DEMAG DRF 200 User manual

Assembly instructions
DRF 200 friction wheel travel drive with travel motor
120914 en GB 214 395 44 719 IS 913.92

Original assembly instructions
Manufacturer
Demag Cranes & Components GmbH
Forststrasse 16
40597 Düsseldorf, Germany
www.demagcranes.com
[e-mail]
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DRF 200 friction wheel travel drive and important information if you ever have to contact the manufacturer or his rep‐
resentative.
Owner
Where in use
Size
Serial number
Travel drive no.
Year of manufacture
Operating voltage
Control voltage
Frequency
Wiring diagram number
Tab. 1
Further documents are available for sub-assemblies/components in addition to these assembly instructions. If required, the
corresponding documents are supplied or can be ordered separately, even if special designs or additional options differing
from these assembly instructions are ordered.
Documents 1) Order no.
Technical data/catalogues
Demag DC-Pro 1 - 25 chain hoist
Demag DCS-Pro 1 - 10 chain hoist 203 525 44
KBK classic (steel, powder-coated) 202 976 44
KBK trailing cable 202 617 44
DEL conductor line 202 673 44
DKK conductor line 202 540 44
DCL conductor line 203 387 44
Fittings + C-rail overview 201 752 44
Cellular foam buffer 202 607 44
Operating instructions/component
parts
DC-Pro 1 - 15 chain hoist 214 741 44
DRF current collector bracket 206 630 44
Assembly – Adjustment – Dimensions ZNA, ZBA, ZBF motors 214 228 44
KBA, KBF motors 214 318 44
Spare parts
DRF 200 friction wheel travel drive 222 572 44
Z 63/Z 71 motor 222 856 44
ZBF 80 motor 222 864 44
KB 71 - 140 motor 217 039 44
Tab. 2
The metric system is used in this document and all figures are shown with a comma as the decimal separator.
1) The documents can be ordered from the relevant Demag office.
2
214 395 44/120914

Table of contents
General........................................................................................................................................................................ 5
DRF 200 friction wheel travel drive ............................................................................................................................. 5
Symbols/signal words.................................................................................................................................................. 5
Information on the assembly instructions .................................................................................................................... 5
Liability and warranty................................................................................................................................................... 5
Copyright ..................................................................................................................................................................... 6
Use of spare parts ....................................................................................................................................................... 6
Definition of personnel................................................................................................................................................. 6
After-sales service....................................................................................................................................................... 7
Safety .......................................................................................................................................................................... 8
General........................................................................................................................................................................ 8
Safety signs on the equipment .................................................................................................................................... 8
Intended use................................................................................................................................................................ 8
Hazards that can be caused by the DRF 200 friction wheel travel drive..................................................................... 9
Responsibility of the owner ....................................................................................................................................... 10
Operating personnel requirements............................................................................................................................ 11
Personal protection equipment.................................................................................................................................. 11
Regular inspections................................................................................................................................................... 11
Technical data ........................................................................................................................................................... 12
Design overview ........................................................................................................................................................ 12
Travel speed, motor size and maximum permissible total displaceable load............................................................ 13
General...................................................................................................................................................................... 13
ZBF motor ................................................................................................................................................................. 13
KBF motor ................................................................................................................................................................. 13
Motor key data........................................................................................................................................................... 14
ZBF motor ................................................................................................................................................................. 14
KBF motor ................................................................................................................................................................. 14
Dimensions................................................................................................................................................................ 15
Transport, packing and storage................................................................................................................................. 17
Technical description................................................................................................................................................. 18
Design ....................................................................................................................................................................... 18
Motor ......................................................................................................................................................................... 18
Trolley........................................................................................................................................................................ 18
Runway ..................................................................................................................................................................... 19
Trolley for KBK crane construction kit ....................................................................................................................... 20
Link bar...................................................................................................................................................................... 20
Load bar .................................................................................................................................................................... 20
Disengaging device ................................................................................................................................................... 21
Buffer fitting ............................................................................................................................................................... 21
Power supply lines .................................................................................................................................................... 22
Assembly................................................................................................................................................................... 23
General assembly information................................................................................................................................... 23
Safety instructions for assembly................................................................................................................................ 23
Tightening torques..................................................................................................................................................... 24
Installation procedure ................................................................................................................................................ 25
Preparing for installation............................................................................................................................................ 25
Trolleys...................................................................................................................................................................... 26
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3
3.1
3.2
3.2.1
3.2.2
3.2.3
3.3
3.3.1
3.3.2
3.4
3.5
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
5
5.1
5.2
5.3
5.4
5.5
5.6
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3

Link bar...................................................................................................................................................................... 30
Load bar .................................................................................................................................................................... 31
Connecting the electric equipment ............................................................................................................................ 31
Putting into service for the first time .......................................................................................................................... 32
Safety instructions when putting into service for the first time................................................................................... 32
Inspection regulations ............................................................................................................................................... 32
Checks on entering service, handover ...................................................................................................................... 33
Operation................................................................................................................................................................... 34
Safety instructions for operation................................................................................................................................ 34
Switching on .............................................................................................................................................................. 34
Checks when starting work ....................................................................................................................................... 34
Function checks ........................................................................................................................................................ 35
Operation................................................................................................................................................................... 35
General...................................................................................................................................................................... 35
Taking the equipment out of operation...................................................................................................................... 36
Taking the equipment out of service when faults occur ............................................................................................ 36
Taking the equipment out of service at the end of the shift....................................................................................... 36
Taking the equipment out of service for maintenance and repairs............................................................................ 36
Maintenance/repair.................................................................................................................................................... 37
Safety instructions for maintenance and repair work ................................................................................................ 37
Basic maintenance requirements .............................................................................................................................. 38
Maintenance schedule .............................................................................................................................................. 39
Maintenance work ..................................................................................................................................................... 40
Oil lubrication............................................................................................................................................................. 40
Grease lubrication ..................................................................................................................................................... 40
Brake ......................................................................................................................................................................... 41
General...................................................................................................................................................................... 41
Checking and adjusting brake air gap s
1
................................................................................................................... 42
Replacing the brake disc ........................................................................................................................................... 44
Friction wheel drive ................................................................................................................................................... 46
Removing and installing the friction wheel ................................................................................................................ 46
Removing and installing the suspension fork and suspension.................................................................................. 47
Malfunctions/warnings............................................................................................................................................... 48
Safety instructions for malfunctions/warnings ........................................................................................................... 48
Disassembly/disposal................................................................................................................................................ 49
General...................................................................................................................................................................... 49
5.7
5.8
5.9
6
6.1
6.2
6.3
7
7.1
7.2
7.2.1
7.2.2
7.3
7.3.1
7.4
7.4.1
7.4.2
7.4.3
8
8.1
8.2
8.3
8.4
8.4.1
8.4.2
8.4.3
8.4.3.1
8.4.3.2
8.4.3.3
8.4.4
8.4.4.1
8.4.4.2
9
9.1
10
10.1
4
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1 General
1.1 DRF 200 friction wheel travel drive
You have purchased a Demag quality product.
This DRF 200 friction wheel travel drive was manufactured to European standards and regulations in accordance
with state-of-the-art engineering principles. The EC Machinery Directive requirements are satisfied.
1.2 Symbols/signal words
Important safety information and instructions are marked by corresponding symbols and signal words in these in‐
structions.
Safety instructions and information must be followed. Exercise particular caution to ensure that accidents, injuries
and damage are avoided in such cases.
Locally applicable accident prevention regulations and general safety regulations must also be followed.
The following symbols and instructions warn against possible injuries or damage and are intended to assist you in
your work.
DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
WARNING
This symbol indicates a possibly hazardous situation which might result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
CAUTION
This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage.
– Follow these instructions at all times and be particularly careful and cautious.
Operating hazard for the machine.
● This symbol indicates information on the appropriate use of the machine.
● This symbol in the operating instructions indicates all warnings which, if not complied with, may result in mal‐
functions or damage.
1.3 Information on the assembly instructions
These assembly instructions are designed to provide the owner and operator with useful instructions for transport‐
ing, installing, putting into service, operating and maintaining our DRF 200 friction wheel travel drive. These as‐
sembly instructions are an integral part of the installation.
Persons entrusted with the various types of work must know and comply with the safety regulations and the as‐
sembly instructions.
The installation may only be operated by personnel who are fully familiar with the assembly instructions. In partic‐
ular, they contain the "Safety" section and the relevant safety instructions in the working sections of these assem‐
bly instructions.
The assembly instructions must be available to operating personnel at all times in order to prevent operating er‐
rors and to ensure smooth and trouble-free operation of our products. They must be kept in the immediate vicinity.
1.4 Liability and warranty
All information included in these instructions has been compiled on the basis of the relevant regulations, state-of-
the-art engineering principles and our many years of experience.
These instructions must be read carefully before starting any work on and with the DRF 200 friction wheel travel
drive, especially before it is put into service for the first time. The manufacturer assumes no liability for any dam‐
age which results from the following:
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5

● non-compliance with the instructions,
● inappropriate use,
● untrained personnel,
● unauthorised conversions,
● technical modifications.
Wearing parts are not subject to liability for defects.
We reserve the right to incorporate technical modifications within the scope of improving the operating character‐
istics and further development of the product.
1.5 Copyright
These instructions are only intended to be used by the people who work with or on the DRF 200 friction wheel
travel drive.
Any and all content, texts, drawings, images and any other information are protected within the sense of copyright
law and are subject to further industrial rights. Any misuse is an offence.
No part of this documentation, in whole or in part, may be reproduced, distributed, shown in public or used in any
other way without specific prior consent. Infringements are an offence resulting in obligatory compensatory dam‐
ages. Further rights reserved.
All industrial rights reserved.
1.6 Use of spare parts
We urgently recommend that only spare parts and accessories approved by us be used. Only then can we ensure
the safety and normal service life of the installation.
Spare parts not approved by us may cause unpredictable hazards, damage, malfunctions or complete failure of
the DRF 200 friction wheel travel drive.
The use of unauthorised spare parts may render null and void any claims for warranty, service, damages or liabili‐
ty against the manufacturer or his appointed personnel, dealers and representatives.
1.7 Definition of personnel
The manufacturer is the person who:
1. manufactures the equipment under his or her own name and places it on the market for the first time;
2. resells other manufacturers' equipment under his or her own name, whereby the reseller is not considered to
be the manufacturer provided the name of the manufacturer (as in 1.) appears on the equipment;
3. imports the equipment into the country and places it on the market for the first time or
4. exports equipment to another member state of the European Union and hands it over direct to a user in that
country.
Owner
Owners (employer, company) are defined as persons who own the machine and who use it as intended or allow it
to be operated by suitable and trained persons.
Operating personnel/operator
Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper‐
ate the machine. This person must be trained by the owner in accordance with the tasks to be performed.
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 inappropriate conduct. Personnel must be informed about the required pro‐
tective devices, protective measures, relevant regulations, codes of practice, accident prevention regulations and
operating conditions and must provide verification of their competence. This person must be trained by the owner
in accordance with the tasks to be performed.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks,
such as installation, setting-up, maintenance and fault elimination. This person must be trained by the owner in
accordance with the tasks to be performed.
6
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Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of
electric machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. This person must be
trained by the owner in accordance with the tasks to be performed.
Experienced technician
Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐
cient knowledge in the field of the machine. They must be familiar with the relevant national industrial safety regu‐
lations, codes of practice, accident prevention regulations, directives and generally accepted engineering stand‐
ards enabling them to judge the safe operating condition of machines.
Assigned expert engineer (in the Federal Republic of Germany according to BGV D8, Section 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 the machine (S.W.P. = safe working period) and to
carry out a general overhaul of the machine.
Authorised expert engineer (according to BGV D6, Section 28 in the Federal Republic of Germany)
In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorised expert engi‐
neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers’ Mu‐
tual Insurance Association.
1.8 After-sales service
If you have any questions on our products or need technical information, please contact our after-sales service.
Please keep the serial or order number (see test and inspection booklet, load capacity plate on the crane) for any
correspondence or spare part orders. Specifying this data ensures that you receive the correct information or the
required spare parts.
The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found
on the Demag Cranes & Components GmbH homepage at www.demagcranes.com/Contact
214 395 44/120914
7

2Safety
2.1 General
The "Safety" chapter provides an overview of all important safety aspects for optimum protection of personnel as
well as safe and trouble-free operation.
When it is placed on the market, the DRF 200 friction wheel travel drive is built according to generally accepted
engineering standards and is considered to be safe to operate. It may may still be a cause of danger if it is not
used correctly or as intended by suitably trained personnel.
Knowledge of the contents of the assembly instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the DRF 200 friction wheel travel drive safely
and reliably.
Any conversions, modifications or additions to the DRF 200 friction wheel travel drive are prohibited unless ap‐
proved by Demag in writing.
2.2 Safety signs on the equipment
Fig. 1 Example: capacity plate
Any pictograms, signs or labels on the machine must be obeyed and
must not be removed. Pictograms, signs or labels that are damaged or
no longer legible must be replaced immediately.
2.3 Intended use
The DRF 200 friction wheel travel drive may only be used as intended and in compliance with the requirements
for the owner and the following limitations as specified in these assembly instructions. Any other use may result in
a danger to life and limb and/or cause damage to the DRF 200 friction wheel travel drive and/or load.
● The support superstructure for the DRF 200 friction wheel travel drive must be designed to accommodate
loads resulting from operation of the hoist unit. The maximum safe working load is the load capacity specified
on the capacity plate. This must not be exceeded. The maximum permitted load includes the load and any load
handling attachment.
● The DRF 200 friction wheel travel drive may only be installed, used, operated, maintained and removed by
trained personnel when it is in perfect working order. Personnel must meet the requirements according to
 "Operating personnel requirements", Page 11.
● Intended use includes compliance with the safety instructions as well as any other instructions on assembly
and disassembly, commissioning, function and operation, maintenance and fault elimination as well as compli‐
ance with the instructions on the installation safety devices, any possible remaining hazards and protection
against hazards.
●The DRF 200 friction wheel travel drive may only be used subject to the permissible technical data,  "Techni‐
cal data", Page 12.
● The DRF 200 friction wheel travel drive must be maintained regularly and appropriately by trained personnel in
line with the specified deadlines and checked according to  "Maintenance schedule", Page 39. Wearing
parts must be replaced in good time.
● UVV/BGV D8, Section 23 (2) and BGV D6 (1) guidelines must be not be ignored.
No liability for inappropriate use
The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐
ceptable according to these assembly instructions. In particular, the manufacturer assumes no liability for damage
due to inappropriate or any other prohibited use of the DRF 200 friction wheel travel drive in the sense of the "In‐
tended use" section.
8
214 395 44/120914

No liability for structural modifications
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the DRF 200 friction wheel travel drive to devices or equipment that do not
belong to our scope of delivery, or the installation or use of third-party accessories, equipment or sub-assemblies
that are not approved by the manufacturer.
Depending on the type and scope of the DRF 200 friction wheel travel drive, it may be necessary to have an in‐
spection carried out by an expert engineer before it is handed over to the owner.
2.4 Hazards that can be caused by the DRF 200 friction wheel travel drive
The DRF 200 friction wheel travel drive has been subjected to a risk assessment. The design and execution
based on this analysis corresponds to state-of-the-art engineering principles. However, residual risks remain.
The DRF 200 friction wheel travel drive operates with high electric voltage.
DANGER
Live components
Danger to life and limb.
Electric energy may cause very severe injuries. Danger of death caused by electric current if the insulation or
individual components are damaged.
– Switch the machine off and secure it against restoration of the power supply before any maintenance,
cleaning or repair work is carried out.
– Switch the power supply off before any work is carried out on the electric equipment. Check to ensure that
the components to be replaced are de-energised.
– Do not remove any safety equipment or render it inoperative by modifications.
WARNING
Crushing hazard
There is a risk of injury due to parts of the body being crushed/sheared or clothing or hair becoming entangled.
Protection must be provided if the DRF 200 friction wheel travel drive is suspended at a height within normal
reach.
WARNING
Suspended load. Falling parts.
Danger to life and limb from falling parts.
The track ends must be provided with elastic buffers.
WARNING
Danger to life and limb if the operating and maintenance instructions are not followed.
Required tests and inspections must be carried out.
In the course of the annual inspection, the trolley must be checked for:
– deformation or cracks,
– chipping or wear of the travel wheels,
– completeness of all parts,
– correct adjustment of the DRF 200 friction wheel travel drive.
Certain work and practices are prohibited when using the machine as they may involve danger to life and limb
and result in lasting damage to the machine. Observe the safety instructions in the sections:
● "Assembly", Page 23
● "Putting into service for the first time", Page 32
214 395 44/120914
9

● "Operation", Page 34
● "Maintenance/repair", Page 37
2.5 Responsibility of the owner
Information on safety at work refers to the regulations of the European Union that apply when the DRF 200 friction
wheel travel drive is manufactured. The owner is obliged to ensure that the specified industrial safety measures
comply with the latest rules and regulations and to observe new regulations during the entire service life of the
DRF 200 friction wheel travel drive. Local industrial safety legislation and regional regulations and codes of prac‐
tice applicable at the site of operation of the DRF 200 friction wheel travel drive must be observed outside the
European Union.
General safety, accident prevention and environmental protection regulations that apply where the DRF 200 fric‐
tion wheel travel drive is in operation must be observed and complied with in addition to the safety instructions
contained in these assembly instructions.
The owner and any personnel authorised by him are responsible for correct operation of the DRF 200 friction
wheel travel drive and for clearly defining responsibilities for installation, operation, maintenance and cleaning.
The assembly instructions must be followed in full and without any limitations.
Special local conditions or applications may lead to situations which are not considered in these assembly instruc‐
tions. In such cases, the required safety measures must be defined and implemented by the owner. Necessary
measures may also relate, for example, to the handling of hazardous materials or tools and the provision/wearing
of personal protection equipment. The assembly instructions must, if required, be supplemented by the owner
with instructions relating to organisation of work, working procedures, authorised personnel, supervising and re‐
porting obligations, etc. For further information, see  "Safety instructions for operation", Page 34.
Furthermore, the owner must ensure that
● any further working and safety instructions resulting from the risk assessment of the workplaces at the installa‐
tion are specified in operating procedures.
● personnel who work with or on the installation are provided with appropriate first-aid equipment. Personnel
must be trained in the use of the first-aid equipment.
● the assembly instructions are always kept available in the immediate vicinity of the installation for installation,
operating, maintenance and cleaning personnel.
● personnel are trained in accordance with the work to be performed.
● the installation is only operated when in safe and proper working order.
● safety devices are always kept freely accessible and are checked regularly.
● national regulations for the use of cranes and lifting appliances are observed.
● any specified regular checks and inspections are carried out on time and are documented.
The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these
instructions at a suitable place where they can be easily seen.
10
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2.6 Operating personnel requirements
Only authorised and trained personnel may work on the installation. The personnel must have received instruction
on the installation functions and any hazards that may occur.
Every individual given the task of working on or with the installation must have read and understood the instruc‐
tions before any work starts.
Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with
the installation.
Age and job-specific regulations relevant at the place where the installation is operated must be observed for the
selection of any personnel.
Personnel are obliged to report to the owner without delay any changes to the installation that impair safety.
For independent operation (operator) or maintenance (trained maintenance fitter) of the installation, 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 the installation and who have proven their quali‐
fication to the owner in this respect.
2.7 Personal protection equipment
When work is carried out on or with the installation, the following protective equipment is recommended to be
worn according to the owner's hazard assessment:
● Protective clothing, closely fitting working clothes (low tear strength, no loose sleeves, no rings or any other
jewellery, etc.);
● Safety shoes to protect against falling parts and against slipping;
● Safety helmet to be worn by everybody in the danger zone.
2.8 Regular inspections
The owner of the installation may be obliged to carry out regular inspections by national industrial safety legisla‐
tion and regional regulations. In Germany, this is specified by the accident prevention regulations for winches,
hoists and towing devices (BGV D8) and the accident prevention regulations for cranes (BGV D6), for example.
These specify that
● the installation must be inspected before it is put into operation,
● the installation must be inspected regularly.
The owner is obliged to ensure that the installation complies with the latest rules and regulations and to observe
new regulations at all times.
If no comparable inspection regulations or requirements apply at the place where the installation is operated, we
recommend compliance with the above-mentioned regulations.
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11

3 Technical data
3.1 Design overview
Fig. 2
Item Designation Item Designation
A For straight travel B For travel on curved tracks
1 Load trolley 1 Load trolley
2 Load bar 2 Load bar
3 DC chain hoist 3 DC chain hoist
4 KBK I, II-L, II, II-H link bar, short for straight travel 4 KBK I, II-L, II, II-H link bar, long for travel on curved tracks
5 Tractor trolley 5 Tractor trolley
6 Dished washer stack 6 Dished washer stack
7 DRF 200 7 DRF 200
8 Curve travel guide arm
Tab. 3
12
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3.2 Travel speed, motor size and maximum permissible total displaceable load
3.2.1 General
● Friction wheel travel drive without a motor weighs 12 - 14 kg.
● Motor duty factor 40% CDF or 40/20% CDF for pole-changing motors.
● Calculated with a travel resistance of 160 N/t.
● Permissible tangential force ≤ 1500 N.
● Only for operation on dry horizontal tracks. Operation on inclined tracks or damp running surfaces on request.
● Motors for other voltages and frequencies, KBF motors with microspeed unit or motors for frequency inverter
operation on request.
3.2.2 ZBF motor
1 travel speed 2 travel speeds
Load ca‐
pacity
Possible travel
speeds
Travel drive Brake iges Possible travel
speeds
Travel drive Brake iges
[kg] [m/min] [m/min]
1500 10/40 ZBF 63 A8/2 B004 43,7
1800 40 ZBF 63 A2 B004 43,7
2000 8/31,5 ZBF 63 A8/2 B004 55,1
2200 10/40 ZBF 71 A8/2 B004 43,7
2300 16 ZBF 63 A4 B004 55,1
31,5 ZBF 63 A2 B004 55,1
2500
6,3/25 ZBF 63 A8/2 B004 68,9
8/50 ZBF 80 A12/2 B020 34,6
12,5/50 ZBF 80 A8/2 B020 34,6
2800 8/31,5 ZBF 71 A8/2 B004 55,1
3000 12,5 ZBF 63 A4 B004 68,9 5/20 ZBF 63 A8/2 B004 84,6
25 ZBF 63 A2 B004 68,9
3200 16 ZBF 80 A4 B020 54,6
25 ZBF 80 A2 B020 67,0
3400 31,5 ZBF 80 A2 B020 54,6 6,3/25 ZBF 71 A8/2 B004 68,9
3500
10 ZBF 63 A4 B004 84,6 6,3/40 ZBF 80 A12/2 B020 43,7
20 ZBF 63 A2 B004 84,6 10/40 ZBF 80 A8/2 B020 43,7
50 ZBF 80 A2 B020 34,6
4000 4/25 ZBF 80 A12/2 B020 67
6,3/25 ZBF 80 A8/2 B020 67
4200 40 ZBF 80 A2 B020 43,7 5/20 ZBF 71 A8/2 B004 84,6
4500 5/31,5 ZBF 80 A12/2 B020 54,6
8/31,5 ZBF 80 A8/2 B020 54,6
Tab. 4
3.2.3 KBF motor
1 travel speed 2 travel speeds
Load capacity Possible travel speeds Travel drive iges Load capacity Possible travel speeds Travel drive iges
[kg] [m/min] [kg] [m/min]
1710 40 KBF 71 A 2 44,4 1750 8/31,5 KBF 71 A 8/2 56
2170 31,5 KBF 71 A 2 56 1990 10/40 KBF 71 B 8/2 44,4
2230 16 KBF 71 A 4 56 2200 6,3/25 KBF 71 A 8/2 68,8
2740 25 KBF 71 A 2 68,8 2530 8/31,5 KBF 71 B 8/2 56
2800 12,5 KBF 71 A 4 68,8 2710 5/20 KBF 71 A 8/2 85,9
3390 20 KBF 71 A 2 85,9 3180 6,3/25 KBF 71 B 8/2 68,8
3450 10 KBF 71 A 4 85,9 3930 5/20 KBF 71 B 8/2 85,9
Tab. 5
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13

3.3 Motor key data
3.3.1 ZBF motor
Size P
N
n
N
I
N
for 50 Hz, 3 ~ 2) I
A
/I
N
cos
φN
230 V 400 V 500 V
[kW] [rpm] [A] [A] [A]
ZBF 63 A 2 B004 0,26 2630 1,30 0,76 0,61 3,40 0,78
ZBF 63 A 4 B004 0,13 1370 0,75 0,43 0,34 3,70 0,62
ZBF 63 A 8/2 B004 0,06 675 1,20 0,66 0,53 1,40 0,59
0,25 2745 1,70 0,95 0,76 2,65 0,71
ZBF 71 A 8/2 B004 0,09 675 1,40 0,76 0,61 1,60 0,61
0,34 2785 1,80 1,00 0,80 3,50 0,73
ZBF 80 A 2 B020 0,50 2630 2,30 1,30 1,10 3,50 0,87
ZBF 80 A 8/2 B020 0,13 630 2,10 1,20 0,96 1,25 0,64
0,50 2790 2,50 1,40 1,10 4,50 0,73
ZBF 80 A 12/2 B020 0,06 415 2,70 1,50 1,20 1,00 0,71
0,50 2790 2,50 1,40 1,20 4,50 0,73
Tab. 6
Size M
N
M
A
/M
N
M
H
J
mot
AM
OpHrs
Weight
[Nm] [Nm] [kgm
2
][1/h] [Nm] [kg]
ZBF 63 A 2 B004 0,94 3,20 2,50
0,00461
550
1,3
12
ZBF 63 A 4 B004 0,91 3,30 720
ZBF 63 A 8/2 B004 0,85 2,20 1,70 720 12,5
0,87 2,10 1,50 550
ZBF 71 A 8/2 B004 1,25 2,70 2,50 0,00692 620 1,8 13
1,15 2,60 500
ZBF 80 A 2 B020 1,80 2,90 4,20
0,01275
500
3,3
18,5
ZBF 80 A 8/2 B020 1,95 2,10 3,50 620
19,5
1,70 2,60 4,00 500
ZBF 80 A 12/2 B020 1,40 2,40 3,00 620
1,70 2,60 4,00 500
Tab. 7
3.3.2 KBF motor
Size P
N
n
N
I
N
for 50 Hz, 3 ~ 2) I
A
/I
N
cos
φN
230 V 400 V 500 V
[kW] [rpm] [A] [A] [A]
KBF 71 A 2 0,26 2550
On request
0,90
On request
3,20 0,83
KBF 71 A 4 0,13 1340 0,57 2,45 0,65
KBF 71 A 8/2 0,04 640 0,76 1,25 0,71
0,20 2650 0,62 3,55 0,80
KBF 71 B 8/2 0,06 660 1,20 1,15 0,55
0,30 2750 1,10 3,55 0,70
Tab. 8
Size M
N
M
A
/M
N
M
H
J
mot
AM
OpHrs
Weight
[Nm] [Nm] [kgm
2
][1/h] [Nm] [kg]
KBF 71 A 2 0,97 3,1 2,5 3,8 940 1,4 9,6
KBF 71 A 4 0,93 2,8 2,1 3,8 1080 1,4 9,6
KBF 71 A 8/2 0,60 3,2 1,7 3,8 1400 1,1 9,6
0,72 2,5 1,5 600
KBF 71 B 8/2 0,87 4,4 2,5 3,9 1250 1,6 11,0
1,05 3,1 2,7 500
Tab. 9
2) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
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3.4 Dimensions
DRF 200 with ZBF motor
Fig. 3
Item Designation Item Designation
A) DRF 200 with ZBF 63/71 motor B) Narrow version with ZBF 63/71 motor only for KBK III
C) DRF 200 with ZBF 80 motor D) Narrow version with ZBF 80 motor only for KBK III
Tab. 10
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15

Trolley for DRF 200
Fig. 4
Item Designation Item Designation
A) Trolley for straight travel as tractor trolley B) Trolley with curve travel guide arm as tractor trolley
Tab. 11
16
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3.5 Transport, packing and storage
Safety instructions
WARNING
Falling parts
Risk of injury from falling parts during transport, loading and unloading operations.
– Do not step under the suspended load. Keep a sufficient safety distance.
– Cordon off a large area around the working zone.
WARNING
Damage caused during transport
The DRF 200 friction wheel travel drive may be damaged or destroyed by inappropriate transport.
Attach lifting and handling equipment only at the correspondingly marked points.
Scope of delivery
If special designs or additional options are ordered or the latest technical modifications are incorporated, the ac‐
tual scope of supply may differ from the data and information as well as from the illustrations described here. If
you have any questions, please contact the manufacturer.
Transport inspection
● Check the delivery immediately on receipt to ensure that it is complete and examine it for any damage caused
in transit.
● If any transport damage is visible from the outside, do not accept the delivery or only on condition. Note the
scope of damage in the shipping documents/delivery note of the forwarding company. Lodge a claim.
● Lodge a claim for any defects as soon as they are detected, since claims for damages may only be asserted
within the relevant claim notification periods.
Packing
DRF 200 friction wheel travel drives, the accessories and the trolleys are shipped in cardboard packing.
If no agreement has been made on the return of the packing material, separate the materials according to type
and size and make them available for further use or recycling.
Environmental protection:
● Always dispose of packing materials in an environmentally compatible way and according to locally applicable
disposal regulations.
● If required, utilise the services of a recycling company.
Storage
Until they are installed, the equipment and accessories must be kept closed and may only be stored under the
following conditions:
● Do not store outdoors.
● Store in dry and dust-free places, relative air humidity: max. 60%.
● Do not expose to aggressive media.
● Protect against direct sunlight.
● Avoid mechanical vibrations.
● Storage temperature: -25 to +70 °C.
● Avoid strong temperature fluctuations (condensation).
● Oil all bare machine parts (rust protection).
● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
protection.
● If stored in a damp location, the equipment must be packed tight and protected against corrosion (use desic‐
cant).
214 395 44/120914
17

4 Technical description
4.1 Design
The friction wheel with HydroPUR tyre is driven via a gearbox and electric motor.
The gearbox of the DRF 200 is a 3-stage spur wheel gearbox. The gearbox housing is designed in such a way
that it can be fitted direct to the relevant trolleys.
The motor shaft features a tapered opening. The pinion bonded into the tapered opening transfers the motor tor‐
que to the gearbox.
4.2 Motor
The drive is an electric motor. The equipment is designed in accordance with the VDE regulations. The type of
enclosure is IP 55. Refer to the relevant motor operating instructions for further details.
4.3 Trolley
Fig. 5
The trolley has been specially developed as a tractor trolley for the
DRF 200 friction wheel travel drive.
The drive unit has been developed as a component particularly for I-
beam girders and box-section girders that have parallel flanges for
flange thicknesses from 10 mm to 30 mm. The flange width range from
82 mm to 300 mm (100 mm - 300 mm for travel on curved tracks) is
covered by load bar pins on four different lengths; fine adjustment can
be achieved by means of spacer rings.
The trolley has only one polyamide travel wheel on each side to ensure
that the unit can travel on curved tracks and to enable transfer to a gra‐
dient radius.
Lateral guidance of the trolley on the girder section is ensured by by
two polyamide guide rollers on each trolley side cheek.
Tilting of the trolley caused by acceleration and braking is prevented by anti-tilt rollers. A certain amount of play is,
however, necessary in order to avoid positive guidance. The special design of the deep-drawn side cheek en‐
sures that the trolley has both an anti-derailment feature as well as an integral drop stop.
The use of a guide arm for travel on curved tracks enables the trolley to travel through a horizontal curve radius of
approx. 800 mm and a vertical gradient radius of approx. 2000 mm.
The maximum travel speed in both horizontal and vertical curves must not exceed 10 m/min. For curve-negotiat‐
ing trolleys, we recommend the use of a pole-changing motor and selection of the lower speed for travel on
curved track.
In this case, the anti-tilt guide rollers are not fitted in the trolley side cheek. The function of these rollers is then
provided by the anti-tilt guide rollers of the curve travel guide arm.
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4.4 Runway
Fig. 6
Item Designation
A) Hatched areas with primer coat only
Tab. 12
WARNING
Overload
Danger to life and limb if the trolley is subjected to an
overload.
The load capacity of the hoist unit must not exceed the
load capacity of the trolley.
When selecting a track, we recommend you specify the special profile
sections (see  "Trolley for KBK crane construction kit", Page 20) of
our Demag KBK crane construction kit. They are characterised by their
low deadweight. The cold-rolled track sections feature a smooth run‐
ning surface and offer the advantage of simple power supply by means
of trailing cables or integrated conductor lines.
I-beam girders and box-section girders that have parallel flanges can al‐
so be used tracks.
In the interest of good travel characteristics, we recommend the use of much larger curve radii, see  Tab. 13,
Page 19.
● Wear of the travel wheels is highly dependent on the curve radius. The force required to move the load may
be much higher on small curve radii in connection with heavy loads.
● The travel wheels and guide rollers may display increased wear in installations featuring intensive operation.
Displacement between the rails and gaps at the joint must be avoided. Any displacement between the rails should
be ground flat, if required.
I-beam tracks should be bent with the utmost care to obtain an even and regular curve. Ready-made curved sec‐
tions are available for our special track.
Travel on I-beam tracks must in no way be obstructed by protruding suspension pins, bolt heads, clamping plates
and butt straps, etc. These types of obstruction can be avoided by using our special track section.
In unclean environments, the running surface of the track should be cleaned regularly and should be free of oil
and grease.
Resilient buffers should be mounted at the level of the travel wheel axle at the ends of tracks to prevent the trolley
from derailing (see  "Buffer fitting", Page 21).
The running surfaces of rails and for friction wheel travel drives on crane girders and runways must only be given
a primer coat of 40 µ in the area of the wheels, see (A)  Fig. 6, Page 19. Travel characteristics would be im‐
paired by a top coat.
Curve radii
Minimum medium horizontal curve radius
Flange width b [mm] ≥ 100 < 200 < 300
Curve radius R
hor min
[mm] > 800 > 850 > 900
Minimum medium vertical curve radius (gradient radius)
Flange thickness t [mm] 10 - 19 20 - 25 28 - 30
Curve radius R
vert min
[mm] > 2000 > 2500 > 3000
Tab. 13
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4.5 Trolley for KBK crane construction kit
Fig. 7
Item Designation Item Designation
A) KBK II-L, KBK II, KBK II-R B) KBK III
Tab. 14
DRF 200 friction wheel travel drives transmit the output of the travel motor, which is specially developed for the
crane construction kit, via a spring-mounted friction wheel to the bottom flange of KBK rails. The wide friction
wheel should be used for KBK II, and the narrow friction wheel for KBK III. DRF 200 mounting components can be
relocated to vary the position of the spring assembly and motor as required. Contactor control and timed mechani‐
cal braking, or timed mechanical braking elements in the control pendant are required if pole-changing travel
drives are used.
4.6 Link bar
Two different lengths of link bar are available to connect the tractor trolley to the load trolley, see also the "KBK
classic technical data" document  Tab. 2, Page 2.
The short link bar (l = 130 mm) is sufficient for straight travel, the long link bar (l = 270 mm) is required for travel
on curved tracks. The long link bar is available for travel on horizontal curve radii up to R = 800 mm and there is a
second bar for travel on radii up to R = 2000 mm.
4.7 Load bar
The tractor trolley can also be used as a load trolley when a load bar is used. Load and tractor trolleys are availa‐
ble in variants for travel on straight and curved tracks.
The load bar pin is retained on the trolley by a load bar and distance sleeve that corresponds to the flange width.
The load bar (see  "Load bar", Page 31) is suitable for attaching a DC 1 or DC 2 chain hoist. The maximum
permissible safe working load of the load trolley is 270 kg for non-guided loads which are allowed to swing freely.
20
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