DEMAG DC-Com 1 User manual

Operating instructions/accessories/component
parts
Demag DC-Com 1 - 10 chain hoist
291113 en GB 214 802 44 720 IS 817
Distributed by Ergonomic Partners
S[email protected]
www.ErgonomicPartners.com
Tel: [phone]

Original operating instructions
Manufacturer
Demag Cranes & Components GmbH
PO Box 67
58286 Wetter, Germany
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative.
Owner
Where in use
Size
Serial number
Year of manufacture
Operating voltage
Control voltage
Frequency
Wiring diagram number
Tab. 1
Fig. 1 Example of a rating plate
Item Designation
1 Manufacturer See above
2 Chain hoist type  "Model code", Page 18,
 "Selection table", Page 19
3Serial no., calendar week, year
of manufacture
4Load capacity, group of mecha‐
nisms
 "Model code", Page 18,
 "Selection table", Page 19
5 Chain type, hook path
 "Available hoist chains", Page 77,
 "Model code", Page 18,
 "Selection table", Page 19
6 Voltage, frequency  "Hoist motor data", Page 20
7Type of enclosure, insulation
class
 "Operating conditions", Page 27,
 "Hoist motor data", Page 20
8 Ambient temperature  "Operating conditions", Page 27
9Motor Type  "Selection table", Page 19,
 "Hoist motor data", Page 20
10 Electric key data  "Hoist motor data", Page 20
11 Conformity symbol
12 Manufacturer's address See above
Tab. 2
The metric system is used in this document and all figures are shown with a comma as the decimal separator.
2
214 802 44/291113
Distributed by Ergonomic Partners
[email protected]
www.ErgonomicPartners.com
Tel: [phone]

Table of contents
General........................................................................................................................................................................ 7
DC-Com chain hoist .................................................................................................................................................... 7
DC-Com documents.................................................................................................................................................... 7
Symbols/signal words.................................................................................................................................................. 7
Information on the operating instructions .................................................................................................................... 8
Liability and warranty................................................................................................................................................... 9
Copyright ..................................................................................................................................................................... 9
Use of spare parts ....................................................................................................................................................... 9
Definition of personnel............................................................................................................................................... 10
Test and inspection booklet....................................................................................................................................... 10
After-sales service..................................................................................................................................................... 10
Safety ........................................................................................................................................................................ 12
General information on safety ................................................................................................................................... 12
Safety signs on the equipment .................................................................................................................................. 12
Intended use.............................................................................................................................................................. 12
Hazards that can be caused by the machine ............................................................................................................ 13
Responsibility of the owner ....................................................................................................................................... 14
Operating personnel requirements............................................................................................................................ 14
Personal protection equipment.................................................................................................................................. 15
Emergency-stop device............................................................................................................................................. 15
Regular inspections................................................................................................................................................... 16
Technical data ........................................................................................................................................................... 17
Design overview ........................................................................................................................................................ 17
Model code................................................................................................................................................................ 18
Selection table........................................................................................................................................................... 19
Electric key data ........................................................................................................................................................ 20
Hoist motor data ........................................................................................................................................................ 20
Mains connection delay fuse links............................................................................................................................. 23
Supply cables ............................................................................................................................................................ 23
Hook dimension C ..................................................................................................................................................... 24
Noise emission/sound pressure level........................................................................................................................ 25
Transport, packing and storage................................................................................................................................. 25
Safety instructions ..................................................................................................................................................... 25
Scope of delivery ....................................................................................................................................................... 25
Transport inspection.................................................................................................................................................. 25
Packing...................................................................................................................................................................... 25
Storage ..................................................................................................................................................................... 26
Materials.................................................................................................................................................................... 26
Linings ....................................................................................................................................................................... 26
Housing .................................................................................................................................................................... 26
Surface protection and paint finish ............................................................................................................................ 26
Operating conditions ................................................................................................................................................. 27
Technical description................................................................................................................................................. 28
Drive and brake ......................................................................................................................................................... 28
Gearbox and slipping clutch ..................................................................................................................................... 28
Chain drive ............................................................................................................................................................... 28
Electric equipment..................................................................................................................................................... 28
Control system .......................................................................................................................................................... 28
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
3.5
3.6
3.7
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.8
3.8.1
3.8.2
3.8.3
3.9
4
4.1
4.2
4.3
4.4
4.4.1
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3

7-segment display for operating status and fault display .......................................................................................... 29
Display of software version, operating hours, number of cycles ............................................................................... 30
Central service enclosure.......................................................................................................................................... 31
Control pendant/control cable height adjustment ...................................................................................................... 31
Control pendant ........................................................................................................................................................ 31
Assembly................................................................................................................................................................... 32
General...................................................................................................................................................................... 32
Safety instructions for assembly................................................................................................................................ 32
DC-Com chain hoist tightening torques..................................................................................................................... 34
Installation procedure ................................................................................................................................................ 34
Connecting the control pendant ................................................................................................................................ 35
Control cable ............................................................................................................................................................. 36
Control cable technical data ...................................................................................................................................... 36
Handling the control cable......................................................................................................................................... 36
Control pendant height adjustment ........................................................................................................................... 37
Mobile control system................................................................................................................................................ 38
Suspending the chain hoist ....................................................................................................................................... 40
Supporting structure .................................................................................................................................................. 40
Suspension bracket................................................................................................................................................... 41
Mains connection ...................................................................................................................................................... 42
Circuit diagrams and control boards.......................................................................................................................... 44
DC-Com 1 - 10 solo hoist circuit diagram.................................................................................................................. 44
Circuit diagram with E11 - E34 DC travel drive ......................................................................................................... 47
Control board............................................................................................................................................................. 47
Programming parameters with the control pendant .................................................................................................. 49
General...................................................................................................................................................................... 49
Meaning of the buttons.............................................................................................................................................. 49
Meaning of the parameters ....................................................................................................................................... 49
Starting parameter programming mode .................................................................................................................... 50
Adjusting the lower hook position.............................................................................................................................. 52
Putting into service for the first time .......................................................................................................................... 53
Safety instructions when putting into service for the first time................................................................................... 53
Inspection regulations ............................................................................................................................................... 53
Inspections before putting into service for the first time ............................................................................................ 54
Checks on entering service, handover ...................................................................................................................... 54
Operation................................................................................................................................................................... 55
Safety instructions for operation................................................................................................................................ 55
Switching on .............................................................................................................................................................. 56
Checks when starting work ....................................................................................................................................... 56
Function checks ........................................................................................................................................................ 56
Operation................................................................................................................................................................... 57
Safety during operation ............................................................................................................................................. 57
Load pick-up.............................................................................................................................................................. 57
Moving the load ......................................................................................................................................................... 58
Load distribution ........................................................................................................................................................ 58
Emergency-stop device operating function ............................................................................................................... 59
Slipping clutch operating function.............................................................................................................................. 59
Lifting path limiter operating function......................................................................................................................... 59
Emergency stop ........................................................................................................................................................ 59
4.4.2
4.4.3
4.5
4.6
4.7
5
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.7
5.7.1
5.7.2
5.8
5.9
5.9.1
5.9.2
5.9.3
5.10
5.10.1
5.10.2
5.10.3
5.10.4
5.11
6
6.1
6.2
6.3
6.4
7
7.1
7.2
7.2.1
7.2.2
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
7.3.7
7.4
4
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Taking the equipment out of operation...................................................................................................................... 60
Taking the equipment out of service when faults occur ............................................................................................ 60
Taking the equipment out of service at the end of the shift....................................................................................... 60
Taking the equipment out of service for maintenance and repairs............................................................................ 60
Maintenance/repair.................................................................................................................................................... 62
Safety instructions for maintenance and repair work ................................................................................................ 62
Basic maintenance requirements .............................................................................................................................. 63
Regular inspections................................................................................................................................................... 64
Required tests and inspections ................................................................................................................................. 64
Special operating conditions ..................................................................................................................................... 64
Service life of the contactor ....................................................................................................................................... 64
S.W.P. measures for achieving safe working periods ............................................................................................... 65
General...................................................................................................................................................................... 65
Calculating the actual duration of service S .............................................................................................................. 66
Example: DC-Com 10-1000 1/1 H5 V4/1 in 1Am ...................................................................................................... 66
GO general overhaul ................................................................................................................................................. 68
Maintenance schedule .............................................................................................................................................. 68
Maintenance work ..................................................................................................................................................... 70
Suspension................................................................................................................................................................ 70
Electric equipment cover ........................................................................................................................................... 70
Removing the chain collector box ............................................................................................................................. 71
Operating limit switches (standard for DC-Com 10 with 2/1 reeving)........................................................................ 71
Checking operating limit switches ............................................................................................................................. 71
Checking the operating limit switch actuator ............................................................................................................. 72
Chain drive ................................................................................................................................................................ 73
Checking the sprocket wheel .................................................................................................................................... 73
Checking the chain guide .......................................................................................................................................... 73
Checking the guide plate/chain entry plate ............................................................................................................... 74
Checking the hoist chain ........................................................................................................................................... 74
Chain set scope of supply ......................................................................................................................................... 76
Available hoist chains................................................................................................................................................ 77
Replacing the chain set ............................................................................................................................................. 78
Lubricating the hoist chain......................................................................................................................................... 82
Load hook.................................................................................................................................................................. 83
Checking the load hook............................................................................................................................................. 83
Hook safety catch...................................................................................................................................................... 83
Checking the return sprocket .................................................................................................................................... 83
Replacing the hook with fittings for 1/1 reeving......................................................................................................... 84
Replacing the bottom block (standard) with internal cut-off springs for 2/1 reeving.................................................. 85
Replacing the bottom block (option) with external cut-off springs for 2/1 reeving ..................................................... 86
Buffer (only with optional operating limit switches DC-Com 1-10 with 1/1 reeving) .................................................. 86
Checking the cut-off buffers/cut-off springs............................................................................................................... 86
Buffer arrangement ................................................................................................................................................... 87
Brake ......................................................................................................................................................................... 88
Brake assignment...................................................................................................................................................... 88
Check brake wear ..................................................................................................................................................... 88
Slipping clutch ........................................................................................................................................................... 90
Checking the slipping clutch...................................................................................................................................... 90
Adjusting the slipping clutch ...................................................................................................................................... 90
Gearbox/oil change ................................................................................................................................................... 91
Replacing the contactor on the control board............................................................................................................ 92
Replacing the control cable ....................................................................................................................................... 94
7.5
7.5.1
7.5.2
7.5.3
8
8.1
8.2
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.4.1
8.3.4.2
8.3.4.3
8.3.5
8.4
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.5.4.1
8.5.4.2
8.5.5
8.5.5.1
8.5.5.2
8.5.5.3
8.5.5.4
8.5.5.5
8.5.5.6
8.5.5.7
8.5.5.8
8.5.6
8.5.6.1
8.5.6.2
8.5.6.3
8.5.6.4
8.5.6.5
8.5.6.6
8.5.7
8.5.7.1
8.5.7.2
8.5.8
8.5.8.1
8.5.8.2
8.5.9
8.5.9.1
8.5.9.2
8.5.10
8.5.11
8.5.12
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5

Malfunctions/warnings............................................................................................................................................... 96
Safety instructions for malfunctions/warnings ........................................................................................................... 96
7-segment display ..................................................................................................................................................... 96
Operating statuses/general messages...................................................................................................................... 97
Warning messages.................................................................................................................................................... 98
Error messages ......................................................................................................................................................... 99
Disassembly/disposal.............................................................................................................................................. 100
General.................................................................................................................................................................... 100
Accessories ............................................................................................................................................................. 101
Assemblies .............................................................................................................................................................. 101
Spare parts .............................................................................................................................................................. 102
Overview ................................................................................................................................................................. 102
Motor ....................................................................................................................................................................... 103
Parts on the gearbox ............................................................................................................................................... 104
Chain drive .............................................................................................................................................................. 106
Hook assembly........................................................................................................................................................ 108
Bottom block with internal cut-off springs (standard) .............................................................................................. 109
Bottom block with external cut-off springs (option).................................................................................................. 110
Electric equipment cover ......................................................................................................................................... 111
Control pendant, control cable, service cover ......................................................................................................... 112
Index......................................................................................................................................................................................... 113
9
9.1
9.2
9.3
9.4
9.5
10
10.1
11
11.1
12
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
6
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1 General
1.1 DC-Com chain hoist
You have purchased a Demag quality product.
This chain hoist was manufactured to European standards and regulations in accordance with state-of-the-art en‐
gineering principles. The EC machinery directive requirements are satisfied.
1.2 DC-Com documents
Further documents are available for sub-assemblies/components in addition to these operating instructions. The
corresponding documents are supplied as necessary or can be ordered separately – also for special designs or if
additional options are ordered which differ from these operating instructions.
Documents 1) Order no.
Technical data/catalogues
Demag DC-Pro 1 - 25 chain hoist
Demag DCS-Pro 1 - 10 chain hoist 203 525 44
Demag DC-Com chain hoist 203 571 44
CF5-DC/DCM trolley 203 568 44
U11-U34/DC/DCM/DK trolley 203 569 44
RU/EU56 trolley 203 691 44
DC electric accessories 203 656 44
POLU box electric accessories 203 682 44
Clamp-fitted buffer 203 313 44
Operating instructions/component
parts
DC-Pro 1 - 15 chain hoist 214 741 44
DC-Pro 16 - 25 chain hoist 211 033 44
DC-Com chain hoist 214 802 44
DCS-Pro chain hoist 214 827 44
DC-Di chain hoist 211 068 44
DC-Wind chain hoist 211 010 44
PGS parallel gripper 214 095 44
Assembly – Adjustment – Dimen‐
sions
Crane hook adapter 211 240 44
KDDC/UDDC articulated trolley 211 159 44
E11-E34 DC travel drive (I) 214 810 44
E11-E34 DC travel drive (II) (circuit diagrams) 211 229 44
DRC-DC radio control system 214 689 44
DRC-DC radio control system quick-step instructions 211 045 44
DC geared limit switches 211 011 44
KDC chain hoist 211 017 44
DC protective sleeve 203 673 44
Friction force checking device 206 973 44
DC PWM/3ST signal converter 211 094 44
DSC-EX control pendant 214 832 44
DSE10-C control pendant 214 998 44
DC tandem box 211 108 44
VG11-34 EU11-34 dual-output gearbox 211 122 44
DC 1 - 15 guide plate accessories 211 095 44
DSC strain relief device 211 092 44
Test and inspection booklet DC test and inspection booklet 214 745 44
Certificates 235 309 44
Tab. 3
1.3 Symbols/signal words
Important safety information and instructions are marked by corresponding symbols and signal words in these in‐
structions.
Safety instructions and information must be followed. Exercise particular caution to ensure that accidents, injuries
and damage are avoided in such cases.
Locally applicable accident prevention regulations and general safety regulations must also be followed.
1) The documents can be ordered from the relevant Demag office.
214 802 44/291113
7

The following symbols and instructions warn against possible injuries or damage and are intended to assist you in
your work.
DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
WARNING
This symbol indicates a possibly hazardous situation which might result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
CAUTION
This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage.
– Follow these instructions at all times and be particularly careful and cautious.
Operating hazard for the machine.
● This symbol indicates information on the appropriate use of the machine.
● This symbol in the operating instructions indicates all warnings which, if not complied with, may result in mal‐
functions or damage.
1.4 Information on the operating instructions
These operating instructions are designed to provide the owner and operator with useful instructions for transport‐
ing, putting into service, operating and maintaining our chain hoists. These operating instructions are an integral
part of the machine.
Persons entrusted with the various types of work must know and comply with the safety regulations and the oper‐
ating instructions.
The machine may only be operated by personnel who are fully familiar with the operating instructions. In particu‐
lar, they contain the "Safety" section and the relevant safety instructions in the working sections of these operat‐
ing instructions.
The operating instructions must be available to operating personnel at all times to prevent operating errors and to
ensure smooth and trouble-free operation of our products. They must be kept in the immediate vicinity.
Demag chain hoists are delivered ready for operation as a complete machine with a control pendant or as partly
completed machinery without a control pendant.
Complete machine
Based on Machinery Directive 2006/42/EC, the chain hoist is also designated as a machine in the sense of a
complete machine in the following.
For a chain hoist delivered ready for operation in the sense of a complete machine, we confirm conformity with
the requirements of Directive 2006/42/EC by means of the attached EC declaration of conformity.
Partly completed machinery
These instructions inform the manufacturer of an installation with a chain hoist about:
● basic technical information,
● some typical risks,
● the assembly and operation of the chain hoist.
The instructions contained in this document may be used as the basis for the risk assessment and operating in‐
structions which must be compiled by the manufacturer of the installation in compliance with the Machinery Direc‐
tive.
8
214 802 44/291113

For operation of the installation, the manufacturer of the installation must provide additional operating instructions
as the result of the risk assessment, as required, and inform the owner about any remaining hazards.
A declaration of incorporation is enclosed for a chain hoist supplied as partly completed machinery which is as‐
sembled with additional parts to form a machine that is ready for operation. The declaration of incorporation refers
to the scope of delivery of the partly completed or non-assembled machinery. The owner must take additional
measures to satisfy the safety requirements for the machine before the unit is put into operation.
Installation of a partly completed or non-assembled chain hoist to create machinery ready for operation must be
carried out in compliance with the information provided by the manufacturer for the machinery. Installation and
operating instructions for the chain hoist contained in this document must be observed.
A conformity inspection in accordance with the Machinery Directive must be carried out for the assembled ma‐
chine when it is ready for operation and a declaration of conformity must be produced. The information contained
in the declaration of incorporation for the chain hoist may be used for the conformity inspection.
1.5 Liability and warranty
All information included in these instructions has been compiled on the basis of the relevant regulations, state-of-
the-art engineering principles and our many years of experience.
These instructions must be read carefully before starting any work on and with the chain hoist, especially before
it is put into service for the first time. The manufacturer assumes no liability for any damage which results from
the following:
● non-compliance with the instructions,
● inappropriate use,
● untrained personnel,
● unauthorised conversions,
● technical modifications.
Wearing parts are not subject to liability for defects.
We reserve the right to incorporate technical modifications within the scope of improving the operating character‐
istics and further development of the product.
1.6 Copyright
These instructions are only intended to be used by people who work with or on the chain hoist.
Any and all content, texts, drawings, images and any other information are protected within the sense of copyright
law and are subject to further industrial rights. Any misuse is an offence.
No part of this documentation, in whole or in part, may be reproduced, distributed, shown in public or used in any
other way without specific prior consent. Infringements are an offence resulting in obligatory compensatory dam‐
ages. Further rights reserved.
All industrial rights reserved.
1.7 Use of spare parts
We urgently recommend that only spare parts and accessories approved by us be used. Only then can we ensure
the safety and normal service life of the installation.
Spare parts not approved by us may cause unpredictable hazards, damage, malfunctions or complete failure of
the chain hoist.
The use of unauthorised spare parts may render null and void any claims for warranty, service, damages or liabili‐
ty against the manufacturer or his appointed personnel, dealers and representatives.
214 802 44/291113
9

1.8 Definition of personnel
The manufacturer is the person who:
1. manufactures the equipment under his or her own name and places it on the market for the first time;
2. resells other manufacturers' equipment under his or her own name, whereby the reseller is not considered to
be the manufacturer provided the name of the manufacturer (as in 1.) appears on the equipment;
3. imports the equipment into the country and places it on the market for the first time or
4. exports equipment to another member state of the European Union and hands it over direct to a user in that
country.
Owner
Owners (employer, company) are defined as persons who own the machine and who use it as intended or allow it
to be operated by suitable and trained persons.
Operating personnel/operator
Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper‐
ate the machine. This person must be trained by the owner in accordance with the tasks to be performed.
Trained person
Trained persons are defined as persons who have been instructed and trained for the tasks assigned to them and
on the possible hazards resulting from inappropriate conduct. Personnel must be informed about the required pro‐
tective devices, protective measures, relevant regulations, codes of practice, accident prevention regulations and
operating conditions and must provide verification of their competence. This person must be trained by the owner
in accordance with the tasks to be performed.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks,
such as installation, setting-up, maintenance and fault elimination. This person must be trained by the owner in
accordance with the tasks to be performed.
Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of
electric machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. This person must be
trained by the owner in accordance with the tasks to be performed.
Experienced technician
Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐
cient knowledge in the field of the machine. They must be familiar with the relevant national industrial safety regu‐
lations, codes of practice, accident prevention regulations, directives and generally accepted engineering stand‐
ards enabling them to judge the safe operating condition of machines.
Assigned expert engineer (in the Federal Republic of Germany according to BGV D8, Section 23, for determining
the S.W.P.)
An assigned expert engineer is defined as an experienced technician specifically assigned by the manufacturer to
determine the remaining duration of service (service life) of the machine (S.W.P. = safe working period) and to
carry out a general overhaul of the machine.
Authorised expert engineer (according to BGV D6, Section 28 in the Federal Republic of Germany)
In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorised expert engi‐
neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers’ Mu‐
tual Insurance Association.
1.9 Test and inspection booklet
A test and inspection booklet filled in with all details must be available for the hoist (according to BGV D6 Section
28 in the Federal Republic of Germany). The results of the regular tests and inspections must be entered into the
test and inspection booklet and must be certified by the inspector. Test and inspection booklet order no.:
 Tab. 3, Page 7.
1.10 After-sales service
If you have any questions on our products or need technical information, please contact our after-sales service.
10
214 802 44/291113

Please keep the serial or order number (see test and inspection booklet, load capacity plate on the crane) for any
correspondence or spare part orders. Specifying this data ensures that you receive the correct information or the
required spare parts.
Demag Cranes & Components GmbH
Telephone: [phone]
www.demagcranes.com
214 802 44/291113
11

2Safety
2.1 General information on safety
The "Safety" chapter provides an overview of all important safety aspects for optimum protection of personnel as
well as for safe and reliable operation of the machine.
When it is placed on the market, the machine is built according to generally accepted engineering standards and
is considered to be safe to operate. It may still be a cause of danger if it is not used correctly or as intended by
suitably trained personnel.
Knowledge of the contents of the operating instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the machine safely and reliably.
Any conversions, modifications or additions to the machine are prohibited unless approved by Demag in writing.
2.2 Safety signs on the equipment
Fig. 2
Any pictograms, signs or labels on the machine must be obeyed and
must not be removed. Pictograms, signs or labels that are damaged or
no longer legible must be replaced immediately.
2.3 Intended use
The machine may only be used as intended and in compliance with the requirements for the owner and the fol‐
lowing limitations as specified in these operating instructions. Any other use may result in a danger to life and limb
and/or cause damage to the machine and/or load.
● Chain hoists are only intended for lifting, lowering and moving loads and may be used as stationary or travel‐
ling units.
● The suspension/support structure for the chain hoist must be designed to accommodate loads resulting from
operation of the chain hoist. The maximum safe working load is the load capacity specified on the capacity
plate. This must not be exceeded. The maximum permitted load capacity of the chain hoist includes the load
and any load handling attachment.
● The machine may only be installed, used, operated, maintained and removed by trained personnel when it is in
perfect working order. Personnel must meet the requirements according to  "Operating personnel require‐
ments", Page 14.
● Intended use includes compliance with the safety instructions as well as any other instructions on assembly
and disassembly, commissioning, function and operation, maintenance and fault elimination as well as compli‐
ance with the instructions on the machine safety devices, any possible remaining hazards and protection
against hazards.
●The machine may only be used subject to the permissible technical data,  "Technical data", Page 17.
● The machine must be maintained regularly and appropriately by trained personnel in line with the specified
deadlines and checked according to  "Maintenance schedule", Page 68. Wearing parts must be replaced in
good time.
● UVV/BGV D8, Section 23 (2) and BGV D6 (1) guidelines must be not be ignored.
No liability for inappropriate use
The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐
ceptable according to these operating instructions. In particular, the manufacturer assumes no liability for damage
due to inappropriate or any other prohibited use of the machine in the sense of the "Intended use" section.
No liability for structural modifications
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of de‐
livery, or the installation or use of third-party accessories, equipment or sub-assemblies that are not approved by
the manufacturer.
12
214 802 44/291113

Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by an
expert engineer before it is handed over to the owner.
DC chain hoists are designed for operation at temperatures from - 20 °C to + 45 °C. At extreme temperatures and
in aggressive atmospheres or conditions differing from those specified in the "Operating conditions" section, the
owner must implement special measures after consulting Demag.
Use of the control pendant
Powered lifting and lowering and, if applicable, cross-travel and long-travel motions are controlled by means of
the corresponding control elements on the control unit. The slow speeds are intended for attaching the load, lifting
it free and depositing it. Loads can be precisely positioned at slow speeds.
Short transport times can be achieved at higher speeds. They are suitable for travelling without a load or with a
safely suspended load if no hazard can be caused by the faster motion sequences.
Inching (flick switching) must be avoided, as it causes increased wear and load sway.
2.4 Hazards that can be caused by the machine
The machine has been subjected to a risk analysis. The design and execution based on this analysis corresponds
to state-of-the-art engineering principles. However, residual risks remain.
DANGER
Live components
Danger to life and limb.
Electric energy may cause very severe injuries. Danger of death caused by electric current if the insulation or
individual components are damaged.
– Switch the machine off and secure it against restoration of the power supply before any maintenance,
cleaning or repair work is carried out.
– Switch the power supply off before any work is carried out on the electric equipment. Check to ensure that
the components to be replaced are de-energised.
– Do not remove any safety equipment or render it inoperative by modifications.
WARNING
Crushing hazard
Body parts can be crushed when loads are lifted or lowered.
Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered.
WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
Keep out of the danger zone at all times
– Keep a sufficient safety distance.
– Never step under a suspended load.
Certain work and practices are prohibited when using the machine as they may involve danger to life and limb
and result in lasting damage to the machine. Observe the safety instructions in the sections:
● "Assembly", Page 32
● "Putting into service for the first time", Page 53
● "Operation", Page 55
● "Maintenance/repair", Page 62
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2.5 Responsibility of the owner
Information on safety at work refers to the regulations of the European Union that apply when the machine is
manufactured. The owner is obliged to ensure that the specified industrial safety measures comply with the latest
rules and regulations and to observe new regulations during the entire service life of the machine. Local industrial
safety legislation and regional regulations and codes of practice applicable at the site of operation of the machine
must be observed outside the European Union.
General safety, accident prevention and environmental protection regulations that apply where the machine is in
operation must be observed and complied with in addition to the safety instructions contained in these operating
instructions.
The owner and any personnel authorised by him are responsible for correct operation of the machine and for
clearly defining responsibilities for installation, operation, maintenance and cleaning. The operating instructions
must be followed in full and without any limitations.
Special local conditions or applications may lead to situations which are not considered in these operating instruc‐
tions. In such cases, the required safety measures must be defined and implemented by the owner. Necessary
measures may also relate, for example, to the handling of hazardous materials or tools and the provision/wearing
of personal protection equipment. The operating instructions must, if required, be supplemented by the owner with
instructions relating to organisation of work, working procedures, authorised personnel, supervising and reporting
obligations, etc. For further information, see  "Safety instructions for operation", Page 55.
Furthermore, the owner must ensure that
● any further working and safety instructions resulting from the hazard assessment of the machine workplaces
are specified in operating procedures.
● personnel who work with or on the machine are provided with appropriate first-aid equipment. Personnel must
be trained in the use of the first-aid equipment.
● the operating instructions are always kept available in the immediate vicinity of the machine for installation, op‐
erating, maintenance and cleaning personnel.
● personnel are trained in accordance with the work to be performed.
● the machine is only operated when in safe and proper working order.
● the safety devices are always kept freely accessible and are checked regularly.
● national regulations for the use of cranes and lifting appliances are observed.
● any specified regular checks and inspections are carried out on time and are documented.
The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these
instructions at a suitable place where they can be easily seen.
2.6 Operating personnel requirements
Only authorised and trained personnel may work on the installation. The personnel must have received instruction
on the installation functions and any hazards that may occur.
Every individual given the task of working on or with the installation must have read and understood the instruc‐
tions before any work starts.
Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with
the installation.
Age and job-specific regulations relevant at the place where the installation is operated must be observed for the
selection of any personnel.
Personnel are obliged to report to the owner without delay any changes to the installation that impair safety.
For independent operation (operator) or maintenance (trained maintenance fitter) of the installation, the owner
may only employ persons
● who are at least 18 years of age,
● who are mentally and physically suitable,
● who have been instructed in the operation and maintenance of the installation and who have proven their quali‐
fication to the owner in this respect.
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2.7 Personal protection equipment
When work is carried out on or with the installation, the following protective equipment is recommended to be
worn according to the owner's hazard assessment:
● Protective clothing, closely fitting working clothes (low tear strength, no loose sleeves, no rings or any other
jewellery, etc.);
● Safety shoes to protect against falling parts and against slipping;
● Safety helmet to be worn by everybody in the danger zone.
2.8 Emergency-stop device
Fig. 3 Position of the emergency stop (1)
The machine is fitted with an emergency-stop device (1) to prevent damage and injuries. This is located on the
control unit. The emergency-stop operating function must be checked regularly.
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2.9 Regular inspections
The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation
and regional regulations. In Germany, this is specified by the accident prevention regulations for winches, hoists
and towing devices (BGV D8) and the accident prevention regulations for cranes (BGV D6), for example. These
specify that
● the machine must be inspected before it is put into operation,
● the machine must be inspected regularly,
● the elapsed share of the theoretical safe working period must be calculated,
● a record of tests and inspections must be kept.
The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe
new regulations at all times.
If no comparable inspection regulations or requirements apply at the place where the machine is operated, we
recommend compliance with the above-mentioned regulations.
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3 Technical data
3.1 Design overview
Fig. 4 Single-fall design
Item Designation Item Designation Item Designation
1 Electric equipment cover 11 Chain guide 21 Adjusting mechanism for control cable
2 Control system 12 Chain sprocket 22 Cut-off buffer for operating limit switch
2)
3 Elapsed operating time counter 13 Round section steel chain 23 Hook assembly with load capacity
plate 2)
4Window 2) 14 Slipping clutch 24 Motor shaft
5 Pulse wheel for speed monitoring 15 Dished washer pack 25 Winding head cap
6 Magnet brake 16 Slipping clutch adjusting nut 26 Stator
7 Brake disc with linings 17 DC 1 - 5 two-stage helical gearbox
DC 10 three-stage helical gearbox 27 Rotor
8 Brake springs 18 Suspension bracket 28 Fan
9 Brake magnet 19 Suspension pin 29 Fan cover
10 Gearbox housing 20 Service cover 30 Mounting points
Tab. 4
2) Illustration differs from scope of delivery
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3.2 Model code
E K L D DC-Com 10 - 2000 2/1 H5 V6/1,5 380 - 415 / 50 24/6 200 220 - 480
Travel drive voltage range/
voltage [V]
Max. flange width of the trolley [mm]
Travel speed [m/min]
Frequency [Hz]
Chain hoist voltage range [V]
Lifting speed [m/min]
V 2-stage= Main/creep lifting
VS Stepless = VS at nominal load up to VS
max
in the partial load range
Hook path [m]
Reeving
Load capacity [kg]
Size 3)
DC-Pro product range DC-Pro product range
DC-Pro 2-stage chain hoist (Demag chain hoist) DC-ProDC 2-stage chain hoist for direct control
DCM-Pro 2-stage Manulift DC-ProCC 2-stage chain hoist for conventional contac‐
tor control
DCS-Pro Variable-speed chain hoist
DCMS-Pro Variable-speed Manulift DC-ProFC Variable-speed chain hoist for control by
means of an external frequency inverter
DCRS-Pro Stepless rocker switch
DC-Com product range
DC-Com 2-stage chain hoist
DArticulated trolley
L Long trolley
K Low-headroom hoist
U Standard-headroom monorail hoist
11 Trolley size load capacity [kg • 100]
22
34
56
R Push-travel trolley
E Travel drive
C F 5 Click-fit (push-travel trolley)
Tab. 5
Not all features of the mounting code can be combined.
3) Since 04/2006, the designation for sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 respectively.
18
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3.3 Selection table
Load ca‐
pacity
Size 4) Reeving Group of mechanisms 5)
DIN EN 14492
Chain size Lifting speed Standard
hook path 6)
Motor size 7) Max. weight
for hook path
Chain
hoist
from 01/2014 until 12/2013 at 50 Hz at 60 Hz H 4 m 5 m 8 m
[kg] DC-Com FEM/ISO FEM/ISO [mm] [m/min] [m/min] [m] [kg] [kg] [kg]
80
1
1/1
4m/M7 3m/M6
4,2x12,2
8,0/2,0 9,6/2,4
4, 5 and 8
ZNK 71 A 8/2 8)
21 22 24
100
3m/M6 2m/M5125
160
2 6,0/1,5 7,2/1,8 ZNK 71 B 8/2
200 2m/M5 1Am / M4
250
315
5
3m/M6 2m/M5
5,3x15,2 4,5/1,1 5,4/1,3 ZNK 80 A 8/2 27 28 30400 2m/M5 1Am / M4
500
630
10
3m/M6 2m/M5
7,4x21,2 4,0/1,0 4,8/1,2
ZNK 100 A 8/2 47 48 52800 2m/M5 1Am / M4
1000
1250
2/1
3m/M6 2m/M5
ZNK 100 B 8/2 63 65 731600 2m/M5 1Am / M4
2000
Tab. 6
Lifting speeds until 09/2008 (no longer available)
Load ca‐
pacity
Size Reeving Group of mecha‐
nisms
Chain size Lifting speed Standard
hook path 6)
Motor size 7) Max. weight
for hook path
Chain
hoist
DIN EN 14492 at 50 Hz at 60 Hz H 4 m 5 m 8 m
[kg] DC-Com FEM/ISO [mm] [m/min] [m/min] [m] [kg] [kg] [kg]
160
2
1/1
2m/M5
4,2x12,2
4,0/2,0 4,8/2,4 4, 5 and 8
ZNK 71 B 8/4 21 22 24200 1Am / M4
250
315
5
2m/M5
5,3x15,2 ZNK 80 A 8/4 27 28 30
400 1Am / M4
500
Tab. 7
4) Since 04/2006, the designation for sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 respectively.
5) Replacement gearboxes for DC-Com units delivered until 12/2013 will be supplied with higher FEM classification as of 01/2014.
6) Larger hook paths on request.
7) Motor key data  "Hoist motor data", Page 20.
8) ZNK 71 A 8/2 with 380-415 V / 50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.
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3.4 Electric key data
3.4.1 Hoist motor data
Size Motor size No. of
poles
P
N
CDF
9)
n
N
Starts/h Min./max. currents and start-up current
I
N min.
I
N max.
I
max.
10) I
A
/I
N max.
cos
φN
[kW] [%] [rpm] [A] [A] [A]
220-240 V, 50 Hz, 3 ~ (CE) 11)
DC-Com 1 ZNK 71 B 8/2 8 0,05 20 720 240 1,75 2,10 2,10 1,45 0,48
2 0,18 40 2950 120 2,10 2,80 2,80 2,75 0,46
DC-Com 2 ZNK 71 B 8/2 8 0,07 20 695 240 1,80 2,10 2,35 1,45 0,52
2 0,30 40 2880 120 2,30 2,80 3,20 2,75 0,55
DC-Com 5 ZNK 80 A 8/2 8 0,10 20 720 240 1,90 1,90 2,15 2,50 0,46
2 0,41 40 2910 120 3,60 4,70 5,50 4,70 0,49
DC-Com 10
ZNK 100 A 8/2 8 0,19 20 705 240 2,80 3,10 3,65 1,90 0,48
2 0,75 40 2850 120 3,50 4,00 4,50 4,85 0,65
ZNK 100 B 8/2 8 0,37 20 735 240 -
2 1,50 40 2955 120
380-415 V, 50 Hz, 3 ~ (CE) 11)
DC-Com 1
ZNK 71 A 8/2 12) 8 0,05 20 700 240 0,95 1,10 1,10 1,20 0,66
2 0,18 40 2840 120 1,20 1,40 1,40 2,60 0,57
ZNK 71 B 8/2 8 0,05 20 700 240 1,00 1,20 1,20 1,45 0,48
2 0,18 40 2840 120 1,20 1,60 1,60 2,75 0,46
DC-Com 2 ZNK 71 B 8/2 8 0,10 20 675 240 1,00 1,20 1,35 1,45 0,52
2 0,37 40 2825 120 1,30 1,60 1,85 2,75 0,55
DC-Com 5 ZNK 80 A 8/2 8 0,18 20 665 240 1,10 1,10 1,25 2,50 0,46
2 0,72 40 2745 120 2,10 2,70 3,20 4,70 0,49
DC-Com 10
ZNK 100 A 8/2 8 0,27 20 690 240 1,60 1,80 2,10 1,90 0,48
2 1,10 40 2745 120 2,00 2,30 2,60 4,85 0,65
ZNK 100 B 8/2 8 0,57 20 675 240 3,90 4,60 5,40 2,30 0,42
2 2,30 40 2790 120 5,40 6,30 7,70 5,10 0,49
500-525 V, 50 Hz, 3 ~ (CE) 11)
DC-Com 1 ZNK 71 B 8/2 8 0,05 20 720 240 0,75 0,95 0,95 1,45 0,48
2 0,18 40 2925 120 0,90 1,25 1,25 2,75 0,46
DC-Com 2 ZNK 71 B 8/2 8 0,10 20 675 240 0,80 0,95 1,10 1,45 0,52
2 0,37 40 2825 120 1,10 1,25 1,45 2,75 0,55
DC-Com 5 ZNK 80 A 8/2 8 0,18 20 665 240 0,90 0,90 1,00 2,50 0,46
2 0,72 40 2745 120 1,70 2,15 2,55 4,70 0,49
DC-Com 10
ZNK 100 A 8/2 8 0,27 20 690 240 1,30 1,40 1,70 1,90 0,48
2 1,10 40 2745 120 1,70 1,80 2,00 4,85 0,65
ZNK 100 B 8/2 8 0,57 20 675 240 3,30 3,70 4,30 2,27 0,42
2 2,30 40 2790 120 4,15 5,00 6,10 5,13 0,49
Tab. 8
9) DC-Com 2–10 CDF 15/25% until 12/2013
10) I
max
= maximum rated current for lowering motion.
11) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2 % are possible. Motors are rated to insulation class F.
12) ZNK 71 A 8/2 with 380-415 V / 50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.
20
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