demag drs maintenance

8/11/2019 Demag Drs Maintenance

http://slidepdf.com/reader/full/demag-drs-maintenance 1/52

Assembly, installation and operating

instructionsDRS 112, 125, 160, 200 wheel block system

160408 EN 720 IS 845.5

41238844.eps

214 276 44



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Contents

Accompanying documents

Manufacturer

0 Foreword 4

0.1 Copyright 4

0.2 After-sales service 4

0.3 Liability for defects 40.4 Limitations of liability 5

0.5 Definitions 5

1 Safety 6

1.1 Symbol description 6

1.2 Intended use 6

1.3 Prohibited practises, improper use 61.3.1 Specification 6

1.3.2 Assembly 6

1.3.3 Environmental influences 6

1.3.4 Maintenance 6

2 Brief technical description 7

2.1 Overview 72.2 Type designation key (example) for basic wheel blocks 8

2.3 Type plate 102.4 Paint finish 11

3 Receiving and storage 12

3.1 Checking goods on receiving 12

3.2 Transport 123.3 Storage 12

Demag Cranes & Components GmbH

Drives

P.O. Box 67, D-58286 Wetter

Telephone +49 (0) 2335 92-5555 · Telefax +49 (0) 2335 92-2406

E-mail: [email protected]

www.drives.demagcranes.com

General documents Part no.

DE EN FR ES

Brochures

Demag Drives brochure 208 732 44 208 734 44 208 735 44 208 736 44

Demag wheel range brochure 208 722 44 208 724 44 208 725 44 208 726 44

Catalogues / technical data

Drive Designer Online www.demag-drivedesigner.com

Geared motors catalogue – DE / EN / FR 203 150 44 –

Geared motors catalogue – IT / EN / ES – 203 250 44 – 203 250 44

DRS wheel block system 203 350 44 203 352 44 203 353 44 203 354 44

Demag RAE/RNE wheel sets technical data 203 687 44 203 688 44 203 689 44 203 690 44

Geared travel motors catalogue – Volume 3 – Quick selection and gearbox limit torque – DE / EN / FR 203 013 44 –

Geared travel motors catalogue – Volume 3 – Quick selection and gearbox limit torque – IT / EN / ES – 203 014 44 – 203 014 44

Operating instructions

D 11 – D 41 helical gearbox operating instructions 214 719 44 214 720 44 214 721 44 214 722 44

D 50 – D 90 helical gearbox operating instructions 214 150 44 214 151 44 214 152 44 214 153 44

W 10 – W 100 angular gearbox operating instructions 214 057 44 214 058 44 214 059 44 214 060 44

A 10 – A 90 offset gearbox operating instructions 214 205 44 214 206 4 214 207 44 214 208 44

Motor operating instructions – Z motor range 214 227 44 214 228 44 214 229 44 214 230 44

KBA - KBF motor operating instructions 214 317 44 214 318 44 214 319 44 214 320 44

Brake accessories for Z motor range, operating instructions 214 040 44 214 041 44 214 042 44 214 043 44

Operating instructions / Plug connection for KB and Z motor ranges 214 021 44 214 022 44 214 023 44 214 024 44

DRS 112 – 200 wheel block system assembly and operating instructions 214 275 44 214 276 44 214 277 44 214 278 44

DRS 250 – 500 wheel block system assembly and operating instructions 214 326 44 214 327 44 214 328 44 214 329 44



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4 Assembly and alignment 13

4.1 Travel wheel types 13

4.2 Assembly instructions 14

4.2.1 Top connection 14

4.2.1.1 Fitting universal shaft F for top connection 15

4.2.2 Side connection 16

4.2.2.1 Fitting universal shaft F for side connection 174.2.3 DRS 200 side connection with AD.50/WU.60 gearboxes 18

4.2.4 DRS 112 – 200 pin connection 20

4.2.5 DRS 200 pin connection with AD.50/WU.60 gearboxes 22

4.2.6 Fitting the wheel block 23

4.2.6.1 Axial retaining arrangement with track gauge adjustment 23

4.2.6.2 Pin set 244.2.6.3 Fitting pin connection (without welded plate) 25

4.2.6.4 Fitting pin connection (with welded plate) 25

4.2.6.5 Fitting universal shaft F for pin connection 26

4.2.6.6 Fitting pin connection with distance plates DRS 200 – AD50/WU60 264.2.6.7 Fitting end connection with distance plates 274.2.6.8 Fitting torque brackets for pin and end connection 27

4.2.6.9 Fitting torque brackets for pin and end connection

DRS 200 AD50 / WU60 27

4.2.7 DRS 112 – 200 end connection 28

4.3 Manufacturing tolerances of crane runways 29

5 Assembling drive elements 30

5.1 Torque brackets for individual and central drive units 30

5.1.1 A type offset gearboxes / W type angular gearboxes 30

5.1.2 A 50 type offset gearboxes 325.1.3 W 60 type angular gearboxes 33

5.2 Individual drive units 34

5.2.1 A type offset gearboxes 345.2.2 W type angular gearboxes 34

5.3 Central drive units 35

5.3.1 A type offset gearboxes 355.3.2 W type angular gearboxes 36

5.4 Central drive units with shaft protection 37

5.4.1 A 50 type offset gearboxes 37

5.4.2 W 60 type angular gearboxes 38

6 Fittings 40

6.1 Horizontal guide rollers 406.1.1 Fitting to wheel blocks 40

6.1.2 Fitting to steel superstructure 42

6.2 Buffer elements 43

6.2.1 DPZ cellular foam buffer 43

6.2.2 DPG rubber buffer 43

7 Maintenance 45

7.1 Maintenance instructions 45

7.2 Travel wheel wear 46

7.2.1 Flange wear 46

7.2.2 Tread wear 46

7.3 Possible fault sources 47

8 Removing and fitting travel wheels 47

9 Forms 48

9.1 Forms for documenting the installation 48

9.1.1 Type plates 489.1.2 Type code 49

9.2 Fax form 50

EC manufacturer’s declaration 51



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0.3 Liability for defects

0 Foreword

You have purchased a Demag product. This equipment was manufactured in

accordance with state-of-the-art engineering principles.

These operating instructions are designed to provide the operator with appropriateinstructions for safe and correct operation and to facilitate maintenance.

Every individual given the task of transporting, installing, commissioning, operat-

ing, maintaining and repairing our DRS wheel block system and additional equip-ment must have read and understood

• the operating instructions

• the safety regulations

• the safety instructions in the individual chapters and sections.

The operating instructions must be available to the operating personnel at all times

in order to prevent operating errors and to ensure smooth and trouble-free opera-

tion of our products.

These operating 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 of fice in Wetter.

These operating instructions must be read carefully before installing and putting

the product 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

immediately on detecting the defect.

Liability claims for defects are void in the event of:

• inappropriate use,

• faulty devices or equipment connected or attached to the product 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.

0.2 After-sales service

0.1 Copyright



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All technical information, data and instructions for operation contained in these op-

erating 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

further development of the wheel blocks which are the subject of these operating

instructions.

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 neces-

sarily 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 defects, damage and malfunctions caused as a result of

operating errors, non-compliance with these operating instructions or omitted and/

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, our liability for defects and liability obliga-

tions for any defects pertaining to the products supplied or faults in the documenta-

tion delivered or any negligence on our part are exclusively based on the stipula-

tions of 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.

Owner

Owners (employer, company) are defined as persons who own the product and

who use it appropriately or allow it to be operated by suitable persons.

Operating personnel

Operating personnel are defined as persons assigned by the owner of the product

to carry out special tasks such as installation, operation, setting-up, maintenance

including cleaning, fault elimination and transportation.

Specialist personnel

Specialist personnel are defined as persons assigned by the owner to carry out

specific tasks.

• Qualified personnel Qualified personnel are defined as persons, who, owing to their technical

training, knowledge and experience as well as knowledge of the relevant

standards, are able to assess the tasks given to them and identify 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 in-

correct handling and who have been informed about the required protective

devices, protective measures, relevant regulations, codes of practice, accidentprevention 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 suf ficient knowledge of the product and are fa-

miliar with the relevant national industrial safety regulations, codes of practice,

accident prevention regulations, directives and generally accepted engineering

standards (e.g. EC Directives, German VDE and VBG regulations) enabling

them to judge the safe operating condition of the DRS wheel block system.

0.4 Limitations of liability

0.5 Definitions



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1.3 Prohibited practises,

improper use

1.3.2 Assembly

1.3.3 Environmental influences

1.3.1 Specification

1 Safety

1.1 Symbol description The following symbols and recommendations indicate potential safety hazards or

causes of damage:

Hazard warningThis symbol appears in the operating instructions next to all instructions relating to

safety at work wherever a potential hazard to life and limb exists if the instructionsare 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 product

including the power supply.

In addition to the safety instructions, observe all general safety regulations andcodes of practise at all times.

Warning against dangerous electrical voltage

Contact with live parts (e.g. motors connected to the unit) can result in immediate

death. Protective covers (e.g. covers and enclosures) marked with this sign may

only be opened by qualified electricians. Before opening, all relevant operating,

control, feed or other voltages must be disconnected.

Operating hazard for the installation

This symbol in the operating instructions indicates all warnings which, if not com-

plied with, may result in damage to the product, the installation or the goods to be

transported.

Demag DRS wheel blocks are complete travel units for materials handling instal-lations and general engineering applications, designed for moving loads over a

wide range of speeds. They feature prepared connecting surfaces and are ready

for fitting to adjoining structures.

The relevant engineering guidelines must be observed when specifying the de-

sign. See list of documents on page 2.

Under certain conditions, operation of the DRS wheel block system is prohibited

as this could result in malfunctions, equipment failure or hazard to life and limb,

e.g. in the case of:

• Exceeding permissible loads

• Exceeding the design service life

• Occurrence of peak loads which were not considered in the design

• Use of connecting elements not designed for use with the unit• Use of non-genuine Demag parts

• Not complying with the assembly instructions

• Tightening bolted connections without using a torque wrench

• Incomplete assembly of connecting elements

Note: Safety measures must not be rendered inoperative or modified or used

contrary to the purposes for which they are intended.

• Acidic, corrosive air as coolant

• Explosion hazard atmospheres

• Operation outside the permitted temperature range

• Operation under prohibited ambient conditions

Note: Measures must be taken to ensure the travel wheels do not freeze upunder conditions of high humidity and low temperatures.

• Exceeding the design service life

1.2 Intended use

1.3.4 Maintenance



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2 Brief technical description

2.1 Overview

41621344.eps

The Demag DRS 112 to 200 wheel block system, suitable for loads up to

10,000 kg, is a concept designed to meet customer whishes.

The advantages of the system are:• Most favourable ground clearance conditions with Demag travel drives.

• Robust aluminium housing with very good shape and position tolerances.

• Variable basic design by fitting various travel wheel materials and shapes.

• Weather-resistant due to surface powder coating (RAL 7001, silver grey).

Special paint finish available on request. For further details on the paint finish,

see section 2.4.• Compensation of track gauge deviations of up to 8 mm possible.

• Protected internal bearing arrangement.

• Minimum maintenance due to bearings lubricated for life.

• Travel wheel and bearings can be replaced thanks to bolted housing.

• High installation availability since the housing does not necessarily need to be

removed to replace the travel wheel. Not having to realign the housing savestime.

• A damping element in the travel wheel reduces the load on the gearbox.• Sixth connection surface for fitting (e.g. switching flag).

• High-tensile bolted connections are dacromatised and therefore provided with a

special surface protection.

41621255.eps

41641055.eps

Flange wear

indicator

Involute spline

to DIN 5480

Alignment• Fast and optimum alignment of

wheel blocks using the Demagalignment device with sliding nuts

and prepared connection openings

in the wheel block housing.

• Precisely aligned wheels reduce

wear to a minimum. Achievable

accuracy with measuring device:

1,6 ‰.

• Sliding nut arrangement, used foralignment, offers a lateral alignment

path of ± 3 mm.

• The flange wear indicator facilitates

preventive maintenance without any

hazard to the installation.

Flange wear indicator



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2.2 Type designation key (example) for basic wheel blocks

DRS 112 A30 A 47 K H A10

Prepared for fitting torque bracket

Gearboxes:

A Offset 10/20/30/40/50/60/70/80/90

W Angular 10/20/30/40/50/60/70/80/90/100

X indicates: no gearbox considered

Guide roller arrangements, prepared for:

H Horizontal guide rollers, standard

X indicates: no guide rollers

Connection variants, prepared for:

K Top connection

W Side connection

B Pin connection

Travel wheel types

A GJS (GGG) with flanges on both sides

B GJS (GGG) without flangeC Polyamide without flange, with larger diameter

D GJS (GGG) with flange on one side

E GJS (GGG) without flange, with larger diameter

F Hydropur without flange, with larger diameter

S Special travel wheel

Travel wheel tread b1:

for types A and D: see section 4.1

for types B, C, E, F: indicate 0

Basic type

A . . Driven wheel block, for torque bracket fitting

and indication of hub profiles

MA . . Wheel block also driven

and indication of hub profiles

NA .. Non-driven wheel block

Wheel block sizes 112, 125, 160, 200, 250, 315, 400, 500

Demag wheel block system



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Travel carriage with 4 wheel blocks anda central drive unit

41239655.eps

1 DRS125-NA-A-47-K-X-X


3 DRS125-A35-A-47-K-X-A20

4 DRS125-MA35-A-47-K-X-X

Travel carriage with 4 wheel blocks and2 individual drive units



3 DRS125-A47-A-47-K-X-A20

4 DRS125-A47-A-47-K-X-A20

41641155.eps

Example for using the type designation key

1

2

3

4

1

2

4

3



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Example

Serial number

Order number/ASN number

Type code

41239044.eps

Serial number

Order number/ASN number

Type code

41239144.eps

2.3 Type plate A type plate is applied to each of the end faces of DRS wheel blocks to identify the

unit for possible spare part orders.

The type plate may be covered by buffer or guide roller assemblies on one side

depending on the design of the wheel block. In this case, the information can beread off the second type plate or relevant fittings can be relatively easily disassem-

bled.

Forms for type plates and type designation keys can be found in section 9 for use

in your documentation. Fill in the data of the wheel blocks used in your installation.

41239344.eps

Type plates are applied to both end

faces



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2.4 Paint finish

DRS 112 to 200

Standard

The aluminium wheel block housings are provided with a weather-resistant powder

coating in RAL 7001 (silver grey) with a minimum thickness of 90 μm beforeleaving the factory.

Continuous coating quality is ensured by our works standard for wheel block

housings (ident. no. 012 326 99).

Special paint finish

For special paint finishes, wheel blocks can be supplied with a dual component

PUR finish coat at the request of the customer.

If the paint finish is to be applied by the customer, attention must be paid to theworks standard for special paint finish on powder-coated wheel block surfaces

(ident no. 012 328 99).

Acid-resistant paint finish

The surfaces of wheel blocks with a powder-coated finish may be used in environ-

ments with acid vapours without any treatment. Alternatively, a dual component

acid protection paint finish may be applied to appropriately pre-treated housings.Wheel blocks must also be fitted with ball bearings featuring double lip seals.

The gap between the housing and the cover is sealed with an acid-proof varnish.



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3 Receiving and storage

3.1 Checking goods on

receiving

• The scope of delivery is specified in the shipping papers.

• Check the delivery immediately on receipt to ensure that it is complete and

examine it for damage caused in transit.

• In any case, leave the goods and the packaging material unchanged. Do not

use the goods yet!

• Report the damage to the forwarding agent and request the required papers as

listed below!

• Then contact the supplier!

• Never return the damaged goods prior to agreement with the supplier!

For transport outside Germany, the relevant country-specific conditions have to be

adhered to.

The wheel block is supplied made up into one unit. Additional equipment may be

supplied in separate packaging.

The wheel block is packed depending on the transport method and its size.

Unless otherwise agreed in the purchase contract, the packaging corresponds

to the packaging guidelines of Demag Cranes & Components GmbH.

Symbols used on the packing

3.3 Storage

Handle wheel block units with utmost care to avoid damage caused by careless

loading and unloading, for example.

Wheel blocks must be stored in dry places which are not subject to extreme tem-

perature fluctuations, e.g. on a wooden support.

Unpacked wheel blocks must not be stacked on top of each other.

Note: Do not damage the paint finish.

Mechanical (scratches), chemical (acid, alkaline) or thermal (sparks,

welding beads, heat) damage will result in corrosion and failure of theexterior protection.

3.2 Transport

Protect from heatKeep dryFragileThis way up

Top-heavy No hooks Attach sling here Centre of gravity

412 83944 - 41284644.eps



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Travel wheel type A B C

Flange-guided travel wheel

Spheroidal graphite cast iron

Travel wheel without flange



Polyamide

Wheel block size

Max. wheelload 2)

d1 1)

-0,2d2 b1max b2 s

Max. wheelload 2)

d1 1)

-0,2b2

Max. wheelload 2) d4 1) b2

t mm mm mm mm mm t mm mm t mm mm

DRS 112 2,75 112 132 60 80 10 2,75 112 80 0,75 130 80

DRS 125 5,0 125 150 60 80 10 5,0 125 80 1,0 140 80

DRS 160 7,0 160 188 65 89 12 7,0 160 89 1,7 180 90

DRS 200 10,0 200 230 65 101 18 10,0 200 101 2,7 225 102

Travel wheel type D E F

Travel wheel with one flange





Hydropur

Wheel block size

Max. wheel

load 2)d1 1)

-0,2d2 b2

b1

2s

Max. wheel

load 2)d31)

-0,2b2

Max. wheel

load 2) d41) b2

t mm mm mm mm mm t mm mm t mm mm

DRS 112 2,75 112 132 80 30 10 2,75 126 80 0,59 130 68

DRS 125 5,0 125 150 80 30 10 5,0 145 80 0,79 140 68

DRS 160 7,0 160 188 89 32,5 12 7,0 183 89 1,18 180 75

DRS 200 10,0 200 230 101 32,5 18 10,0 226 101 1,7 225 86

4.1 Travel wheel types

Standard DRS112 – DRS200 designs

41618744.eps 41618844.eps 41618944.eps

41619044.eps 41619144.eps 41619244.eps

d 3

b2

4 Assembly and alignment

1) Travel wheel diameter

2) Max. wheel load in group of mechanisms 1Bm, 40 m/min, 40 °C



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4.2 Assembly instructions4.2.1 Top connection

Lock nut

Zinc-flake coated

threaded pin

Grade: 10.9

42092344.eps

x

Holes to accommodate

optional aligning pins

Sliding nut

DRS Part no. Dimensions in mm

wheel block a2 a3 a4 a17 d5 d12 d13 l1 l2 l3

size 1) min-max min-max

112 75362044 145 70 45+ 4

– 745 M12 14

14,5

65 18,5-19 8-25

125 75362044 170 86 55+ 4

– 755 M12 14 65 22,5-23 8-25

160 75252044 220 118 55+ 3

– 555 M16 18 75 24,5-25 15-25

200 75252044 275 175 65+ 3

– 565 M16 18 75 28,5-29 15-25

1) Part no. includes: Threaded pins and lock nut

T h r e a d

d e p t h

Fig. 1

Bore hole

arrangement



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4.2.1.1 Fitting universal shaft F for

top connection

41757644.eps 41757744.eps

Tools

Torque wrench, ring type, hexagon socket screw key, hexagon-socket offset screw

key

Preparation

• Drill bore holes in connecting structure according to bore hole arrangement

(see page 14, fig. 1.)

• The bore holes to accommodate the eccentric aligning arrangement are only

required in connection with the aligning device, part no. 752 100 44 (see section4.4 “Alignment”).

Assembly

• Screw the threaded pins by hand into the sliding nuts already fitted in the

factory until they stop, and then screw them back out by a quarter of a turn.

• Fit and tighten the lock nuts by hand (counter by holding the threaded pin).Then position and align the wheel block (see section 4.4 “Alignment”).

• Counter the threaded pins (by holding in place using the hexagon socket at

the end of the pin) and tighten the lock nuts with the corresponding tighteningtorque.

Tightening torque DRS 112/125 = 130 Nm

DRS 160/200 = 330 Nm

• After fitting, close all unused through holes with the plastic plugs included in the

supply.

Fitting universal shaft F

• Fit grooved ball bearing (5) onto drive shaft (1) and secure in the axial directionusing retaining ring (8).

• Fit the pre-completed shaft in bearing seat (3) and secure using retaining

ring (7).

• Then assemble entire shaft unit with connecting plate (2) and secure using

retaining ring (6). (Compensate axial play with shims (9/10)).

• Remove lock nut (11) of the housing/cover connection.

• Centre the drive shaft unit on the wheel block using two split sleeves (4) and

bolt together as a unit using the wheel block housing bolts.

• Finally counter the drive shaft unit with lock nuts (11).

Tightening torque DRS 112/125 = 36 Nm

DRS 160/200 = 72 Nm

DRS Dimensions in mm

wheel

blockD1 D2 L1 L2 L3

size f8

112 45

90

182 74 36

125 55 195 78

38

160 65

120

235 85

200 75 305 95 53

Wheel block in basic design A30/112 – A35/125 – A45/160 – A50/200

•



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1 Roll pin → fitted in wheel block in the factory2 Flanged washer

3 Washer

4 Hexagon bolt

5 Lock nut

41619544.eps

4.2.2 Side connection

d14

l1

c3c4

d8

a5

d9

a6

h 4 a

7

a 8

C

C

C -C

42092044.eps

Bore hole arrangement

Wheel centre

MA/NA

A

1) Part no. includes: collared sleeve and dacromatised bolted fastening parts

2) Torque bracket for pin connection


wheel block a5 a6 a7 a8 c3 c4 d8 d9 d14 h4 l1

size 1) ± 0,1 ± 0,1 ± 0,1 ± 0,1 min-max D9 min-max

112 75362244 145 145 30 40 20-23 10,4 10,5 18,5 50 47 12-15

125 75222244 175 175 20 40 24,5-27,5 12 13 21 60 53,5 15-18

160 75252244 220 220 25 55 35,5-41,5 14,5 16,5 3080

70 14-20

200 75302244 275 275 35 75 38,5-43,5 19 20,5 35 90 20-25

(only for drive on side plate side)

Drive on wheel block side (W1)

Drive on side plate side (W2)(wheel block only in MA basic

design)

2)



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Tools

Torque wrench

Assembly• When the hexagon bolts are tightened, the roll pins fitted in the upper part of the

wheel block are pulled into the mounting plate of the steel support structure by

the flange washers. The bevel on the roll pins must face towards the connecting

structure.

• Then fit two further hexagon bolts to the lower part of the wheel block withwashers on both sides.

Tightening torque DRS 112 = 55 Nm,

DRS 125 = 95 Nm

DRS 160 = 230 Nm

DRS 200 = 450 Nm

• After fitting, close all unused through holes with the plastic plugs included in thesupply.


side connection

41757944.eps41757844.eps


wheel

blockD1 D2 L1 L2 L3

size f8

112 45

90

182 74 36

125 55 195 78

38

160 65

120

235 85

200 75 305 95 53


Note

For DRS125 units, the protruding housing / cover bolted connection must be

replaced with the enclosed shorter cheese head screws with hexagon nuts.

• Fit grooved ball bearing (5) onto drive shaft (1) and secure in the axial direction

using retaining ring (8).

• Fit the pre-completed shaft in bearing seat (3) and secure using retaining

ring (7).

• Then assemble entire shaft unit with connecting plate (2) and secure usingretaining ring (6). (Compensate axial play with shims (9/10)).

• Remove both upper lock nuts from the wheel block.

• Push the drive shaft unit onto both upper hexagon bolts.

• Finally fix the drive shaft unit in place using the two adapter nuts (4) and the bolt

retaining arrangement included in the supply;

Tightening torque DRS 112 = 55 Nm

DRS 125 = 95 Nm

DRS 160 = 230 Nm

DRS 200 = 450 Nm



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4.2.3 DRS 200 side connection with AD. 50/WU. 60 gearboxes

d14

d8

a5 d9

a6

a 7

a 8

C - C

c6

l1

c5

c3 c4 C

C

42092146.eps

Bore hole arrangement of the connecting structure

MA/AA

1) Part no. includes: pins, spacer sleeve, retaining elements and zinc-flake coated bolted fastening parts

2) Part no. includes: collared sleeves, adapter sleeve, retaining elements and zinc-flake coated bolted fastening parts

(only for drive on side plate side)

Drive on wheel block side (W1)


wheel

blocka5 a6 a7 a8 c3 c4 c5 c6 d8 d9 d14 h4 l1

size ± 0,1 ± 0,1 ± 0,1 ± 0,1 min-max min-max H13 min-max

200MA/NA 75302244 1)

275 275 35 7538,5-43,5

1938,5-43,5

33 20,5 35 D9 80 90 20-25A 75302644 2) 39-44 33-38



19 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

41833644.eps

1 Roll pin → fitted in wheel block in the factory

2 Component parts→ included in the “torque bracket set”

3 Retaining ring

4 Shim

5 Thrust washer

6 Hexagon socket screw

7 Adapter sleeve

8 Flanged washer

9 Hexagon bolt

10 Washer 11 Washer

12 Lock nut

Tools

Torque wrench

Assembly

• When the hexagon bolts are tightened, the roll pins fitted in the upper part of the

wheel block are pulled into the mounting plate of the steel support structure by

the flange washers. The bevel on the roll pins must face towards the connecting

structure.

• Then fit two further hexagon bolts to the lower part of the wheel block with

washers on both sides.

Tightening torque DRS 200 = 450 Nm

• After fitting, close all unused through holes with the plastic plugs included in the

supply.



20 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

4.2.4 DRS 112 – 200 pin connection

42278544.eps

42278644.eps

Drive side Non-driven side

42279344.eps42279044.eps

Bore hole arrangement

Hollow profile section to DIN 59410/59411

1) See section 4.2.6.1 for use of threaded pins or distance elements.

41752544.eps

Wheel centre

Wheel centre

Wheel centre

1)

1)

Bore hole

arrangement for

side with welded

plate

Welded plate Connecting

structure

1

)

1)

1

)

(without tolerance)

Assembly bore hole forcentral drive arrangement


wheel block a4 a5 a7 a8 a9 a10 a11 a12 a13 a14 a15 a16

size 1) ± 0,05 ± 0,1 1) ± 0,1 ± 0,1 ± 0,1 ± 0,1 ± 0,1 ± 0,1

112 148 145 52 40 64 10 – 50 60 – 79 93

125 162 175 60 40 72 41 10 58,5 68,5 92 77,5 108

160 206 220 70 55 90 56 12 75 90 110 97,5 135

200 266 275 90 75 118 70 10 105 115 140 120 168



21 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

42278744.eps

42279144.eps 42279244.eps

without welded plate with welded plate:

suitable for aligning pin sets (L) or bolting

MA./MW torque brackets

see section 4.2.6.3 for welded plate

1) See section 4.2.6.1 for use of threaded pins or distance elements.

2) Check l1 dimension, see section 4.2.6.2 pin set.

3) See section 4.2.6.2 pin set.

1)

3) 3)

see section 4.2.6.3 for welded plate

Dimensions in mm DRS

a18 c1 d9 d10 d14 d15 d16 l1 2) l2 Hollow profile section to DIN wheel block

3) D9/h8 1) min max min a19 a20 size

75 96 18,5 20 50 M10 M8119,5 127,5

8 200 x 120 x 8 24 47 112129,2 137,2

74 98 21 23 60 M10 M8119,0 127,0

8 200 x 120 x 8 24 54 125128,2 140,2

86 110 30 32 80 M12 M10138,0 150,0

10 260 x 140 x 10 30 70 160150,2 160,2

103 130 35 38 80 M12 M10

170,0 182,0

10 260 x 180 x 10 30 90 200182,2 194,2



22 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

4.2.5 Pin connection B

DRS 200 with AD.50/WU.60 gearboxes

42091846.eps

Wheel centre

Note: See section 4.2.6.1 for fitting distance elements

1) Check l1 dimension, see section 4.2.6.2 pin set.

2) See section 4.2.6.2 for pin set

2)

Pin connection B

A

without welded plate with welded plate

Wheel centre

A

Pin connection B

Bore hole arrangement for A Bore hole arrangement for A (welded plate side)


wheel block a5 a7 a8 a18 a19 a20 c1 d9 d10 d14 l1 1) l2

size ± 0,05 D9 max min

200 275 90 75 108,5 127 168 130 35 38 80 194 10



23 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

The track gauge can be changed using interchangeable distance elements.

Standard assignments and maximum adjustment are shown in the table.The distance elements must be secured during transport to prevent them from

being lost.

Spacer plate

Spacer plates

Thrust washer

(compensate play

with shims)

Pin

Retaining ring

The zinc-flake coated threaded pins are used to align the alignable pin connection

and then to fix the wheel block in the axial direction.

41758944.eps

1) Part no. includes per DRS: 4 threaded pins and 4 lock nuts

2) DRS 200 with AD50/WU60 gearbox only possible with spacer plates, see page 27

Spacer plates

Threaded pins

1 Pin

2 Threaded pin

3 Lock nut

4 Retaining ring5 Thrust washer

6 Shim7 Spacer plate

Adjusting the track gauge with

threaded pin and lock nut


distance elements

41758844.eps

DRS Part no.

Set 1)

Threaded pin grade:

45 H

Tightening torque

nut (3)

112 / 125 752 147 44 M10 x 40 60 Nm

160 / 200 2) 752 148 44 M12 x 50 104 Nm

Dimensions in mm Set per DRS consisting of

DRS Part no. l max b max Max. adjustment range Number and thickness

112 752 139 44 111 7,5 ± 7 2 x 2mm + 2 x 3mm + 2 x 5mm

125 752 140 44 114 8 ± 7,5 2 x 2mm + 2 x 3mm + 2 x 5mm

160 752 141 44 130 10 ± 9,5 3 x 2mm + 2 x 3mm + 2 x 5mm

200 752 142 44 162 16 ± 15,5 4 x 2mm + 2 x 3mm + 4 x 5mm

41758744.eps

4.2.6 Fitting the wheel block

4.2.6.1 Axial retaining arrangement

with track gauge adjustment

not included in scope of supply

42275744.eps



24 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

4.2.6.2 Pin set

41751344.eps

Pin set DRS 200 with AD50 / WU60 gearbox

41752644.eps

1) Pin set for the driven type.

DRS Part no. Type Weight Materials Surfaceprotection

Dimensions in mm

wheel

blockDIN EN 10083

dD9 /

h8l

l1 Washers 4 x shaft

retainers

DIN 471size kg min. max. 1 2 2,5 3 3,5

112753 737 44 S 00,6 42CrMo4+QT

Pin surface

Zinc-flake

coated

18,5143,5 119,5 127,5

4 8 – – – 18 x 1,5753 738 44 L 00,7 36NiCrMo16+QT 153 129,2 137,2

125752 337 44 S 00,8 42CrMo4+QT

21143,5 119,0 127

48

– – – 20 x 1,75752 338 44 L 00,9 36NiCrMo16+QT 161 128,2 140,2 12

160752 637 44 S 02,0 42CrMo4+QT

30168 138,0 150

412

– – – 30 x 2752 638 44 L 02,1 42CrMo4+QT 178 150,2 160,2 10

200753 137 44 S 03,2 42CrMo4+QT

35202 170,0 182

4 12 – – – 35 x 2,5753 138 44 L 03,4 42CrMo4+QT 214 182,2 194,2

DRS Part no. Type Weight Materials Surface protection Dimensions in mm

wheel

blockDIN EN 10083 d

D9 / h8

D l

l1 Washers 2x shaft

retainers

DIN 471size kg min. max. 1 2

200752 947 44

1)L 03,9 42CrMo4+QT Pin surface zinc-flake coated 35 40 235,5 170 194

2 x Ø402 x Ø35

24 x Ø35Ø35 x 2,5Ø40 x 2,5



25 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

Tools

Torque wrench, hexagon socket key

PreparationDrill holes (bore holes must be free of paint) in the connecting structure (hollowprofile section or similar) according to the above bore hole arrangement taking

the basic types (NA, A, MA) into consideration.

4.2.6.3 Fitting pin connection (without welded plate)

• Fit the wheel block into the prepared hollow profile section and connect with

the pin.

• Fit the retaining rings and thrust washers included in the supply to secure

against axial movement and to fix the connecting pin in position free of play.

Adjusting the track gauge with threaded pin and lock nut:

(Not possible for DRS 200 with AD50/WU60)

• Turn threaded pins (2) into the hollow profile above the pin. Counter threadedpins (2) and secure with lock nuts (3).

Tightening torque for M8 = 36 Nm, M10 = 65 Nm.

Adjusting the track gauge with distance elements:

• Fit distance elements (7).

Fit the geared motor unit (with torque bracket fitted as in section 5) by bolting the

complete drive to the hollow profile section using the retaining bolts included in thesupply.

4.2.6.4 Fitting pin connection (with welded plate)

• Fit the wheel block into the prepared hollow profile section and connect with the

pin.

• Place welding plate onto the correspondingly drilled side.

• Fit the retaining rings and thrust washers included in the supply to secure

against axial movement and to fix the connecting pin in position free of play.

• Align the wheel block.

• Fix welding plate by tacking and then weld in accordance with the welding in-structions (fig. 1).

Adjusting the track gauge with threaded pin and lock nut:

(Not possible for DRS 200 with AD50/WU60, see page 27)

• Turn threaded pins (2) into the hollow profile above the pin. Counter threaded

pins (2) and secure with lock nuts (3).

Tightening torque for M8 = 36 Nm, M10 = 65 Nm.

Adjusting the track gauge with distance elements:

••Fit distance elements (7).

Welding instructions for welding

plate

Weld seam thickness a: DRS 112/125 = 3 mm DRS 160/200 = 4 mm

41759144.epsFig. 1

1 Pin

2 Threaded pin

3 Lock nut

4 Retaining ring5 Thrust washer

6 Shim7 Spacer plate


threaded pin and lock nut


distance elements

41758844.eps41758744.eps



26 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

4.2.6.6 Fitting pin connection with

distance plates

DRS 200 – AD50/WU60

41759044.eps

Assembly

• Place the wheel block in the completed hollow profile.

• Variant with welded plate:

Place the welding plate on the correspondingly drilled side and secure, usingpins. Align the wheel block. Fix welding plate by tacking and then weld in ac-

cordance with the welding instructions (see page 25, fig. 1).

Variant without welded plate:

Secure using pins

• Fit retaining rings and thrust washers to secure the pin in the axial direction andfix it in position with little play on the non-driven side (small pin diameter).

• Fit distance plates

• Fit the geared motor (with torque bracket fitted as in section 5) on the large pin

diameter and then fit retaining rings and thrust washers.


pin connection

41758144.eps41758044.eps


• Fit grooved ball bearing (5) onto drive shaft (1) and secure in the axial direction

using retaining ring (8).

• Fit the pre-completed shaft in bearing seat (3) and secure using retainingring (7).

• Then assemble entire shaft unit with connecting plate (2) and secure using re-

taining ring (6). (Compensate axial play with shims (9/10)).

• Remove retaining rings (13), thrust washers (12) and lock nuts (11) from the

existing pin connection.

• Push drive shaft unit onto the two pins.

• Then fit thrust washers (12) and retaining rings (13) again.

• Fit lock nuts (11).


wheel

blockD1 D2 L1 L2 L4 L5

size f8 max

112 45

90

182 74

12

127

125 55 195 78 130

160 65

120

235 85

12

148

200 75 305 95 182



27 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

Assembly

• Weld end connection to the existing structure according to welding instructions

on page 28.

• Fit wheel block in end connection and secure using pins.

• For the driven variant: place the welding plate on the corresponding side and

weld according to welding instructions (see page 25, fig. 1).

• Fit retaining rings and thrust washers to secure the pin in the axial direction and

fix it in position with little play.

• Fit distance elements (7).

Fitting end connection with distance plates with DRS 200-AD50/WU60, see

section 4.2.6.6.

41644555.eps

4.2.6.7 Fitting end connection with

distance plates

41759744.eps

4.2.6.8 Fitting torque brackets for

pin and end connection

DRS 112 – 200

Tightening torque

see section 5.1

The geared motor (with torque bracket fitted as described in section 5) is fitted

by bolting the complete drive to the welded-on plate using the enclosed locking

bolts (1) for DRS 112/200.

Fit the geared motor (with torque bracket fitted as in section 5) on thelarge pin diameter and then fit retaining rings and thrust washers.

41850444.eps

4.2.6.9 Fitting torque brackets for pinand end connection

DRS 200 AD50 / WU60

1



28 2 1 4 2 7 6 k 2 . i n

d d / 1 6 0 4 0 8

41756744.eps

not included in scope of supply

Bore hole arrangement for alignable end connection and axial securing arrangement with threaded pins (by the

customer)

41681444.eps


wheel block a4 a6 a9 d10 d15

size

112 148 145 64 20M 10

125 162 175 72 23

160 206 220 90 32M 12

200 266 275 118 38

Side withwelded plate

drilled by the customer

4.2.7 DRS 112 – 200 end connection

End connection dimensions

DRS Part no. Dimensions in mm Options

wheel

blocka5 a6 a7 a8 a16 d9 d14 b1 b2 h l t1 t2 w1 w2 w3

Welded

plate

Pin set Spacer

plate set

size 1) 1) 1)

112 A

753 714 44 145 7 45 40 93 18,5 50 30 111 150 223 8 7 3 4 4753 829 44 753 738 44

752 139 44NA/MA – 753 737 44

125 A

752 314 44 175 8 54 40 110 21,0 60 40 111 200 265 8 8 3 4 4752 429 44 752 338 44

752 140 44NA/MA – 752 337 44

160 A

752 614 44 220 10 70 55 140 30,0 80 50 129 250 330 8 10 4 4 5752 729 44 752 638 44

752 141 44NA/MA – 752 637 44

200 A

753 114 44 275 10 90 75 170 35,0 80 50 154 300 395 8 10 4 4 5753 229 44 753 138 44

752 142 44NA/MA – 753 137 44



29 2 1 4 2 7 6 k 2 .

i n d d / 1 6 0 4 0 8

4.3 Manufacturing tolerances ofcrane runways

S m i n

S

S m a x

41409444.eps

- B - B

+ B

20002 0 0 0

2 0 0 0

b

b b

41409544.eps

2 0 0 0

- C

+ C

2000

2 0 0 0

c

c

c

41409644.eps

s

E

+ E

41409744.eps

Source: VDI 3576 Recommendation: Tolerance class 2

41760144.eps

End connection with drive example

Tolerance Crane runways

Designation Diagram Tolerance class 1 Tolerance class 2 Tolerance class 3

Tolerance A

of track gauge dimension s of cra-

ne rails with reference to the rail

centre and crane runway length

Smax = s + A Smin = s - A

for s ≤ 16 m:

A = ± 3 mm

for s > 16 m:

A = ± [3 + 0,25 (s - 16)]

A in mm

use s in m

for s ≤ 16 m:

A = ± 5 mm

for s > 16 m:

A = ± [5 + 0,25 (s - 16)]

A in mm

use s in m

for s ≤ 16 m:

A = ± 8 mm

for s > 16 m:

A = ± [8 + 0,25 (s - 16)]

A in mm

use s in m

Tolerance B

of the lateral straightness of the

rail head with reference to the

crane runway length.

Tolerance b

of the lateral straightness with

reference to 2000 mm measured

length (sample length) at any side

of the rail head

Position of a rail seen in plan

B = ± 5 mm

b = 1 mm

B = ± 10 mm

b = 1 mm

B = ± 20 mm

b = 2 mm

Tolerance C

of the straightness with reference

to the height of the crane rail

centre and crane rail lengthTolerance c

of the lateral straightness with

reference to 2000 mm measured

length (sample length) at any side

of the crane runway Position of a rail seen in elevation

(longitudinal slope)

C = ± 5 mm

c = 1 mm

C = ± 10 mm

c = 2 mm

C = ± 20 mm

c = 4 mm

Tolerance E

of the height with reference to

perpendicular measuring points at

every point of the crane runway.

Position of runway in relation to oneanother in elevation (transverse slope)

E = ± 0,5‰ x s

in mm

use s in mm

Emax = ± 5 mm

E = ± 1‰ x s

in mm

use s in mm

Emax = ± 10 mm

E = ± 2‰ x s

in mm

use s in mm

Emax = ± 20 mm



30 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8

5.1 Torque brackets for individual

and central drive units

5.1.1 A type offset gearboxes / W type angular gearboxes

5 Assembling drive elements

Step 1:

Fitting the torque bracket to the geared motor

Example illustrations:

Offset gearbox

Angular gearbox Before bolting on the torque bracket, check whether

depending on the mounting position of the gearbox, the

fastening screws of the second step (if covered by thegearbox) must already be inserted in the corresponding

bore holes of the torque bracket prior to fitting the torque

bracket to the gearbox.

Tightening torques All screws are coated with a micro-encapsulated layer and must only be used once!

Step 1 4 screws

T o r q u e

b r a c k e t

a.) Hexagonal socket screws with packing plate

b.) Locking bolt

Offset gearbox

MA112-1 23 Nm a.) M8x35

MA125-1 23 Nm a.) M8x35

MA125-2 20 Nm b.) M10x20

MA160-1 23 Nm a.) M8x35

MA160-2 20 Nm b.) M10x20

MA200-1 20 Nm b.) M10x20

Winkelgetriebe

MW112-1 42 Nm b.) M8x25

MW125-1 42 Nm b.) M8x25

MW125-2 85 Nm b.) M10x30

MW160-1 85 Nm b.) M10x35

MW160-2 130 Nm b.) M12x35

MW200-1 85 Nm b.) M10x35

MW200-2 130 Nm b.) M12x35

MW200-3 330 Nm b.) M16x35

b.)

a.)

42754544.eps

b.)

42754644.eps

42754744.eps



31 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8

Step 2:

Fitting the geared motor with torque bracket to the wheel block or connecting structure

Example illustrations:

1) After having tightened the nuts, check the bolted connections of the wheel block

Step 2 4 or 6 bolts/nuts

T o r q u e

b r a c k e t

Fitted with lock nuts

directly to the driven wheel block Fitted with locking bolts to the connecting structure

Offset gearboxM8 / 35 Nm M8x20 / 35 Nm

M10 / 65 Nm M10x25 / 75 Nm

for angular gearbox

M8 / 35 Nm M8x20 / 35 Nm

M10 / 65 Nm M10x25 / 75 Nm

M10 / 85 Nm 1) M10x25 / 85 Nm

Tightening torques All screws are coated with a micro-encapsulated layer and must only be used once!

Lock nut

Connecting structure

Locking bolt

42754844.eps

42755044.eps 42755144.eps



32 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8

5.1.2 A 50 type offset gearboxes Fitting for top, side and pin connection arrangements

MA200-2 torque bracket connection

42115144.eps

42115244.eps

1 Offset gearbox

2 Torque bracket

3 Locking bolt

1 Offset gearbox

4 Pin (adapter sleeve for side con-

nection)

5 Polyamide collared sleeve

6 Polyamide washer

7 Thrust washer (40 x 58 x 2,5)

Note outer diameter of 58 mm

8 Thrust washer

9 Retaining ring

10 Shim

11 Shim

12 Retaining ring

123

15410812

4

6 711

9 6 711

9

10812

Assembly

• Remove corrosion protection and paint from contact surface of gearbox and torque bracket.

• Fit torque bracket (2) to gearbox (1) using locking bolts (3) included in the supply.

Assembly

• Insert pin (4) into wheel block and secure against axial movement with thrust washers (8), shims (10) and retaining ring (12).

• Place polyamide collared sleeves (5) and drive unit (1) onto pin (4).

• Fit polyamide washer (6), thrust washer (7), shim (11) and retaining ring (9) in the sequence indicated.

Tightening torque 130 Nm

Size Torque bracket Locking bolt (3)

Wheel block Gearbox Number Dimensions

DRS 200 AD 50 MA200-2 8 M12x25



33 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8

5.1.3 W 60 type angular gearboxes Fitting for top, side and pin connection arrangements

MW200-4 torque bracket connection

42116744.eps

1 Angular gearbox

2 Torque bracket

3 Locking bolts

Assembly

• Remove corrosion protection and paint from contact surface of gearbox and torque bracket.

• Fit torque bracket (2) to gearbox (1) using locking bolts (3) included in the supply.

42116644.eps

Assembly

• Insert pin (4) into wheel block.

• Place polyamide collared sleeves (5) and drive unit (1) onto pin (4).

• Fit polyamide washer (6), thrust washer (7), shim (11) and retaining ring (9) in the sequence indicated.

• Secure pin (4) against axial displacement with thrust washers (8), shims (10) and retaining ring (12) on the second side.

123

4 5

1

6 711

9911

764108

12108

12 1 Angular gearbox

4 Pin (adapter sleeve for side

connection)

5 Polyamide collared sleeve

6 Polyamide washer

7 Thrust washer (40 x 58 x 2,5)

Note outer diameter of 58 mm

8 Thrust washer

9 Retaining ring

10 Shim

11 Shim

12 Retaining ring

Tightening torque 130 Nm

Size Torque bracket Locking bolt (3)

Wheel block Gearbox Number Dimensions

DRS 200 WU 60 MW200-4 8 M12x25



34 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8

5.2 Individual drive units

Journal shaft on one side with involute splines

41807044.eps

5.2.2 W type angular gearboxes

41807355.eps

Clean drive shaft before fitting, check splined profile section and grease with grease

(Klueber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).

Assembly

Connect travel drive (2) with wheel block (1) as described in section 5.1.

Assembly

Connect travel drive (2) with wheel block (1) as described in section 5.1.

1 2

After fitting an angular gearbox type W 50, check the

bolted connections of the wheel block for the correct

tightening torque (72 Nm).

5.2.1 A type offset gearboxes





35 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8

5.3 Central drive units

41806944.eps

41807144.eps

Assembly

• Connect travel drive (2) with wheel block (1) as described in section 5.1.

Journal drive shaft arrangements do not need to be secured against axial displacement. Hollow drive shaftarrangements (12) must be secured against axial displacement by fitting retaining rings (8/9) and thrust washers (7/13)

as well as spacer ring (10) included in the supply.

• Insert roll pin (5) into connector (4).

• Slide connector (4) onto drive shaft (11/12).

• Insert central drive shaft (6) into wheel block (3).

• Place spacer rings (10) onto central drive shaft (6) and push the shaft into the connector until it stops against the roll

pin.

• Determine the quantity of spacer rings (10) required until the retaining ring groove is reached.

• Secure central drive shaft (6) against axial displacement by fitting retaining ring (9).

Drive arrangement: Hollow shaft with solid shaft

8 7 1013 9

12

11 5 4 6 9 10

Drive arrangement: Journal shaft on both sides with involute splines

5.3.1 A type offset gearboxes

41833844.eps

10

7

8

9

13

12





36 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8


41807255.eps

41807444.eps


Assembly

• Connect travel drive (2) with wheel block (1) as described in section 5.1.

Journal drive shaft arrangements do not need to be secured against axial displacement. Hollow drive shaft

arrangements (12) must be secured against axial displacement by fitting retaining rings (8/9) and thrust washers (7/13)

as well as spacer ring (10) included in the supply.


• Slide connector (4) onto drive shaft (11/12).

• Insert central drive shaft (6) into wheel block (3).

• Place spacer rings (10) onto central drive shaft (6) and push the shaft into the connector until it stops against the rollpin.

• Determine the quantity of spacer rings (10) required until the retaining ring groove is reached.• Secure central drive shaft (6) against axial displacement by fitting retaining ring (9).

7 10 2 12 13 98

11 5 4 6 9 10

2 3

1

After fitting an angular gearbox type W 50, check the bolted connections of the wheel block for

the correct tightening torque (72 Nm).


41833944.eps

10

7

8

12

13

9





37 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8

11 5 4 6 9 10

14 15

32

1

42753044.eps

Dimensions L1 and L2 for the length

of the shaft protection tube

5.4 Central drive units with shaft protection5.4.1 A type offset gearboxes

42065846.eps

41833844.eps

Assembly of central drive unit with shaft protection

• Connect travel drive (2) with wheel block (1) as described in section 5.1. Journal drive shaft arrangements do not need

to be secured against axial displacement. Hollow drive shaft arrangements (12) must be secured against axial displace-

ment by fitting retaining rings (8/9) and thrust washers (7/13) as well as spacer ring (10) included in the supply.


• Slide connector (4) onto drive shaft (11/12) and determine distance L1.

• Cut shaft protection tube (14) to length L1 + 10%.

• Remove connector (4) again and slide on tube (14).

• Insert central drive shaft into wheel block (3) and slide connector (4) back onto the shaft (11/12).

• Place spacer rings (10) onto central drive shaft (6) and push the shaft into the connector until it stops against the roll pin.

Determine the quantity of spacer rings (10) required until the retaining ring groove is reached.

• Determine distance L2 and cut shaft protection tube (15) to length L2 +10%.

• Push through central drive shaft (6) in the direction of wheel block (3) and slide on cut shaft protection tube (15) over theshaft.

• Slide back central drive shaft (6) until reaching stop in connector (4) and secure against axial displacement by fitting

spacer rings (10) and retaining ring (9).


8 7 1013 9

12


10

7

8

9

13

12

41807144.eps


(e.g. Klueber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).



38 2 1 4 2 7 6 k 3 . i n

d d / 1 6 0 4 0 8

11 5 4 6 9 10

2 3

1

14 15


42065946.eps

41807444.eps


7 10 2 12 13 98


Assembly of central drive unit with shaft protection

• Connect travel drive (2) with wheel block (1) as described in section 5.1. Journal drive shaft arrangements do not need to

be secured against axial displacement. Hollow drive shaft arrangements (12) must be secured against axial displacement

by fitting retaining rings (8/9) and thrust washers (7/13) as well as spacer ring (10) included in the supply.


• Slide connector (4) onto drive shaft (11/12) and determine distance L1.

• Cut shaft protection tube (14) to length L1 + 10%.

• Remove connector (4) again and slide on tube (14).

• Insert central drive shaft into wheel block (3) and slide connector (4) back onto the shaft (11/12).

• Place spacer rings (10) onto central drive shaft (6) and push the shaft into the connector until it stops against the roll pin.

Determine the quantity of spacer rings (10) required until the retaining ring groove is reached.

• Determine distance L2 and cut shaft protection tube (15) to length L2 +10%.

• Push through central drive shaft (6) in the direction of wheel block (3) and slide on cut shaft protection tube (15) over the

shaft.

• Slide back central drive shaft (6) until reaching stop in connector (4) and secure against axial displacement by fitting

spacer rings (10) and retaining ring (9).

41833944.eps

10

7

8

12

13

9

Clean drive shaft before fitting, check splined profile section and grease with grease(e.g. Klueber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).

42753044.eps

Dimensions L1 and L2 for the length

of the shaft protection tube



40 2 1 4 2 7 6 k 3 . i n

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DRS

wheel

block

size

Tightening

torquesDimensions in mm

in Nm

Locking bolt

1 2 3 xmin

xmax

a a7 bmin

bmax

b1 d h h1 h2 l l1 l3 m n

112 130 1 5 80,5 4,5 30 70 20,6 52 126,5 38,2 76 180 5 60 125 24,5

125 130 1 5 88 4,5 30 70 20,6 62 143 50 95,5 192 5 60 140 25,4

160 330 130 1 5 109 7,5 30 80 23,8 72 162 65 93,5 230 6 72 173,5 29

200 330 130 1 5 133 8 40 90 27 80 174 75 92 250 6 80 210 33

6 Fittings

Permissible horizontal load: Maximum 15 % of the wheel load.The guide roller arrangement as a solo component can transmit at least 20 % of

the permissible wheel load.

Ordering information:

If a guide roller arrangement is specified in the type key when ordering a single

wheel block, this is prepared for fitting before leaving the factory.

Exception: DRS 200 with top connection

The permissible horizontal force is limited to 10 % of the permissible wheel load.

DRS 112 – 200 with travel wheel type E

The permissible horizontal force is limited to 12 % of the permissible wheel load.

Rails with sloping head flank surfaces must not be used.

6.1 Horizontal guide rollers

DRS 112 – 200

6.1.1 Fitting to wheel blocks

42015744.epsk = Rail width

DRS 112 – 125 – 160 DRS 200

41641644.eps



41 2 1 4 2 7 6 k 3 . i n

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41641944.eps

Assembly

• Fit the washer with the wide slot facing downwards on the raised guide toprevent turning.

• Fit the pins with the flat-sided heads in the slot to prevent turning.

• Fit guide rollers to wheel block as shown above and tighten by hand.

• Tighten locking bolts (2/3) with specified tightening torque (see table).

• Adjust roller distance dimension “x” and align guide rollers to rail.• Tighten locking bolts (1) with specified torque (see table).

Fitting for wheel block not prepared before leaving the factory

If a wheel block is fitted with a roller guide arrangement at a later date, the

following additional measures must be carried out:

• Drill bore holes on cover side to diameter d4 and depth a8 and fit roll pins with

slot facing “upwards”.

• Subsequently fit two threaded inserts into the end face.

41641844.eps

d 4

a8

Rz63

x k x

DRS wheel block

Travel wheel typea

mm

Part no. Retrofitting set part no.

sizeHorizontal guide roller

assembly1)Fitted to wheel block 2) Fitted to connecting structure 1)

112B 81 753 610 44 753 611 44 753 610 44

E 87 753 710 44 753 711 44 753 710 44

125B 88 752 210 44 752 211 44 752 210 44

E 98 752 310 44 752 311 44 752 310 44

160B 109 752 510 44 752 511 44 752 510 44

E 119 752 610 44 752 611 44 752 610 44

200B 133 753 010 44 753 011 44 753 010 44

E 145 753 110 44 752 111 44 753 110 44

1) Part no. includes roller guide arrangement and bolted fastening parts

2) Part no. includes roller guide arrangement, threaded sleeves and roll pins

Roll pin

(slot faces upwards)

Locking bolt 1

Locking bolt 3

Locking bolt 2

Threaded insert

Washer

Pin

Size

Tightening torques

Locking boltDimensions in mm

1 2 3 xmin

xmax

a8 d4

DRS 112 130 Nm 1 5 35 13

DRS 125 130 Nm 1 5 35 18

DRS 160 330 Nm 130 Nm 1 5 40 23

DRS 200 330 Nm 130 Nm 1 5 45 28



42 2 1 4 2 7 6 k 3 . i n

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6.1.2 Fitting to steel superstructure Permissible horizontal load: Maximum 20% of the wheel load

41679055.eps 41679155.eps

→ Drill out holes for roll pins to d5

H12 after fitting.

Wheel block

size

Dimensions in mm

a a1 a2 a3 a4 a5 a6 a9 a10 a11 d1 d2 d3 d5

DRS 112 40 – 48 22 40 76 102 – – – 13 6 12,5 8

DRS 125 50 – 56 20,5 38,5 95 113 – – – 13 6 12,5 8

DRS 160 54 – 58 26 49,5 93,5 148,5 – – – 13 8 16,5 10

DRS 200 62 22 62 28 54 92 157 16 132 36 13 10 16,5 12

d2

d 1

a 6

a 5

a2

a d 2

d

3

a 4

a 3

a 6

a 1 0

a 5

d 3

d 1

d 2

a 9 a

3 a 1 1 a

4

a

a1

•



43 2 1 4 2 7 6 k 3 . i n

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41642444.eps

• Screw threaded pin (2) into

buffer (1) until max. dimension I2 is

reached.

• Screw buffer into threaded insert in

wheel block.

6.2 Buffer elements6.2.1 DPZ cellular foam buffer

Possible fitting arrangement to end of DRS 112 – 200 wheel blocks without horizontal guide roller arrangement

41671244.eps

DPZ cellular foam buffer DRS wheel

block sizeBuffer

Dimensions in mm

w/o guide rollers with guide rollers

d1 d2 l1 l2 Threaded pins (2)

112

125160

200

DPZ 070 70 65 70 26 M12 x 30 M12 x 55

DPZ 100 100 95 100 26 M12 x 30 M12 x 55

–DPZ 130 130 122 120 26 M12 x 30 M12 x 55

DPZ 160 160 155 150 40 M12 x 30 M12 x 55

41671744.eps

DPG rubber buffer

6.2.2 DPG rubber buffer

DRS wheel

block sizeBuffer

Dimensions in mm

w/o

guide rollers

with

guide rollers

d1 d2 l1 l2 Threaded pins (2)

112

125 160200

DPG 063 063 56 067 26 M12 x 30 M12 x 55

DPG 080 080 71 084 26 M12 x 30 M12 x 55

– DPG 100 100 90 105 26 M12 x 30 M12 x 55



44 2 1 4 2 7 6 k 3 . i n

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41642555.eps

To ensure uniform buffer impact with a

horizontal guide roller arrangement fit-

ted to only one wheel block, two shims,

type E2 must be fitted between the

buffer and wheel block on the opposite

side.

41642244.eps

41642344.eps

2 3 E1 1

• Remove the locking bolt and screw

threaded pin (2) up to max. dimen-

sion l4 into the tapped insert in the

wheel block.

• Tighten lock nut (3) on threaded pin

and counter using hexagon socket

(tightening torque 130 Nm).

• Fit shim, type E1, with the ribs facing

the wheel block side and screw the

buffer onto the threaded pin.

2xE2 1xE1

s 2

s 2 s

1

Stop

1) Only one type E2 shim required.

Fig. 11

Possible fitting arrangement to end of DRS 112 – 200 wheel blocks with horizontal guide roller arrangement

(figs. 11 – 12)

Fig. 12

DRS 112 – 200

Guide roller assembly including

spacer elements

DRS wheel

block sizeBuffer

l4

mm

112 / 125DPZ 070

11 ± 0,5DPZ 100

160 / 200

DPZ 070

14 ± 0,5DPZ 100

DPZ 130

DPZ 160

Buffer Shim type

E1 E2

s1 s2

DPG 63 / DPZ 70 14 10

DPG 80 / DPZ 100 20 12,5

DPZ 130 / DPG 100 25 16

DPZ 160 1) 15 21



45 2 1 4 2 7 6 k 4 . i n

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7 Maintenance

7.1 Maintenance

instructions

DRS wheel blocks

Owing to their design, DRS wheel blocks are maintenance free.

ZNA – ZBA – ZBF motors

See Operating instructions ident no. 214 228 44

AU – AD – AG – AF – AM offset geared motors


WU – WG – WF angular geared motors


Refer to the above mentioned operating instructions for information on gearbox

lubrication intervals, lubricants and quantities of lubricants.

Shafts

Lubrication interval: 10000 hours of operation, at least every 4 years.

Under extreme operating conditions (e.g. multiple shift op-

eration) shorter intervals (every quarter) must be selected.

Lubricant: Grease

Klueber Staburags NBU12 Alltemp or Fuchs Gleitmo

WSP 5040

Bolted connections

Bolted connections must be inspected annually.

Under extreme operating conditions (e.g. multiple shift operation) shorter intervals

(every quarter) must be selected.



46 2 1 4 2 7 6 k 4 . i n

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7.2 Travel wheel wear 7.2.1 Flange wear The wear indicator on the flange facilitates preventive inspections of the installation.

Travel wheel when new

41239444.eps 41239544.eps

7.2.2 Tread wear

41620844.eps

Travel wheels must be replaced when the following limit values are reached:

Worn travel wheel

s s

d 1

The travel wheel must already be replaced even if only one segment of the wear

indicator is open.

Nominal travel wheel

diameter

Minimum remaining flange width s Minimum travel wheel diameter d1 Max. difference in travel wheel diameters for coupled

wheels

Dimensions in mm

112 5,0 105,4 0,1

125 6,0 118,4 0,1

160 7,0 153,4 0,15

200 8,4 193,0 0,15

41620944.eps



47 2 1 4 2 7 6 k 4 . i n

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8 Removing and fitting travel wheels

7.3 Possible fault sources

41445544.eps 41445344.eps

Remove the travel wheel

Remove the travel wheel with the ball bearings.

Bolt the cover and housing together with the corre-

sponding tightening torque (see table below).

41458444.eps

41445444.eps

Wheel

block size

Tightening torque

DRS 112 36 Nm

DRS 125 36 Nm

DRS 160 72 Nm

DRS 200 72 Nm

Description of fault Possible cause of fault Fault elimination

Increased travel wheel wear

(tread or flange)

Wheel block is misaligned Re-align the wheel blocks

Rail is dirty Clean the rail

Running noises

Wheel block is misaligned Re-align the wheel blocks

Rail is dirty Clean the rail

Defective bearing Replace the travel wheel

Remove the cover

Undo the cover screws of the cover.

Lever off the wheel block cover using the recess on the side of the wheel

block housing without twisting the cover.

Fit the travel wheel with pre-assembled bearings into the wheel block

housing. Fit the wheel block cover using a rubber hammer by gently knock-

ing it evenly until it is flush with the wheel block.



48 2 1 4 2 7 6 k 4 . i n

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9 Forms

9.1 Forms for documenting

the installation

9.1.1 Type plates

41239044.eps

41239044.eps

41239044.eps

41239044.eps



49 2 1 4 2 7 6 k 4 . i n

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9.1.2 Type code

G e a r b o x s i z e fi t t e d :

A 1 0 . . . A 9 0

W 1

0 . . . W 1

0 0

N o g e a r b o x s p e c i fi e d :

I n d i c a t e X

G e a r b o x s i z e fi t t e d :

A 1 0 . . . A 9 0

W 1

0 . . . W 1

0 0

N o g e a r b o x s p e c i fi e d :

I n d i c a t e X

H o r i z o n t a l g u i d e r o l l e r s :

H

S t a n d a r d

X

i n d i c a t e s : N o g u i d e r o l l e r s

C o n n e c t i o n v a r i a n t :

K , W

, B

N o c o n n e c t i o n v a r i a n t :

i n d i c

a t e X

T r a v e l w h e e l t r e a d :

f o r t y p e s A a n d D :

s

e e s e c t i o n 4 . 1

f o r t y p e s B , C , E , F :

i n d i c a t e 0

T r a v e l w h e e l t y p e :

A , B , C , D

, E , F , S

B a s i c t y p e :

A . .

D r i v e n w

h e e l b l o c k ,

f o r t o r q u e b r a c k e t fi t t i n g

a n d i n d i c a t i o n o f h u b p r o fi l e s

M A . .

W h e e l b

l o c k a l s o d r i v e n a n d i n d i c a t i o n o f t h e

h u b p r o fi l e s

N A . .

N o n - d r i v

e n w h e e l b l o c k

W h e e l b l o c k s i z e 1 1 2 , 1 2 5 , 1 6 0

, 2 0 0 , 2 5 0 , 3 1 5 , 4 0 0 , 5 0 0

D e m a g w h e e l b l o c k s y s t e m

H o r i z o n t a l g u i d e r o l l e r s :

H

S t a n d a r d

X

i n d i c a t e s : N o g u i d e r o l l e r s

C o n n e c t i o n v a r i a n t :

K , W

, B

N o c o n n e c t i o n v a r i a n t :

i n d i c

a t e X

T r a v e l w h e e l t r e a d :

f o r t y p e s A u n d D :

s

e e s e c t i o n 4 . 1

f o r t y p e s B , C , E , F :

i n d i c a t e 0

T r a v e l w h e e l t y p e :

A , B , C , D

, E , F , S

B a s i c t y p e :

A . .

D r i v e n w

h e e l b l o c k ,

f o r t o r q u e b r a c k e t fi t t i n g

a n d i n d i c a t i o n o f h u b p r o fi l e s

M A . .

W h e e l b

l o c k a l s o d r i v e n a n d i n d i c a t i o n o f t h e

h u b p r o fi l e s

N A . .

N o n - d r i v

e n w h e e l b l o c k

W h e e l b l o c k s i z e 1 1 2 , 1 2 5 , 1 6 0

, 2 0 0 , 2 5 0 , 3 1 5 , 4 0 0 , 5 0 0

D e m a g w h e e l b l o c k s y s t e m

4 1 2 3 9 2 5 5 . e p s

4 1 2 3 9 2 5 5 . e p s



50 2 1 4 2 7 6 k 4 . i n

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9.2 Fax form

Fax order Simply copy, fill in and fax

To:

Fax no.

Contact

Company address (stamp)

Customer number (if known)

Company/Dept.

Street, no.

Town/post code

Contact

Tel./fax no.

Customer order no.:

Date

Delivery address (if different)

Company/Dept.

Street, no.

Town/post code

Notes

Required delivery date:

Signature

.......................................................................................................

Item Part no. Designation Quantity



51 2 1 4 2 7 6 k 4 . i n

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Ident. no.

Page 1

Issue 1204 EN

1 page(s)

# = Modifications compared

to previous issue

Class. no.

Reproduction in whole or in part only with prior consent of Demag Cranes & Components, D-58286 Wetter

715 IS 845

204 400 44

Hereby we,

Demag Cranes & Components GmbH

Antriebstechnik,

declare that the products

Demag DRS / RS wheel block

Demag LRS travel wheel system

of serial design are intended to be incorporated into machinery and that the ma-

chinery must not be put into service until the machinery into which these productsare to be incorporated has been declared in conformity with the provisions of the

following relevant regulations:

EC Machinery Directive 98/37/EC

Applied harmonised standards:

EN ISO 12100-1, 2 Safety of Machinery

Wetter, 1 December 2004

Place and date of issue

EC manufacturer’s declaration

Demag DRS / RS, LRS wheel blockin accordance with EC directive 98/37/EEC, Annex IIB

Normung

Subject to change. Not liable for errors or omissions.

ppa. Schulte ppa. Hoffmann

Technik Antriebstechnik GZ Handling Technology

#

#

#

#

#

#

#



Addresses

The current addresses of the sales of fices in Germany and the subsidiaries and

agencies worldwide can be found on the

Demag Cranes & Components homepage at

www.demagcranes.com ► Contact and Demag worldwide

demag drs maintenance

Documents