Table of contents

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

2 Safety ...................................................................................................................................................................... .. 11
2.1 General information on safety ................................................................................................................................. .. 11
2.2 Safety signs on the equipment ................................................................................................................................ .. 11
2.3 Intended use............................................................................................................................................................ .. 11
2.4 Hazards that can be caused by the machine .......................................................................................................... .. 12
2.5 Responsibility of the owner ..................................................................................................................................... .. 13
2.6 Operating personnel requirements.......................................................................................................................... .. 13
2.7 Personal protection equipment................................................................................................................................ .. 14
2.8 Emergency-stop device........................................................................................................................................... .. 15
2.9 Regular inspections................................................................................................................................................. .. 15

3 Technical data ......................................................................................................................................................... .. 16

3.1 Design overview ...................................................................................................................................................... .. 16
3.2 Model code.............................................................................................................................................................. .. 17
3.3 Selection tables ....................................................................................................................................................... .. 18
3.3.1 DC-Pro .................................................................................................................................................................... .. 18
3.3.2 DC-Com .................................................................................................................................................................. .. 19
3.4 Electric key data ...................................................................................................................................................... .. 19
3.4.1 DC-Pro .................................................................................................................................................................... .. 19
3.4.1.1 Hoist motor data ..................................................................................................................................................... .. 19
3.4.1.2 Mains connection delay fuse links and supply lines ................................................................................................ .. 21
3.4.2 DC-Com .................................................................................................................................................................. .. 21
3.4.2.1 Hoist motor data ...................................................................................................................................................... .. 21
3.4.2.2 Mains connection delay fuse links and supply lines ................................................................................................ .. 23
3.5 Dimensions.............................................................................................................................................................. .. 23
3.6 Noise emission/sound pressure level...................................................................................................................... .. 23
3.7 Transport, packing, scope of delivery, storage........................................................................................................ .. 24
3.8 Materials.................................................................................................................................................................. .. 25
3.9 Operating conditions ............................................................................................................................................... .. 25

4 Technical description............................................................................................................................................... .. 26
4.1 Drive and brake ....................................................................................................................................................... .. 26
4.2 Gearbox and slipping clutch ................................................................................................................................... .. 26
4.3 Chain drive ............................................................................................................................................................. .. 26
4.4 Electric equipment................................................................................................................................................... .. 26
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4.4.1 Control system ........................................................................................................................................................ .. 26

4.4.2 7-segment display for operating status and fault display ........................................................................................ .. 27
4.4.3 Display of software version, operating hours, number of cycles ............................................................................. .. 28
4.5 Central service enclosure........................................................................................................................................ .. 28 3
 4.6 Control pendant/control cable height adjustment ...................................................................................................... 29
4.7 Control pendant......................................................................................................................................................... 29

5 Assembly................................................................................................................................................................... 30
5.1 General...................................................................................................................................................................... 30
5.2 Safety instructions for assembly................................................................................................................................ 30
5.3 Chain hoist tightening torques................................................................................................................................... 32
5.4 Installation procedure ................................................................................................................................................ 32
5.5 Connecting the control pendant ................................................................................................................................ 33
5.6 Control cable ............................................................................................................................................................. 34
5.6.1 Control cable technical data ...................................................................................................................................... 34
5.6.2 Handling the control cable......................................................................................................................................... 34
5.6.3 Control pendant height adjustment ........................................................................................................................... 35
5.6.4 Installing the support sleeve on DSC, DSK or DST control pendants....................................................................... 36
5.6.5 Mobile control system................................................................................................................................................ 38
5.7 Suspending the chain hoist ....................................................................................................................................... 39
5.7.1 Safety information for suspending the chain hoist..................................................................................................... 39
5.7.2 Supporting structure .................................................................................................................................................. 39
5.7.3 Suspension bracket................................................................................................................................................... 40
5.8 Plug screw, vent valve............................................................................................................................................... 40
5.9 Mains connection ...................................................................................................................................................... 42
5.10 Circuit diagrams and control boards.......................................................................................................................... 44
5.10.1 General information on the circuit diagrams.............................................................................................................. 44
5.10.2 DC 1 - 15 solo hoist circuit diagram .......................................................................................................................... 45
5.10.3 Control board............................................................................................................................................................. 48
5.11 Programming parameters with the control pendant .................................................................................................. 49
5.11.1 General...................................................................................................................................................................... 49
5.11.2 Meaning of the buttons.............................................................................................................................................. 50
5.11.3 Meaning of the parameters ....................................................................................................................................... 50
5.11.4 Starting parameter-programming mode .................................................................................................................... 50
5.12 Adjusting the lower hook position.............................................................................................................................. 52

6 Putting into service for the first time .......................................................................................................................... 53

6.1 Safety instructions when putting into service for the first time................................................................................... 53
6.2 Inspection regulations ............................................................................................................................................... 53
6.3 Inspections before putting into service for the first time ............................................................................................ 54
6.4 Checks on entering service, handover ...................................................................................................................... 54

7 Operation................................................................................................................................................................... 55
7.1 Safety instructions for operation................................................................................................................................ 55
7.2 Switching on .............................................................................................................................................................. 56
7.2.1 Checks when starting work ....................................................................................................................................... 56
7.2.2 Function checks ........................................................................................................................................................ 56
7.3 Operation................................................................................................................................................................... 57
7.3.1 Safety during operation ............................................................................................................................................. 57
7.3.2 Load pick-up.............................................................................................................................................................. 58
7.3.3 Moving the load ......................................................................................................................................................... 58
7.3.4 Load distribution ........................................................................................................................................................ 59
7.3.5 Emergency-stop device operating function ............................................................................................................... 59
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7.3.6 Slipping clutch operating function.............................................................................................................................. 59

7.3.7 Lifting path limiter operating function......................................................................................................................... 59
7.4 Emergency stop ........................................................................................................................................................ 60
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 7.5 Taking the equipment out of operation.................................................................................................................... .. 61
7.5.1 Taking the equipment out of service when faults occur .......................................................................................... .. 61
7.5.2 Taking the equipment out of service at the end of the shift..................................................................................... .. 61
7.5.3 Taking the equipment out of service for maintenance and repairs.......................................................................... .. 61
8 Maintenance/repair.................................................................................................................................................. .. 62
8.1 Safety instructions for maintenance and repair work .............................................................................................. .. 62
8.2 Basic maintenance requirements ............................................................................................................................ .. 63
8.3 Regular inspections................................................................................................................................................. .. 64
8.3.1 Required tests and inspections ............................................................................................................................... .. 64
8.3.2 Special operating conditions ................................................................................................................................... .. 64
8.3.3 Service life of the contactor ..................................................................................................................................... .. 64
8.3.4 S.W.P. measures for achieving safe working periods ............................................................................................. .. 65
8.3.4.1 General.................................................................................................................................................................... .. 65
8.3.4.2 Calculating the actual duration of service S ............................................................................................................ .. 66
8.3.4.3 Example: DC-Pro 10-1250 1/1 H5 V8/2 in 1Am ...................................................................................................... .. 66
8.3.5 GO general overhaul ............................................................................................................................................... .. 68
8.4 Maintenance schedule ............................................................................................................................................ .. 68
8.5 Maintenance work ................................................................................................................................................... .. 70
8.5.1 Suspension.............................................................................................................................................................. .. 70
8.5.2 Electric equipment cover ......................................................................................................................................... .. 70
8.5.3 Removing the chain collector box ........................................................................................................................... .. 71
8.5.4 Operating limit switches (standard for DC-Pro 1-15 and DC-Com 10 with 2/1 reeving) ......................................... .. 72
8.5.4.1 Checking operating limit switches ........................................................................................................................... .. 72
8.5.4.2 Checking the operating limit switch actuator ........................................................................................................... .. 72
8.5.5 Chain drive .............................................................................................................................................................. .. 73
8.5.5.1 Checking the sprocket wheel .................................................................................................................................. .. 73
8.5.5.2 Checking the chain guide ........................................................................................................................................ .. 73
8.5.5.3 Checking the guide plate/chain entry plate ............................................................................................................. .. 74
8.5.5.4 Checking the hoist chain ......................................................................................................................................... .. 74
8.5.5.5 Chain set scope of supply ....................................................................................................................................... .. 76
8.5.5.6 Available hoist chains.............................................................................................................................................. .. 77
8.5.5.7 Replacing the chain set ........................................................................................................................................... .. 78
8.5.5.8 Lubricating the hoist chain....................................................................................................................................... .. 82
8.5.6 Load hook................................................................................................................................................................ .. 84
8.5.6.1 Checking the load hook........................................................................................................................................... .. 84
8.5.6.2 DC-Pro hook safety catch ....................................................................................................................................... .. 84
8.5.6.3 Checking the return sprocket .................................................................................................................................. .. 84
8.5.6.4 Replacing DC-Pro hook with fittings for 1/1 reeving................................................................................................ .. 85
8.5.6.5 Replacing DC-Com hook with fittings for 1/1 reeving.............................................................................................. .. 86
8.5.6.6 Replacing bottom block with external cut-off springs, 2/1 reeving .......................................................................... .. 87
8.5.7 Buffers ..................................................................................................................................................................... .. 87
8.5.7.1 Checking the cut-off buffers/cut-off springs............................................................................................................. .. 87
8.5.7.2 Buffer/cut-off spring arrangement............................................................................................................................ .. 88
8.5.8 Brake ....................................................................................................................................................................... .. 90
8.5.8.1 Brake assignment.................................................................................................................................................... .. 90
8.5.8.2 Check brake wear ................................................................................................................................................... .. 90
8.5.9 Slipping clutch ......................................................................................................................................................... .. 91
8.5.9.1 Checking the slipping clutch.................................................................................................................................... .. 91
8.5.9.2 Adjusting the slipping clutch .................................................................................................................................... .. 92
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8.5.10 Gearbox/oil change ................................................................................................................................................. .. 92

8.5.11 Replacing the contactor on the control board.......................................................................................................... .. 94
8.5.12 Replacing the relay on the control board................................................................................................................. .. 95
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 8.5.13 Replacing the control cable .................................................................................................................................... ... 96
9 Malfunctions/warnings............................................................................................................................................ ... 98
9.1 Safety instructions for malfunctions/warnings ........................................................................................................ ... 98
9.2 7-segment display .................................................................................................................................................. ... 98
9.3 Operating statuses/general messages................................................................................................................... ... 99
9.4 Warning messages.................................................................................................................................................. 100
9.5 Error messages ....................................................................................................................................................... 101

10 Disassembly/disposal .............................................................................................................................................. 102

10.1 General.................................................................................................................................................................... 102

11 Spare parts.............................................................................................................................................................. 103

11.1 Motor ....................................................................................................................................................................... 103
11.2 Parts on the DC 1-10 gearbox................................................................................................................................. 104
11.3 Parts on the DC-Pro 15 gearbox ............................................................................................................................. 106
11.4 Chain drive .............................................................................................................................................................. 108
11.5 DC-Pro hook assembly ........................................................................................................................................... 110
11.6 DC-Com hook assembly ......................................................................................................................................... 111
11.7 DC 10 bottom block with external cut-off springs .................................................................................................... 112
11.8 DC-Pro 15 bottom block with external cut-off springs ............................................................................................. 113
11.9 Electric equipment cover ......................................................................................................................................... 114
11.10 Control pendant, control cable, service cover ......................................................................................................... 115
Index......................................................................................................................................................................................... 116

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