DEMAG DR Series Instruction manual

720 IS 800
214 912 44
201204 EN
DR crane set
Standard cranes with EKDR
Technical data and instructions for assembly

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2
Manufacturer:
Operating instructions
EKDR Com rope hoist
(Technical data and spare parts) 214 916 44 720 IS 813
DRS 112 – 200 wheel block system 214 276 44 720 IS 845.5
DFW-L-L travel units 214 331 44 720 IS 845.1
DFW-L-E travel units 214 362 44 720 IS 845.1
Demag EKDR Pro rope hoist 214 725 44 720 IS 813
DRC-10 radio remote control systems 214 920 44 720 IS 975
DRC-J radio remote control systems 214 975 44 720 IS 975
DSE-8R, 16 R control pendants 214 940 44 720 IS 975
Technical data
EKDR Pro rope hoist 203 520 44 714 IS 813
Demag DRS travel unit components 203 352 44 714 IS 845
KBK 0, KBK 25, KBK 100 power supply
via trailing cables 202 617 44 714 IS 963
KP-A / T clamp-type buffer 203 313 44 714 IS 888
Assembly instructions
KP-A / T clamp-type buffer 214 354 44 720 IS 888
Accompanying documents
Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone [phone] · Telefax ([phone]
www.demagcranes.com

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21491244.p65/201204
Page
0 Foreword 4
0.1 Copyright 4
0.2 Customer service 4
0.3 Liability for defects 5
0.4 Limitations of liability 5
0.5 Definitions 6
1 Safety instructions 7
1.1 Symbols 7
1.2 Intended use 7
1.3 Inappropriate use 8
1.4 Basic information on safety 8
1.5 Selection and qualification of operating personnel 9
1.6 Safety instructions for assembly and disassembly 10
1.7 Safety instructions when first putting the unit into service
after completing assembly 10
1.8 Safety instructions for operation 10
1.9 Safety instructions for maintenance 11
2 Scope of delivery 13
3 Overview of DR rope hoist assembly 14
3.1 Adjusting the EKDR Pro/Com 3 - 5 – 10 low-headroom monorail hoist,
4/1, 2/1 and 4/2 rope reeving 14
3.1.1 Assembling trolleys of the DR 3, 5 and 10 range 14
4 Manufacturing tolerances of crane runways 16
5 Technical Description DFW travel unit 17
5.1 DFW-L-E overview 17
5.2 DFW-L-L overview 19
6 Crane set 21
6.1 Crane set with DFW travel unit 21
6.1.1 Design of the travel unit 21
6.1.2 Changing the span 22
6.2 KP-T16 clamp-type buffer 23
7 Electrical components 24
7.1 Illustration of the scope of supply of the flange clamps 26
7.2 Connector overview 27
7.3 Plug-and-socket connection for motors of the KB and Z series 28
7.3.1 Safety instructions 28
7.3.2 General 28
7.4 Electrical design and connector insert 29
7.4.1 ZBF two-speed motor with brake 29
7.4.2 GF combined brake module 29
8 Crane anti-collision device 30
9 Geared limit switch for the DR rope hoist 33
9.1 Geared limit switch 33
9.1.1 Determining the cut-out points for the geared limit switch 33
9.2 Instructions for adjusting the geared limit switch 35
These instructions are no operating instructions for the end user, but assem-
bly instructions for the company being responsible for assembly and erection
of the rail-guided handling equipment.
Special operating instructions for the overall installation must be prepared by
the corresponding crane manufacturer.
Table of contents

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0 Foreword
You have purchased a Demag product.
This rail-guided handling equipment was manufactured in accordance with German
and European standards and regulations, e.g. EC Machinery Directive 98/37/EC,
and state-of-the-art engineering principles.
These assembly instructions are designed to provide the crane manufacturer with
appropriate instructions for safe and correct assembly and installation. The operat-
ing and assembly instructions of the corresponding products stated in the individual
sub-chapters form parts of these assembly instructions.
Every individual given the task of transporting, installing, commissioning, operating,
maintaining and repairing our rail-guided handling equipment and additional equip-
ment must have read and understood
• the assembly instructions
• the operating instructions,
• the safety regulations and
• the safety instructions in the individual chapters and sections.
The assembly instructions must be available to the assembly personnel at all times
in order to prevent assembly errors and to ensure smooth and trouble-free opera-
tion of our products.
These assembly instructions must be treated confidentially. They should only be
used by authorized personnel. They may only be entrusted or made available to
third parties with the prior written consent of Demag.
All documents are protected within the sense of copyright law.
No part of this documentation may be reproduced, utilized or transmitted without
specific prior consent. Infringements are an offence resulting in obligatory compen-
satory damages.
All industrial rights reserved.
For technical information on Demag products and their systematic application,
please refer to one of our after-sales service stations, the relevant representative
or to our main office in Wetter.
Our after-sales service will provide you with all technical information on Demag
products and their systematic application.
Should you have any questions regarding our products, please refer to one of our
after-sales service stations, the relevant representative or the manufacturer.
Kindly quote the serial or order number (see test and inspection booklet, load
capacity plate on the crane) in any correspondence or for spare part orders.
Specifying this data ensures that you receive the correct information or the required
spare parts.
The relevant after-sales service station of Demag is specified for example on the
back page of the hoist unit test and inspection booklet.
0.2 Customer service
0.1 Copyright

5
21491244.p65/201204
These operating instructions must be read carefully before installing and putting the
rope hoist into operation.
We assume no liability for any damage and malfunctions resulting from failure to
comply with the operating instructions.
Any liability claims for defects must be made by quoting the order number immedi-
ately 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 system which are not
part of our scope of supplies and services,
• use of non-genuine spare parts and accessories,
• refurbishment or modification of the product unless approved in writing by
Demag.
Wearing parts are not subject to liability for defects.
All technical information, data and instructions for operation contained in these
operating instructions were up-to-date on going to print and are compiled on the
basis of our experience and to the best of our knowledge.
We reserve the right to incorporate technical modifications within the scope of fur-
ther development of the rope hoists which are the subject of these operating in-
structions.
The information, illustrations and descriptions contained in these operating instruc-
tions are therefore only intended for information purposes.
The descriptions and illustrations contained in this documentation do not necessari-
ly 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 damage and malfunctions caused as a result of operating
errors, non-compliance with these operating instructions or inappropriate repairs
and maintenance.
We expressly point out that only genuine Demag spare parts and accessories ap-
proved by us may be used. Accordingly, this also applies to other manufacturers’
parts supplied by us.
For safety reasons, the fitting and use of spare parts or accessories which have not
been approved and unauthorized modification and conversion of the product are
not permitted and exempt Demag from any liability for damages resulting therefrom.
With the exclusion of any further claims, we are liable for any defects or omissions
on our part in the products or documentation supplied within the scope of the liabil-
ity obligations entered into in 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.
0.3 Liability for defects
0.4 Limitations of liability

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0.5 Definitions Owner
Owners (employer, company) are defined as persons who own the rail-guided
handling equipment and who use it appropriately.
Operating personnel/operator
Operating personnel or operators are defined as persons entrusted by the owner
of the rail-guided handling equipment with operation of the equipment.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner of the rail-
guided handling equipment to carry out special tasks such as installation, setting-
up, maintenance and fault elimination.
Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training,
knowledge and experience of electrical installations as well as knowledge of the
relevant standards, codes of practice and regulations, are able to assess the tasks
given to them and to identify and eliminate potential hazards.
Trained person
Trained persons are defined as persons who have been instructed and trained for
the tasks assigned to them and on the possible hazards resulting from incorrect
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 qualifications.
Experienced technician
Experienced technicians are defined as persons, who, owing to their technical
training and experience, have sufficient knowledge of rail-guided handling equip-
ment and are familiar with the relevant national industrial safety regulations, codes
of practice, accident prevention regulations, directives and generally accepted
engineering standards enabling them to judge the safe operating condition of rail-
guided handling equipment.
Assigned expert engineer (in the Federal Republic of Germany according to
BGV D8, § 23, for determining the S.W.P.)
An assigned expert engineer is defined as an experienced technician specifically
assigned by the manufacturer to determine the remaining duration of service
(service life) of rail-guide handling equipment (S.W.P. = safe working period) and
to carry out a general overhaul of rail-guided handling equipment.
Authorized expert engineer (in the Federal Republic of Germany according to
BGV D6, § 28)
In addition to the expert engineers of the Technical Supervisory and Inspection
Board, an authorized expert engineer for the inspection of rail-guided handling
equipment is defined as an expert engineer authorized by the Industrial Employers’
Mutual Insurance Association.
Rail-guided handling equipment
Rail-guided handling equipment are systems used for lifting and moving loads, such
as cranes, crabs and travelling hoist units, rail systems.

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1 Safety instructions
1.1 Symbols The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.
Hazard warning
This symbol appears in the assembly instructions next to all instructions relating to
safety at work wherever a potential hazard to life and limb exists if the instructions
are not complied with.
Follow these instructions at all times and be particularly vigilant and cautious.
Pass on safety instructions to all persons entrusted with working on the equipment
including the track and power supply.
In addition, observe all general safety regulations at all times.
Warning against dangerous electrical voltage
Contact with live parts can result in immediate death. Protective covers (e.g. covers
and enclosures) of electrical assemblies or those marked with this sign may only be
opened by qualified electricians. Before opening, all relevant operating, control, feed
or other voltages must be disconnected.
Warning against suspended load
Any person remaining in this danger zone may suffer serious injury or death.
Operating hazard for the installation
This symbol in the assembly instructions indicates all warnings which, if not com-
plied with, may result in damage to the rail-guided equipment or the load.
Rail-guided handling equipment is only intended for lifting and moving loads and
may be used as stationary or travelling units.
Rail-guided handling equipment may only be operated when in perfect working
order by trained personnel in accordance with the relevant safety and accident
prevention regulations. This also includes compliance with the operating and main-
tenance conditions specified in the assembly and operating instructions.
Rail-guided handling equipment is industrial equipment operated with a rated volt-
age of up to 1000 V from high-voltage supply systems.
Power feed is via power supply lines (mobile cables, open or enclosed power con-
ductor systems, cable drums). These systems lead up to the terminals of the main
switch (mains connection switch, isolating switch).
The relevant isolating switches must be switched off and secured when performing
maintenance/repair work. During operation or when the main switch is not switched
off, electrical components inside enclosures, motors, switchgear cabinets, terminal
boxes, etc., carry dangerous voltages.
Serious personal injury or damage to property may occur in the event of:
• unauthorized removal of covers,
• inappropriate use of rail-guided handling equipment
• incorrect operation
• insufficient maintenance,
• exceeding the maximum permitted load (The rated load capacity/S.W.L. is the
maximum permitted load. Pay attention to the sum of the load to be lifted and
the load handling attachment.)
• Working on live parts.
1.2 Intended use

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1.3 Inappropriate use Certain work and practices are prohibited when using rail-guided handling equip-
ment as they may involve danger to life and limb and result in lasting damage to
rail-guided handling equipment, e.g.:
• Unsafe load handling (e.g. swinging the load)
• Handling suspended loads above persons
• Pulling or dragging suspended loads at an angle
• Pulling free fixed or obstructed loads
• Exceeding the maximum permitted load and permitted load dimensions
• Leaving suspended loads unsupervised
• Running load-supporting means (chains and ropes) over edges.
• Using load-supporting means (chains and ropes) as a load bearing sling.
• Subjecting the control pendant to inappropriate mechanical loads
• Allowing loads to drop when the load-supporting means are in a slack condition
• Failing to pick up loads from a solid base, but, for example, from a load handling
attachment
• Transporting persons, unless lifting devices are specifically approved for trans-
porting persons
• Manipulating electrical equipment
Persons under the influence of drugs, alcohol or medicines which affect reactions
must not install, operate, put into service, maintain, repair or disassemble rail-guid-
ed handling equipment.
Any conversions and modifications to the installation must comply with the technical
safety requirements. Work on electrical equipment of rail-guided handling equip-
ment may only be carried out by qualified electricians in accordance with electrical
regulations. In the event of malfunctions, rail-guided handling equipment must be
stopped, switched off and the relevant main switches locked immediately. Defects
must be rectified immediately.
National accident prevention regulations and codes of practice and general safety
regulations must be observed when operating our products. Important information
and instructions are marked by corresponding symbols. Follow these operating and
safety instructions to avoid personal injury and damage to machinery.
The operating instructions must be kept available at the place where rail-guided
handling equipment is in use at all times.
They include significant aspects and appropriate excerpts from the relevant guide-
lines, standards and regulations.
The owner must instruct his personnel appropriately.
If the safety instructions given in these operating instructions are not observed in
any way, personal injury or even death can result.
Observe general statutory and other obligatory regulations relating to accident pre-
vention and environmental protection and basic health and safety requirements in
addition to those included in these operating instructions.
Such requirements may relate, for example, to the handling of hazardous materials
or the provision/wearing of personal protection equipment.
Comply with these regulations and general accident prevention regulations relevant
for the place at which rail-guided handling equipment is used and follow the instruc-
tions therein when working with the equipment.
Rail-guided handling equipment may still constitute a danger to life and limb if it is
not installed, operated, maintained or used appropriately by personnel which have
not been trained or specially instructed.
The operating instructions must, if required, be supplemented by the owner with
instructions and information (e.g. factory regulations) relating to organization of
work, working procedures, operating personnel, etc. Supervising and reporting
obligations as well as special operating conditions must also be taken into
consideration.
1.4 General safety
information

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Personnel assigned to working with rail-guided handling equipment must have read
and understood the operating instructions and, in particular, the section on safety
information.
All activities relating to rail-guided handling equipment which are not described in
these operating instructions may only be carried out by specialist personnel
specifically trained for rail-guided handling equipment.
The owner must ensure that personnel work in a safety and hazard-conscious
manner in compliance with the operating instructions.
The owner must ensure that rail-guided handling equipment is only operated when
in proper working order and that all relevant safety requirements and regulations are
complied with.
Rail-guided handling equipment must be taken out of service immediately if func-
tional defects or irregularities are detected.
In the event of a stoppage (e.g. if defects regarding safe and reliable operation are
detected, in emergency situations, in the event of operating malfunctions, for repairs
and maintenance purposes, if damage is detected or after finishing work) the opera-
tor/experienced technician must carry out all prescribed safety measures (e.g. for
cranes operating outdoors, ensure wind drift safety catch is fitted) or observe that
they are automatically carried out.
Personal protective clothing must be worn
as necessary or as required by regulations.
Personnel must not wear loose clothing, jewellery including rings or long hair loose.
Injury may occur, for example, by being caught or drawn into the mechanism.
All safety and hazard warnings on rail-guided handling equipment, their access
routes and their mains connection switches must be preserved completely and in
legible condition.
Inching (i.e. giving short pulses to the motor) must always be avoided.
Emergency limit stop devices (e.g. slipping clutch or emergency limit switch) must
not be approached in normal operation.
Modifications, additions to and conversions of rail-guided handling equipment
which may impair safety in any way must not be carried out without the approval
of Demag. This also applies to the fitting and adjusting of safety devices as well as
for performing welds on load bearing parts.
Safety devices must not be rendered inoperative.
Only genuine Demag spare parts may be used.
Observe prescribed deadlines or those specified in the operating instructions for
routine checks/inspections.
For independent operation or maintenance of rail-guided handling equipment, the
owner may only employ persons
• who are at least 18 years of age,
• who are mentally and physically suitable,
• who have been instructed in the operation and maintenance of rail-guided han-
dling equipmentand have proven their qualification to the owner in this respect
(in addition to theoretical training, instruction also includes sufficient practical
operating experience as well as acquiring the ability to identify defects which are
a hazard to safe operation),
• who can be expected to carry out the work assigned to them reliably.
The owner must assign operating and maintenance personnel to their relevant
tasks.
1.5 Selection and qualifi-
cation of operating
personnel

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• Installation and disassembly work may only be performed by experienced techni-
cians.
• Installation and disassembly work must be co-ordinated by the person carrying
out the work and the owner within the scope of their responsibility.
• The danger zone must be made safe.
• The installation must be isolated in accordance with the relevant electrical regula-
tions.
• Customer-specific regulations must be observed.
• Only appropriate, tested and calibrated tools and equipment may be used.
• The electrode holder and earth must be connected to the same assembly when
welding work is carried out. If the current flow is returned via protective conduc-
tors, screening elements or anti-friction bearings, serious damage may be
caused to these or other components.
• The working area must be made safe.
• First check that the voltage and frequency specified on the data plates match the
owner’s mains power supply
• All clearance dimensions and safety distances (see approval drawing) must be
checked before putting the unit into service.
• In the course of putting the product into service, it may be necessary to render
safety devices or features inoperative when carrying out adjustments or function
checks.
• When putting the unit into service, it may be necessary to perform work in the
danger zone, therefore, it must be ensured that only appropriately trained per-
sonnel are employed for this work.
The operator must check the function of the brakes and emergency limit stop de-
vices before starting work.
All instructions and measures described in the assembly and operating instructions
with regard to safe operation and items concerning general safety and accident
prevention which have to be observed before, during and after putting into service
must be strictly complied with. Any failure to comply can lead to accidents resulting
in fatalities.
Rail-guided handling equipment must be taken out of service immediately or not put
into operation if any defects relating to operating safety and reliability are detected.
Safety devices must not be rendered inoperative or modified in contradiction to their
intended use.
Only operate rail-guided handling equipment when all protective devices and safety-
relevant equipment, e.g. movable protective devices and emergency-stop devices,
are fitted and fully functioning.
Anybody who identifies an immediate danger of personal injury must actuate the
emergency stop button without delay. This also applies in the case of damage oc-
curring to parts of the installation and equipment which makes immediate stoppage
necessary. After an ”emergency-stop”, the operator must not switch on and restart
rail-guided handling equipment until an experienced technician is satisfied that the
cause which led to actuation of this function has been rectified and that continued
operation of the installation constitutes no further hazard.
1.6 Safety instructions for
assembly and disas-
sembly
1.7 Safety instructions
when first putting the
unit into service after
completing assembly
1.8 Safety instructions for
operation

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Rail-guided handling equipment must be switched off immediately in the event of
the following faults:
• Damage to electrical devices and cables as well as parts of the insulation.
• Brake and safety device failure.
Ensure that nobody is endangered by operation of rail-guided handling equipment
before switching it on or putting it into operation.
If the operator notices persons who may be exposed to a risk to health or personal
safety by operation of the equipment, he must suspend operation immediately and
may not resume operation again until the persons are outside the danger zone.
Before putting rail-guided handling equipment into operation, the operator must be
satisfied that it is in safe and correct operating condition.
Work on rail-guided handling equipment may only be carried out when instructions
to this effect have been issued, when operation and function of the equipment have
been explained and when the working and danger zone has been made safe.
Cooling devices and ventilation openings, may not be rendered permanently inoper-
ative (e.g. covered or closed).
Special local conditions or special applications can lead to situations which were
not known when this chapter was written. In such cases, special safety measures
must be implemented by the owner.
Maintenance measures are defined as regular maintenance, inspection and repair
work.
Mechanical and electrical repairs and maintenance work may only be carried out by
appropriately trained personnel (experienced technicians). Demag specialists are
also trained to work on specific products.
Adjustment, maintenance and inspection activities and inspection deadlines includ-
ing specifications concerning replacement of parts/assemblies prescribed in the
assembly and operating instructions must be observed.
Ensure that all electrical components are de-energized before commencing work on
electrical installations and devices. When all work on rail-guided handling equipment
has been completed, operation of the equipment must not resume until the owner
has given approval to this effect.
Unauthorized persons must be prohibited from carrying out work on machinery or
parts of rail-guided handling equipment. Before starting all repair and maintenance
work, the product must be switched off, taken out of operation and secured
(switches must be locked) against accidental or unauthorized putting into operation
(restarting).
It must be ensured that
• rail-guided handling equipment is switched off and checked that it is de-ener-
gized and, in special cases, isolated,
• moving parts are stationary and stopped,
• moving parts cannot start moving while maintenance work is being carried out,
• the power supply cannot be accidentally restored as long as the rail-guided
handling equipment has been taken out of service for maintenance and repair
purposes, Ensure that operating and auxiliary materials as well as replaced parts
are disposed of in a safe and environmentally sound way.
1.9 Safety instructions for
maintenance

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Instructions for repair work in the course of operation
The danger zone must be marked off with red/white safety chains or safety tape
and indicated with warning signs.
In each individual case, the owner or the person specified by him must check
whether the relevant work may be carried out in the course of operation without risk
of personal injury owing to the particular local conditions.
Use only calibrated and appropriate tools and auxiliary materials for maintenance,
inspection and repair work, in order to avoid injury.
If there is a risk of objects falling, the danger zone must be made safe.
Maintain a sufficient safety distance to rotating parts to prevent clothing, parts of
the body or hair becoming entangled.
Avoid naked flames, extreme heat and sparks in the vicinity of cleaning agents and
flammable parts or parts liable to deformation (e.g. wood, plastic parts, oil, grease)
in electrical installations – non-compliance may result in fire hazard. Harmful gases
may evolve or insulation may be damaged.
Additional instructions for repair work on electrical equipment
Only genuine fuse links with specified amperage and tripping characteristics may be
used.
Defective fuse links must not be repaired or bridged and must only be replaced by
fuse links of the same type.
Switch off rail-guided handling equipment immediately in the event of electrical
power supply malfunctions.
Work on the electronic and electrical components or equipment may only be car-
ried out by qualified electricians.
If inspection, maintenance and repair work is to be carried out on parts, these must
– if prescribed by regulations – be isolated. First verify the safe isolation of the parts
from the supply before commencing work.
The electrical equipment of rail-guided handling equipment must be inspected and
checked at regular intervals. Defects, such as loose connections, damaged cables
and worn contactor contacts must be rectified immediately.
Electrical equipment must be replaced as a preventive measure on reaching the
limit of its service life.
If work has to be carried out on live parts, a second person must be available to
actuate the emergency-stop button or mains connection switch/isolating switch in
order to disconnect the power supply in an emergency. The second person must
be familiar with resuscitation measures.
Only use insulated tools.
Before disconnecting and connecting electrical plug-and-socket connections,
always disconnect them from the supply (this does not apply to mains connections,
provided they do not represent a dangerous contact voltage in the sense of the
safety regulations).

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42678444.eps
2 Scope of delivery
1 Monorail hoist with travel drive
2 Crane girder 1)
3 Travel unit with drive
4 Control pendant/Radio remote control
5 Power supply
6 Crane runway 1)
7 Electrical equipment of the crane
8 Electrical equipment of the monorail hoist
– with lifting limit switch
– with load detector
EKKE single-girder crane
9 Clamp-type buffer
10 C-rail subassembly
11 Power supply of the
monorail hoist
32
8
1
4
576
10
9
4
11
1) Not included in the scope of supply

21491244.p65/201204
14
Overview of the necessary assembly work.
The following illustarations show the general work steps.
For correct assembly observe the specifications in the corresponding
Operating instructions: EKDR Pro 3 - 5 - 10 214 725 44
Operating instructions: EKDR Com 3 - 5 – 10 214 916 44
1
46
3
2
5
75
4/1 reeving
3.1.1 Assembling trolleys of the 3,
5 and 10 range
3 Overview of DR rope hoist assembly
3.1 Adjusting EKDR Pro/-Com 3 – 5 – 10 low-headroom monorail hoists,
4/1, 2/1 and 4/2 rope reeving
2/1 reeving
42576445.eps
4/2 reeving
EKDR Pro 10
42063545.eps
42583644.eps
42584244.eps
Safely support the travel unit, before you place it onto the
girder in order to avoid any danger due to
• crushing hazard
• shearing hazard.
This support may only be removed after supporting roller
(6) has been adjusted.
Slide wheel legs (1) – travel motor side – on connecting rods
(2 + 3)(loosen threaded pin (5) before).

15
21491244.p65/201204
x1 x2
b + 1mm
2
6
3
1
2
4
5
6
75
b1
b2
6
7
491
8
b1
2
42583844.eps
Place the travel rollers of wheel legs (4) – drum side – onto the girder flange and slide wheel legs (1) on the opposite
side – travel motor side – towards the girder.
Reference dimension between both opposite guide rollers is flange width b +1 mm.
After adjusting the travel unit, press supporting roller (6) against the bottom flange of the girder by means of tensioning
screw (7). Tension supporting roller (6) until the travel wheel is in contact with the girder flange.
Assembly of the travel unit on the track girder
Assembly of the spacer sleeves
(only on the crossbar side with supporting roller)
1. Measure distance x1 between wheel legs (4) and supporting roller (6).
2. Measure distance x2 between wheel legs (1) and retaining ring with washer (8).
3. This is done to determine the number of spacer sleeves (9).
Spacer sleeve (9) is now opened and fitted on connecting rods (2).
Spacer sleeve dimensions (9)
egnaR mmnihtdiW
1b2b2b+1b
5RD/3RD9,222,511,83
01RD3,228,411,73
Determine dimension L of pre-tensioned pressure spring (10).
To obtain the pressure force of supporting rollers (6), shorten
length L of pressure spring (10) by “dimension x”.
egnaR3RD5RD01RD
]mm[x-.miD2,6-2,5-5,7-
42583744.eps
Final adjustment of the supporting rollers
L
66
7
10
Fit the clamps for fastening
the cable in one row.
Locking hook
Pre-tensioning of pressure spring (10)
After having adjusted the travel unit, press support-
ing roller (6) against the bottom flange of the girder
by means of tensioning screw (7). Tension support-
ing roller (6) until the travel wheel is in contact with
the girder flange.
42584044.eps
42583944.eps
Fix side cheek (1) on connecting rod (2+3)
with threaded pins (5).
DR 3 range = 150 Nm
DR 5/10 range = 200 Nm
Minimum flange thickness
DR 3 min. 10 mm
DR 5 min. 12 mm
DR 10 min. 15 mm

21491244.p65/201204
16
4 Manufacturing tolerances of crane runways
S min
S
S max
41409444.eps
-B-B +B
2000
2000
2000
b
b
b
41409544.eps
2000
-C +C
2000
2000
c
c
c
41409644.eps
s
E
+E
41409744.eps
Quelle: VDI 3576 Recommendation: Tolerance class 2
ecnareloT syawnurenarC
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17
21491244.p65/201204
5 Technical Description DFW travel unit
Assembling the travel unit/supporting
structure
The counterbores in the travel units and the distance washers fixed in the connect-
ing plate must be free of rust, dust, grease, paint and other contaminants.
Execution of the bolted connection:
• Remove covers of the access holes.
• The distance washers on the connecting plate in the recess of the bore hole are
always welded on the bottom (tack-welded).
• Connect the travel unit to the crane girder according to the above illustration
(bolt heads in the travel unit).
Only the parts included in the supply may be used for the connection.
1. Hex. bolt M20 x 85 x 46, DIN 6914, strength class 10.9 HV
2. Hex. nut M20 DIN 6915, strength class 10 HV
3. Hardened washer 21 x 37 x 8, DIN 6916, strength class C45 VHV
4. Distance washer 22 x 50 x 10, min. tensile strength 520 N/mm2
• Tighten diagonal pairs of all screws using a torque wrench.
Tightening torque: 554 Nm
• Close access holes with covers.
• For outdoor operation the gap between the travel unit and the connecting plate
is sealed with silicone sealing compound on the top and on the sides.
Demag DFW travel units are driven rail-mounted travel units of compact design
and can be connected direct to load-bearing structures by means of an existing
mounting surface.
The travel unit girder, designed on the basis of the latest findings in the steelwork
sector, consists of a box girder profile resistant to torsion. Low tolerances for differ-
ences in the runway gauge, skewing and misalignment provide for excellent travel
characteristics, even at high loads.
The travel unit features a driven Demag DRS wheel block, to which a gearbox and
motor are fitted, as well as a non-driven DRS wheel block.
Specially matched motors of heavy-duty design ensure smooth starting of the travel
unit, whether with or without a load, with favourable speed/torque characteristics.
Only perfect crane alignment geometry ensures good operating characteristics of
the crane. Thus, in order to maintain the manufacturing accuracy once reached, the
assembly of travel units and crane girder must be carried out carefully.
5.1 DFW-L-E travel unit
overview
21436102.eps
Travel unit with a side crane girder connection (standard)
42672644.eps
Counterbores
Distance washers tack-welded in the recess (always on the bottom)
Connecting plate
Crane girderTravel unit
3
132
4
HT mark
Bevel on nut side
Bevel under bolt
head

21491244.p65/201204
18
Jacking up the travel unit
Certain assembly work requires that the travel unit is jacked up, in order to remove
the load from the travel wheels (wheel block).
For this purpose a winch or similar lifting device is fixed under the diaphragm plate
of the travel unit and the travel unit is lifted.
It is sufficient to lift the travel unit by a few millimeters.
The lifted travel unit must be secured by spacers between the travel unit and the
travel rail. In order to avoid damage, the spacers must be arranged in the position
shown above.
21436103.eps
203 for travel wheel 112
233 for travel wheel 125
288 for travel wheel 160
353 for travel wheel 200
Connecting side
Diaphragm
plate

19
21491244.p65/201204
5.2 DFW-L-L travel unit
overview
Demag travel units as driven rail-mounted travel units of compact design can be
connected direct to load-bearing structures.
The travel unit girder, designed on the basis of the latest findings, consists of a box
girder profile resistant to torsion with welded diaphragm plates. Low tolerances for
differences in the runway gauge, skewing and misalignment provide for excellent
travel characteristics, even at high loads.
Each of the two travel wheels of the travel unit is mounted in a wheel block. One
of the two wheel blocks can be driven by a Demag travel drive (offset gearbox +
motor).
Specially matched Demag squirrel-cage rotor brake motors ensure smooth starting
of the travel unit, whether with or without a load, with favourable speed/torque
characteristics.
Only perfect crane alignment geometry ensures good operating characteristics of
the crane. Thus, in order to maintain the manufacturing accuracy once reached, the
assembly of travel units and crane girder must be carried out carefully.
The contact surface on the travel unit and crane girder as well as the bore holes for
the bolted connection must be free of rust, dust, grease, paint and other contami-
nants.
For the bolted connection only high-tensile (HT) bolts M16 may be used and tight-
ened with the corresponding tightening torque (see bolted connection).
For the welded connection the travel units and the crane girder must be aligned
paralel to each other. No air gap may be added, when the components are welded
together.
Assembling the travel unit/supporting
structure
21433002.eps
21433001.eps
3
Crane girder
HT nut
DIN 6915
HT bolt
DIN 6914
Crane girder
Bolted connection For crane girder HE-A 180 to 280:
HT bolt: M16x50 DIN 6914 Part no.: 316 091 99
For crane girder HE-A 300 to 400:
HT bolt: M16x55 DIN 6914 Part no.: 316 095 99
For crane girder HE-A 450 to 550:
HT bolt: M16x65 DIN 6914 Part no.: 316 060 99
For crane girder HE-A 180 to 550:
HT nut: M16 DIN 6915 Part no.: 316 207 99
HT washer: 17x30x4 DIN 6916 Part no.: 316 211 99
Only the parts included in the supply may be used for the connection. Tighten
diagonal pairs of all screws using a torque wrench.
Tightening torque: 284 Nm
HT bolt
DIN 6916

21491244.p65/201204
20
Jacking up the travel unit
Certain assembly work requires that the travel unit is jacked up, in order to remove
the load from the travel wheels.
For this purpose a winch or similar lifting device is fixed in the travel wheel area of
the travel unit (for example: the winch is fixed approx. 300 mm from the end of the
travel uni and the travel unit is lifted.
It is sufficient to lift the travel unit by a few millimeters.
The lifted travel unit must be secured against leaving the rails by spacers between
the travel unit girder and the travel rail. Subsequently the winch or similar lifting
device is unloaded so that it can be removed.
In order to avoid damage, the spacers must be arranged in the position shown
above and removed after assembly.
21433003.eps
205
Spacer