.0/6.0 6.8 28. Under certain ambient conditions DK bottom block with external switch-off springs.6/2.6/2.8 28.0 8.6/2.0/3.8 9.0/2.0/4.0/2.0/4.6/2.6 9.8 28.6/2.0 8.0/1.0 24.0/6.0 8.0/2.5 12.4/3.6 28.0 8.0 8.0/1.0/3.2/4.0 8.4 7.51) J .8/7.8/7.0 24.0/6.8 28.2 9.5 12.5 8.4 19.0/4.2/4.2/1.2 9.6 28. 76 10 15 10 15 10 15 15 2/1 1/1 2/1 1/1 12.4 19.4 19.0/1.0/6.0/2.4 9.4 7.6 7.0/6.0 16.8 14.2 7.2/4.0 8.5 1000 15 1250 10 15 1600 2000 2500 3200 Tab.6/2.0/2.0 8.0 6.8/1.4 14.2/1.0/1.0/6.8/7.2 9.0 16.4/3.0 16.8/7.0 630 10 800 6.0/6.2 5 and 8 4 ZNK 100 B 8/2 Motor size Buffer / switch-off springs see figure ⇒ Fig.0 12.2/1.4 7.0 12.0/6.0/4.6/2.4/3.0/2.2 9.0/3.0 24.4/3.0/6.2/4.0/3.4 19.0/2.2/1.0/3.0/2.0 24.0 24.4 14.2/4.0/2.4 19. 111 .4/3.2/1.0 16.0/2.4 19.8/7.0/1.8/7.0 24.8 Chain collec‐ tor box side B D H B D H B D H B D H B D H B D H B D H B D H B D H B D B D B D K D B K D K D K B K 4m 5m H5 H8 H5 H8 H5 H8 H5 H8 H5 H8 H5 8m - H8 H5 H8 H5 H8 H5 H8 H5 H8 H5 H8 H5 H8 H8 S S S S S H8 H5 H8 H8 H8 - Flex H8 Flex Flex Flex - A 2xJ .0/1.0 4. 0 14.4 19. 78 5 1/1 6.2/4.0 16.8/7.0 24.0 at 60 Hz [m/min] 9.8/7.2/4.0/4.8 and 4.0 16.4 19.0/1.8 and 4.0/4.6/2.0 16.Buffer arrangement DCM Pro SWL Chain hoist DCMPro 1 80 2 5 1 125 2 5 200 250 Tab.2 9.2 9.3 Hook path H [m] ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 71 B 8/2 ZNK 80 B 8/2 Motor size Buffer / switch-off springs see figure Load hook side A C G A C G A C A C Chain collector box side B D F B D F B D B D Chain collector box size at hook path 2.0/2.0 24.4/3.8 2.2/4.0/3. hoist speeds until 03/2007 (no longer available) SWL Chain hoist DCMPro 5 1/1 Reeving Hoist speed at 50 Hz [kg] 200 250 Tab.2/4.6/2.6/2.8 9.0/4. 77 2 5 2 5 1/1 Reeving Hoist speed at 50 Hz [kg] [m/min] 8.3 m H8 C D 112 214 741 44/210610 .0/2.6 Hook path H [m] 2.0/3.8 12.0/4.8 28.0 8.4 19. 79 [m/min] 12.0 at 60 Hz [m/min] 14. hoist speeds until 03/2007 (no longer available) SWL Chain hoist DC-Pro Reeving Hoist speed at 50 Hz [kg] 160 200 250 315 400 500 Tab.4 19.8 m H8 4.4/3.8 m H5 H8 H5 H5 H8 H5 H5 H8 H5 H8 4.8 28.0 16.0 8.0/2.5 7.0 8.0/6.3 ZNK 80 A 8/2 Motor size Buffer / switch-off springs see figure Load hook side Chain collector box side Chain collector box size at hook path 2.6/2.2/1.0/2.6 5 and 8 ZNK 80 A 8/2 A B [m/min] at 60 Hz [m/min] Hook path H [m] ZNK 71 B 8/2 Motor size Buffer / switch-off springs see figure Load hook side C Chain collector box side D H5 H8 Chain collector box size at hook path 5m 8m Buffer arrangement DCM-Pro.0/6.3 m Buffer arrangement DC-Pro. 80.5. Brake wear is checked via the air gap. the brake can still be used until the next maintenance is due. From year of manufacture 04/2009 Fig. ● Open the electrical equipment cover.1250 1250 .6 BK03 Reeving Motor size Brake Max.5 mm. Page 113). depending on the size.1 Brake Brake assignment SWL [kg] 80 . Disconnect chain hoist from power supply (mains connection switch) and secure against restarting. the brakes have gradually been equipped with plugs in the brake housing. 80. ● For brake displacements up to 0.3200 Tab.8.2 Check brake wear Check brake wear depending on the year of manufacture of your chain hoist: ● When the max. brake displacement [mm] 8.250 80 .9. 84 Since 04/2009.5.1000 315 . 80 15 10 2/1 1/1. the brake must be immediately replaced. so that the brake does not have to be dismantled for checking brake wear. 2/1 ZNK 100 B 8/2 Chain hoist DC-Pro 1 2 5 1/1 ZNK 71 B 8/2 ZNK 80 B 8/2 ZNK 100 A 8/2 BK07 0.9 8. ● Check brake wear using a feeler gauge (2) (see ⇒ Tab.500 200 .5. brake displacement is reached (see ⇒ Tab.125 80 .2500 1000 . 113 . Page 113). 214 741 44/210610 ● Unscrew screw plug (1) from the brake.9. The continuous sealing lip must be in full contact on the brake rear side. ● Measure the distance from brake rear side to brake disk with depth gauge or calliper gauge when the brake is actuated. ● Dismantle brake. Ensure that no grease penetrates into the inside of the brake. ● Open the electrical equipment cover. to do this. Measure brake wear with calliper gauge as follows: ● Measure the distance from brake rear side to brake disk with depth gauge or calliper gauge when the brake is not actuated. 86 During assembly of the brake. Assembly and maintenance Fig.Until year of manufacture 03/2009 Fig. make sure that the area of the V sealing ring (1) on the brake base is slightly greased. 007 177 84). In the course of the annual inspection the V sealing ring (1) of the brake must be re-greased (grease part no. this difference is the brake displacement. press the brake disk against the springs until it stops. 214 741 44/210610 114 . 85 Disconnect chain hoist from power supply (mains connection switch) and secure against restarting. ● Disconnect brake connector. ● Use both measured values to calculate the difference. Page 124. a load of 110% of the load capacity must be lifted within the dynamic overload test (without any change in the setting of the slipping clutch). Under normal operating conditions. Adjustment of the slipping clutch may only be carried out by authorized specialists. The slipping clutch is maintenance-free for up to 10 years. Page 48. 87 When the slipping clutch function has been checked. 88 The slipping clutch is protected against overload by slip monitoring so that re-setting is only necessary during the general overhaul. If the slipping clutch is functioning correctly.5. 8. An increase of the tripping torque which exceeds the factory setting is not permitted.5. must be used. the limit stop must be fitted again to the section of chain which is not under load. Page 98 from the chain fall which is not under load and fit it above the hook assembly.5 9.Tightening torques [Nm] Brake Electrical equipment cover Tab. If owing to the operating conditions or malfunctions. Remove the limit stop ⇒ Fig.1 Slipping clutch Checking the slipping clutch The slipping clutch performs the function of an emergency limit stop de‐ vice and protects the chain hoist against overloads. 3. the slipping clutch is set to the load capacity of the chain hoist. In the course of the annual inspection. the slipping clutch does not need to be adjusted. During the acceptance test of the hoist or crane installation. Page 7. the chain collector box must be dis‐ connected. Fig.2 Adjusting the slipping clutch During the final inspection in the factory. Check the slipping clutch function as follows: ● In order to remove the limit stop. The slipping clutch is initially set in the factory. ⇒ "Warning messages". An increase of the tripping torque which exceeds the factory setting is not permitted.10. ⇒ part no. (EN 14492-2 "Directly acting overload protections"). the friction force checking device. The operating limit switches must not be actuated while this is being done. Page 87. For DC-Pro chain hoists ≥ 1000 kg the setting complies with the require‐ ments of EN 14492-2 for slipping clutches as overload protection. Inspection and adjustment may only be carried out by an experienced technician in compliance with the brochure "Friction force checking device" ⇒ Tab. 81 DC-Pro 1 / 2 / 5 / 10 / 15 5. Run the limit stop against the guide plate at creep speed. ⇒ "Dismantling the chain collector box". see also ⇒ "Suspending the chain hoist". 836 708 44.10.5 8.10 8. 68. Fig. the setting needs to be checked. the following will be observed: ● the hoist motor fan is still turning while there is no lifting motion.5. Over‐ load protections are prescribed for load capacities ≥ 1000 kg. A load > 160% must not be lifted. ● The 7-segment display shows the SLIP LIFTING V1 warning. the slipping clutch must be checked. 214 741 44/210610 115 . 11 Gearbox / oil change Fig. Part no.35 DC-Pro 1 / 2 DC-Pro 5 0. For higher or lower ambient temperatures than -20 °C to + 45 °C. 116 . General on oil change Drain the old oil at operating temperature. see Spare parts. 89 Chain hoist Oil quantities Tightening torques Gearbox cover Gearbox housing 2-piece Oil fill opening and breather M16 Service cover Tab.5. 214 741 44/210610 DC 15 The oil can be changed by unscrewing the vent valve (4). increased ambient temperatures.90 DC-Pro 10 DC-Pro 15 1. contact the manufacturer.g. The flushing oil should have a viscosity of 46-68 mm2/s at rated temperature.8. 82 [Nm] [Nm] [Nm] [Nm] 5. we recommend that oil changes be adapted to suit these conditions.5 DC-Pro 10 0. range of viscosity 10W-30. DC 1-10 Remove the control unit with the plug-and-socket connections (2) under the electrical equipment cover set (3).50 DC-Pro 5 5. Under exceptional con‐ ditions. malfunctions of the slipping clutch may occur. Oil quality Universal gear oil Shell Donax TD 10W-30 with wear-minimising additives. Now remove the screws of the gearbox cover (1). Turn the gearbox in such a way that the oil is drained. the lubricant must be changed at least every 10 years.5 7. Then drain the flushing oil and refill the gearbox with new oil. Then flush the gears by switching the hoist on and allowing the hook to run several times over the entire length of its path. For the required oil quantities please refer to the table above.5 [l] DC-Pro 1 / 2 0. The quantity of flushing oil used should be approximately twice that specified for lubrication. If oils are used that are not approved. Oil lubrication Under normal operating conditions. e.3 DC-Pro 15 25 15 25 Dispose of waste oil in accordance with environmental protection requirements. Pull off the contactor. 214 741 44/210610 117 .12 Replacing the contactor on the control card Fig. 90 1. 2.8. Press contactor onto the contactor socket until both locking arms latch into place. 5.5. 4. 3. 6. Carefully unlock the locking arms on both sides of the contactor using a screwdriver. Contactor socket without contactor Lower side of the contactor The spare contactor can only be inserted in the socket in one position. 5.13 8.1 Replacing cables Replacing the control cable 118 214 741 44/210610 Fig.5.8. 91 .13. It must be ensured that ● the groove of the connector holder matches the swivel lock in the enclosure and ● that the two pins on the enclosure match the bayonet lock. Unscrew electrical equipment cover. 4.DANGER Live components Danger to life and limb.5 11. Page 51. Work on the electrical equipment may only be carried out by a qualified electrician or by trained personnel. 6. 5. 1. Take the control cable out of the pocket. Loosen the screw (3) on the control cable lock and remove the lock. Remove and open the bag (1) with the control cable.0 DC-Pro 1 DC-Pro 2 DC-Pro 5 9. Disconnect chain hoist from power supply (mains connection switch) and secure against restarting. Tightening torques [Nm] Electrical equipment cover Service cover Control cable lock Tab. Open and disengage the service cover. Loosen bayonet lock (2) by turning and remove control cable plug connection. Remove the control cable. 83 5.5 7.5 25 DC-Pro 10 DC-Pro 15 214 741 44/210610 119 . Page 46. 2. 3. Fit the new control cable in reverse order. Fitting the control pendant ⇒ "Connecting the control pendant". Height adjustment of the control pendant ⇒ "Height adjustment of the control pendant". 8.13.5.2 Replacing the helical cable Fig. 92 214 741 44/210610 120 . 5. Work on the electrical equipment may only be carried out by a qualified electrician or by trained personnel. remove helical cable (7).0 DC-Pro 1 DC-Pro 2 9.3 DC-Pro 5 214 741 44/210610 121 . ● Depending on the hook path the limit stop (9) must be fitted: . with a screwdriver). Loosen flanged cable entry sleeve (6). Loosen cap screws (4).to the 17th chain link for a hook path of 2. 3. Remove the control cable. Tightening torques [Nm] Electrical equipment cover Service cover Limit stop Control cable lock Tab. Loosen the screw on the control cable lock and remove the lock.DANGER Live components Danger to life and limb. screws and pipe clamps from the adapter ring. 2.8 m.g. slide cap (5) upwards and secure against dropping (e.3 m. Disconnect chain hoist from power supply (mains connection switch) and secure against restarting. Disconnect electrical connections (4). 84 4. Fit the new helical cable in reverse order. Unscrew electrical equipment cover.to the 21st chain link for a hook path of 4. . First fit helical cable inlet (8) to centering rib of housing and ensure helical cable is correctly arranged.0 11.5 5. Disconnect helical cable. All further steps as ⇒ "Replacing the control cable". Page 118 – – – – Open and disengage the service cover. Undo the four screws (2) to remove cover (1).5 4. It must be ensured that ● the groove of the connector holder matches the swivel lock in the enclosure and ● that the two pins on the enclosure match the bayonet lock. 1. When fitting the new cable. seal by tightening the flanged cable entry sleeve with rubber seal. 4. Tighten diagonal pairs of screws when re-fitting the cover. Loosen bayonet lock by turning and remove control cable plug connection. Before restarting make sure that – – – the fault and the cause of the fault have been eliminated. In the case of faults which constitute an immediate danger for persons and property and/or operating safety. 4. Let motor cool down. Danger of machine damage. Have the fault and the cause of the fault determined and eleminated by authorized specialist personnel. Do not touch the hot motor housing. Page 10 ) in compli‐ ance with the safety instructions.1 Safety instructions for faults / warnings WARNING Inappropriate fault elimination Danger to life and limb. Before starting work. no persons are in the danger zone of the unit. Work on electrical equipment may only be carried out by qualified specialist personnel(⇒ "Definition of personnel". WARNING Risk of burning There is a risk of burning when touching the chain hoist after operation. DANGER Live components Danger to life and limb. 2. 3.9 Faults / Warnings 9. the electrical supply must be switched off. What to do after the fault has been eliminated WARNING Check appropriate assembly. What to do in case of faults 1. all safety devices have been fitted properly and are in perfect working order. before eliminating the fault. The mains connection or isolator switch must be secured against unauthorized or accidental reconnection by means of a padlock. 122 214 741 44/210610 . the machine must immediately be shut down by means of the emergency stop device. Switch off the chain hoist on the mains connection switch or isolator switch and secure it against restarting. Page 10 ) in compliance with the safety instructions. Faults may only be eliminated by qualified instructed personnel(⇒ "Definition of personnel". Inform the responsible person on site about the fault. check the control pendant and the control cable for damage and the plug-in connector on the pendant and in the service enclosure for correct fit. 86 Possible cause Incorrect direction of motor rotation. 85 Possible cause Emergency stop actuated. 9. Fig. When the power supply is switched on or the emergen‐ Release button and actuate it again! cy-stop is unlocked. 94 Before a new movement can be started. Remarks Unlock emergency-stop switch by turning it. 87 Check connections of the control cable on the pendant and in the service enclosure. Fig. therefore first check cables. In the event of a failure. operation may only be continued after repair. Error messages Error messages start with an Error. strain relief and power supply connections. Failed safety functions If a safety function has failed. 97 Upper or lower end position is reached. the error message must be ac‐ knowledged by means of the emergency stop. check mains connector in the service enclosure. The symbols are shown one after the other. Malfunctions may also be caused by incorrect trans‐ mission of commands from the control pendant.3 General messages Possible cause No power supply (display dark) Fig. Check motor connector X8 for continuity between terminal 4 and 8. ● Please contact our after-sales service if the cause of the fault cannot be eliminated with the given measures. check connection ca‐ ble for interruption.2 7-segment display The 7-segment display is located on the bottom side of the chain hoist behind a window. a button is already actuated. 93 Movement in the opposite direction is possible. no lowering No lifting. Check dummy plug for trolley connection. Check control cable for continuity. no lowering Tab. Therefore. Remarks Check mains connection and fuse link. 96 No lifting.9. Faults The chain hoist can only function when it is correctly connected to the power supply. Warning messages Warning messages start with the lightning symbol. Control cable interrupted. No lifting. no lowering Remarks Two phases of the mains connection cable must be changed. 214 741 44/210610 123 . Fig. the warning message does not have to be acknowledged by means of the emergency stop. Emergency-stop cable inter‐ rupted. Check PE phase for correct connection. no lowering Tab. Check connections of the control cable on the pendant and in the service enclosure. Bimetal contact open. 95 No lifting. Tab. Fig. First disconnect unit from the power supply. 88 Possible cause Operating limit switch con‐ tact is no longer actuated. Possible cause Hardware monitoring faulted. Tab. 103 SLIP LOWERING start-up: No lowering Tab. have the brake and control system checked by an experienced technician. 91 Fig. (-. 101 Internal data memory defective. Remarks Check mains connection and fuse link. 94 Possible cause Chain blocked. Tab. 89 Possible cause Operating limit switch con‐ tact is no longer actuated. the slipping clutch acts as an emergen‐ cy-stop device: Connection and functioning of the operating limit switch contact must be inspected by an experienced technician. Fig. if load does not move. if required. the slipping clutch acts as an emergen‐ cy-stop device: Connection and functioning of the operating limit switch contact must be inspected by an experienced technician. No lift‐ ing with load. the slipping clutch acts as an emergen‐ cy-stop device: Connection and functioning of the operating limit switch contact must be inspected by an experienced technician. In the case of an error. 102 No speed information. Operating limit switch con‐ tact is no longer actuated. Ensure appro‐ priate mains voltage. check mains connector in the service enclosure. In the case of an error.) is displayed when the limit switches function correctly. check connection ca‐ ble for interruption. (-. Remarks Check chain running in. Tab.9. Remarks Replace control system. Switch-off in the lower end position Fig.4 Warning messages Possible cause A mains phase is missing or the motor is blocked. Fig. Tab.) is displayed when the limit switches function correctly. In the case of an error. Remarks (-. 99 SLIP LIFTING V1: Switch-off in the upper end position. Reduce load to the permissible load capacity. Fig. Tab.) is displayed when the limit switches function correctly. Tab. replace chain. 98 SLIP LIFTING start-up: No lifting. Tab. Remarks Check mains connection and fuse link. lower end position is not reached. 105 SLIP LOWERING V2: Lowering is switched off. check connection ca‐ ble for interruption. check mains connector in the service enclosure. Remarks (-. if required. 95 214 741 44/210610 Remarks Check chain running in. Switch-off in the lower end position 124 . 100 SLIP LIFTING V2: Switch-off in the up‐ per end position. the slipping clutch acts as an emergen‐ cy-stop device: Connection and functioning of the operating limit switch contact must be inspected by an experienced technician. 93 Possible cause Chain blocked. Operating limit switch con‐ tact is no longer actuated. Fig. replace chain. 90 Possible cause Control system defective. Fast lifting with load is switched off. Reduce load to the permissible load capacity. Remarks Repeat lifting process.) is displayed when the limit switches function correctly. Chain hoist overloaded. lower end position is not reached. 92 Fig. Possible cause A mains phase is missing or the motor is blocked. Fig. In the case of an error. Chain hoist overloaded or undervoltage. 104 SLIP LOWERING V1: Lowering is switched off. 214 741 44/210610 125 . Fig. Tab. 98 Possible cause Hardware error of control system. 100 Fig. Remarks Check error message by actuating and unlocking the emer‐ gency stop. Then actuate Lowering. 97 Remarks Reduce load to the permissible load capacity. check mains connector in the service enclosure. Replace hoist control system. Fig. Remarks Check error message by actuating and unlocking the emer‐ gency stop. Then actuate Lowering. Tab. Remarks Check error message by actuating and unlocking the emer‐ gency stop. 110 Hoist unit: Motor runs in wrong direction. Chain hoist is blocked. Remarks Check error message by actuating and unlocking the emer‐ gency stop. Tab. Fig. If necessary. Speed measurement failed. Chain hoist is blocked. Fig. 107 Hoist unit: Overspeed or load cannot be held. Monitoring electronics defec‐ Replace hoist control system. If necessary. Lowering with load is switched off. Tab.9. tive. 108 Hoist unit: Monitoring electronics defec‐ tive. 109 Hoist unit: Monitoring electronics defec‐ tive. 96 Possible cause Lowering speed too high. remove suspended load. Possible cause Hardware error of control system. Then actuate Lowering. If necessary. Replace hoist control system. If necessary. Chain hoist is blocked. 106 Hoist unit: Speed error or drive is ob‐ structed. Then actuate Lowering. Tab. remove suspended load. Check mains connection and fuse link. remove suspended load. Chain hoist is blocked. Monitoring electronics defec‐ Replace hoist control system. tive. remove suspended load.5 Error messages Possible cause Drive blocked. check connection cable for inter‐ ruption. 99 Possible cause Direction cannot be switch‐ ed. 10 Disassembly / Disposal 10.1 General WARNING Before disassembly, follow the safety instructions in ⇒ "Maintenance / repair", Page 78 of these operating in‐ structions. For information on removing track sections, trolleys and current collector trolleys refer to chapter ⇒ "Assembly", Page 43 of these operating instructions. Other parts are removed in reverse order to assembly. Unless a return or disposal agreement has been concluded, separated components must be recycled after proper removal: ● Scrap any remaining metallic material, ● Dispose of plastic elements for recycling, ● Separate and dispose of any other components by material type. Electric scrap, electronic components, lubricants and other auxiliary materials are subject to special disposal reg‐ ulations and may only be disposed of by certified companies. National disposal regulations must be considered regarding environmentally friendly disposal. Further information can be obtained from corresponding local authorities. 126 214 741 44/210610 11 Accessories 11.1 Components Fig. 111 Item 1 Description Bottom block with switch-off springs (e.g. for hot applications) consisting of: bottom block, switch-off springs, grooved pins with round head, capacity plates Size DC-Pro 10 2/1 Part no.: 715 431 45 717 808 45 718 808 45 715 808 45 721 845 45 717 250 45 718 250 45 715 250 45 718 249 45 715 249 45 717 306 45 718 306 45 721 753 45 773 509 44 773 511 44 773 513 44 773 514 44 2 DC-Pro 1 / 2 Return sprocket assembly: DC-Pro 5 1 return sprocket, 1 pin, 1 retaining ring, 1 supporting washer, 2 thrust washers, 2 DC-Pro 10 needle-roller assemblies DC-Pro 15 Switch-off spring (e.g. for hot applications) consisting of: 2 switch-off sleeves, 1 pressure spring (for DC 10, 2/1 reeving: 2x part no.) Switch-off spring (e.g. for hot applications) consisting of: 2 switch-off sleeves, 1 pressure spring V6,0/1,5 V12,0/3,0 V24,0/6,0 DC-Pro 1 / 2 DC-Pro 5 DC-Pro 10 DC-Pro 5 DC-Pro 10 DCM-Pro 1 / 2 DCM-Pro 5 DC-Pro 15 DCM-Pro 1 / 2 H2,8 DCM-Pro 5 H2,8 DCM-Pro 1 / 2 H4,3 DCM-Pro 5 H4,3 3 4 Swivel unit - swivel joint for Manulift (since 04/2009 in the Manulift as standard), consisting of: 1 swivel unit, 1 pin Switch-off spring (standard) consisting of:: 2 switch-off sleeves, 1 pressure spring for V1 (for V2: 2x part no.) Assembly for converting DC-Pro to Manulift DCM-Pro, consisting of: Manulift handle, helical cable, helical cable clamp, swivel unit, load hook, 2 x link sections, buffer plate, 2 x buffers 5 No fig. Tab. 101 214 741 44/210610 127 12 Spare parts Spare parts for DC 15 are being prepared. Please contact our customer service department. 12.1 Overview 1/1 reeving 2/1 reeving 128 42764249.eps 214740ET.indd/210610 5 Nm 380 V .480 V. 9. 60 Hz. 50 Hz. 9.400 V.240 V. 50 Hz / 575 V. ZNK 80 4 Nm 4 Nm Material Standard 220 V .5 Nm 380 V . 25 Nm 380 V .480 V. 9. 9. 60 Hz.5 Nm 500 V . 60 Hz. 60 Hz.480 V.5 Nm 440 V .525 V.2 Motor 42763744. 60 Hz. 9.415 V. 60 Hz.240 V. 9. 60 Hz.5 Nm 220 V .240 V.indd/210610 129 .240 V. 25 Nm 380 V .5 Nm 220 V . 25 Nm 380 V . 50 Hz.525 V. 25 Nm 440 V .5 Nm 380 V .525 V. 9. 60 Hz. 50 Hz. 9.5 Nm 500 V .240 V. 60 Hz.400 V. 25 Nm 500 V .525 V. ZNK 71 4 Nm. 60 Hz.415 V. 25 Nm 500 V . 50 Hz / 575 V. 60 Hz. 60 Hz. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation DC Pro 1/2 Fan set DC 2 DC-Pro 5 Fan set DC 5 DC-Pro 10 Fan set ZNK 100A Fan set ZNK 100B DC Pro 1/2 Motor set 240V50Hz Motor set 415V50Hz Motor set 525V50Hz Motor set 460V60Hz Motor set 240V60Hz Motor set 380V60Hz DC-Pro 5 Motor set 240V50Hz Motor set 415V50Hz Motor set 525V50Hz Motor set 460V60Hz Motor set 240V60Hz Motor set 380V60Hz DC-Pro 10 Motor set 240V50Hz A Motor set 415V50Hz A Motor set 575V60Hz A Motor set 460V60Hz A Motor set 240V60Hz A Motor set 380V60Hz A Motor set DC10/16 B 50Hz Motor set DC10/16 B 60Hz Motor set DC10/16 B 60Hz Motor set DC10/16 B 60Hz 4 Nm. 9. 50 Hz / 575 V. 25 Nm 220 V .tbl 214740ET.eps Item 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Part no.400 V. 50 Hz. 60 Hz. 71785033 71885033 71585033 71585133 71784133 71784233 71784433 71784533 71784633 71784733 71884133 71884233 71884433 71884533 71884633 71884733 71584133 71584233 71584433 71584533 71584633 71584733 71583233 71583433 71583533 71583733 Qty. 9. 25 Nm 440 V .400 V. 50 Hz. 25 Nm 380 V . 50 Hz. 25 Nm 21474011. 9.415 V.5 Nm 220 V .5 Nm 440 V . 60 Hz. 50 Hz / 575 V. 60 Hz. 9.5 Nm 220 V .415 V.12. 50 Hz.5 Nm 380 V .240 V.480 V. 12.3 Parts on gearbox 130 42763845.indd/210610 .eps 214740ET. V8/2 DC-Pro 2. 50 Hz.35 litres. V8/2 DC-Pro 2.240 V. V16/4 DC-Pro 5. 5.415 V.1/1 reeving. V8/2 DC-Pro 5.5 Year of manufacture 2004 until 03/2007 Gearbox set DC-PRO5 V6/1. 50/60 Hz. 1/1 reeving.5 DC-Pro 10.tbl 214740ET.480 V.5 Nm 500 V .5 Nm 220 V .5 Suspension set DC10 Gear oil/seal Pro 2 Gear oil/seal Pro 5 Gear oil/seal DC10 Adjusting nut/pulse wheel Adjusting nut/pulse wheel DC Pro 1/2/5 Brake set 180V Brake set 216V Brake set DCS 1-5 104V Brake set 258V DC-Pro 10 Brake set DC10 180V Brake set DC 10 216V Brake set DC/DCS10 Brake set DC10 258V Insert/plug 5. 5.5 DC-Pro 5.Item 3 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 5 5 5 6 6 7 7 7 7 7 7 7 7 8 Part no. 50 Hz.5 Nm 440 V . 5.5 Nm. V8/2 DC-Pro 10. 50 Hz / 575 V.5 Nm 380 V . DC-Pro 1 / 2 5. 5. 60 Hz. V4/1 DC-Pro 10.415 V. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation Gearbox set DC-PRO 1 V8/2 Gearbox set DC-PRO 2 V8/2 Gearbox set DC-PRO 2 V16/4 Gearbox set DC-PRO 5 V8/2 Gearbox set DC-PRO 5 V16/4 Gearbox set DC5 V3 Gearbox set DC-PRO10V6/1.525 V.2/1 reeving. 0. V6/1.5 litres 5. 0. V12/3 DC-Pro 10.5 Nm.indd/210610 131 . 50/60 Hz.5 Nm 220 V . V24/6 DC-Pro 10.525 V. 71771533 71790533 71790633 71890833 71890933 71800933 71590533 71590833 71590633 71500933 71590933 71590733 71890533 71890633 71897433 71597433 71791933 71891933 71591933 71894733 71594733 71887133 71887233 71887333 71887433 71587133 71587233 71587333 71587433 71885633 Qty. 1/1 reeving.5 DC-Pro 5.480 V. V12/3 Material Standard 380 V . 0. 5.5 Nm 440 V . 5. 60 Hz.9 litres DC1/2/5 DC10 DC-Pro 1.5 Nm 21474012. V16/4 DC-Pro 5. 2/1 reeving. 60 Hz. 5.5 Gearbox set DC-PRO 10 V8/2 Gearbox set DC-PRO10 V12/3 Gearbox DC-Pro10 V24 Gearbox set DC-PRO 10 V4/1 Gearbox set DC-PRO10V6/1. V6/1. V6/1.240 V. 60 Hz. 50 Hz / 575 V.5 Nm. 5. 1/1 reeving.5 Gearbox set DC-PRO 5 V12/3 Suspension set DC 1.5 Nm 500 V . V24/6 DC-Pro 10. 4 Chain drive 1/1 reeving 2/1 reeving 132 42764348.eps 214740ET.indd/210610 .12. 5.7 133 . for GGS 1) 7. 3 Nm DC 10. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation Chain set DC/DCM 1/2 H 5 Chain set DC 1/2 H 8 Chain set DC/DCM 5 H 5 Chain set DC 5 H 8 Chain set DC10 1/1 H 5 Chain set DC10 1/1 H 8 Chain set DC 10 5m 1/1 Chain set DC 10 8m 1/1 Chain set DC10 2/1 H 5 Chain set DC10 2/1 H 8 Chain set DC 10 5m 2/1 Chain set DC 10 8m 2/1 Limit switch set Limit switch set Chain anchorage 2/1 set Buffer set DC 1/2 Buffer set DC5 Buffer set DC10 Chain collector set DC1/2 5m Chain collector set DC1/2 8m Chain collector set DC5 5m Chain collector set DC5 8m Chain collector DC10 1/1 5m Chain collector DC10 1/1 8m Chain collector flexible 20 m 4. 7.4 Nm 7. 7.4 Nm DC 10 2/1.4 Nm.5. for GGS 1) DC 10 2/1.4 Nm.indd/210610 1) See section 8.3 Nm 7. 3 Nm DC 10 2/1 Material Standard # DC 10 2/1 H5 DC 10 2/1 H8 21474015.4 Nm. 7.tbl 214740ET.0 Nm 4. 7. 71795033 71795133 71895033 71895133 71595033 71595133 75263733 75263833 71596033 71596133 75263933 75264033 71888033 71588033 71527933 71795333 71895333 71595333 71798633 71798733 71898633 71898733 71598633 71598733 71535045 Qty.4 Nm 7. for GGS 1) DC 10 2/1.4 Nm DC 10 2/1. for GGS 1) DC 1 2/5.0 Nm 4.3 Nm 4.Item 11 11 11 11 11 11 11 11 12 12 12 12 13 14 15 16 16 16 17 17 17 17 17 17 17 Part no.4 Nm. 3 x4 Hook safety catch set S.tbl 134 214740ET.5 Hook assembly 42764044.eps Item 18 18 18 19 19 19 20 20 20 21 21 21 22 22 22 Part no. w/o hook 25 Nm. w/o hook 11. 4 Hook safety catch set S. 71798033 71898033 71598033 71728133 71828133 71528133 83565033 83665033 83765033 83565933 83665933 83765933 71724033 71393433 71528033 Qty. 4 x5 Load capacity plate set DC1/2 Pro Load capacity plate set DK5 1/1 Load capacity plate set DC10 1/1 6. 2 400kg Load hook set no. w/o hook DC Pro 1/2 DC-Pro 5 DC-Pro 10 DC Pro 1/2 DC-Pro 5 DC-Pro 10 Material Standard 21474016.8 Nm 11. 2 Hook safety catch set S. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation Load hook assembly set DC1/2 Load hook assembly set DC 5 Hook assembly set DC10 Hook assembly half set DC1/2 Hook assembly half set DC5 Hook assembly half set DC10 Load hook set no. 3 800kg Load hook set no.5 Nm 25 Nm 6.12.indd/210610 .5 Nm.8 Nm. 12.6 Bottom block with internal switch-off springs (standard) 42764145.eps Item 23 24 25 26 Part no. 71598533 71544233 83865633 75262033 Qty. 1 1 1 1 Designation Bottom block set DC 2/1 Bottom block half set DC10 2/1 Hook safety catch set S. 5 x5 Load capacity plate set DC10 2/1 Material Standard 21474017.tbl 214740ET.indd/210610 135 12.7 Bottom block with external switch-off springs (option) 42778044.eps Item 28 29 30 31 32 Part no. 83785233 83865033 83865633 83592833 Qty. 1 1 1 1 Designation Bottom block with switch-off spring Bottom block half set DK10 Load hook DC16/25 DK10/20 Hook safety catch set S. 5 x5 Capacity plate DK10 1) 6.8 Nm Material Standard 21474019.tbl 136 1) See chapter 11 214740ET.indd/210610 12.8 Electrical cover 42763945.eps Item # # # # # # # # 50 50 50 50 50 50 50 50 51 51 51 52 Part no. 77222033 77202033 77232033 77212033 77226033 77206133 77236033 77216033 71792133 71892133 71592133 71582533 Qty. 1 1 1 1 1 1 1 1 1 1 1 1 Designation DC-Pro 1 - 5 Control set DC1-5, 230V Control set DC1-5, 400V Control set DC1-5, 575V Control set DC1-5, 460V DC-Pro 10 Control set Control set Control set Control set DC10, DC10, DC10, DC10, 230V 400V 575V 460V Material 220 V - 240 V, 50/60 Hz; 3 Nm 380 V - 415 V, 50 Hz / 380 V - 400 V, 60 Hz; 3 Nm 500 V - 525 V, 50 Hz / 575 V, 60 Hz; 3 Nm 440 V - 480 V, 60 Hz; 3 Nm 220 V - 240 V, 50/60 Hz; 3 Nm 380 V - 415 V, 50 Hz / 380 V - 400 V, 60 Hz; 3 Nm 500 V - 525 V, 50 Hz / 575 V, 60 Hz; 3 Nm 440 V - 480 V, 60 Hz; 3 Nm 9.5 Nm 9.5 Nm 9.5 Nm DC-Pro 10 Standard Electrical cover set DC 2 Electrical cover set DC 5 Electrical cover set DC10 Contactor set 21474013.tbl 214740ET.indd/210610 137 indd/210610 .eps 214740ET.12.9 Manulift 138 42509045. 33.3x15. H 2. 38 . 35 .1m Chain set DC 5 5m 1) Material Standard # # 4.tbl 214740ET. (part no. H 4.3 DCM 5. 71831533 77206833 77203933 77207333 77201133 77204733 77207533 77200133 77207933 77345233 77202333 77207633 77201833 77345733 77345933 77345033 77345533 83566544 71794833 71795033 71894833 71895033 Qty.3 Nm.8 4. 33.36. H 2. 4300 Control unit DSM-C 1/2 Control unit DSM-C 5 Load hook DKDSM5 250KG Chain set 3.8 DCM 5.3 21474018.45) DCM 1 / 2.2 Bracket chain 5. H 2.45) cpl. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Designation Control cable mounting set DCM Twist adapter Cap DSM 5 set Helical cable entry Bracket chain 4. H 4.8 DCM 1 / 2. H 4. 35 .2x12.3 cpl.36.2 Emergency stop button set Bearing DSM 5 Haousing set DSM 5 Switching element CBDN 3OE Switching element set Cap set Load bearing element 125/250 Unlocking half Helical cable cpl. 38 .1m Chain set DC 1/ 2 5m Chain set 3.indd/210610 1) See chapter 11 139 . 2800 Helical cable cpl.Item 33 34 35 36 37 37 38 39 40 41 42 43 44 45 46 46 47 47 48 49 49 49 49 Part no.3 Nm. (part no. eps Item 53 53 53 54 54 54 56 57 58 Part no.tbl 214740ET.5 Nm 7.5 Nm 5. service cover 42764446.12.indd/210610 140 . 71792033 71892033 71592033 71881033 71880933 72003745 77330033 71880433 72004145 Qty. control cable.5 Nm 11 Nm 11 Nm 11 Nm Material Standard 21474014. hose 5. 1 1 1 1 1 1 1 1 1 Designation Service cover set DC 2 Service cover set DC 5 Service cover set DC10 Control cable set 5m Control cable set 8m DC control cable 11m DSC control pendant Emergency stop set / rubber cap DSC-S Bag.10 Control pendant. 37. 110 C Cable collector 52 Canopy 30 Chain link section 101 Chain wear 92 Closing eye 37 Contactor control 32 Continuity of the PE conductor connection 44 Control cable stop 51 Counterweight compensation 49 Coupling pin 37 Curve radii for trolleys 40 D Discarding status of the chain 90 E Emergency limit switch 32 F Factor depending on the type of recording 81 Fahrwerkpuffer 41 Flange width 41 G Gripping hook 37 I Infrared interface 32 K KBK crane construction kit 42 KBK track 42 214 741 44/210610 Number of operating hours 81 O Oil change 116 Oil lubrication 116 Oil quality 116 Optional suspension 38 P Pantograph tongs 37 Parallel gripper 37 Phase sequence 55 Q Quick-release coupling 36 R R-S-T network 55 Reeving 49 Retaining clip 49 Rolling resistance 42 S Self-locking nut 44 Special fittings 49 Strain relief attachment 54 Strain relief hose 35 Stromzuführung 40 Supporting rollers 41 Suspension bracket 38 Switch-off spring 110 Switching cycles 34 Switching frequency 80 Swivel lock 36. 119 Belt sling 37 Bend protection sleeve 46 Buffer 67 Buffer plate 67. 78 Winding protection control cable 50 Window 33 L Length adjustment belt sling 37 Load spectrum factor 82 N 141 .Index A Actual duration of service 81 Actual load spectrum factor 81 Actuator plate 67 AC asynchronous motor 31 B Bayonet lock 35. 46. 119 T Theoretical duration of service 84 Tracks 40 Tri-state signals 32 Type plate 2 W Wear of individual link 90 Welding work 43. Original EC conformity declaration for a machine according to Directive 2006/42/EC. 58300 Wetter declare that the electrically driven hoist for lifting loads Demag DC chain hoist Model code: Serial no.Part 32: Requirements for hoisting machines Industrial Cranes Segment Subject to change. 58286 Wetter m pl e ppa. Harkort Wetter Factory Manager Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH. number / Language 19961044 / EN Issue Page 0110 1/ 1 Hereby we. Schulte Engineering/Development HT/AT The safety objectives of Low Voltage Directive 2006/95/EC are achieved. 58286 Wetter Wetter. 24. Sa Authorised representative for technical documentation Hans-Jörg Böttcher. Demag Cranes & Components GmbH Ruhrstraße 28.Power driven winches and hoists Part 2: Power driven hoists Safety of machinery . The product additionally complies with the following relevant directives/provisions: EC EMC Directive 2004/108/EC Cranes . Demag Cranes & Components GmbH. D.with a cable-connected control pendant/wireless control unit complies with all relevant requirements of EC Machinery Directive 2006/42/EC. Applied harmonised standards.2010 ppa.Electrical equipment of machines . Dr. No liability for errors or omissions . in particular EN 14492-2 EN 60204-32 The relevant technical documentation according to Annex VII Part A of Directive 2006/42/EC has been compiled and will be made available to authorised national authorities by the designated authorised representative in response to a justified request.: nnnnnnnn ready for service .08. Annex IIA Ident.as a series product or manufactured to order . 58300 Wetter declare that the electrically driven hoist / hoist with trolley for lifting loads / lifting and moving loads Demag DC chain hoist/Demag DC chain hoist with trolley Model code: Serial no.Power driven winches and hoists Part 2: Power driven hoists EN 60204-32 Safety of machinery . number / Language 19961244 / EN Issue Page 0110 1/ 1 Hereby we. (* insofar as this machinery is subject to the scope of application) Industrial Cranes Segment Subject to change. No liability for errors or omissions . insofar as they are relevant for the scope of delivery.: nnnnnnnn supplied as partly completed machinery is intended to be incorporated into machinery and that it must not be put into serviceuntil the machinery* into which this partly completed machinery is to be incorporated has been declared in conformity with all relevant provisions of Basic requirements of the EC Machinery Directive. Demag Cranes & Components GmbH. Demag Cranes & Components GmbH Ruhrstraße 28.Original Declaration for fitting partly completed machinery according to Machinery Directive 2006/42/EC. Schulte Engineering/Development HT/AT EC Machinery Directive 2006/42/EC.08.2010 The special technical documentation according to Annex VII Part B of Directive 2006/42/EC has been compiled and will be made available to authorised national authorities by the designated authorised representative in response to a justified request. 58286 Wetter m pl e ppa. 24.Part 32: Requirements for hoisting machines The safety objectives of Low Voltage Directive 2006/95/EC are achieved The product additionally complies with the following relevant directives/provisions: EC EMC Directive 2004/108/EC Sa Wetter. Harkort Wetter Factory Manager Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH. Annex IIB Ident. D. 58286 Wetter ppa. Authorised representative for technical documentation Hans-Jörg Böttcher. are met by application ofthe following harmonised standards or C standard drafts: EN 14492-2 Cranes . Dr.Electrical equipment of machines . com/Contact Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH. Not liable for errors or omissions.The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found on the Demag Cranes & Components homepage at www. Printed in Germany .demagcranes. 58286 Wetter (Germany) Subject to change.