Instrucciones de Operacion Biriel

Operating instructions
Demag DMR modular rope hoist

Double-rail crab
EZ-DMR 5 – 16
43718344_xml.eps
170619 en GB 211 395 44 720 IS 813

Original operating instructions
Manufacturer:
Demag Cranes & Components GmbH
Forststrasse 16
40597 Düsseldorf, Germany
www.demagcranes.com
Email: info@demagcranes.com
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DMR rope hoist and important information if you ever have to contact the manufacturer or his representative.
Owner
Where in use
Range
Serial number
Main hoist motor number
Operating voltage
Control voltage
Frequency
Circuit diagram number
Tab. 1
Further documents are available for sub-assemblies/components in addition to these operating instructions. These possible
sub-assemblies/components are listed below. The corresponding documents are supplied as necessary or can be ordered
separately.
Documents 1) Part no.:

Spare parts lists
Demag EZ-DMR 5 – 16 rope hoist 217 202 44
F-, EU-, EK-, EZ-DMR 3 – 16 SafeControl 217 207 44
F-, EU-, EK-, EZ-DMR 3 – 16 ContactorControl 217 208 44
Technical data/catalogues
Demag EZ-DMR 5 – 16 rope hoist 203 777 44
KP-S 70 and KP-S 100 clamp-fitted buffers 203 652 44
Operating, assembly, fitting instructions
ZBT/ZBC motors 211 294 44
DSE-10R control pendant 214 795 44
DST control pendant 206 165 44
DRC-10 D3 radio control unit (optional) 211 266 44
DRC-J D3 radio control unit (optional) 211 271 44
DRC-MJ D3 radio control unit (optional) 211 338 44
DMR SafeControl 211 809 44
ContactorControl (with OWL load detector) 211 377 44
OWL load detector 211 379 44
Demag log book for cranes and hoist units 206 124 44
GES3, GES4, GES5, GEK2 travel drive owner’s manual 211 366 44
Tab. 2
NOTE. The metric system is used in this document and all figures are shown with a comma as the decimal sep‐
arator.
211 395 44/170619
2 1) The documents can be ordered from the relevant Demag office.

Table of contents
1 General ....................................................................................................................................................................... 7
1.1 Information on the operating instructions .................................................................................................................... 7
1.2 Copyright ..................................................................................................................................................................... 7
1.3 Log book...................................................................................................................................................................... 7
2 Safety.......................................................................................................................................................................... 8
2.1 General........................................................................................................................................................................ 8
2.2 Structure and meaning of the instructions................................................................................................................... 8
2.2.1 Safety warnings ........................................................................................................................................................... 8
2.2.2 Structure of safety warnings ........................................................................................................................................ 8
2.2.3 Further information ...................................................................................................................................................... 8
2.3 Labels and markings on the product ........................................................................................................................... 9
2.4 Intended use................................................................................................................................................................ 9
2.5 Personnel requirements ............................................................................................................................................ 10
2.5.1 Responsibility of the owner ....................................................................................................................................... 10
2.5.2 Qualification of personnel.......................................................................................................................................... 10
2.5.3 These operating instructions are intended for the following target groups................................................................ 11
2.6 Personal protection equipment.................................................................................................................................. 11
2.7 Emergency-stop device ............................................................................................................................................. 12
2.8 Regular inspections................................................................................................................................................... 13
2.9 Inspection regulations ............................................................................................................................................... 13
3 Technical data ......................................................................................................................................................... 14

3.1 Explanation of size designations/type assignment ................................................................................................... 14
3.2 Motor data ................................................................................................................................................................. 15
3.2.1 MBV hoist motors, pole-changing ............................................................................................................................. 15
3.2.2 MBV hoist motors, inverter-controlled ....................................................................................................................... 16
3.2.3 MF cross-travel motors, inverter-controlled............................................................................................................... 18
3.3 Hook dimension C ..................................................................................................................................................... 19
3.4 Gearbox oil filling ....................................................................................................................................................... 19
3.5 Operating conditions ................................................................................................................................................. 20
3.6 Noise emission .......................................................................................................................................................... 20
3.7 Paint finish ................................................................................................................................................................. 21
3.8 Deadweight of the crab without bottom block [kg] ..................................................................................................... 21
3.9 Track girder requirements ......................................................................................................................................... 22
3.9.1 Runway ..................................................................................................................................................................... 22
3.9.2 Travel unit.................................................................................................................................................................. 23
4 Design and function ................................................................................................................................................ 24
4.1 EZ-DMR double-rail crab design overview ............................................................................................................... 24
4.2 Drives ....................................................................................................................................................................... 24
4.2.1 MBV hoist motors ...................................................................................................................................................... 24
4.2.2 Travel drive................................................................................................................................................................ 24
4.2.3 Gearbox/rope reeving components ........................................................................................................................... 24
4.3 Geared limit switch .................................................................................................................................................... 25
4.4 Control system and control pendant.......................................................................................................................... 25
4.5 Load measurement ................................................................................................................................................... 25
4.6 Type plate (example)................................................................................................................................................. 26
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5 Transport, packing, storage ................................................................................................................................... 27

5.1 Safety warnings ......................................................................................................................................................... 27
5.2 Personnel requirements ............................................................................................................................................ 27 3
5.3 Transport inspection .................................................................................................................................................. 28
5.4 Packing...................................................................................................................................................................... 28
5.5 Storage ...................................................................................................................................................................... 28
6 Installation and putting into operation for the first time...................................................................................... 29

6.1 Safety warnings......................................................................................................................................................... 29
6.2.1 Target group .............................................................................................................................................................. 30
6.3 Installing the rope hoist ............................................................................................................................................. 31
6.3.1 Safety warning........................................................................................................................................................... 31
6.3.2 Checking dimensional accuracy of the tracks ........................................................................................................... 31
6.3.2.1 Tolerance of the individual girder .............................................................................................................................. 31
6.3.2.2 Twisting ..................................................................................................................................................................... 32
6.3.2.3 Tolerance of the crab track gauge............................................................................................................................. 32
6.3.2.4 Gradient of the crab rails ........................................................................................................................................... 32
6.3.2.5 Difference in rail height.............................................................................................................................................. 33
6.3.2.6 Rail level difference ................................................................................................................................................... 33
6.3.3 Placing the rope hoist on the track ............................................................................................................................ 33
6.3.4 Fitting and adjusting the guide rollers (optional)........................................................................................................ 34
6.3.5 Fitting stops/clamp-fitted buffers ............................................................................................................................... 34
6.4 Connecting the electric equipment ............................................................................................................................ 35
6.4.1 Safety warnings......................................................................................................................................................... 35
6.4.2 Wiring ........................................................................................................................................................................ 35
6.4.2.1 General...................................................................................................................................................................... 35
6.4.2.2 Connecting the control system .................................................................................................................................. 35
6.4.2.3 Checking the direction of movement ......................................................................................................................... 36
6.5 Rope reeving ............................................................................................................................................................. 36
6.5.1 Safety warnings......................................................................................................................................................... 36
6.5.2 Reeving methods ...................................................................................................................................................... 37
6.5.3 Rope reeving of the rope hoist .................................................................................................................................. 37
6.5.4 Assembling the bottom block .................................................................................................................................... 38
6.5.5 Installing the wire rope in the rope socket ................................................................................................................. 39
6.5.6 Installing the rope socket in the crosshead with ELM load detector (Electronic Load Management) ....................... 40
6.6 Putting into operation for the first time....................................................................................................................... 41
6.6.1 Safety warnings......................................................................................................................................................... 41
6.6.2 Checks before the equipment is put into operation for the first time ......................................................................... 41
6.6.3 Inspection regulations ............................................................................................................................................... 42
6.6.4 Geared limit switches ............................................................................................................................................... 42
6.6.4.1 Safety warning........................................................................................................................................................... 42
6.6.4.2 Geared limit switch function ...................................................................................................................................... 42
6.6.4.3 Set the cut-off points ................................................................................................................................................. 44
6.6.4.4 Set the upper cut-off points ....................................................................................................................................... 44
6.6.4.5 Set the lower cut-off points........................................................................................................................................ 44
6.6.5 Checking crane structural design ............................................................................................................................. 45
6.6.5.1 Checking with SafeControl ........................................................................................................................................ 45
6.6.5.2 Checking with ContactorControl................................................................................................................................ 45
6.6.6 Travelling hoist travel characteristics and run-on paths when stopping .................................................................... 45
7 Operation ................................................................................................................................................................ 46
7.1 Safety warnings......................................................................................................................................................... 46
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7.2.1 Target group .............................................................................................................................................................. 47
7.3 Switching on .............................................................................................................................................................. 47
4
7.3.1 Checks when starting work ....................................................................................................................................... 47
7.3.2 Visual inspection ....................................................................................................................................................... 48
7.3.3 Check the limit switches ............................................................................................................................................ 48
7.3.3.1 Safety warning........................................................................................................................................................... 48
7.3.3.2 SafeControl: check using DSE-10R control pendant ................................................................................................ 48
7.3.3.3 ContactorControl: check using DST 7 and 9 control pendants ................................................................................. 49
7.3.4 Check strain relief elements of the control pendant .................................................................................................. 49
7.3.5 Check operation of the brake .................................................................................................................................... 50
7.3.6 Check hook safety catch ........................................................................................................................................... 50
7.4 Button assignment for control pendant or radio control............................................................................................. 50
7.5 Switching off ............................................................................................................................................................. 52
7.6 Stopping operation in an emergency......................................................................................................................... 52
8 Maintenance ............................................................................................................................................................ 53
8.1 Safety warnings ......................................................................................................................................................... 53
8.2.1 Target group .............................................................................................................................................................. 54
8.3 Spare parts ................................................................................................................................................................ 54
8.4 Routine inspections ................................................................................................................................................... 54
8.5 Maintenance schedule .............................................................................................................................................. 55
8.5.1 Safety warning........................................................................................................................................................... 55
8.5.2 Inspection and maintenance intervals ....................................................................................................................... 56
8.6 Wire ropes ................................................................................................................................................................. 58
8.7 Replacement criteria for the wire rope ...................................................................................................................... 59
8.7.1 Safety warning........................................................................................................................................................... 59
8.7.2 General...................................................................................................................................................................... 59
8.7.3 Replacement criteria ................................................................................................................................................. 60
8.8 Wear limits on rope drums ........................................................................................................................................ 62
8.9 Wear limits on rope sheaves ..................................................................................................................................... 63
8.10 Installing wire rope .................................................................................................................................................... 64
8.10.1 Safety warnings ......................................................................................................................................................... 64
8.10.2 Unwinding wire rope .................................................................................................................................................. 64
8.10.3 Securing the wire rope ............................................................................................................................................. 65
8.10.3.1 Fitting the wire rope ................................................................................................................................................... 65
8.10.3.2 Prepare the (reinforced) rope guide and place it on the rope drum .......................................................................... 66
8.10.3.3 Connect the rope guide segments and install side section I ..................................................................................... 67
8.10.3.4 Remove torque bracket and split pin from rope guide rollers.................................................................................... 68
8.11 Shortening the wire rope ........................................................................................................................................... 68
8.12 Lubricating the wire rope ........................................................................................................................................... 68
8.13 Regular inspections and monitoring measures for load hooks.................................................................................. 68
8.14 Wear limits on travel wheels...................................................................................................................................... 69
8.15 Oil change ................................................................................................................................................................. 70
8.15.1 Safety warnings ......................................................................................................................................................... 70
8.15.2 Oil change procedure ................................................................................................................................................ 70
8.16 Maintaining the brake on M motors ........................................................................................................................... 71
8.16.1 Safety warnings ......................................................................................................................................................... 71
8.16.2 Preparation work ....................................................................................................................................................... 71
8.16.3 Replacement when maximum service life has elapsed............................................................................................. 71
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8.16.4 Replacing the motor shaft ......................................................................................................................................... 71

8.16.5 Dismantle brake ........................................................................................................................................................ 72
8.16.6 Check brake disc ....................................................................................................................................................... 72
8.16.7 Check friction disc ..................................................................................................................................................... 73
5
8.16.8 Install brake ............................................................................................................................................................... 73
8.16.9 MBC travel motor: check friction disc and adjust air gap .......................................................................................... 74
8.17 General overhaul (GO) .............................................................................................................................................. 75
8.17.1 Safety warning........................................................................................................................................................... 75
8.17.2 Procedure for general overhaul................................................................................................................................. 75
9 Malfunctions ............................................................................................................................................................ 76
9.1 Safety warnings......................................................................................................................................................... 76
9.2.1 Target groups ............................................................................................................................................................ 76
9.3 Conduct when malfunctions occur ............................................................................................................................ 77
9.4 Conduct after malfunctions have been eliminated .................................................................................................... 77
9.4.1 Safety warning........................................................................................................................................................... 77
9.4.2 Malfunctions, causes and remedy ............................................................................................................................. 77
10 Actual duration of service ...................................................................................................................................... 78
10.1.1 Target groups ............................................................................................................................................................ 78
10.2 Calculating the actual duration of service.................................................................................................................. 78
10.2.1 General...................................................................................................................................................................... 78
10.2.2 With SafeControl system ........................................................................................................................................... 79
10.2.3 With ContactorControl system................................................................................................................................... 79
11 Tapered bore holes for fittings............................................................................................................................... 80
11.1 Arrangement and size of bore holes ......................................................................................................................... 80
12 Disposal ................................................................................................................................................................... 81
12.1.1 Target groups ............................................................................................................................................................ 81
12.2 Disassembly and disposal of the rope hoist .............................................................................................................. 81
13 Regulations, standards, directives........................................................................................................................ 82

13.1.1 Target groups ............................................................................................................................................................ 82
13.2 Inspection regulations ............................................................................................................................................... 82
14 Information............................................................................................................................................................... 83
14.1 After-sales service..................................................................................................................................................... 83
Declaration of conformity ........................................................................................................................................................ 84
Declaration of incorporation ................................................................................................................................................... 86
Index .......................................................................................................................................................................................... 87
211 395 44/170619
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1 General
1.1 Information on the operating instructions

These operating instructions are designed to provide you with instructions on safe and correct work with and
maintenance of the product.
The operating instructions must be kept in the immediate vicinity of the product and must be available to operating
personnel at all times in order to prevent operating errors and to ensure smooth and trouble-free operation of the
crane.
Every individual who works on or with the product must be familiar with the contents of the operating instructions
that refer to their relevant working area. In addition, any accident prevention regulations and safety regulations
applicable where the product is used and for use of the product also apply.
The details, information and diagrams contained in these instructions can differ from the delivered product (rea‐
sons may include: special designs, additional order options, technical modifications, etc.). If you have any ques‐
tions, please contact the manufacturer.
Note. Based on EC Machinery Directive 2006/42/EC, the rope hoist is also designated as a machine in the
sense of a complete machine in the following. This always refers to all possible DMR rope hoist types.
1.2 Copyright
Any and all content, texts, drawings, images and any other information contained in these operating instructions
are protected within the sense of copyright law.
The operating instructions are only intended to be used by people who work with or on the product.
Any use beyond this is not permitted unless approved by the manufacturer in writing.
1.3 Log book

A log book filled in with all details must be available for every Demag DMR rope hoist.
The results of the regular tests and inspections must be entered into the log book and must be certified by an
inspector. Log book part no.: see  Tab. 2, Page 2.
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2 Safety
2.1 General
The “Safety” section provides you with an overview of all important safety aspects which are necessary for your
protection and for the protection of individuals who work on or with the product.
Further task-related warnings can be found in the descriptive sections of the instructions.
2.2 Structure and meaning of the instructions
2.2.1 Safety warnings

Warnings in these instructions are marked by corresponding symbols and signal words to indicate the type and
severity of the hazard:
DANGER
This warning in combination with a symbol and signal word indicates an immediate danger that will result in se‐
vere injuries or death if it is not avoided.
WARNING
This warning in combination with a symbol and signal word indicates a potentially dangerous situation that can
result in severe injuries or death if it is not avoided.
CAUTION
This warning in combination with a symbol and signal word indicates a potentially dangerous situation that can
result in slight injuries if it is not avoided.
2.2.2 Structure of safety warnings
WARNING
Type and source of hazard
Possible consequences of the hazard
– Measures required to avoid the hazard
2.2.3 Further information

IMPORTANT. Failure to follow these instructions can result in malfunctions, damage or pollution of the environ‐
ment.
NOTE. These instructions provide useful information and tips on smooth and efficient use of the product.
211 395 44/170619
8
2.3 Labels and markings on the product
A B
2.4 in
60 mm
110 mm
4.3 in
71388345
MA
siehe Betriebsanleitung
1 see operating instructions
C D
43649345_xml.eps
Fig. 1 Labels and pictograms
A Rope retaining arrangement in rope socket C Refer to the operating instructions

1 = see operating instructions D Do not attach loads
B Attachment points
– Pay attention to any pictograms, signs or labels on the rope hoist.

– Never remove any pictograms, signs or labels on the rope hoist.
– Immediately replace any pictograms, signs or labels that are damaged or no longer legible.
2.4 Intended use

Demag DMR rope hoists are only intended for lifting and lowering loads. The load (lifted load plus load handling
attachments, etc.) must not exceed the maximum load capacity given on the load capacity plate. Intended use
also includes reading the operating instructions, compliance with all safety warnings contained in them as well as
any other instructions in the following sections.
Any other use of the rope hoist is not as intended and is forbidden. No liability is assumed by the manufacturer or
supplier for any damage resulting therefrom. In such cases, the risk is borne by the user alone.
211 395 44/170619
9
2.5 Personnel requirements
2.5.1 Responsibility of the owner
Owner
The owner is the person who operates the product for commercial purposes or lends it to third parties for use/
operation. While it is use, the owner bears legal product responsibility for the protection of individuals who work
on or with the product or any third parties.
The owner is obliged to ensure that the specified health and safety measures comply with the latest rules and
regulations and to observe new regulations over the entire service life of the product.
Special local conditions or applications can lead to situations which are not considered in these operating instruc‐
tions. In such cases, the required safety measures must be defined and implemented by the owner.
Owner’s obligations
The product is used for commercial purposes. Therefore, the owner is subject to the legal obligations for health
and safety at the place of work.
General health and safety, accident prevention and environmental protection regulations that apply where the
product is in operation must be observed and complied with in addition to the safety warnings contained in these
operating instructions.
The owner must ensure that
● he specifies any further working instructions and safety warnings in operating procedures resulting from the
hazard assessment of the workplaces in the area of the product.
● he always keeps the operating instructions available in the immediate vicinity of the product for installation, op‐
erating, maintenance and cleaning personnel.
● he trains personnel in accordance with the work to be performed.
● he only allows the product to be operated when it is in safe and proper working order.
● he always keeps the safety devices freely accessible and checks them regularly.
● he observes national regulations for use of the product.
● he performs any specified regular checks and inspections on time and documents them.
● he adequately illuminates the operating/travel area.
● he provides and uses suitable and tested load handling attachments.
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.
2.5.2 Qualification of personnel

A specialist must have the following qualifications:
● Specialist training as well as knowledge and experience
● Must have knowledge of the relevant specialist terms and regulations
● Can assess the tasks given to him or her, identify potential hazards and take suitable safety measures
211 395 44/170619
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2.5.3 These operating instructions are intended for the following target groups
Designation Activities Qualification

- Checks correct operation of the safety devices - Has been trained to operate hoists and cranes
Operator - Operates the machine - Has been informed about possible hazards resulting from in‐
appropriate conduct
- Repairs malfunctions and defects Trained specialist with mechanical and/or electrical training
- Takes the machine out of operation - Has been trained in the repair of hoists and cranes by the
Repair personnel
- Is authorised to be present in the entire surround‐ manufacturer or by a company authorised by the manufactur‐
ings of the machine er
- Performs safety-related modifications or repairs to - Trained specialist with mechanical and/or electrical training
the machine
Service personnel
- Is authorised to be present in the entire surround‐ - Has been trained to service hoists and cranes by the manu‐
ings of the machine facturer
- Can judge the safe operating condition of the ma‐ - Technical training and experience as well as sufficient knowl‐
chine edge in the field of hoists and cranes
- Training relating to relevant national industrial safety regula‐
Experienced technician tions, codes of practice, accident prevention regulations, di‐
rectives and generally accepted engineering standards ena‐
bling them to judge the safe operating condition of hoists and
cranes.
Tab. 3 Target groups
2.6 Personal protection equipment

The following protective equipment is recommended when working on or with the product:
● Safety helmet
● Protective clothing/closely fitting working clothes
● Safety shoes
● Gloves for handling the wire rope.
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2.7 Emergency-stop device
A B C D E
1 2
2
1+
1
F1 F2
2 F3
ON
I /
1 F2
I
0
43709944_xml.eps
Fig. 2 Control pendants/radio transmitters for DMR rope hoists
A DST control pendant D DRC-J(S) joystick transmitter (optional)

(Standard for ContactorControl) E DRC-MJ hand-held transmitter (optional)
B DSE-10R control pendant 1 Emergency-stop switch
(Standard for SafeControl) 2 Emergency-stop button/switch
C DRC-10 hand-held transmitter (optional)
The machine is fitted with an emergency-stop device to prevent damage and injuries. This is located on the con‐
trol unit. The emergency-stop device operating function must be checked regularly.
NOTE. Control devices used by the customer which are not supplied by Demag must be fitted with an emergen‐
cy-stop switch if they are used together with a Demag product.
211 395 44/170619
12
2.8 Regular inspections
– Comply with the instructions and requirements in section  "Inspection regulations", Page 82.
The owner of the product may be obliged to carry out further regular inspections by national health and safety
legislation and regional regulations.
This is regulated by the rules and regulations of the German Social Accident Insurance (DGUV) in the Federal
Republic of Germany, for example.
These specify that
● the machine must be inspected before it is put into operation,
● the machine must be inspected regularly,
● the elapsed share of the theoretical service life must be calculated,
● a record must be kept in a log book.
The owner is obliged to ensure that the product 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 product is operated, we rec‐
ommend compliance with the above-mentioned regulations.
The maintenance and inspection regulations as well as the specified inspection and maintenance intervals speci‐
fied in the product operating instructions must be complied with.
2.9 Inspection regulations

See section  " Regulations, standards, directives", Page 82
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3 Technical data
3.1 Explanation of size designations/type assignment

E K- DMR- 3 - –16 H20/ 10– 4/1– –Z VS 12,5–19– 380–415/50– SC - V6,3/24 - 300– A1
A or B = Mounting posi‐
tion
1–4 = Rope lead-off
F = No value
EK/EU = Flange width [mm]
EZ = Track gauge [mm]
EZ for V-type = Track gauge/
upper flange width [mm]/[mm]
Cross-travel speed [m/min]
V6,3/24 = 2-stage low/high travel speed
VS3–30 = Variable travel speed
Type of control
SC = SafeControl
CC = ContactorControl
NC = No control system
Voltage [V]/frequency [Hz]
Lifting speed [m/min]
V0,8/5 = 2-stage creep/main lifting
VS 12,5–19 = Variable lifting speed
Motor type
Z = Cylindrical-rotor motor
F = KBH conical-rotor motor with mechanical microspeed
No. of hooks
No value = Solo hook
Reeving
Hook path for selected reeving [m]
Drum length, with reference to 2/1 reeving
Load capacity [t]
Model
A = Co-axial design
No value = C-design
Size: 3; 5; 10; 16; 20
Demag rope hoist range: DMR
D = Trolley for travel on curved track
L = Longitudinal trolley arrangement
No value = Standard design
G = Basic hoist
F = Foot-mounted hoist
K = Low-headroom monorail hoist
U = Standard-headroom monorail hoist
Z = Double-rail crab
E = Electric travel trolley
Tab. 4
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14
3.2 Motor data
3.2.1 MBV hoist motors, pole-changing
The equipment is designed in accordance with the VDE regulations and the FEM design rules to meet the high
demands made on electric hoists.
Main/creep lifting F6
Motor Brake No. of PN CDF n Starts/h Rated current IN and cos cos Weight
size poles start-up current IA
[kW] % [min-1] IN [A] IA [A] φN φA [kg]
380–415 V/50 Hz
MBV 100 NM38720 12 0,50 20 400 240 3,7 5,74 0,63 0,78
31
B 12/2 DNR2 2 3,60 40 2780 120 7,8 37,36 0,85 0,83
MBV 100 NM38730 12 0,83 20 410 240 9,5 10,45 0,59 0,78
44
C 12/2 DNR2 2 5,20 40 2750 120 11,3 54,69 0,90 0,81
MBV 12 1,20 20 400 240 8,40 14,95 0,55 0,70
NM38740
112 A 57
DNR2 2 7,00 40 2840 120 15,7 95,77 0,80 0,73
12/2
MBV 132 NM38741 12 1,65 20 425 240 9,5 19,95 0,49 0,61
82
B 12/2 DNR2 2 10,50 40 2750 120 23,0 115,00 0,85 0,73
MBV 132 NM38741 12 2,50 20 420 240 14,0 25,20 0,59 0,68
86
C 12/2 DNR2 2 15,00 40 2740 120 32,0 144,00 0,87 0,67
460–480 V/60 Hz
MBV 100 NM38720 12 0,60 20 500 240 3,7 5,74 0,62 0,78
31
B 12/2 DNR2 2 4,30 40 3380 120 7,8 37,36 0,84 0,83
MBV 100 NM38730 12 1,00 20 510 240 9,5 10,45 0,58 0,78
44
C 12/2 DNR2 2 6,20 40 3350 120 11,3 54,69 0,89 0,81
MBV 12 1,45 20 500 240 9,5 14,25 0,54 0,7
NM38740
112 A 57
DNR2 2 8,40 40 3440 120 15,8 91,64 0,79 0,73
12/2
MBV 132 NM38741 12 2,00 20 525 240 9,5 19,48 0,48 0,61
82
B 12/2 DNR2 2 12,60 40 3350 120 22,5 103,50 0,84 0,73
MBV 132 NM38741 12 3,00 20 520 240 14,0 25,20 0,58 0,68
86
C 12/2 DNR2 2 18,00 40 3340 120 32,0 144,00 0,86 0,67
380 V/60 Hz
MBV 100 NM38720 12 0,60 20 500 240 4,7 7,29 0,62 0,77
31
B 12/2 DNR2 2 4,32 40 3380 120 9,9 47,42 0,84 0,82
MBV 100 NM38730 12 1,00 20 510 240 12 13,20 0,58 0,77
44
C 12/2 DNR2 2 6,24 40 3350 120 14,3 69,21 0,89 0,8
MBV 12 1,44 20 500 240 10,1 17,98 0,55 0,68
NM38740
112 A 57
DNR2 2 8,40 40 3440 120 18,9 115,29 0,79 0,69
12/2
MBV 132 NM38741 12 1,98 20 525 240 12,0 24,60 0,47 0,62
82
B 12/2 DNR2 2 12,60 40 3350 120 28,0 131,1 0,84 0,64
MBV 132 NM38741 12 3,00 20 520 240 17,7 31,86 0,58 0,68
86
C 12/2 DNR2 2 18,00 40 3340 120 40,5 182,25 0,86 0,67
440 V/60 Hz
MBV 100 NM38720 12 0,60 20 500 240 4,0 6,20 0,62 0,78
31
B 12/2 DNR2 2 4,30 40 3380 120 8,5 40,72 0,84 0,83
MBV 100 NM38730 12 1,00 20 510 240 10,4 11,44 0,58 0,78
44
C 12/2 DNR2 2 6,20 40 3350 120 12,3 59,53 0,89 0,81
MBV 12 1,45 20 500 240 10,4 18,51 0,54 0,7
NM38740
112 A 57
DNR2 2 8,40 40 3440 120 17,2 104,92 0,78 0,73
12/2
MBV 132 NM38741 12 2,00 20 525 240 10,4 21,32 0,48 0,61
82
B 12/2 DNR2 2 12,60 40 3350 120 24,5 112,70 0,84 0,73
211 395 44/170619
MBV 132 NM38741 12 3,00 20 520 240 15,3 27,54 0,58 0,68
86
C 12/2 DNR2 2 18,00 40 3340 120 35,0 157,50 0,86 0,67
500 V/50 Hz
15
Motor Brake No. of PN CDF n Starts/h Rated current IN and cos cos Weight
size poles start-up current IA
[kW] % [min-1] IN [A] IA [A] φN φA [kg]
MBV 100 NM38720 12 0,50 20 400 240 3,10 3,10 0,63 0,78
31
B 12/2 DNR2 2 3,60 40 2780 120 6,50 6,50 0,85 0,83
MBV 100 NM38730 12 0,83 20 410 240 7,90 7,90 0,59 0,78
44
C 12/2 DNR2 2 5,20 40 2750 120 9,40 9,40 0,9 0,81
MBV 12 1,20 20 400 240 7,90 7,90 0,55 0,7
NM38740
112 A 57
DNR2 2 7,20 40 2840 120 13,20 13,20 0,8 0,73
12/2
MBV 132 NM38741 12 1,65 20 425 240 7,9 7,90 0,49 0,61
82
B 12/2 DNR2 2 10,50 40 2750 120 18,8 18,80 0,85 0,73
MBV 132 NM38741 12 2,50 20 400 240 12,2 12,20 0,58 0,66
86
C 12/2 DNR2 2 15,00 40 2750 120 26,7 26,70 0,84 0,65
575 V/60 Hz
MBV 100 NM38720 12 0,60 20 500 240 3,09 3,09 0,63 0,78
31
B 12/2 DNR2 2 4,32 40 3380 120 6,51 6,51 0,85 0,83
MBV 100 NM38730 12 1,00 20 510 240 7,93 7,93 0,59 0,78
44
C 12/2 DNR2 2 6,24 40 3350 120 9,43 9,43 0,9 0,81
MBV 12 1,44 20 500 240 7,93 7,93 0,55 0,7
NM38740
112 A 57
DNR2 2 8,40 40 3440 120 13,19 13,19 0,8 0,73
12/2
MBV 132 NM38741 12 1,98 20 525 240 7,93 7,93 0,49 0,61
82
B 12/2 DNR2 2 12,60 40 3350 120 7,6 7,60 0,85 0,73
MBV 132 NM38741 12 3,00 20 500 240 12,19 12,19 0,58 0,66
86
C 12/2 DNR2 2 18,00 40 3350 120 26,71 26,71 0,84 0,65
Tab. 5
Required supply cable conductor cross-sections and fuse links
Motor type Brake Mains connection 2) delay fuse Supply lines 3) for 5% voltage drop ∆U and start-up current IA
link for for
50 Hz 400 V 50 Hz 400 V (∆U 20 V)
[A] [mm²] [m]
MBV 100 B12/2 NM38720DNR2 20 49
MBV 100 C12/2 NM38730DNR2 25 2,5 36
MBV 112 A12/2 NM38740DNR2 35 25
MBV 132 B12/2 NM38741DNR2 63 47
6
MBV 132 C12/2 NM38741DNR2 80 20
Tab. 6
3.2.2 MBV hoist motors, inverter-controlled

The equipment is designed in accordance with the VDE regulations and the FEM design rules to meet the high
demands made on electric hoists.
Inverter-fed hoist motor acceleration current= 1,2 x rated current I(A).
Inverter-fed hoist motor rated cos phi= 1,0
Motor type Brake No. of poles PN % CDF n cos Weight

[kW] [rpm] φN [kg]
Delta 220 V/50 Hz
MBV 100 A4 NM38720DNR2 4 2,2 60 1343 0,85 25,6
MBV 100 B4 NM38734DNR2 4 4,7 60 1305 0,82 42,0
MBV 112 B4 NM38746DNR2 4 17,0 60 1380 0,83 57,0
MBV 132 A4 NM38753DNR2 4 22,0 60 1372 0,88 90,0
Tab. 7
211 395 44/170619
2) Fuse links also apply in connection with a cross-travel motor.

16 3) The cable lengths are calculated on the basis of an earth-loop impedance of 200 mΩ.
Motor/frequency inverter combinations
Size Load capacity Group of mech‐ Reeving Lifting speed4) Motor type Brake Frequency in‐
DMR [t] anisms [m/min] verter
FEM/ISO DIC-4-xxx-E-
5 1,6 4m/M7 2/1 1-25-38 MBV 100 B4 NM38734DNR2 017
5 1,6 4m/M7 4/2 1-25-38 MBV 100 B4 NM38734DNR2 017
5 2 3m/M6 2/1 0,5-12,5-19 MBV 100 B4 NM38734DNR2 014
5 2 3m/M6 4/2 0,5-12,5-19 MBV 100 B4 NM38734DNR2 014
5 2 3m/M6 2/1 1-25-38 MBV 112 B4 NM38746DNR2 025
5 2 3m/M6 4/2 1-25-38 MBV 112 B4 NM38746DNR2 025
5 2,5 2m/M5 2/1 0,32-6,4-9,6 MBV 100 A4 NM38720DNR2 007
5 2,5 2m/M5 4/2 0,32-6,4-9,6 MBV 100 A4 NM38720DNR2 007
5 2,5 2m/M5 2/1 0,5-12,5-19 MBV 100 B4 NM38734DNR2 017
5 2,5 2m/M5 4/2 0,5-12,5-19 MBV 100 B4 NM38734DNR2 017
5 2,5 2m/M5 2/1 1-25-38 MBV 112 B4 NM38746DNR2 025
5 2,5 2m/M5 4/2 1-25-38 MBV 112 B4 NM38746DNR2 025
5 3,2 1Am/M4 2/1 0,32-6,4-9,6 MBV 100 A4 NM38720DNR2 014
5 3,2 1Am/M4 4/2 0,32-6,4-9,6 MBV 100 A4 NM38720DNR2 014
5 3,2 4m/M7 4/1 0,5-12,5-19 MBV 100 B4 NM38734DNR2 017
5 4 3m/M6 4/1 0,32-6,4-9,6 MBV 100 B4 NM38734DNR2 014
5 4 3m/M6 4/1 0,5-12,5-19 MBV 112 B4 NM38746DNR2 025
5 5 2m/M5 4/1 0,16-3,2-4,8 MBV 100 A4 NM38720DNR2 007
5 5 2m/M5 4/1 0,32-6,4-9,6 MBV 100 B4 NM38734DNR2 017
5 5 2m/M5 4/1 0,5-12,5-19 MBV 112 B4 NM38746DNR2 025
5 6,3 1Am/M4 4/1 0,16-3,2-4,8 MBV 100 A4 NM38720DNR2 014
10 3,2 4m/M7 5) 2/1 0,5-12,5-19 MBV 112 B4 NM38746DNR2 040
10 3,2 4m/M7 4/2 0,5-12,5-19 MBV 112 B4 NM38746DNR2 040
10 3,2 4m/M7 5) 2/1 1-25-38 MBV 112 B4 NM38746DNR2 040
10 3,2 4m/M7 4/2 1-25-38 MBV 112 B4 NM38746DNR2 040
10 4 3m/M6 2/1 0,5-12,5-19 MBV 112 B4 NM38746DNR2 025
10 4 3m/M6 4/2 0,5-12,5-19 MBV 112 B4 NM38746DNR2 025
10 4 3m/M6 2/1 1-25-38 MBV 132 A4 NM38753DNR2 040
10 4 3m/M6 4/2 1-25-38 MBV 132 A4 NM38753DNR2 040
10 5 2m/M5 2/1 0,32-6,4-9,6 MBV 100 B4 NM38734DNR2 017
10 5 2m/M5 4/2 0,32-6,4-9,6 MBV 100 B4 NM38734DNR2 017
10 5 2m/M5 2/1 0,5-12,5-19 MBV 112 B4 NM38746DNR2 025
10 5 2m/M5 4/2 0,5-12,5-19 MBV 112 B4 NM38746DNR2 025
10 5 2m/M5 2/1 1-25-38 MBV 132 A4 NM38753NR2 040
10 5 2m/M5 4/2 1-25-38 MBV 132 A4 NM38753NR2 040
10 6,3 1Am/M4 2/1 0,32-6,4-9,6 MBV 100 B4 NM38734DNR2 017
10 6,3 1Am/M4 4/2 0,32-6,4-9,6 MBV 100 B4 NM38734DNR2 017
10 6,3 1Am/M4 2/1 0,64-12,5-19,2 MBV 112 B4 NM38746DNR2 025
10 6,3 1Am/M4 4/2 0,64-12,5-19,2 MBV 112 B4 NM38746DNR2 025
10 6,3 4m/M7 4/1 0,5-12,5-19 MBV 112 B4 NM38746DNR2 040
10 8 3m/M6 4/1 0,32-6,4-9,6 MBV 112 B4 NM38746DNR2 025
10 8 3m/M6 4/1 0,5-12,5-19 MBV 132 A4 NM38753DNR2 040
10 10 2m/M5 4/1 0,16-3,2-4,8 MBV 100 B4 NM38734DNR2 017
10 10 2m/M5 4/1 0,32-6,4-9,6 MBV 112 B4 NM38746DNR2 025
10 10 2m/M5 4/1 0,5-12,5-19 MBV 132 A4 NM38753DNR2 040
10 12,5 1Am/M4 4/1 0,16-3,2-4,8 MBV 100 B4 NM38734DNR2 017
10 12,5 1Am/M4 4/1 0,32-6,4-9,6 MBV 112 B4 NM38746DNR2 025
10 13,6 1Am/M4 4/1 0,16-3,2-4,8 MBV 100 B4 NM38734DNR2 017
16 12,5 3m/M6 6/1 0,22-4,3-6,4 MBV 112 B4 NM38746DNR2 025
16 16 1Bm/M3 4/1 0,16-3,2-4,8 MBV 112 B4 NM38746DNR2 025
16 16 1Bm/M3 4/1 0,16-3,2-4,8 MBV 112 B4 NM38746DNR2 025
211 395 44/170619
16 16 2m/M5 6/1 0,22-4,3-6,4 MBV 112 B4 NM38746DNR2 040
4) Inverter-fedoperation/variable = minimum speed (min) - rated speed (rated) - ProHub speed (only with Demag frequency inverters)
5) FEM 3m reeving arrangement 17
Size Load capacity Group of mech‐ Reeving Lifting speed4) Motor type Brake Frequency in‐
DMR [t] anisms [m/min] verter
FEM/ISO DIC-4-xxx-E-
16 20 1Am/M4 8/1 0,16-3,2-4,8 MBV 112 B4 NM38746DNR2 040
MI: V47
Tab. 8
Required supply cable conductor cross-sections and fuse links
Size DMR 5 – 16 Supply lines 3) for 5% voltage drop ∆U and

Fuse 2) (time delay)
start-up current IA for
400 V/50 Hz
400 V/50 Hz (∆U 20 V)
Motor type Brake Frequency inverter [A] [mm²] [m]
DIC-4-xxx-E-
007 20 2,5 105
MBV 100 A4 NM38720DNR2
014 25 2,5 71
014 25 4 97
MBV 100 B4 NM38734DNR2
017 35 4 97
025 50 6 88
MBV 112 B4 NM38746DNR2
040 63 6 47
MBV 132 A4 NM38753DNR2 040 63 10 95
Tab. 9
Inverter input voltage: 380–480 V, 50/60 Hz

Example for calculating cross-sections Q of the conductors of cables exceeding the length indicated in the table:
ZBV 112 A4, 400 V required length 110 m
Known cross-section
6 mm2 x 110 m
Q= x required length = = 7,5 mm²
Known cable length 88 m
Tab. 10
3.2.3 MF cross-travel motors, inverter-controlled
Range Motor type Brake Frequency inverter

DIC-4-xxx-E-
2x MF06LA20P
Compact
2x MF06LA200 007
EZ-DMR 5 – 16 2x MF06LB100 DC 014
2x MF06LB200 DC 025
2x MF07XA200 DC
Tab. 11
NOTE. Two cross-travel motors are included in the Dual Drive Plus option for DMR 5 – 10. Two cross-travel
motors are always needed for DMR 10 (12,5 t) and for DMR 16.
Motor size Frequency No. of poles PN CDF n Rated cur‐ Weight

rent IN
[Hz] [kW] % [min-1] IN [A] [kg]
Y 400 V
2x MF MF06LA20P 100 0,65 2.800 2,1 6,8
2x MF MF06LA200 100 0,45 2850 2,1 6,8
2x MF06LB100 80 4 1,1 40 4500 2,9 7,8
2x MF06LB200 100 1,1 2770 3,0 7,8
2x MF07XA200 100 1,5 2850 3,9 13
Tab. 12
211 395 44/170619
18 4) Inverter-fed operation/variable = minimum speed (min) - rated speed (rated) - ProHub speed (only with Demag frequency inverters)
3.3 Hook dimension C
43706544_xml.eps
Fig. 3
The hook dimensions C specified in the following (for operation with standard rope guide/reinforced rope guide)
apply to the upper emergency-stop cut-off point.
The emergency limit switch for the highest hook position must be set so that hook dimension C (see table below)
is reached when the switch cuts off the lifting motion.
Reeving
Range FEM/ISO 2/16)7) 4/1 4/26)7) 6/1 8/1
1Am – 4m/
EZ-DMR 5
M4 – M7
1Am – 4m/
EZ-DMR 10 752/752 519/694 1200/1705 -
M4 – M7
LKA1400–22406): LKA
LKA 1400–22406):
519/694 22406)=823,5/923,5
784/884
LKA1588–27987): LKA2428–27987):
LKA1588–22087):
2m – 4m/ 519/694 784/884
EZ-DMR 16 - - 784/884
M5 – M7 LKA2800–35506): LKA 2800–35506)=
LKA 2800–35506): 919
564/739 989,5/1089,5
LKA2428–41087):
LKA3208–41087): LKA3208–41087):
919/1019
564/739 989,5/1089,5
Tab. 13 Hook dimension C from girder running surface
In connection with an operating limit switch, hook dimension C is increased with reference to the operating cut-off
point.
3.4 Gearbox oil filling

The quantity of oil needed in the hoist gearbox depends on the DMR 5 – 16 size. The hoist gearbox is filled ac‐
cordingly before it leaves the factory.
Under normal operating conditions, the lubricant does not need to be changed until a general overhaul is carried
out.
Under exceptional conditions, e.g. increased ambient temperatures, we recommend that the lubricant be changed
to suit these operating conditions.
Gearbox Oil type8) EZ-DMR 5 EZ-DMR 10/16

Hoist gearbox [litres] CLP 220 EP mineral oil 4,0 7,0
472 902 44 (1,0 l)
GES39)travel gearbox [litres] Mobilux EP 004 0,25
Tab. 14
211 395 44/170619
6) Installed
on box-section girder
7) Installed
on V-type girder
8) Under normal operating conditions
9) The gearbox type is specified on the travel motor rating plate. 19
3.5 Operating conditions
Ambient temperature range -10 to +45 °C
Max. air humidity 80 %
Max. altitude/air pressure 1000 m above sea level
Tab. 15
NOTE. Safe operation is only possible under the conditions specified above.
● Please contact the manufacturer for any other operating conditions.
NOTE. The rope hoist can be damaged if it is operated outdoors in poor weather.
● If it is operated outdoors, provide the rope hoist with a cover to protect it from the weather and keep travelling
hoists under a protective canopy when they are not in use.
3.6 Noise emission
Sound pressure level measurement to DIN 45635

Sound pressure level LpAF in relation to the load capacity and size of the rope hoist at a distance of 1 m:
Range Hoist unit

EZ-DMR Max. sound pressure level LpAF in dB(A), measured at a distance of 1 m 10)
No load Under load
Main lifting speed Main lowering speed Main lifting speed Main lowering speed
5 - 4/1 77 dB 77 dB 79 dB 80 dB
10 - 4/1 77 dB 77 dB 78 dB 79 dB
16 - 4/1 77 dB 77 dB 78 dB 79 dB
Tab. 16
Range Cross travel

EZ-DMR Max. sound pressure level LpAF in dB(A), measured at a distance of 1 m 10)
No load Under load
Right V2 Left V2 Right V2 Left V2
5 - 4/1 73 dB 68 dB 76 dB 72 dB
10 - 4/1 75 dB 75 dB 80 dB 79 dB
16 - 4/1 75 dB 75 dB 80 dB 79 dB
Tab. 17
The specified values (emission levels) were measured under maximum load.
The following structural influences were not considered in the measurements:
● transmission of noise via steel structures
● reflection of noise from walls, etc.
NOTE. The sound pressure level is reduced by approx. 3 dB(A) each time the distance is doubled.
211 395 44/170619
20 10) All noise level data are subject to a tolerance of ± 2 dB (A).

3.7 Paint finish
The machine is supplied in the following standard colours:
RAL 5009 azure blue

Hoist unit
RAL 7001 silver grey
RAL 1007 chrome yellow
Bottom block
RAL 9005 jet black
Hook RAL 9005 jet black
RAL 5009 azure blue
Travel unit
RAL 9005 jet black
Tab. 18
3.8 Deadweight of the crab without bottom block [kg]

Track gauge LKa
Box-section girder V-type girder
Size Reev‐ Drum 1400 1800 2240 2800 3550 1588 1808 1988 2208 2428 2648 2798 3208 3358 3958 4108
DMR ing lengt
h
H12 673 690 708 732 873 681 690 698 707 716 726 732 847 858 903 914
2/1 H20 738 754 773 796 937 745 755 762 771 781 790 796 912 923 967 978
H30 - 835 854 877 1018 - - 843 852 862 871 877 993 1004 1048 1059
H12 691 707 726 834 890 699 708 716 725 807 824 835 865 876 921 932
5
4/1 H20 761 778 796 905 961 769 778 786 795 877 894 905 935 946 991 1002
H30 - 866 885 993 1049 - - 874 883 966 982 993 1023 1035 1079 1090
H20 617 634 653 676 817 625 635 642 651 661 670 676 791 803 847 858
4/2
H30 - 668 686 710 850 - - 675 685 694 703 709 825 836 880 892
H12 841 867 896 933 1101 853 868 879 894 908 923 933 1066 1081 1143 1158
H20 - 912 941 978 1146 898 912 924 939 953 968 977 1111 1126 1188 1203
2/1
H30 - - 998 1035 1203 - - 981 996 1010 1024 1034 1168 1183 1244 1260
H40 - - 1056 1093 1262 - - - - 1069 1083 1093 1226 1242 1303 1318
H12 879 905 934 1062 1139 891 906 917 932 1024 1047 1062 1104 1119 1192 1208
H20 - 962 991 1119 1196 949 963 975 989 1081 1104 1119 1161 1177 1250 1265
10 4/1
H30 - - 1057 1186 1263 - - 1041 1056 1148 1170 1186 1228 1243 1316 1332
H40 - - 1093 1217 1294 - - - - 1179 1201 1217 1259 1274 1346 1362
H12 845 871 900 936 1105 857 871 883 897 912 926 936 1069 1085 1046 1162
H20 - 918 947 984 1152 904 918 930 945 959 974 983 1117 1132 1194 1209
4/2
H30 - - 1004 1041 1209 - - 987 1002 1016 1030 1040 1174 1189 1250 1266
H40 - - 1066 1103 1271 - - - - 1078 1092 1102 1235 1251 1312 1328
H12 923 949 1049 1106 1268 937 1005 1024 1046 1069 1091 1107 1226 1245 1319 1338
H20 - 1007 1107 1164 1326 994 1062 1081 1103 1126 1149 1164 1283 1302 1376 1395
4/1
H30 - - 1173 1230 1392 - - 1148 1170 1193 1215 1231 1350 1369 1443 1462
H40 - - 1204 1261 1421 - - - - 1224 1246 1262 1380 1398 1473 1491
16
H20 - 1095 1137 1255 1352 1075 1096 1113 1134 1211 1237 1255 1311 1329 1481 1502
6/1 H30 - - 1184 1302 1399 - - - 1181 1258 1284 1302 1358 1376 1521 1542
H40 - - - 1352 1448 - - - - - 1333 1351 1400 1418 1570 1591
8/1 H40 - - - 1323 1410 - - - - 1282 1305 1321 1365 1388 1517 1535
Tab. 19
Bottom block weights [kg]
DMR size
Reeving 5 10 16
2/1 29 50 -
4/1 37 68 -
4/2 21 37 -
211 395 44/170619
6/1 - - 100
Tab. 20
21
Control system weights [kg]
DMR size
Control
Housing 5 10 16
system
Contactor‐ Alumini‐
Control (CC) um elec‐
20 20 20
SafeControl tric enclo‐
(SC) sure
Electric
Variable fre‐
enclosure
quency con‐ 50 64 64
+ braking
trol (VFC)
resistors
Tab. 21
Cross-travel speed [m/min]
Drum length
Drive H12 H20 H30 H40
Inverter-con‐
3–30
trolled
Tab. 22
3.9 Track girder requirements
3.9.1 Runway
43311244.eps
Fig. 4 Runway paint finish
NOTE. Only apply a primer coat to the running surfaces, as the travel characteristics would be impaired by a
finish coat.
Minimum requirements for runways:

● Do not use beams with profile sections and cross-sections that are smaller than the minimum dimensions
specified in our documents for track girders of double-rail crabs as otherwise deformation of the girders can
occur. Permissible deviations in dimension and shape of the track girder according to DIN EN 10034.
The special travel unit requirements are listed in accordance with the ranges in the following chapter  "Travel
unit", Page 23:
- Dimensional accuracy of the tracks
211 395 44/170619
- Tolerance of the individual girder, of the crab track gauge

- Difference in rail height
- Gradient of the crab rails
22
● Hoist travel on track beams must in no way be obstructed by protruding suspension bolts, screw heads, butt
straps, clamping plates, etc.
● Track gradients should not exceed 2%.
● Appropriately dimensioned end stops must be fitted at both ends of the trolley runway.
● Track joints must be clean and smooth. Bolted joints must be outside the travel area of the travel wheels (ob‐
serve maximum web thickness).
● Installing the cross-travel unit  "Checking dimensional accuracy of the tracks", Page 31.
● The running surfaces of rails and track beams must only be given a primer coat of 40 µ in the area of the
wheels and guide rollers. Travel characteristics would be impaired by a finish coat ( Fig. 4, Page 22).
● Rails and track beams should be kept clean; oil, grease, ice and dirt on the running surfaces will cause travel
wheels to skid.
3.9.2 Travel unit
The travel units have a fixed width. See  technical data 203 796 44
Before installing the travel unit on the track, it must be checked for dimensional accuracy,  "Checking dimen‐
sional accuracy of the tracks", Page 31.
Do not use the double-rail crab to pull free, pull or drag loads on the ground.
It must never run against the buffer stops at full speed, as otherwise damage or accidents may occur.
211 395 44/170619
23
4 Design and function
4.1 EZ-DMR double-rail crab design overview
3
2 4
1
7
43719544_xml.eps
Fig. 5
1 Top block 5 Electric equipment box

2 Rope drum 6 Hoist motor and hoist gearbox
3 Cross-travel drive 7 Bottom block
4 EZ-DMR crab frame
Demag EZ-DMR double-rail crabs are manufactured in two ranges, each with three groups of mechanisms.
The design is characterised by parallel arrangement of the rope drum and the hoist motor. The gearbox housing
and the electric equipment enclosure are central components of the rope hoist. These two components are bolted
together to form the hoist frame by means of three connecting rods.
The crab frame consists of a welded steel structure for accommodating the hoist unit and the rope reeving com‐
ponents as well as the travel wheels and the cross-travel drive.
4.2 Drives
4.2.1 MBV hoist motors

A Demag MBV cylindrical-rotor motor with a DC brake is used as the hoist motor. The 12/2-pole motor enables a
creep lifting speed of 1/6 of the main lifting speed to be achieved. A 4-pole hoist motor used in connection with a
frequency inverter enables a variable lifting speed to be achieved with a control ratio of up to 1/25.
4.2.2 Travel drive

The standard travel drive is an inverter-controlled motor with a cylindrical squirrel-cage rotor. This motor is either
equipped with an integrated brake (compact brake), which does not needs to be controlled, or with a DC brake
with separate control. The DC double-sided brake can be separately controlled and is released by means of an
electromagnet. The brake is applied when no power is supplied to the magnet coil.
4.2.3 Gearbox/rope reeving components
The hoist gearbox is a three-stage helical gearbox. The hoist gearbox transfers the motor torque to the rope
drum.
211 395 44/170619
24
4.3 Geared limit switch
The geared limit switch (see section  "Geared limit switches ", Page 42) is installed in the foot flange of Demag
DMR modular rope hoists.
4.4 Control system and control pendant

The control pendant is an integral part of the control system as ordered.
Refer to the relevant operating/assembly instructions:
● ContactorControl operating instructions (with OWL load detector)  211 377 44
● SafeControl operating instructions  211 809 44
● Assembly instructions for DMR without electric equipment  211 326 44
4.5 Load measurement
1
43719644_xml.eps
Fig. 6
1 ELM load detector (Electronic Load Manage‐

ment)
ELM load detection protects the Demag DMR modular rope hoist and its supporting structure against overloads.
211 395 44/170619
25
4.6 Type plate (example)
1 'HPDJ&UDQHV &RPSRQHQWV*PE+
2
3 10
4 11
5 12
6 13
7 14
8 15
9
71391646.eps
Fig. 7
The type plate contains the following information 8 Rope diameter [mm]
1 Manufacturer 9 Order number
2 Year of manufacture 10 Load capacity [kg]
3 Serial no. 11 Hook path [m]
4 Group of mechanisms to FEM/ISO 12 Main lifting speed [m/min]
5 Gearbox transmission ratio i 13 Creep lifting speed [m/min]
6 Size 14 Calculated rope breaking force [kN]
7 Reeving 15 Minimum rope breaking force [kN]
The type plate of the rope hoist is located on the side of the gearbox housing.
211 395 44/170619
26
5 Transport, packing, storage
5.1 Safety warnings
WARNING
Risk of injury from falling parts
Danger to life and limb.
– Secure components during transport.
– Never step under suspended loads.
WARNING
Crushing hazard
Body parts can be crushed when loads are lifted or lowered.
– Only attach load handling attachments and lifting equipment at the lifting points marked by a label to lift and
transport the rope hoist.
– Only use suitable lifting equipment, load handling attachments and slings which have sufficient load capaci‐
ty.
43649744_xml.eps
Fig. 8 Lifting point label
IMPORTANT. The product can be damaged by inappropriate transport.

Follow in-house company regulations when using forklifts and other in-house handling equipment such as cranes.
211 395 44/170619
27
5.3 Transport inspection
– Check that the delivery is complete and check it for any transport damage immediately on receipt.
– If any transport damage is visible from the outside, only accept the delivery on condition. Note the scope of
damage in the shipping documents/delivery note of the forwarding company and lodge a claim.
– Lodge a claim for any defects that are detected as soon as they are discovered, since claims for damages
can only be asserted within the relevant claim notification periods.
5.4 Packing
If no agreement has been made on the return of the packing material, separate the materials according to type
and size and make them available for further use or recycling.
Consider the environment:
– Always dispose of packing materials in an environmentally compatible way and according to locally applica‐
ble disposal regulations.
– If required, utilise the services of a recycling company.
5.5 Storage
Until it is installed, keep the product and its accessories closed and only store them under the following condi‐
tions:
● Do not store outdoors.
● Store in dry and dust-free places, relative air humidity: max. 60%.
● Do not expose to aggressive media.
● Protect against direct sunlight.
● Avoid mechanical vibrations.
● Storage temperature: -25 to +55 °C.
● Avoid strong temperature fluctuations (condensation).
● Oil all bare machine parts (rust protection).
● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
protection.
● If stored in a damp location, the equipment must be packed tight and protected against corrosion (use desic‐
cant).
211 395 44/170619
28
6 Installation and putting into operation for the first time
6.1 Safety warnings
WARNING
Dangerous electric current
Work on electric equipment may only be carried out by qualified specialist personnel in compliance with the
safety regulations.
– Disconnect the installation from the power supply and secure it against reconnection before starting work.
WARNING
Risk of injury if incorrectly assembled
Incorrect installation can result in severe injuries and/or damage to property.
This work may only be carried out by authorised, trained personnel who are familiar with the principle of opera‐
tion of the machine in compliance with all safety regulations.
Special information for assembly
a) b)
43311344.eps
Fig. 9 Example of safe assembly
a) Example: fence off the required working area

b) Example: use a suitable working platform
Further safety measures:

– Wear personal protection equipment.
– Ensure that sufficient working clearance is available before starting assembly work.
– Secure and fence off the working and danger zone (see  Fig. 9, Page 29).
– Only use lifting equipment for assembly with appropriate attachments for the lifting of persons which ensure
211 395 44/170619
that work is carried out in a safe and stable position (see  Fig. 9, Page 29).
– First check that the voltage and frequency specified on the data plates match the owner’s mains power sup‐
ply.
29
– Check all clearance dimensions and safety distances (see approval drawing) when the equipment is put into
operation.
– Work may need to be carried out in the danger zone when the equipment is put into operation. Be particular‐
ly careful and cautious when moving and working in these areas.
– When the equipment is put into operation, it may be necessary to render safety devices or features tempora‐
rily inoperative. Work with particular care and caution in such cases.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any unneeded machine or installation parts and tools in such a
way that there is no risk of them falling.
– Install parts correctly and tighten bolted connections to the specified tightening torques.
– Do not perform welding on the product as this can cause severe damage to the product. Contact the Demag
service department if welding work needs to be performed.
– Attach lifting equipment to the product only at the marked lifting points. (See  Fig. 8, Page 27).
IMPORTANT. Only attach load handling attachments and lifting equipment at the lifting points marked by a label
to lift and transport the rope hoist.
43649744_xml.eps
Fig. 10 Lifting point label
– Only install the product when all requirements regarding the installation and operating location are met (see
section  "Operating conditions", Page 20).
6.2.1 Target group

the machine
Service personnel
211 395 44/170619
30
6.3 Installing the rope hoist
6.3.1 Safety warning
WARNING
Loose connections
Loose connections are a danger to life and limb.
– Tighten the connections to the tightening torques and use bolt-retaining arrangement as specified below.
CAUTION
Incomplete or technically faulty products
Dangerous situations and risk of injury
Check that the product is complete and in perfect technical condition before installation.
CAUTION
Minimum installation height requirement must be met
Crushed limbs
– Install the rope hoist with a distance of at least 2,70 m from the bottom edge of the rope hoist to the work‐
shop floor.
– If the minimum installation height requirement cannot be met for structural reasons, install corresponding
protective devices and/or warning signs.
6.3.2 Checking dimensional accuracy of the tracks
6.3.2.1 Tolerance of the individual girder

The steel girders must be aligned properly before fitting the cross-travel units, therefore, the dimensional accuracy
of the tracks must be checked before fitting.
Lateral deviation
n s
L
2 L
2
L
L
2 L
L
2
43245944.eps
Fig. 11
211 395 44/170619
n = ± 2 mm, maximum lateral deviation

s = ± 2 mm, maximum lateral rail deviation
– Measure lateral girder/rail deviation “n” or “s” by means of a cord, laser or theodolite at half of the girder
length. 31
6.3.2.2 Twisting
Any twist must be compensated when the connecting plates are fitted.
● Max. permissible twist “y” is 0,5 mm/m
Calculation based on formula: ymax = 0,5 x LTr
Example for calculating permissible twist “y” for a girder length of 10 m

● y max. = 0,5 x LTr
● y max. = 0,5 mm/m x 10 m = 5 mm
43246144.eps
Fig. 12
6.3.2.3 Tolerance of the crab track gauge
b
L + 4 mm
a KA - +2 mm
-2 mm
43246244.eps
Fig. 13
a Track gauge: LKA ± 4 mm

b Centre of web plate
– Check track gauge over the entire travel path.
6.3.2.4 Gradient of the crab rails

a
43246344.eps
Fig. 14
a Max. gradient dimension 1 mm
– Gradient of the crab rails to be measured at points spaced 1 m apart over the entire track gauge.
211 395 44/170619
32
6.3.2.5 Difference in rail height
43246444.eps
Fig. 15
a Max. permissible difference in height 5 mm
– To be measured at points spaced 1 m apart over the entire length of the girder.
The maximum permissible difference in rail height is 5 mm.
6.3.2.6 Rail level difference
5 mm
4 mm
43246544.eps
Fig. 16
∆H = max. 1,5 mm
– To be measured at points spaced 1 m apart over the entire length of the girder.
The maximum permissible difference in height between two measuring points arranged next to each other along
one rail is 1,5 mm.
6.3.3 Placing the rope hoist on the track

– Before you place the rope hoist on the track, completely remove the corrosion protection from all travel
wheels with a degreasing cleaning agent.
211 395 44/170619
33
6.3.4 Fitting and adjusting the guide rollers (optional)
1 2
3
1
1 6
5 2
2
7 5
43738444_xml.eps
Fig. 17
1 Guide roller 5 Buffer extension

2 End stop/buffer 6 M12 retaining bolts
3 Foot flange/limit switch 7 M16 retaining bolts for roller spacing
4 Gearbox
Guide rollers and buffer extensions can be installed on the rope hoist travel units as an option.
– Remove all installed stops.
– Install both guide rollers with 4 bolts11) and washers (M12, torque: 86 Nm) each on the travel unit on the limit
switch side12).
– Install both buffer extensions with 4 bolts11) and washers (torque: 86 Nm) each on the other travel unit.
– Unscrew each of the four retaining bolts (M16) for the rollers.
– Position each of the rollers at a distance of 2 mm to the crab rails.
– Tighten each of the four retaining bolts11) (M16) for the rollers (torque: 210 Nm).
– Fit the stops to the guide rollers/buffer extensions.
6.3.5 Fitting stops/clamp-fitted buffers
Installation of the end stops/clamp-fitted buffers is described in detail in the separate installation instructions 
(203 652 44).
IMPORTANT. The double-rail crab must never run against the buffer stops at full speed, as otherwise damage
to the hoist unit or even accidents may occur.
211 395 44/170619
The hoist unit is counter-balanced by the thrust rocker which presses against the track from below.
11) Also use a suitable bonding agent as a bolt-retaining arrangement.

34 12) For DMR 10 rope hoists with 4/2 reeving, 1588 track gauge H20 with QNC–11 trolley, use the travel unit on the gearbox side instead.
6.4 Connecting the electric equipment
DANGER
Live components
All wiring and connection work may only be carried out by an instructed and qualified electrician according to the
specifications of the electric connection diagram included in the supply.
WARNING
Risk of injury if incorrectly assembled
Incorrect installation can result in severe injuries and/or damage to property.
This work may only be carried out by authorised, trained personnel who are familiar with the principle of opera‐
tion of the machine in compliance with all safety regulations.
6.4.2 Wiring
6.4.2.1 General
Each machine is provided with a circuit diagram showing details of the controls.
The wiring of Demag products complies in all respects with current DIN VDE and accident prevention regulations.
Please note that unauthorised intervention and modifications can result in infringement of these regulations.
The service life of the switchgear depends on usage.
Advise operators that,
– inching or flick-switching must be avoided.
Inching or flick-switching means giving short pulses to the motor to obtain small movements, e.g. when sus‐
pending loads. Inching or flick-switching can cause excessive wear and premature failure of the switchgear.
– corrosion on plastic and metal components in enclosed switchgear housings can be caused by too frequent
inching.
– corroded parts must be replaced in good time.
6.4.2.2 Connecting the control system

Refer to the relevant operating/assembly instructions:
● ContactorControl operating instructions (with OWL load detector)  211 377 44
● SafeControl operating instructions  211 809 44
● Assembly instructions for DMR without electric equipment  211 326 44
211 395 44/170619
35
6.4.2.3 Checking the direction of movement
The direction in which the DMR rope hoist moves depends on the phase sequence in the power supply line. The
load hook must move upwards when you press the “Lift” switch element on the control pendant.
If the direction of motion is not correct and the DMR is equipped with a ContactorControl system, two of the sup‐
ply cable conductors should be swapped over again to ensure that the emergency limit switches operate correct‐
ly.
If the phases are incorrectly connected on a DMR unit equipped with SafeControl, the control system will auto‐
matically switch the hoist motor motion off after it briefly starts up. Error code 38 appears on the display of the
DSE-10R control pendant or on the (optional) radio control.
– Check the top and bottom hook positions and, if necessary, adjust them accordingly (see section  "Geared
limit switches ", Page 42).
6.5 Rope reeving
WARNING
Danger if incorrectly fitted
The rope must not be secured with a rope clamp fitted over both rope ends. This would cause bruising and un‐
even stress in the carrying fall of the rope and thus lead to its destruction.
– Ensure that the parts are correctly arranged.
– Check tight fit of the overload sensor.
WARNING
Reeving the wire rope
Crushing or shearing off fingers between the top block and rotating rope sheave.
– Do not reach between the spokes of the rope sheave when reeving the rope.
– Keep a safe distance from rotating or moving parts.
CAUTION
Tighten to the specified tightening torques
Incorrectly tightened bolts can loosen or break off.
Use a torque wrench to ensure that bolted connections are tightened to the specified tightening torque.
CAUTION
Risk of injury
Risk of injuring fingers/hands on sharp edges and strands of the wire rope when working with wire rope.
– Always wear protective gloves when working with wire rope.
NOTE. Keep the rope tight and do not allow it to twist when it is reeved.
211 395 44/170619
36
6.5.2 Reeving methods
2/1 4/1 4/2 6/1 8/1
43710144_xml.eps
Fig. 18 EZ-DMR reeving methods, 2/1, 4/1, 4/2, 6/1 and 8/1 reeving arrangements
6.5.3 Rope reeving of the rope hoist

Refer to the diagram for the rope arrangement for the various reeving methods.
For single-groove rope drums, the rope is retained by a rope wedge and a rope socket anchorage that is incorpo‐
rated in the rope-retaining crosshead.
NOTE. The rope can be replaced by Demag service engineers or an authorised specialist company.
Reeving the rope:

● Insert the end of the rope from the rope drum through the rope
sheave into the bottom block.
● Run the rope end through and out of the rope sheave over the top
block.
● Insert the end of the rope through the second rope sheave into the
bottom block.
2 3 1 4 ● Run the rope end through and out of the rope sheave and secure the
rope to the rope socket.
43720344_xml.eps
Fig. 19
211 395 44/170619
37
6.5.4 Assembling the bottom block
A
B
43625944_xml.eps
Fig. 20 Bottom block protective cover
A Protective cover part A

B Protective cover part B
CAUTION
Drawing-in and crushing hazard
Damaged or missing protective cover on the bottom block can result in crushing or drawing-in hazard.
The machine must only be operated with a complete and intact protective cover on the bottom block.
Demag DMR modular rope hoists are always supplied with the rope separate from the bottom block.
Installing the protective cover:
1. Place part (A) of the protective cover in the rope opening of the bottom block.
2. Bolt part (A) of the protective cover to part (B) of the protective cover. Tightening torque 4 Nm
3. Repeat these steps for the other three rope openings.
211 395 44/170619
38
6.5.5 Installing the wire rope in the rope socket
Secure the rope in rope socket (2) with rope wedge (1) and rope clamp (3 to 5).
● Insert the load-bearing rope together with the rope wedge into the vertical part of the rope socket.
● Allow the dead end of the rope to protrude from rope socket (6) by approx. 10 cm.
● Fit the rope clamp.
Tighten the bolts to the following tightening torque:
Range Rope clamp tightening torque [Nm]

DMR 5 6
DMR 10 33
DMR 16 33
Tab. 24
NOTE. Ensure that the load-bearing end of the rope en‐

ters the vertical part of the rope socket. The rope is prop‐
erly secured if the rope wedge remains visible above the
rope socket and the dead end of the rope protrudes by
approx. 10 cm when under load.
5 4 3
43719744_xml.eps
Fig. 21
211 395 44/170619
39
6.5.6 Installing the rope socket in the crosshead with ELM load detector (Electronic Load Management)
● Insert rope socket (4) into the crosshead from below and align it with the bore holes in the crosshead.
● Position one magnetic washer (5) between the rope socket and mounting hole on each side of the crosshead.
● Insert load-measuring pin (3) into the bore hole in such a way that the slot at the end of the load-measuring pin
is in line with pin retainer (1), which still needs to be installed.
● Install the pin retainer below the slot in such a way that the load-measuring pin is fixed in position and can no
longer turn.
1 2 3
5 4
43720444_xml.eps
Fig. 22
211 395 44/170619
40
6.6 Putting into operation for the first time
WARNING
Live components
Danger to life and limb
– Before adjusting the switching points of the geared limit switch, ensure that any live contacts are provided
with a guard to protect against accidental contact. Pay attention to run-on in each direction of movement.
WARNING
Incorrect setting
Commissioning work may only be carried out by qualified specialist personnel in compliance with the safety reg‐
ulations. Some safety devices need to be rendered inoperative when the equipment is put into service. When
the equipment is put into operation for the first time, the following must be observed:
– Put on any necessary protective equipment.
– Ensure that sufficient working clearance is available before starting assembly work.
– Secure and fence off the working and danger zone adequately.
CAUTION
– Secure any parts that have been removed during commissioning and are not protected against falling to
prevent them being dropped.
– Ensure that the working area is adequately fenced off.
– Ensure that nobody is present in the danger zone.
6.6.2 Checks before the equipment is put into operation for the first time
The owner is obliged to carry out the following checks before putting the unit into operation for the first time (see
section  "Regular inspections", Page 13).
Activity See section

Check oil level in the rope hoist gearbox  "Gearbox oil filling", Page 19
Check rope securing devices and rope guide Visual inspection
Check electric switchgear and wiring  "Wiring", Page 35
Check operation of the limit switch  "Switching on", Page 47
Check strain relief elements, cable & control pendant housing for damage Visual inspection
Check operation of the brake Function check
Check operation of overload protection device Function check
Lubricate rope  "Lubricating the wire rope", Page 68
Check load hook and hook safety catch  "Regular inspections and monitoring
measures for load hooks", Page 68
Check with an overload of 125%  "As part of the compulsory accept‐
ance process required when hoists/
cranes are first put into service, an over‐
load test (110–125%) must be carried out
by an expert engineer of the relevant in‐
spection body. The corresponding in‐
spection must be documented in the
211 395 44/170619
hoist unit/crane log book.", Page 45

Tab. 25
41
6.6.3 Inspection regulations
NOTE. Inspection before the equipment is put into service for the first time:
● If hoist units are used as cranes, an inspection must be carried out by an expert engineer in accordance with
the rules and regulations of the German Social Accident Insurance (DGUV) Regulation 52, for example.
● Hoist units must be inspected by an experienced technician in accordance with the rules and regulations of
the German Social Accident Insurance (DGUV) Regulation 54, for example.
The inspection in accordance with the rules and regulations of the German Social Accident Insurance (DGUV)
Regulation 54 mainly consists of a visual inspection and a function check. It is designed to ensure that the equip‐
ment is in a safe condition and that any defects and damage, e.g. caused by inappropriate handling during trans‐
port, are identified and repaired.
In addition, regulations specific to cranes must also be taken into consideration during acceptance and other in‐
spections in accordance with the rules and regulations of the German Social Accident Insurance (DGUV) Regula‐
tion 52.
6.6.4 Geared limit switches
6.6.4.1 Safety warning
CAUTION
– Secure any parts that have been removed during maintenance and are not protected against falling to pre‐
vent them being dropped.
– Ensure that nobody is present in the danger zone
CAUTION
Incorrect adjustment
Ensure that the minimum number of retaining windings are wound on the drum when setting the bottom hook
position.
6.6.4.2 Geared limit switch function

The geared limit switch is installed in the foot flange of Demag DMR modular rope hoists. It is used to limit the
upper and lower hook positions of the rope hoist as standard (emergency limit switch).
In general, the geared limit switch is provided with 4 contacts. The contacts are assigned in the factory as stated
in the order of the rope hoist.
The geared limit switch switches off the rope hoist when the top or bottom hook position is reached. The direction
of movement can be reversed. The emergency limit switch must not be approached in normal operation. The
emergency limit switches trigger the emergency-stop function.
A solution with an operating limit switch (optional) is required if the limit positions are approached regularly dur‐
ing normal operation.
In such cases, the switches must be adjusted so that the operating limit switch is actuated first and then, i.e. if this
fails to operate, the emergency limit switch is actuated. The operating limit switch only switches the hoist unit off.
Accident prevention regulations require that the crane operator checks the emergency limit switch before starting
work (see section  "Check the limit switches", Page 48).
211 395 44/170619
Please refer to the relevant circuit diagram for the functions performed by the geared limit switch.
42
Geared limit switch adjustment
1 2
43239444.eps
Fig. 23
1 "Block" adjusting screw

2 "Individual" adjusting screw
You need to remove the cover on the foot flange to make adjustments to the geared limit switch. Unscrew the four
M8x35 hexagon socket bolts.
A 4 mm hexagon socket key is needed to adjust the geared limit switch.
Operating principle
Each contact is allocated to a cam disc which is infinitely adjustable. The cam discs can be adjusted independent‐
ly by means of "individual" adjusting screws (2).
Adjustment
When “individual” adjusting screw (2) is turned clockwise, the cam disc is also turned clockwise. The switching
point is shifted upwards in accordance with the hook path.
When the screw is turned counter-clockwise, the switching point is shifted downwards. Standard cam discs are
designed in such a way that a maximum useful path and a run-on path are available.
Adjusting individual contacts (2)
The geared limit switch is already permanently connected to the control system via the system connector cable.
Move the load hook of the rope hoist into the specified cut-off position. Turn the "individual" adjusting screw until
the contact maker opens the contact to adjust the contacts.
If the run-on path is exceeded, the contact either opens or closes.
See also  "Set the cut-off points", Page 44

Adjusting blocks of contacts (1)
The contacts are adjusted in blocks by means of "block" adjusting screw (1). All cam discs are adjusted together,
while the relative adjustment of the individual contacts remains unchanged. When the "block" adjusting screw is
turned clockwise, the cam discs are also turned clockwise.
NOTE. For adjustment, please note:
● The geared limit switch is adjusted before leaving the factory to avoid complete unwinding of the rope, only.
● Approach cut-off points several times to check the limit switch functions are operating correctly.
211 395 44/170619
43
6.6.4.3 Set the cut-off points
The emergency limit switches must be properly adjusted to ensure that accidents are prevented and to avoid
damage to the rope hoist. The emergency limit switches are adjusted before leaving the factory to avoid complete
unwinding of the rope, only. Following installation of the rope hoist, they must be readjusted and checked for the
particular operating conditions.
If you want to set the maximum possible lifting height for your specific operating conditions, you must observe the
following:
● The emergency limit switch for the highest hook position must be set in such a way that hook dimension C is
reached when the emergency limit switch cuts off the lifting motion (see section  "Hook dimension C",
Page 19).
● The emergency limit switch for the lowest hook position must be set in such a way that the load hook does
not touch the floor.
The cut-off points of the geared limit switch have already been set to default values when the machine leaves our
factory.
If you want to set different cut-off points than those for the standard values, proceed as described in sections
 "Set the upper cut-off points", Page 44 and  "Set the lower cut-off points", Page 44.
6.6.4.4 Set the upper cut-off points

– Determine the cut-off points for the emergency limit switch and operating limit switch (optional) (see section
 "Hook dimension C", Page 19).
– Adjust the cut-off points on the geared limit switch (emergency limit switch and operating limit switch).
NOTE. Pay attention to function of the cut-off points
● Cut-off points must be adjusted in such a way that the operating limit switch (optional) is actuated first and
then, i.e. if this fails to operate, the emergency limit switch is actuated.
● Emergency limit switches must not be approached in normal operation.
– For standard equipment (without operating limit switch):

Adjust hook dimension C setting for the highest hook position. Determine the distance based on the tables
 "Hook dimension C", Page 19.
– For units fitted with emergency and operating limit switches (optional):
Set the upper emergency-stop cut-off point (emergency limit switch) in such a way that the permissible set‐
ting for hook dimension C is maintained when the lifting motion has been switched off by the emergency limit
switch (see section  "Hook dimension C", Page 19).
6.6.4.5 Set the lower cut-off points
Range Required rope windings on the drum

Reeving
2/1 4/1 4/2 6/1 8/1
EZ-DMR 5 3,5 - -
2,5
EZ-DMR 10 2,5 - -
EZ-DMR 16 - - - 2,5
Tab. 26 Minimum number of retaining windings
– Use the control pendant to set the bottom hook position for the emergency limit switch so that the load hook
does not touch the floor.
– Adjust the cut-off points (see above).
When the geared limit switch has been adjusted, re-install the cover on the foot flange with the M8x35 hexagon
socket bolts. Tightening torque 15 Nm
211 395 44/170619
44
6.6.5 Checking crane structural design
6.6.5.1 Checking with SafeControl
The switch setting for the overload test is located in the electric equip‐
ment enclosure of the SafeControl system.
789
● To deactivate the overload protection (110%) for 15 minutes13) to
perform an overload test at 125%, turn DIP switch 6 from OFF to
456
AB
ON14).
CDE
23
F0 1
● To re-activate the overload protection (110%),
789 - turn DIP switch 6 (1) from ON to OFF or
456
AB
- re-start the hoist unit (boot the control system) or

CDE
- wait until the 15-minute test period has elapsed.

23
F0 1
NOTE. All DIP switches are set to OFF by default.

789
456
AB
CDE
23
F0 1
9 10
1
8
7
6
5
4
3
2
ON
43239545.eps
Fig. 24
6.6.5.2 Checking with ContactorControl
Refer to the OWL load detector technical documentation for details on possible settings for the overload test (see
 211 379 44).
6.6.6 Travelling hoist travel characteristics and run-on paths when stopping
Cross-travel movements that can occur when the travelling hoist is braked are caused by load sway. In this way,
sway motions are reduced and the load is steadied.
211 395 44/170619
13) For safety reasons, load pick-up is limited to 146% of the permitted payload even when the overload protection function is deactivated.
14) If the DIP switch is already in the ON position, first set the switch to OFF. 45
7 Operation
7.1 Safety warnings
WARNING
Incorrect operation
Incorrect operation can result in severe injuries and/or damage to property.
The machine may only be operated by authorised and trained personnel in compliance with all accident-preven‐
tion and safety regulations.
– Comply with national regulations for the use of cranes and lifting appliances.
WARNING
Danger if duty to exercise care is neglected
Danger to life and limb if the machine is operated with little care.
Requirements for operating the machine include:
– All installation/assembly work has been carried out according to the operating instructions.
– The rope must be adequately lubricated.
– The rope must be in good condition.
Operation with defective or damaged ropes results in a high risk of accidents with personal injuries and is
therefore prohibited. Risk of damage to the machine.
– Any changes or modifications which prejudice safety must be reported to the nearest person responsible
immediately.
– Defects may only be eliminated by experienced technicians.
WARNING
Falling loads
Any person remaining in the danger zone may suffer serious injury or death.
Only use suitable and tested load handling attachments.
– Follow the operating instructions for the load handling attachment.
– Do not exceed the maximum permissible load capacity of the load handling attachment.
– Never handle suspended loads above people.
WARNING
Danger resulting from incorrect load pick-up
– Ensure that loads are attached at the intended lifting points.
– Ensure that no load is attached to the handle recesses on the bottom block of the hoist unit.
– Ensure that loads are always picked up with the corresponding load handling attachment, e.g. chain, rope,
sling, etc.
– Ensure that the load is picked up at its centre of gravity and, therefore, balanced.
WARNING
Damaged components/malfunctions on the machine
Danger to life and limb
– If obvious defects or malfunctions occur, stop the machine without delay and secure it against switching on
again.
211 395 44/170619
46
CAUTION
Danger due to premature wear/corrosion
Corrosion on plastic and metal components in enclosed switchgear housings can be caused by too fre‐
quent inching.
– Avoid inching/flick-switching
– Corroded parts must be replaced in good time.
NOTE. Advise operators that inching/flick-switching must be avoided. Inching or flick-switching means giving
short pulses to the motor to obtain small movements, e.g. when suspending loads. Inching or flick-switching can
cause excessive wear and premature failure of the switchgear.
Before starting work:

– Put on any necessary protective equipment.
– Check to ensure that nobody is present in the danger zone of the machine.
– Check operation of the brakes, emergency limit stop devices and emergency-stop devices.
During operation:
– Do not approach emergency limit stop devices (e.g. emergency limit switch) in normal operation.
– Never render safety devices inoperative.
– Adopt a position that ensures a clear view of the danger zone for lifting and travel motions.
– Never touch the ropes while the machine is in operation.
7.2.1 Target group

appropriate conduct
7.3 Switching on
7.3.1 Checks when starting work
The operator is obliged to carry out the following checks before starting work (see section  "Regular inspec‐
tions", Page 13):
Activity Section
Visual inspection  "Visual inspection", Page 48
Check operation of the limit switch  "Check the limit switches", Page 48
Check strain relief elements, cable & control pendant housing for dam‐  "Check strain relief elements of the control pendant", Page 49
age
Check operation of the brake  "Check operation of the brake", Page 50
Check hook and hook safety catch  "Check hook safety catch", Page 50
Check rope for damage and broken wires  "Replacement criteria for the wire rope", Page 59
Tab. 28
211 395 44/170619
47
7.3.2 Visual inspection
– Check the machine to ensure it is complete. Do not operate the machine if parts have been removed or are
defective (covers, limit stop buffers, ...).
– Check the machine for any visible external damage.
7.3.3 Check the limit switches
7.3.3.1 Safety warning
WARNING
Bypassed operating limit switch
Danger caused by inappropriate use of the test button.
– Only actuate the test button to check the limit switches.
– The rope hoist must not be operated while the operating limit switch is bypassed.
7.3.3.2 SafeControl: check using DSE-10R control pendant
– Press test button (4) to bypass the operating limit switch.

– Approach the emergency limit switch using motion axis control buttons (3).
– Hold test button (4) down and simultaneously press motion axis control buttons (3) to back away from the
emergency limit switch.
43239744.eps
Fig. 25
211 395 44/170619
48
7.3.3.3 ContactorControl: check using DST 7 and 9 control pendants
The “Lifting motion” operating limit switch can be bypassed with test button (1). If this function is configured or set,
it can be used to check the emergency limit switch for the lifting motion.
– Press button (1). The limit switch is bypassed.
– Press button (2). The limit switch is approached. The hoist unit must then switch off.
– Press button (3) after the hoist unit has switched off. The hoist unit backs out of the area controlled by the
limit switch.
DST 7 DST 9
2
3
43363045_xml.eps
Fig. 26
7.3.4 Check strain relief elements of the control pendant

– Carry out a visual inspection of the strain relief elements:
The strain relief cords must be firmly attached. No forces must act on the connector plug when the control
pendant is moved.
211 395 44/170619
49
7.3.5 Check operation of the brake
IMPORTANT. Only operate the machine if it is in safe operating condition.
● If the check reveals that a brake is not properly adjusted or is not operating correctly, it must be adjusted or
repaired.
● Do not operate the machine if the brake is not properly adjusted or is not operating correctly.
– Press the buttons to control the motion axes to raise and lower the load hook. The load hook must only run
on a short distance when the button is released.
The load hook must stay at the same height (i.e. it must not lower without a button being actuated) when a
load is attached to it.
Significant run-on or lowering when in the idle position indicates that the brake is worn.
– Press the buttons to control the motion axes to move the hoist right/left. Deceleration of the travelling hoist
must be clearly noticeable when the button is released.
It must not be possible to move the travelling hoist by pulling the ropes to the side.
Significant run-on or the possibility of moving it when in the idle position indicates that the brake is worn.
– Check the brake linings every year:
To install the brake on an MBV hoist motor, see section  "Maintaining the brake on M motors", Page 71
For travel drive owner’s manual, see  211 366 44
7.3.6 Check hook safety catch
To check the hook safety catch, see section  "Regular inspections and monitoring measures for load hooks",
Page 68.
7.4 Button assignment for control pendant or radio control

DSE-10R control pendant and DRC-10 radio control
The motion directions of the crane/load hook are clearly identified with
fixed symbols regardless of the control pendant type:
Lower load
Lift load
Cross travel to the left
Cross travel to the right
Long travel backwards
Long travel forwards

F1/F2: see user manual/assembly instructions for DSE-10R control
pendant or DRC-10 radio transmitter switch assignment
43297844.eps
Fig. 27
211 395 44/170619
50
DST control pendant
Lower load
Lift load
1 Cross travel to the left
2 Cross travel to the right

For function and assignment of buttons 1 + 2, see user manual/assem‐
bly instructions for DST control pendant
43297845.eps
Fig. 28
DRC-J radio control
Lower load
Lift load

43297846.eps
Fig. 29
DRC-MJ hand-held transmitter
Lift load
Lower load

43710044_xml.eps
Fig. 30
For function and assignment of function keys F1 + F2, see user man‐
ual/assembly instructions for DRC-MJ hand-held transmitter
211 395 44/170619
51
7.5 Switching off
NOTE. Pay attention to the operating instructions for other parts of the installation when the crane installation is
switched off, as required.
– When work has been completed, position the unloaded bottom block outside the travel area.
– Press the emergency-stop button on the control unit.
– Switch off the power supply at the mains connection or isolating switch.
7.6 Stopping operation in an emergency

– Press the emergency-stop switch or button on the control unit (see section  "Emergency-stop device",
Page 12).
211 395 44/170619
52
8 Maintenance
8.1 Safety warnings
DANGER
Live components
Electric current can cause danger to life and limb.
safety regulations.
WARNING
Risk of injury.
Incorrect maintenance work can result in severe injury and/or damage to property.
Maintenance work may only be carried out by authorised and trained specialist personnel in compliance with all
safety regulations.
CAUTION
– Secure any parts that have been removed during maintenance and are not protected against falling to pre‐
vent them being dropped.
– Ensure that nobody is present in the danger zone
Always:
– Wear any necessary protection equipment.
– Cordon off a sufficiently large area around the working zone.
– Disconnect the installation from the power supply and secure it against reconnection before starting work.
– Switch off the power supply at the mains connection or isolating switch. Check to ensure that the equipment
is de-energised.
– Ensure that there is sufficient freedom of movement.
– Parts of the body can be crushed when working on the machine. Secure the machine/machine parts against
unintended movement and work with the utmost care and caution.
– Ensure the working area is kept clean and tidy. Loose parts or tools left lying around can cause accidents.
– Re-install safety devices as required by relevant regulations after maintenance work is complete. Check the
safety devices for correct operation.
– Check the phase sequence if you have performed work on the electric equipment, especially the power sup‐
ply.
211 395 44/170619
53
8.2.1 Target group

- Repairs malfunctions and defects - Trained specialist with mechanical and/or electrical training
Repair personnel
the machine
Service personnel
cranes.
8.3 Spare parts

IMPORTANT. Incorrect or defective spare parts can cause damage, malfunctions or complete failure of the ma‐
chine.
● Only use genuine Demag spare parts or parts approved by the manufacturer.
● Use only genuine Demag spare parts for safety-relevant wearing parts. Examples: all parts driving the load,
rope guide, rope drum, gearbox, brake, motor, ...
Only genuine Demag spare parts may be used.

The use of unauthorised spare parts renders null and void any claims for warranty, service, damages or liability
against the manufacturer or his appointed personnel, dealers and representatives.
8.4 Routine inspections

The Demag DMR modular rope hoist must be inspected by an experienced technician at least once a year. Regu‐
lar inspections mainly consist of visual inspections and function checks which should include a check to determine
the condition of components and equipment regarding damage, wear, corrosion or other alterations and a check
to determine the integrity and efficiency of safety devices.
It may be necessary to remove parts in order to inspect wearing parts.
Load-bearing media and suspensions must be inspected along their entire length, including those parts which
cannot normally be seen. A function and brake test with a load (test load = maximum permissible load capacity)
must be carried out.
NOTE. Updating the log book: the owner must arrange for all inspections to be carried out and documented in
the hoist or crane log book.
211 395 44/170619
54
8.5 Maintenance schedule
WARNING
Danger due to incomplete maintenance.
Danger to life and limb since safe operation of the machine is not ensured.
– Carry out all specified maintenance work appropriately and in time.
– Please contact after-sales service for any work that you cannot carry out yourself.
– Make sure that the entries in the crane installation log book are complete.
211 395 44/170619
55
8.5.2 Inspection and maintenance intervals
NOTE. The specified inspection and maintenance intervals refer to normal operating conditions. If routine main‐
tenance reveals that the maintenance intervals are too long, they must be shortened according to the specific
operating conditions.
Check before putting into operation, before starting work and during operation
Activity See section Before the Before start‐ Every 6 Once per
unit is first ing work Months year
put into op‐
eration
Check coupling halves of main hoist motor for
KD 15) Every 4 – 5 years
tight fit.
Check roller spiders for signs of wear and re‐
KD 15) Every 4 – 5 years
place them
Check lubrication of rope, lubricate as required  "Lubricating the wire rope",
X X
Page 68
Check rope for damage and broken wires  "Replacement criteria for the
X X X
wire rope", Page 59
Check rope securing devices and play of rope  "Securing the wire rope ",
guide on drum Page 65
X X X X
 "Installing wire rope",
Page 64
Check load hooks for cracks, deformation and  "Regular inspections and
wear monitoring measures for load X
hooks", Page 68
Check hook and hook safety catch  "Regular inspections and
monitoring measures for load X X X
hooks", Page 68
Check adhesive lubricant in bearing points of
top blocks, crossheads, compensating sheaves  "Lubricating the wire rope",
X
and pins of the rope socket, re-grease as re‐ Page 68
quired
Check bottom block KD 15) X
Check electric switchgear and wiring  "Connecting the electric
X X
equipment", Page 35
Check operation of the limit switch  "Check the limit switches",
X X X
Page 48
Check strain relief elements, cable and control  "Check strain relief elements
X X X
pendant housing for damage of the control pendant", Page 49
Check operation of the brake  "Check operation of the
X X X
brake", Page 50 KD 15)
Check brake displacement, adjust as required KD 15) X X
Check condition of the brake lining KD 15) X X
Check operation of overload protection device KD 15) X X
Check all connections (bolts, weld seams, etc.) KD 15) X
Check alignment of the individual travel wheels
and of the crab travel units with reference to the KD 15) X
running surface
Check condition and wear of the travel wheels  "Wear limits on travel
X
wheels", Page 69
Clean the travel motor cooling ribs X
Check securing elements (clips, bolts, etc.) for
KD 15) X
tight fit and corrosion
Check and apply or supplement corrosion pro‐
KD 15) X
tection, as required
Change oil in main hoist gearbox/cross-travel
Every 8 – 10 years
gearbox
Check plastic components of the limit switch for
KD 15) X
corrosion
Check electric enclosure seals KD 15) X
211 395 44/170619
Check condition of all buffers KD 15) X
56 15) The inspection may only be carried out by Demag Customer Service (KD) or by authorised specialist personnel.
Activity See section Before the Before start‐ Every 6 Once per
unit is first ing work Months year
put into op‐
eration
Check power supply lines (main and crab power
supply). For current collectors: check sliding
KD 15) X
contacts and travel rollers for wear and sliding
contacts for contact pressure
Check wear of the tension rollers KD 15) X
Tab. 30
General overhaul (GO)
The general overhaul should coincide with the annual inspection On reaching the theoretical duration of service
Fit rope hoist-specific Demag GO set X
Tab. 31
211 395 44/170619
57
8.6 Wire ropes
Construction, application and reeving of wire ropes
Range DMR 5
Reeving arrangement 2/1 4/1 4/2
Drum length H12 H20 H30 H12 H20 H30 H20 H30
Hook path [m] 12 20 30 6 10 15 9,9 16,3
Rope 8x19 W 8x19 W+SES 16x7+ESS 8x19 W 8x19 W+SES 8x19 W 8x19 W 8x19 W+SES
structure +SES +SES +SES +SES
1Am/M4,
Group of 2m/M5,
X X X X X X X X
mechanisms 3m/M6,
4m/M7
Wire rope di‐ 9 9 9 9 9 9 7 7
[mm]
ameter
Theoretical approx.
77,32 77,32 80,00 77,32 77,32 77,32 49,08 49,08
breaking force [kN]
Minimum
[kN] 64 64 74 64 64 64 40,6 40,6
breaking force
Free of
No No Yes No No No No No
twist
Lay zS zS sZ zS zS zS zS zS
Rope grade [N/mm²] 1960 1960 1960 1960 1960 1960 1960 1960
Rope length [m] 27,8 43,8 63,8 29,3 45,3 65,3 49,2 74,8
Tab. 32
Range DMR 10
Drum length H12 H20 H30 H40 H12 H20 H30 H40 H12 H20 H30 H40
Hook path [m] 12 20 30 40 6 10 15 20 5,8 11,4 18,4 25,2
Rope 8x19 W 8x19 W 6x7+6x7 6x7+6x 8x19 W 8x19 W 8x19 W 8x19 W 8x19 W 8x19 W 8x19 W 8x19 W
structure +SES +SES +7x7 7+7x7 +SES +SES +SES +SES +SES +SES +SES +SES
1Am/M4,
Group of 2m/M5, X X X X X X X X X X X X
mechanisms 3m/M6
4m/M7 X16) X 16) X16) X 16) X 16) X16) X16) X16) X X X X
Wire rope di‐
[mm] 13 13 13 13 13 13 13 13 9 9 9 9
ameter
Theoretical
approx.
breaking 164,93 164,93 186,6 186,6 164,93 164,93 164,93 164,93 77,32 77,32 77,32 77,32
[kN]
force
Minimum
breaking [kN] 132,0 132,0 152,7 152,7 132,0 132,0 132,0 132,0 64,0 64,0 64,0 64,0
force
Free of
No No Yes Yes No No No No No No No No
twist
Lay zS zS zZ zZ zS zS zS zS zS zS zS zS
Rope grade [N/mm²] 1960 1960 1960 1960 1960 1960 1960 1960 1960 1960 1960 1960
Rope length [m] 28,3 44,3 64,3 84,3 30,4 46,4 66,4 86,0 34,6 56,8 85,0 112,2
Tab. 33
211 395 44/170619
58 16) 3m/M6 rope reeving components

Range DMR 16
Drum length H12 H20 H30 H40 H20 H30 H40 H40
Hook path [m] 6 10 15 20 6,7 10 13,3 10
Rope
10x26 -SES 10x26 -SES 10x26 -SES 10x26 -SES 10x26 -SES 10x26 -SES 10x26 -SES 10x26 -SES
structure
1Bm/M3 X X X X
1Am/M4 X
Group of
mechanisms 2m/M5,
X X X
3m/M6
4m/M7 X 16) X 16) X 16)
Wire rope di‐
[mm] 13 13 13 13 13 13 13 13
ameter
Theoretical approx.
197,9 197,9 197,9 197,9 197,9 197,9 197,9 197,9
breaking force [kN]
Minimum
[kN] 166,2 166,2 166,2 166,2 166,2 166,2 166,2 166,2
breaking force
Free of
No No No No No No No No
twist
Lay zS zS zS zS zS zS zS zS
Rope grade [N/mm²] 2160 2160 2160 2160 2160 2160 2160 2160
Rope length [m] 30,5 46,5 66,5 86,0 47,3 67,3 87,3 89,8
Tab. 34
8.7 Replacement criteria for the wire rope
CAUTION
Risk of injury
8.7.2 General
The following information on the assessment and maintenance of wire ropes has been compiled on the basis of
German, European and international standards as well as relevant trade literature and is to be regarded only as
the most significant information that is not intended to be complete, but to help the owner of a Demag rope hoist
to become familiar with “Replacement criteria for wire ropes”.
Furthermore, all national standards, regulations or any legislation of other countries must be fulfilled and consid‐
ered together with the above information or they take priority, as applicable.
NOTE. Assessment of the replacement criteria for wire ropes requires experience and expert knowledge. The
replacement criteria for your rope can be assessed and the rope can be replaced by Demag service engineers
or an authorised specialist company.
You must wear thick gloves and work with utmost care to avoid injures when inspecting the wire rope.
A visual check must always be carried out over the entire length of the rope, including points which cannot nor‐
mally be seen, critical points must be inspected with particular care and attention.
In order to discover broken wires more easily, the load must be removed from the hoist and the wire rope must be
bent manually along its entire working length. The bending radius should be approximately the same as the rope
sheave radius.
A wire rope must be discarded when its condition is no longer considered to be safe for continued operation:
211 395 44/170619
● If there are any structural changes, such as swelling, loosening.
59
The installation must be stopped immediately if this type of damage occurs.
● When the number of visible broken load-carrying wires in the external strands at the worst spot has reached
the following figures, counted over a reference length of rope of 6 times or 30 times the rope diameter,
whichever gives the worst result (see section  "Replacement criteria", Page 60).
Critical points, for example, include:
1. Rope zones subject to the highest number of alternating bending cycles and in particular to alternating de‐
flection. This also applies to rope zones on compensating sheaves which are subject to a very high number
of reversed bending cycles due to rope swing or uneven winding on rope drums. These rope sections show
increased abrasion and a higher number of broken wires.
2. The zones in which loads are picked up, i.e. rope zones which are on a rope sheave at a preferred load pick-
up point or rope zones which are wound onto or off a rope drum.
3. Rope anchorages that subject the wire rope to a load in addition to normal tensile load. Vibrations in the tran‐
sition area and moisture penetrating into the rope anchorage result in corrosion and broken wires.
4. Rope zones on rope drums. The load pick-up point on the rope drum is subject to increased wear (abrasion,
broken wires and/or structural changes).
5. Rope zones exposed to aggressive media, general weather conditions or high temperatures. Observe the
manufacturer’s specifications for the wire rope and the lubricant to be used.
8.7.3 Replacement criteria

Extract from DIN ISO 4309:2013–06, Section 6.2.4 Single-layer ropes with parallel strands
Table 3 — Number of visible broken wires which, when reached or exceeded, indicates replacement criteria for
single layer ropes with parallel strands
Total number of load-bearing Number of visible broken outer wires

wires in the rope’s outer layer of Rope sections that run over steel sheaves and/or are wound onto Rope sections that are wound
strands a single-layer drum onto a multi-layer drum
(random distribution of broken wires)
Classes M1 to M4, or class unknown All classes
Ordinary lay Lang’s lay Ordinary lay and Lang’s lay
over a length of over a length of over a length of
6d 30d 6d 30d 6d 30d
n ≤ 50 2 4 1 2 2 4
51 ≤ n ≤ 75 3 6 2 3 3 6
76 ≤ n ≤ 100 4 8 2 4 4 8
101 ≤ n ≤ 120 5 10 2 5 5 10
121 ≤ n ≤ 140 6 11 3 6 6 11
141 ≤ n ≤ 160 6 13 3 6 6 13
161 ≤ n ≤ 180 7 14 4 7 7 14
181 ≤ n ≤ 200 8 16 4 8 8 16
201 ≤ n ≤ 220 9 18 4 9 9 18
221 ≤ n ≤ 240 10 19 5 10 10 19
241 ≤ n ≤ 260 10 21 5 10 10 21
261 ≤ n ≤ 280 11 22 6 11 11 22
281 ≤ n ≤ 300 12 24 6 12 12 24
n > 300 0,04 x n 0,08 x n 0,02 x n 0,04 x n 0,04 x n 0,08 x n
Tab. 35 Source: DIN ISO 4309:2013–06
Extract from DIN ISO 4309:2013–06, Section 6.2.5 Rotation resistant ropes
Table 4 — Number of visible broken wires which, when reached or exceeded, indicates replacement criteria for
rotation-resistant ropes
211 395 44/170619
60
Total number of load-bearing Number of visible broken outer wires
wires in the rope’s outer layer of Rope sections that run over steel sheaves and/or Rope sections that are wound onto a multi-layer
strands are wound onto a single-layer drum (random dis‐ drum
tribution of broken wires)
over a length of over a length of
6d 30d 6d 30d
4 strands
2 4 2 4
n ≤ 100
3 or 4 strands
2 4 4 8
n ≤ 100
At least 11 strands in the outside
layer
71 ≤ n ≤ 100 2 4 4 8
101 ≤ n ≤ 120 3 5 5 10
121 ≤ n ≤ 140 3 5 6 11
141 ≤ n ≤ 160 3 6 6 13
161 ≤ n ≤ 180 4 7 7 14
181 ≤ n ≤ 200 4 8 8 16
201 ≤ n ≤ 220 4 9 9 18
221 ≤ n ≤ 240 5 10 10 19
241 ≤ n ≤ 260 5 10 10 21
261 ≤ n ≤ 280 6 11 11 22
281 ≤ n ≤ 300 6 12 12 24
n > 300 6 12 12 24
Tab. 36 Source: DIN ISO 4309:2013–06
211 395 44/170619
61
8.8 Wear limits on rope drums
Ds D d Di R
h b
e
V
43720244_xml.eps
Fig. 31
Size Drum length Rope Number Pitch h V17) Perm. Wear

dia. of rope im‐ depth
groove pression
s
d
When
ds s Di (+0,05 R D Ds Wear e18) b19)
new
[mm] [mm] [mm] –0,15) [mm] [mm] [mm] [mm] [mm] [mm]
[mm]
[mm]
H12/H20/H30 9 1 10 210 4,8 215,4 219 2,70 0,59 0,45 3,3
DMR 5 198,2
H20/H30 7 2 7,8 210,8 3,8 215,4 217,8 2,30 0,63 0,35 2,9
DMR H12/H20/ 13 1 14 261 7,1 268,9 274 3,95 0,74 0,65 4,7
246,2
10/16 H30/H40 9 2 10 262,8 4,6 268,8 271,8 3,00 0,83 0,45 3,8
Tab. 37
Important. Note on rope drum wear.

● The wear depth on the rope drum must not exceed the specified maximum dimension b at any position.
● Negative impressions in the rope groove root must not exceed the specified maximum dimension e.
211 395 44/170619
17) Wear V: max. 10% of the drum wall thickness

18) Perm.rope impression e: max. 5% of the wire rope diameter
62 19) Wear depth b = h + max (V ; e)
8.9 Wear limits on rope sheaves
43240444.eps
Fig. 32
Rope sheave without Rope sheave with

spokes spokes
Max. depth of strand
Groove root dia. Rope dia. Min. flange plate thickness impressions
Size Reeving [mm] [mm] tmin [mm] [mm]
4/2 180 7 6 4,5 0,5
DMR 5
2/1, 4/1
225 9 7 5 0,7
4/2
DMR 10
2/1, 4/1
4/1, 6/1, 270 13 7,5 5,5 0,9
DMR 16
8/1
Tab. 38
Important. Note on rope sheave wear.

● The cross-section of the rope groove must not be less than the specified minimum dimension tmin at any posi‐
tion.
● Negative impressions in the rope groove root must not exceed the specified maximum dimension.
● The cross-section of the rope groove must not be less than the specified minimum dimension tmin of the flange
plate thickness at any position.
The specified dimensions for negative impressions in the rope groove root are guide values for the condition of
the sheave when the rope is due to be replaced. If the values are reached or exceeded, the sheave should be
replaced or re-machined. The minimum wall thicknesses must be maintained. If the sheave develops negative im‐
pressions during the service life of a wire rope, the sheave does not need to be replaced, since ideal contact con‐
ditions for that rope will have developed.
211 395 44/170619
63
8.10 Installing wire rope
DANGER
Pre-tensioned components
Pay attention to the following hazards when replacing wire ropes:
– Crushing hazard/cutting hazard
– Shearing hazard
– Danger of entanglement or winding
– Hazards arising from drawing-in or entanglement
CAUTION
Risk of injury
8.10.2 Unwinding wire rope
43297544.eps
Fig. 33 Unrolling wire rope that is supplied loose

211 395 44/170619
43314844.eps
Fig. 34 Unrolling with a reel
– Before a wire rope is reeved, the whole length of the rope should be rolled out on the ground below the rope
64 hoist. Any twisting of the wire rope should be strictly avoided.
8.10.3 Securing the wire rope
8.10.3.1 Fitting the wire rope
43633345_xml.eps
Fig. 35
– Loosen the bolts of the three rope clamps (1) that are arranged around the rope drum.
– Insert the first winding of the wire rope under the three rope clamps (1) so that the rope leads off to the front.
– Tighten the bolts to the specified tightening torque, see  Tab. 39, Page 65
– Check tight fit of the rope clamps.
Range Reeving Bolt Rope clamp tightening torque [Nm]

DMR 5 2/1, 4/1, 4/2
M6 x 20 10.9 15,5
4/2
DMR 10
2/1, 4/1
M10 x 30 10.9 75
DMR 16 4/1, 6/1, 8/1
Tab. 39
You must wear thick gloves and work with utmost care to avoid injures when securing the wire rope.
– Tightly wind approx. 4 turns of the rope onto the drum.
To do this, switch on the hoist motor lifting motion to wind the wire rope onto the rope drum.
Ensure that the wire rope is kept tight and does not twist while reeving.
– Install the rope guide (see section  "Prepare the (reinforced) rope guide and place it on the rope drum",
Page 66).
211 395 44/170619
65
8.10.3.2 Prepare the (reinforced) rope guide and place it on the rope drum
2 2
A 3 B 3
1 4
12
4
1 11c
8
8 5
11a
6 7 6
5
7 X
11b
4 43706744_xml.eps
Fig. 36 Rope guide (A) and optional reinforced rope guide (B)
1 Side section 1 7 Side section 2

2 Rope guide rollers 8 Lower segment connection
3 Segment I (with rope guide rollers) 11 Cover plates
4 Upper segment connection a-c
5 Torque bracket 12 Retaining bolt
6 Segment II
Rope guide (A) or optional reinforced rope guide (B) must be partially dismantled before it is installed.
– Remove side section 1 (1) (and relevant cover plate (11a) for the reinforced rope guide).
– Remove torque bracket (5) (and relevant cover plate (11b) for the reinforced rope guide).
– Remove the nut and bolt of lower segment connection (8).
– On reinforced rope guides, also remove retaining bolt (12) of cover plate (11c) above upper segment con‐
nection (4)
– Pull the cover plate above the upper segment connection up. To do this, unscrew the remaining retaining
bolt, if required.
– Unscrew the nut of upper segment connection (4).
– Pull segment I (3) and segment II (6) apart leaving upper segment connection (4) closed.
– Place segment I (3) and segment II (6) onto the rope drum from above.
– Slide the rope guide sideways until it rests in the empty drum groove next to the wire rope on the drum so
that rope guide rollers (2) lie over the fitted wire rope.
211 395 44/170619
66
8.10.3.3 Connect the rope guide segments and install side section I
1.3 1.4
1.5
43352345_xml.eps
Fig. 37
– Insert bolt (8.1) and nut (8.2) into lower segment connection (8) and tighten them. Tightening torque 6 Nm.
See  Fig. 36, Page 66.
Push the segments as close together as possible so that adjustment marker (X) of lower segment connec‐
tion (8) is no longer in alignment. See  Fig. 36, Page 66.
– Check the position of the rope guide in the groove of the drum. The rope guide must be in close contact with
the wire rope.
– Tighten the bolt of upper segment connection (4). Tightening torque 6 Nm
– Place side section I (1) in the bore holes on the segment.
– Insert bolts (1.3) through the bore holes from behind and fit nuts (1.4).
– Push segments I + II as close together as possible so that adjustment marker (X) is no longer in alignment at
the top.
In this way, you ensure that the rope guide is in tight contact with the wire rope.
– Tighten the bolts. Tightening torque 6 Nm.
211 395 44/170619
67
8.10.3.4 Remove torque bracket and split pin from rope guide rollers
Important. When the rope guide is installed, the bolts must always be tightened with a torque wrench (6 Nm),
the locknuts only have to be countered.
– Align the rope guide in such a way that torque bracket (5) can be fitted, see  Fig. 38, Page 68.
– Place torque bracket (5) onto guide rod (9) and slide it into the guide holes of segment I (1).
– Insert bolts (5.3) through the bore holes from behind and fit nuts (5.4).
– Tighten the bolts. Tightening torque 6 Nm
– Lift rope guide rollers (2) off the wire rope by pressing them against the spring with a screwdriver (in the di‐
rection of the arrow) and remove split pin (10).
5 5.4
10
9
5.3 43633244_xml.eps 43633344_xml.eps
Fig. 38 Fig. 39
8.11 Shortening the wire rope

If it is necessary to shorten the wire rope, this must be done in compliance with engineering standards.
NOTE. The rope can be shortened by Demag service engineers or an authorised specialist company.
8.12 Lubricating the wire rope

The wire rope must be greased with Demag lubricant and preservative, part no. 665 020 44. Ensure that the
agent reaches the interior of the rope structure.
Grease the bearing points of the top block, crosshead, compensating sheave, the pin of the rope socket and the
guide rod of the rope guide with a suitable adhesive lubricant supplied by Demag, part no. 472 933 44.
8.13 Regular inspections and monitoring measures for load hooks

If a check or inspection reveals that these components are worn beyond the dimensions shown in  Fig. 40,
Page 69 and the table, or if deformations and cracks can be seen in these parts, the affected parts must be
replaced at once with genuine spare parts.
NOTE. The ball bearing must not be removed from the hook shaft. The ball bearing must only be replaced to‐
gether with the hook.
211 395 44/170619
68
Load hook inspection
Range DMR 5 DMR 10 DMR 16

Reeving 2/1, 4/2 4/1 2/1, 4/2 4/1 4/1 6/1 8/1
a2 Hook size 1,6 2,5 2,5 4 4 6 8
a a Hook opening 40 41 41 49 49 59 77
a1 56 63 63 71 71 90 100
a2 Nominal di‐ 45 50 50 56 56 71 80
mension 20)
a2 Maximum di‐ 49,5 55 55 61,6 61,6 78,1 88
a1
mension
h2 Nominal di‐ 48 58 58 67 67 85 95
mension21)
h2
h2 minimum di‐ 45,6 55,1 55,1 63,6 63,6 80,75 90,25

mension
43240044.eps
Tab. 40
Fig. 40
Check the hook safety catch for correct operation and for any damage.
The ball bearing must not be removed from the hook shaft. The ball bearing must only be replaced together with
the load hook.
8.14 Wear limits on travel wheels

● Replace the travel wheels when the following limit values [mm] are reached:
Rated diameter Replace as of Minimum diam‐ Minimum thick‐

D diameter D1 eter D2 ness of guide
flange F
90 87 84 6
100 97 94 7
110 107 104 8
140 135 130 8
200 195 190 11
250 245 240 11
Tab. 41
D2
D1
D
F
43720744_xml.eps
Fig. 41
211 395 44/170619
20) Permissible difference: +10%

21) Permissible difference: -5% 69
8.15 Oil change
CAUTION
Lubricants/oils
Risk of injury resulting from contact with the body/skin. Oils and lubricants are a health hazard.
Contact with these media can result in serious damage to health (poisoning, allergies, skin irritation, etc.)
– Pay attention to the manufacturer’s safety data sheets and instructions.
CAUTION
Risk of injury. Risk of slipping.
Leaking oils and lubricants are hazards due to the increased risk of slipping.
– Scatter sawdust or oil absorbent to absorb any spilt oils and lubricants without delay.
– Dispose of any spilt oils and lubricants in an environmentally compatible way.
8.15.2 Oil change procedure

The hoist gearbox is filled with the required quantity of lubricant before leaving the factory. In normal cases, it is
not necessary to change or supplement it.
Important. Oil leaks/loss of oil in the course of operation can cause damage to or complete failure of the ma‐
chine.
● Bring the machine to standstill.
● Notify Service.
– Place a container below the oil drain screw to catch the oil.
– Remove the oil drain screw.
– Wait until the gear oil has fully drained from the gearbox.
– Clean the gearbox parts and gearbox casing thoroughly with commercially available cleaning agents.
– Screw the oil drain screw back in.
– Fill with new gear oil.
For the required quantity and grade of oil, please refer to the technical data (see section  "Gearbox oil fill‐
ing", Page 19).
211 395 44/170619
70
8.16 Maintaining the brake on M motors
DANGER
Working on electric equipment
Danger of death due to electric shock.
Work on electric equipment may only be carried out by qualified electricians or by trained personnel.
Disconnect the installation from the power supply and secure it against reconnection before starting any mainte‐
nance work.
WARNING
Brake failure due to insufficient maintenance
Danger of death due to falling load
– Maintain the brake at the specified intervals.
– Replace the brake disc before it drops below its minimal permissible thickness.
– Replace the brake no later than after 1 million brake cycles.
8.16.2 Preparation work

– Lower the crane hook to the ground.
– Disconnect the installation from the power supply.
– Block the rope drum in such a way that it can no longer turn.
8.16.3 Replacement when maximum service life has elapsed

– Replace the complete brake when the its maximum service life is reached (1 million brake cycles).
– After replacement of the complete brake, reset the parameter to determine the calculated service life (7-24
Br Count) to zero.
8.16.4 Replacing the motor shaft
Wn ● Replace the motor shaft when its splines are worn or damaged:
43715744_xml.eps
Fig. 42
Splines on the motor shaft Motor type

MBV 100 MBV 112 MBV 132
Module [mm] 1,25 1,25 1,25
Number of teeth 18 26 26
Original condition 13,46–13,48 17,32–17,35 17,32–17,35
[mm]
Replacement recom‐ 13,4 17,2 17,2
211 395 44/170619
Wn mended [mm]
Min. permissible [mm] 13,3 17,1 17,1
Quantity of measured 4 5 5
teeth
Tab. 42 71
8.16.5 Dismantle brake
10
9
8
7
6 5
4 3
12
2
1
11
43715544_xml.eps
Fig. 43
– Remove the 2 retaining bolts.

– Remove fan cover (1).
– Remove retaining ring (2).
– Carefully pull fan (3) off the shaft.
– Remove retaining ring (4).
– Remove the 3 brake retaining bolts.
– Pull brake (5) off the shaft.
– Remove sleeve (6) and retaining ring (7).
– Pull brake discs (8) and friction disc (9) off the shaft.
– Press armature plate (12) onto the brake while you remove the 3 retaining bolts from the armature plate,
which is under pressure from the springs.
– Carefully remove the armature plate so that springs (11) each remain in their recesses.
– Mark the springs and relevant recesses so that the springs can be installed in their original position again at
a later date.
8.16.6 Check brake disc

The individual parts of brake types NM409 (stamped in red: RSM) and NM387 (stamped in red: RSM or RSM-H)
are not compatible with each other and, therefore, must not be swapped.
211 395 44/170619
– Measure the thickness of the brake disc.

– Compare the measured value with the values given in the following table. Refer to the brake for details on
the brake type.
72
– Replace the brake disc before it drops below its minimal permissible thickness.
– Replace the brake disc when the splines are worn or damaged.
Thickness of the brake disc [mm]

Brake type Original condition Replacement recommended Minimum permissible
NM41051DNR# 14 13,4 13
NM41040DNR# 11,15 10,6 10
NM40980DNR# 15,5 14,4 14
NM40951DNR# 14 13,4 13
NM40940DNR# 11,15 10,6 10
NM39972DNR# 7 6,8 6,6
NM38753DNR# 14 13,8 13,6
NM38751DNR# 14 13,4 13,2
NM38741DNR# 11,15 10,6 10,4
NM38740DNR# 11,15 10,6 10,4
NM38730DNR# 10,4 10,2 10,1
NM38721DNR# 8 7,8 7,6
NM38720DNR# 8 7,8 7,6
Tab. 43
8.16.7 Check friction disc

MBV 13x motors do not have a friction disc.
1 2 3 The brakes of M-type motors are equipped with different types of fric‐
tion discs (1–3) (A = working direction of the brake disc).
0.1
● If problems occur with the brake during operation, always replace the
installed friction disc with the current type with a machined sur‐
A A A face (3).
● Replace the friction disc if grooves can be seen on the friction sur‐
face or the friction disc is bent by more than 0,05 mm (“dished”).
A A A
43715644_xml.eps
Fig. 44
8.16.8 Install brake

– Install the individual parts in reverse order.
– Do not use any lubricants when installing the brake disc on the shaft.
– Install the brake and armature plate retaining bolts with the following torques:
Retaining bolt torque [Nm]
Brake type Brake Armature plate
NM41051DNR# 22 8
NM41040DNR# 22 3,5
NM40980DNR# 22 8
NM40951DNR# 22 8
NM40940DNR# 22 3,5
NM39972DNR# 5 3,5
NM38753DNR# 22 8
NM38751DNR# 22 8
NM38741DNR# 22 3,5
211 395 44/170619
NM38740DNR# 22 3,5
NM38730DNR# 9 2
NM38721DNR# 9 2
NM38720DNR# 9 2
Tab. 44 73
8.16.9 MBC travel motor: check friction disc and adjust air gap
3
4
5
6
43716844_xml.eps
Fig. 45
3 Friction disc 6 Adjusting bolt

4 Brake disc 7 Motor cover
5 Aluminium ring 8 Power supply plug
– Pull travel motor power supply plug (8).

– Open motor cover (7).
– Unscrew adjusting nut (6).
– Remove aluminium ring (5), brake disc (4) and friction disc (3).
– Measure the thickness of the friction material. If the material measures < 5 mm, replace the brake disc and
the friction disc.
– Install the friction disc, the brake disc, the aluminium ring and the adjusting nut.
– Adjust the air gap between the adjusting nut and aluminium ring to a distance 0,2 – 0,3 mm. Press the brake
disc against the pressure of the springs and adjust the air gap with the adjusting nut.
– Attach the motor cover
– Connect the travel motor power supply plug.
211 395 44/170619
74
8.17 General overhaul (GO)
WARNING
Operating safety at risk
Any failure to comply with the intervals for a general overhaul can result in serious injury or death.
Specified general overhaul intervals must be strictly complied with.
8.17.2 Procedure for general overhaul

The owner is obliged to carry out a general overhaul when the theoretical duration of service is reached (see sec‐
tion  "Regular inspections", Page 13).
When 90% of the theoretical duration of service has elapsed – after 8 to 10 years if the hoist is correctly classified
– the owner must arrange for a GO general overhaul to be carried out.
A GO general overhaul must be carried out by the end of the theoretical duration of service.
NOTE. The general overhaul may be carried out by Demag expert engineers or an authorised specialist compa‐
ny.
● The general overhaul carried out by the manufacturer or a specialist company authorised by him satisfies the
requirement to be met for continued operation of the machine.
During the general overhaul, the following parts must be replaced in addition to the checks and work specified in
the inspection and maintenance schedule:
● Gear wheels of the gearbox
● Gearbox bearings
● Motor
● Rope drum
● Gear oil
● Connecting elements
● Switchgear in the control system
The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not
listed separately.
Therefore, the provisions of the German Social Accident Insurance (DGUV) are satisfied.
The equipment may continue to be used when an expert engineer has entered the conditions for continued opera‐
tion in the log book. Completion of the general overhaul must be confirmed in the log book and a further period of
utilisation in accordance with FEM 9.755 must be entered.
211 395 44/170619
75
9 Malfunctions
9.1 Safety warnings
DANGER
Live components
Electric current can cause danger to life and limb.
safety regulations.
WARNING
Risk of injury.
Incorrect elimination of malfunctions can result in severe injuries and/or damage to property.
Malfunctions may only be eliminated by authorised and trained specialist personnel in compliance with all safety
regulations.
9.2.1 Target groups

appropriate conduct
Repair personnel
the machine
Service personnel
cranes.
211 395 44/170619
76
9.3 Conduct when malfunctions occur
Always:
1. Bring the machine to an immediate standstill by actuating the emergency stop without delay if malfunctions
occur that result in an immediate danger of injuries, damage and/or an operating safety hazard.
2. Disconnect the machine from the power supply and secure the machine against re-connection.
3. Inform the person responsible at the operating location about the malfunction.
4. Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per‐
sonnel.
9.4 Conduct after malfunctions have been eliminated
WARNING
Putting into operation again
Before switching on again, check that:
– Malfunction and cause of malfunction have been eliminated.
– All safety devices have been fitted properly and are in perfect condition and working order.
– Nobody is present in the danger zone of the machine.
9.4.2 Malfunctions, causes and remedy

For information on malfunctions, causes and remedy, see:
● ContactorControl (with OWL load detector)  211 377 44
● Operating instructions for DMR with SafeControl (SC)  211 809 44
● Assembly instructions for DMR without electric equipment (NC)  211 284 44
211 395 44/170619
77
10 Actual duration of service
10.1.1 Target groups

appropriate conduct
Repair personnel
the machine
Service personnel
cranes.
10.2 Calculating the actual duration of service
10.2.1 General
NOTE. A general overhaul must be arranged to be carried out when 90% of the service life has elapsed (when
10% is shown on the display).
Safe working period (S.W.P.)

The theoretical duration of service (to ISO 4301/FEM 9.755) in connection with the actual mode of operation (see
 Technical data, 203 769 44) results in the S.W.P. (safe working period).
NOTE. For further information, see control pendant operating instructions  Tab. 2, Page 2.
211 395 44/170619
78
10.2.2 With SafeControl system
A B C D
2
1+
1
F2
F1
ON /
I
F3
F2
I
0
43708144_xml.eps
Fig. 46 Control units for DMR
A DSE-10R control pendant (standard for Safe‐ C DRC-J joystick transmitter (optional)
Control) D DRC-MJ D3 hand-held transmitter
B DRC-10 hand-held transmitter (optional)
The load spectrum is recorded and calculated for the DMR rope hoist by the SafeControl system. The elapsed
duration of service is shown on the display of the control unit. Read the value and enter it into the log book when
the annual inspection is carried out. The value displayed is indicated in %.
10.2.3 With ContactorControl system

DMR rope hoists equipped with the ContactorControl system are supplied without an elapsed operating time
counter, as standard. An elapsed operating time counter can be added as an option to determine the actual dura‐
tion of service.
The duration of service can only be determined without an elapsed operating time counter by estimating the hours
of operation for DMR rope hoists equipped with the ContactorControl system.
211 395 44/170619
79
11 Tapered bore holes for fittings
11.1 Arrangement and size of bore holes
a 2 b
8
3; 4 8
1 5 6 5
1 1 1 3; 4 1 1
c
43650844_xml.eps
Fig. 47 Arrangement of EZ-DMR bore holes
Designation Max. permissible load [kg]

DMR 5 DMR 10/16
a Gearbox housing front and back 30 50
b Electric enclosure 5 22) 5 22)
c Foot flange front and back 20 40
Tab. 47
Tightening tor‐
Thread depth [mm] Max. permissible load Max. load
que
Transverse
Image Axial force FA force FQ
Bore hole size item Min. Max. N N kg Nm
KM5 x 10 8 7,5 10,0 600 300 5 22) 6
2 5
KM6 x 9 7,2 9,0 1000 500 10
7 2 23)
KM8 x 12 5 9,6 12,0 20
2000 1000 25
KM8 x 16 1 12,0 16,0 20
KM10 x 15 6 12,0 15,0 20
3000 1500 50
KM10 x 20 3 15,0 20,0 24)
KM12 x 18 4 14,4 18,0 4000 2000 25) 86

Tab. 48 KM bore hole sizes
IMPORTANT. A rigid connection must not be established between the gearbox and foot flanges under any cir‐
cumstances. The structure of the rope hoist must remain elastic. All requirements with reference to maximum
forces and loads given in  Tab. 48, Page 80 must be met.
211 395 44/170619
22) Only
for electric fittings
23) Only
for cable attachment
24) DMR 5
80 25) DMR 10/–16

12 Disposal

- Repairs malfunctions and defects - Trained specialist with mechanical and/or electrical training
Repair personnel
the machine
Service personnel
12.2 Disassembly and disposal of the rope hoist

Unless a return or disposal agreement has been concluded, recycle separated components after proper removal:
● Scrap any remaining metallic material
● Dispose of plastic elements for recycling
● Separate and dispose of any other components by material type
NOTE. Electric scrap, electronic components, lubricants and other auxiliary materials are subject to special dis‐
posal regulations and may only be disposed of by certified companies.
National disposal regulations must be considered regarding environmentally friendly disposal of the machine. Fur‐
ther information can be obtained from corresponding local authorities.
211 395 44/170619
81
13 Regulations, standards, directives

appropriate conduct
Repair personnel
the machine
Service personnel
cranes.
13.2 Inspection regulations

Notes on inspections in accordance with:
● UVV Winches, lifting and towing devices, DGUV Regulation 54
● UVV Cranes, DGUV Regulation 52
● EN 14492-2 – Cranes; Power-driven winches and hoists; Part 2: Power-driven hoists
● EN 15011 Cranes – Bridge and gantry cranes
EC Machinery Directive 2006/42/EC requirements are, therefore, also fulfilled.
211 395 44/170619
82
14 Information
14.1 After-sales service

If you have any questions about our products or need technical information, etc., please contact our after-sales
service.
Please keep the serial or order number (see log book, 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.
The relevant after-sales service centre is specified for example on the back page of your Demag rope hoist log
book.
Addresses and contacts

The current addresses of our sales offices in Germany and our subsidiaries and agencies worldwide can be found
on our homepage at www.demagcranes.com.
211 395 44/170619
83
Original Ident. number / Language
EC conformity declaration for a machine 19800644 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
1217 1/ 2
Hereby we,

Forststrasse 16, 40597 Düsseldorf, Germany
declare that the product
Demag EZ-DMR double-rail crab

Serial no.: XXX-XXX-XXX
ready for service - as a series product or manufactured to order - after completion of
assembly/being put into service including function check and load test prior to being
put into service to be confirmed on page 2 complies with all relevant requirements of
EC Machinery Directive 2006/42/EC.
The safety objectives of Low Voltage Directive 2014/35/EU are achieved.

The product additionally complies with the following relevant directives/provisions:
EU EMC Directive 2014/30/EU
e
pl Applied harmonised standards and/or C standard drafts, in particular:
EN 14492-2 Cranes - Power driven winches and hoists -

Part 2: Power driven hoists
EN 60204-32 Safety of machinery - Electrical
equipment of machines - Part 32:
Requirements for hoisting machines
EN 61000-6-2 Electro-magnetic compatibility (EMC), Part 6-2:
am
Generic standards - Immunity for

industrial environments
Generic standards - Emission for
Authorised representative for technical documentation:

Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany
S
Düsseldorf, 22.10.2019
ppa. Thomas Wiesmann i.V. Oliver Moll

Head of Plant Wetter Hoist Platform
Industrial Equipment
U04281
Subject to change. No liability for errors or omissions

EC conformity declaration for a machine 19800644 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
1217 2/ 2

-----------------------------------------------------------------------------------------------------------
For assembly / first putting into service including function check
...................................., date ................................................
Company that carries out the work: ................................................
Function in the company: ................................................
Name: ................................................
Signature: ................................................
e
pl ------------------------------------------------------------------------------------------------------------
For the load test in the scope of the acceptance test
...................................., date ................................................
Company that carries out the work: ................................................

am
Function in the company: ................................................
Name: ................................................
Signature: ................................................
S
U04281

Declaration for fitting partly completed machinery 19800544 / EN
according to Machinery Directive 2006/42/EC, Annex IIB Issue Page
1217 1/ 1
Hereby we,

Forststrasse 16, 40597 Düsseldorf, Germany
declare that the product

supplied as partly completed machinery is intended to be incorporated into machinery and its
initial bringing into service is prohibited until the machinery* into which this partly completed
machinery is to be incorporated has been declared in conformity with all relevant provisions of
EC Machinery Directive 2006/42/EC.

(* insofar as this machinery is subject to the scope of application)
Basic requirements of the EC Machinery Directive, insofar as they are relevant for the scope of
delivery, are met by application of the following harmonised standards or C standard drafts:
e
EN 14492-2 Cranes - Power driven winches and hoists -
Part 2: Power driven hoists
EN 60204-32 Safety of machinery - Electrical
equipment of machines - Part 32:
pl EN 61000-6-2
Requirements for hoisting machines
Electro-magnetic compatibility (EMC), Part 6-2:
Generic standards - Immunity for
am
Generic standards - Emission for

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

The product additionally complies with the following relevant directives/provisions:
EU EMC Directive 2014/30/EU
The special technical documentation according to Annex VII Part B of Directive 2006/42/EC has
been compiled and will be made available to authorised national authorities by the designated
S
authorised representative in response to a justified request.

Authorised representative for technical documentation
Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany
Düsseldorf, 22.10.2019
ppa. Thomas Wiesmann i.V. Oliver Moll

Head of Plant Wetter Hoist Platform
U04281

Index
A Symbols 8
S.W.P. 78
After-sales service address 83
B
Block adjustment 43
C
Checking crane structural design 45
Cylindrical-rotor motor 24
D
DC brake 24
Design overview 24
Drives 24
E
ELM load detector 25
Emergency limit switch 42
G
Geared limit switch 42
GO (general overhaul) 75
H
Helical gearbox 24
I
Individual adjustment 43
Installing the EOD 40
M
Maintenance 53
Manufacturer’s address 2
Minimum requirements for runways 22
Model code 14
O
Operating limit switch 42
Operation 46
P
Protective cover 38
R
Rope anchorage 65
S
211 395 44/170619
Signal words 8
Size designations 14
Switching off 52
87
The current addresses of our sales offices, subsidiaries and agencies worldwide can be
found on the homepage
www.demagcranes.com

PO Box 67 · 58286 Wetter (Germany)
Phone +49 (0)2335 92-0
Printed in Germany
Fax +49 (0)2335 92-7676

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

Instrucciones de Operacion Biriel

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Instrucciones de Operacion Biriel

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Operating instructions

Demag DMR modular rope hoist

170619 en GB 211 395 44 720 IS 813

Main hoist motor number

Circuit diagram number

Documents 1) Part no.:

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

3 Technical data ......................................................................................................................................................... 14

5 Transport, packing, storage ................................................................................................................................... 27

6 Installation and putting into operation for the first time...................................................................................... 29

7.2 Personnel requirements ............................................................................................................................................ 47

8.16.4 Replacing the motor shaft ......................................................................................................................................... 71

13 Regulations, standards, directives........................................................................................................................ 82

1.1 Information on the operating instructions

1.3 Log book

2.2 Structure and meaning of the instructions

2.2.1 Safety warnings

2.2.2 Structure of safety warnings

2.2.3 Further information

Fig. 1 Labels and pictograms

A Rope retaining arrangement in rope socket C Refer to the operating instructions

– Pay attention to any pictograms, signs or labels on the rope hoist.

2.4 Intended use

2.5.2 Qualification of personnel

Designation Activities Qualification

2.6 Personal protection equipment

Fig. 2 Control pendants/radio transmitters for DMR rope hoists

A DST control pendant D DRC-J(S) joystick transmitter (optional)

211 395 44/170619

2.9 Inspection regulations

3.1 Explanation of size designations/type assignment

Required supply cable conductor cross-sections and fuse links

3.2.2 MBV hoist motors, inverter-controlled

Motor type Brake No. of poles PN % CDF n cos Weight

2) Fuse links also apply in connection with a cross-travel motor.

16 16 2m/M5 6/1 0,22-4,3-6,4 MBV 112 B4 NM38746DNR2 040

Required supply cable conductor cross-sections and fuse links

Size DMR 5 – 16 Supply lines 3) for 5% voltage drop ∆U and

Inverter input voltage: 380–480 V, 50/60 Hz

3.2.3 MF cross-travel motors, inverter-controlled

Range Motor type Brake Frequency inverter

Motor size Frequency No. of poles PN CDF n Rated cur‐ Weight

3.4 Gearbox oil filling

Gearbox Oil type8) EZ-DMR 5 EZ-DMR 10/16

3.6 Noise emission

Sound pressure level measurement to DIN 45635

Range Hoist unit

Range Cross travel

20 10) All noise level data are subject to a tolerance of ± 2 dB (A).

RAL 5009 azure blue

3.8 Deadweight of the crab without bottom block [kg]

Bottom block weights [kg]

Cross-travel speed [m/min]

3.9 Track girder requirements

Fig. 4 Runway paint finish

Minimum requirements for runways:

- Tolerance of the individual girder, of the crab track gauge

3.9.2 Travel unit

4.1 EZ-DMR double-rail crab design overview

1 Top block 5 Electric equipment box

4.2.1 MBV hoist motors

4.2.2 Travel drive

4.2.3 Gearbox/rope reeving components