181111 enGB 203 321 44 714 IS 845.1

DFW-L-E travel unitswith DRS 112 to 200

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20332001.eps

Steel structure

Torque bracket

Buffer

DFW-L-E / S

Contents

Page1 DFW product description 31.1 Application 31.2 Modular travel unit system 31.3 Anti-corrosion protection and painting 31.4 Documentation 3

2 Design and installation instructions 42.1 Steel structure 42.2 Mounting possibilities 42.3 DRS wheel block system 52.4 Adjusting the span 52.5 Wind drift safety catch 62.6 Optimising the speed 6

3 Type code 73.1 Type designation 73.2 Order information 7

4 DFW-L-E / S travel unit 84.1 Data and dimensions 8

5 DFW-L-E / O travel unit 105.1 Data and dimensions 10

6 Fittings for DFW-L-E travel units 126.1 Anti-run-off device complete with buffer 126.2 Guide roller bracket complete with buffer 126.3 Connecting plate for DFW-L-E / S 136.4 Connecting and welding plates for DFW-L-E / O 146.5 Torque brackets 156.6 Buffers and spacer elements 156.7 Guide rollers 15

7 Order form for DFW-L-E travel units 16

Connecting plate Geared motor

Wheel blocknon-driven

High-tensile bolted connection

Cover plateonly for outdoor operation1x for Ax<=500 mm2x for Ax>500 mm

Wheel block fi tting elements

Spacer element Driven wheel block

Threaded pin set

Buffer

Buffer adaptor and screwonly for DFW-L-E 112

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1 Product description

DFW-L-E travel units are used for travel applications for crane and hoist steelwork and related mechanical engineering structures.

DFW-L-E travel units are compact, driven rail-mounted travel units and can be connected direct to load-bearing structures. In addition to the steel section, a rigid box girder profile, the travel units feature a driven wheel block, to which a gearbox and motor are fitted, as well as a non-driven wheel block.The travel unit profile section, designed on the basis of the latest findings in the steelwork sector, displays excellent travel characteristics, even at high loads due to tight tolerances regarding e.g. differences in the runway gauge, skewing and misalignment. Specially matched heavy-duty motors ensure smooth starting of the travel unit, whether with or without a load, with favourable speed/torque character-istics.

We offer the following mounting combinations to meet your design needs:Connection• Travel units with a side connection to the crane girder (standard)• Travel units with a top connection to the crane girder

Travel unit / travel wheel• Wheel block DRS 112, 125, 160, 200 mm• Maximum wheel loads up to 10000 kg• Wheel bases 2000, 2500, 3150, 4000 mm

Travel drive (drives optionally fitted to the right or left-hand side)• AM offset gearbox• ZBF travel motor• MA torque bracket

Buffers• DPZ cellular foam buffer

Corrosion protection• Pre-treatment of structural steel parts in a shot-blasting unit

(degree of rust removal Sa2 acc. to DIN 55 928).• Protected against corrosion by means of prime coat RAL 1004 golden yellow

(coat thickness 60 μm)• Hot galvanized design on request• Other anti-corrosion protections on request.

Painting• If required also finishing coat RAL 1007 daffodil yellow or others on request.

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

DRS wheel block, gearbox, travel motor and buffer• Demag DRS wheel block system, volume 1 1) 203 352 44 • Geared motors 203 150 44

1.1 Application

1.2 Modular travel unit system

1.4 Documentation

1.3 Anti-corrosion protection and painting

1) required for designing the travel units

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20332002.eps

Steel construction with top connection of the crane girder

Steel construction with side connection of the crane girder

The connecting structure can be mounted on the travel unit:• flush with the bottom edge (side crane girder connection)• flush with the top edge (side crane girder connection)• raised (side crane girder connection),• lowered (side crane girder connection),• top-mounted (top crane girder connection)

2 Design and installation instructions

The steel construction is specified to DIN 15018, lifting class H2, loading group B3.The steel construction features:• High stability thanks to torsion-resistant enclosed box girder profile. Exactly

welded diaphragm plates reinforce the connection area.• Precise position of the travel wheel axes in relation to the connecting surfaces

thanks to machining in a NC machine tool.• Easy assembly and accessibility. Detachable high-strength connection with the

connecting structure resistant to shearing stress.• Optimum travel characteristics and, if required, reliable replacement thanks

to reproducible connection geometry. Tight tolerances for differences in the runway gauge, diagonal wheel positions and misalignment are achieved by precisely aligning the machined connecting surfaces of the end carriages.

2.1 Steel structure

2.2 Mounting possibilities

20332003.eps

fl ush with the bottom edge fl ush with the top edge raised lowered top-mounted

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ZX

ZX

20332004.eps

b 2

d 2

d 1

brail

bwheel

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 lubri-

cated for life.• Simple adjustment of span by re-arranging spacer elements between the wheel

block and the inside of the carriage girder.• Greatly reduced wear on travel wheels (wear indicator) and track rails as a re-

sult of the self-lubricating effect of spheroidal graphite cast iron compared with steel.

• Low-noise running due to high self-damping effect of the travel wheel material.

2.3 DRS wheel block system

Travel wheel profile

1) Other treads on request2) Max. wheel loads with linear contact (flat rail to DIN 1014 or A-type rail to DIN 536) depending on the

FEM group, useful rail width and crane travel speed see catalogue 203 352 44 section 2.6.5

By re-arranging the spacer elements and adjusting the threaded pins, the span can be adjusted.

2.4 Adjusting the span

Dimensions in mm max wheel loads 2)

d1 d2 b2 max bwheel Standard bwheel 1) [kg]

112 132 80 60 47,60 3500

125 150 80 60 47,60 5000

160 188 89 65 47,60,65 7000

200 230 101 65 65 10000

d 1 Spacer elements

[mm] Thickness [mm] max. adjusting range [mm]

112

2, 3 and 5

± 6

125 ± 4

160 ± 6

200 ± 10

20332005.eps

Threaded pinSpacer elements

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2001501005040302520151098765

12,516

20

25

31,540

50

63

80100

125

According to accident prevention regulations (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 manuallly operated wind safety catch should be preferred.

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

2.5 Wind drift safety catch

2.6 Optimising the speed

20332008.eps

Trav

el s

peed

in m

/min

Crane runway length or span in m

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3 Type code

3.2 Order information The following information is required:• Travel unit type: E - single-girder crane

• Travel wheel diameter or wheel block size / Wheel base: 112 / 2000, 2500 125 / 2000, 2500, 3150, 4000 160 / 2000, 2500, 3150, 4000 200 / 2000, 2500, 3150, 4000 (other wheel bases on request)

• Distance between high-tensile bolted connections for DFW-L-E / S: Ax

• Crane girder connection: S - side O - top

• Travel wheel tread: see section 2.3

• Travel wheel variant: A - with flange on both sides (other travel wheel variants on request, see catalogue 203 352 44 section 2.6.3)

• Drive variant, view to connecting plate: L - 1 travel unit, left-hand side R - 1 travel unit, right-hand side RL - 2 travel units arranged in pairs

(right-hand side and left-hand side)

• Number of drives per travel unit: 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: yes / no (see section 6.2 and catalogue 203 352 44 section 4.6)

• DPZ buffers: 100, 130, 160 (see catalogue 203 352 44 section 4.4 and 4.5)

• Anti-run-off device: (see section 6.1)

• Connecting plate DFW-L-E/S: countersunk / non-countersunk bore holes (see section 6.3)

• Connecting plate DFW-L-E/O: Connecting plate, welding pate (see section 6.4)

DFW-L-E 112 / 2000 / SCrane girder connection

Wheel base ekt

Travel wheel diameter d1

Overhead travelling cranes

3.1 Type designation

Single-girder crane

Demag travel unit

20332030.eps

Drive arrangementleft

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X

A

A

B

B

4 DFW-L-E / S travel unit

20332009.eps

L

ekt

Ay1

h12 d1

Ax

Ay2

Ay3

h1

100

sta

ndar

d bu

ffer h

eigh

t

a4

21

51,5

4.1 Data and dimensions

95

M10

65 250

a5

Dimensions in mm

d1 brad ekt Gearboxes Ax Ay1 Ay2 Ay3 a4 a5 b3 b4 b8

112 max. 60

2000 A10A20 280

150 --

100for

DPZ100

120for

DPZ130

150for

DPZ160

20 71,5 70136

2500 95 150 135

125 max. 60

2000

A10A20A30

280

95 150

-

- 77,5 70

138

2500

1403150

500

4000280

220500

160 max. 65

2000

A20A30A40

28095 150 220

- 88 85

158

2500

1603150

500

4000280

150 220 290500

200 max. 65

2000

A30A40

280

150 220 290 - 105,5 95

183

2500

1853150

500

4000280

500

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20332010.eps 20332011.eps

20

b4

brad

b3

5

Travel unit

Y

b8

View X Section B-BSection A-A

Whe

el c

entre

Crane 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

h9H

AP

The supply of a DFW travel unit includes: travel unit, connecting plate with securing bolts and buffer.bwheel - standard travel wheel tread see section 2.3; other travel wheel treads on request.Travel unit weight with DRS without connecting plate, motor and gearbox.

b9

Dimensions in mm Weightin kgb9 h1 h7 h9 h12 HAP L

12 149244

22,513

3082190 131

247 14 2690 164

15

162,5

281

42,5

15 308

2220 164

285 2720 214

289

3370

281

232,5 359 30 400

15

217

353

32

17

308

2275 222

357 2775 284

361

3425

368

294 441 39 385 510

15 277

440

42 20 385

2340 300

442 2840 383

444

3490 486

4340 586

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X

A

A

B

B

5 DFW-L-E / O travel unit

20332012.eps

a4h12 d1

L

ektB

y1

Bx1

Bx2

Dimensions in mm

d1 bwheel ekt Gearboxes Bx1 Bx2 By1 a4 a5 b3 b4 b8 b10

112 max. 602000 A10

A20 360 360 56

100for

DPZ 100

120for

DPZ 130

150for

DPZ 160

20 71,5 70136

222500 135

125 max. 60

2000A10A20A30

360 440 44 - 77,5 70

138

552500140

3150

160 max. 65

2000A20A30A40

470 470 64 - 88 85

158

652500160

3150

200 max. 65

2000

A30A40

470or

560see page

14

470or

560see page

14

85 - 105,5 95

183

732500

1853150

4000

Illustration: Bolted type mounting

5.1 Data and dimensions

100

sta

ndar

d bu

ffer h

eigh

t

95

M10

65 250

a5

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The supply of a DFW travel unit includes: travel unit, connecting plate with securing bolts and buffer.bwheel - standard travel wheel tread see section 2.3; other travel wheel treads on request.Travel unit weight with DRS without connecting plate, motor and gearbox.

20332013.eps

b10b4

bwheel

b3

b8

View X Section B-BSection A-A

h7

h24h2

5

Dimensions in mm Weightin kgh7 h12 h24 h25 L

244 13 259 281 2190 131

247 14 262 284 2690 164

281

15

296 318 2220 164

285 300 322 2720 214

289 304 326 3370 281

353

17

371 393 2275 222

357 375 397 2775 284

361 379 401 3425 368

440

20

455 477 2340 300

442 457 479 2840 383

444 459 481 3490 486

444 459 481 4340 586

Illustration: Bolted type mounting

for bolted type mounting

for bolted and welded type mounting

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6 Fittings for DFW-L-E travel units

6.1 Anti-run-off device complete with buffer

20332032.eps

b11

b12

100

c1

c2

Sta

ndar

d bu

ffer h

eigh

t

20332031.eps

6.2 Guide roller bracket complete with buffer

DFW Part no. b11 b12 c1 c2

112 652 888 44

75

130

95

120

125 652 892 44 140

160 652 895 44

85

170

122

200 652 885 44 190

b13

100

Sta

ndar

d bu

ffer h

eigh

t

DFW Part no. b13

112 652 889 44

30 - 70

125 652 893 44

160 652 896 44 30 - 80

200 652 886 44 40 - 90

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d 3

BAP

Ax

Ay2Ay

1

Ay3

Ay

20

HA

P

Ay4

6.3 Connecting plate for DFW-L-E / S

20332018.eps

Connecting plates with non-countersunk bore holes

20332019.eps

Connecting plates with countersunk bore holes

BAP

HAP

Ax

d3 d4

Ay2

Ay3

Ay1

Ay4

Ay

2,5 ±0,5

20

DFW Part no.: Dimensions in mm Weight in kgd1 ekt Ax Ay1 Ay2 Ay3 Ay4 Ay BAP HAP d3 d4

1122000

810 706 44280

95 1)

150

-

-

182,5375

308

21 -

17,92500

95125

2000, 2500, 31504000 810 778 44 220 2653150 658 199 44

500- 182,5

60028,8

4000 811 283 44220 265

35,6

160

2000, 2500, 3150 810 778 44280 375 17,9

4000 655 031 44 150 220 290 335 3853150 811 283 44

50095 150 220 265

600308

35,64000 655 033 44

150 220 290 335 385200

2000, 2500, 3150, 4000 655 031 44 280 375 17,93150, 4000 655 033 44 500 600 35,6

DFW Part no.: Dimensions in mm Weight in kgd1 ekt Ax Ay1 Ay2 Ay3 Ay4 Ay BAP HAP d3 d4

1122000

810 265 44280

95 1)

150

-

-

182,5375

308

21 50,1

17,92500

95125

2000, 2500, 31504000 959 347 44 220 2653150 658 198 44

500- 182,5

60028,8

4000 811 285 44220 265

35,6

160

2000, 2500, 3150 959 347 44280 375 17,9

4000 655 032 44 150 220 290 335 3853150 811 285 44

50095 150 220 365

600308

35,64000 655 034 44

150 220 290 335 385200

2000, 2500, 3150, 4000 655 032 44 280 375 17,93150, 4000 655 033 44 500 600 35,6

1) Do not use bore holes for this combination

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6.4 Connecting and welding plates for DFW-L-E / O

d3

E

B

G

T

A

H

F

By1

Bx1

20332020.eps

Connecting plates

Bx2

DFW Buin mm

Part no.: Dimensions in mm Weight in kg

d1 Bx1 Bx2 By1 E F G H T A B d3

112 200 or 300 652 789 44360

360 56

150

40 112 120

22

460 140 17 8,8

125 200 or 300 652 823 44 440 44 73 138 150 540 170

21

12,1

160 200 or 400 652 856 44470 470

64 83 168 177570

200 15,2

200200 or 400 653 749 44

85 91 198 210 23016,5

400 or 500 652 879 44 560 560 360 660 18,3

Bu - width of crane girder bottom fl ange

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Welding plates

E

B

T

A

H

F

DFW Buin mm

Part no.: Dimensions in mm Weight in kg

d1 E F H T A B

112 200 or 300 652 791 44

150

40 12015

360 140 6,1

125 200 or 300 652 825 44 73 150 540 170 8,6

160 200 or 400 652 858 44 83 177 18570

200 12,8

200200 or 400 653 750 44

91 210 15 23014,5

400 or 500 652 881 44 360 660 12,8

Bu - width of crane girder bottom fl ange

6.5 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 connec-tion.For data, dimensions and ordering, see catalogue 203 352 44• Torque bracket section 4.1 For data, dimensions and ordering, see catalogue 203 150 44• Offset gearbox• Cylindrical rotor motors

6.6 Buffers and spacer elements

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

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

7 Order form for DFW-L-E travel units

Order data

From company:

Mr./Ms.:

Department:

Address:

Date:

Telephone:

Telefax:

Prin

ted

in G

erm

any

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

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

Wheel block size: 112 125 160 200

Wheel base: 2000 2500 3150 4000

Crane girder connection: S O

Distance between HT connections Ax: 280 500

Travel wheel tread:

Travel wheel type: A-with fl ange on both sides B-no fl ange

D-fl ange on one side others:

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

No. of drive units: 0 1 2

Drive shaft diameter: 30 35 45 50

Guide rollers: yes no

Anti-run-off device: yes no

Buffers: 100 130 160

Connecting plate DFW-L-E / S: countersunk non-countersunk

Connecting plate DFW-L-E / O: Connecting plate Welding plate

Anti-corrosion protection: RAL1004 golden yellow others:

Paint fi nish: RAL1007 daffodil yellow others:

Classifi cation: H2 B3 (indoor operation) others on request