manual DEMAG de gruas puente.pdf

010802 EN/DE 203 321 44 714 IS 845.1

DFW-L-E end carriageswith DRS 112 to 200

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20332001.eps

Steel structure Bolted mounting plate Geared motor

Torque bracket

Wheel blockDriven

DFW-L-E / S

For outdoor operation only1x for Ax<=500 mm2x for Ax>500 mm

Contents

Page

1 DFW product description 3

1.1 Application 3

1.2 Modular carriage system 3

1.3 Protection against corrosion, paint finish 3

1.4 Documentation 3

2 Design and mounting information 4

2.1 Steel construction 4

2.2 Types of connection 4

2.3 DRS wheel block system 5

2.4 Adjusting the span 5

2.5 Wind safety catches 6

2.6 Optimizing the travel speed 6

3 Mounting code 7

3.1 Type designation 7

3.2 Order information 7

4 DFW-L-E/S end carriages 8

4.1 Data and dimensions 8

5 DFW-L-E/O end carriages 10

5.1 Data and dimensions 10

6 DFW-L-E end carriage attachments 12

6.1 End plates 12

6.2 Bolted mounting plates with non-countersunk bore holesand with countersunk bore holes for DFW-L-E/S 14

6.3 Bolted and welded mounting plates for DFW-L-E/O 16

6.4 Torque brackets 18

6.5 Buffers and spacers 18

6.6 Guide rollers 18

7 Order form for DFW-L-E end carriages 19

Wheel blockNon-driven

Endplate

Buffer SpacerWheel blockfitting elements

High-tensileboltedconnection

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1 Product description

DFW-L-E carriages are used for steel structures in the crane and lifting equipmentindustry and also for applications in related mechanical engineering.

DFW-L-E carriages are compact, driven, rail-mounted carriages for direct connectionto load-bearing structures. In addition to the steel structure part, a torsionallyresistant box section, the end carriage includes a driven wheel block for fitting thegearbox and the motor as well as a non-driven wheel block. The carriage design isbased on the latest principles for steel structures and, even with high loads, hasexcellent travelling characteristics due to the fine tolerances of the carriage regardingtrack gauge errors, diagonal position and misalignment. Specially adapted heavy-duty motors provide excellent speed/torque characteristics, which ensure smoothstarting for both the unloaded and the loaded carriage.

The following equipment can be combined to form a complete carriage:

Connection

• Carriages with one crane girder connection on the side (standard)

• Carriages with one crane girder connection on the top

Travel unit/travel wheel

• DRS wheel blocks 112, 125, 160, 200 mm

• Max. wheel loads up to 10000 kg

• Wheel bases 2000, 2500, 3150, 4000 mm

Travel drive (drive units fitted either on right-hand or left-hand side)

• AM offset gearboxes

• ZBF travel motors

• MA torque brackets

Buffers

• DPZ Cellular plastic buffers

Protection against corrosion

• Structural steel shot-blasted (Sa2 rust removal factor to DIN 55 928).

• Rust protection with primer paint in RAL 1004 golden yellow (thickness 60 µm)

• Galvanized finish available on request

• Other provisions for corrosion protection available on request.

Paint coat

• A final coat in RAL 1007 daffodil yellow or other colours can be provided onrequest.

Travel unit

• Operating instructions 214 362 44

• Component parts list 222 736 44

DRS wheel blocks, gearboxes, travel motors and buffers

• Demag DRS wheel block system Volume 1 1) 203 352 44

• Geared motors for travel applications Volume 2 203 355 44

1.1 Application

1.2 Modular carriagesystem

1.4 Documentation

1.3 Protection againstcorrosionPaint coat

1) required for rating the end carriages

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The carriage can be connected to the structure in the following ways:

• bottom flush (side connection of main girder),

• top flush (side connection of main girder),

• raised (side connection of main girder),

• lowered (side connection of main girder),

• top connection (top connection of main girder),

2 Design and mounting information

The steel structure is designed in accordance with DIN 15018, lifting class H2, stressgroup B3.

Steel structure characteristics:

• High stability due to enclosed, torsion-resistant box section girder. Greatstrength in connection area due to diaphragm plates welded into the carriage.

• Machining on NC machines provides precise positioning of travel wheel axleswith respect to mating surfaces.

• Easy assembly and access. Detachable and anti-shear high-tensile connectionwith adjoining structure.

• Optimum travel characteristics. Can be easily exchanged due to accuracy of theconnection geometry. Fine tolerances for track gauge errors, diagonal wheelposition and misalignment are met as a result of the precise alignment andmachining of the connection surfaces.

2.1 Steel structure

2.2 Types of connection

20332002.eps

Steel structure with top connection of main girder

Steel structure with side connection of main girder

20332003.eps

Bottom flush Top flush Raised Lowered Top connection

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Wheel blocks feature:

• Positive travel wheel/shaft connection resulting from the splined shaft section.

• Simple, fast assembly and replacement with commercially available tools.

• High wheel loads, long service life due to dust-proof anti-friction bearings lubricat-ed for life.

• Simple adjustment of span by re-arranging spacer elements between the wheelblock and the inside of the carriage girder.

• Considerably reduced wear on travel wheels (wear indicator) and track rails as aresult of the self-lubricating effect of spheroidal graphite cast iron compared withsteel.

• Silent running due to self-damping properties of the travel wheel material.

2.3 DRS wheel blocks

Travel wheel profile

1) other treads on request2) max. wheel loads for linear contact (flat rail to DIN 1014 or A rail to DIN 536) depending on FEM group, useful rail width and

long travel speed, see catalogue 203 352 44, section 2.6.5

By re-arranging the spacer elements, the span can be adjusted.2.4 Adjusting the span

20332004.epsb 2

d 2

d 1

b rail

b wheel

Spacer elementsSpacer elements

20332005.eps

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002 032 101 56 56 00001

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2 Design and mounting information

According to accident prevention regulations (UVV, BGV D6 § 14.1 (VBG 9)), cranesmust have their power-driven travelling and slewing movements braked, thuspreventing unintended movement. According to the regulations UVV 18.2 BGV D6§ 30.6 (VBG 9), the crane operator must ensure that cranes exposed to the wind aresecured during storms and at the end of work.

According to the surface area exposed to the wind, one or two safety catches arerequired per crane.

Depending on accessibility, the manually operated wind safety catch should bepreferred.

2.5 Wind safety catches

Optimum handling capacity can only be achieved by correctly selecting the workingspeeds. For this, the average speed of the individual movements is the determiningfactor.

2.6 Optimizing the travelspeed

20332008.eps

Trav

el s

peed

(m/m

in)

Crane runway length or span (m)2001501005040302520151098765

12,516

20

25

31,540

50

63

80100

125

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3 Mounting code

3.2 Order information The following information is required:

• End carriage type: E - single-girder crane

• Travel wheel dia. or wheel block size/wheel base:112 / 2000, 2500125 / 2000, 2500, 3150160 / 2000, 2500, 3150200 / 2000, 2500, 3150, 4000

Other wheel bases on request

• Main girder connection: S - sideO - top

• Travel wheel tread: See section 2.3

• Travel wheel variants: A - with flange on both sidesOther travel wheel variants on request, see catalogue 203 352 44 section 2.6.3

• Drive variant, view to mounting plate:L - 1 end carriage, left-hand sideR - 1 end carriage, right-hand sideRL - 2 end carriages arranged in pairs(right-hand side and left-hand side)

• Number of drives per end carriage:0 - no drive1 - one drive2 - two drives

• Drive shaft diameter or gearbox size:30, 35, 45 or 50

See catalogue 203 352 44 section 2.3

• Guide rollers: Standard guide rollers yes/noSee section 6.1 and catalogue 203 352 44 section 4.6

• DPZ buffers: 100, 130, 160See catalogue 203 352 44 sections 4.4 and 4.5

• End plate variant: Standard, variant for Italy, USA or for guide rol-lersSee section 6.1

• DFW-L-E/S mounting plate: with countersunk bore holes,with non-countersunk bore holes

See section 6.2

• DFW-L-E/O mounting plate: bolted type, welded typeSee section 6.3

DFW-L-E 112 / 2000 / SConnection of main girder

Wheel base ekt

Travel wheel diameter d1

Overhead travelling crane

3.1 Type designation

Single-girder crane

Demag end carriage

20332030.wmf

Drive variantleft

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4 DFW-L-E/S end carriages

20332009.eps

L

ekt a 3

Ay1

h 19

a11

h 21

h 12

h 18

S

d 3d 4

a 9

a10 d 1

a 12

Ax

A

h 20

B

X

A Bh

8

Ay2

Ay3

h 17

h 1

h 23

100

(S

tand

ard

buffe

r hei

ght)

a 7a 8

44

a 4

21

51,5

i - Number of securing bolts for torquebracket

4.1 Data and dimensions

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- 39

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716

29

831

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0513 2911

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0002

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022

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851

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0513 005 5311

0002

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011

851

0052 528061

0513 005 5311

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245

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381

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2701

0004 7941

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20332010.eps 20332011.eps

20

h22

b2

b4

bwheel

b3

5

End carriageY

b8

View X Section B-BSection A-A

Trav

el w

heel

cent

re

Main girder

Detail Y

67,5 ± 1 DFW-L-E 11267,5 ± 1 DFW-L-E 12582,5 ± 1 DFW-L-E 16092,5 ± 1 DFW-L-E 200

h7

h9h1

3

h10

b9

The supply of a DFW end carriage includes: End carriage, mounting plate with securing bolts and buffer

bwheel – standard travel wheel tread see item 2.3; other travel wheel treads on request

End carriage weight without mounting plate, motor and gearbox

Assignment of end carriages: For SWL – span, see standard overhead travelling cranes brochure 203 317 44(crane selection tables and wheel loads/mass forces/forces resulting from running at an angle/buffer forces/dead loads of the crane)

S

mmnisnoisnemiD rebmuN thgieW

9b 3d 4d 1h 7h 8h 9h 01h 21h 31h 71h 81h 91h 02h 12h 22h 32h L S i gk

21 5,81 8M 941342

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4311

742 4072 9 351

51 12 8M 5,261

182

052 5,24 82 51 803 5,74 04 5,86 14

-

9 9

4222 8

4

251

582 4272 01 202

982 4733 21 962

182

01

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6

251

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003

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4446843

21264

6334 685

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5 DFW-L-E/O end carriages

20332012.eps

Figure: Bolted connection

h23

a4

100

(S

tand

ard

buffe

r he

ight

)

a3

h12

d3d4

d1

h17

a7a8

Sa

L

ektB

y1h8

Si

h19

a11

h21 h1

8

a9

a10

a12

h20

Bx1

X

A

BA

B

i - Number of securing bolts for torque bracket

Bx2

5.1 Data and dimensions

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1d b leehw tke xobraeG 1xB 2xB 1yB 3a 4a 7a 8a 9a 01a 11a 21a 2b 3b 4b 8b 9b 01b

211xam

06

0002 01A02A

063 063 65 39

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621rofZPD031

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716

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-

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831

51 55

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0513 2911

0002

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716

29

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0052 768041

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0002

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575

022

-

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851

51 56

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575

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0513 5311

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0002

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074ro065.s61S

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245

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381

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0004 7941

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The supply of a DFW end carriage includes: End carriage, mounting plate with securing bolts and buffer

bwheel – standard travel wheel tread see item 2.3; other travel wheel treads on request

End carriage weight without mounting plate, motor and gearbox

Assignment of end carriages: For SWL – span, see standard overhead travelling cranes brochure 203 317 44(crane selection tables and wheel loads/mass forces/forces resulting from running at an angle/buffer forces/dead loads of the crane)

20332013.eps

b10

h22

b2

b4

bwheel

b3

b8

View X Section B-BSection A-A

h7

h10

b9

h24

S

h25

Figure: Bolted connection

For bolted connection

For bolted and welded connection

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4 4 4311

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9 9

692 813 4222 8

4 4

4

251

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982 403 623 4733 21 962

182

01

692 813 4222 8

6

251

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982 403 623 4733 21 962

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-

01 01

173 393 0822 01

4 4

4

591

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21

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6

591

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4 4 6

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444 954 184 6334 21 685

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6 DFW-L-E end carriage attachments

6.1 End plates

Standard version (buffer height = 100 mm)

130

229

60

65

8687

138

266

60

70

8510

9

158

328

85

7713

4

20332012.eps

DFW-L-E 112 DFW-L-E 125 DFW-L-E 160 DFW-L-E 200652 771 44 652 798 44 652 832 44 652 865 44

185

410

95

7316

9Variant for Italy (buffer height = 0,6 x travel wheel diameter)

Due to the application of the EC Machine Directive 98/37/ECin Italy, the buffer height of 100 mm has been adapted to ourstandard.

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130

229

60

65

120

87

75

301

50

70

46

120

158

346

85

54

122


85

432

62

122

459

Variant for USA (buffer height = 100 mm; with derailment guard)

20332014.eps

263

75

34

46

138

276

85

54

373

58

185

95

Variant for guide rollers (buffer height = 100 mm)

130

87

20332015.eps


142

138

109

160

158

134

208

185

169

283

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6.2 Bolted mounting plates for DFW-L-E/S end carriages

20332018.eps

Bolted mounting plates with non-countersunk bore holes

d 3

A

Ax ±0,2A

y2Ay1

Ay3

Ay

20

B

B =

h13

Sta

ndar

d m

ount

ing

plat

e

Ay4

1) The open bore holes dia. 21 mm in the bolted mounting plate are closed with plugs

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803

12 -

9,71521 0513,0052,0002

061 0052,0002 44877018 082 59 051 022 - 562 573 9,71

061 0513 44382118 005 59 051 022 - 562 006 6,53

002 0052,0002 44328959 082 051 022 092 - 533 573583

9,71

002 0004,0513 44428959 005 051 022 092 - 533 006 6,53

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20332019.eps

Bolted mounting plates with countersunk bore holes

1) The open bore holes dia. 21 mm in the bolted mounting plate are closed with plugs

WFD .ontraP mmnisnoisnemiD thgieW

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803

12 -

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002 0052,0002 44227959 082 051 022 092 - 533 573583

9,71

002 0004,0513 44027959 005 051 022 092 - 533 006 6,53

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6.3 Bolted and welded mounting plates for DFW-L-E/O

d 3

E

B

G

T

A

H

F

By1

Bx1

203 320 20.eps

Bolted mounting plates

Bx2

WFD uB.ontraP

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1d mmni 1xB 2xB 1yB E F G H T A B 3d gkni

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12

1,21

061 014redo002 44658256 074 074 46 051 38 861 771 22 075 002 2,51

002014redo002 44947356 074 074 58 051 19 891 012 22 075 032 5,61

005redo014 44978256 065 065 58 063 19 891 012 22 066 032 3,81

mottob,egnalfredrigenarcfohtdiW-uB

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203 320 21.eps

Welded mounting plates

E

B

T

A

H

F

WFD uB.ontraP

mmnisnoisnemiD thgieW

1d mmni E F H T A B gkni

211 003redo002 44197256 051 04 021 51 063 041 1,6

521 003redo002 44528256 051 37 051 51 045 071 6,8

061 014redo002 44858256 051 38 771 81 075 002 8,21

002014redo002 44057356 051 19 012 51 075 032 5,41

005redo014 44188256 063 19 012 51 066 032 8,21

mottob,egnalfredrigenarcfohtdiW-uB

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6.4 Torque brackets In standard cranes, the torque brackets are used in conjunction with AM offset gear-boxes, ZBF cylindrical rotor motors and DRS wheel blocks with pin connection.

For data, dimensions and ordering, see catalogue 203 352 44

• Torque brackets section 4.1


• Offset gearboxes

• Cylindrical rotor motors

6.5 Buffers and spacers Buffers with high buffering forces are required to avoid hazardous deformations of thesupporting structure in the event of end carriage collisions or when running againstthe end stop at the runway end.


• Buffers and spacers sections 4.4

6.6 Guide rollers The horizontal guide rollers always have to be considered in conjunction with theDRS wheel block. When ordering the end carriage, information on the guide rollers isrequired.


• Guide rollers section 4.6

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Wheel block size: 112 125 160 200

Wheel base: 2000 2500 3150 4000

Connection of main girder: S O

Travel wheel tread:

Travel wheel type: A flange on both sides B without flange

D flange on one side Others:

Drive arrangement: L- left R- right RL - right or left

Number of drives: 0 1 2

Drive shaft diameter: 30 35 45 50

Guide rollers (standard): yes no

Buffers: 100 130 160

Version: Standard USA

DFW-L-E/S mounting plate: Countersunk Non-countersunk

DFW-L-E/O mounting plate: Bolted Welded

Protection against corrosion: RAL1004 golden yellow Others:

Paint finish: RAL1007 daffodil yellow Others:

Classification: H2 B3 (indoor operation) Others on request

7 Order form for DFW-L-E end carriages

Order data:

From company:

Ms./Mr.:

Department:

Address:

Date:

Telephone:

Telefax:

# =

Mod

ifica

tions

com

pare

d to

pre

viou

s is

sue

Prin

ted

in G

erm

any

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3100

5/5H

Demag Cranes & Components GmbH

P.O. Box 67 · D-58286 Wetter

Telephone (+49/2335) 92-0 · Telefax (+49/2335) 927676

www.demagcranes.com

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.

manual DEMAG de gruas puente.pdf

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