DFW-L-E end carriages - Demag Cranes & Components

DFW-L-E end carriages
with DRS 112 to 200
010802 EN/DE 203 321 44 714 IS 845.1

Contents
DFW-L-E / S
1 DFW product description
Page
3
1.1 Application 3
1.2 Modular carriage system 3
1.3 Protection against corrosion, paint finish 3
1.4 Documentation 3
2 Design and mounting information 4
2.1 Steel construction 4
2.2 Types of connection 4
2.3 DRS wheel block system 5
2.4 Adjusting the span 5
2.5 Wind safety catches 6
2.6 Optimizing the travel speed 6
3 Mounting code 7
3.1 Type designation 7
3.2 Order information 7
4 DFW-L-E/S end carriages 8
4.1 Data and dimensions 8
5 DFW-L-E/O end carriages 10
5.1 Data and dimensions 10
6 DFW-L-E end carriage attachments 12
6.1 End plates 12
6.2 Bolted mounting plates with non-countersunk bore holes
and with countersunk bore holes for DFW-L-E/S 14
6.3 Bolted and welded mounting plates for DFW-L-E/O 16
6.4 Torque brackets 18
6.5 Buffers and spacers 18
6.6 Guide rollers 18
7 Order form for DFW-L-E end carriages 19
Steel structure Bolted mounting plate Geared motor
Torque bracket
Buffer Wheel block High-tensile For outdoor operation only Wheel block Spacer
End
Non-driven bolted
1x for Ax500 mm
Driven
20332001.eps
2 20332144.p65/010802

1.1 Application
1.2 Modular carriage
system
1.3 Protection against
corrosion
Paint coat
1.4 Documentation
20332144.p65/010802 1 Product description
DFW-L-E carriages are used for steel structures in the crane and lifting equipment
industry and also for applications in related mechanical engineering.
DFW-L-E carriages are compact, driven, rail-mounted carriages for direct connection
to load-bearing structures. In addition to the steel structure part, a torsionally
resistant box section, the end carriage includes a driven wheel block for fitting the
gearbox and the motor as well as a non-driven wheel block. The carriage design is
based on the latest principles for steel structures and, even with high loads, has
excellent travelling characteristics due to the fine tolerances of the carriage regarding
track gauge errors, diagonal position and misalignment. Specially adapted heavyduty
motors provide excellent speed/torque characteristics, which ensure smooth
starting for both the unloaded and the loaded carriage.
The following equipment can be combined to form a complete carriage:
Connection
• Carriages with one crane girder connection on the side (standard)
• Carriages with one crane girder connection on the top
Travel unit/travel wheel
• DRS wheel blocks 112, 125, 160, 200 mm
• Max. wheel loads up to 10000 kg
• Wheel bases 2000, 2500, 3150, 4000 mm
Travel drive (drive units fitted either on right-hand or left-hand side)
• AM offset gearboxes
• ZBF travel motors
• MA torque brackets
Buffers
• DPZ Cellular plastic buffers
Protection against corrosion
• Structural steel shot-blasted (Sa2 rust removal factor to DIN 55 928).
• Rust protection with primer paint in RAL 1004 golden yellow (thickness 60 µm)
• Galvanized finish available on request
• Other provisions for corrosion protection available on request.
Paint coat
• A final coat in RAL 1007 daffodil yellow or other colours can be provided on
request.
Travel unit
• Operating instructions 214 362 44
• Component parts list 222 736 44
DRS wheel blocks, gearboxes, travel motors and buffers
• Demag DRS wheel block system Volume 1 1) 203 352 44
• Geared motors for travel applications Volume 2 203 355 44
1) required for rating the end carriages
3

2 Design and mounting information
2.1 Steel structure
Steel structure with side connection of main girder
2.2 Types of connection
The steel structure is designed in accordance with DIN 15018, lifting class H2, stress
group B3.
Steel structure characteristics:
• High stability due to enclosed, torsion-resistant box section girder. Great
strength in connection area due to diaphragm plates welded into the carriage.
• Machining on NC machines provides precise positioning of travel wheel axles
with respect to mating surfaces.
• Easy assembly and access. Detachable and anti-shear high-tensile connection
with adjoining structure.
• Optimum travel characteristics. Can be easily exchanged due to accuracy of the
connection geometry. Fine tolerances for track gauge errors, diagonal wheel
position and misalignment are met as a result of the precise alignment and
machining of the connection surfaces.
The carriage can be connected to the structure in the following ways:
• bottom flush (side connection of main girder),
• top flush (side connection of main girder),
• raised (side connection of main girder),
• lowered (side connection of main girder),
• top connection (top connection of main girder),
Steel structure with top connection of main girder
20332002.eps
Bottom flush Top flush Raised Lowered Top connection
20332003.eps
4 20332144.p65/010802

20332144.p65/010802
2.3 DRS wheel blocks
b wheel
b 2
d 1
b rail
d 2
2.4 Adjusting the span
Spacer elements
20332004.eps
Wheel blocks feature:
• Positive travel wheel/shaft connection resulting from the splined shaft section.
Simple, fast assembly and replacement with commercially available tools.
High wheel loads, long service life due to dust-proof anti-friction bearings lubricated
for life.
Simple adjustment of span by re-arranging spacer elements between the wheel
block and the inside of the carriage girder.
Considerably reduced wear on travel wheels (wear indicator) and track rails as a
result of the self-lubricating effect of spheroidal graphite cast iron compared with
steel.
Silent running due to self-damping properties of the travel wheel material.
Travel wheel profile
1) other treads on request
2) max. wheel loads for linear contact (flat rail to DIN 1014 or A rail to DIN 536) depending on FEM group, useful rail width and
long travel speed, see catalogue 203 352 44, section 2.6.5
By re-arranging the spacer elements, the span can be adjusted.
d 1
Spacer
elements
[ mm]
T hickness
[ mm]
Max.
adjustment
[ mm]
112
D imensions
in
mm
Max.
wheel
loads
2)
d1d2 b2 Max. bwheel
Standard b 1 ) w heel
[ 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
± 6
125± 4
2 and
5
160± 6
200 ± 10
Spacer elements
20332005.eps
5

2 Design and mounting information
2.5 Wind safety catches
2.6 Optimizing the travel
speed
Travel speed (m/min)
125
100
80
63
50
40
31,5
25
20
16
12,5
5
According to accident prevention regulations (UVV, BGV D6 § 14.1 (VBG 9)), cranes
must have their power-driven travelling and slewing movements braked, thus
preventing unintended movement. According to the regulations UVV 18.2 BGV D6
§ 30.6 (VBG 9), the crane operator must ensure that cranes exposed to the wind are
secured during storms and at the end of work.
According to the surface area exposed to the wind, one or two safety catches are
required per crane.
Depending on accessibility, the manually operated wind safety catch should be
preferred.
Optimum handling capacity can only be achieved by correctly selecting the working
speeds. For this, the average speed of the individual movements is the determining
factor.
6 7 8 9 10 15 20 25 30
Crane runway length or span (m)
20332008.eps
6 20332144.p65/010802
40
50
100
150
200

3.1 Type designation
3.2 Order information The following information is required:
• End carriage type: E - single-girder crane
Drive variant
left
20332030.wmf
20332144.p65/010802 3 Mounting code
DFW-L-E 112 / 2000 / S
• Travel wheel dia. or wheel block size/wheel base:
112 / 2000, 2500
125 / 2000, 2500, 3150
160 / 2000, 2500, 3150
200 / 2000, 2500, 3150, 4000
Other wheel bases on request
• Main girder connection: S - side
O - top
• Travel wheel tread: See section 2.3
• Travel wheel variants: 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 mounting plate:
L - 1 end carriage, left-hand side
R - 1 end carriage, right-hand side
RL - 2 end carriages arranged in pairs
(right-hand side and left-hand side)
• Number of drives per end carriage:
0 - no drive
1 - one drive
2 - two drives
• Drive shaft diameter or gearbox size:
30, 35, 45 or 50
See catalogue 203 352 44 section 2.3
• Guide rollers: Standard guide rollers yes/no
See section 6.1 and catalogue 203 352 44 section 4.6
• DPZ buffers: 100, 130, 160
See catalogue 203 352 44 sections 4.4 and 4.5
Wheel base ekt
Travel wheel diameter d1
Overhead travelling crane
Demag end carriage
Single-girder crane
Connection of main girder
• End plate variant:
lers
See section 6.1
Standard, variant for Italy, USA or for guide rol-
• DFW-L-E/S mounting plate:
See section 6.2
with countersunk bore holes,
with non-countersunk bore holes
• DFW-L-E/O mounting plate: bolted type, welded type
See section 6.3
7

4 DFW-L-E/S end carriages
4.1 Data and dimensions
X
d1bwheel 112 max 60
A B
h 19
a 9
a 12
h 21
h 20
h 18
S
h 8
Ay3
L
ekt a 3
a10 a11
21
d 1
A
51,5
a 8
a 7
i - Number of securing bolts for torque
bracket
B
4
4
Ax
Ay2
Ay1
Dimensions
in
mm
20332009.eps
ekt Gearbox Ax Ay1 Ay2 Ay3 a3 a4 a7 a8 a9 a10 a11 a12 b2 b3 b4 b8
2000
150 -
672
A10
280
- 93
203
A20
2500 95 150 922
2000
2500 A10
A20
867
3150 1192
125 max 60
2000
280 95 150 - 108 233
617
2500 A30
106
867
3150 for
DPZ100
1192
2000
2500 A20
280
126
for
DPZ130
575
825
3150 500 158
1135
160 max 65
2000
95150 220 135, 5 for
DPZ160
288
575
2500 A30
A40
280
825
3150 500 1135
200 max 65
8 20332144.p65/010802
617
2000
542
280
2500 3150
A30
A40
150 220 290 168 353
792
1072
500
4000 1497
h 17 h 1
h 12
d 4
d 3
h 23
a 4
100 (Standard buffer height)
145 - 79 50 80 71, 5 70 135
175
220
-
92
-
110
77, 5 58, 5 80 77, 5 70
97, 5 75 89 88 85
275 140 120 105 101 105, 5 95
138
140
138
140
158
160
158
160
183
185

20332144.p65/010802
The supply of a DFW end carriage includes: End carriage, mounting plate with securing bolts and buffer
b – standard travel wheel tread see item 2.3; other travel wheel treads on request
wheel
End carriage weight without mounting plate, motor and gearbox
Assignment of end carriages: For SWL – span, see standard overhead travelling cranes brochure 203 317 44
(crane selection tables and wheel loads/mass forces/forces resulting from running at an angle/buffer forces/dead loads of the crane)
h7
h22
View X Section A-A
Section B-B
b3
b wheel
b2
b4
h10
S
b8
b9
Y
5
20
h9 h13
End carriage
Travel wheel
centre
Detail Y
Main girder
67,5 ± 1 DFW-L-E 112
67,5 ± 1 DFW-L-E 125
82,5 ± 1 DFW-L-E 160
92,5 ± 1 DFW-L-E 200
20332010.eps 20332011.eps
Dimensions in
mm
Number Weight
b9d3 d4 h1 h7 h8 h9 h10 h12 h13 h17 h18 h19 h20 h21 h22 h23 L S i kg
1218, 5 M 8 149
1521 M 8 162,
5
1530 M 10
217
1535 M 10
277
243
2204 7
113
215 22, 5 24 14 308 42 40 60 10 - 9, 5 -
4
247 2704 9 153
281
2224 8
285 -
2724 10 4 202
289 3374 12 269
250 42, 5 28 15 308 47, 5 40 68, 5 41
9 9
281
2224 8
152
285 10
2724 10 6 202
289 3374 12 269
353
2280 8
357 -
2780 10 4 257
361 3430 12 341
320 32 31 17 308 63 55 90 56
1010 353
2280 8
195
357 12
2780 10 6 257
361 3430 12 341
440
2336 8
442 2836 10 380
400 42 35 20 385 80 75 115 70 10 10 15
6
3486
462
444
12
4336 586
152
195
300
9

5 DFW-L-E/O end carriages
5.1 Data and dimensions
Figure: Bolted connection
X
d1bwheel 112
125
160
200
A
h19
a10
a9
a12
a11
h21
h20
h18
A
i - Number of securing bolts for torque bracket
max
60
max
60
max
65
max
65
h8
By1
B
B
L
ekt
Bx1
Bx2
20332012.eps
10 20332144.p65/010802
Si
Dimensions
in
mm
ekt Gearbox Bx1 Bx2 By1 a3 a4 a7 a8 a9 a10 a11 a12 b2 b3 b4 b8 b9 b10
2000
A10
672
360 360 56 93
203
2500 A20
922
2000
617
2500 A10
A20
867
3150 1192
2000
360 440 44 108 106
for
233
617
2500 A30
DPZ
100
867
3150 1192
2000
126
for
575
2500 A20
DPZ
130
825
3150 1135
2000
470 470 64 135, 5 158
for
288
575
2500 A30
A40
DPZ
160
825
3150 1135
2000
470
470
542
2500 3150 A30
A40
or
560
s.
or
560
s.
85168 353
792
1072
4000 S16
S16
1497
a8
h12
h17
Sa
d4
d1
a7
a3
d3
145- 79 50 80 71, 5 70 135 12 22
175
220
-
92
-
110
a4
h23
77, 5 58, 5 80 77, 5 70
97, 5 75 89 88 85
275 140 120 105 101 105, 5 95
100 (Standard buffer height)
138
140
138
140
158
160
158
160
183
185
1555 1565 1573

20332144.p65/010802
The supply of a DFW end carriage includes: End carriage, mounting plate with securing bolts and buffer
b – standard travel wheel tread see item 2.3; other travel wheel treads on request
wheel
End carriage weight without mounting plate, motor and gearbox
Assignment of end carriages: For SWL – span, see standard overhead travelling cranes brochure 203 317 44
(crane selection tables and wheel loads/mass forces/forces resulting from running at an angle/buffer forces/dead loads of the crane)
Figure: Bolted connection
h25
h24
h7
View X Section A-A
Section B-B
h22
For bolted connection
For bolted and welded connection
Dimensions in
mm
Number
d1d3 d4 h7 h8 h10 h12 h17 h18 h19 h20 h21 h22 h23 h24 h25 L S Sa Si
i
112 18, 5 M8
125 21 M8
160 30 M10
200 35 M10
b3
b wheel
b2
b4
h10
S
b8
b10
b9
20332013.eps
243
258 280 2204 7
113
215 24 14 42 40 60 10 - 9, 5 -
4 4 4
247 262 284 2704 9 153
281
85
89
281
85
89
296 318 2224 8
2 -
300 322 2724 10 4 202
2 304 326 3374 12 269
285 28 15 47, 5 40 68, 5 41
9 9
4 4
296 318 2224 8
152
2 10
300 322 2724 10 6 202
2 304 326 3374 12 269
353
57
61
353
57
61
371 393 2280 10
3 -
375 397 2780 10 4 257
Weight
in
kg
3 379 401 3430 12 341
320 31 17 63 55 90 56
1010 4 4
371 393 2280 10
195
3 12
375 397 2780 10 6 257
3 379 401 3430 12 341
440
42
44
44
455 477 2336 10
4 457 479 2836 10 380
400 35 20 80 75 115 70 10 10 15
4 4 6
4 459 481 3486 12 462
4 459 481 4336 12 586
152
195
300
11

6 DFW-L-E end carriage attachments
6.1 End plates
Standard version (buffer height = 100 mm)
DFW-L-E 112 DFW-L-E 125 DFW-L-E 160 DFW-L-E 200
652 771 44 652 798 44 652 832 44 652 865 44
60
130
65
86 87
229
138
Variant for Italy (buffer height = 0,6 x travel wheel diameter)
60
70
85 109
266
12 20332144.p65/010802
158
85
77 134
328
Due to the application of the EC Machine Directive 98/37/EC
in Italy, the buffer height of 100 mm has been adapted to our
standard.
185
95
73 169
410
20332012.eps

20332144.p65/010802
Variant for USA (buffer height = 100 mm; with derailment guard)
46
DFW-L-E 112 DFW-L-E 125 DFW-L-E 160 DFW-L-E 200
652 770 44 652 800 44 652 833 44 652 866 44
60
34
75
130
65
120 87
229
263
46
50
75
138
Variant for guide rollers (buffer height = 100 mm)
70
120
276
301
DFW-L-E 112 DFW-L-E 125 DFW-L-E 160 DFW-L-E 200
652 769 44 652 831 44 652 864 44 652 868 44
130
87
142
138
109
160
54
54
85
158
158
85
122
134
346
208
373
58
62
85
185
185
95
122
169
432
459
20332014.eps
283
20332015.eps
13

6 DFW-L-E end carriage attachments
6.2 Bolted mounting plates for DFW-L-E/S end carriages
Bolted mounting plates with non-countersunk bore holes
d 3
Ax ±0,2
1) The open bore holes dia. 21 mm in the bolted mounting plate are closed with plugs
A
20332018.eps
14 20332144.p65/010802
Ay1
D FW
Part no.
Dimensions in
mm
Weight
d1e kt
1) Ax Ay1 Ay2 Ay3 Ay4 Ay A B d3 d4 in
kg
112 2000,
2500
810 706
44
280 95 150 - - 182, 5 375
17,
9
125 2000,
2500,
3150
308
160 2000, 2500
810 778
44
280 95 150 220 - 265 375 17,
9
21- 160 3150 811 283
44
500 95 150 220 - 265 600 35,
6
200 2000, 2500
959 823
44
280 150 220 290 - 335 375
17,
9
385
200 3150, 4000
959 824
44
500 150 220 290 - 335 600 35,
6
Ay2
Ay3
Ay4
Ay
B
B = h13 Standard mounting plate
20

20332144.p65/010802
Bolted mounting plates with countersunk bore holes
1) The open bore holes dia. 21 mm in the bolted mounting plate are closed with plugs
20332019.eps
D FW
Part no.
Dimensions in
mm
Weight
d1e kt
1) Ax Ay1 Ay2 Ay3 Ay4 Ay A B d3 d4 in
kg
112 2000,
2500
810 265
44
280 95 150 - - 182, 5 375
17,
9
125 2000,
2500,
3150
308
160 2000, 2500
959 347
44
280 95 150 220 - 265 375 17,
9
21- 160 3150 811 285
44
500 95 150 220 - 265 600 35,
6
200 2000, 2500
959 722
44
280 150 220 290 - 335 375
17,
9
385
200 3150, 4000
959 720
44
500 150 220 290 - 335 600 35,
6
15

6 DFW-L-E end carriage attachments
6.3 Bolted and welded mounting plates for DFW-L-E/O
Bolted mounting plates
Bu
-
G
By1
d 3
F
Bx2
Bx1
E
A
16 20332144.p65/010802
H
T
B
203 320 20.eps
DFW Bu
Dimensions in
mm
Weight
Part
no.
d1inmm Bx1 Bx2 By1 E F G H T A B d3 in
kg
112 200 oder
300
652 789
44
360 360 56 150 40 112 120 22 460 140 17 8,
8
125 200 oder
300
652 823
44
360 440 44 150 73 138 150 22 540 170
160 200 oder
410
652 856
44
470 470 64 150 83 168 177 22 570 200 15,
2
21
200 oder
410
653 749
44
470 470 85 150 91 198 210 22 570 230 16,
5
200
410 oder
500
652 879
44
560 560 85 360 91 198 210 22 660 230 18,
3
Width
of
crane
girder
flange,
bottom
12,
1

20332144.p65/010802
Welded mounting plates
Bu
-
F
E
A
H
B
T
203 320 21.eps
DFW Bu
Dimensions in
mm
Weight
Part
no.
d1inmm E F H T A B in
kg
112 200 oder
300
652 791
44
150 40 120 15 360 140 6,
1
125 200 oder
300
652 825
44
150 73 150 15 540 170 8,
6
160 200 oder
410
652 858
44
150 83 177 18 570 200 12,
8
200
200 oder
410
653 750
44
150 91 210 15 570 230 14,
5
410 oder
500
652 881
44
360 91 210 15 660 230 12,
8
Width
of
crane
girder
flange,
bottom
17

6.4 Torque brackets In standard cranes, the torque brackets are used in conjunction with AM offset gearboxes,
ZBF cylindrical rotor motors and DRS wheel blocks with pin connection.
For data, dimensions and ordering, see catalogue 203 352 44
• Torque brackets section 4.1
For data, dimensions and ordering, see catalogue 203 355 44
• Offset gearboxes
• Cylindrical rotor motors
6.5 Buffers and spacers Buffers with high buffering forces are required to avoid hazardous deformations of the
supporting structure in the event of end carriage collisions or when running against
the end stop at the runway end.
For data, dimensions and ordering, see catalogue 203 352 44
• Buffers and spacers sections 4.4
6.6 Guide rollers The horizontal guide rollers always have to be considered in conjunction with the
DRS wheel block. When ordering the end carriage, information on the guide rollers is
required.
For data, dimensions and ordering, see catalogue 203 352 44
• Guide rollers section 4.6
18 20332144.p65/010802

20332144.p65/010802
# = Modifications compared to previous issue
7 Order form for DFW-L-E end carriages
From company:
Ms./Mr.:
Department:
Address:
Order data:
Wheel block size: 112 125 160 200
Wheel base: 2000 2500 3150 4000
Connection of main girder: S O
Travel wheel tread:
Date:
Telephone:
Telefax:
Travel wheel type: A flange on both sides B without flange
D flange on one side Others:
Drive arrangement: L- left R- right RL - right or left
Number of drives: 0 1 2
Drive shaft diameter: 30 35 45 50
Guide rollers (standard): yes no
Buffers: 100 130 160
Version: Standard USA
DFW-L-E/S mounting plate: Countersunk Non-countersunk
DFW-L-E/O mounting plate: Bolted Welded
Protection against corrosion: RAL1004 golden yellow Others:
Paint finish: RAL1007 daffodil yellow Others:
Classification: H2 B3 (indoor operation) Others on request
19

Demag Cranes & Components GmbH
P.O. Box 67 · D-58286 Wetter
Telephone (+49/2335) 92-0 · Telefax (+49/2335) 927676
www.demagcranes.com
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.
Printed in Germany Basse/131005/5H