Talhas DC

Operating instructions / accessories /
component parts
Demag DC-Pro 16 and DC-Pro 25 chain hoists
42711344.jpg
110707 EN/PDF 211 033 44 720 IS 817

Manufacturer Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone +49 (0) 2335 92-0 Telefax +49 (0) 2335 927676
www.demagcranes.de
Please ll in the following table before rst putting the chain hoist into service.
This provides you with a denitive documentation of your chain hoist and important
information if you ever have to contact the manufacturer or his representative.
Owner
Where in use
Size
Serial number
Accompanying documents Technical data

Demag DC-Pro 1 to DC-Pro 25 chain hoists 203 525 44 714 IS 817
U 11 / U 22 / U 34 trolley 203 569 44 714 IS 845
Clamp-tted buffers 203 313 44 714 IS 888
Operating instructions Assembly Adjustment Dimensions

DSE10-C control pendant 214 998 44 720 IS 951
E 11 / E 22 / E 34 travel drive 214 810 44 720 IS 845
ZNA, ZBA, ZBF motors 214 228 44 720 IS 919
EUDC10-25 crane set 211 029 44 720 IS 800
DRC-DC radio remote control system 214 689 44 720 IS 975
KBK installations 206 076 44 720 IS 152
Test and inspection booklet 214 745 44 720 IS 817

Certicates 235 309 44
211033k1.indd/110707
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Contents
0 Foreword 5
0.1 Copyright 5
0.2 After-sales service 5
0.3 Liability for defects 5
0.4 Limitations of liability 6
0.5 Denitions 7
1 Safety instructions 8
1.1 Symbol description 8
1.2 Intended use 9
1.3 Inappropriate use 10
1.4 Basic information on safety 10
1.5 Selection and qualication of operating and maintenance personnel 11
1.6 Safety instructions for installation and disassembly 11
1.7 Safety instructions when rst putting the unit into service
after completing installation 12
1.8 Safety instructions for operation 12
1.9 Safety instructions for maintenance 13
2 Technical data 14
2.1 Design overview 14
2.2 Selection table 15
2.3 Model code 16
2.4 Electrical key values 16
2.5 Hook dimension C 18
2.6 Sound pressure level 19
2.7 Transportation and storage 19
2.8 Surface protection and painting 19
2.9 Operating conditions 19
3 Description 20
3.1 Drive 20
3.2 Gearing and slipping clutch 20
3.3 Chain drive 21
3.4 Housing 21
3.5 Electrical equipment 22
3.6 Control pendant height adjustment 23
3.7 Control pendant 23
3.8 Suspension 23
3.9 Trolley 24
4 Installation and commissioning 26

4.1 General 26
4.2 Connecting the control pendant 27
4.3 Suspending the chain hoist 28
4.4 Control cable 29
4.4.1 Fitting the control cable stop on the cable collector 29
4.4.2 Control pendant height adjustment 30
4.4.3 Mobile control system 31
4.4.4 Handling the control cable 32
4.5 Mains connection 32
4.6 Geared limit switch 34
4.6.1 Technical data of geared limit switch 34
4.6.2 Setting the lowest hook position on the geared limit switch 35
4.6.3 Geared limit switch setting instructions 36
4.6.4 Removing and tting the geared limit switch 36
4.7 Setting the parameters 37
4.7.1 Starting parameter setting mode 37
4.7.2 Meaning of keys 37
4.7.3 Meaning of parameters 38
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Contents
5 Circuit diagrams and additional electrical modules 39

5.1 Schematic diagrams 39
5.2 Hoist control system and additional electrical modules 50
5.2.1 Hoist control system 50
5.2.2 Pulse generator module 54
5.2.3 Control pendant jumper module 55
5.2.4 Radio receiver module 56
5.2.5 Trolley module 60
5.2.6 KT3 signal conversion module (conventional input) 62
5.2.7 3TK signal conversion module for crane axis (conventional input) 64
5.2.8 Cable set crane plug-in connector 67
5.3 Circuit diagrams 70
5.3.1 Circuit diagram solo hoist 70
5.3.2 Circuit diagram DC 16/25 with EU 22 / EU 34 74
5.3.3 Circuit diagram DC 16/25 with trolley module
for pole-changing travel motor 78
5.4 Cabling DC 16/25 with trolley 82
5.4.1 Cabling DC 16/25 with EU 22 / EU 34 82
5.4.2 Cabling DC 16/25 with EU 56 pole-changing trolley motor 84
5.4.3 Cabling DC 16/25 with cross travel limit switch on EU 56 trolley motor 86
6 Taking the hoist out of service at the end of the shift /

for maintenance 88
6.1 Emergency stop 88
6.2 Taking the hoist out of service at the end of the shift 88
6.3 Taking the hoist out of service for maintenance 88
7 Inspections/maintenance/general overhaul GO 89
7.1 Inspection before starting work and during operation 89
7.2 Checking the emergency stop 89
7.3 Inspection and maintenance schedule 89
7.4 Operating status and error display 89
7.5 General overhaul GO 90
7.6 Inspection and maintenance schedule 91
7.7 Display of operating hours / statuses 92
7.8 Measures for achieving safe working periods S.W.P. 93
7.8.1 Calculating the actual duration of service S 94
7.8.2 Example: DC-Pro 25-2500 2/1 H4 V8/2 in 1Am 95
8 Maintenance 96
8.1 Replacing the hook 96
8.1.1 1/1 reeving 96
8.1.2 Replacing the bottom block for 2/1 reeving 97
8.2 Dismantling the chain collector box 97
8.3 Assembly and disassembly of chain set 98
8.4 Hoist chain 102
8.5 Suspension bracket, load hook 106
8.6 Brake 107
8.7 Checking the slipping clutch 108
8.8 Adjusting the slipping clutch 108
8.9 Gearbox / oil change 109
8.10 7-segment display 110
8.10.1 General messages 110
8.10.2 Warning messages 111
8.10.3 Error messages 112
9 Accessories 113
10 Spare parts 120
Declaration of conformity
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0 Foreword
You have purchased a Demag quality product.

This chain hoist was manufactured to European standards and regulations in
accordance with state-of-the-art engineering principles. The requirements of EC
directive 98/37/EC are complied with.
These operating instructions are designed to provide the owner and operator with
useful instructions for transportation, putting into service, operation and mainte-
nance of our chain hoists.
Persons entrusted with the various types of work must know and comply with the
safety regulations and the operating instructions.
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 opera-
tion of our products.
0.1 Copyright These operating instructions are protected within the sense of copyright law.
No part of this documentation may be reproduced, utilized or transmitted without
specic prior consent.
0.2 After-sales service Should you have any questions regarding application or in the event of errors,
contact our after-sales service:
Demag Cranes & Components GmbH
+49 (0)180 / 5 - 741268
For information on our products, please refer to one of our Demag ofces, the
relevant representative, authorized resellers, head ofce in Wetter or the Internet:
www.demagcranes.com
By quoting the serial number, the type or the order number of your Demag chain
hoist, you enable us to process any enquiries or spare parts orders without delay.
0.3 Liability for defects These operating instructions must be read carefully before installing and putting
the chain hoist into operation.
We assume no liability for any damage and malfunctions resulting from failure to
comply with the operating instructions.
Any liability claims for defects must be made by quoting the order number immedi-
ately on detecting the defect.
Any liability claims for defects are void in the event of:
inappropriate use,
faulty devices or equipment connected or attached to the system which are not
part of our scope of supplies and services,
use of non-genuine spare parts and accessories,
refurbishment or modication of the product unless approved in writing by
Demag.
Wearing parts are not subject to liability for defects.

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0.4 Limitations of liability All technical information, data and instructions for operation contained in these
operating instructions were up-to-date on going to print and are compiled on the
basis of our experience and to the best of our knowledge.
We reserve the right to incorporate technical modications within the scope of
further development of the chain hoists which are the subject of these operating
instructions.
The information, illustrations and descriptions contained in these operating
instructions are therefore only intended for information purposes.
The descriptions and illustrations contained in these operating instructions do
not necessarily correspond to the scope of delivery or any subsequent spare part
delivery, either; the drawings and illustrations are not to scale.
Only documentation belonging to the actual order is valid.
We assume no liability for defects, damage and malfunctions caused as a result
of operating errors, non-compliance with these operating instructions or omitted
and/or inappropriate repairs and maintenance.
We expressly point out that only the use of genuine Demag parts and accessories
approved by us ensures safe operation. Accordingly, this also applies to other
manufacturers parts supplied by us.
For safety reasons, the tting and use of spare parts or accessories which have
not been approved and unauthorized modication and conversion of the product
are not permitted and exempt Demag from any liability for damages resulting
therefrom.
With the exclusion of any further claims, our liability for defects and liability obliga-
tions for any defects pertaining to the products supplied or faults in the documenta-
tion delivered or any negligence on our part are exclusively based on the stipula-
tions of the original contract. Any further claims, in particular any and all claims
for damages, are excluded with the exception of legal claims in accordance with
product liability legislation.
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0.5 Denitions Owner
Owners (employer, company) are dened as persons who own the chain hoist and
who use it appropriately or allow it to be operated by suitable and trained persons.
Operating personnel/operator
Operating personnel are dened as persons entrusted by the owner of the chain
hoist with operation of the equipment.
Specialist personnel
Specialist personnel are dened as persons assigned by the owner to carry out
special tasks such as installation, setting-up, maintenance and fault elimination.
Qualied electrician
Qualied electricians are dened as persons who, owing to their technical training,
knowledge and experience of electrical installations as well as knowledge of the
relevant standards, codes of practice and regulations, are able to assess the tasks
given to them and to identify and eliminate potential hazards.
Trained person
Trained persons are dened as persons who have been instructed and trained
for the tasks assigned to them and on the possible hazards resulting from incor-
rect handling and who have been informed about the required protective devices,
protective measures, relevant regulations, codes of practice, accident prevention
regulations and operating conditions and who have proven their qualications.
Experienced technician
Experienced technicians are dened as persons, who, owing to their technical
training and experience, have sufcient knowledge of chain hoists and are familiar
with the relevant national industrial safety regulations, codes of practice, accident
prevention regulations, directives and generally accepted engineering standards
enabling them to judge the safe operating condition of chain hoists.
Assigned expert engineer (in the Federal Republic of Germany according to

BGV 8, 23, for determining the S.W.P.)
An assigned expert engineer is dened as an experienced technician specically
assigned by the manufacturer to determine the remaining duration of service
(service life) of the chain hoist (S.W.P. = safe working period) and to carry out a
general overhaul of the chain hoist.
Authorized expert engineer (according to BGV 9, 28)

In addition to the expert engineers of the Technical Supervisory and Inspection
Board, an authorized expert engineer for the inspection of chain hoists is dened
as an expert engineer authorized by the Industrial Employers Mutual Insurance
Association.
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1 Safety instructions
1.1 Symbol description The following symbols and instructions are used to warn against potential safety
hazards or causes of damage or provide useful information.
Hazard warning
This symbol indicates all instructions relating to safety at work. Any failure to
comply with these instructions will result in danger to life and limb.
Follow these instructions at all times and be particularly vigilant and cautious.
Warning against dangerous electrical voltage

Contact with live parts can result in immediate death. Access (e.g. opening of
covers and enclosures of electrical equipment) only by qualied personnel after
the stipulated protective measures have been taken.
Warning against suspended load

Any person remaining in this danger zone may suffer serious injury or death.
Operating hazard for the installation

This symbol indicates information on the appropriate use of machinery.
In the operating instructions, it indicates all warnings which, if not complied with,
may result in damage to the chain hoist or the load.
Information
This symbol indicates tips and useful information.
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1.2 Intended use Chain hoists are only intended for lifting, lowering and moving loads and may be
used as stationary or travelling units. The suspension/support structure for the
chain hoist must be designed for loads caused by operation of the chain hoist.
The chain hoists are designed for a period of use of at least 10 years until the rst
general overhaul is carried out. This is based on the condition that the operating
conditions (section 2.9), inspection and maintenance (section 7.3) are complied
with and that the specied group of mechanisms is not exceeded by the actual
duration of service. When the actual duration of service has reached the theoreti-
cal duration of service valid for the group of mechanisms, further operation of the
chain hoist is only permissible after a general overhaul.
The chain hoists are supplied with power from an AC power network. The voltage
and frequency of the AC power network must match the data specied on the
rating plate of the chain hoist. It must be possible to switch off powerfeed by
means of a device for disconnecting the powerfeed.
Electric chain hoists must only be operated when in perfect working order by
trained operating personnel. The relevant safety and accident prevention regula-
tions as well as the operating instructions must be complied with.
The load specied on the capacity plate indicates the highest permissible load
which must not be exceeded by the sum total of lifting load and load handling
attachment. Only approved load handling attachments may be used. The load
capacity of the load handling attachment must not be exceeded.
For attaching the load, attention must be paid to the following:
- the hook must not be hindered in its movement by the load handling
slings, e.g. getting caught in an inclined position,
- when the load is lifted, the hook must move to an upright position so that
the safety catch is not loaded by the load handling slings and, as a result,
may be damaged.
To protect the chain from impermissible torsion when the load turns, move-
ment of the hook assembly/bottom block must not be restricted.
The powered motions of lifting and lowering and, if applicable, cross travel and
long travel are controlled by means of the corresponding control elements of the
control pendant. The slow speeds are intended for attaching the load, lifting it
free and depositing it. Loads can be precisely positioned at slow speeds. At fast
speeds, short transport times can be reached. They are suitable for travelling
without load or safely suspended load, if no hazard may be caused by the faster
motion sequences.
Inching is to be avoided at fast speeds, as it causes increased wear and load

sway.
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1.3 Inappropriate use Certain work and practices are prohibited when using the chain hoist as they
may cause danger to life and limb and damage to the chain hoist, e.g.:
Do not handle the load in an unsafe manner (e.g. swinging the load).
Do not handle suspended loads above persons.
Do not pull or drag suspended loads at an angle.
Do not pull free xed or obstructed loads.
Do not exceed the maximum permitted load and permitted load dimensions.
Do not leave suspended loads unsupervised.
Do not touch the chain while lifting or lowering the load.
Do not allow chains to run over edges.
Do not use the chain as a load bearing sling.
Do not move loads by dragging on the control pendant.
Do not allow loads to drop when the chain is in a slack condition.
Do not subject the control switch to inappropriate mechanical loads.
Do not allow the control cable to be wound around the chain when lifting
motions are performed.
Transporting persons with the hoist unit is not permitted unless hoist units are
specically approved for transporting persons.
Do not manipulate electrical equipment.
Chain hoists must be suspended in such a way that they do not collide with
stationary equipment and structures, e.g. when slewing pivoting cranes.
The bottom block must not be twisted or turned over for 2/1 reeving arrange-
ments; chain links facing the same direction must be arranged opposite each
other without being twisted.
1.4 Basic information on The owner must ensure that the chain hoist is only operated when in proper work-
ing order and that the relevant safety requirements and regulations are complied
safety with.
Chain hoists must be taken out of service immediately if functional defects or irreg-
ularities are detected. When the chain hoist has been stopped as a consequence
of safety-relevant defects, it must be secured against putting into operation again
until an experienced technician is satised that the cause of the hazard situation
has been eliminated and that operation of the installation is possible without any
hazard.
To avoid accidents and damage, observe general statutory and other obligatory
regulations relating to accident prevention and environmental protection and basic
health and safety requirements as well as these operating instructions. Important
information and instructions are marked by corresponding symbols. The operating
instructions must be kept available at the place where they are available for infor-
mation to the operating personnel responsible at all times.
If the operating and safety instructions are not observed in any way, personal injury
or even death can result. The owner must instruct his personnel accordingly.
Special local conditions or applications can lead to situations which are not taken
into consideration in these operating instructions. In such cases, the required
safety measures must be determined and implemented by the owner. Necessary
measures may also relate, for example, to the handling of hazardous materials or
tools and the provision/wearing of personal protection equipment.
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The operating instructions must, if required, be supplemented by the owner with
instructions relating to the organization of work, working procedures, authorized
personnel, supervising and reporting obligations, etc..
Hazards for persons and property may be caused by chain hoists which are
not installed, operated and maintained appropriately or operated by unsuitable
personnel.
Persons under the inuence of drugs, alcohol or medicines which affect reactions
must not install, operate, put into service, maintain, repair or disassemble chain
hoists.
Any conversions and modications to the installation require the written consent
of Demag. This also applies to the subsequent installation of safety devices as
well as for performing welds on load bearing parts. Safety devices must not be
rendered inoperative. All safety and hazard information on the chain hoist, at ac-
cess points and mains connection switches must be maintained in complete and
legible condition.
Installation, repair and maintenance work relating to chain hoists which are not
described in these operating instructions may only be carried out by qualied
specialist personnel with the specied equipment.
Work on electrical equipment of chain hoists may only be carried out by qualied
electricians in accordance with electrical regulations.
We urgently recommend you use genuine spare parts and accessories that have
been approved by Demag. This will ensure that the safety and service life of the
chain hoist is guaranteed. In the circuits, only fuse links with specied amperage
and tripping characteristics may be used. Defective fuse links must not be bridged.
Observe prescribed deadlines or those specied in the operating instructions for
routine checks/inspections.
1.5 Selection and quali- For independent operation or maintenance of the chain hoist, the owner may only
assign persons
cation of operating
who are mentally and physically suitable,
and maintenance who have been instructed in the operation or maintenance of the chain hoist
personnel and have proven their qualication to the owner in this respect (this also in-
cludes practical application and the ability to identify defects which are a hazard
to safe operation),
who can be expected to carry out the work assigned to them reliably.
If the chain hoist is used as the hoist unit in a crane, operating persons must also
be at least 18 years of age.
1.6 Safety instructions Installation and disassembly work may only be performed by experienced
technicians.
for installation and Installation and disassembly work must be co-ordinated by the person carrying
disassembly out the work and the owner within the scope of their responsibility.
The working and danger zone must be made safe.
The installation must be isolated in accordance with the relevant electrical
regulations.
Customer-specic regulations must be observed.
Only appropriate, tested and calibrated tools and equipment may be used.
The electrode holder and earth must be connected to the same assembly
when welding work is carried out (if the current ow is returned via protective
conductors, screening elements or anti-friction bearings, serious damage may
be caused to these or other components).
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1.7 Safety instructions The working and/or danger zone must be made safe.
when rst putting Before the chain hoist is rst put into operation, an experienced technician must
carry out the following checks:
the unit into serv-
The voltage and frequency specied on the capacity plates must match the
ice after completing owners mains power supply.
installation The supporting structure must be in proper condition and be sufciently rated
for the load capacity of the chain hoist.
Safety devices must be completely tted and effective.
Clearances and safety distances must be complied with.
The emergency stop device must be checked by actuating the emergency stop
button.
For powered chain hoists with a load capacity of more than 1000 kg and/or ap-
plication of a powered chain hoist with an electrical travel drive as a rail-mounted
travelling hoist or a crane, these checks must be carried out by an expert engineer.
1.8 Safety instructions Before starting operation of the chain hoist, it must be ensured that nobody is en-
dangered by operation of the hoist. During lifting processes, mechanical hazards
for operation may be caused, for example, by falling loads, collision of the chain hoist or the load
or by effects of the load, the load handling attachment or the chain on persons or
objects. If the operator notices that persons are endangered during operation, he
must suspend operation until a sufcient distance to the person(s) endangered is
guaranteed.
When starting work, the operator must be satised that the chain hoist is in safe
and correct operating condition. This includes checking the function of the brakes,
end position limitations and emergency stop devices. All protection devices must
have been installed and must be fully functioning.
In the event of defects which endanger safe and reliable operation, the chain hoist
must be taken out of service without delay. Defects relevant to safety in this sense
are, for example:
Damage to electrical devices, cables or insulation,
Delayed functioning or failure of brakes and safety devices,
Missing covers or housing parts,
Damage to the chain or to supporting parts,
Damage to the chain collector or its suspension arrangement.
Anybody who identies an immediate danger of personal injury must actuate the
emergency stop button without delay. This also applies in the case of damage oc-
curring to parts of the installation and equipment which makes immediate stoppage
necessary.
When the chain hoist has been stopped as a consequence of safety-relevant
defects by an emergency stop, it must be secured against putting into operation
again until an experienced technician is satised that the cause of the hazard
situation has been eliminated and that operation of the installation is possible
without any hazard.
Functioning of the emergency stop device

When the emergency stop button is actuated, the hoist motor is disconnected
immediately from the electrical power supply, the mechanical brake is applied
and stops the movement. Resuming operation by unlatching the emergency stop
button is only possible, if no lifting or lowering commands are applied (off-posi-
tion constraint). The effectiveness of the emergency stop function depends on the
proper condition of the mechanical brake.
If an unusually long braking distance is noted, impermissible wear on the brake
may be the cause. In this case, the brake must be inspected by an experienced
technician without delay.
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Functioning of the slipping clutch
The chain hoist is tted with a slipping clutch that is tripped in the event of over-
load. The brake is then automatically applied and the motor is switched off. In this
situation, only lowering is still possible. It is therefore not possible to lift an overload
from the ground. A load already suspended can be safely deposited by actuating
the lowering button. When the lowering motion has been completed, lifting is pos-
sible again.
If the slipping clutch switches off already at rated load, the slipping force must be
measured by an experienced technician and re-adjusted, as required.
Functioning of the lifting path limiter

After the lifting path limiter has been tripped, only the opposite motion is still
possible. The lifting path is limited by limit stops on the ends of the chain. As a
consequence, the slipping clutch becomes effective as an emergency stop de-
vice, the brake is automatically applied and the motor is switched off. Tripping of
the emergency stop device causes a warning message on the display. Travelling
against the emergency-stop device is prevented by a geared limit switch with
contacts with positive opening operation which switches off the movement before.
1.9 Safety instructions for The owner of the chain hoist must ensure that the specied maintenance work is
carried out appropriately on the chain hoist. Maintenance measures are dened as
maintenance regular maintenance, inspection and repair work.
Maintenance work must be carried out by sufciently qualied specialist personnel
(experienced technicians). Unauthorized personnel must not be allowed to carry
out maintenance work on the chain hoist.
The necessary inspection, adjustment and maintenance work and the relevant
time intervals are specied in the operating instructions, section 7.
Before starting any maintenance work, the chain hoists must be switched off and
taken out of service and secured against accidental or unauthorized putting into
operation (restarting), unless specied otherwise in section 7. Ensure that all
switches are locked.
It must be ensured that

the chain hoist is switched off, checked that it is de-energized and, in special
cases, isolated,
moving parts are stationary and stopped,
moving parts cannot start moving while maintenance work is being carried out,
the power supply cannot be accidentally restored,
operating and auxiliary materials as well as replacement parts are appropriately
disposed of.
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, special safety precautions are necessary, depending on the operating
situation.
In each individual case, the owner or the person assigned by him must check
whether the maintenance work may be carried out in the course of operation with-
out risk of personal injury and, taking into account the local conditions, implement
all necessary safety precautions.
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2 Technical data
2.1 Design overview
Two-fall illustration
1 2 4 6 5 3 7 8 9 13
19
14
15
12 10
20
11
16
1 Electrical equipment cover

with control system
2 Brake 17
3 Slipping clutch
4 Gearbox
5 Chain guide
6 Suspension bracket
7 Stator
8 Rotor
18
9 Motor shaft
10 Fan cover
11 Chain
12 Control cable lock
13 Fan
14 Pulse wheel
15 Slipping clutch adjustment
211033k1.indd/110707
16 Bottom block
17 Load hook
18 Control pendant
19 Geared limit switch
20 Chain collector
14 42719444.tif
2.2 Selection table
DC-Pro (2 hoist speeds)
Load capacity Chain hoist Reeving Group of mechanisms Hoist speed Standard Motor size 1) Max. weight
DIN EN 14492 hook path 3) for hook path
Type FEM / ISO at 50 Hz at 60 Hz H 4m 5m 8m
[kg] [m/min] [m/min] [m] [kg] [kg] [kg]
DC-Pro 1 8,0/2,0 4) 9,6/2,4
ZNK 71 B 8/2 22 24
80 DC-Pro 2 16,0/4,0 19,2/4,8
DC-Pro 5 24,0/6,0 5) 28,8/7,2 ZNK 80 B 8/2 28 30
DC-Pro 1 8,0/2,0 4) 9,6/2,4
ZNK 71 B 8/2 22 24
100 DC-Pro 2 16,0/4,0 19,2/4,8
DC-Pro 5 24,0/6,0 5) 28,8/7,2 ZNK 80 B 8/2 28 30
4m / M7
DC-Pro 1 8,0/2,0 4) 9,6/2,4
ZNK 71 B 8/2 22 24
125 DC-Pro 2 16,0/4,0 19,2/4,8
DC-Pro 5 24,0/6,0 5) 28,8/7,2 ZNK 80 B 8/2 28 30
DC-Pro 2 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22 24
160 16,0/4,0 19,2/4,8
DC-Pro 5 ZNK 80 B 8/2 28 30
24,0/6,0 5) 28,8/7,2
DC-Pro 2 3m / M6 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22 24
200 DC-Pro 5 16,0/4,0 19,2/4,8 ZNK 80 B 8/2 28 30
4m / M7
DC-Pro 10 24,0/6,0 5) 28,8/7,2 ZNK 100 A 8/2 48 52
DC-Pro 2 2m+ 2) / M5+ 8,0/2,0 9,6/2,4 ZNK 71 B 8/2 22 24
250 DC-Pro 5 1/1 16,0/4,0 19,2/4,8 ZNK 80 B 8/2 28 30
DC-Pro 10 24,0/6,0 5) 28,8/7,2 5 and 8 ZNK 100 A 8/2 - 48 52
DC-Pro 5 4m / M7 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28 30
315 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48 52
DC-Pro 10
24,0/6,0 5) 28,8/7,2 ZNK 100 B 8/2 56 60
DC-Pro 5 3m / M6 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28 30
400 4m / M7 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48 52
DC-Pro 10
3m / M6 24,0/6,0 5) 28,8/7,2 ZNK 100 B 8/2 56 60
DC-Pro 5 2m+ 2) / M5+ 8,0/2,0 9,6/2,4 ZNK 80 B 8/2 28 30
500 4m / M7 12,0/3,0 14,4/3,6 ZNK 100 A 8/2 48 52
2m+ 2) / M5+ 24,0/6,0 5) 28,8/7,2 ZNK 100 B 8/2 56 60
6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48 52
630 4m / M7
12,0/3,0 14,4/3,6 ZNK 100 B 8/2 56 60
6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48 52
800 DC-Pro 10 3m / M6
12,0/3,0 14,4/3,6 ZNK 100 B 8/2 56 60
6,0/1,5 7,2/1,8 ZNK 100 A 8/2 48 52
1000 2m+ 2) / M5+
12,0/3,0 14,4/3,6 56 60
2/1 4m / M7 6,0/1,5 7,2/1,8 ZNK 100 B 8/2 65 73
1250 1Am 8) / M4 8,0/2,0 9,6/2,4 56 60
1/1
DC-Pro 16 3m 7) / M6 12,0/3,0 14,4/3,6 4 ZNK 100 C 8/2 111 113 118
DC-Pro 10 2/1 3m / M6 6,0/1,5 7,2/1,8 5 and 8 - 65 73
ZNK 100 B 8/2
1600 2m+ 2) 7) / M5+ 8,0/2,0 9,6/2,4 103 105 110
DC-Pro 16 1/1 4
2m+ 2) 8) / M5+ 12,0/3,0 14,4/3,6 ZNK 100 C 8/2 111 113 118
DC-Pro 10 2/1 2)
6,0/1,5 7,2/1,8 5 and 8 ZNK 100 B 8/2 - 65 73
2000 2m+ / M5+
DC-Pro 25 1/1 8,0/2,0 9,6/2,4 4 ZNK 100 C 8/2 113 115 123
DC-Pro 10 1Am 8) / M4 4,0/1,0 4,8/1,2 5 and 8 ZNK 100 B 8/2 - 65 73
2/1
2500 DC-Pro 16 3m 6) / M6 6,0/1,5 7,2/1,8 110 113 124
ZNK 100 C 8/2
DC-Pro 25 1/1 1Am / M4 8,0/2,0 9,6/2,4 113 115 123
2m+ 2) 6) / M5+ 4,0/1,0 4,8/1,2 ZNK 100 B 8/2
3200 DC-Pro 16 4 110 113 124
2m+ 2) 7) / M5+ 6,0/1,5 7,2/1,8
2/1
4000 2m+ 2) / M5+ ZNK 100 C 8/2
DC-Pro 25 4,0/1,0 4,8/1,2 125 130 145
5000 1Am / M4
1) For motor key data, see page Electrical key values.

2) 2m+ corresponds to 1900 hours operation at full load.
211033k1.indd/110707
3) Larger hook paths on request.

4) For replacement requirements, the ZNK 71 A 8/2 at 380-415 V / 50 Hz is replaced by the ZNK 71 B 8/2 motor.
5) Only with operating limit switch for lifting; operating limit switch for lowering on request (the lower end position must not be approached in normal operation)
6) Chain drive FEM 1Am according to EN 818-7
7) Chain drive FEM 1Bm according to EN 818-7
8) Chain drive FEM 1Cm according to EN 818-7 15
2.3 Model code
E U D DC-Pro 10 - 1000 2/1 H5 V6/1,5 380 - 415 / 50 24/6 200 220 - 480
Travel drive voltage range / voltage [V]
Max. ange width of trolley [mm]
Travel speed [m/min]
Frequency [Hz]
Chain hoist voltage range [V]
Hoist speed [m/min]
V 2-stage = Main/creep lifting

VS Stepless = VS at nominal load up to VSmax in the partial load range
Hook path [m]
Reeving
Load capacity [kg]
Size
DC Demag chain hoist
DCM Manulift
DCS Chain hoist stepless
DCMS Manulift stepless
DCRS Rocker switch stepless
Trolley type
C F 5 Click-Fit (push-travel trolley)
R Push-travel trolley
E Travel drive
U Standard-headroom monorail hoist

11 Trolley size load capacity [kg x 100]
22
34
56
D Articulated trolley (curve-negotiating)
2.4 Electrical key values

Hoist motor data (The tolerance of the voltage range must not exceed 10 %.)
Min. / max. currents and starting current
No. of 380-415 V, 50 Hz, 3 ~ (CE) 220-240 V, 50 Hz, 3 ~ (CE)

Size Motor size
poles PN CDF nN Starts/h IN 380 IN 415 Imax 1) IA/IN 415 cos N IN 220 IN 240 Imax 1) IA/IN 240 cos N
[kW] [%] [rpm] [A] [A] [A] [A] [A] [A]
8 0,57 20 675 240 3,00 3,40 3,90 1,85 0,58 5,20 5,90 6,80 1,85 0,58
ZNK 100 B 8/2
2 2,30 40 2790 120 5,50 6,20 6,40 4,15 0,77 9,50 10,70 11,00 4,15 0,77
DC-Pro 16
8 0,93 20 685 240 4,30 4,70 5,10 2,35 0,55
ZNK 100 C 8/2
2 3,70 40 2820 120 8,20 8,40 8,90 4,95 0,82
-
8 0,93 20 685 240 4,30 4,70 5,10 2,35 0,55
DC-Pro 25 ZNK 100 C 8/2
2 3,70 40 2820 120 8,20 8,40 8,90 4,95 0,82

500-525 V, 50 Hz, 3 ~ (CE)
No. of
Size Motor size
poles PN CDF nN Starts/h IN 500 IN 525 Imax 1) IA/IN 525 cos N
[kW] [%] [rpm] [A] [A] [A]
8 0,57 20 675 240 2,50 2,70 3,10 1,85 0,58
ZNK 100 B 8/2
2 2,30 40 2790 120 4,60 4,90 5,10 4,15 0,77
DC-Pro 16
8 0,93 20 685 240 3,50 3,70 4,00 2,35 0,55
ZNK 100 C 8/2
2 3,70 40 2820 120 6,60 6,70 7,00 4,95 0,82
8 0,93 20 685 240 3,50 3,70 4,00 2,35 0,55
DC-Pro 25 ZNK 100 C 8/2
2 3,70 40 2820 120 6,60 6,70 7,00 4,95 0,82
211033k1.indd/110707
1) Imax = maximum rated current for lowering operation.
16
440-480 V, 60 Hz, 3 ~
No. of
Size Motor size
[kW] [%] [rpm] [A] [A] [A]
8 0,68 20 825 240 3,10 3,50 4,00 1,85 0,57
ZNK 100 B 8/2
2 2,80 40 3390 120 5,70 6,40 6,60 4,15 0,76
DC-Pro 16
8 1,15 20 835 240 4,50 4,90 5,30 2,35 0,54
ZNK 100 C 8/2
2 4,50 40 3420 120 8,50 8,70 9,20 4,95 0,81
8 1,15 20 835 240 4,50 4,90 5,30 2,35 0,54
DC-Pro 25 ZNK 100 C 8/2
2 4,50 40 3420 120 8,50 8,70 9,20 4,95 0,81

220-240 V, 60 Hz, 3 ~
No. of
Size Motor size
[kW] [%] [rpm] [A] [A] [A]
8 0,68 20 825 240 6,20 7,10 8,10 1,85 0,57
ZNK 100 B 8/2
2 2,80 40 3390 120 11,40 12,90 13,30 4,15 0,76
DC-Pro 16
8 1,15 20 835 240
ZNK 100 C 8/2
2 4,50 40 3420 120
-
8 1,15 20 835 240
DC-Pro 25 ZNK 100 C 8/2
2 4,50 40 3420 120

380-400 V, 60 Hz, 3 ~ (CE) 575 V, 60 Hz, 3 ~
No. of
Size Motor size
poles PN CDF nN Starts/h IN 380 IN 400 Imax 1) IA/IN 400 cos N IN 575 Imax 1) IA/IN 575 cos N
[kW] [%] [rpm] [A] [A] [A] [A] [A]
8 0,68 20 825 240 3,90 4,30 4,90 1,85 0,57 2,40 2,70 1,85 0,62
ZNK 100 B 8/2
2 2,80 40 3390 120 7,20 7,70 8,00 4,15 0,76 4,40 4,50 4,15 0,83
DC-Pro 16
8 1,15 20 835 240 5,50 5,80 6,30 2,35 0,54 3,40 3,70 2,35 0,62
ZNK 100 C 8/2
2 4,50 40 3420 120 10,50 10,60 11,00 4,95 0,81 6,50 6,90 4,95 0,89
8 1,15 20 835 240 5,50 5,80 6,30 2,35 0,54 3,40 3,70 2,35 0,62
DC-Pro 25 ZNK 100 C 8/2
2 4,50 40 3420 120 10,50 10,60 11,00 4,95 0,81 6,50 6,90 4,95 0,89
1) Imax = maximum rated current for lowering operation.
Mains connection delay fuse links
Size Motor size 380-415V 220-240V 500-525V 440-480V 220-240V 380-400V 575V
50Hz 60Hz
[A] [A] [A] [A] [A] [A] [A]
ZNK 100 B 8/2 16 20 10 15 25 15 10
DC-Pro 16
ZNK 100 C 8/2 20 - 16 20 - 25 15
DC-Pro 25
Supply cables 2) for 5% voltage drop U and starting current IA
Size Motor size 380-415V 220-240V 500-525V 440-480V 220-240V 380-400V 575V
50Hz 60Hz
[mm2] [m] [mm2] [m] [mm2] [m] [mm2] [m] [mm2] [m] [mm2] [m] [mm2] [m]
ZNK 100 B 8/2 1,5 46 2,5 25 73 1,5 52 2,5 21 1,5 36 90
DC-Pro 16
1,5 1,5
ZNK 100 C 8/2 2,5 47 - 45 2,5 53 - 2,5 36 51
DC-Pro 25
211033k1.indd/110707
2) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 m.
17
2.5 Hook dimension C Size Reeving Suspension bracket
DC-Pro chain hoist C C1

Chain collector
Size 1 Hook path Size 2 Hook path
1/1 640 813 H14 893 H30
DC-Pro 16
2/1 735 813 H7 893 H15
1/1 640 813 H10 893 H20
DC-Pro 25
2/1 770 813 H5 893 H10
1/1 reeving 2/1 reeving
42700346.jpg
DC-Pro chain hoist Size Reeving Trolley Transverse to girder Parallel to girder
with trolley U 22, U 34, RU 56 C C1 C C1
Chain collector Chain collector
S. 1 S. 2 S. 1 S. 2
1/1 U 22 704 877 957 736 909 989
DC-Pro 16
2/1 799 877 957 831 909 989
U 34
1/1 704 877 957 736 909 989
DC-Pro 25
2/1 RU 56 850 893 973 882 925 1005
Transverse to girder Parallel to girder

211033k1.indd/110707
18 42718744.jpg
2.6 Sound pressure level The sound pressure level to DIN 45635 (LpAF) is:
DC-Pro 16 to 8 m/min 69+2 dB(A)
DC-Pro 25 to 8 m/min 69+2 dB(A)
at a distance of 1 m from the chain hoist.
These noise emission levels were measured under maximum load.
Structural inuences such as
transmission of noise via steel structures,
reection of noise from walls, etc.
were not allowed for in the above measurements.
2.7 Transportation and Demag chain hoists, the accessories and the trolleys are shipped in cardboard
packaging or on pallet.
storage
Owing to the horizontal arrangement of the chain hoist on the pallet during trans-
port/storage, a plug screw suitable for transport is tted instead of the vent valve
to avoid oil leakage. Before putting the chain hoist into operation, replace it by the
vent valve included in the supply, see section 4.3.
Store chain hoists and accessories in a dry place.
Temperature range for transportation and storage -25 oC to +55 oC.
2.8 Surface protection As standard, the chain hoist is supplied with corrosion protection (powder coating/
paint nish) in the following colours:
and painting
Chain hoist RAL 5009 Azure blue
Hook assembly RAL 1007 Chrome yellow
Load hook and suspension bracket RAL 9005 Jet black
Trolley RAL 5009 Azure blue
Other paint coats as well as special paints are possible.
2.9 Operating conditions The chain hoist and the trolley can be operated at:
Ambient temperature: -20 C to +40 C,
Humidity: max. 80 % relative humidity,
Height: up to 1000 m above sea level,
Type of enclosure: IP55,
Electromagnetic compatibility: Immunity for industrial environments,
Emission standard for residential, commercial
and light-industrial environments
Demag chain hoists operating outdoors should be provided with a cover for
protection against the weather or chain hoists, trolleys and travel drives should
be kept under shelter if they are not used.
Special operating conditions may be agreed with the manufacturer in individual

cases. Such operating conditions may occur for the following application, for
example:
Galvanizing, electroplating facilities, hygiene areas, low temperatures, hot
applications.
On request, suitable optimised equipment and important information for safe,
low-wear operation may be supplied for these applications
211033k1.indd/110707
19
3 Description
3.1 Drive A robust pole-changing AC asynchronous motor is used as hoist motor. The brake
is arranged on the load side so that after tripping of the slipping clutch, a slipping
load is braked. The bake is released electrically. Pressure springs ensure auto-
matic brake application when the motor current is switched off or in the event of
a power failure. The control system automatically switches the brake in the upper
and lower end positions of the lifting path, when the slipping clutch is tripped and
in the event of error statuses. From the fast speed (8-pole winding), the hoist drive
is decelerated to creep speed (2-pole winding) by means of a speed-controlled
electrical brake. Mechanical braking is only effective for braking from creep lifting
to standstill or when the emergency-stop button is actuated at main hoist speed.
The brake is maintenance-free for up to 5 years.
3.2 Gearing and slipping The slipping clutch is arranged between the motor shaft and the gearbox input
shaft. It performs the function of the emergency limit stop device for the highest
clutch and lowest hook position and protects the Demag chain hoist against overloads.
The geared limit switch prevents that the slipping clutch as an emergency-stop
device is approached during normal operation. The fast-to-slow switching contact
of the geared limit switch prevents that the slipping clutch is approached at fast
speed when the operating limit switch is passed. The slipping clutch also fullls the
EC directive requirements regarding a load control device starting with an SWL of
1000 kg.
The brake arranged on the load side prevents load sinking when the unit is at rest.
Monitoring of the slipping clutch and automatic cut-out of the drive in the event of
slip increase the service life and protect the slipping clutch against overload and
incorrect use. The gearbox and the slipping clutch are maintenance-free for up to
10 years.
Parts in which the load is borne Driving Braking

Slipping clutch Speed detection
Motor Chain drive Brake
Gearbox
211033k1.indd/110707
20 42721945.tif
3.3 Chain drive The special Demag chain is of high strength ageing-resistant material with a high
degree of surface hardening, galvanised with additional surface treatment. The
dimension tolerances of this chain have been precisely adapted to the chain drive.
We therefore urgently recommend that the Demag special chain be used to ensure
safe operation. The maximum service life of the chain can only be reached, if the
specied regular lubrications are appropriately carried out. When a chain is re-
placed, the entire chain drive is always replaced. For this purpose a chain set that
can be easily replaced is available. The chain set offers the following benets:
the optimum duration of service is ensured for the chain;

reliable decision for replacing the individual chain drive components;
reduction in service costs by replacement in one installation process; it is not
necessary to dismantle the motor or the gearbox.
In the case of special ttings on the chain hoist, 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.
3.4 Housing The housing of the chain hoist is of strong light-weight cast aluminium. The fan
cover on the motor, the movable chain collector and the electrical equipment cover
are of particularly impact-resistant plastic material.
Opening the electrical equipment cover
Slot vertical Electrical equipment

cover open
Slot horizontal Electrical equipment
cover closed
42722944.eps
211033k1.indd/110707
21
3.5 Electrical equipment The chain hoist is provided with a modular 24-V contactor control system. The
contactor control system is supplemented by an electronic system with program-
controlled functions. This electronic system detects the control commands that are
tripped by the operator with the control pendant. Permissible control commands
generate switching commands for the contactors to control the hoist motor. The
electronic system monitors the control sequence specied by the operator based
on the speed feedback from the drive shaft, the limit switch contacts and, if ap-
plicable, from the thermal contacts of the motor. In the event of any discrepancies,
the chain hoist is automatically brought to a safe status and warning or error mes-
sages are generated. 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. As standard, the control system
features the following characteristics:
Geared limit switches with 4 contacts for fast-to-slow and nal cut-off;
Plug-type connections for control pendant, power supply, motor connection,
brake, limit switches;
7-segment display for operating hours, operating status and error messages;
Infrared interface for wireless transmission of service data.
For manual control, Demag control pendants are connected via plug-in connectors.
For Demag DC chain hoists without electric trolleys, the compact DSC optimised
for this application is used, the DSE-C for applications with electric trolleys.
4
42722044.jpg
1 Hoist control system

3 Brake
4 Window
211033k1.indd/110707
22
3.6 Control pendant The control cable is protected by a exible easily bent strain relief hose. It can be
specically adapted in its suspension height to the requirements at the workplace
height adjustment at any time by means of an adjusting mechanism. To do this, it is not necessary
to cut the cable conductors or to shorten the strain relief hose. The control cable
that is not required is accommodated in the cable collector. The strain relief hose
is xed at the selected suspension height by means of a self-locking clamping
mechanism. The control pendant can be adjusted to a different suspension height
by unlocking the clamping mechanism.
The strain relief hose for the control pendant consists of an abrasion-resistant
fabric hose with ame-protection impregnation.
In the gripping area (0,8) of the strain relief hose, the control cable is re-inforced by
means of rubber-elastic ller material.
3.7 Control pendant For manual cable-connected control of the chain hoist, the DSC control pendants
(lifting/lowering) or the DSE-C (2 to 3 axes) are to be used. Both control pendants
feature the same plug-in connection for the control cable. The control cable and
the control pendant are connected by means of a bayonet lock.
The shock and impact-resistant DSC and DSE-C housings of high quality thermo-
plastic are resistant to fuels, salt water, greases, oils and alcaline solutions, type
of enclosure IP 65.
Strong mineral (e.g. hydrochloric or sulphuric) acids may, however, corrode pen-
dant switch housings. To avoid this, they must be replaced in good time.
The rubber button caps may be subject to premature wear under aggressive oper-
ating conditions (contact with corrosive substances or special chemicals). Replace
any damaged button caps in good time.
3.8 Suspension The suspension bracket facilitates installation. The chain hoist can be directly sus-
pended in the trolley. The suspension bracket is also suitable for quickly changing
the installation site since it performs the function of the suspension hook. It is not
necessary to dismantle existing trolleys.
The suspension bracket is asymmetrical and must be correctly positioned for tting
(depending on the reeving arrangement, see section 4.3) to ensure straight sus-
pension of the chain hoist. If the suspension bracket is tted inappropriately, the
elements of the chain drive are subject to premature wear.
The chain hoists can be combined with the following trolleys:
DC-Pro 16 / 25
Suspension bracket
Fitted as standard,
Use on trolley
EU 22 DC
EU 34 DC
EU 56 DC
EU 22 DK
EU 36 DK
EU 55 DK 42699244.jpg
211033k1.indd/110707
23
3.9 Trolley The load capacity of the Demag chain hoist must not exceed the load capacity of
the trolley.
I beam track
The use of I beams with parallel or sloping anges according to DIN 1025 as
tracks is possible.
The track radius should be as large as possible in order to ensure good travel
characteristics.
I beam tracks should be bent with the utmost care in order to obtain a clean,
regular curve.
Hoist travel on I beam tracks must in no way be obstructed by protruding suspen-
sion bolts, screw heads, clamping plates, joint anges, etc.
Resilient buffers should be mounted at travel wheel axle level at the ends of tracks
in order to prevent the trolley from derailing (e.g. Demag clamp-tted buffers).
For further information on the trolleys and the power supply, see:
U 11 / U 22 / U 34 trolley 203 569 44 714 IS 845
E 11 / E 22 / E 34 travel drive 214 810 44 720 IS 817
KBK 0 + 25 trailing cable power supply 202 487 44 714 IS 963
KBK 0 + 25 power supply lines 202 386 44 714 IS 963
Clamp-tted buffers 203 313 44 714 IS 888
U 11 / U 22 / U 34 EU 11 / EU 22 / EU 34 EU 56
42647644.eps 42669244.eps 42719544.jpg

211033k1.indd/110707
24
Curve radii of trolleys The specied curve radii apply for normal applications.
Contact the manufacturer or his representative for frequent curve travel
operation (e.g. automatic installations).
Curve radii in mm
Trolley size Load capacity Runway girder Travel wheel
Push travel Electric travel material
[kg] Flange width Rmin Flange width Rmin
CF 5 550 50-91 800 - - Plastic
U 11 DC EU 11 DC 1100 58-310 1000 58-310 2000
Plastic 3)
U 22 DC EU 22 DC 2200
82-310 1) 2000 82-310 1) 3000
U 34 DC EU 34 DC 3400 Spheroidal graphite
RU 56 DC EU 56 DC 5600 98-310 2000 2) 98-310 2500 2) cast iron
1) Flange width for DC 16/25 = 98-310 mm.

2) From ange width 106 mm
3) Steel travel rollers on request
Travel speeds
Load Possible cross-travel speeds in approx. ... m/min
Chain hoist Reeving
capacity V14/3 V12/4 V24/6 V40/10
[kg] Type Trolley Travel drive Trolley Travel drive Trolley Travel drive Trolley Travel drive
80 DC-Pro 1
to to 1/1 U 11 DC E 11 DC
1000 DC-Pro 10 - - - -
2/1
DC-Pro 10
U 22 DC E 22 DC
1250
1/1 - -
DC-Pro 16 EU 56 DC ZBF 80 A 12/4 EU 56 DC ZBF 80 A 8/2
EU 56 DC ZBF 71 A 8/2
DC-Pro 10 2/1 - - - -
U 22 DC E 22 DC
1600
DC-Pro 16 1/1 EU 56 DC ZBF 80 A 12/4 EU 56 DC ZBF 80 A 8/2
EU 56 DC ZBF 71 A 8/2
DC-Pro 10 2/1 - - U 22 DC E 22 DC - -
2000
DC-Pro 25 1/1 EU 56 DC ZBF 80 A 12/4 EU 56 DC ZBF 71 A 8/2 EU 56 DC ZBF 80 A 8/2
DC-Pro 10 - - - - - -
2/1
2500 DC-Pro 16 U 34 DC E 34 DC
DC-Pro 25 1/1
ZBF 80 A 8/2
3200 DC-Pro 16 EU 56 DC ZBF 80 A 12/4 EU 56 DC ZBF 71 A 8/2 EU 56 DC
4000 2/1
DC-Pro 25 - -
5000 ZBF 90 B 8/2
211033k1.indd/110707
25
4 Installation and putting into operation
Dispose of packing material in an

Unpack the hoist environmentally compatible way

In the case of damage or missing parts in the
Check for completeness and damage caused
during transport delivery, send a claim for these parts,
see section 0.2

Connect control pendant, as required see section 4.2

Suspend chain hoist see section 4.3

Adjust control pendant height see section 4.4

Connect to power supply see section 4.5

Adjust geared limit switch see section 4.6

Carry out checks before putting the hoist into
operation for the rst time see inspection and maintenance schedule table

Unit ready for operation
4.1 General Electrical equipment

Work on electrical equipment may only be carried out by qualied electricians or
trained personnel, see also chapter 1 Safety instructions.
The wiring of the Demag chain hoist complies in all respects with current DIN VDE
and accident prevention regulations. Unauthorized intervention and modications
result in eliminating compliance with these regulations.
The switchgear is subject to wear during operation of the chain hoist. Its service
life has been rated for the specied loading group. In the case of extreme switch-
ing frequencies, premature wear is possible.
Instructions relating to safety at work

All tting and assembly work must be completed in accordance with the operating
instructions and the hoist chain must be greased.
Operation with defective or damaged chains results in a high risk of accident for
persons and the chain hoist and is therefore prohibited.
Any change or modication which prejudices safety must be reported to the near-
211033k2.indd/110707
est person responsible immediately. Elimination of faults may only be carried out
by experienced technicians.
26
4.2 Connecting the control pendant
Bend protection sleeve
42596046.jpg 42596144.jpg
c
b
42596244.jpg 42596344.jpg
The control pendant is of plug-in de- 3. Slide the bend protection sleeve 4. Slide the bend protection sleeve
sign. The connector on the end of the onto the control cable. over the control pendant again.
control cable is locked in the bayonet Plug the control cable into the con- Pay attention to the positioning
sleeve and can be turned. If a control pendant and turn the bayonet help.
nector is not locked, it can be pulled lock until it is locked. Press the bend protection sleeve
out and must be locked again by Ensure that rmly onto the control pendant.
pressure. Connect the DSC control - the groove (a) of the connector
pendant with the control cable and holder matches the swivel lock (b) The control pendant can be
lock the connection with the bayonet in the control pendant housing tted on the chain hoist as a
lock. and stationary unit or installed as
- that the two pins (c) on the control a travelling unit (section 4.4).
1. Lift the bend protection sleeve on
211033k2.indd/110707
the control pendant off the two pendant housing match the bayo-
pins. net lock (d).
2. Then pull the bend protection
sleeve from the control pendant.
27
4.3 Suspending the chain hoist
The chain hoist is delivered with the

suspension bracket completely tted
to the chain hoist.
Make sure that the suspension

bracket is tted in accordance with
the reeving arrangement of the chain
hoist. For the chain hoist with 1/1
reeving, a counterweight is required
for balanced suspension.
Remove the retaining clip and pin on

one side.
42597745.eps 42597845.eps Suspend the suspension bracket in
the trolley.
1/1 reeving 2/1 reeving Slide the pin through the suspension
and the suspension bracket, secure
with the retaining clip again.
Do not move the chain

hoist or leave it
unsupervised when the
suspension bracket is
open.
The suspension bracket must be
tted appropriately positioned for the
relevant reeving. If the suspension
42713244.eps 42713344.eps bracket is tted inappropriately, the
chain hoist is suspended at an angle
and elements of the chain drive are
subject to premature wear.
1/1 reeving with counterweight
Counterweight 11,6 kg
Screw size M8x45
Tightening torque 27.5 Nm
211033k2.indd/110707
42713544.eps 42713444.eps
28
Vent valve Before putting the chain hoist into operation, remove the screw plug (plug and
O-ring) and screw-in the vent valve included in the supply (tightening torque
5 Nm).
Screw plug
42728845.jpg
4.4 Control cable

4.4.1 Fitting the control cable stop
on the cable collector
Screw size M6x10

Tightening torque 9,5 Nm
11 Nm
211033k2.indd/110707
42720644.jpg
29
4.4.2 Control pendant height 1 Control cable lock
adjustment 2 Cable collector
Control cable lock
xed released
42597146.jpg
As standard, the control pendant is supplied with a cable length of:

- H4 0,8 m to 2,8 m;
- H5 0,8 m to 3,8 m;
- H8 3,8 m to 6,8 m or
- H11 6,8 m to 9,8 m.
The adjustable height variation is 2 or 3 m.
The suspension height can be adjusted by means of a self-locking mechanism at
any time to suit individual requirements.
To ensure an ergonomic position for operation of the control pendant, adjust the
suspension height in such a way that the operating elements are arranged at el-
bow height.
Longer control cable lengths than 9,8 m (H 11) are provided, for example, by a 2TY
control cable and DST-C or DSE-C control pendants.
Height adjustment of the control pendant:

1. Lift the control cable completely out of the cable collector (2).
2. Slide the operating button (1) of the control cable stop upwards and hold it.
At the same time, pull the control cable until the correct height has been
reached for the control pendant.
If the position is too low, pull on the hanging control cable hose above the cable
collector (2).
Slide the operating button (1) of the control cable stop downwards and x the
stop by a short, strong pull on the control cable.
3. Lay the remaining control cable in loops and store it in the cable collector (2).
211033k2.indd/110707
30
4.4.3 Mobile control system
1
1
5 2
2
3
3
1 Connector enclosure
2 Connector adapter
3 Cable collector
4 Control pendant
5 Flat cable
6 Control cable lock
42711244.jpg 42360744.jpg
Plug-in connections
Pin Signal Cond.
A1 Forward 1
A2 Emergency stop 2
A3 Lifting 3
A4 Left 4
A5 Special 1 (F1/F2) 5
B
A6 Reverse 6
A7 - -
X40
A8 Lowering 7
A
B1 Special 2 (horn) 8
B2 - -
B3 PE PE
B4 Control voltage (24 V, STS) 9
B5 Right 10
B6 - -
B7 - -
B8 Control voltage reference 11 42724245.jpg
Component parts
Item Designation comprising Part no.
Socket enclosure
Fitting frame
1 Connector enclosure cpl. 720 187 45
Pin insert VC-AMS8
Flat cable union
Bayonet lock
Bush enclosure VC-MP-1-R-M25
2 Connector adapter cpl. 720 087 45
Bush frame VC-TR1/2M
Socket insert VC-TFS8
3 Cable collector 720 065 45
211033k2.indd/110707
4 Control pendant DSE-10C 773 352 44

5 11-pole + PE at cable 720 139 45
For use of the cable collector, the height-adjustable standard control cables H4,
H5, H8, H11 are used.
31
4.4.4 Handling the control cable Do not allow the control cable
to be wound around the chain
when lifting motions are per-
formed.
A winding protection for the
upper area of the control cable
is available from the manufac-
turer on request.
42599955.eps
4.5 Mains connection To connect the chain hoist to the power supply, the mains connection cable, the
mains connection fuse links and the devices for disconnecting and switching the
powerfeed must be available on site. For power supply, a 4-lead cable with an
earth lead (PE), which complies with the table in section 2.4, is required.
The earth lead must always be connected and the continuity of the earth
lead connection up to the connection point of the chain hoist must be
checked in order to safely obtain the stipulated protection against contact
voltages.
Please note that the length of the supply cable specied 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.
First check whether the voltage and frequency specied on the capacity plate
match your mains supply. Ensure that the mains connection cable is at zero
voltage and secured against accidental restoration of the power supply.
Use the mains connection set included in the delivery to produce the plug-in
connection for the mains connection cable.
Mains connection X1
Control connection X3 42711444.jpg
The plug-in connection for the mains connection is the upper 4-pole connector,
the lower plug-in connector is provided for the control voltage and the control
signal.
211033k2.indd/110707
The mains connector must never be disconnected under load.

32
Connector insert - Slide the union or the sealing lip including connector enclosure onto the mains
cable.
- Connect the mains cable on the connector insert. If required, use the wire end
sleeves included in the delivery.
3
- Bolt the connector insert together with the connector enclosure.

2
- Plug-in the relevant connector and tighten the locking screws by hand.
- Secure the cables against impermissible strain load by means of cable ties on
1 PE
the vertical enclosure edge.
42711545.jpg
for round and at cables

(4 x 1,5 mm to 4 x 4 mm)
42731044.jpg
42723144.jpg
Phase sequence for connection to the AC power network

The chain hoist is congured for connection to a R-S-T network turning clockwise.
For connection of the mains phases R-S-T to L1-L2-L3 in the specied sequence,
the lifting and lowering buttons correspond to the movements of the load hook.
Then check the movement directions as described in the following. If the phase
sequence of the connection cable is unknown, this is the way to establish the
connection with the correct phases.
Checking the direction of movement

To check whether all phases are correctly connected, the chain hoist must be
switched. Switch on the power supply, unlock the emergency stop and actuate
the Lifting pushbutton on the control pendant. The load hook must now move
upwards.
If the direction is not correct, leads L2 and L3 of the supply cable should be
changed over at the mains connection. (Switch off the mains supply before
changing over the leads!)
211033k2.indd/110707
33
4.6 Geared limit switch Demag DC16/25 chain hoists are provided with a geared limit switch as standard.
The signals of the geared limit switch are only used for the internal control system,
wiring by the customer is not possible at the moment.
The geared limit switch is tted under the electrical equipment cover and limits the
lifting path in the upper and lower end positions. Limit switching in each direction
is via a fast-to-slow switch which cuts out the fast speed stage and a following limit
switch which stops the movement. The fast-to-slow switch guarantees that the end
position can only be approached at slow speed so that the max. lifting path can
be used for operation. If the nal limit switch is passed in the event of an error, the
monitored slipping clutch is tripped as the emergency cut-off device. The lifting
motion and the motor are switched off and a warning is displayed.
When the hoist is delivered, the fast-to-slow switch and the nal limit switch are set
in such a way that the max. lifting path can be used for operation. If required, the
usable lifting path can be shortened by a different setting of the cut-out points.
For tolerance reasons, the min. distance between lower edge of chain entry plate
and upper edge of hook assembly / bottom block is approx. 22 mm.
Any settings of the cut-out points which extend the lifting path beyond the pre-set
points are not permissible and result in tripping of the emergency cut-off device
with increased wear on the chain.
In section 4.6.3, setting instructions for the geared limit switch are provided. Any
changes to the setting of the geared limit switch may only be carried out by expe-
rienced technicians. In most cases, only the lower cut-out position needs to the
adapted to the actual suspension height when the chain hoist is installed.
In the case of a low suspension height of the chain hoist, if the upper end position
is within hand range of the operating personnel, crushing or shearing points may
be caused by the load or the load handling attachment when the upper end posi-
tion is approached. In these cases, the approachable upper position can be set
at a lower point, as required, by means of the geared limit switch in order to avoid
any hazard.
4.6.1 Technical data of geared limit Chain hoist Reeving Hook path 1) 1) Larger hook path for 4 contacts on application
switch Type [m]
DC 16 / 25 1/1 44
DC 16 / 25 2/1 22
Mechanical key data 4 contacts

Setting accuracy 1:1000
Useful revolutions 205
Cam width corresponds to 5 revolutions
1/1 reeving reeving = Lifting path 0,8 m
2/1 reeving reeving = Lifting path 0,4 m
Mechanical service life 1 x 107 switching operations
211033k2.indd/110707
Electrical key values 4 contacts

Type of enclosure IP 55 (in electrical equipment cover)
Operating voltage 24 V AC
34
4.6.2 Setting the lowest hook In order to avoid accident risk and damage, the lowest hook position should be
position on the geared limit set in such a way that the hook rests on the ground as shown in the gure. The
switch lowest hook position is set with adjusting screws 3 (fast-to-slow switch) and 4
(limit switch), see also section 4.6.3. When the lowest hook position is set, the
fast-to-slow switch and the limit switch are set upwards starting from the factory
setting, i.e. turn the adjusting cams clockwise. The setting steps are described
in 4.6.3. Set the fast-to-slow switch in such a way that the fast hoist speed is
switched off rst and is braked down to slow speed, when the limit switch is
reached.
1 2 3
42713644.jpg

2 Individual setting
42599947.eps 3 Block setting
211033k2.indd/110707
35
4.6.3 Geared limit switch setting
instructions Block setting adjusting Individual setting adjusting
screw screw
A 4 mm hexagon socket key is needed to adjust the geared limit switch.
42589446.eps
Allow for run-on.
Operating principle Each contact is allocated to a cam disk which is innitely adjustable.
The cam disks can be adjusted independently by means of the individual adjusting
screws.
Adjustment When the individual adjusting screw is turned clockwise, the cam disk is also
turned clockwise. The switching point is shifted upwards in accordance with the
hook path.
When the screw is turned anti-clockwise, the switching point is shifted downwards.
Setting the contacts for individual The geared limit switch is already permanently connected with the control system
adjustment: via the system connector cable. Move the load hook of the chain hoist into the
specied switch-off position. Turn the individual adjusting screw until the contact
maker opens the contact to set the contacts.
If the run-on path is exceeded, the contact either opens or closes.
Setting the contacts for adjustment The contacts are adjusted in blocks by means of the block adjusting screw. All cam
in blocks: disks are adjusted together, while the relative adjustment of the individual contacts
remains unchanged. When the block adjusting screw is turned clockwise, the cam
disks are also turned clockwise.
Approach switch-off points several times to check the limit switch functions
are operating correctly!
4.6.4 Removing and tting the If the geared limit switch is removed and tted again, secure the screws with
geared limit switch Loctite 290, for example. The tightening torque is 1,6 Nm.
211033k2.indd/110707
36
4.7 Setting the parameters It is possible to set parameters in order to adapt the chain hoist to specic applica-
tions. 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.
4.7.1 Starting parameter setting 1. Disconnect the chain hoist from the
mode power supply
(Display dark).
2. Actuate the Lift key and switch the
power on (hold key down).
3. Wait for approx. 10 sec.
4. If P is displayed, release the Lift

key.
5. When P is off, press the Lift key

again until o (for O.K.) is displayed.
6. Release the key. Parameter setting

42698145-49.jpg
mode is now active.
4.7.2 Meaning of keys Lift - Accept selection

Lower - Move to next parameter or selection value
Emergency stop - End parameter setting (changes are saved.)
When parameter setting mode has been activated, the gures 0 up to max. 9
are displayed successively for 2 seconds, each. The maximum value depends
on the number of parameters which can be changed via this function. Press the
Lower key to move faster through the menu items. Each gure represents a
parameter (see section 4.7.3). Actuate the Lift key to select the currently dis-
played parameter. At the same time, the value selection menu of the parameter is
opened. The currently set values are displayed with the characters A, b, C, etc.
The specic meaning of the characters for the individual parameters is explained
in section 4.7.3. To set a different value, actuate the Lower key until the required
value is shown in the display. The value is selected by means of the Lift key, the
system then also returns to parameter selection mode.
When the Emergency stop key has been actuated, the unit switches back to
normal operation. First all changes are saved.
211033k2.indd/110707
37
4.7.3 Meaning of parameters From software version SW 1.10, the following parameters can be programmed:
Parallel operation with 2 DC chain hoists A Off

0
Start-up of hoist only time-controlled, not speed-dependent b On
A Off
1 Hoist only V2 speed
b On
A 200
b 600
C 1000
2 Trolley BE function (brake application) 1) [ms]
d 1500
E 2000
- Factory setting F 3000
1) When pole-changing squirrel cage rotor travel drives are switched down from fast to slow speed
without special measures, unwanted loads on mechanical components and load sway result owing to
regenerative braking.
This effect is reduced by changing the BE time for the trolley. Instead of regenerative braking, mechan-
ical braking is applied for a specic time. The mechanical braking time corresponds to the BE time.
211033k2.indd/110707
38
5 Circuit diagrams and additional electrical modules
5.1 Schematic diagrams See section 9 Accessories
Item Designation Part no.

1 Mains socket DC 16 / 25 720 357 45
2 Connector signal adapter 720 087 45
5 Cable set E 22 - E 34 720 369 45
6 Limit switch kit E 22 - E 34 716 663 45
E 22 716 590 45
7 Travel drive
E 34 716 740 45
8 Trolley module DC 16 / 25 720 335 45
9 Motor connection cable EU 55 DK / EU 56 DC 720 364 45
Schematic diagram DC 16/25 with EU 22 / EU 34 trolley drive
Cross travel limit switch

(optional)
4-pole at mains cable

Trolley
DC 16 / 25
EU 22 / 34
DSE-10C
42724844.jpg
Schematic diagram DC 16/25 with trolley drive and pole-changing motor (EU 55 / EU 56) with trolley module

(optional)

DC 16 / 25
Trolley motor
DSE-10C
211033k3.indd/110707
42724944.jpg
39
1 Mains socket DC 16 / 25 720 357 45
2 Receiver module DRC-DC 773 720 44
3 Horn set DC 16 / 25 720 349 45
4 Shorting plug 720 348 45
5 Cable set E 22 - E 34 720 369 45
E 22 716 590 45
7 Travel drive
E 34 716 740 45
Schematic diagram DC 16/25 with EU 22 / EU 34 trolley drive with radio module

Trolley DC 16 / 25
EU 22 / 34
42725044.jpg
Schematic diagram DC 16/25 with trolley drive and pole-changing motor (EU 55 / EU 56) with trolley module and radio
module

DC 16 / 25
Trolley
211033k3.indd/110707
42725144.jpg
40
1 Mains socket DC 16 / 25 720 357 45
5 Cable set E 22 - E 34 720 369 45
E 22 716 590 45
7 Travel drive
E 34 716 740 45
Plug connector for DC 25 crane DC 25 720 365 45
8
Signal connector DC 16 / 25 720 356 45
9 Flat cable 2x6x0,5mm2 720 139 45
10 Crane bridge enclosure KRBG 2 772 178 45
Schematic diagram DC 16/25 in crane, EU 22 / EU 34 trolley drive with control pendant on DC
Long travel motor 1 Long travel motor 2
Cross travel limit switch Long travel limit switch

(optional) (optional)
24 V
Power supply
Trolley DC 16 / 25 Polu
EU 22 / 34 box
Signal Crane enclo-

sure e.g. with
transformer
and contactor
DSE-10C
Power supply
42725244.jpg
Schematic diagram DC 16/25 in crane, trolley drive with pole-changing motor (EU 55 / 56) with trolley module and
control pendant on DC

24 V
Power supply
Polu
DC 16 / 25
box
Trolley Signal Crane enclo-

motor sure e.g. with
transformer and
contactor
DSE-10C
211033k3.indd/110707
Power supply
42725344.jpg
41
1 Mains socket DC 16 / 25 720 357 45
5 Cable set E 22 - E 34 720 369 45
E 22 716 590 45
7 Travel drive
E 34 716 740 45
8 Connector enclosure for mobile control system 720 187 45
9 Flat cable 2x6x0,5mm2 720 139 45
13 Signal connector DC 16 / 25 720 356 45
Schematic diagram DC 16/25 in crane, EU 22 / EU 34 trolley drive with mobile control pendant

24 V
Power supply
Trolley DC 16 / 25 Polu
EU 22 / 34 box
Signal
Crane enclo-
sure e.g. with
transformer and
DSE-10C contactor
Power supply
42725444.jpg
mobile control pendant

24 V
Power supply
Polu
DC 16 / 25
box
Signal
Trolley
motor
Crane enclo-
sure e.g. with
transformer
211033k3.indd/110707
DSE-10C and contactor Power supply
42725544.jpg
42
1 Mains socket DC 16 / 25 720 357 45
3 Horn set DC 16 / 25 720 349 45
5 Cable set E 22 - E 34 720 369 45
E 22 716 590 45
7 Travel drive
E 34 716 740 45
Plug connector for DC 25 crane DC 25 720 365 45
8
Signal connector DC 16 / 25 720 356 45
9 Flat cable 2x6x0,5mm2 720 139 45
Schematic diagram DC 16/25 in crane, EU 22 / EU 34 trolley drive with radio module
24 V
Power supply
Trolley Polu
EU 22 / 34 DC 16 / 25 box
Signal Crane enclo-

sure e.g. with
transformer
and contactor
Power supply
42725644.jpg
radio module
24 V
Power supply
Polu
DC 16 / 25
box

transformer
and contactor
211033k3.indd/110707
Power supply
42725744.jpg
43
Schematic diagram replacement of DK 10-20 with contactor control 42 240 V control voltage, mobile control
pendant
Power supply
Old DK 10-20
Trolley
motor Signal
Crane enclo-
sure e.g. with
transformer Power
and contactor supply
Power supply
Trolley DC 16 / 25
New EU 22 / 34
Signal
Crane enclo-
sure e.g. with
transformer Power supply
and contactor
Connections X3
Pin Signal Old
42725844.jpg
A1 -
A2 - New
A3 Lifting
A4 Left
A5 -
A6 -
A7 -
A8 Lowering
B1 -
B2 Right / left fast
B3 - Item Designation Part no.
B4 - 1 Mains socket DC 16 / 25 720 357 45
211033k3.indd/110707
B5 Right 2 Signal converter module KT3 720 340 45

B6 Lift / Lower fast 3 Signal connector for 2x6x0,5 or 13x1,5mm2 720 356 45
Voltage supply crane reference 4 Cable set E 22 - E 34 720 369 45
B7
(42-230V) E 22 716 590 45
5 Travel drive
44 B8 - E 34 716 740 45
Schematic diagram replacement of DK 10-20 with contactor control 42 240 V control voltage, mobile control
pendant
Power supply
Old DK 10-20
Trolley
motor Signal
Crane enclo-
sure e.g. with
transformer Power
and contactor supply
Power supply
New DC 16 / 25
Trolley Signal
motor
Crane enclo-
sure e.g. with
transformer Power supply
and contactor
Connections X3
Pin Signal Old
42725944.jpg
A1 -
A2 - New
A3 Lifting
A4 Left
A5 -
A6 -
A7 -
A8 Lowering
B1 -
B3 -
B4 -
211033k3.indd/110707
B5 Right Item Designation Part no.

B6 Lift / Lower fast 1 Mains socket DC 16 / 25 720 357 45
Voltage supply crane reference 2 Signal converter module KT3 720 340 45
B7
(42-230V) 3 Signal connector for 2x6x0,5 or 13x1,5mm2 720 356 45
B8 - 4 Trolley module DC 16 / 25 720 335 45 45
Schematic diagram replacement of DK 10-20 with contactor control 42 240 V control voltage, control pendant on DC
Power supply
Old DK 10-20
Trolley motor
Signal Crane enclo-
sure e.g. with
transformer
and contactor
Power supply
DC 16 / 25
Power supply
Trolley
New EU 22 / 34
Signal Crane enclo-

sure e.g. with
transformer
and contactor
DSE-10C
Power supply
Connections X40
Pin Signal Old
42726044.jpg
A1 Forward
A2 Emergency stop New
A3 -
A4 -
1 Mains socket DC 16 / 25 720 357 45
A5 Special 1 (F1/F2)
A6 Reverse
A7 -
A8 -
B1 Forward/reverse fast 5 Cable set E 22 - E 34 720 369 45
B2 - 6 Crane module 3TK 720 345 45

B3 PE E 22 716 590 45
7 Travel drive
B4 Voltage supply from crane (42-230V) E 34 716 740 45
211033k3.indd/110707
B5 - Plug connector crane 3TK DC 16 / 25 720 363 45

8
B6 - Signal connector for 2x6x0,5 or 13x1,5mm2 720 356 45
Voltage supply crane reference Control transformer 48V/50/60Hz 42-48 V 720 373 45
B7
(42-230V) 9 Control transformer 110V/50/60Hz 110/115 V 720 374 45
46 B8 - Control transformer 230V/50/60Hz 220-240V 720 375 45
Schematic diagram replacement of DK 10-20 with contactor control 42 240 V control voltage, control pendant on DC
Power supply
Old DK 10-20
Trolley motor
Signal Crane enclo-
sure e.g. with
transformer
and contactor
Power supply
DC 16 / 25
Power supply
New

transformer
and contactor
DSE-10C
Power supply
Connections X40
Pin Signal Old
42726144.jpg
A1 Forward
A2 Emergency stop New
A3 -
A4 -
A5 Special 1 (F1/F2)
A6 Reverse
1 Mains socket DC 16 / 25 720 357 45
A7 -
A8 -
B1 Forward/reverse fast
B2 -
B3 PE 5 Trolley module DC 16 / 25 720 335 45
B4 Voltage supply from crane (42-230V) 6 Crane module 3TK 720 345 45
211033k3.indd/110707
B5 - Plug connector crane 3TK DC 16 / 25 720 363 45

7
B6 - Signal connector for 2x6x0,5 or 13x1,5mm2 720 356 45
Voltage supply crane reference Control transformer 48V/50/60Hz 42-48 V 720 373 45
B7
(42-230V) 8 Control transformer 110V/50/60Hz 110/115 V 720 374 45
B8 - Control transformer 230V/50/60Hz 220-240V 720 375 45 47
Schematic diagram replacement of DK 10-20 with contactor control 42 240 V control voltage, conversion to
DRC-DC radio
Power supply
Old DK 10-20
Trolley
motor Signal Crane enclo-
sure e.g. with
transformer
and contactor
Power
supply
DC 16 / 25
Power supply
Trolley
New EU 22 / 34
Signal Crane enclo-

sure e.g. with
transformer-
and contactor
Power
supply
Old
New 42729044.jpg

1 Mains socket DC 16 / 25 720 357 45
3 Horn set DC 16 / 25 720 349 45
5 Cable set E 22 - E 34 720 369 45
E 22 716 590 45
7 Travel drive
E 34 716 740 45
8 Crane module 3TK 720 345 45
211033k3.indd/110707
Plug connector crane 3TK DC 16 / 25 720 363 45

9
Signal connector for 2x6x0,5 or 13x1,5mm2 720 356 45
Control transformer 48V/50/60Hz 42-48 V 720 373 45
10 Control transformer 110V/50/60Hz 110/115 V 720 374 45
Control transformer 230V/50/60Hz 220-240V 720 375 45
48
Schematic diagram replacement of DK 10-20 with contactor control 42 240 V control voltage, conversion to
DRC-DC radio
Power supply
Old DK 10-20
Trolley motor
Signal Crane enclo-
sure e.g. with
transformer
and contactor
Power supply
DC 16 / 25
Power supply
New
Trolley motor Signal Crane enclo-

sure e.g. with
transformer
and contactor
Power supply
Old
New 42729144.jpg

1 Mains socket DC 16 / 25 720 357 45
3 Horn set DC 16 / 25 720 349 45
7 Crane module 3TK 720 345 45
211033k3.indd/110707
Plug connector crane 3TK DC 16 / 25 720 363 45

8
Signal connector for 2x6x0,5 or 13x1,5mm2 720 356 45
Control transformer 48V/50/60Hz 42-48 V 720 373 45
9 Control transformer 110V/50/60Hz 110/115 V 720 374 45
Control transformer 230V/50/60Hz 220-240V 720 375 45 49
5.2 Hoist control system The hoist control system is the main module of the DC 16/25 electrical equipment.
and additional electri- It is used for controlling the motion sequences of the lifting axis, in particular the
co-ordinated effect of hoist motor and brake.
cal modules
In addition, it also provides all interfaces to the other modules:
5.2.1 Hoist control system
Pulse generator module (always included in basic scope of delivery).
Control pendant jumper module (always included in basic scope of delivery, if
no other module is tted at this place).
Optional - Radio receiver module,
- Trolley module,
- KT3 signal conversion module (conventional input),
- 3TK signal conversion module for crane axis (conventional output).
Application of the individual modules is described by way of example in sec-

tion 5.1, Schematic diagrams.
In addition, the following interfaces are also available for:

Mains plug connector,
Control pendant signal connector,
Geared limit switch connector.
42722244.jpg
1 Mains supply cable

2 Signal cable
211033k3.indd/110707
Make sure that under the upper cable retaining tape only mains/power supply
cables (1) and under the lower cable retaining tape only signal cables (2) are laid.
50
Hoist control system components
Lifting contactor
V2 contactor
Transformer
Lowering contactor
LED LED
42712844.jpg
EEProm PIN 1
The EEProm saves the chain hoist-
specic parameters, such as: Fastening screws M3,5x7
- Operating hours,
- Contactor operations,
- Parameter settings deviating from
X20:16
the status as delivered from the
Plug-in jumper brake for mains voltage
factory 220 - 240 V, 50 / 60 Hz
In the event of a hoist control system
failure, the EEProm can be removed
and connected in the replacement
211033k3.indd/110707
When supplied
hoist control system.
42712846.jpg
51
The following table shows the connectors and the associated signals:
Connector
Connection Function Signals Remarks
designation
1 L1
2 L2 4-pole connection Phoenix connector
X1 Mains input
3 L3 (see list of accessories)
PE PE
X2 Pulse generator input 10-pole Flat cable with connector
A1 Forward (crane)
A2 Emergency stop
A3 Lifting (hoist)
A4 Left (trolley)
Control signals input
A5 F1/F2
A6 Reverse (crane)
A7 24 V AC internal
A8 Lowering (hoist)
16-pole connection Phoenix connector
X3 B1 Signal horn
(see list of accessories)
B3 Supply radio module
B4 Voltage supply from crane (42-230V)
B5 Control signals input Right (trolley)
B6 Lift / Lower fast
Voltage supply crane reference
B7
(42-230V)
B8 24 V AC reference
1 Finallim/lift +
2 Finallim/lift -
3 Fast-to-slow lift +
4 Fast-to-slow lift -
X4 Geared limit switch input
5 Fast-to-slow lower +
6 Fast-to-slow lower -
7 Finallim/lower +
8 Finallim/lower -
1 F1/F2
2 Forward (crane)
3 Reverse (crane)
4 Emergency stop
RJ45 connector socket for signal Combined mains / signal cable set
5 Supply control pendant
X5 cable to E22/E34 DC 16 / 25 to E 22 / E 34
6 Not assigned
(see list of accessories)
7 24 V AC reference
8 Right (trolley)
9 Left (trolley)
10 Signal horn
1 Emergency stop In
2 Emergency stop, 24 V AC
3 24 V AC
4 F1/F2
5 Plug-in connection for 3TK Forward (crane) If no 3TK module or crane plug-in
signal converter or crane plug-in connector, then X6 has a plug-in jumper
X6 6 Reverse (crane)
connector
7 (see list of accessories) 24 V AC reference (When supplied)
8 Voltage supply from crane (42-230V)

Voltagesupply crane reference
9
(42-230V)
10 Not assigned
1 Plug-in connection mains L1 (power supply)
2 transformer Not assigned Pin (2) in the middle is not assigned
X7
(Mains transformer included in (If X7 is assigned, X15 is not)
3 basic scope of delivery) L3 (power supply)
1 W1
2 V1 U1, V1, W1 slow (low speed winding)
3 U1
211033k3.indd/110707
X8 Hoist motor plug

4 W2
5 V2 U2, V2, W2 fast (fast speed winding)
6 U2
52
Connector
designation
1 Brake +
X9 Hoist brake connector
2 Brake -
X10 Plug-in jumper 1
1 Change-over 3 U In
X13 2 contact 1 Ready
3 Pilot relay 2 Error
1 Plug-and-socket connector Voltage supply crane reference
X15 (If X15 is assigned, X7 is not)
2 Control transformer Voltagesupply from crane
Control pendant jumper, KT3 signal
X19 Interface I for plug-in module 20-pole multiple connector
converter or radio module
Control pendant jumper, KT3 signal
X22 Interface II for plug-in module 20-pole multiple connector
converter or radio module
1 Motor thermal contact -
2 Motor thermal contact + 24 V AC, 10 mA
X23 Digital inputs
3 Overload contact + (If not used, X23 has a plug-in jumper)
4 Overload contact -
1 Enable +
X24 Enable circuit for parallel operation 24 V AC, 10 mA
2 Enable -
1 L1 4-pole connector: for trolley module
2 L2 connector X7 or combined mains / signal
Power supply for trolley module or
X27 cable set
3 E 22 / E 34 travel drive L3 DC 16 / 25 to E 22 / E34 (see list of
PE PE accessories)
Control signals trolley to connector
X28 20-pole at cable connector
X6 on trolley module
1 24 V AC external (I) 8 VA
2 Connector input for 24 V AC extern (I) - reference
3 Signal voltage transformer 12 V AC (II) 4 VA Only used for 3TK applications and must
X29 replace the mains transformer (see list of
4 3 x secondary voltage 12 V AC (II) - reference accessories)
5 42 - 48 V, 110 V, 230 V 24 V AC internal (III) 8 VA
6 24 V AC internal (III) - reference
X30 Control signal connector for HLR for semi-conductor relay 4-pole connector
1 TxD
2 RxD
3 Vcc
X31 RS 232 interface RJ12 connector
4 24 V DC
5 GND
6 CPU An2
LED display LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7

Colour Red Green
The CPU is working, the emergency-stop is unlocked Flashes slowly
The emergency stop is actuated Flashes fast
Irregular ashing
An error has occurred (SOS = 3 x short,
3 x long, 3 x short)
The Lift key is actuated, the chain hoist does not lift Is on Is on Is on
Lifting limit switch actuated Is on Is on Is on
Overload applied Is on Is on
211033k3.indd/110707
Motor overtemperature applied Is on

Fast-to-slow lift switch is actuated Is on
Fast-to-slow lower switch is actuated Is on
The Lower key is actuated Is on
53
5.2.2 Pulse generator module The pulse generator module is always tted together with the hoist control system.
It is used to detect the speed of the slipping clutch.
Speed measurement is optical by means of a double-channel light barrier. In
addition, the pulse generator module includes, the 7-segment display and the
IR transmitter diode for transmission of operating data. This information can be
read through the window on the bottom side of the chain hoist.
The pulse generator module is xed behind the brake on the gearbox housing by
means of two screws.
1
2
3
1 Pulse wheel
2 Brake
42722344.jpg
3 Window
1 2 3 4
1 Plug-in connector to hoist control system

connector X2
2 IR transmitter diode
3 LED 7-segment display 42712744.jpg
4 Board retainer
211033k3.indd/110707
54
5.2.3 Control pendant jumper The control pendant jumper is tted for transmitting control signals 24 V AC (tri-
module state signals) from the DSC and DSE10-C control pendant to the hoist control
system (always included in the basic scope of delivery, unless another module is
tted in this place).
If control pendant signals with a higher control voltage are used (e.g. the DST
control pendant), the KT3 signal converter must be connected instead of the
control pendant jumper (see section 5.2.6). For the radio control system, the
DRC-DC radio receiver module is connected at this place (see section 5.2.4).
The control pendant jumper is plugged directly onto the hoist control system (be-
tween multiple connectors X19 and X22) and locked by means of a plastic spacer.
1 42722444.jpg
1 Control pendant jumper

2 Spacer
42712244.jpg
211033k3.indd/110707
55
5.2.4 Radio receiver module The radio receiver module is needed for operation with the wireless DRC-DC6 and
DCR-DC10 hand-held transmitters.
In this case, the DC 16/25 hoist control system must be provided with the receiver
module instead of the control pendant jumper.
The radio receiver module is plugged directly onto the hoist control system (be-
tween multiple connectors X19 and X22) and locked by means of a plastic spacer
(see section 5.2.1).
A dummy plug (lower plug on the outer side of the electrical equipment cover)
must be tted at the control pendant input of the hoist control system (X3).
The dummy plug is provided with a wire jumper between X3.A7 and X3.B3 which
supplies the voltage for the radio receiver module.
1 2 3
42722644.jpg
1 Connection of horn
2 Radio module
3 Signal horn
211033k3.indd/110707
56
1 1
42712444.jpg
2 J3 1
1 Spacer
Jumper eld J1/J2 2 Status LED
Connection of horn
Parking position
42709645.eps 42709745.eps
The jumper of jumper eld J1 must be applied between pins 1 and 2!
Item Designation Function

J1 Jumper J1 Receiver module internal in
DC 16 / 25
42709645.eps
Receiver module external

in receiver box on
DC 1 10
42709645.eps
J2 Jumper J2 Not used at present

J3 Jumper J3 BE function and Reset, see next page
X8 Connection of horn / X8.1: 30 V DC+
signal X8.2: GND-
max. current 2 A,
suitable for signal horn, part no. 720 349 45
Status LED Continuously lit: Voltage available, no radio signal
LED ashes: Radio reception: Transmitter is in Stop
mode or Run mode
211033k3.indd/110707
57
BE function When pole-changing squirrel cage rotor travel motors are switched down from fast
to slow speed, unwanted loads on mechanical components and load sway result.
It is therefore recommended to use the integral BE (brake application) function in
conjunction with the DRC-DC radio remote control system. This ensures that me-
chanical braking is started when the fast travel speed has been switched off. Only
after expiration of an adjustable delay time can the slow travel speed be switched
on again.
Description of BE function
This BE function is only available for long travel. The time is set on the receiver
module by means of jumper J3. It is possible to set deceleration times of 0 (0 =
switched off, factory setting), 1, 2, 2.5, 3 seconds.
After the fast speed (V2) signal has been switched off, the fast and the slow speed
(V1) contacts open and thus generate mechanical braking. Upon expiration of the
time interval set and if the control signal (slow) is available, the drive is switched on
again at slow speed. If V2 is switched on again during the braking time, the con-
tacts for V1 and V2 close without delay, i.e. the fast speed is switched on again.
Select time interval so that upon expiration of this braking time the travel drive is
braked from V2 to V1.
The times can be set as follows by means of the jumper for the parking position:
1. Switch off the power,

2. Apply jumper of the parking posi-
tion to the required time (e.g. g. 1 =
Fig. 1 2 seconds),
3. Switch on the power,
4. Switch off the power again,
5. Remove jumper and re-apply on
parking position,
Parking position 42709745.eps 6. Switch on the power again.
The time now remains saved until a new value is set, also if a reset has been car-
ried out.
Ensure that the jumper is removed again, as otherwise the radio control system is
not ready for operation.
211033k3.indd/110707
58
Emergency control
Emergency control by means of a cable-connected control pendant is easily pos-
sible with a DSE10-C. Instead of the dummy plug, the DSE10-C is connected and
thus it is possible to control the crane axes without any further adjustments.
Control pendant stationary on the DC chain hoist

Remove the dummy plug at the control pendant input of the hoist control system
(X3). Fit the cable collector and connect the cable with bayonet lock and adapter.
Adjust the height of the control pendant (section 4.4).
Mobile control pendant

Remove the dummy plug at the control pendant input of the hoist control system
(X3). Remove the trailing control cable from the crane plug-in connector (X40) and
plug it onto the control pendant input of the hoist control system (X3).
For further information on DRC-DC radio control systems, see publication

214 689 44.
211033k3.indd/110707
59
5.2.5 Trolley module The trolley module is required for controlling an AC asynchronous motor as travel
or slewing drive.
The motor may have one or two numbers of poles and be provided with an electro-
mechanical brake.
The trolley module has the following plug connections:

Motor connector X1,
Brake connector X3,
PE connection X2,
Mains connector X7 with cable ( Hoist control system X27),
Control pendant signal connector X6 (at cable),
Connector for motor thermal contact X5,
Connector for fast-to-slow and limit switch X4 (in both directions).
1 Trolley module
1 2 Connector X7 2 42722744.jpg
The trolley module is provided with 6 light emitting diodes to facilitate diagnosis.
LED display Designation LED 1 LED 2 LED 3 LED 4 LED 5 LED 6

Colour Red Green
The emergency-stop is unlocked Emergency stop Is on
The board is supplied with voltage 5V Is on
211033k3.indd/110707
Fast-to-slow switch right is closed, the jumper is plugged Fast-to-slow right Is on

The limit switch (or wire jumper) is closed and the travel command is
Right Is on
applied, light is slightly darker for V1 than for V2
Fast-to-slow switch right is closed, the jumper is plugged Fast-to-slow left Is on
The limit switch (or wire jumper) is closed and the travel command is
Left Is on
60 applied, light is slightly darker for V1 than for V2
to mains connection of hoist
PE L1 L2
control system (X27)
X7
PIN 1
Fastening screws M3,5x7
42718844.jpg 42724344.jpg
Connector
designation
1 PE
2 U1/U2
6-pole connector
3 V1
X1 Motor U1, V1, W1 slow (low speed winding)
4 W1
U2, V2, W2 fast
5 V2
6 W2
X2 PE Earth PE Tab connector blade 6,3 mm
1 UBrake AC
X3 2 Brake UBrake Reference UBrake DC by half-wave rectier
3 UBrake DC
1 Fast-to-slow right +
2 Fast-to-slow right -
3 Finallim right +
4 Finallim right - For connecting limit switches, remove wire
X4 Fast-to-slow and limit switch inputs
5 Fast-to-slow left + jumpers
6 Fast-to-slow left -
7 Finallim left +
8 Finallim left -
1 Motor thermal contact - Remove mating connector with wire jumper,
X5 Motor thermal contact
2 Motor thermal contact + if thermal contact is used
Control signals to hoist control
211033k3.indd/110707
X6 20-pole at cable connector

system ( X28)
PE
L1 Supply voltage trolley module
X7
L2 ( X27)
L3 61
5.2.6 KT3 signal conversion module KT3 Conventional to tri-state
(conventional input) The KT3 signal converter is required to convert conventional control signals from
42 to 230 V AC, 50/60 Hz, into tri-state signals on 24 V AC basis. It can also be
used for 24 V DC signals (e.g. PLC).
For conversions, for example, as many existing installation parts as possible are
to be maintained. The control signals are controlled by DST, DSE or third party
control pendants. Normally, the control voltage is then higher than 24 V.
In these cases, the DC 16 / 25 hoist control system must be provided with a
KT3 signal converter instead of the control pendant bridge.
The KT3 signal converter is plugged directly onto the hoist control system
(between multiple connectors X19 and X22) and locked by means of a plastic
spacer (see section 5.2.1).
1 42722544.jpg
1 KT3 signal converter

211033k3.indd/110707
62
Not visible components side
42712344.jpg
Visible soldering side
LED 6 5 4 3 2 1
42724444.jpg
The KT3 signal converter module is provided with 6 light emitting diodes to facilitate diagnosis.

Colour Green
Lift key is actuated Lifting V1 Is on
Lower key is actuated Lowering V1 Is on
Lift key is actuated in stage 2 Lifting V2 Is on Is on
211033k3.indd/110707
Lower key is actuated in stage 2 Lowering V2 Is on Is on

Right key is actuated Right V1 Is on
Left key is actuated Left V1 Is on
Right key is actuated in stage 2 Right V2 Is on Is on
Left key is actuated in stage 2 Left V2 Is on Is on 63
5.2.7 3TK signal conversion module 3TK Tri-state to conventional
for crane axis (conventional The 3TK signal converter is required to convert 24 V AC tri-state control signals
output) into conventional control signals from 42 to 230 V AC for the crane axis.
In addition, it also isolates the emergency-stop contact via two interlocked safety
relays.
For use of the 3TK module, crane plug-in connector 720 363 45 must always be
used.
Control pendant on the chain hoist:
If the 3TK module is used and the control pendant is tted on the chain hoist (see
section 5.1 Schematic diagrams), one of the three control transformers (see list of
accessories) must be selected for signal voltage 42-48 V, 110 V or 230 V, depend-
ing on the control voltage of the crane. This must be tted instead of the mains
voltage transformer.
The control transformer is used for providing the 24 V AC for the control pendant
and the 5 V AC for the hoist control system from the available control voltage of the
crane.
DRC-DC radio module:
The 3TK signal converter is required, when the DRC-DC radio receiver module is
integrated in the hoist control system and a conventional contactor control system
with a control voltage from 42 to 230 V AC is to be implemented for the long travel
drives.
In addition, the mains transformer also must be replaced by a control transformer
in accordance with the control voltage of the crane (42 V 230 V AC).
A DC crane (24 V AC) without 3TK signal converter with DRC-DC module in the
DC 16 / 25 keeps the tted mains transformer but receives the 24 V supply voltage
from the crane bridge enclosure.
1 3TK signal converter
2 Transformer
211033k3.indd/110707
64 2 1 42722844.jpg
The 3TK signal converter module is provided with 6 light emitting diodes to facilitate diagnosis.

Colour Green
Emergency-stop circuit is closed Emergency stop Is on
Emergency-stop circuit is closed Emergency stop Is on
Reverse key is actuated Reverse Is on
Reverse or Forward key is actuated in stage 2 V2 Is on
Forward key is actuated Forward Is on
Special function key is actuated Special function Is on
1 2
PIN 1 42711644.jpg 42711744.jpg
1 X1a to hoist control system

2 X2 to crane plug-in connector
3 Board retainer 5
4 Pine-tree clip
5 Locking tab of board retainer 42711844.jpg 42724544.jpg
The 3TK signal converter is tted on the hoist control system.

The 3TK signal converter can be xed above the K1/K2 contactor of the hoist con-
trol system by means of the board retainer included in the supply. The four locking
tabs of the board retainer must be secured by means of 4 pine-tree clips.
211033k3.indd/110707
65
Connector designation Connection Function Signals Remarks

1 24 V AC
2 24 V AC
3 not assigned
4 Special 24 V AC
5 Forward 24 V AC Is connected with hoist control system
X1a Signal input 24 V AC
6 Reverse 24 V AC connector X6
7 Reference 24 V AC
8 U_Control
9 U_Control reference
10 not assigned
1 U_Control
2 Emergency stop
3 Conventional
4 Supply
Is connected with crane plug-in connector
5 V2 / 3-state
X2 Signal output 42 to 230 V AC 3TK
6 Forward
See section 9 for accessories
7 Reverse
8 Special
211033k3.indd/110707
66
5.2.8 Cable set crane plug-in Via crane plug-in connector 720 365 45, the control signals of the chain hoist
connector (24 V AC) are exchanged with the crane bridge enclosure (24 V AC).
Via crane plug-in connector 720 363 45 in connection with the 3TK module, the
control signals of the chain hoist (24 V AC) are exchanged with the crane bridge
enclosure (42 V-230 V AC).
8
6
1
42712044.jpg
Item Designation Qty. Type

1 Socket enclosure 1 VC-MP-S1-2MG
2 Fitting frame 1 VC-AR1/2M-PEA
3 Contact insert 2 VC-AMS 8
4 Cable union 1 VC-K-KV-PG16
5 Round cable 1 YMHYK-O 10X 0,75
6 Plug-in module 1
7 Socket connector 1 with cage clamp terminals and lock, 10-pole
8 Mounting plate 1
9 Fastening screws 2
211033k3.indd/110707
67
Plug connector crane DC25, Plug connector crane 3TK,
connections X40 part no. 720 365 45 connections X40, part no. 720 363 45
Pin Signal Cond. Pin Signal Cond.
A1 Forward 1 A1 Forward 1
A2 Emergency stop 2 A2 Emergency stop 2
A3 - 3 A3 - 3
A4 - 4 A4 - 4
A5 Special 1 (F1/F2) 5 A5 Special 1 (F1/F2) 5
A6 Reverse 6 A6 Reverse 6
B
A7 - - A7 - -
A8 - 7 A8 - 7
X40
B1 - 8 B1 Forward/reverse fast 8
B2 - - B2 - -
A
B3 PE PE B3 PE PE
B4 Control voltage (24 V, STS) 9 Voltage supply from crane
B4 9
B5 - 10 (42-230V)
B6 - - B5 - 10
B7 - - B6 - -
B8 Control voltage reference 11 Voltage supply crane reference
42724244.jpg B7 -
(42-230V)
B8 - 11
211033k3.indd/110707
68
X40
42724044.jpg
1 2
42724144.jpg
1 Multiple connector X6 on hoist control system

2 Crane plug-in connector 720 365 45
211033k3.indd/110707
If the geared limit switch needs to be removed for laying the cable, comply with
installation instructions, section 4.6.4.
69
5.3 Circuit diagrams
5.3.1 Circuit diagram solo hoist
211033k3.indd/110707
70 63115046_L1_EN.eps
211033k3.indd/110707
63115046_L2_EN.eps 71
211033k3.indd/110707
72 63115046_I1_EN.eps
211033k3.indd/110707
73
5.3.2 Circuit diagram DC 16/25 with
EU 22 / EU 34
211033k3.indd/110707
74 63115146_L1_EN.eps
211033k3.indd/110707
63115146_L2_EN.eps 75
211033k3.indd/110707
76 63115146_L3_EN.eps
211033k3.indd/110707
63115146_I1_EN.eps 77
5.3.3 Circuit diagram DC 16/25
with trolley module for pole-
changing travel motor
211033k3.indd/110707
78 63115246_L1_EN.eps
211033k3.indd/110707
63115246_L2_EN.eps 79
211033k3.indd/110707
80 63115246_L3_EN.eps
211033k3.indd/110707
63115246_I1_EN.eps 81
5.4 Cabling DC 16/25 with 4x1,5 mm 2
trolley
5.4.1 Cabling DC 16/25 with EU 22 /

EU 34
1
1 Strain relief
2 Plug-in module 2
3 M20 union 3 42723444.jpg
4
5
1 Power cable connector hoist control system
(X27)
2 Retaining tape power / mains supply cable
3 Retaining tape signal cable
4 Signal cable connector hoist control system X5 42723344.jpg
5 Cable set 720 369 45
Connection to E 22 / E 34, see circuit diagram in 21481044 section 4.3.5.
Installation information for cable set part no. 720 369 45

Slide the plug-in module of the power cable into the appropriate position on the
gearbox housing and x the cable with the strain relief. Pick-up the cable under
the power/mains retaining tape and plug connector of cable onto X27 of the hoist
control system.
Insert signal cable into lower M20 union. Lead the cable under the signal retaining
tape and plug connector of cable onto X5 of the hoist control system.
Secure both cables on the outside on the cable collector or the service cover by
means of a cable retainer.
211033k3.indd/110707
82
1
2
3
1 Cable strap
2 Signal cable
3 Power cable 42723244.jpg
211033k3.indd/110707
83
5.4.2 Cabling DC 16/25 with EU 56
pole-changing trolley motor
1 2 3 4
5
6
42723644.jpg
1 Connector trolley module X1 Installation information for cable set part no. 720 364 45
2 Connector trolley module X3
Slide the plug-in module of the power cable into the appropriate position on the
3 Retaining tape power / mains
4 Motor connection cable 8x1,5mm2
gearbox housing and x the cable with the strain relief. Pick-up the cable under the
5 Strain relief power/mains retaining tape and plug connector/s of cable onto X1 and/or X3 of the
6 Plug-in module trolley module.
Secure motor connection cable on the outside on the cable collector or the service
cover by means of a cable retainer.
211033k3.indd/110707
84
1
1 Cable strap 42723544.jpg

211033k3.indd/110707
85
5.4.3 Cabling DC 16/25 with cross
travel limit switch on EU 56
trolley motor
42723744.jpg
1 2 3 4 2 5
42723844.jpg
1 Retaining tape signal

2 Cable cross travel limit switch
3 Plug-in module
4 Strain relief
5 M20 union
6 Connector X4 on trolley module
6 2
42723944.jpg
When the EU 56 travel drive with limit switch is used, the limit switches are
connected direct on the trolley module (X4) of the DC 16 / 25 chain hoist.
211033k3.indd/110707
86
Circuit diagram cross travel limit
Travel limit switch procedure
switch for E 22 / E 34 travel drive
Fast-to-slow and nal limit switch switching sequence

42706845.jpg
Final and fast-to-slow limit switches
Final limit switch Fast-to-slow switch
42706846.jpg
Fast-to-slow switch as nal limit switch
Final limit switch Fast-to-slow switch
42706847.jpg
Only valid until software version 1.70 of the travel drive.

Parameters are set via the cross travel keys of the control pendant.
For activating fast-to-slow switching, set parameter 6 in the travel drive to y.
For activating nal limit switching, remove plug-in jumpers JP8 and JP10 in the
travel drive.
For further information about cross travel limit switches part no. 716 663 45
see Operating instructions travel drives 214 810 44.
211033k3.indd/110707
87
6 Taking the unit out of service
6.1 Emergency stop Every chain hoist features an emergency-stop device with which all motions can
be stopped in the event of a hazard.
The emergency-stop button is arranged in the control pendant.
To actuate the emergency-stop button, press the button until it reaches the end
stop. It then locks automatically.
To unlock the actuated emergency-stop button, turn the pushbutton in the direction
of the arrow and release.
The emergency-stop device must only be reset after the hazard and its cause have
been eliminated.
DSC DSE-10C
Emergency Emergency
stop stop
42647745.eps 42698044.eps
6.2 Taking the hoist out of When the work has been completed, position the hook assembly or bottom block
outside the travel area. Switch off the power supply at the mains connection or
service at the end of isolating switch.
the shift
6.3 Taking the hoist out Maintenance work on the Demag chain hoist must not commence before the load
has been removed and the mains connection switch or isolating switch has been
of service for mainte- switched off.
nance The relevant accident prevention regulations and statutory regulations must be
observed for operation and maintenance.
Required tests and inspections must be carried out. Adhere to: Section 1 Safety
instructions and information in the inspection and maintenance schedule, see
section 7.6.
211033k3.indd/110707
88
7 Inspections/maintenance/general overhaul GO
7.1 Inspection before The operator must carry out the relevant inspections in accordance with sec-
tion 7.6 before starting work. Chain hoists must be taken out of service immedi-
starting work and ately if any defects relating to operating safety and reliability are detected.
during operation Such defects are e.g.:
damaged components,
brake and safety device failure,
damage to the chain,
unusual noise in the gearbox, etc.
7.2 Checking the After switching on the voltage supply for the chain hoist/crane, rst the emergency
stop button must be actuated. It locks when it is pressed down. In the 7-segment
emergency stop display in the window of the electrical equipment cover, the gure 8 is shown. The
crane operator must make sure that no movement can be started by actuating the
command buttons for the crane movements.
7.3 Inspection and The specied inspection and maintenance intervals (section 7.6) are adapted to
single-shift operation, the FEM loading group and chain hoist service conditions
maintenance schedule (section 2.9).
In the course of the annual inspection, all wearing parts are checked.
If routine maintenance reveals that the intervals are too long, they should be
adapted to the specic operating conditions.
Only use genuine Demag parts or parts approved by Demag for repairs (see
accessories/component parts list).
The use of spare parts not approved by Demag renders any liability and guarantee
claims void.
7.4 Operating status and The 7-segment display is arranged on the control card under the electrical equip-
ment cover, it can be read through the window (lower side of electrical equipment
error display cover).
The following data can be read:
Operating hours (section 7.7),
Operating statuses (section 7.7),
Warning messages (section 8.10.2),
Error messages (section 8.10.3),
211033k3.indd/110707
89
7.5 General overhaul GO The theoretical duration of service D (hours at full load h) depends on the group of
mechanisms classication of the chain hoist. The actual duration of service is to be
determined annually in accordance with FEM 9.755. During the annual inspection
by our after-sales service, you may have the actual service life determined.
Upon expiration of 90% of the theoretical duration of service if the chain hoists
are correctly classied after 8 to 10 years the owner must arrange for a general
overhaul GO to be carried out. A general overhaul must be carried out on reaching
the end of the theoretical duration of service, at the latest.
During the general overhaul the following parts must be replaced in addition to the
checks and work specied in the inspection and maintenance schedule:
Gearing parts,
Gear oil and seal,
Connecting elements,
Shaft sealing rings, bearings, plugs,
Brake,
Slipping clutch.
The small parts (screws, washers, etc.) to be replaced during maintenance and
assembly work are not listed separately.
The general overhaul carried out by the manufacturer or an authorized specialist
company fullls the condition for continued operation of the chain hoist.
Thus the relevant accident prevention regulations and the BGV D8 (VBG 8) are
complied with.
Further utilization is approved when an expert engineer has entered the condi-
tions for further utilization into the test and inspection booklet. The completion of
the general overhaul must be conrmed in the test and inspection booklet and a
further period of utilization in accordance with FEM 9.755 must be entered.
211033k3.indd/110707
90
7.6 Inspection and
maintenance schedule
Before rst During the
See When star-
putting into annual
section ting work
operation inspection
Check emergency stop 7.2 X X
Check direction of movement 4.5 X
Check 7-segment display 7.1 X X
Check chain lubrication (under arduous conditions, the chain must be lubricated more frequently) 8.4 X X X
Check function of geared limit switch 8.10.3 X X X
Check control cable and control pendant housing for damage X X X
Check operation of brake X X X
Check hook and hook safety catch X X X
Read operating hours for determining the remaining duration of service 7.7 X
Check electrical switchgear and wiring X
Check function of slipping clutch 8.7 X
Check brake wear Every 5 years 1)
Check suspension, suspension bracket and securing elements (clip, etc.) 8.5 X
Check fastening screws on hook assembly / bottom block X
Check hooks for cracks, deformation and wear X
Check hook safety catch for deformation X
Check hook bearing for wear X
Check sprocket of chain guide, chain sprocket of bottom block, chain guide X
Check chain anchorage and securing of chain collector X
Check chain for deformation, damage, cracks, corrosion pits, reduction of link thickness or pitch increase by
8.4 X
wear, elongation caused by plastic deformation
Check securing elements (clips, bolts etc.) for tight t and corrosion X
Check and apply or supplement corrosion protection, as required X
Check electrical enclosure and gearbox for leakage X
Check trolley, crossbar and status of buffers X
Oil change 8.9 Every 10 years 1)
General overhaul
Upon expiration of 90 % of the theo-
The general overhaul should coincide with the annual inspection
retical duration of service
Fit chain hoist-specic Demag GO set X
The small parts (screws, washers ...) to be replaced during maintenance and assembly work are not listed separately. During
the general overhaul, the checks and work specied in the inspection and maintenance schedule must be carried out.
1) For use in accordance with the FEM classication
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. This does not apply to slipping
211033k3.indd/110707
clutches used as an emergency-stop device which need not be checked when

starting work (BGV D06, 30). DC chain hoists are tted with a slipping clutch as
an emergency-stop device which needs not be checked by the crane operator,
therefore a device for by-passing the limit switches which are approached during
normal operation is not tted.
91
7.7 Display of operating The 7-segment display is located on the bottom side of the chain hoist behind a
window.
hours / statuses
Software version
Every time, power is switched on or after an emergency-stop, the software version
is displayed:
Example: Software version 1.01
0,8 sec 0,8 sec 0,8 sec 0,8 sec

Break 0,2 sec Break 0,2 sec Break 0,2 sec
42718444.jpg
Operating hours
Display appears after 3 sec without lifting motion (example 123 operating hours)
0,8 sec 0,8 sec 0,8 sec 0,8 sec

42599844.jpg
Number of cycles K1 contactor

Display alternates with display of operating hours
0,8 sec 0,8 sec 0,8 sec

< H123 >
42599845.jpg
C 5 corresponds to 5 x 100.000 = 500.000 K1 switching cycles

Example: C 15 corresponds to 15 x 100.000 = 1,5 m K1 switching cycles
Operating statuses
1. Flashing: 6. Emerg. stop pressed

READY
2. Upper limit switch ap- 7. Lower limit switch ap-

proached proached
3. LIFTING start-up 8. LOWERING start-up
4. LIFTING V1 9. LOWERING V1
5. LIFTING V2 10. LOWERING V2
42599746.jpg
211033k3.indd/110707
92
7.8 Measures for achieving The safety and health provisions of EC directive 98/37/EC make it a legal require-
ment to eliminate special hazards which may be caused by, for example, fatigue
safe working periods and ageing.
S.W.P. This requirement is also reected in the third supplement to German accident
prevention regulations UVV/BGV D8 (VBG 8) of 1.4.1996.
This requirement obliges the owner of serial hoist units to determine the actual
duration of service of the chain hoist on the basis of the operating hours, load
spectra and/or recording factors. This is based on FEM 9.755/06.1993 Measures
for achieving safe working periods for powered serial hoist units (S.W.P.).
The objective of this rule is to determine measures for achieving safe working
periods over the entire duration of service, although, according to the state-of-
the-art, the hoist units are designed for specic periods of operation.
Premature failure cannot, however, be ruled out.
The following items have been taken from FEM rule 9.755 with reference to the
electric chain hoist:
1. The actual duration of service determined on the basis of operating time and
load must be documented at least once per year.
2. The operating time Ti (number of operating hours) can be estimated or read on
an elapsed time indicator.
3. The load kmi (load spectrum) must be estimated.
4. The value determined for operating time Ti using an elapsed time indicator must
be multiplied by the type of recording factor f = 1,1.
5. The value determined for the estimated operating hours and load spectrum
must be multiplied by the type of recording factor f = 1,2.
6. The actual duration of service S is calculated as: S = kmi x Ti x f
7. A general overhaul must be carried out on reaching the theoretical duration of
service.
8. All checks and inspections and the general overhaul must be arranged by the
owner of the hoist unit.
A general overhaul is dened 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 com-
ponents and parts. Following a general overhaul, the machinery is in a condition
similar to that of the same machinery in new condition as far as the principle of
operation and performance values are concerned.
For electric chain hoists classied according to FEM 9.511, the following theoreti-
cal durations of service apply (converted into full load hours):
1Cm 1Bm 1Am 2m 2m+ 3m 4m

[h] 200 400 800 1600 1900 3200 6300
The actual duration of service is considerably increased if the chain hoist is only
operated with partial load. For a chain hoist operated on average with half load,
for example, this results in an 8-fold increase in the actual duration of service, with
operation at one quarter of the full load, a 64-fold increase.
211033k3.indd/110707
93
7.8.1 Calculating the actual The actual duration of service S of the electric chain hoist can be determined as
duration of service S follows:
S = kmi x Ti x f
kmi : Actual load spectrum factor

Ti : Number of operating hours
f : Factor depending on the type of recording
Calculating the number of hours of The operating time can be calculated by means of an elapsed time indicator or
operation (operating time) Ti (by the according to the following method:
owner) Operating time per inspection interval:
Ti = (Lifting+lowering) x cycles/h x working time/day x days/inspection interval

60 x hoist speed
Only lifting and lowering movements are counted, long and cross travel times are
not taken into consideration.
Estimating the load spectrum factor To simplify estimation, each type of load can be grouped together into km load
kmi (by the owner) spectrum modules. The types of load are simplied and quoted as 1/4, 1/2, 3/4
load and full load.
Dead loads are added to the loads. Loads up to 20% of the rated load capacity are
not taken into consideration.
The operating time for each type of load is divided up within the inspection interval
(e.g. 1 year) in terms of percentage.
The following bar diagram shows the km load spectrum modules for the load condi-
tions without load up to full load in time increments of 5 and 10%. Larger shares of
the time period must be correspondingly added together.
The load spectrum factor kmi can be obtained by adding together the individual km
load spectrum modules.
0,0062
0,0125
0,0008
0,0016
0,021
0,042
Load
0,05
0,10
Full load
3/4-load km values
1/2-load
Dead load
1/4-load
No load Time
5 10 5 10 5 10 5 10 40
100 [%]
Factor depending on the type of f = 1,1 For calculating the operating hours using an elapsed time indicator
recording f (included in the DC-Pro standard scope of delivery)
f = 1,2 For estimating the operating hours and the load spectrum
211033k3.indd/110707
94
7.8.2 Example: Lifting speed : 8/2 m/min
DC-Pro 25-2500 1/1 H4 V8/2 No. of cycles per hour : 10 cycles/h
in 1Am Lifting and lowering : (2+2) m/cycle = 4 m/cycle
Operating time per day : 8 h/day
Days per inspection interval : 250 days/inspection interval
10 x 4 x 8 x 250
Ti = =
60 x 8
With operating time read With operating time estimated

167 166,6
In the operating time as read / estimated above, the chain hoist has transported
the following loads:
0,0125 +
0,0016 +
0,0125
0,0008
0,042
0,05
5 % of time with full load
10 % of time with load
50 % of time without load Time
5 10 20 15 50
[%]
100
Adding the load spectrum modules km together results in the load spectrum factor
kmi = 0,119
Thus, the actual duration of service amounts to S [h] = kmi x Ti x f =

0,119 x 167 x 1,1 =21,9 0,119 x 166,6 x 1,2 =23,8
For classication 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

778,1 hours 776,2 hours
Documentation:
Enter these values in your test and inspection booklet or crane installation test and
inspection booklet. This entry may appear as follows:
Date Operating Act. du- Remaining
Theoretical duration
hours Load factor ration of duration of
of service
service service
Load [%] km factor

from to Ti value [h] full 3/4 1/2 1/4 none kmi f S [h] D [h] Group of mech. D-S [h]
Read 5 10 20 15 50
3.1.-- 30.12.-- 0,119 1,1 21,9 800 / 1Am 778,1
167 0,05 0,042 0,025 0,002 -
Estimated 5 10 20 15 50
3.1.-- 30.12.-- 0,119 1,2 23,8 800 / 1Am 776,2
166,6 0,05 0,042 0,025 0,002 -
211033k3.indd/110707
95
8 Maintenance
8.1 Replacing the hook

8.1.1 1/1 reeving
41053344.eps 41058944.eps
41058545.eps 41058644.eps
Fix limit stop to the 5th link of the

unloaded chain fall.
Tightening torque Tightening torque

DC Pro 16 = 27,5 Nm DC Pro 16 = 4,3 Nm
DC Pro 25 = 27,5 Nm DC Pro 25 = 7,4 Nm
41058746.eps 41058844.eps
211033k4.indd/110707
96
8.1.2 Replacing the bottom block
for 2/1 reeving
Tightening torque
DC Pro 16 = 55 Nm
DC Pro 25 = 55 Nm
41057244.eps 41057344.eps
8.2 Dismantling the chain

collector box
Retaining spring
42713744.jpg 42713844.jpg
Actuate Lower key until chain is al-

most completely out of chain collector.
Remove retaining spring from the pin
and pull out pin. While doing so, hold
the chain collector.
Now deposit the chain collector on the
ground.
While tting the chain collector, make
sure that the spring with its ends ts in
the recesses of the chain entry plate
211033k4.indd/110707
again.
Spring
42713844.jpg
97
8.3 Assembly and disas- On reaching the permissible limit of chain wear, the chain set must be replaced
(for determining the wear limit of the chain, see section 8.4).
sembly of chain set
The chain sets comprise the following parts:
Chain with standard or special length,
Sprocket,
Chain guide with deector guide plate,
Chain entry plate,
Demag chain grease tube,
Retaining ring,
Chain anchorage for 2/1 reeving.
For tting the new chain set, proceed accordingly in reverse order. Pay attention to
the following:
Before you slide on the chain sprocket, lubricate the splining of the output shaft
with Molykote or similar.
The stamped burr of the retaining ring must face the motor.
Correct t of the retaining ring is ensured when it can be easily turned on the
output shaft after assembly.
Fit the hook assembly or bottom block to the chain end as described in the g-
ures (section 8.1).
When tting the chain, it must be ensured that the chain is introduced in the
same position and orientation. The chain must operate without any twist.
Orientation of the weld bead on the chain link to the outside is not necessary.
After replacing the chain set, the chain must be lubricated (see section 8.4).
Dismantling the chain set

- Disconnect chain hoist from power
supply (mains connection switch).
211033k4.indd/110707
42714044.jpg 42714144.jpg
- Dismantle and deposit chain collec- - Remove chain set cover plate
tor (see section 8.2). (tightening torque 9,5 Nm).
98
42714244.jpg 42714344.jpg 42714444.jpg
- Chain set cover plate removed. - Remove chain entry plate Chain entry plate removed.
(tightening torque 25 Nm). Do not damage split sleeve.
42714544.jpg 42714644.jpg 42714744.jpg

- Slide out chain anchorage - Remove limit stop.
(only for 2/1 reeving).
42714844.jpg 42714944.jpg 42715044.jpg

- Turn the block setting on the - Remove the retaining ring by means - Loosen the chain guide with
geared limit switch 20 revolutions of straight Seeger ring pliers. sprocket from the output shaft; to
anti-clockwise, let the chain run do this, slide the complete assem-
out of the chain set by means bly in the direction of the motor
of the Lower key, see also sec- until the sprocket is free. Remove
tion 4.6.3. the worn chain set from the serv-
ice enclosure downwards.
211033k4.indd/110707
99
Fitting the chain set
For 1/1 reeving, there is no tting of
the chain anchorage.
After replacing the chain set, the chain
must be lubricated (see section 8.4).
42715044.jpg 42714944.jpg
- Before you slide on the chain - Fit retaining ring by means of
sprocket, lubricate the splining of the straight Seeger ring pliers.
output shaft with Molykote or similar. The stamped burr of the retaining
Slide chain guide with sprocket onto ring must face the motor.
output shaft. If only the chain is re- Correct t of the retaining ring is
placed, check the chain sprocket for ensured when it can be easily
wear on the surface. turned on the output shaft after
assembly.
42719644.jpg 42719744.jpg 42719844.jpg
- Secure chain entry plate with - Slide chain into opening in the - Pull chain into chain set by means
1 screw. Do not damage split middle by using the pilot section. of Lift key.
sleeve (only for 2/1 reeving).
- For 1/1 reeving, bolt chain entry
plate completely and close opening
for anchorage in chain entry plate
with plug.
42714744.jpg 42719944.jpg 42720044.jpg
- Fix limit stop to the 5th link of the - Loosen chain entry plate. - Lead chain through retainer and
211033k4.indd/110707
unloaded chain fall. Pull the other end of the chain from insert it into the link sections.
below through the chain entry plate
in the same position and orientation.
100
42720144.jpg 42720244.jpg 42720344.jpg
- Insert the halves of the chain link - Identical chain links must have the - Insert complete chain anchorage
section into the retainer of the same position and orientation. The into chain hoist.
chain anchorage. Ensure correct chain must operate without any twist.
orientation.
42720444.jpg 42714344.jpg 42714144.jpg
- Fit chain entry plate (tightening - Fit chain set cover plate (tightening
torque 25 Nm). torque 9,5 Nm).
The split sleeve on the chain entry
plate prevents shifting of the chain
anchorage to the side.
- Let the chain run through the chain

set by means of the Lift key in or-
der to facilitate tting of the bottom
block. While doing so, check posi-
tion and orientation of the chain.
- Fit the hook assembly or bottom
block to the chain end as described
in the gures (section 8.1).
- Lower chain.
- Fit chain collector (section 8.2).
42714844.jpg
- Turn the block setting on the geared

211033k4.indd/110707
limit switch 20 revolutions back

again (clockwise).
101
8.4 Hoist chain The original Demag chain is a tested round section steel chain which is subject
to the directives for round section steel chains in hoisting operation of the Main
Association of Industrial Employers Mutual Insurance Societies, Central Depart-
ment 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. 1981 as well as BGV D8 (VBG 8) and BGV D6 (VBG 9).
Standard chain Demag RDC
Chain hoist DC 16 DC 25
Dimension [mm] 8,7 x 24,2 10,5 x 28,2
Stamp DAT / RDC
Weight per meter [kg] 1,67 2,49
Test force during manufacturing [kN] 59 87
Min. breaking force [kN] 95 138
Min. elongation at rupture % 10
for 1/1 reeving [kg] 1600 2500
Max. load capacity
for 2/1 reeving [kg] 3200 5000
High strength ageing-resistant material with a high degree of surface hardening, galvanised with additional
Properties
surface treatment, blue chromated, colour: silver
Material Ni-Mo special chain steel acc. to EN 818-7, part 5.3.1
Lubrication GP00H-30REN.SO-GFB grease
Note load capacity reduction!

Deviating from the standard operating conditions for which RTS chains are used,
the special chains listed in the following are available for special ambient condi-
tions.
Special chains Demag Corrud Demag HS7 Demag RS6

Galvanizing, electroplating facili-
Application e.g. Foundry, dust, emery Foodstuffs sector
ties
Chain hoist DC 16 DC 25 DC 16 DC 25 DC 16 DC 25
Dimension [mm] - 10,5 x 28,2 - 10,5 x 28,2 - 10 x 28,2
Stamp DAT / RDC RSX / DS
Weight per meter [kg] - 2,49 - 2,49 - 2,23
Test force during manufacturing [kN] - 87 - 78 - 50
Min. breaking force [kN] - 138 - 121 - 80
Min. elongation at rupture % 10 10 10
for 1/1 reeving [kg] - 2500 - 1600 - 630 - 800 1)
Max. load capacity
for 2/1 reeving [kg] - 5000 - 3200 - 1250 - 1600 2)
ageing resistant, corrosion free,
corrosion protection micro-layer ageing-resistant, blue chromated, Non-rusting chain, not hardened,
Properties
Corrud DS black coating, colour: with deeper hardening surface bright
black, Stabylan 2001
Ni-Mo special chain steel acc. to Ni-Mo special chain steel acc. to Stainless steel AISI 316 (V4A)
Material
EN 818-7, part 5.3.1 EN 818-7, part 5.3.1 1,4401
dry or with dry lubricant, e.g. Edible lubricant, e.g. Paraliq chain
Lubrication Acid-resistant chain grease
Klber UNIMOLY C220 spray
211033k4.indd/110707
1) For max. 10 cycles per day = 800 kg

For max. 25 50 cycles per day = 630 kg
2) For max. 5 cycles per day = 1600 kg
102 For max. 12 25 cycles per day = 1250 kg
Lubricating the chain when putting the hoist into operation and during
subsequent operation
After tting, before lifting a test load and putting the hoist into operation
as well as during normal operation, the chain link contact areas must be
lubricated with a gear grease, part no. 665 009 44, along the entire length
of the chain, which must be free of load.
The chain link contact areas must be relubricated appropriately after being
cleaned at intervals depending on service and load conditions. The lubricant
should preferably be applied with a brush.
A dry lm lubricant should be used in environments where abrasives occur (emery,
sand, etc.).
41059444.eps
Checking wear or deformation of the original Demag chain

In addition to selecting the correct hoist unit, owners of electric chain
hoists are obliged by DIN 685 part 5 regulations to constantly check the
round section steel chain in order to ensure optimum operating safety
and, therefore, to avoid serious accidents.
For single-shift operation, operation in accordance with FEM specication and for
operating conditions of the chain hoist in accordance with section 2.9, the chain
should be checked once a year (see inspection and maintenance schedule).
If routine maintenance reveals that the intervals are too long, they should be
adapted to the specic operating conditions.
A partial load must be suspended from the load hook when measuring the
chain for wear or deformation.
This measurement can be taken in two different ways.
1. Measuring with a calliper gauge
2. Measuring with a chain gauge
Wear of individual link

The chain link contact areas must be visually checked for traces of wear. If the
chain hangs at angle while it is unloaded, for example, this usually indicates wear
of an individual chain link, see gure on the side.
Measure the wire diameter of the chain in the chain link contact area by means
of a calliper gauge, as required. Min. values of the wire diameter are specied in
table 3.
42726244.jpg
211033k4.indd/110707
42726344.jpg
103
Measuring with a calliper gauge
Calliper gauge
Measurements on 11 chain links may be taken in steps of 2 x 3 and 1 x 5 chain
links (see table 3, next page).
The sum total of the 3 readings taken, i.e. a1 + a2 + a3 must not exceed limit a in
d1 + d2
dm = table 3. Otherwise the chain must be replaced.
2
Demag is stamped on every 12th link of genuine Demag chains.
Do you nd that, on tting a new chain, it does not run smoothly over the sprocket?
Please contact our after-sales service centre.
We urgently recommend you use genuine Demag parts. This will ensure that the
safety and service life of the chain hoist is guaranteed.
40460845.eps
211033k4.indd/110707
104
Table 3
Demag chain hoist DC-Pro 16 DC-Pro 25
Chain designation d x t 8,7 x 24,2 10,5 x 28,2
Limit measuring values to DIN 685, part 5
Measurement over 11 chain links outside, max. dimension a = a 1 + a 2 + a 3 [mm] 289,2 337,4
Measurement over 1 chain link inside, max. dimension t [mm] 25,5 29,8
Measurement of chain link diameter, min. dimension d m = 0,9 x d [mm] 7,8 9,45
Refer to sections 8.2 and 8.3 for replacing the chain when required.
When a new standard RTS chain is ordered, a chain set is always supplied
(consisting of chain, chain sprocket, chain guide with deector guide plate).
To protect the chain from impermissible torsion when the load turns,
movement of the hook assembly/bottom block must not be restricted.
Chain gauge
Part no. 836 025 44
11th chain link

The discarding status has been
reached.
Measuring pin
The discarding status has not yet

been reached.
It is not yet necessary to replace the
chain.
It is necessary to replace the chain,
211033k4.indd/110707
when the measuring pin can no

longer move into the 11th chain link.
42648245.jpg
105
8.5 Suspension bracket, If a check or inspection reveals that these components are worn beyond the
dimensions specied or if cracks can be seen in these parts, they must be
load hook replaced at once.
Replacing the hook, see section 8.1.
Suspension bracket
Range DC Pro 16/25
Suspension bracket min. dimension e [mm] 31,5
Suspension ring transverse 90 (chain hoist parallel to girder)
[mm] 34,2
min. dimension e
42599447.jpg
Load hook
Load Chain Load Max. Max.
Reeving Dimensions [mm]
capacity hoist hook test force hook force
[kg] DC Pro Type a1 a2 b1 h1 h2 L2 L4 d1 [kN] [kN]
1600 1/1 5 50 43,7 29 44 34 45 159 41,8 50 100
16
3200 2/1 6 56 49 30 55 38 56 187 49,8 65 130
2500 1/1 5 50 43,7 29 44 34 45 159 41,8 50 100
25
5000 2/1 7 64 52 38 70 48 59 200 49,8 126 252
42707344.jpg 211033k4.indd/110707
106
8.6 Brake Plug-in jumper on hoist control system for brake for mains voltage 220 240 V,
50 / 60 Hz, see section 5.2.1.
Check brake wear

1. Disconnect the chain hoist from the power supply (mains connection switch),
2. Open electrical equipment cover (section 3.4),
3. Disconnect brake connector,
4. Dismantle brake
DC16 = three M5 screws, tightening torque 5,5 Nm,
DC25 = three M6 screws, tightening torque 9,5 Nm,
5. 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;
- measure the distance from brake rear side to brake disk with depth gauge
or calliper gauge when the brake is actuated, to do this, press the brake disk
against the springs until it stops; A G clamp or similar item may be used to
press the brake together.
- use both measured values to calculate the difference;
- if the difference is not exceeded, the chain hoist may continue to be operated
with the existing brake; if the difference is exceeded, the brake must be re-
placed;
During assembly, make sure that the area of the V ring on the brake base is
slightly greased. Ensure that no grease penetrates into the inside of the brake. The
continuous sealing lip must be in full contact on the brake rear side.
Load capacity Chain hoist Reeving Hoist speed Brake Difference

Type at 50 Hz at 60 Hz Type
[kg] [m/min] [m/min] [mm]
1600 DC Pro 16 -... 1/1 8,0/2,0 9,6/2,4 BK07
2000 DC Pro 25 -... 1/1 8,0/2,0 9,6/2,4
BK20
2500 DC Pro 25 -... 1/1 8,0/2,0 9,6/2,4
4,0/1,0 4,8/1,2 BK07 0,65
3200 DC Pro 16 -...
6,0/1,5 7,2/1,8
2/1
4000 BK20
DC Pro 25 -... 4,0/1,0 4,8/1,2
5000
211033k4.indd/110707
42722144.JPG 42651044.JPG 42651144.JPG 107

8.7 Checking the slipping The slipping clutch is the emergency-stop device and the overload protection of
the chain hoist. In the course of the annual inspection, its functioning must be
clutch checked.
Check the slipping clutch function as follows:
- In order to remove the limit stop, the chain collector must be disconnected, see
section 8.2. Remove the limit stop from the section of chain which is not under
load, see section 8.1, and t it above the hook assembly. Run the limit stop
against the chain entry plate at creep lifting speed. The limit switches must not
be actuated while this is being done. If the slipping clutch is functioning cor-
rectly, the following will be observed:
The fan of the hoist motor continues to turn for several revolutions until slip
monitoring switches off the motor and the brake is applied.
The 7-segment display shows the SLIP ERROR warning message, see
section 8.10.2. If the motor does not switch off, slipping clutch monitoring is
defective and the control system must be replaced.
- When the slipping clutch function has been checked, the limit stop must be
tted again to the section of chain which is not under load.
8.8 Adjusting the slipping During the nal inspection in the factory, the slipping clutch is set to the load
capacity of the chain hoist. The setting complies with the requirements of
clutch EN 14492 -2 for slipping clutches as overload protection. An increase of the
tripping torque which exceeds the factory setting is not permitted.
The slipping clutch is protected against overload by slip monitoring so that re-set-
ting is only necessary during the general overhaul. If owing to the operating condi-
tions or malfunctions, the setting needs to be checked, the friction force checking
device, part no. 836 708 44, must be used. Inspection and adjustment may only be
carried out by an experienced technician in compliance with the instructions, publi-
cation 206 974 44. The adjustment is shown in the gure below. In order to meas-
ure the set slipping force with the checking device, the chain must be inserted in
the slipping force sensor at the chain entry point of the load chain. Then unlock the
emergency-stop button and run the slipping force sensor against the chain entry
point at creep lifting speed. After unlocking the emergency-stop and actuating the
lifting motion, slip monitoring is by-passed for 3 seconds so that the slipping force
can be read in the display of the checking device. After this period, slip monitoring
switches off the slipping clutch with an error message. If required, this process can
be repeated after the emergency-stop has been actuated and unlocked again.
42657644.eps
The slipping clutch is set by means of an 8 mm hexagon socket key

Direction of rotation Tighten = clockwise
Loosen = counter-clockwise
20 revolutions correspond to 50 kg.
42720544.jpg
211033k4.indd/110707
108
8.9 Gearbox / oil change Oil lubrication
Under normal operating conditions, the lubricant must be changed at least every
10 years.
Under exceptional conditions, e.g. increased ambient temperatures, we recom-
mend that oil changes be adapted to suit these conditions.
Oil change
Drain the old oil at operating temperature. To do this, rst remove the left air vent
screw and the screw plug on the right. Turn the gearbox in such a way that the oil
is drained. The ushing oil should have a viscosity of 46 68 mm2/s at 40 C.
The quantity of ushing oil used should be approximately twice that specied for
lubrication. Then ush the gears by switching the hoist on and allowing the hook to
run several times over the entire length of its path. Then drain the ushing oil and
rell the gearbox with new oil. The required quantity and grade of oil are specied
below.
Oil grades
Universal gear oil Shell Donax TD 10W-30 with wear-minimising additives, range
of viscosity 10W-30.
For higher or lower ambient temperatures than -20 C to + 40 C, contact the
manufacturer.
Dispose of waste oil in an environmentally compatible way.
Quantity of oil in litres.

Range DC-Pro 16 / 25 1,5 l
Part no., see component parts
1 2
1 Vent screw
Tightening torque 5 Nm
2 Screw plug
42728844.jpg
Tightening torque 15 Nm
211033k4.indd/110707
109
8.10 7-segment display The 7-segment display is located on the bottom side of the chain hoist behind a
window.
Warning messages
Warning messages start with the lightning symbol.
Error messages
Error messages start with an Error.
Failed safety functions

If a safety function has failed, operation may only be continued after repair.
Errors
Functioning of the chain hoist is only possible when it is correctly connected to the
power supply. In the event of a failure, therefore rst check cables, strain relief and
power supply connections. Malfunctions may also be caused by incorrect transmis-
sion of commands from the control pendant. Therefore, 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 t.
The symbols are shown one after the other.

Please contact our after-sales service if the cause of fault cannot be elimi-
nated with the above measures.
8.10.1 General messages
No. Error Display Possible cause Remarks

Check mains connection and fuse
link; check connection cable for inter-
1 No lifting, no lowering Display dark No power supply.
ruption; check mains connector in the
service enclosure.
Unlock emergency button by turning.
Check dummy plug for trolley con-
Emerg. stop actuated nection.
2 No lifting, no lowering
Emergency-stop cable interrupted. Check connections of the control ca-
ble on the pendant and in the service
enclosure.
Upper end position reached. End position reached.

3 Upper limit switch approached.
No lifting Lowering
Lower end position reached. End position reached.

4 Lower limit switch approached.
No lowering Lifting
When the voltage is switched on or

5 No lifting, no lowering the emergency-stop is unlocked, a Release button and actuate it again!
button is already actuated.
Check connections of the control ca-

ble on the pendant and in the service
6 No lifting, no lowering Control cable interrupted.
enclosure. Check control cable for
42649351.jpg continuity.
211033k4.indd/110707
110
8.10.2 Warning messages

SLIP LIFTING start-up
No lifting A mains phase is missing Check mains connection and fuse link; check connec-
or the motor is blocked. tion cable for interruption; check mains connector in the
1
service enclosure.
No lifting with load. Chain hoist overloaded or Reduce load to the permissible load capacity. Ensure
undervoltage. appropriate mains voltage.
SLIP LIFTING V1
Cut-out in the upper end Limit switch contact is no In the case of error-free functioning of the limit switches,
position. longer actuated. (-.) is displayed. In the case of an error, the slipping clutch
2
acts as an emergency-stop device: Connection and func-
tioning of the limit switch contact must be inspected by an
experienced technician.
SLIP LIFTING V2
Cut-out in the upper end Limit switch contact is no In the case of error-free functioning of the limit switches,
3 Fast lifting with load is Chain hoist overloaded. acts as an emergency-stop device: Connection and func-
switched off. tioning of the limit switch contact must be inspected by an
Reduce load to the permissible load capacity.
Internal data memory defec- Control system defective Replace control system
4 tive.
Control system has no valid Does not result in incorrect functioning of the chain hoist
5 serial no.
No load movement for Drive blocked. Repeat lifting process, if load does not move, have the
6 lifting. brake and control system checked by an experienced
technician.
SLIP LOWERING start-up

No lowering. A mains phase is missing Check mains connection and fuse link; check connec-
7
or the motor is blocked. tion cable for interruption; check mains connector in the
service enclosure.
SLIP LOWERING V1
Lowering is switched off, Chain blocked. Check chain running in, replace chain, if required.
lower end position is not
reached.
8 Cut-out in the lower end Limit switch contact is no In the case of error-free functioning of the limit switches,
SLIP LOWERING V2
Lowering is switched off, Chain blocked. Check chain running in, replace chain, if required.
lower end position is not
reached.
9 Cut-out in the lower end Limit switch contact is no In the case of error-free functioning of the limit switches,
No lifting. Chain hoist has overload. Reduce load to the permissible load capacity.
10
No lifting. Chain hoist has overtem- Allow chain hoist to cool.

11 perature.
No lifting. Chain hoist has undervol- Ensure appropriate mains voltage.

12 tage.
211033k4.indd/110707
111
8.10.3 Error messages

Hoist unit: Speed error or
drive is obstructed.
Chain hoist is blocked. Drive blocked or speed detec- Check error message by actuating and unlocking the
1
tion failure. emergency stop. Then actuate Lowering.
If necessary, remove suspended load.
Replace hoist control system.
Hoist unit: Overspeed or load
cannot be held.
Lowering with load is
2 switched off. Lowering speed too high. Reduce load to the permissible load capacity. Check
mains connection and fuse link; check connection
cable for interruption; check mains connector in the
service enclosure.
Hoist unit: Monitoring electro-
nics defective.
Chain hoist is blocked. Hardware error of control Check error message by actuating and unlocking the
3
system. emergency stop. Then actuate Lowering.
Monitoring electronics defecti- If necessary, remove suspended load.
ve. Replace hoist control system.
Hoist unit: Incorrect direction
of rotation. Direction cannot be switched. Check error message by actuating and unlocking the
4 Chain hoist is blocked. emergency stop. Then actuate Lowering.
Lowering is switched off. Brake defective or slipping Check brake and slipping clutch.
5 clutch set incorrectly. If there is no fault, replace electronics.
Trolley: Monitoring electronics

defective. Hardware error of control Check error message by actuating and unlocking the
6 Cross travel blocked. system. emergency stop.
If necessary, remove suspended loads.
Trolley: Incorrect direction of
rotation.
7 Cross travel blocked. Direction cannot be switched. Check error message by actuating and unlocking the
emergency stop.
If necessary, remove suspended loads.
Emergency-stop circuit
defective. Emergency-stop circuit of Check error message by actuating and unlocking the
8 Chain hoist is blocked. control system defective emergency stop. Then actuate Lowering.
211033k4.indd/110707
112
9 Accessories
- Control pendant bridge (if no other

module is tted in this place)
(included in the basic scope of de-
livery, eliminated for DRC-DC and
KT3)
Part no. 720 370 45
42730744.jpg
- Trolley module
Contactor control for AC travel
motor, modular plug-in supplement
for hoist control system
Part no. 720 335 45
42731244.jpg
- Motor connection cable set

DC 16 / 25 to EU 55 DK / EU 56 DC
KBF 71 to KBF 90
Part no. 720 364 45
42731344.jpg
- Power / control cable set

DC 16 / 25 to E 22 / E 34 trolley
Part no. 720 369 45
211033k5.indd/110707
42731444.jpg 113
- Crane plug-in connector for
DC crane in tri-state
Weight 0,570 kg
Part no. 720 365 45
42729344.jpg
- Control transformer for mains

voltage on hoist control system
(included in basic scope of delivery,
needs to be replaced only for 3TK
applications by control transformer
for signal voltage)
Weight 0,430 kg
Voltages Part no.

220-240V / 50/60Hz 720 376 45
380-415V / 50/60Hz 720 377 45
440-480V / 60Hz 720 378 45
500-525V / 50Hz 720 379 45
42730044.jpg
575V / 60Hz 720 380 45
- Phoenix electrical equipment cover

mains connector for at/round cable
(4x1,5 mm2 and 4x2,5 mm2)
(included in basic scope of delivery)
Part no. 720 357 45
42731044.jpg

signal connector for at cables from
2x6x0,5 mm2 (720 139 45) to
13x1,5mm2
(included in basic scope of delivery)
Part no. 720 356 45
211033k5.indd/110707
114 42731145.jpg
signal connector RJ bayonet adapter
(included in the basic scope of de-
livery, eliminated for option Without
control cable)
Part no. 720 087 45
42730244.jpg
- Connector enclosure for mobile

control system
Part no. 720 187 45
42730344.jpg
- DC 16 return sprocket
Part no. 721 845 45
- DC 25 return sprocket
Part no. 721 850 45
42730144.jpg
Designation Part no.

- Flat cable 2x6x0,5 mm2 720 139 45
211033k5.indd/110707
- Limit switch kit EU 11 to EU 56 716 663 45
115
For integration of the DC16/25 into - KT3 signal converter module
existing installations, the following (for conversion of conventional con-
modules may be necessary: trol signals/contacts 42 V-230 V AC,
50/60 Hz to 24 V AC tri-state)
Part no. 720 340 45
42729844.jpg
- 3TK signal converter module for

crane axis
(for conversion to conventional con-
trol signals/contacts from 24 V AC
tri-state to 42 V-230 V AC, 50/60 Hz)
(control transformer for mains volt-
age on hoist control system needs to
be replaced by control transformer
for the relevant signal voltage)
Part no. 720 345 45
42729944.jpg
- Control transformer for signal

voltage on hoist control system
(only necessary in conjunction with
3TK signal converter)
Weight 0,430 kg
Voltages Part no.

42-48V / 50/60Hz 720 373 45
110V / 50/60Hz 720 374 45
230V / 50/60Hz 720 375 45
42730044.jpg

3TK module
(only necessary in conjunction with
3TK signal converter)
Weight 0,570 kg
Part no. 720 363 45
211033k5.indd/110707
116 42729344.jpg
DRC-DC radio remote control system - DRC-DC receiver module
(Depending on the chain hoist congu- (Modular plug-in supplement for
ration, individual accessory compo- hoist control system, plug-in jumper
nents may already be included in the on hoist control system)
basic scope of delivery) Part no. 773 720 44
42729244.jpg

DC crane in tri-state
Part no. 720 365 45
42729344.jpg
- Signal horn set for DRC-C

Part no. 720 349 45
42729444.jpg
- Shorting plug for DRC-DC

Part no. 720 348 45
211033k5.indd/110707
42729544.jpg 117
10 Spare parts
Overview
211033k5.indd/110707
42728644.eps
118
Motor
42728244.jpg
Item Part no. Qty. Designation Material Standard
1 71585133 1 Fan set ZNK 100B 4 Nm

1 72185233 1 Fan set ZNK 100C 4 Nm
2 71583233 1 Motor set DC10/16 B 50Hz 380 V - 415 V, 50 Hz, 25 Nm
2 71583433 1 Motor set DC10/16 B 60Hz 500 V - 525 V, 50 Hz/ 575 V, 60 Hz, 25 Nm
2 72123633 1 Motor set DC16/25 C 50HZ 380 V - 415 V, 50 Hz, 25 Nm
2 72123933 1 Motor set DC16/25 C 50HZ 500 V - 525 V, 50 Hz/ 575 V, 60 Hz, 25 Nm
4 72115933 1 Chain drive cover plate 9,5 Nm
5 72127433 1 Suspension bracket DC16/25
6 72110933 1 Gear oil set DC16/25
21103202.tbl
211033k5.indd/110707
119
Parts on gearbox
211033k5.indd/110707
42730444.jpg
120
Parts on gearbox
7 72115133 1 Slipping clutch adjusting nut 9,5 Nm

8 72035533 1 Pulse generator module DC16/25 3 Nm
9 72123033 1 Brake set BK07 (DC16) 9,5 Nm
9 72123133 1 Brake set BK20 9,5 Nm
32 72181545 1 Geared limit switch set 1,6 Nm
33 72032633 1 Small parts set DC 16/25
21103208.tbl
211033k5.indd/110707
121
Electrical cover
211033k5.indd/110707
42728345.eps
122
Electrical cover
10 72037345 1 Control transformer S 48/10/20,4 42-48V / 50/60Hz

10 72037445 1 Control transformer S 110/10/20,4 110V / 50/60Hz
10 72037545 1 Control transformer S 230/10/20,4 230V / 50/60Hz
10 72037645 1 Control transformer N 230/10/20,4 220-240V / 50/60Hz
10 72037745 1 Control transformer N 400/10/20,4 380-415V / 50/60Hz
10 72037845 1 Control transformer N 460/10/20,4 440-480V / 60Hz
10 72037945 1 Control transformer N 510/10/20,4 550-525V / 50Hz
10 72038045 1 Control transformer N 575/10/20,4 575V / 60Hz
11 72033545 1 Trolley module DC16/25
12 72112233 1 Electr. equipment cover DC16/25 without control system, without transformer
33 72032633 1 Small parts set DC 16/25
35 72032533 1 Electr. equipment cover DC16/25 with control system, without transformer
21103207.tbl
211033k5.indd/110707
123
Chain drive
211033k5.indd/110707
42728144.jpg
124
Chain drive
14 72120033 1 Chain set DC16 1/1 H4

14 72120433 1 Chain set DC16 1/1 H4
15 72120133 1 Chain set DC16 2/1 H4
15 72120533 1 Chain set DC16 2/1 H4
16 72117133 1 Chain entry plate DC16 DC 16, 25 Nm
16 72117033 1 Chain entry plate DC25 DC 25, 25 Nm
25 72182045 1 Anchorage/limit stop DC 16, 4.3 Nm
25 72182545 1 Anchorage/limit stop DC 25, 7.4 Nm
26 72183045 1 Chain collector set S. 1
26 72183545 1 Chain collector set S. 2
21103203.tbl
211033k5.indd/110707
125
Hook assembly
42727944.jpg
17 83865633 1 Hook safety catch set S.5

18 83865033 1 Load hook DC16/25 DK16/20 S. 5
19 72144533 1 Hook assembly DC16/DK16 1/1 27,5 Nm, w/o hook
19 72144733 1 Hook assembly DC25/DK20 1/1 27,5 Nm, w/o hook
20 72144133 1 Hook assembly DC16/DK16 27,5 Nm
20 72144333 1 Hook assembly DC25/DK20 27,5 Nm
34 72144933 1 Capacity plate DC16/DK16 1/1
34 72145133 1 Capacity plate DC25/DK 1/1
21103204.tbl
211033k5.indd/110707
126
Bottom block
42728044.jpg

22 82903433 1 Load hook DC16/DK16 2/1 S. 6
22 83884233 1 Load hook DC25 DK20 2/1 S. 7
23 72144633 1 Bottom block set DC16/DK16 2/1 55 Nm, w/o hook
23 72144833 1 Bottom block set DC25 2/1 55 Nm, w/o hook
24 72144233 1 Bottom block set DC16/DK16 2/1. 55 Nm
24 72144033 1 Bottom block set DC25 2/1 55 Nm
34 72145033 1 Capacity plate DC16/DK16 2/1
34 72145233 1 Capacity plate DC25/DK 2/1
21103205.tbl
211033k5.indd/110707
127
Accessories
211033k5.indd/110707
42730544.jpg
128
Accessories
3 72317145 1 Service cover DC 16/25 9,5 Nm

13 72181045 1 Counterweight set 27,5 Nm; 1/1 reeving
28 72006545 1 Cable collector, cpl. 9,5 Nm
29 71881033 1 Control cable set 5m 11 Nm
29 71880933 1 Control cable set 8m 11 Nm
29 72003745 1 DC control cable 11m 11 Nm
30 77330033 1 DSC control pendant
31 71880433 1 Emergency stop set / rubber cap DSC-S
21103209.tbl
211033k5.indd/110707
129
1 page(s) Page 1
EC manufacturers declaration Ident. no.
Demag chain hoist trolley 204 417 44
in accordance with EC Directive 98/37/EEC, Annex IIB Issue 1104 EN
Hereby we,
Demag Cranes & Components

declare that the product
Demag chain hoist trolley U, E, CF, RU, EU, HU

of serial design is intended to be incorporated into machinery and that the machinery
must not be put into service until the machinery into which this product is to be
incorporated has been declared in conformity with the provisions of the following
relevant regulations:
EC Machinery Directive 98/37/EC
The load capacity of the trolley is dependent on compliance with the load of the ap-
propriate serial hoist unit designed to be fitted to the trolley.
If the trolley is subjected to other loads, this can result in unfavourable wheel load
distribution and excessive stress on parts of the trolley.
Applied EC Directives
73/23/EEC EC Low Voltage Directive
93/68/EEC amendment to Low Voltage Directive
89/336/EEC EC EMC directive
92/31/EEC 1st amendment to EMC Directive
93/68/EEC 2nd amendment to EMC Directive
Applied harmonised standards

EN ISO 12100-1, 2 Safety of Machinery
EN 60 034-1 Rating and performance for rotating electrical machines
EN 60 034-5 Types of enclosures for rotating electrical machines
EN 60 204-32 Electrical equipment of machines, requirements for
hoisting machines
EN 60 529 Types of enclosure (IP code)
EN 61000-6-2 Electromagnetic compatibility, Immunity for industrial
environments
EN 61000-6-4 Electromagnetic compatibility, Emission standard for
industrial environments
Applied standards and technical specifications:

FEM 9.683 Selection of hoist and travel motors
Wetter, 1 November 2004
Place and date of issue
ppa. Gersemsky ppa. Hoffmann

Technik GZ Handling Technology
Handling Technology
# = Modifications compared to Cass. no.

2002 Normung
previous issue 715 IS 845
1
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. No liability accepted for errors or omissions.
1 page(s) Page 1
EC conformity declaration
Ident. no.
Demag DC chain hoist
in accordance with EC directive 89/336/EEC, Annex I, 98/37/EU, Annex II A and 199 151 44
73/23/EEC, Annex III Issue 0605 EN
Hereby we,
declare that the product
Demag chain hoist DC, DCS, DCM, DCMS

of serial design ready for service 1) with or without the relevant serial trolleys including
the Demag serial accessories has been declared in conformity with the provisions of
the following relevant regulations:
EC EMC directive 89/336/EEC

amended by 92/31/EEC, 93/68/EEC
EC Machinery Directive 98/37/EC
EC Low voltage Directive 73/23/EEC
amended by 93/68/EEC
Applied harmonised standards:

EN 292-1, 292-2 Safety of machinery
EN 818 -7 Chains for hoist units, grade T
EN 954 -1 Safety related parts of control systems Design Principles
EN 50178 Installation of electronic equipment in power systems
EN 60034 -1 Rating and performance for rotating electrical machines
EN 60034 -5 Types of enclosures for rotating electrical machines
EN 60204 -32 Electrical equipment, requirements for hoists
EN 60529 Types of enclosure (IP code)
EN 60947 -1 Low voltage switchgear, general specifications
EN 61000-6-2 Electromagnetic compatibility, resistance to interference in
industrial areas
EN 61000-6-3 Electromagnetic compatibility, resistance to interference in
commercial areas (DC, DCM)
EN 61000-6-4 Electromagnetic compatibility, interference emission in
industrial areas (DCS, DCMS)
Applied standards and technical specifications:
FEM 9.511 Classification of mechanisms
FEM 9.683 Selection for travel and hoist motors
FEM 9.751 Powered serial hoist units - Safety
FEM 9.755 Measures for achieving safe working periods
Wetter, 01.06.05
Place and date of issue
ppa. Gersemsky ppa. Hoffmann

HT Engineering Handling Technology Business Unit
1) Hoist ready for service includes a scope of parts as specified in Works standard 012 313 99.
# = Modifications compared Class. no.

Normung
to previous issue 715 IS 817
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. Not liable for errors or omissions.
Handling Technology
Postfach 67 D-58286 Wetter
Telephone (+49-2335) 92-0
Telefax (+49-2335) 922406
Printed in Germany
E-mail handling@demagcranes.com
www.demagcranes.de
Reproduction in whole or in part only with prior consent of Demag Cranes & Components, D-58286 Wetter Subject to change. Not liable for errors or omissions.

Talhas DC

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Operating instructions / accessories /

110707 EN/PDF 211 033 44 720 IS 817

Accompanying documents Technical data

Operating instructions Assembly Adjustment Dimensions

Test and inspection booklet 214 745 44 720 IS 817

4 Installation and commissioning 26

5 Circuit diagrams and additional electrical modules 39

6 Taking the hoist out of service at the end of the shift /

10 Spare parts 120

You have purchased a Demag quality product.

+49 (0)180 / 5 - 741268

Wearing parts are not subject to liability for defects.

Assigned expert engineer (in the Federal Republic of Germany according to

Authorized expert engineer (according to BGV 9, 28)

Warning against dangerous electrical voltage

Warning against suspended load

Operating hazard for the installation

Inching is to be avoided at fast speeds, as it causes increased wear and load

Functioning of the emergency stop device

Functioning of the lifting path limiter

It must be ensured that

Instructions for repair work in the course of operation

2.1 Design overview

1 Electrical equipment cover

1) For motor key data, see page Electrical key values.

3) Larger hook paths on request.

V 2-stage = Main/creep lifting

C F 5 Click-Fit (push-travel trolley)

U Standard-headroom monorail hoist

D Articulated trolley (curve-negotiating)

2.4 Electrical key values

Min. / max. currents and starting current

No. of 380-415 V, 50 Hz, 3 ~ (CE) 220-240 V, 50 Hz, 3 ~ (CE)

Min. / max. currents and starting current

1) Imax = maximum rated current for lowering operation.

Min. / max. currents and starting current

Min. / max. currents and starting current

1) Imax = maximum rated current for lowering operation.

Mains connection delay fuse links

Supply cables 2) for 5% voltage drop U and starting current IA

DC-Pro chain hoist C C1

1/1 reeving 2/1 reeving

Transverse to girder Parallel to girder

Special operating conditions may be agreed with the manufacturer in individual

Parts in which the load is borne Driving Braking

Motor Chain drive Brake

the optimum duration of service is ensured for the chain;

Opening the electrical equipment cover

Slot vertical Electrical equipment

1 Hoist control system

The chain hoists can be combined with the following trolleys:

42647644.eps 42669244.eps 42719544.jpg

1) Flange width for DC 16/25 = 98-310 mm.

Dispose of packing material in an

4.1 General Electrical equipment

Instructions relating to safety at work

Bend protection sleeve

The chain hoist is delivered with the

Make sure that the suspension

Remove the retaining clip and pin on

Do not move the chain

1/1 reeving with counterweight

4.4 Control cable