DFW-L-E end carriages

with DRS 112 to 200

010802 EN/DE

203 321 44

714 IS 845.1

Contents

Page 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 4 4.1 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 7 DFW product description Application Modular carriage system Protection against corrosion, paint finish Documentation Design and mounting information Steel construction Types of connection DRS wheel block system Adjusting the span Wind safety catches Optimizing the travel speed Mounting code Type designation Order information DFW-L-E/S end carriages Data and dimensions DFW-L-E/O end carriages Data and dimensions DFW-L-E end carriage attachments End plates Bolted mounting plates with non-countersunk bore holes and with countersunk bore holes for DFW-L-E/S Bolted and welded mounting plates for DFW-L-E/O Torque brackets Buffers and spacers Guide rollers Order form for DFW-L-E end carriages 3 3 3 3 3 4 4 4 5 5 6 6 7 7 7 8 8 10 10 12 12 14 16 18 18 18 19

DFW-L-E / S
Steel structure Bolted mounting plate Geared motor

Torque bracket

Buffer

Wheel block Non-driven

High-tensile bolted connection

For outdoor operation only 1x for Ax<=500 mm 2x for Ax>500 mm

Wheel block Spacer End fitting elements Wheel block plate Driven

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Product description

1.1 Application 1.2 Modular carriage system

DFW-L-E carriages are used for steel structures in the crane and lifting equipment industry and also for applications in related mechanical engineering. DFW-L-E carriages are compact, driven, rail-mounted carriages for direct connection to load-bearing structures. In addition to the steel structure part, a torsionally resistant box section, the end carriage includes a driven wheel block for fitting the gearbox and the motor as well as a non-driven wheel block. The carriage design is based on the latest principles for steel structures and, even with high loads, has excellent travelling characteristics due to the fine tolerances of the carriage regarding track gauge errors, diagonal position and misalignment. Specially adapted heavyduty motors provide excellent speed/torque characteristics, which ensure smooth starting 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

1.3 Protection against corrosion Paint coat

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 m) 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 on request.

1.4 Documentation

Travel unit Operating instructions Component parts list 214 362 44 222 736 44

DRS wheel blocks, gearboxes, travel motors and buffers Demag DRS wheel block system Volume 1 1) Geared motors for travel applications Volume 2
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203 352 44 203 355 44

1) required for rating the end carriages

Design and mounting information

2.1 Steel structure

The steel structure is designed in accordance with DIN 15018, lifting class H2, stress group B3. Steel structure characteristics: High stability due to enclosed, torsion-resistant box section girder. Great strength in connection area due to diaphragm plates welded into the carriage. Machining on NC machines provides precise positioning of travel wheel axles with respect to mating surfaces. Easy assembly and access. Detachable and anti-shear high-tensile connection with adjoining structure. Optimum travel characteristics. Can be easily exchanged due to accuracy of the connection geometry. Fine tolerances for track gauge errors, diagonal wheel position and misalignment are met as a result of the precise alignment and machining of the connection surfaces.

Steel structure with top connection of main girder

Steel structure with side connection of main girder

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2.2 Types of connection

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),

Bottom flush

Top flush

Raised

Lowered

Top connection
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2.3 DRS wheel blocks

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 lubricated for life. Simple adjustment of span by re-arranging spacer elements between the wheel block and the inside of the carriage girder. Considerably reduced wear on travel wheels (wear indicator) and track rails as a result of the self-lubricating effect of spheroidal graphite cast iron compared with steel. Silent running due to self-damping properties of the travel wheel material.

Travel wheel profile

Dimensions in mm d1 112 d2 132 150 188 230 b2 80 80 89 101 Max. bwheel 60 60 65 65 Standard bwheel 1) 47, 60 47, 60 47, 60, 65 65 Max. wheel loads 2) [kg] 3500 5000 7000 10000

d1

d2

125 160 200

b rail b wheel b2
1) 2) other treads on request 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

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2.4 Adjusting the span

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

d1 [m m ] 112 125 2 and 5 160 200 6 10 Thickness [mm] Spacer elements Max. adjustment [mm] 6 4

Spacer elements Spacer elements

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Design and mounting information

2.5 Wind safety catches

According to accident prevention regulations (UVV, BGV D6 14.1 (VBG 9)), cranes must have their power-driven travelling and slewing movements braked, thus preventing 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 are secured during storms and at the end of work. According to the surface area exposed to the wind, one or two safety catches are required per crane. Depending on accessibility, the manually operated wind safety catch should be preferred.

2.6 Optimizing the travel speed

Optimum handling capacity can only be achieved by correctly selecting the working speeds. For this, the average speed of the individual movements is the determining factor.

125 100 80 63 50 40 31,5 25 20 16 12,5 5 6 7 8 9 10 15 20 25 30 40 50 100 150 200

20332008.eps Crane runway length or span (m)

Travel speed (m/min)

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Mounting code

3.1 Type designation

DFW-L-E 112 / 2000 / S

Connection of main girder Wheel base ekt Travel wheel diameter d1 Single-girder crane Overhead travelling crane Demag end carriage

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, 2500 125 / 2000, 2500, 3150 160 / 2000, 2500, 3150 200 / 2000, 2500, 3150, 4000
Other wheel bases on request

Drive variant left

Main girder connection: S - side O - top Travel wheel tread: Travel wheel variants: See section 2.3 A - with flange on both sides

20332030.wmf

Other 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 side R - 1 end carriage, right-hand side RL - 2 end carriages arranged in pairs (right-hand side and left-hand side) Number of drives per end carriage: 0 - no drive 1 - one drive 2 - 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/no

See section 6.1 and catalogue 203 352 44 section 4.6

DPZ buffers:

100, 130, 160

See catalogue 203 352 44 sections 4.4 and 4.5

End plate variant: lers

See section 6.1

Standard, variant for Italy, USA or for guide rol-

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DFW-L-E/S mounting plate:

See section 6.2

with countersunk bore holes, with non-countersunk bore holes

DFW-L-E/O mounting plate:

See section 6.3

bolted type, welded type

DFW-L-E/S end carriages

4.1 Data and dimensions

L ekt A
S

a3
(Standard buffer height)

Ax

a 12
h 21 h 18 Ay3 h 19 h8

Ay2 Ay1

a9

d4
h1

d3

h 17

h 20

h 12

a10 A

a11

21 51,5 B 4 a8

d1 a7 4

a4

i - Number of securing bolts for torque bracket

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Dimensions in mm d1 112 bwheel

max 60

ekt 2000 2500 2000 2500 3150

Gearbox
A10 A20

Ax 280

Ay1 150 95

Ay2 -

Ay3 -

a3 93

a4

a7 203

a8 672

a9 145

a10 -

a11 79

a12 50

b2 80

b3 71,5

h 23

b4 70

150

922 617 138 140 1192 175 617 867 1192 575 825 1135 288 575 825 110 160 220 97,5 75 89 88 85 158 160 158 92 140 77,5 58,5 80 77,5 70 138

A10 A20

867 280 95 150 108

106 for DPZ100 126 for DPZ130 158 for DPZ160

125

max 60

233

2000 2500 3150 2000 280 2500 3150 160

max 65 A20 A30

500 95 150 220 135,5 280 500 280

2000 2500 3150 2000 2500 200

max 65 A30 A40 A30 A40

1135 542 792 150 220 290 168 353 1072 1497 275 140 120 105 101 105,5 95 185
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3150 4000

500

100
b8 135 183

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)

View X

Section A-A

Section B-B

Detail Y

b3

b4

b9 Y

End carriage

Main girder

h13

h7

Travel wheel centre

b2

b8 5

20

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h9

bwheel

67,5 1 67,5 1 82,5 1 92,5 1

DFW-L-E 112 DFW-L-E 125 DFW-L-E 160 DFW-L-E 200

h22

h10

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Dimensions in mm b9 12 d3 18,5 d4 M8 h1 149 247 281 285 289 15 21 M8 162,5 281 285 289 353 357 361 15 30 M 10 217 353 357 361 440 442 15
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Number Weight h18 40 h19 60 h20 10 h21 h22 9,5 h23 2704 2224 2724 3374 9 10 9 2224 2724 3374 2280 2780 3430 10 12 10 2280 2780 3430 2336 2836 8 10 12 8 10 6 3486 462 12 4336 586 6 195 257 341 300 380 8 10 12 8 10 12 4 6 152 202 269 195 257 341 9 8 10 12 4 L 2204 S 7 4 153 152 202 269 i kg 113

h7 243

h8 215

h9 22,5

h10 24

h12 14

h13 308

h17 42

250

42,5

28

15

308

47,5

40

68,5

41

320

32

31

17

308

63

55

90

56

35

M 10

277 444

400

42

35

20

385

80

75

115

70

10

10

15

DFW-L-E/O end carriages

5.1 Data and dimensions

Figure: Bolted connection

L ekt a3
(Standard buffer height)

B A

a9
h21 h18

a12
h19

d4
h8

d3

h17

h20

a10

a11

d1

B A
i - Number of securing bolts for torque bracket Bx1 Si

a8 Sa

a7

a4

By1

Bx2

h23

h12

100

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Dimensions in mm d1 112 bwheel max 60 ekt 2000 2500 2000 2500 125 max 60 3150 360 2000 2500 3150 2000 2500 160 max 65 3150 470 2000 2500 3150 2000 200 max 65 2500 3150 4000 A30 A40 470 or 560 s. S16 470 or 560 s. S16 A30 A40 470 64 135,5 158 for DPZ 160 288 575 825 1135 542 792 85 168 353 1072 1497
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Gearbox A10 A20

Bx1 360

Bx2 360

By1 56

a3 93

a4

a7 203

a8 672

a9 145

a10 -

a11 79

a12 50

b2 80

b3 71,5

b4 70

b8 135 138

b9 12

b10 22

922 617

A10 A20 440 44 108 106 for DPZ 100 126 for DPZ 130 233

867 1192 175 617 867 1192 575 825 1135 220

140 77,5 58,5 92 140 158 160 97,5 110 160 183 275 140 120 105 101 105,5 95 185 15 73 75 89 88 85 158 15 65 80 77,5 70 138 15 55

A30

A20

10

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)

Figure: Bolted connection

For bolted connection For bolted and welded connection

View X

Section A-A b3 b4

Section B-B b10

S
h25 h24 h7

b9

h22

bwheel b2

h10

b8

20332013.eps

Dimensions in mm d1 112 d3 18,5 d4 M8 247 281 285 289 125 21 M8 281 285 289 353 357 361 160 30 M10 353 357 361 440 442 200 35 M10 444 444
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Number

h7 243

h8 215

h10 24

h12 14

h17 42

h18 40

h19 60

h20 10

h21 -

h22 9,5

h23 -

h24 258 262 296

h25 280 284 318 322 326 318 322 326 393 397

L 2204 2704 2224 2724 3374 2224 2724 3374 2280 2780

S 7

Sa 4

Si 4

Weight in kg 113

4 153 152 4 202 269

9 8 10 12 4 4 8 10 12 10 10 12 4 4 10 10 12 10 10 4 4 6 12 12 6 4 6

285 28 15 47,5 40 68,5 41 10 9 9

300 304 296 300 304 371

152 202 269 195 257 341 195 257 341 300 380 462 586

320 31 17 63 55 90 56 12 10 10

375 379 371 375 379 455 457

401 3430 393 397 2280 2780

401 3430 477 479 2336 2836

400

35

20

80

75

115

70

10

10

15 459 459 481 3486 481 4336

11

DFW-L-E end carriage attachments

6.1 End plates

Standard version (buffer height = 100 mm)

DFW-L-E 112
652 771 44

DFW-L-E 125
652 798 44

DFW-L-E 160
652 832 44

DFW-L-E 200
652 865 44

60
109

134

60

169 266 77 328

87

229

65 130 138

86

70 158

85

85 185

95

73
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Variant for Italy (buffer height = 0,6 x travel wheel diameter)

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

410

12

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

DFW-L-E 112
652 770 44

DFW-L-E 125
652 800 44

DFW-L-E 160
652 833 44

DFW-L-E 200
652 866 44

60

432 58

87

276

229

120

263

120

301

346

373

46

34 75 65 130

46

50 75 70 138

54

54 85 85 158

122

62 85 95 185

122

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Variant for guide rollers (buffer height = 100 mm)

DFW-L-E 112
652 769 44

DFW-L-E 125
652 831 44

DFW-L-E 160
652 864 44

DFW-L-E 200
652 868 44

158

185

138
134 169

130
109

208

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142

160

87

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283

459

13

DFW-L-E end carriage attachments

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

Bolted mounting plates with non-countersunk bore holes

d3

Ax 0,2

B = h13 Standard mounting plate

Ay1

Ay2 Ay3

Ay4

Ay

20

20332018.eps

DFW d1 112 125 160 160 200 200 ekt 2000, 2500

Part no. 1) 810 706 44 Ax 280 280 500 280 500 Ay1 95 95 95 150 150 Ay2 150 150 150 220 220 Ay3 220 220 290 290

Dimensions in mm Ay4 Ay 182,5 265 265 335 335 A 375 308 375 21 600 375 385 600 B d3 d4

Weight in kg 17,9 17,9 35,6 17,9 35,6

2000, 2500, 3150 2000, 2500 3150 2000, 2500 3150, 4000 810 778 44 811 283 44 959 823 44 959 824 44

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

14

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Bolted mounting plates with countersunk bore holes

20332019.eps

DFW d1 112 125 160 160 200 200 ekt 2000, 2500

Part no. 1) 810 265 44 Ax 280 280 500 280 500 Ay1 95 95 95 150 150 Ay2 150 150 150 220 220 Ay3 220 220 290 290

Dimensions in mm Ay4 Ay 182,5 265 265 335 335 A 375 308 375 21 600 375 385 600 B d3 d4

Weight in kg 17,9 17,9 35,6 17,9 35,6

2000, 2500, 3150 2000, 2500 3150 2000, 2500 3150, 4000 959 347 44 811 285 44 959 722 44 959 720 44

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

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15

DFW-L-E end carriage attachments

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

Bolted mounting plates

Bx2 Bx1

By1

d3
H B

E A

203 320 20.eps

DFW d1 112 125 160

Bu Part no. in mm 200 oder 300 200 oder 300 200 oder 410 200 oder 410 652 789 44 652 823 44 652 856 44 653 749 44 652 879 44 Bx1 360 360 470 470 560 Bx2 360 440 470 470 560 By1 56 44 64 85 85 E 150 150 150 150 360

Dimensions in mm F 40 73 83 91 91 G 112 138 168 198 198 H 120 150 177 210 210 T 22 22 22 22 22 A 460 540 570 570 660 B 140 170 200 21 230 230 d3 17

Weight in kg 8,8 12,1 15,2 16,5 18,3

200 410 oder 500

Bu - Width of crane girder flange, bottom

16

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Welded mounting plates

E A

203 320 21.eps

DFW d1 112 125 160

Bu Part no. in mm 200 oder 300 200 oder 300 200 oder 410 200 oder 410 652 791 44 652 825 44 652 858 44 653 750 44 652 881 44 E 150 150 150 150 360 F 40 73 83 91 91

Dimensions in mm H 120 150 177 210 210 T 15 15 18 15 15 A 360 540 570 570 660 B 140 170 200 230 230

Weight in k g 6,1 8,6 12,8 14,5 12,8

200 410 oder 500 Bu - Width of crane girder flange, bottom

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6.4 Torque brackets

In standard cranes, the torque brackets are used in conjunction with AM offset gearboxes, ZBF cylindrical rotor motors and DRS wheel blocks with pin connection. For data, dimensions and ordering, see catalogue 203 352 44 Torque brackets Offset gearboxes Cylindrical rotor motors section 4.1 For data, dimensions and ordering, see catalogue 203 355 44

6.5 Buffers and spacers

Buffers with high buffering forces are required to avoid hazardous deformations of the supporting structure in the event of end carriage collisions or when running against the end stop at the runway end. For data, dimensions and ordering, see catalogue 203 352 44 Buffers and spacers sections 4.4

6.6 Guide rollers

The horizontal guide rollers always have to be considered in conjunction with the DRS wheel block. When ordering the end carriage, information on the guide rollers is required. For data, dimensions and ordering, see catalogue 203 352 44 Guide rollers section 4.6

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Order form for DFW-L-E end carriages

From company: Ms./Mr.: Department: Address:

Date: Telephone: Telefax:

Order data:

Wheel block size: Wheel base: Connection of main girder: Travel wheel tread: Travel wheel type:

112 2000 S

125 2500 O

160 3150

200 4000

A flange on both sides D flange on one side

B without flange Others: RL - right or left 2 45 50

Drive arrangement: Number of drives: Drive shaft diameter: Guide rollers (standard): Buffers: Version: DFW-L-E/S mounting plate: DFW-L-E/O mounting plate: Protection against corrosion: Paint finish: Classification:

L- left 0 30 yes 100 Standard

R- right 1 35 no 130 USA

160

Countersunk Bolted RAL1004 golden yellow RAL1007 daffodil yellow H2 B3 (indoor operation)

Non-countersunk Welded Others: Others: Others on request

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# = Modifications compared to previous issue

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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.

Printed in Germany Basse/131005/5H