Demag DVR

Objectives

After the training, participants can...

…explain Rope hoist components and features.

...carry out annual maintenance.
…carry out maintenance and replace a brake.
…check and replace a rope guide and a wire rope.
...carry out maintenance on the rope anchorage, the rope pulley and the bottom block.
...check and replace the coupling between the hoist motor and hoist gear.
...carry out maintenance on the cable drum. (renew drum bearing)
...perform settings on the limiting device of the hoist.
...know additional components such as the drum brake and the additional brake.

2 05/04/24
Agenda day 1

Welcome, introduction & overview of the training, safety briefing

General overview of the DVR Rope Hoist
General maintenance instructions
Lunch break
Maintenance and inspection of the hoist brake and the trolley brake
Maintenance and inspection of the rope guide, the wire rope, the rope anchorage, the rope
pulley and the bottom block

3 05/04/24
Agenda day 2

Brief recap of day 1

Maintenance and inspection of the lifting gear and hoist gear coupling
Maintenance and dismantling of the cable drum
Lunch break
Reassembly of the hoist and adjustment of the limiting device
Maintenance instructions drum brake, auxiliary brake
Rating / Feedback / end the training

4 05/04/24
Safety
DVR Hoist
Owerview
 42673
F-DVR: Food-mounted rope hoist

42671-1
EK–DVR: Low headroom trolley

42675
42698 EU-DVR: Standard-headroom trolley

42677
EZ-DVR: Double-girder trolley
5 sizes at a glance

Load capacity [t] F

EK
Size EU
1 1,25 1,6 2 2,5 3,2 4 5 6,3 8 10 12,5 16 20 32 40 50 63 80 EZ

DVR 3
F
DVR 5 EU
EZ

DVR 10

DVR 20 F
EZ
DVR 40

8 05/04/24
 Product Overview: DVR 3 - 10

Lifting Lifting speed [m/min 50 Hz]

Load capacity [t] Configuration
Frame height Dual speed
Reeving
size
F- EK- EU- EZ-
1.0 1,25 1,6 2.0 2.5 3.2 4.0 5.0 6.3 8.0 10 12.5 16 20 25 32 40 50 63 80 [m]
DVR DVR DVR DVR
Entry Standard Medium Fast

2/1 M6 M6 M5 12 ; 19 ◼ ◼ ◼ ◼ 10 / 1.7 12.5 / 2.1 16 / 2.7

DVR 3
4/1 M6 M5 6; 9.5 ◼ ◼ ◼ ◼ 5 / 0,8 6.3 / 1.1 8 / 1.3

2/1 M6 M5 M4 12; 18; 24; 30 ◼ ◼ ◼ ◼ 10 / 1.7 16 / 2.7

DVR 5
4/1 M6 M5 M4 6; 9; 12; 15 ◼ ◼ ◼ ◼ 4.0 / 7 5 / 0,8 8 / 1.3

2/1 M6 M5 M4 18; 24; 32; 40 ◼ ◼ ◼ ◼ 10 / 1.7 16 / 2.7 20 / 3.3

4/1 M6 M6 M6 M5 M4 9; 12; 16; 20 ◼ ◼ ◼ ◼ 4.0 / 7 5 / 0,8 8 / 1.3 10 / 1.7

6/1 M6 M5 6; 8; 10; 13 ◼ ◼ ◼ 3.2 / 0.5 5 / 0.8 6.3 / 1.1

8/1 M5 M4 4.5; 6; 8; 10 ◼ ◼ ◼ 2.5 / 0.4 4 / 0.7 5 / 0.8

DVR 10
4/2 M6 M5 8.5 - 46 ◼ ◼ ◼ 10 / 1.7 16 / 2.7 20 / 3.3

8/2 M6 M6 M5 4 - 23 ◼ ◼ ◼ 5 / 0.8 8 / 1.3 10 / 1.7

12/2 M6 M5 4 - 15 ◼ ◼ ◼ 3.2 / 0.5 5 / 0.8 6.3 / 1.1

16/2 M5 M4 4.5 - 11,5 ◼ ◼ ◼ 2.5 / 0.4 4 / 0.7 5 / 0.8

9 05/04/24
 Product Overview: DVR 20 & 40

Lifting Lifting speed [m/min 50 Hz]

Load capacity [t] Configuration
Frame height Dual speed
Reeving
size
F- EK- EU- EZ-
1.0 1,25 1,6 2.0 2.5 3.2 4.0 5.0 6.3 8.0 10 12.5 16 20 25 32 40 50 63 80 [m]
DVR DVR DVR DVR
Entry Standard Medium Fast

2/1 M6 M5 M4 12 ; 19 ◼ ◼ ◼ 8 / 1.3 10 / 1.7 12.5 / 2.1

4/1 M6 M5 M4 6; 9.5 ◼ ◼ ◼ 4 / 0.7 5 / 0.8 6.3 / 1.1

6/1 M6 M5 12; 18; 24; 30 ◼ ◼ ◼ 2.5 / 0.4 3.2 / 0.5 4 / 0.7

8/1 M5 M4 6; 9; 12; 15 ◼ ◼ ◼ 2.0 / 0.3 2.5 / 0.4 3.2 / 0.5

DVR 20
4/2 M6 M5 M4 18; 24; 32; 40 ◼ ◼ ◼ 8 / 1.3 10 / 1.7 12.5 / 2.1

8/2 M6 M5 M4 9; 12; 16; 20 ◼ ◼ ◼ 4 / 0.7 5 / 0.8 6.3 / 1.1

12/2 M6 M5 6; 8; 10; 13 ◼ ◼ ◼ 2.5 / 0.4 3.2 / 0.5 4/ 0.7

16/2 M5 M4 4.5; 6; 8; 10 ◼ ◼ ◼ 2.7 / 0.3 2.5 / 0.4 3.2 / 0.5

4/2 M6 M5 M4 8.5 - 46 ◼ ◼ 8 / 1.3 10 / 1.7 12.5 / 2.1

8/2 M6 M5 M4 4 - 23 ◼ ◼ 4 / 0.7 5 / 0.8 6.3 / 1.1

DVR 40
12/2 M6 M5 4 - 15 ◼ ◼ 2.5 / 0.4 3.2 / 0.4 4 / 0.7

16/2 M5 M4 4.5 - 11,5 ◼ ◼ 2.0 / 0.3 2.5 / 0.4 3.2 / 0.5

10 05/04/24
F-DVR: Food-mounted rope hoist

Ideal for stationary applications or for special

crabs
Reeving parts for all common reeving
arrangements are fitted to the hoist unit –
enabling foot hoists to be integrated direct into
prepared steel structures or special crabs
Up to 80 t load capacity
42673

11 05/04/24
EK-DVR: Low Headroom Design

Short hook end approach

Jump-off and axle failure protection
Two driven trolley wheels
Infinitely adjustable trolley flange width
Up to 12,5 t load capacity

42671-1

12 05/04/24
EU-DVR: Standard-headroom hoist

EU-DVR for standard headroom

Variable flange width: 80 – 610 mm
EUD-DVR with articulated trolley,
suitable for travel on curved track
▪ Radius 1.500 - 2.500 mm

B Radius R min
90 – 109 2.500
42675

110 - 119 2.000

120 - 350 1.500

13 05/04/24
EZ-DVR: Double-girder-trolley

Short track gauge (starting with 900mm) and

end truck length
Equal wheel load distribution
Versatile designs (low, medium, high
connection)
Two drive units (no open gearings)
42677 Up to 80t load capacity

14 05/04/24
Demag-Code example
(Demag: DVR (Factory code: Q)

15 05/04/24
Reeving Code

▪ Codes are used to describe reeving arrangements: Number falls per rope + the number of ropes
▪ E.g. 4 falls and only 1 rope = 041
▪ When ropes are fixed to both sides of the drum, it is referred to as ‘True Vertical Lift’ (TVL)

021 041 061 081 101 082

16 05/04/24
DVR: Lifting motor Pro Hub & Pro Hub+

Pro Hub with A Motor

DVR10-10 ASR Dual speed
▪ Bearing pulse sensor
Lifting speed m/min 0.3...2.5 (7.5) 1/6
▪ Integrated fan ventilation
▪ Open loop Motor output kW 4.5 9.0

▪ Inverter controls speed, but does not Daily usage hours 1 1

change speed Annual workdays days 240 240

Energy consumption kWh/a 1,080 2,160

Pro Hub+ with S motor
Crane lifetime years 10 10
▪ Encoder Lifetime energy
kWh 10,800 21,600
▪ External motorized fan consumption
€/kWh
▪ Closed loop Cost per kWh ~0,3189 ~0,3189

▪ Inverter controls & changes speed Lifecycle cost € ~3,444€ ~6,888€

42442

42441
17 05/04/24
Secure & safe: Rope guide

All rope guides made from metal

Bracket type metal rope guide up to DVR 10
Optional full-wrap rope guide on DVR 10
Standard full-wrap rope guide on DVR 20/40

Benefits:
Safe guidance of ropes on drum
Extended rope lifetime

42679

18 05/04/24
Gear limit switch

Direct drum position socket

4 adjustable switching points
New limit switch with black adjustment
screw for central adjustment
Approach S2, S3 and S4 and compare
dimensions
S1 can be located in front of the main
contactor as well as in front of the sink
contactor as a break contact, check it in
the circuit diagram if necessary

c_holi2a
19 05/04/24
Ergonomic control pendants

DSB (Standard): DST (Option):

4 sizes with up to 10 User-friendly design in various
buttons and 1 emergency off configurations with up to 9 control
elements
2-stage buttons and 1
emergency off for crane Low-fatigue operation thanks to
motions in 3 axes ergonomic housing design

42772-1
42792-6
42790-1
42682
Up to 4 other control elements Sloping pendant controller design
(freely assignable) permits operators to work in a
natural, comfortable posture
IP 65 enclosure
High operating reliability thanks to
additional strain relief elements

20 05/04/24
Further options to meet specific application needs

Radio control
Second hoist brake for DVR 3, 5, 10
Drum brake for DVR 20 and 40
DIN single or double hooks
Rope pressure roller
Cable reels
Horn
Large load display
Maintenance platform
Stainless-steel switchgear cabinets
Rain cover

42669-2
Ex-proof construction

21 05/04/24
DMI inverter: Configured to meet specific application needs

DVR units can offer variable-speed drive

solutions for lifting and travel motions at different
technology levels.

The benefits of their inverters are self-evident:

▪ Variable speeds: 1:10, 1:25, ESR 1:37
▪ Reduced wear: Gentle start-up/lifting reduces the load

42754-3
on the crane system
DMI 045 ▪ Longer motor/brake service life

42753-3
▪ Significant energy savings by up to 50%

DMI 017/028 ▪ Load-dependent lifting speed for higher productivity:

▪
42752-3

High speed without load (up to 10%)

▪ Medium speed with partial load
DMI 009
42751-3

▪ Precise speed with full load

DMI 004

22 05/04/24
DMI: App connection

42754-3
DMI 045

42753-3

DMI 017/028
42752-3

DMI 009
42751-3

DMI 004

23 05/04/24
Control units

OWL DMU
Overload protection for individual hoists Overload protection

42445-3
Simple condition monitoring Monitoring for sudden load increase

42680
Number of switching operations Temperature monitoring for motors
Operating time SWP hour counter
Number of braking operations
Monitoring of the motor function
Number of control operations
Monitoring of the supply voltage phase
ON time
Motor start/stop due to slow speed
Temperature index
Multi-hoisting tandem (up to five units)
Number of events with overload
Design limits (warnings)
Can be used for SWP calculation
Optional remote monitoring modem
Smart functions
CAN bus functionalities

24 05/04/24
Comfort & safety: Smart features

Follow me Area-specific load reduction

Makes lifting operations much faster because the crane can be Areas can be defined which the travelling hoist may only enter
moved above the load by simply guiding the hook by hand. if the load does not exceed a reference value. This reduces the
(Recommended for cranes up to 10 t) load on the runway and building structure – especially when
several cranes operate on one runway.
Slack-rope prevention
Anti-sway control
Continuous monitoring of the rope tension: The hoist drive
automatically switches off when the load has been lowered to its Prevents increased load sway by active counter-motions
target position or if the hook is accidentally snagged. Reduces the of the crane. Active system based on rope angle measurement
risk of damage to the load, crane and surrounding area. to detect and dampen any existing load sway.

Tandem control Target positioning

Loads can be safely transported by two DVR rope hoists – Loads can be automatically transported to a selected
via a single control unit. Two cranes with up to four rope hoists target position as long as the crane operator presses the
can also be synchronised. corresponding button on the radio control.

Bypass control
Areas to be blocked for the travelling hoist can be specified.
In this way, you can safely by-pass high parts of machinery
or zones that are out of bounds.

25 05/04/24
DVR: Compact. Versatile. High performance.
Periodic inspections and maintenance tasks

Bridge and Railway Rope reeving system

Trolley Wire rope
Traveling machinery Rope guide
Hoisting gearbox Overload protection
Hoisting motor Ultimate hoisting limit switch
Hoisting brake Hook-block
Hoisting limit switch Electrics
Rope drum Machinery reevings
Drum brake Rope sheave maintenance

27 05/04/24
Hoist gearbox

Compact design
Lifetime lubrication
Powder coated case
Low-noise operation due to helical gearing
Hardened, robust gears

Drive pinion of the rope drum

Motor shaft coupling
Gear limit switch

28 05/04/24
Motor/hoist gear removal

29 05/04/24
Hoist brake

Reliable magnetic brake

Dust protected
High ED rating (ED 100%)
Brake lining with a long service life
Air gap control not possible

30 05/04/24
Inspection hoist brake

Brake air gap not self-adjusting

Capsuled
Air gap not controllable

Dentate brake disc

Gearing of the brake hub
Brake disc wear
Friction disc condition
Installation position of the brake disc

31 05/04/24
Inspection hoist brake

Dentate of the brake disc

If there are cracks or damage to the teeth,
replace the brake disc immediately!

32 05/04/24
Inspection hoist brake

33 05/04/24
Second brake

A second brake can optionally be located on the transmission side

The same procedure as for the lifting brake on the motor side

34 05/04/24
Checking the coupling – Gearbox and motor removal

35 05/04/24
Checking the coupling – Gearbox and motor removal

36 05/04/24
Checking the coupling – Gearbox and motor removal

37 05/04/24
Checking the coupling – Gearbox and motor removal

38 05/04/24
Checking the coupling – Gearbox and motor removal

39 05/04/24
Disassembly of QD and QE hoist

Motor is outside drum.

Motors and gearboxes can be

removed separately.

Coupling inspection is the same.

40 05/04/24
Gearbox – motor coupling

Remove fan cover

Remove bolts to remove motor

Carefully lift straight up on motor to

separate from gearbox.

Remove coupling and inspect for damage.

41 05/04/24
Coupling inspection
Inspect Motor and Gearbox shaft splines—Shafts
are case hardened. Replace component if any
FEM 1Am, 1Bm: 1x every 8 years wear is visible
FEM > 2m: 1x every 4 years Inspect snap rings and splines around them for
Temperature > 40C: halving time damage
If any damage is found or any question on coupling
or o-ring condition dispose of properly and replace
with new.

Groove to gear side! Incorrectly installed coupling

05/04/24
Trolley drive

MF06 with service-friendly compact brake

Gearbox lubricated for life
Autotuning possible during parameterization
Compact design
Encapsulated, one-sided roller drive

43 05/04/24
Trolley brake

MF06, MF07 and MF10 with DC brake

min. brake disc thickness based on the type.

44 05/04/24
Trolley brake

Compact brake MF06 holding brake, i. H. it is braked via

the FU
Minimum brake disc thickness 5 mm
Air gap 0.2….0.3 mm

45 05/04/24
Drum Brake

1. Brake pad
2. Cam ring
3. Brake pawl
4. Detent spring
5. Scooter
6. Micro switch
7. Drum
8. Holding brake pawl
9. Magnet
10.Holding brake magnet
11.Micro switch

46 05/04/24
Drum Brake

Cam Wheel

Holding Brake
Overspeed Brake

Brake Rim

Follower
Detent Arm

47 05/04/24
Control of rope anchorage

Check the fastening bolts for tightness

Check the tripping of the emergency circuit breaker

Measure the distance

between the end of the rope and the rope clamp = 50
between the end of the rope and the rope pocket = 100.

Check the correct installation position of the rope pocket and

the rope wedge

Check mobility and lightly oil

48 05/04/24
Control of the rope guide

Guide rod
Edge of the rope guide
pinch roller
Worn shafts can be exchanged for each other

49 05/04/24
Control of the rope guide

The distance between the start of the groove

and the screw head should be 15 mm

Excessive tightening of the screws will result

in damage. If necessary, install expansion
plates

50 05/04/24
Control of the rope guide

Incorrectly installed rope guide &

diagonal pull

51 05/04/24
Rope inspection

Every year or 10% SWP

Use sturdy gloves!
Check wire rope only when stationary! - Risk of injury
Lubricate with suitable oil (e.g. Shell Tellus 32)
Check for:
▪ wire breaks
▪ diameter reduction
▪ Deformation and changes in the rope structure

52 05/04/24
Rope inspection

With a conventional rope test you can only

check about 20% of the rope.
The remaining 80% are not visible from the
outside.
Ropes that therefore show external
defects or visible deformations should be
replaced immediately!

53 05/04/24
 Rope inspection

Rope clamps

Check for a tight fit

Excess length of the loose
end ➔ 5x rope diameter

54 05/04/24
Rope drum / pulleys

Check drum grooves for sharp edges and entry

If in doubt, compare used grooves with unused

ones

When using the gauge: max. deviation = rope

diameter + 4% to 6%

55 05/04/24
Hook / hook block

Check the safety latch for ease of movement

and oil it

Control sheaves

Control measure dimensions

Check the hook block thrust bearing for

rotation

56 05/04/24
Hook / hook block

With the hook blocks of newer design, the complete

hook block no longer has to be dismantled in order to
exchange hooks and axial bearings.
The opening plate is provided for this purpose.

57 05/04/24
Lubrication - General lubrication instructions

Most bearings are lubricated for life. Under normal operating conditions, bearings lubricated for life
do not need to be lubricated.
Do not use too much grease. Too much lubricant can cause bearings to overheat and shorten
bearing life.
Use only compatible lubricants to top up gear oil. If the transmission oil needs to be replaced, first
flush the transmission.
The product may be factory-filled with synthetic lubricant. See order confirmation.
The slide bearings must not be under pressure so that the grease can penetrate.
When lubricating the bearings, check that they are functioning correctly.
Check the bearings for play.
The specified lubrication intervals apply to favorable conditions during normal operation.
The gears of the open gear must be fully lubricated

58 05/04/24
 Schmierung Getriebe

Lubricated for life

Control:
Gear hoist
Gearbox trolley
Leak control
Clean ventilation
!

59 05/04/24
Hoist - Trolleys Pos component Intervall

1 Traveling gear Lifetime lubricated

2 Traveling Annual
transmission
3 Rope anchorage Annual
4 Hoisting gear Lifetime lubricated
5 Drum gear rim Annual

6 Rope Monthly-Annual
7 Rope drum Annual if not life time
bearings lubricated

8 Rope guide Annual

9 Drum Annual

10 Hook thrust/slide Annual if not life time

bearings lubricated

60 05/04/24
Rope anchorage, Hoist gearbox, rope

61 05/04/24
Rope drum bearings, Rope guide

62 05/04/24
Hook thrust/slide bearings

Figure A and B:
these hook blocks include a thrust bearing, but
no slide bearings. - Hook block disassembly is
always needed for lubricating the thrust
bearing.

Figure C and D:
grease nipples for slide bearings and thrust
bearing. If there is only one grease nipple at
each end of the cross bar, then the hook block
must be disassembled for lubricating the thrust
bearing.

63 05/04/24
Rope drum

Gear rim

Left and right: 1x up 1x down

Always lubricate only one lubrication point

per side

64 05/04/24
Rope drum

Lubricate while the drum is rotating!

2 x pump stroke
2 turns

65 05/04/24