Assembly, installation and operating

instructions
DRS 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 4
0.4 Limitations of liability 5
0.5 Denitions 5
1 Safety 6
1.1 Symbol description 6
1.2 Intended use 6
1.3 Prohibited practises, improper use 6
1.3.1 Specication 6
1.3.2 Assembly 6
1.3.3 Environmental inuences 6
1.3.4 Maintenance 6
2 Brief technical description 7
2.1 Overview 7
2.2 Type designation key (example) for basic wheel blocks 8
2.3 Type plate 10
2.4 Paint nish 11
3 Receiving and storage 12
3.1 Checking goods on receiving 12
3.2 Transport 12
3.3 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: drives@demagcranes.com
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 17
4.2.3 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 24
4.2.6.3 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 26
4.2.6.7 Fitting end connection with distance plates 27
4.2.6.8 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 32
5.1.3 W 60 type angular gearboxes 33
5.2 Individual drive units 34
5.2.1 A type offset gearboxes 34
5.2.2 W type angular gearboxes 34
5.3 Central drive units 35
5.3.1 A type offset gearboxes 35
5.3.2 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 40
6.1.1 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 tting travel wheels 47
9 Forms 48
9.1 Forms for documenting the installation 48
9.1.1 Type plates 48
9.1.2 Type code 49
9.2 Fax form 50
EC manufacturers 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 appropriate
instructions 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 condentially. 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
specic 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 ofce 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 modication 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 modications 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 tting and use of spare parts or accessories which have
not been approved and unauthorized modication 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 dened 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 dened 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 dened as persons assigned by the owner to carry out
specic tasks.
Qualied personnel
Qualied personnel are dened 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 dened 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, accident
prevention regulations and operating conditions and who have proven their
qualications.
Experienced technician
Experienced technicians are dened as persons, who, owing to their technical
training and experience, have sufcient 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 Denitions
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1.3 Prohibited practises,
improper use
1.3.2 Assembly
1.3.3 Environmental inuences
1.3.1 Specication
1 Safety
1.1 Symbol description
The following symbols and recommendations indicate potential safety hazards or
causes of damage:
Hazard warning
This 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 instructions
are not complied with.
Follow these instructions at all times and be particularly vigilant and cautious.
Pass on safety instructions to all persons entrusted with working on the product
including the power supply.
In addition to the safety instructions, observe all general safety regulations and
codes 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 qualied 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 tting 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 modied 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 up
under 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 tting various travel wheel materials and shapes.
Weather-resistant due to surface powder coating (RAL 7001, silver grey).
Special paint nish available on request. For further details on the paint nish,
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 saves
time.
A damping element in the travel wheel reduces the load on the gearbox.
Sixth connection surface for tting (e.g. switching ag).
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 Demag
alignment 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 for
alignment, offers a lateral alignment
path of 3 mm.
The ange 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 tting 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 anges on both sides
B GJS (GGG) without ange
C Polyamide without ange, with larger diameter
D GJS (GGG) with ange on one side
E GJS (GGG) without ange, with larger diameter
F Hydropur without ange, with larger diameter
S Special travel wheel
Travel wheel tread b
1
:
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 tting
and indication of hub proles
MA . . Wheel block also driven
and indication of hub proles
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 and
a central drive unit
41239655.eps
1 DRS125-NA-A-47-K-X-X
2 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 and
2 individual drive units
1 DRS125-NA-A-47-K-X-X
2 DRS125-NA-A-47-K-X-X
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
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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 be
read off the second type plate or relevant ttings 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 nish
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 m before
leaving the factory.
Continuous coating quality is ensured by our works standard for wheel block
housings (ident. no. 012 326 99).
Special paint nish
For special paint nishes, wheel blocks can be supplied with a dual component
PUR nish coat at the request of the customer.
If the paint nish is to be applied by the customer, attention must be paid to the
works standard for special paint nish on powder-coated wheel block surfaces
(ident no. 012 328 99).
Acid-resistant paint nish
The surfaces of wheel blocks with a powder-coated nish may be used in environ-
ments with acid vapours without any treatment. Alternatively, a dual component
acid protection paint nish may be applied to appropriately pre-treated housings.
Wheel blocks must also be tted 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 specied 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-specic 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 uctuations, e.g. on a wooden support.
Unpacked wheel blocks must not be stacked on top of each other.
Note: Do not damage the paint nish.
Mechanical (scratches), chemical (acid, alkaline) or thermal (sparks,
welding beads, heat) damage will result in corrosion and failure of the
exterior protection.
3.2 Transport
Protect from heat Keep dry Fragile This 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 ange
Spheroidal graphite cast iron
Travel wheel without ange
Polyamide
Wheel block size
Max. wheel
load
2)
d1
1)
-0,2
d2 b1
max
b2 s
Max. wheel
load
2)
d1
1)
-0,2
b2
Max. wheel
load
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 ange
Spheroidal graphite cast iron
Travel wheel without ange
Spheroidal graphite cast iron
Travel wheel without ange
Hydropur
Wheel block size
Max. wheel
load
2)
d1
1)
-0,2
d2 b2
b1
2
s
Max. wheel
load
2)
d3
1)
-0,2
b2
Max. wheel
load
2)
d4
1)
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 instructions
4.2.1 Top connection
Lock nut
Zinc-ake 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
7
45 M12 14
14,5
65 18,5-19 8-25
125 75362044 170 86 55
+ 4
7
55 M12 14 65 22,5-23 8-25
160 75252044 220 118 55
+ 3
5
55 M16 18 75 24,5-25 15-25
200 75252044 275 175 65
+ 3
5
65 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, g. 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 section
4.4 Alignment).
Assembly
Screw the threaded pins by hand into the sliding nuts already tted 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 tightening
torque.
Tightening torque DRS 112/125 = 130 Nm
DRS 160/200 = 330 Nm
After tting, 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 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 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
block
D1 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 tted in wheel block in the factory
2 Flanged washer
3 Washer
4 Hexagon bolt
5 Lock nut
41619544.eps
4.2.2 Side connection
d14
l1
c3 c4
d8
a5
d9
a6
h
4a
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
DRS Part no. Dimensions in mm
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 30
80
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)
17 2
1
4
2
7
6
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0
8
Tools
Torque wrench
Assembly
When the hexagon bolts are tightened, the roll pins tted in the upper part of the
wheel block are pulled into the mounting plate of the steel support structure by
the ange washers. The bevel on the roll pins must face towards the connecting
structure.
Then t two further hexagon bolts to the lower part of the wheel block with
washers on both sides.
Tightening torque DRS 112 = 55 Nm,
DRS 125 = 95 Nm
DRS 160 = 230 Nm
DRS 200 = 450 Nm
After tting, close all unused through holes with the plastic plugs included in the
supply.
4.2.2.1 Fitting universal shaft F for
side connection
41757944.eps 41757844.eps
DRS Dimensions in mm
wheel
block
D1 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
Fitting universal shaft F
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 using
retaining 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 x 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
18 2
1
4
2
7
6
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8
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/A
A
1) Part no. includes: pins, spacer sleeve, retaining elements and zinc-ake coated bolted fastening parts
2) Part no. includes: collared sleeves, adapter sleeve, retaining elements and zinc-ake coated bolted fastening parts
(only for drive on side plate side)
Drive on wheel block side (W1)
DRS Part no. Dimensions in mm
wheel
block
a5 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
200
MA/NA 75302244 1)
275 275 35 75
38,5-43,5
19
38,5-43,5
33 20,5 35 D9 80 90 20-25
A 75302644 2) 39-44 33-38
19 2
1
4
2
7
6
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2
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0
8
41833644.eps
1 Roll pin tted 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 tted in the upper part of the
wheel block are pulled into the mounting plate of the steel support structure by
the ange washers. The bevel on the roll pins must face towards the connecting
structure.
Then t two further hexagon bolts to the lower part of the wheel block with
washers on both sides.
Tightening torque DRS 200 = 450 Nm
After tting, close all unused through holes with the plastic plugs included in the
supply.
20 2
1
4
2
7
6
k
2
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4
0
8
4.2.4 DRS 112 200 pin connection
42278544.eps
42278644.eps
Drive side Non-driven side
42279344.eps 42279044.eps
Bore hole arrangement
Hollow prole 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 for
central drive arrangement
DRS
Dimensions in mm
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
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2
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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 l
1
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 prole section to DIN wheel block
3) D9/h8 1) min max min a19 a20 size
75 96 18,5 20 50 M10 M8
119,5 127,5
8 200 x 120 x 8 24 47 112
129,2 137,2
74 98 21 23 60 M10 M8
119,0 127,0
8 200 x 120 x 8 24 54 125
128,2 140,2
86 110 30 32 80 M12 M10
138,0 150,0
10 260 x 140 x 10 30 70 160
150,2 160,2
103 130 35 38 80 M12 M10
170,0 182,0
10 260 x 180 x 10 30 90 200
182,2 194,2
22 2
1
4
2
7
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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 tting distance elements
1) Check l
1
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)
DRS Dimensions in mm
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
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2
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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-ake coated threaded pins are used to align the alignable pin connection
and then to x 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 ring
5 Thrust washer
6 Shim
7 Spacer plate
Adjusting the track gauge with
threaded pin and lock nut
Adjusting the track gauge with
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
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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 Surface
protection
Dimensions in mm
wheel
block
DIN EN 10083
dD9 /
h8
l
l1 Washers
4 x shaft
retainers
DIN 471
size kg min. max. 1 2 2,5 3 3,5
112
753 737 44 S 00,6 42CrMo4+QT
Pin surface
Zinc-ake
coated
18,5
143,5 119,5 127,5
4 8 18 x 1,5
753 738 44 L 00,7 36NiCrMo16+QT 153 129,2 137,2
125
752 337 44 S 00,8 42CrMo4+QT
21
143,5 119,0 127
4
8
20 x 1,75
752 338 44 L 00,9 36NiCrMo16+QT 161 128,2 140,2 12
160
752 637 44 S 02,0 42CrMo4+QT
30
168 138,0 150
4
12
30 x 2
752 638 44 L 02,1 42CrMo4+QT 178 150,2 160,2 10
200
753 137 44 S 03,2 42CrMo4+QT
35
202 170,0 182
4 12 35 x 2,5
753 138 44 L 03,4 42CrMo4+QT 214 182,2 194,2
DRS Part no. Type Weight Materials Surface protection Dimensions in mm
wheel
block
DIN EN 10083
d
D9 / h8
D l
l1 Washers
2x shaft
retainers
DIN 471
size kg min. max. 1 2
200
752 947 44
1)
L 03,9 42CrMo4+QT Pin surface zinc-ake coated 35 40 235,5 170 194
2 x 40
2 x 35
24 x 35
35 x 2,5
40 x 2,5
25 2
1
4
2
7
6
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8
Tools
Torque wrench, hexagon socket key
Preparation
Drill holes (bore holes must be free of paint) in the connecting structure (hollow
prole 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 prole section and connect with
the pin.
Fit the retaining rings and thrust washers included in the supply to secure
against axial movement and to x 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 prole 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).
Fit the geared motor unit (with torque bracket tted as in section 5) by bolting the
complete drive to the hollow prole section using the retaining bolts included in the
supply.
4.2.6.4 Fitting pin connection (with welded plate)
Fit the wheel block into the prepared hollow prole 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 x 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 (g. 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 prole 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.eps Fig. 1
1 Pin
2 Threaded pin
3 Lock nut
4 Retaining ring
5 Thrust washer
6 Shim
7 Spacer plate
Adjusting the track gauge with
threaded pin and lock nut
Adjusting the track gauge with
distance elements
41758844.eps 41758744.eps
26 2
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2
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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 prole.
Variant with welded plate:
Place the welding plate on the correspondingly drilled side and secure, using
pins. Align the wheel block. Fix welding plate by tacking and then weld in ac-
cordance with the welding instructions (see page 25, g. 1).
Variant without welded plate:
Secure using pins
Fit retaining rings and thrust washers to secure the pin in the axial direction and
x it in position with little play on the non-driven side (small pin diameter).
Fit distance plates
Fit the geared motor (with torque bracket tted as in section 5) on the large pin
diameter and then t retaining rings and thrust washers.
4.2.6.5 Fitting universal shaft F for
pin connection
41758144.eps
41758044.eps
Fitting universal shaft F
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 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 t thrust washers (12) and retaining rings (13) again.
Fit lock nuts (11).
DRS Dimensions in mm
wheel
block
D1 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
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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, g. 1).
Fit retaining rings and thrust washers to secure the pin in the axial direction and
x 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 tted as described in section 5) is tted
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 tted as in section 5) on the
large pin diameter and then t retaining rings and thrust washers.
41850444.eps
4.2.6.9 Fitting torque brackets for pin
and end connection
DRS 200 AD50 / WU60
1
28 2
1
4
2
7
6
k
2
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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
DRS Dimensions in mm
wheel block a4 a6 a9 d10 d15
size
112 148 145 64 20
M 10
125 162 175 72 23
160 206 220 90 32
M 12
200 266 275 118 38
Side with
welded plate
drilled by the customer
4.2.7 DRS 112 200 end connection
End connection dimensions
DRS Part no. Dimensions in mm Options
wheel
block
a5 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 4
753 829 44 753 738 44
752 139 44
NA/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 4
752 429 44 752 338 44
752 140 44
NA/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 5
752 729 44 752 638 44
752 141 44
NA/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 5
753 229 44 753 138 44
752 142 44
NA/MA 753 137 44
29 2
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4.3 Manufacturing tolerances of
crane runways
S

m
i
n
S
S

m
a
x
41409444.eps
-
B
-
B
+
B
2000
2000
2
0
0
0
b
b
b
41409544.eps
2
0
0
0
-
C
+
C
2000
2000
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
S
max
= s + A S
min
= 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 length
Tolerance 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 one
another in elevation (transverse slope)
E = 0,5 x s
in mm
use s in mm
E
max
= 5 mm
E = 1 x s
in mm
use s in mm
E
max
= 10 mm
E = 2 x s
in mm
use s in mm
E
max
= 20 mm
30 2
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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 the
gearbox) must already be inserted in the corresponding
bore holes of the torque bracket prior to tting 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
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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 gearbox
M8 / 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
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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
1 2 3
1 5 4 10 8 12
4
6 7
11
9 6 7
11
9
10 8 12
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
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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.
1 2 3
4 5
1
6 7
11
9 9
11
7 6 4 10
8
12 10
8
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 tting, check splined prole 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 tting 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
Clean drive shaft before tting, check splined prole section and grease with grease
(Klueber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).
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 shaft
arrangements (12) must be secured against axial displacement by tting 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 tting retaining ring (9).
Drive arrangement: Hollow shaft with solid shaft
8 7 10
13 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
Clean drive shaft before tting, check splined prole section and grease with grease
(Klueber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).
36 2
1
4
2
7
6
k
3
.
i
n
d
d
/
1
6
0
4
0
8
5.3.2 W type angular gearboxes
41807255.eps
41807444.eps
Drive arrangement: Hollow shaft with solid shaft
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 tting 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 tting retaining ring (9).
7 10 2 12 13 9 8
11 5 4 6 9 10
2 3
1
After tting an angular gearbox type W 50, check the bolted connections of the wheel block for
the correct tightening torque (72 Nm).
Drive arrangement: Journal shaft on both sides with involute splines
41833944.eps
10
7
8
12
13
9
Clean drive shaft before tting, check splined prole section and grease with grease
(Klueber Staburags NBU12 Alltemp or Fuchs Gleitmo WSP5040).
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
3
2
1
42753044.eps
Dimensions L1 and L2 for the length
of the shaft protection tube
5.4 Central drive units with shaft protection
5.4.1 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 tting 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) 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 tting
spacer rings (10) and retaining ring (9).
Drive arrangement: Hollow shaft with solid shaft
8 7 10
13 9
12
Drive arrangement: Journal shaft on both sides with involute splines
10
7
8
9
13
12
41807144.eps
Clean drive shaft before tting, check splined prole section and grease with grease
(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
5.4.2 W type angular gearboxes
42065946.eps
41807444.eps
Drive arrangement: Hollow shaft with solid shaft
7 10 2 12 13 9 8
Drive arrangement: Journal shaft on both sides with involute splines
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 tting 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) 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 tting
spacer rings (10) and retaining ring (9).
41833944.eps
10
7
8
12
13
9
Clean drive shaft before tting, check splined prole 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
39 2
1
4
2
7
6
k
3
.
i
n
d
d
/
1
6
0
4
0
8
40 2
1
4
2
7
6
k
3
.
i
n
d
d
/
1
6
0
4
0
8
DRS
wheel
block
size
Tightening
torques
Dimensions in mm
in Nm
Locking bolt
1 2 3 x
min
x
max
a a7 b
min
b
max
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 specied in the type key when ordering a single
wheel block, this is prepared for tting 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 ank surfaces must not be used.
6.1 Horizontal guide rollers
DRS 112 200
6.1.1 Fitting to wheel blocks
42015744.eps k = Rail width
DRS 112 125 160 DRS 200
41641644.eps
41 2
1
4
2
7
6
k
3
.
i
n
d
d
/
1
6
0
4
0
8
41641944.eps
Assembly
Fit the washer with the wide slot facing downwards on the raised guide to
prevent turning.
Fit the pins with the at-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 specied tightening torque (see table).
Adjust roller distance dimension x and align guide rollers to rail.
Tighten locking bolts (1) with specied torque (see table).
Fitting for wheel block not prepared before leaving the factory
If a wheel block is tted 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 t roll pins with
slot facing upwards.
Subsequently t two threaded inserts into the end face.
41641844.eps
d
4
a8
Rz63
x k x
DRS wheel block
Travel wheel type
a
mm
Part no. Retrotting set part no.
size
Horizontal guide roller
assembly1)
Fitted to wheel block 2) Fitted to connecting structure 1)
112
B 81 753 610 44 753 611 44 753 610 44
E 87 753 710 44 753 711 44 753 710 44
125
B 88 752 210 44 752 211 44 752 210 44
E 98 752 310 44 752 311 44 752 310 44
160
B 109 752 510 44 752 511 44 752 510 44
E 119 752 610 44 752 611 44 752 610 44
200
B 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 bolt
Dimensions in mm
1 2 3 x
min
x
max
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
d
d
/
1
6
0
4
0
8
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 d
5
H12
after tting.
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
d
d
/
1
6
0
4
0
8
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 elements
6.2.1 DPZ cellular foam buffer
Possible tting arrangement to end of DRS 112 200 wheel blocks without horizontal guide roller arrangement
41671244.eps
DPZ cellular foam buffer
DRS wheel
block size
Buffer
Dimensions in mm
w/o guide rollers with guide rollers
d1 d2 l1 l2 Threaded pins (2)
112
125
160
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 size
Buffer
Dimensions in mm
w/o
guide rollers
with
guide rollers
d1 d2 l1 l2 Threaded pins (2)
112
125 160
200
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
d
d
/
1
6
0
4
0
8
41642555.eps
To ensure uniform buffer impact with a
horizontal guide roller arrangement t-
ted to only one wheel block, two shims,
type E2 must be tted 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
2s
1
Stop
1) Only one type E2 shim required.
Fig. 11
Possible tting arrangement to end of DRS 112 200 wheel blocks with horizontal guide roller arrangement
(gs. 11 12)
Fig. 12
DRS 112 200
Guide roller assembly including
spacer elements
DRS wheel
block size
Buffer
l4
mm
112 / 125
DPZ 070
11 0,5
DPZ 100
160 / 200
DPZ 070
14 0,5
DPZ 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
d
d
/
1
6
0
4
0
8
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
See Operating instructions ident no. 214 206 44
WU WG WF angular geared motors
See Operating instructions ident no. 214 058 44
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
d
d
/
1
6
0
4
0
8
7.2 Travel wheel wear
7.2.1 Flange wear
The wear indicator on the ange 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 ange 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
d
d
/
1
6
0
4
0
8
8 Removing and tting 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 ange)
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 ush with the wheel block.
48 2
1
4
2
7
6
k
4
.
i
n
d
d
/
1
6
0
4
0
8
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
d
d
/
1
6
0
4
0
8
9.1.2 Type code
G
e
a
r
b
o
x

s
i
z
e

t
t
e
d
:

A

1
0

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1
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N
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x

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:

I
n
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X
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:

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0


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1
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K
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f
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4
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f
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B
,

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,

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:

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a
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0
T
r
a
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w
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t
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p
e
:


A
,

B
,

C
,

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,

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F
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a
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p
e
:

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.
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h
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b
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b
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W
h
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b
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k

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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
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b
l
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c
k

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9.2 Fax form
Fax order
Simply copy, ll 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
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d
d
/
1
6
0
4
0
8
Ident. no.
Page 1
Issue 1204 EN
1 page(s)
# = Modications 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 products
are 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 manufacturers declaration
Demag DRS / RS, LRS wheel block
in 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
#
#
#
#
#
#
#
P
r
i
n
t
e
d

i
n

G
e
r
m
a
n
y
Subject to change. Not liable for errors or omissions. Reproduction in whole or in part only with prior consent of Demag Cranes & Components, D-58286 Wetter
Demag Cranes & Components GmbH
Drives
P.O. Box 67 -58286 Wetter / Germany
Telephone (+49-2335) 02
Telefax (+49-2335) 92-2406
E-mail drives@demagcranes.com
www.drives.demagcranes.de
Addresses
The current addresses of the sales ofces 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