end carriage dfw s e assmebly

290413 enGB 719 IS 845.5

41238844.eps

214 276 44

Assembly instructionsDRS 112, 125, 160, 200 wheel block system

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Contents

Further documents

Manufacturer Demag Cranes & Components GmbHDrivesPO Box 67 · 58286 Wetter, GermanyPhone +49 (0)2335 92-0 · Telefax +49 (0)2335 92-7676Email: [email protected]

Original assembly instructions

General documents Order no.

DE EN FR ES

Brochures

Demag drives brochure 208 732 44 208 734 44 208 735 44 208 736 44

Demag wheel range brochure 208 722 44 208 724 44 208 725 44 208 726 44

Catalogues/technical data

Drive Designer Online www.demag-drivedesigner.com

Geared motors catalogue 203 150 44 203 151 44 203 152 44 203 153 44

DRS wheel block system 203 350 44 203 352 44 203 353 44 203 354 44

Demag DWS wheel set technical data 203 687 44 203 688 44 203 689 44 203 690 44

Geared travel motor catalogue – Volume 3 – Quick selection and gearbox limit torque – DE / EN / FR 203 013 44 –

Geared travel motor catalogue – Volume 3 – Quick selection and gearbox limit torque – IT / EN / ES – 203 014 44 – 203 014 44

Assembly instructions

D 11 - D 41 helical gearbox assembly instructions 214 719 44 214 720 44 214 721 44 214 722 44

D 50 - D 90 helical gearbox assembly instructions 214 150 44 214 151 44 214 152 44 214 153 44

W 10 - W 100 angular gearbox assembly instructions 214 057 44 214 058 44 214 059 44 214 060 44

A 10 - A 90 offset gearbox assembly instructions 214 205 44 214 206 44 214 207 44 214 208 44

FG 06, FG 08, FG 10 gearbox assembly instructions 206 217 44 206 218 44 206 219 44 206 220 44

Motor assembly instructions – Z motor range 214 227 44 214 228 44 214 229 44 214 230 44

KBA - KBF motor assembly instructions 214 317 44 214 318 44 214 319 44 214 320 44

Assembly instructions for brake accessories – Z motor range 214 040 44 214 041 44 214 042 44 214 043 44

Assembly instructions/plug connection for KB and Z motor ranges 214 021 44 214 022 44 214 023 44 214 024 44

Encoders for Z motors, assembly instructions 214 371 44 214 372 44 214 373 44 214 374 44

DRS 112-200 wheel block system assembly instructions 214 275 44 214 276 44 214 277 44 214 278 44

DRS 250-500 wheel block system assembly instructions 214 326 44 214 327 44 214 328 44 214 329 44

DWS wheel set assembly instructions 214 132 44 214 133 44 214 134 44 214 135 44

0 Foreword 40.1 Copyright 40.2 After-sales service 40.3 Liability for defects 40.4 Limitations of liability 50.5 Defi nitions 5

1 Safety 61.1 Symbols 61.2 Intended use 61.3 Prohibited practices, improper use 61.3.1 Specifi cation 61.3.2 Assembly 61.3.3 Environmental infl uences 61.3.4 Maintenance 6

2 Brief technical description 72.1 Overview 72.2 Type designation key (example) for basic wheel blocks 82.3 Type plate 102.4 Paint fi nish 11

3 Receiving and storage 123.1 Checking goods on receiving 123.2 Transport 123.3 Storage 123.4 Weights 12

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4 Assembly and alignment 134.1 Travel wheel types 134.2 Assembly instructions 144.2.1 Top connection 144.2.1.1 Fitting universal shaft F for top connection 154.2.2 Side connection 164.2.2.1 Fitting universal shaft F for side connection 174.2.3 DRS 200 side connection with AD.50/WU.60 gearboxes 184.2.4 DRS 112 – 200 pin connection 204.2.5 DRS 200 pin connection with AD.50/WU.60 gearboxes 224.2.6 Fitting the wheel block 234.2.6.1 Axial retaining arrangement with track gauge adjustment 234.2.6.2 Pin set 244.2.6.3 Fitting pin connection (without welded plate) 254.2.6.4 Fitting pin connection (with welded plate) 254.2.6.5 Fitting universal shaft F for pin connection 264.2.6.6 Fitting pin connection with spacer plates for DRS 200 – AD50/WU60 264.2.6.7 Fitting end connection with spacer plates 274.2.6.8 Fitting torque brackets for pin and end connection 274.2.6.9 Fitting torque brackets for pin and end connection

DRS 200 AD50/WU60 274.2.7 DRS 112 – 200 end connection 284.3 Manufacturing tolerances of crane runways 294.4 Alignment for top connection 30

5 Assembling drive elements 325.1 Torque brackets for individual and central drive units 325.1.1 A type offset gearboxes/W type angular gearboxes 325.1.2 A 50 type offset gearboxes 345.1.3 W 60 type angular gearboxes 355.2 Individual drive unit 365.2.1 A offset gearboxes 365.2.2 W angular gearboxes 365.3 Central drive unit 375.3.1 A offset gearboxes 375.3.2 W angular gearboxes 385.4 Central drive units with shaft protection 395.4.1 A 50 type offset gearboxes 395.4.2 W 60 type angular gearboxes 40

6 Fittings 416.1 Horizontal guide rollers 416.1.1 Fitting to wheel blocks 416.1.2 Fitting to steel superstructure 436.2 Buffer elements 446.2.1 DPZ cellular plastic buffers 446.2.2 DPG rubber buffers 44

7 Maintenance 467.1 Maintenance instructions 467.2 Travel wheel wear 477.2.1 Flange wear 477.2.2 Tread wear 477.2.3 Travel wheels of hardened design 477.3 Possible fault sources 47

8 Removing and fi tting travel wheels 48 EC manufacturer's declaration 51

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0.3 Liability for defects

0 Foreword

You have purchased a Demag product. This equipment was manufactured in accordance with state-of-the-art engineering principles.These assembly instructions are designed to provide the operator with useful instructions for safe and appropriate work on the product and to facilitate maintenance.Every individual given the task of transporting, installing, commissioning, operating, maintaining and repairing our DRS wheel block system and additional equipment must have read and understood• the assembly instructions• the safety regulations• the safety instructions in the individual chapters and sections.The assembly instructions must be available to operating personnel at all times in order to prevent operating errors and to ensure smooth and trouble-free operation of our products.

These assembly instructions must be treated confi dentially. They should only be used by authorised personnel. They may only be made available to third parties with the written approval of Demag. All documents are protected within the sense of copyright law.No part of this documentation, in whole or in part, may be reproduced, distributed, used or published in any way without specifi c prior consent. Infringements are an offence resulting in obligatory compensatory damages. All industrial rights reserved.

For technical information on Demag products and their systematic application, please refer to one of our after-sales service centres, the relevant representative or to our main offi ce in Wetter. See the details at the end of the assembly instruction for Drives contacts in Germany, Austria and Switzerland.

These assembly instructions must be read carefully before installing and putting the product into operation.We assume no liability for any damage or malfunctions resulting from failure to comply with the assembly instructions.Any liability claims for defects must be made by quoting the order number immediately on detecting the defect.Any liability claims for defects are void in the event of:• inappropriate use,• faulty devices or equipment connected or attached to the product which are not

part of our scope of supplies and services,• use of non-genuine spare parts and accessories,• refurbishment or modifi cation of the product unless approved by Demag in writ-

ing.

Wearing parts are not subject to liability for defects.

0.2 After-sales service

0.1 Copyright

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All technical information, data and instructions for operation contained in these assembly instructions were up to date on going to print and have been compiled on the basis of our experience and to the best of our knowledge.We reserve the right to incorporate technical modifi cations within the scope of further development of the wheel block system which is the subject of these assembly instructions. The information, illustrations and descriptions contained in these assembly instructions are therefore only intended for information purposes.The descriptions and illustrations contained in these assembly instructions do not necessarily correspond to the scope of delivery or any subsequent spare part delivery, either; the drawings and illustrations are not to scale. Only documentation belonging to the actual order is valid.We assume no liability for any defects, damage or malfunctions caused as a result of operating errors, non-compliance with these assembly instructions or missing or inappropriate repairs and maintenance.We expressly point out that only genuine Demag spare parts and accessories approved by us may be used. Accordingly, this also applies to other manufacturers' parts supplied by us.For safety reasons, the fi tting and use of spare parts or accessories which have not been approved and unauthorised modifi cation and conversion of the product are not permitted and void any liability for damages resulting therefrom.With the exclusion of any further claims, our liability for defects and liability obligations for any defects pertaining to the products supplied or faults in the documentation delivered or any negligence on our part are exclusively based on the provisions of the original contract. Any further claims, in particular any and all claims for damages, are excluded with the exception of legal claims in accordance with product liability legislation.

OwnerOwners (employer, company) are defi ned as persons who own the product and who use it appropriately or allow it to be operated by suitable persons.

Operating personnelOperating personnel are defi ned as persons assigned by the owner of the product to carry out special tasks such as installation, operation, setting-up, maintenance including cleaning, fault elimination and transportation.

Specialist personnelSpecialist personnel are defi ned as persons assigned by the owner to carry out specifi c tasks.

• Qualifi ed personnel Qualifi ed personnel are defi ned as persons who, owing to their technical train-

ing, knowledge and experience as well as knowledge of the relevant standards, are able to assess the tasks given to them and identify potential hazards.

• Trained person Trained persons are defi ned as persons who have been instructed and trained

for the tasks assigned to them and on the possible hazards resulting from in-correct handling and who have been informed about the required protective devices, protective measures, relevant regulations, codes of practice, accident prevention regulations and operating conditions and who have proven their qualifi cations.

• Experienced technician Experienced technicians are defi ned as persons, who, owing to their technical

training and experience, have suffi cient knowledge of the product and are fa-miliar with the relevant national industrial safety regulations, codes of practice, accident prevention regulations, directives and generally accepted engineering standards (e.g. EC Directives, German VDE and VBG regulations) enabling them to judge the safe operating condition of the DRS wheel block system.

0.4 Limitations of liability

0.5 Defi nitions

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1.3 Prohibited practises, improper use

1.3.2 Assembly

1.3.3 Environmental infl uences

1.3.1 Specifi cation

1 Safety

1.1 Symbols The following symbols and recommendations indicate potential safety hazards or causes of damage:

Hazard warningThis symbol appears in the assembly instructions next to all instructions relating to safety at work wherever a potential hazard to life and limb exists.Follow these instructions at all times and be particularly careful and cautious.Pass on safety instructions to all persons entrusted with working on the product including the power supply.In addition to the safety instructions, observe all general safety regulations and codes of practise at all times.

Warning against dangerous electrical voltageContact with live parts (e.g. motors connected to the unit) can result in immediate death. Protective covers (e.g. covers and enclosures) marked with this sign may only be opened by qualifi ed electricians. Before opening, all relevant operating, control, feed or other voltages must be disconnected.

Operating hazard for the installationThis symbol in the assembly instructions indicates all warnings which, if not com-plied with, may result in damage to the product, the installation or the goods to be transported.

Demag DRS wheel blocks are complete travel units designed for moving loads over a wide range of speeds in materials handling installations and general engi-neering applications. They feature prepared connecting surfaces and are ready for fi tting to support structures.The relevant engineering guidelines must be observed when specifying the design. See list of documents on page 2.

Under certain conditions, operation of the DRS wheel block system is prohibited as this may result in malfunctions, equipment failure or hazard to life and limb, e.g. in the case of:

• Exceeding permissible loads• Exceeding the design service life• Occurrence of peak loads which were not considered in the design

• Use of connecting elements not designed for use with the wheel block• Use of non-genuine Demag parts• Non-compliance with the assembly instructions• Tightening bolted connections without using a torque wrench• Incomplete assembly of connecting elementsNote: Safety measures must not be rendered inoperative or modifi ed or used

contrary to the purposes for which they are intended.

• Acidic, corrosive air as coolant• Explosion hazard atmospheres• Operation outside the permitted temperature range• Operation under prohibited ambient conditionsNote: Measures must be taken to ensure the travel wheels do not freeze up

under conditions of high humidity and low temperatures.

• Exceeding the design service life

1.2 Intended use

1.3.4 Maintenance

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2 Brief technical description

2.1 Overview

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The Demag DRS 112 to 200 wheel block system, suitable for loads up to 10,000 kg, is a concept designed to meet customer whishes.The advantages of the system are:• Most favourable ground clearance conditions with Demag travel drives.• Robust aluminium housing with very good shape and position tolerances.• Variable basic design by fi tting various travel wheel materials and shapes.• Weather-resistant due to surface powder coating (RAL 7001, silver grey).

Special paint fi nish available on request. For further details on the paint fi nish, see section 2.4.

• Compensation of track gauge deviations of up to 8 mm possible.• Protected internal bearing arrangement.• Minimum maintenance due to bearings lubricated for life.• Travel wheel and bearings can be replaced thanks to bolted housing.• High installation availability since the housing does not necessarily need to be

removed to replace the travel wheel. Not having to realign the housing saves time.

• A damping element in the travel wheel reduces the load on the gearbox.• Sixth connection surface for fi tting (e.g. switching fl ags).• High-tensile bolted connections are dacromatised and therefore provided with

special surface protection.• The fl ange wear indicator facilitates preventive maintenance without any hazard

to the installation (see section 7.2).

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Residual fl ange indicator

Splined hub pro-fi le to DIN 5480

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2.2 Type designation key (example) for basic wheel blocks

DRS 112 A30 A 47 K H A10

Prepared for fi tting torque bracket Gearbox:A Offset gearboxes 10/20/30/40/50/

60/70/80/90W Angular gearboxes 10/20/30/40/50/

60/70/80/90/100X indicates: no gearbox considered

Guide roller arrangements, prepared for:H Horizontal guide rollers, standardX indicates: no guide rollers

Connection variants, prepared for:K Top connectionW Side connectionB Pin connection

Travel wheel typesA GJS (GGG) with fl ange on both sidesB GJS (GGG) without fl angeC Polyamide without fl ange, with larger diameterD GJS (GGG) with fl ange on one sideE GJS (GGG) without fl ange, with larger diameterF Hydropur without fl ange, with larger diameterS Special travel wheel

Travel wheel tread b1:for types A and D: see section 4.1for types B, C, E, F: 0 indicated

Basic typeA. . Driven wheel block, for torque bracket fi tting and

indication of hub profi lesMA . . Wheel block also driven and indication of the shaft

profi le diameterNA . . Non-driven wheel block

Size 112, 125, 160, 200

Demag wheel block system

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Travel carriage with 4 wheel blocks and a central drive unit

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1 DRS125-NA-A-47-K-X-X2 DRS125-NA-A-47-K-X-X3 DRS125-A35-A-47-K-X-A204 DRS125-MA35-A-47-K-X-X

Travel carriage with 4 wheel blocks and 2 individual drives

1 DRS125-NA-A-47-K-X-X2 DRS125-NA-A-47-K-X-X3 DRS125-A47-A-47-K-X-A204 DRS125-A47-A-47-K-X-A20

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Example for using the type designation key

1

2

34

1

2

43

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Example

Serial numberOrder number/ASN numberType code

41239044.eps

Serial numberOrder number/ASN numberType code

41239144.eps

2.3 Type plate A type plate is applied to each of the end faces of DRS wheel blocks to identify the unit for possible spare part orders.

The type plate may be covered by buffer or guide roller assemblies on one side depending on the design of the wheel block. In this case, the information can be read off the second type plate or relevant fi ttings can be relatively easily disassembled.A blank type plate form can be found below which you can use for your documentation. Fill in the data of the wheel blocks used in your installation.

41239344.eps

Type plates are applied to both end faces

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2.4 Paint fi nish DRS 112 to 200

StandardThe aluminium wheel block housings are provided with a weather-resistant powder coating in RAL 7001 (silver grey) with a minimum thickness of 90 μm before leaving the factory.Continuous coating quality is ensured by our works standard for wheel block housings (ident. no. 012 326 99).

Special paint fi nishFor special paint fi nishes, wheel blocks can be supplied with a dual component PUR fi nish coat at the request of the customer.If the paint fi nish is to be applied by the customer, attention must be paid to works standard for special paint fi nish on powder-coated wheel block surfaces (ident-no. 012 328 99).

Acid-resistant paint fi nishThe surfaces of wheel blocks with a powder-coated fi nish may be used in environ-ments with acid vapours without any treatment. Alternatively, a dual component acid protection paint fi nish may be applied to appropriately pre-treated housings.Wheel blocks must also be fi tted with ball bearings featuring double lip seals.The gap between the housing and the cover is sealed with an acid-proof varnish.

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3 Receiving and storage

3.1 Checking goods on receiving

• The scope of delivery is specifi ed in the shipping papers.• Check the delivery immediately on receipt to ensure that it is complete and

examine it for any damage caused in transit.• Do not make any changes to the goods and packing material. Do not use the

goods yet.• Report any damage to the forwarding agent and request the required papers as

listed below.• Then contact the supplier.• Do not return the damaged goods until this is agreed with the supplier.

Observe local regulations and requirements for transport outside Germany.

The wheel block is supplied made up into one unit. Additional equipment may be supplied in separate packing.The wheel block is packed depending on the transport method and its size. Unless otherwise agreed in the purchase contract, the packaging corresponds to the pack-aging guidelines of Demag Cranes & Components GmbH.

Symbols used on the packing

3.3 Storage

Handle wheel block units with utmost care to avoid damage caused by careless loading and unloading, for example.

Wheel blocks must be stored in dry places which are not subject to extreme tem-perature fl uctuations, e.g. on a wooden support. Unpacked wheel blocks must not be stacked on top of each other.

Note: Do not damage the paint fi nish. Mechanical (scratches), chemical (acid, alkaline) or thermal (sparks,

welding beads, heat) damage will result in corrosion and failure of the exterior protection.

3.2 Transport

Protect from heatKeep dryFragileTop

Top-heavy No hooks Attach sling here Centre of gravity412 83944 - 41284644.eps

3.4 Weights DRS wheel block size Max. weight in kg

112 8,1

125 11,5

160 20,1

200 41,6

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Travel wheel type A B C

Flange-guided travel wheelSpheroidal-graphite cast iron

Travel wheel without fl angeSpheroidal-graphite cast iron

Travel wheel without fl angePolyamide

SizeMax. wheel

load 2)d1 1)

-0,2 d2 b1max b2 s Max. wheel load 2)

d1 1)

-0,2 b2 Max. wheel load 2) d4 1) b2

t mm mm mm mm mm t mm mm t mm mmDRS 112 2,75 112 132 60 80 10 2,75 112 80 0,75 130 80DRS 125 5,0 125 150 60 80 10 5,0 125 80 1,0 140 80DRS 160 7,0 160 188 65 89 12 7,0 160 89 1,7 180 90DRS 200 10,0 200 230 65 101 18 10,0 200 101 2,7 225 102

Travel wheel type D E F

Travel wheel with one fl angeSpheroidal-graphite cast iron

Travel wheel without fl angeSpheroidal-graphite cast iron

Travel wheel without fl angeHydropur

SizeMax. wheel

load 2)d1 1)

-0,2 d2 b2 b12 s Max. wheel

load 2)d31)

-0,2 b2 Max. wheel load 2) d4 1) b2

t mm mm mm mm mm t mm mm t mm mm

DRS 112 2,75 112 132 80 30 10 2,75 126 80 0,59 130 68

DRS 125 5,0 125 150 80 30 10 5,0 145 80 0,79 140 68

DRS 160 7,0 160 188 89 32,5 12 7,0 183 89 1,18 180 75

DRS 200 10,0 200 230 101 32,5 18 10,0 226 101 1,7 225 86

4.1 Travel wheel types

Standard DRS112 – DRS200 designs

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41619044.eps 41619144.eps 41619244.eps

d3

b2

4 Assembly and alignment

1) Travel wheel diameter2) Max. wheel load in group of mechanisms 1Bm, 40 m/min, 40 °C

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4.2 Assembly instructions4.2.1 Top connection

Lock nut

Zinc-fl ake coated threaded pin grade: 10.9

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x

Holes to accommodate optional aligning pins

Sliding nut

DRS wheel block size

Order no. Dimensions in mm

a2 a3 a4 a17 d5 d12 d13 l1 l2 l3

1) min-max min-max

112 75362044 145 70 45 + 4– 7 45 M12 14

14,5

65 18,5-19 8-25

125 75362044 170 86 55 + 4– 7 55 M12 14 65 22,5-23 8-25

160 75252044 220 118 55 + 3– 5 55 M16 18 75 24,5-25 15-25

200 75252044 275 175 65 + 3– 5 65 M16 18 75 28,5-29 15-25

1) Part no. includes: threaded pins and lock nuts

Thre

ad d

epth

Fig. 1

Bore hole arrangement

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L3

L2

L1

D2 D

1

4.2.1.1 Fitting universal shaft F for top connection

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ToolsTorque wrench, ring type, hexagon socket screw key, hexagon-socket offset screw keyPreparation• Drill bore holes in connecting structure according to bore hole pattern (see page

14, fi g. 1.)• The bore holes to accommodate the eccentric aligning arrangement are only

required in connection with the aligning device, part no. 752 100 44 (see section 4.4 "Alignment").

Assembly• Screw the threaded pins by hand into the sliding nuts already fi tted in the

factory until they stop, and then screw them back out by a quarter of a turn.• Fit and tighten the locknuts by hand (counter by holding the threaded pin). Then

position and align the wheel block (see section 4.4 “Alignment”).• Counter the threaded pins (by holding in place using the hexagon socket at

the end of the pin) and tighten the locknuts with the corresponding tightening torque.

Tightening torque DRS 112/125 = 130 NmDRS 160/200 = 330 Nm

• After fi tting, close all unused through holes with the plastic plugs included in the supply.

Fitting universal shaft F • Fit grooved ball bearing (5) onto drive shaft (1) and secure in the axial direction

using retaining ring (8).• Fit the pre-completed shaft in bearing seat (3) and secure using retaining ring

(7).• Then assemble entire shaft unit with connecting plate (2) and secure using

retaining ring (6). (Compensate axial play with shims (9/10)).• Remove lock nut (11) of the housing/cover connection.• Centre the drive shaft unit on the wheel block using two split sleeves (4) and

bolt together as a unit using the wheel block housing bolts.• Finally counter the drive shaft unit with locknuts (11).

Tightening torque DRS 112/125 = 36 Nm DRS 160/200 = 72 Nm


Dimensions in mm

D1 D2 L1 L2 L3

f8

112 4590

182 74 36

125 55 195 7838

160 65120

235 85

200 75 305 95 53

Wheel block in basic design A30/112 - A35/125 - A45/160 - A50/200

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1 Split pin → fi tted in wheel block in the factory2 Flanged washer 3 Washer4 Hexagon bolt5 Lock nut

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4.2.2 Side connection

d14l1

c3 c4

d8

a5d9

a6

h4

a7a8

C

C

C -C

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Wheel centre

MA/NA

A

1) Part no. includes: collared sleeve and dacromatised bolted fastening parts2) Torque bracket for pin connection



a5 a6 a7 a8 c3 c4 d8 d9 d14 h4 l1

1) ± 0,1 ± 0,1 ± 0,1 ± 0,1 min-max D9 min-max

112 75362244 145 145 30 40 20-23 10,4 10,5 18,5 50 47 12-15

125 75222244 175 175 20 40 24,5-27,5 12 13 21 60 53,5 15-18

160 75252244 220 220 25 55 35,5-41,5 14,5 16,5 30 80

70 14-20

200 75302244 275 275 35 75 38,5-43,5 19 20,5 35 90 20-25

(only for drive on connecting plate side)

Drive on wheel block side (W1)

Drive on connecting plate side (W2) (wheel block only in MA basic design)

2)

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L3

L2

L1

D2 D

1

ToolsTorque wrenchAssembly• When the hexagon bolts are tightened, the split sleeves fi tted in the upper

part of the wheel block are pulled into the mounting plate of the steel support structure by the fl ange washers. The bevel on the split pins must face towards the connecting structure.

• Then fi t two further hexagon bolts to the lower part of the wheel block with washers on both sides.

Tightening torque DRS 112 = 55 Nm, DRS 125 = 95 Nm DRS 160 = 230 Nm DRS 200 = 450 Nm


4.2.2.1 Fitting universal shaft F for side connection

41757944.eps41757844.eps


Dimensions in mm

D1 D2 L1 L2 L3

f8

112 4590

182 74 36

125 55 195 7838

160 65120

235 85

200 75 305 95 53

Fitting universal shaft F Note For DRS125 units, the protruding housing/cover bolted connection must be

replaced with the enclosed shorter cheese head screws with hexagon nuts. • Fit grooved ball bearing (5) onto drive shaft (1) and secure in the axial direction



retaining ring (6). (Compensate axial play with shims (9/10)).• Remove both upper lock nuts from the wheel block.• Push the drive shaft unit onto both upper hexagon bolts.• Finally secure the drive shaft unit in place using the two adapter nuts (4) and

the bolt retaining arrangement included in the supply;

Tightening torque DRS 112 = 55 Nm DRS 125 = 95 Nm DRS 160 = 230 Nm DRS 200 = 450 Nm

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4.2.3 DRS 200 side connection with AD. 50/WU. 60 gearboxes

d14

d8

a5 d9

a6

a7a8

C - C

c6

l1

c5

c3 c4 C

C

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Bore hole arrangement of the connecting structure

MA/AA

1) Part no. includes: pins, spacer sleeve, retaining elements and zinc-fl ake coated bolted fastening parts2) Part no. includes: collared sleeves, adapter sleeves, retaining elements and zinc-fl ake coated bolted fastening parts

(only for drive on connecting plate side)

Drive on wheel block side (W1)



a5 a6 a7 a8 c3 c4 c5 c6 d8 d9 d14 h4 l1

± 0,1 ± 0,1 ± 0,1 ± 0,1 min-max min-max H13 min-max

200MA/NA 75302244 1)

275 275 35 7538,5-43,5

1938,5-43,5

33 20,5 35 D9 80 90 20-25A 75302644 2) 39-44 33-38

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1 Split sleeve → fi tted in wheel block in the factory2 Component parts → included in the “torque bracket set”3 Retaining ring4 Shim5 Supporting washer6 Hexagon socket screw7 Adapter sleeve8 Flanged washer9 Hexagon bolt10 Washer11 Washer12 Lock nut

ToolsTorque wrenchAssembly• When the hexagon bolts are tightened, the split sleeves fi tted in the upper

part of the wheel block are pulled into the mounting plate of the steel support structure by the fl ange washers. The bevel on the split pins must face towards the connecting structure.

• Then fi t two further hexagon bolts to the lower part of the wheel block with washers on both sides.

Tightening torque DRS 200 = 450 Nm


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4.2.4 DRS 112 – 200 pin connection

42278544.eps

42278644.eps

Drive side Non-driven side

42279344.eps42279044.eps


Hollow profi le section to DIN 59410/59411

1) See section 4.2.6.1 for use of threaded pins or spacer elements.

41752544.eps

Wheel centre

Wheel centre

Wheel centre

1)

1)

Bore hole template for side with welded plate

Welded plate Superstructure

1)

1)

1)

(without tolerance)

Assembly bore hole for central drive arrangement


Dimensions in mm

a4 a5 a7 a8 a9 a10 a11 a12 a13 a14 a15 a16

1) ± 0,05 ± 0,1 1) ± 0,1 ± 0,1 ± 0,1 ± 0,1 ± 0,1 ± 0,1

112 148 145 52 40 64 10 – 50 60 – 79 93

125 162 175 60 40 72 41 10 58,5 68,5 92 77,5 108

160 206 220 70 55 90 56 12 75 90 110 97,5 135

200 266 275 90 75 118 70 10 105 115 140 120 168

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42278744.eps

42279144.eps 42279244.eps

Without welded plate With welded plate:suitable for aligning pin sets (L) or bolting MA./MW torque brackets.

See section 4.2.6.3 for welded plate

1) See section 4.2.6.1 for use of threaded pins or spacer elements.2) Check l1 dimension, see section 4.2.6.2 Pin set3) See section 4.2.6.2 Pin set

1)

3) 3)

See section 4.2.6.3 for welded plate

Dimensions in mm DRS wheel block size

a18 c1 d9 d10 d14 d15 d16 l1 2) l2 Hollow profi le section to DIN

3) D9/h8 1) min max min a19 a20

75 96 18,5 20 50 M10 M8119,5 127,5

8 200 x 120 x 8 24 47 112129,2 137,2

74 98 21 23 60 M10 M8119,0 127,0

8 200 x 120 x 8 24 54 125128,2 140,2

86 110 30 32 80 M12 M10138,0 150,0

10 260 x 140 x 10 30 70 160 150,2 160,2

103 130 35 38 80 M12 M10170,0 182,0

10 260 x 180 x 10 30 90 200182,2 194,2

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4.2.5 Pin connection B DRS 200 with AD.50/WU.60 gearboxes

42091846.eps

Wheel centre

Note: See section 4.2.6.1 for fi tting spacer elements1) Check l1 dimension, see section 4.2.6.2 Pin set2) See section 4.2.6.2 Pin set

2)

Pin connection B

A

Without welded plate With welded plate

Wheel centre

A

Pin connection BBore hole template for A Bore hole template for A (welded plate side)


Dimensions in mm

a5 a7 a8 a18 a19 a20 c1 d9 d10 d14 l1 1) l2

± 0,05 D9 max min

200 275 90 75 108,5 127 168 130 35 38 80 194 10

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The track gauge can be changed using interchangeable spacer plates. Standard assignments and maximum adjustment are shown in the table.The spacer plates must be secured during transport to prevent them from being lost.

Spacer plateSpacer plates

Supporting washer (play

compensated by means of shims)

Pin

Retaining ring

The zinc-fl ake coated threaded pins are used to align the alignable pin connection and then to secure the wheel block in the axial direction.

41758944.eps

1) Part no. includes per DRS: 4 threaded pins and 4 lock nuts2) DRS 200 with AD50/WU60 gearbox only possible with spacer plates, see page 27

Spacer plates

Threaded pins

1 Pin2 Threaded pin3 Lock nut4 Retaining ring5 Supporting washer6 Shim7 Spacer plate

Adjusting the track gauge with threaded pin and lock nut

Adjusting the track gauge with spacer plates

41758844.eps

DRS Set part no. 1)

Threaded pin grade: 45 H

Nut (3) tightening torque

112 / 125 752 147 44 M10 x 40 60 Nm

160 / 200 2) 752 148 44 M12 x 50 104 Nm

Dimensions in mm Set per DRS consisting of

DRS Order no. l max b max Max. adjusting range Number and thickness

112 752 139 44 111 7,5 ± 7 2 x 2mm + 2 x 3mm + 2 x 5mm

125 752 140 44 114 8 ± 7,5 2 x 2mm + 2 x 3mm + 2 x 5mm

160 752 141 44 130 10 ± 9,5 3 x 2mm + 2 x 3mm + 2 x 5mm

200 752 142 44 162 16 ± 15,5 4 x 2mm + 2 x 3mm + 4 x 5mm

41758744.eps

4.2.6 Fitting the wheel block

4.2.6.1 Axial retaining arrangement with track gauge adjustment

Not included in scope of supply

42275744.eps

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4.2.6.2 Pin set

41751344.eps

Pin set for DRS 200 with AD50/WU60 gearbox

41752644.eps

1) Pin set for the driven type.

Wheel block

Order no. Type Weight Materials Surface protection

Dimensions in mm

DRS DIN EN 10083dD9 /

h8 ll1 Washers Shaft

retaining rings

4x DIN 471Size kg min. max. 1 2 2,5 3 3,5

112753 737 44 S 00,6 42CrMo4+QT

Pin surfacezinc-fl ake-

coated

18,5143,5 119,5 127,5

4 8 – – – 18 x 1,5753 738 44 L 00,7 36NiCrMo16+QT 153 129,2 137,2

125752 337 44 S 00,8 42CrMo4+QT

21143,5 119,0 127

48

– – – 20 x 1,75752 338 44 L 00,9 36NiCrMo16+QT 161 128,2 140,2 12

160752 637 44 S 02,0 42CrMo4+QT

30168 138,0 150

412

– – – 30 x 2752 638 44 L 02,1 42CrMo4+QT 178 150,2 160,2 10

200753 137 44 S 03,2 42CrMo4+QT

35202 170,0 182

4 12 – – – 35 x 2,5753 138 44 L 03,4 42CrMo4+QT 214 182,2 194,2


Order no. Type Weight Materials Surface protection Dimensions in mm

DIN EN 10083 d

D9 / h8D l

l1 Washers Shaft retain-ing rings

2x DIN 471kg min. max. 1 2

200 752 947 441) L 03,9 42CrMo4+QT Pin surface zinc-fl ake coated 35 40 235,5 170 194

2 x dia. 40

2 x dia. 35

24 x dia. 35

dia. 35 x 2,5dia. 40 x 2,5

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ToolsTorque wrench, hexagon socket key

PreparationDrill holes (bore holes must be free of paint) in the connecting structure (hollow profi le section or similar) according to the above bore hole pattern taking the basic types (NA, A, MA) into consideration.

4.2.6.3 Fitting pin connection (without welded plate)• Fit the wheel block into the prepared hollow profi le section and connect with the pin.• Fit the retaining rings and supporting washers included in the supply to secure

against axial movement and to secure the connecting pin in position free of play.

Adjusting the track gauge with threaded pin and lock nut:(Not possible for DRS 200 with AD50/WU60) • Turn threaded pins (2) into the hollow profi le above the pin. Counter threaded

pins (2) and secure with lock nuts (3).

Tightening torque for M8 = 36 Nm, M10 = 65 Nm.

Adjusting the track gauge with spacer plates• Fit distance elements (7).

Fit the geared motor (with torque bracket fi tted as described in section 5) by bolting the complete drive to the hollow profi le section using the retaining bolts included in the supply.

4.2.6.4 Fitting pin connection (with welded plate)• Fit the wheel block into the prepared hollow profi le section and connect with the

pin.• Place welding plate onto the correspondingly drilled side.• Fit the retaining rings and supporting washers included in the supply to secure

against axial movement and to secure the connecting pin in position free of play.• Align the wheel block.• Secure welding plate by tacking and then weld following welding instructions

(fi g. 1).

Adjusting the track gauge with threaded pin and lock nut:(Not possible for DRS 200 with AD50/WU60, see page 27) • Turn threaded pins (2) into the hollow profi le above the pin. Counter threaded

pins (2) and secure with lock nuts (3).

Tightening torque for M8 = 36 Nm, M10 = 65 Nm.

Adjusting the track gauge with spacer plates• Fit distance elements (7).

Welding instructions for welding plate

Weld seam thickness a: DRS 112/125 = 3 mm DRS 160/200 = 4 mm

41759144.epsFig. 1

1 Pin2 Threaded pin3 Lock nut4 Retaining ring5 Supporting washer6 Shim7 Spacer plate

Adjusting the track gauge with threaded pin and lock nut

Adjusting the track gauge with spacer plates

41758844.eps41758744.eps

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4.2.6.6 Fitting pin connection with spacer plates for DRS 200 – AD50/WU60

41759044.eps

Assembly • Place the wheel block in the completed hollow profi le.

• Variant with welded plate: Place the welding plate on the correspondingly drilled side and secure, using

pins. Align the wheel block. Secure welding plate by tacking and then weld fol-lowing welding instructions (see page 25, fi g. 1).

Variant without welded plate: Secure using pins• Fit retaining rings and supporting washers to secure the pin in the axial direction

and secure it in position with little play on the non-driven side (small pin diam-eter).

• Fit distance plates• Fit the geared motor (with torque bracket fi tted as in section 5) on the large pin

diameter and then fi t retaining rings and supporting washers.

4.2.6.5 Fitting universal shaft F for pin connection

L5L4

L2L1

D2 D

1

41758144.eps41758044.eps

Fitting universal shaft F • Fit grooved ball bearing (5) onto drive shaft (1) and secure in the axial direction



retaining ring (6). (Compensate axial play with shims (9/10)).• Remove retaining rings (13), supporting washers (12) and lock nuts (11) from

the existing pin connection.• Push drive shaft unit onto the two pins.• Then fi t supporting washers (12) and retaining rings (13) again.• Fit lock nuts (11).


Dimensions in mm

D1 D2 L1 L2 L4 L5

f8 max

112 4590

182 7412

127

125 55 195 78 130

160 65120

235 8512

148

200 75 305 95 182

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Assembly• Weld end connection to the existing structure according to welding instructions

on page 28.• Fit wheel block in end connection and secure using pins.• For the driven variant: place the welding plate on the corresponding side and

weld according to welding instructions (see page 25, fi g. 1).• Fit retaining rings and supporting washers to secure the pin in the axial direction

and secure it in position with little play.• Fit distance elements (7).Fitting end connection with spacer plates for DRS 200-AD50/WU60, see section 4.2.6.6.

41644555.eps

4.2.6.7 Fitting end connection with spacer plates

41759744.eps

4.2.6.8 Fitting torque brackets for pin and end connection for DRS 112 – 200

Tightening torque see section 5.1

Fit the geared motor (with torque bracket fi tted as described in section 5) by bolting the complete drive to the welded-on plate using the enclosed locking screws (1) for DRS 112/200.

Fit the geared motor (with torque bracket fi tted as described in section 5) on the large pin diameter. Then fi t retaining rings and supporting washers.

41850444.eps

4.2.6.9 Fitting torque brackets for pin and end connection for DRS 200 AD50/WU60

1

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41756744.eps

Not included in scope of supply

Bore hole template for alignable end connection and axial securing arrangement with threaded pins (by the customer)

41681444.eps


Dimensions in mm

a4 a6 a9 d10 d15

112 148 145 64 20M 10

125 162 175 72 23

160 206 220 90 32M 12

200 266 275 118 38

Side with welded plate

drilled by the customer

4.2.7 DRS 112 – 200 end connectionEnd connection dimensions


Order no. Dimensions in mm Options

a5 a6 a7 a8 a16 d9 d14 b1 b2 h l t1 t2 w1 w2 w3 Welded plate

Pin set Spacer plate set

1) 1) 1)

112A

753 714 44 145 7 45 40 93 18,5 50 30 111 150 223 8 7 3 4 4753 829 44 753 738 44

752 139 44NA/MA – 753 737 44

125A

752 314 44 175 8 54 40 110 21,0 60 40 111 200 265 8 8 3 4 4752 429 44 752 338 44

752 140 44NA/MA – 752 337 44

160A

752 614 44 220 10 70 55 140 30,0 80 50 129 250 330 8 10 4 4 5752 729 44 752 638 44

752 141 44NA/MA – 752 637 44

200A

753 114 44 275 10 90 75 170 35,0 80 50 154 300 395 8 10 4 4 5753 229 44 753 138 44

752 142 44NA/MA – 753 137 44

1) After aligning and tacking, fi rst weld on the inside and then the outside. Welded connections to tolerance class DIN 13920 BF assessment group DIN EN 5817 C

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4.3 Manufacturing tolerances of crane runways

S m

in

S

S m

ax

41409444.eps

-B-B+

B

20002000

2000

b

b b

41409544.eps

2000

-C+

C

2000

2000

c

c

c

41409644.eps

s

E

+E

41409744.eps

Source: VDI 3576 Recommendation: Tolerance class 2

41760144.eps

Example for end connection with drive

Tolerance Crane runways

Designation Diagram Tolerance class 1 Tolerance class 2 Tolerance class 3

Tolerance Aof track gauge dimension s of crane rails with reference to the rail centre and crane runway length

Smax = s + A Smin = s - A

for s ≤ 16 m:A = ± 3 mmfor s > 16 m:

A = ± [3 + 0,25 (s - 16)]A in mm

use s in m

for s ≤ 16 m:A = ± 5 mmfor s > 16 m:

A = ± [5 + 0,25 (s - 16)]A in mm

use s in m

for s ≤ 16 m:A = ± 8 mmfor s > 16 m:

A = ± [8 + 0,25 (s - 16)]A in mm

use s in m

Tolerance Bof the lateral straightness of the rail head with reference to the crane runway length.Tolerance bof the lateral straightness with reference to 2000 mm measured length (sample length) at any side of the rail head

Position of a rail seen in plan

B = ± 5 mmb = 1 mm

B = ± 10 mmb = 1 mm

B = ± 20 mmb = 2 mm

Tolerance Cof straightness with reference to the height of the crane rail centre and crane rail lengthTolerance cof the lateral straightness with reference to 2000 mm measured length (sample length) at any side of the crane runway Position of a rail seen in elevation (longitu-

dinal slope)

C = ± 5 mmc = 1 mm

C = ± 10 mmc = 2 mm

C = ± 20 mmc = 4 mm

Tolerance Eof the height with reference to perpendicular measuring points at every point of the crane runway

Position of runway in relation to one another in elevation (transverse slope)

E = ± 0,5‰ x sin mm

use s in mmEmax = ± 5 mm

E = ± 1‰ x sin mm


E = ± 2‰ x sin mm


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4.4 Alignment for top connection

Installation set

41620744.tif

41642655.eps

Wheel blocks must be precisely aligned to prevent bearing damage and, therefore, premature travel wheel wear.Make up the frame (frame assem-blies) or the support superstructure and roughly align them with the DRS mounting positions.

Example for aligning a travel car-riage.

A laser measuring device is available for aligning.Order no.: 752 100 44

Assembly instructions 214 825 44 for alignment are included in the case.

41621255.eps

Alignment

• Fast and optimum alignment of wheel blocks using the Demag alignment device with sliding nuts and prepared connection openings in the wheel block housing.

• Only well aligned wheels reduce wear to a minimum. Achievable accuracy with measuring device: 1,6 ‰.

• Sliding nut arrangement, used for alignment, offers a lateral align-ment path of ± 3 mm.

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42000444.eps

The values given in the diagram are suffi cient for normal applications.Further information on tolerances is given in the relevant standards and guidelines.DIN 7168 General tolerances (clearance tolerances) Lengths and anglesDIN 8570 Clearance tolerances for welded constructions, Sheet 1 Dimensions for lengths and angles, Sheet 3 Shape and

positionVDI 3571 Manufacturing tolerances for bridge cranesVDI 3576 Rails for crane installations, rail connections, rail mountings, tolerances

a in mm

F ≤

0,5

‰ ·

a (m

m)

Individual drive unit ≤ 2,5 ‰Central drive unit ≤ 1,6 ‰

N ≤ 2 mm central drive unit ≤ 6 mm individual drive unit

L ±

2 m

m fo

r L ≤

10

m

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5.1 Torque brackets for individual and central drive units

5.1.1 A type offset gearboxes/W type angular gearboxes

5 Assembling drive elements

Step 1:Fit the torque bracket to the geared motor

Examples:

Offset gearbox

Angular gearbox Before the torque bracket is installed and depending on the mounting position of the gearbox, check whether the mounting bolts for step 2 (if covered by the gearbox) need to be inserted in the corresponding bore holes of the torque bracket before the torque bracket is attached to the gear-box.

Tightening torquesAll bolts are coated with a micro-encapsulated layer and must only be used once.

Step 1 4 bolts

Torq

ue b

rack

et

a.) Hexagonal socket bolts with packing plateb.) Locking bolt

Offset gearbox

MA112-1 23 Nm a.) M8x35

MA125-1 23 Nm a.) M8x35

MA125-2 20 Nm b.) M10x20

MA160-1 23 Nm a.) M8x35

MA160-2 20 Nm b.) M10x20

MA200-1 20 Nm b.) M10x20

Angular gearbox

MW112-1 42 Nm b.) M8x25

MW125-1 42 Nm b.) M8x25

MW125-2 85 Nm b.) M10x30

MW160-1 85 Nm b.) M10x35

MW160-2 130 Nm b.) M12x35

MW200-1 85 Nm b.) M10x35

MW200-2 130 Nm b.) M12x35

MW200-3 330 Nm b.) M16x35

b.)

a.)

42754544.eps

b.)

42754644.eps

42754744.eps

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Step 2: Fit the geared motor with torque bracket to the wheel block or connecting structure

Examples:

1) After tightening the nuts, check the bolted connections of the wheel block

Step 2 4 or 6 nuts/bolts

Torq

ue b

rack

et

Connected direct to the driven wheel block with lock nuts

Connected to the connecting structure with locking bolts

Offset gearboxM8 / 35 Nm M8x20 / 35 Nm

M10 / 65 Nm M10x25 / 75 Nm

for angular gearbox

M8 / 35 Nm M8x20 / 35 Nm

M10 / 65 Nm M10x25 / 75 Nm

M10 / 85 Nm 1) M10x25 / 85 Nm

Tightening torquesAll bolts are coated with a micro-encapsulated layer and must only be used once.

Lock nut

Connecting structure

Locking bolt

42754844.eps

42755044.eps42755144.eps

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5.1.2 A 50 type offset gearboxes Fitting for top, side and pin connection arrangementsMA200-2 torque bracket connection

42115144.eps

42115244.eps

1 Offset gearbox2 Torque bracket3 Locking bolt

1 Offset gearbox4 Pin (adapter sleeve for side

connection)5 Polyamide collared sleeve6 Polyamide washer7 Supporting washer (40 x 58 x 2,5), note

outside diameter of 58 mm8 Supporting washer9 Retaining ring10 Shim11 Shim12 Retaining ring

123

15410812

4

6 711

9 6 711

9

10812

Assembly• Remove corrosion protection and paint from contact surface of gearbox and torque bracket.• Fit torque bracket (2) to gearbox (1) using locking bolts (3) included in the supply.

Assembly• Insert pin (4) into wheel block and secure against axial movement with supporting washers (8), shims (10) and retaining

ring (12).• Place polyamide collared sleeves (5) and drive unit (1) onto pin (4).• Fit polyamide washer (6), supporting washer (7), shim (11) and retaining ring (9) in the sequence indicated.

Tightening torque 130 Nm

Size Torque bracket Locking screw (3)

Wheel block Gearbox Quantity Dimensions

DRS 200 AD 50 MA200-2 8 M12x25

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5.1.3 W 60 type angular gearboxes Fitting for top, side and pin connection arrangementsMW200-4 torque bracket connection

42116744.eps

1 Angular gearbox2 Torque bracket3 Locking bolts

Assembly• Remove corrosion protection and paint from contact surface of gearbox and torque bracket.• Fit torque bracket (2) to gearbox (1) using locking bolts (3) included in the supply.

42116644.epsAssembly• Insert pin (4) into wheel block.• Place polyamide collared sleeves (5) and drive unit (1) onto pin (4).• Fit polyamide washer (6), supporting washer (7), shim (11) and retaining ring (9) in the sequence indicated.• Secure pin (4) against axial displacement with supporting washers (8), shims (10) and retaining ring (12) on the second

side.

123

4 5

1

6 711

9911

764108

12108

12 1 Angular gearbox4 Pin (adapter sleeve for side connec-

tion)5 Polyamide collared sleeve6 Polyamide washer7 Supporting washer (40 x 58 x 2,5), note

outside diameter of 58 mm8 Supporting washer9 Retaining ring10 Shim11 Shim12 Retaining ring

Tightening torque 130 Nm

Size Torque bracket Locking screw (3)

Wheel block Gearbox Quantity Dimensions

DRS 200 WU 60 MW200-4 8 M12x25

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5.2 Individual drive unit

Journal shaft on one side with involute splines

41807044.eps

5.2.2 W angular gearboxes

41807355.eps

Clean drive shaft before fi tting, check splined profi le section and lubricate with grease (Klüber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).

AssemblyConnect travel drive (2) with wheel block (1) as described in section 5.1.

AssemblyConnect travel drive (2) with wheel block (1) as described in section 5.1.

1 2

After fi tting a W 50 angular gearbox, check the bolted connections of the wheel block for the correct tightening torque (72 Nm).

5.2.1 A offset gearboxes


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5.3 Central drive unit

41806944.eps

41807144.eps

Assembly• Connect travel drive (2) with wheel block (1) as described in section 5.1. Journal drive shaft arrangements do not need to be secured against axial displacement. Hollow drive shaft arrange-

ments (12) must be secured against axial displacement by fi tting retaining rings (8/9) and supporting washers (7/13) as well as spacer ring (10) included in the supply.

• Insert split sleeve (5) into connector (4).• Slide connector (4) onto drive shaft (11/12).• Insert central drive shaft (6) into wheel block (3).• Place spacer rings (10) onto central drive shaft (6) and push the shaft into the connector until it stops against the split

sleeve.• Determine the quantity of spacer rings (10) required until the retaining ring groove is reached.• Secure central drive shaft (6) against axial displacement by fi tting retaining ring (9).

Drive arrangement: Hollow shaft with solid shaft

8 7 1013 9

12

11 5 4 6 9 10

Drive arrangement: Journal shaft on both sides with involute splines

5.3.1 A offset gearboxes

41833844.eps

10

7

8

9

13

12


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41807255.eps

41807444.eps


Assembly• Connect travel drive (2) with wheel block (1) as described in section 5.1. Journal drive shaft arrangements do not need to be secured against axial displacement. Hollow drive shaft arrange-

ments (12) must be secured against axial displacement by fi tting retaining rings (8/9) and supporting washers (7/13) as well as spacer ring (10) included in the supply.

• Insert split sleeve (5) into connector (4).• Slide connector (4) onto drive shaft (11/12).• Insert central drive shaft (6) into wheel block (3).• Place spacer rings (10) onto central drive shaft (6) and push the shaft into the connector until it stops against the split

sleeve.• Determine the quantity of spacer rings (10) required until the retaining ring groove is reached.• Secure central drive shaft (6) against axial displacement by fi tting retaining ring (9).

7 10 2 12 13 98

11 5 4 6 9 10

2 3

1

After fi tting a W 50 angular gearbox, check the bolted connections of the wheel block for the correct tightening torque (72 Nm).


41833944.eps

10

7

8

12

13

9


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11 5 4 6 9 10

14 15

32

1

5.4 Central drive units with shaft protection5.4.1 A offset gearboxes

42065846.eps

41833844.eps

Assembly of central drive unit with shaft protection• Connect travel drive (2) with wheel block (1) as described in section 5.1. Journal drive shaft arrangements do not need

to be secured against axial displacement. Hollow drive shaft arrangements (12) must be secured against axial displace-ment by fi tting retaining rings (8/9) and supporting washers (7/13) as well as spacer ring (10) included in the supply.

• Insert split sleeve (5) into connector (4).• Slide connector (4) onto drive shaft (11/12) and determine distance L1.• Cut shaft protection tube (14) to length L1 + 10%. • Remove connector (4) again and slide on tube (14).• Insert central drive shaft into wheel block (3) and slide connector (4) back onto the shaft (11/12).• Place spacer rings (10) onto central drive shaft (6) and push the shaft into the connector until it stops against the split

sleeve. Determine the quantity of spacer rings (10) required until the retaining ring groove is reached.• Determine distance L2 and cut shaft protection tube (15) to length L2 +10%.• Push through central drive shaft (6) in the direction of wheel block (3) and slide on cut shaft protection tube (15) over the shaft.• Slide back central drive shaft (6) until stop is reached in connector (4) and secure against axial displacement by fi tting

spacer rings (10) and retaining ring (9).


8 7 1013 9

12


10

7

8

9

13

12

41807144.eps

Clean drive shaft before fi tting, check splined profi le section and lubricate with grease (e.g. Klüber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).

42753044.eps

Dimensions L1 and L2 for the length of the shaft protection tubes

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11 5 4 6 9 10

2 3

1

14 15


42065946.eps

41807444.eps


7 10 2 12 13 98


Assembly of central drive unit with shaft protection• Connect travel drive (2) with wheel block (1) as described in section 5.1. Journal drive shaft arrangements do not need

to be secured against axial displacement. Hollow drive shaft arrangements (12) must be secured against axial displace-ment by fi tting retaining rings (8/9) and supporting washers (7/13) as well as spacer ring (10) included in the supply.

• Insert split sleeve (5) into connector (4).• Slide connector (4) onto drive shaft (11/12) and determine distance L1.• Cut shaft protection tube (14) to length L1 + 10%. • Remove connector (4) again and slide on tube (14).• Insert central drive shaft into wheel block (3) and slide connector (4) back onto the shaft (11/12).• Place spacer rings (10) onto central drive shaft (6) and push the shaft into the connector until it stops against the split

sleeve. Determine the quantity of spacer rings (10) required until the retaining ring groove is reached.• Determine distance L2 and cut shaft protection tube (15) to length L2 +10%.• Push through central drive shaft (6) in the direction of wheel block (3) and slide on cut shaft protection tube (15) over the shaft.• Slide back central drive shaft (6) until stop is reached in connector (4) and secure against axial displacement by fi tting

spacer rings (10) and retaining ring (9).

41833944.eps

10

7

8

12

13

9

Clean drive shaft before fi tting, check splined profi le section and lubricate with grease (e.g. Klüber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).

42753044.eps

Dimensions L1 and L2 for the length of the shaft protection tubes

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6 Fittings

Permissible horizontal load: no more than 15 % of the wheel load.The guide roller arrangement as a solo component can transmit at least 20 % of the permissible wheel load.Ordering information:If a guide roller arrangement is specifi ed in the type key when ordering a single wheel block, this is prepared for fi tting before leaving the factory.Exception: DRS 200 with top connectionThe permissible horizontal force is limited to 10 % of the permissible wheel load.DRS 112 – 200 with travel wheel type EThe permissible horizontal force is limited to 12 % of the permissible wheel load. Rails with sloping head fl ank surfaces must not be used.

6.1 Horizontal guide rollers DRS 112 – 200

6.1.1 Fitting to wheel blocks

42015744.epsk = Rail width

DRS 112 – 125 – 160 DRS 200

41641644.eps

s s


Tightening torques Dimensions in mm

in Nm

Locking bolt

1 2 3 smin smax a a7 bmin bmax b1 d h h1 h2 l l1 l3 m n

112 130 1 5 80,5 4,5 30 70 20,6 52 126,5 38,2 76 180 5 60 125 24,5

125 130 1 5 88 4,5 30 70 20,6 62 143 50 95,5 192 5 60 140 25,4

160 330 130 1 5 109 7,5 30 80 23,8 72 162 65 93,5 230 6 72 173,5 29

200 330 130 1 5 133 8 40 90 27 80 174 75 92 250 6 80 210 33

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Assembly• Fit the washer with the wide slot facing downwards on the raised guide to pre-

vent turning.• Fit the pins with the fl at-sided heads in the slot to prevent turning.• Fit guide rollers to wheel block as shown above and tighten by hand.• Tighten locking bolts (2/3) to specifi ed tightening torque (see table).• Adjust roller distance dimension “s” and align the guide rollers with the rail.• Tighten locking bolts (1) with specifi ed torque (see table).

Fitting for wheel block not prepared before leaving the factoryIf a wheel block is fi tted with a roller guide arrangement at a later date, the follow-ing additional measures must be carried out:• Drill bore holes on cover side to diameter d4 and depth a8 and fi t split sleeves

with slot facing “upwards”.• Subsequently fi t two threaded inserts into the end face.

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DRS wheel block size Travel wheel type a

mm

Order no. Retrofi tting set part no.

Horizontal guide roller assembly 1) Fitted to wheel block 2) Fitted to connecting structure 1)

112B 81 753 610 44 753 611 44 753 610 44

E 87 753 710 44 753 711 44 753 710 44

125B 88 752 210 44 752 211 44 752 210 44

E 98 752 310 44 752 311 44 752 310 44

160B 109 752 510 44 752 511 44 752 510 44

E 119 752 610 44 752 611 44 752 610 44

200B 133 753 010 44 753 011 44 753 010 44

E 145 753 110 44 752 111 44 753 110 44

1) Part no. includes roller guide arrangement and bolted fastening parts2) Part no. includes roller guide arrangement, threaded sleeves and roll pins

Split sleeve (slot facing upwards)

Locking bolt 1

Locking bolt 3

Locking bolt 2

Threaded insert

Washer

Pin

Size

Locking bolt tightening torquesDimensions in mm

1 2 3 smin smax a8 d4

DRS 112 130 Nm 1 5 35 13

DRS 125 130 Nm 1 5 35 18

DRS 160 330 Nm 130 Nm 1 5 40 23

DRS 200 330 Nm 130 Nm 1 5 45 28

d4

a8

Rz63

s k s

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6.1.2 Fitting to steel superstructure

Permissible horizontal load: no more than 20% of the wheel load

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Drill out holes for split sleeves to d5H12 after fi tting.

SizeDimensions in mm

a a1 a2 a3 a4 a5 a6 a9 a10 a11 d1 d2 d3 d5

DRS 112 40 – 48 22 40 76 102 – – – 13 6 12,5 8

DRS 125 50 – 56 20,5 38,5 95 113 – – – 13 6 12,5 8

DRS 160 54 – 58 26 49,5 93,5 148,5 – – – 13 8 16,5 10

DRS 200 62 22 62 28 54 92 157 16 132 36 13 10 16,5 12

d2

d1

a6

a5

a2

ad2

d3

a4

a3

a6

a10

a5

d3d1

d2

a9

a3 a11 a4

a

a1

•

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• Screw threaded pin (2) into buffer (1) until maximum I2 dimension is reached.

• Screw buffer into threaded insert in wheel block.

6.2 Buffer elements6.2.1 DPZ cellular plastic buffers

Possible fi tting arrangement to end of DRS 112 – 200 wheel blocks without horizontal guide roller arrangement

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DPZ cellular plastic buffersDRS wheel block size Buffer

Dimensions in mm

no guide rollers with guide rollers

d1 d2 l1 l2 Threaded pins (2)

112125

160200

DPZ 070 70 65 70 26 M12 x 30 M12 x 55

DPZ 100 100 95 100 26 M12 x 30 M12 x 55

–DPZ 130 130 122 120 26 M12 x 30 M12 x 55

DPZ 160 160 155 150 40 M12 x 30 M12 x 55

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DPG rubber buffers

6.2.2 DPG rubber buffers

DRS wheel block size Buffer

Dimensions in mm

no guide rollers with guide rollers

d1 d2 l1 l2 Threaded pin (2)

112125 160

200

DPG 063 063 56 067 26 M12 x 30 M12 x 55

DPG 080 080 71 084 26 M12 x 30 M12 x 55

– DPG 100 100 90 105 26 M12 x 30 M12 x 55

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To ensure uniform buffer impact with a horizontal guide roller arrangement fi tted to only one wheel block, two shims, type E2 must be fi tted between the buffer and wheel block on the opposite side.

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2 3 E1 1 • Remove the locking bolt and screw threaded pin (2) up to max. dimension l4 into the tapped insert in the wheel block.

• Tighten locknut (3) and counter with threaded pin using hexagon socket. (Tightening torque 130 Nm).

• Fit shim, type E1, with the ribs facing the wheel block side and screw the buffer onto the threaded pin.

2xE2 1xE1

s2 s2 s1

End stop

1) Only one type E2 shim required.

Fig. 11

Possible fi tting arrangement to end of DRS 112 – 200 wheel blocks with horizontal guide roller arrangement (fi gs. 11 – 12)

Fig. 12

DRS 112 – 200Guide roller fi tting including distance elements

DRS wheel block size Buffer

l4

mm

112 / 125DPZ 070

11 ± 0,5DPZ 100

160 / 200

DPZ 070

14 ± 0,5DPZ 100

DPZ 130

DPZ 160

Buffer Shim

E1 E2

s1 s2

DPG 63 / DPZ 70 14 10

DPG 80 / DPZ 100 20 12,5

DPZ 130 / DPG 100 25 16

DPZ 160 1) 15 21

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7 Maintenance

7.1 Maintenance instructions

DRS wheel blockOwing to their design, DRS wheel blocks are maintenance free.

ZNA - ZBA - ZBF motorsSee assembly instructions ident no. 214 228 44

AU - AD - AG - AF - AM offset geared motors See assembly instructions ident no. 214 206 44

WU - WG - WF angular geared motorsSee assembly instructions ident no. 214 058 44

Refer to the above mentioned assembly instructions for information on gearbox lubrication intervals, lubricants and quantities of lubricants.

ShaftsLubrication interval: 10000 hours of operation, at least every 4 years. Under extreme operating conditions (e.g. multiple shift

operation) shorter intervals (every quarter) must be selected.

Lubricant: Grease Klüber Staburags NBU12 Alltemp or Fuchs Gleitmo

WSP 5040

Bolted connectionsBolted connections must be inspected annually.Under extreme operating conditions (e.g. multiple shift operation) shorter intervals (every quarter) must be selected.

Cellular plastic buffersCellular plastic buffers must be inspected at least once per year as follows.Under extreme operating conditions, shorter intervals (every quarter) must be selected.

1. Visual inspection of cellular plastic buffers for cracks or other damage: Damaged cellular plastic buffers must be replaced without delay.

2. Finger nail test: It must not be possible to remove small parts from the surface or edges with a

fi nger nail. If this is possible, the cellular foam buffer must be replaced without delay.

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7.2 Travel wheel wear7.2.1 Flange wear The wear indicator on the fl ange facilitates preventive inspections of the

installation.

Travel wheel when new

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7.2.2 Tread wear

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Travel wheels must be replaced when the following limit values are reached:

Worn travel wheel

s s

d1

The travel wheel must already be replaced even if only one segment of the wear indicator is open.

Travel wheel rated diameter

Remaining smallest fl ange width

s

Smallest travel wheel diameter

d1

Maximum difference in travel wheel diameters

for coupled wheels

Dimensions in mm

112 5,0 105,4 0,1

125 6,0 118,4 0,1

160 7,0 153,4 0,15

200 8,4 193,0 0,15

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7.2.3 Travel wheels of hardened design

Since the hardening depth of hardened travel wheels measures approx. 2-3 mm, the wear limit values given above do not apply.The hardened travel surface must be checked regularly for signs of fatigue.

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7.3 Possible fault sourcesDescription of fault Possible cause of fault Fault elimination

Increased travel wheel wear(tread or fl ange)

Wheel block is misaligned Re-align the wheel blocks

Rail is dirty Clean the rail

Running noises

Wheel block is misaligned Re-align the wheel blocks

Rail is dirty Clean the rail

Defective bearing Replace the travel wheel

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Remove the coverUndo the cover screws of the cover. Lever off the wheel block cover using the recess on the side of the wheel block housing without twisting the cover.

8 Removing and fi tting travel wheels

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Remove the travel wheelRemove the travel wheel with the ball bearings.

Bolt the cover and housing together with the corresponding tightening torque (see table below).

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Size Tightening torque

DRS 112 36 Nm

DRS 125 36 Nm

DRS 160 72 Nm

DRS 200 72 Nm

Fit the travel wheel with pre-assembled bearings into the wheel block housing. Fit the wheel block cover using a rubber hammer by gently knocking it evenly until it is fl ush with the wheel block.

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Notes

Hereby we,

Demag Cranes & Components GmbHRuhrstraße 28, 58300 Wetter

declare that the products:

Demag DRS / RS wheel blockDemag LRS travel wheel systemDemag DWS wheel set

as series products are intended to be incorporated into machinery and that they must not be putinto service until the machinery into which these products are to be incorporated has been declaredin conformity with all relevant provisions of

EC Machinery Directive 2006/42/EC.

Basic requirements of the EC Machinery Directive, insofar as they are relevant for the scope ofdelivery, are met by application ofthe following harmonised standards:EN ISO 12100 Safety of machinery -

General principles for designRisk assessment and reduction

The special technical documentation based on Annex VII Part B of Directive 2006/42/EC has beencompiled and will be made availableto authorised national authorities by the designated authorisedrepresentative in response to a justified request.Authorised representative for technical documentationHans-Jörg Böttcher, Demag Cranes & Components GmbH, 58286 Wetter

Wetter, 21.08.2013

ppa. Dr. Rainer Harkort ppa. Dirk SchulteHead of Plant Wetter Handling Technology & Drives

Engineering & Development

Material Handling

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter Subject to change. No liability for errors or omissions

Ident. number / Language

19960444 / ENIssue Page

0811 1/ 1

OriginalDeclaration for fitting partly completed machinery

according to Machinery Directive 2006/42/EC, Annex IIB

U04282

Prin

ted

in G

erm

any

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter, Germany No liability for errors or omissions. Subject to change.

Demag Cranes & Components GmbHPO Box 67 · 58286 Wetter, GermanyPhone +49 (0)2335 92-0Telefax +49 (0)2335 92-7676www.demagcranes.com

The current addresses of the sales offi ces in Germany and the subsidiaries and agencies worldwide can be found on the Demag Cranes & Components GmbH homepage at www.demagcranes.com/Contact

end carriage dfw s e assmebly

Documents

assembly instructionsdrs

drs wheel block system

pin connection

demag dws wheel

wheel block system2

travel wheel types

demag wheel range brochure

z motor ranges