DFW-L-E end carriages

with DRS 112 to 200

010802 EN/DE 203 321 44 714 IS 845.1

 Contents

Page
1 DFW product description 3
1.1 Application 3
1.2 Modular carriage system 3
1.3 Protection against corrosion, paint finish 3
1.4 Documentation 3
2 Design and mounting information 4
2.1 Steel construction 4
2.2 Types of connection 4
2.3 DRS wheel block system 5
2.4 Adjusting the span 5
2.5 Wind safety catches 6
2.6 Optimizing the travel speed 6
3 Mounting code 7
3.1 Type designation 7
3.2 Order information 7
4 DFW-L-E/S end carriages 8
4.1 Data and dimensions 8
5 DFW-L-E/O end carriages 10
5.1 Data and dimensions 10
6 DFW-L-E end carriage attachments 12
6.1 End plates 12
6.2 Bolted mounting plates with non-countersunk bore holes
and with countersunk bore holes for DFW-L-E/S 14
6.3 Bolted and welded mounting plates for DFW-L-E/O 16
6.4 Torque brackets 18
6.5 Buffers and spacers 18
6.6 Guide rollers 18
7 Order form for DFW-L-E end carriages 19

DFW-L-E / S

Steel structure Bolted mounting plate Geared motor

Torque bracket
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Buffer Wheel block High-tensile For outdoor operation only Wheel block Spacer End
Non-driven bolted 1x for Ax<=500 mm fitting elements Wheel block plate
connection 2x for Ax>500 mm Driven
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 1 Product description

1.1 Application DFW-L-E carriages are used for steel structures in the crane and lifting equipment
industry and also for applications in related mechanical engineering.

1.2 Modular carriage DFW-L-E carriages are compact, driven, rail-mounted carriages for direct connection
to load-bearing structures. In addition to the steel structure part, a torsionally
system resistant box section, the end carriage includes a driven wheel block for fitting the
gearbox and the motor as well as a non-driven wheel block. The carriage design is
based on the latest principles for steel structures and, even with high loads, has
excellent travelling characteristics due to the fine tolerances of the carriage regarding
track gauge errors, diagonal position and misalignment. Specially adapted heavy-
duty motors provide excellent speed/torque characteristics, which ensure smooth
starting for both the unloaded and the loaded carriage.

The following equipment can be combined to form a complete carriage:

Connection
• Carriages with one crane girder connection on the side (standard)
• Carriages with one crane girder connection on the top

Travel unit/travel wheel

• DRS wheel blocks 112, 125, 160, 200 mm
• Max. wheel loads up to 10000 kg
• Wheel bases 2000, 2500, 3150, 4000 mm

Travel drive (drive units fitted either on right-hand or left-hand side)

• AM offset gearboxes
• ZBF travel motors
• MA torque brackets

Buffers
• DPZ Cellular plastic buffers

1.3 Protection against Protection against corrosion

corrosion • Structural steel shot-blasted (Sa2 rust removal factor to DIN 55 928).
• Rust protection with primer paint in RAL 1004 golden yellow (thickness 60 µm)
Paint coat • Galvanized finish available on request
• Other provisions for corrosion protection available on request.

Paint coat
• A final coat in RAL 1007 daffodil yellow or other colours can be provided on
request.

1.4 Documentation Travel unit

• Operating instructions 214 362 44
• Component parts list 222 736 44

DRS wheel blocks, gearboxes, travel motors and buffers

• Demag DRS wheel block system Volume 1 1) 203 352 44
• Geared motors for travel applications Volume 2 203 355 44
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1) required for rating the end carriages

3
 2 Design and mounting information

2.1 Steel structure The steel structure is designed in accordance with DIN 15018, lifting class H2, stress
group B3.
Steel structure characteristics:
• High stability due to enclosed, torsion-resistant box section girder. Great
strength in connection area due to diaphragm plates welded into the carriage.
• Machining on NC machines provides precise positioning of travel wheel axles
with respect to mating surfaces.
• Easy assembly and access. Detachable and anti-shear high-tensile connection
with adjoining structure.
• Optimum travel characteristics. Can be easily exchanged due to accuracy of the
connection geometry. Fine tolerances for track gauge errors, diagonal wheel
position and misalignment are met as a result of the precise alignment and
machining of the connection surfaces.

Steel structure with top connection of main girder

Steel structure with side connection of main girder

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2.2 Types of connection The carriage can be connected to the structure in the following ways:

• bottom flush (side connection of main girder),

• top flush (side connection of main girder),

• raised (side connection of main girder),

• lowered (side connection of main girder),

• top connection (top connection of main girder),

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Bottom flush Top flush Raised Lowered Top connection

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 2.3 DRS wheel blocks Wheel blocks feature:
• Positive travel wheel/shaft connection resulting from the splined shaft section.
• Simple, fast assembly and replacement with commercially available tools.
• High wheel loads, long service life due to dust-proof anti-friction bearings lubricat-
ed for life.
• Simple adjustment of span by re-arranging spacer elements between the wheel
block and the inside of the carriage girder.
• Considerably reduced wear on travel wheels (wear indicator) and track rails as a
result of the self-lubricating effect of spheroidal graphite cast iron compared with
steel.
• Silent running due to self-damping properties of the travel wheel material.

Travel wheel profile

Dimensions in mm Max. wheel loads 2)

d1 d2 b2 Max. bwheel Standard bwheel 1) [kg]

112 132 80 60 47, 60 3500

d1

d2

125 150 80 60 47, 60 5000

160 188 89 65 47, 60, 65 7000

200 230 101 65 65 10000

b rail
1) other treads on request
b wheel
2) max. wheel loads for linear contact (flat rail to DIN 1014 or A rail to DIN 536) depending on FEM group, useful rail width and
long travel speed, see catalogue 203 352 44, section 2.6.5
b2
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2.4 Adjusting the span By re-arranging the spacer elements, the span can be adjusted.
d1 Spacer elements

[m m ] Thickness [mm] Max. adjustment [mm]

112 ±6

125 ±4
2 and 5
160 ±6

200 ± 10

Spacer elements
Spacer elements
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 2 Design and mounting information

2.5 Wind safety catches According to accident prevention regulations (UVV, BGV D6 § 14.1 (VBG 9)), cranes
must have their power-driven travelling and slewing movements braked, thus
preventing unintended movement. According to the regulations UVV 18.2 BGV D6
§ 30.6 (VBG 9), the crane operator must ensure that cranes exposed to the wind are
secured during storms and at the end of work.
According to the surface area exposed to the wind, one or two safety catches are
required per crane.
Depending on accessibility, the manually operated wind safety catch should be
preferred.

2.6 Optimizing the travel Optimum handling capacity can only be achieved by correctly selecting the working
speeds. For this, the average speed of the individual movements is the determining
speed factor.

125
100
80
63
50
Travel speed (m/min)

40
31,5
25
20
16
12,5

5 6 7 8 9 10 15 20 25 30 40 50 100 150 200

Crane runway length or span (m)
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 3 Mounting code

3.1 Type designation DFW-L-E 112 / 2000 / S

Connection of main girder
Wheel base ekt

Travel wheel diameter d1

Single-girder crane

Overhead travelling crane

Demag end carriage

3.2 Order information The following information is required:

• End carriage type: E - single-girder crane

• Travel wheel dia. or wheel block size/wheel base:

112 / 2000, 2500
125 / 2000, 2500, 3150
160 / 2000, 2500, 3150
200 / 2000, 2500, 3150, 4000
Drive variant Other wheel bases on request
left
• Main girder connection: S - side
O - top

• Travel wheel tread: See section 2.3

20332030.wmf

• Travel wheel variants: A - with flange on both sides

Other travel wheel variants on request, see catalogue 203 352 44 section 2.6.3

• Drive variant, view to mounting plate:

L - 1 end carriage, left-hand side
R - 1 end carriage, right-hand side
RL - 2 end carriages arranged in pairs
(right-hand side and left-hand side)

• Number of drives per end carriage:

0 - no drive
1 - one drive
2 - two drives

• Drive shaft diameter or gearbox size:

30, 35, 45 or 50
See catalogue 203 352 44 section 2.3

• Guide rollers: Standard guide rollers yes/no

See section 6.1 and catalogue 203 352 44 section 4.6

• DPZ buffers: 100, 130, 160

See catalogue 203 352 44 sections 4.4 and 4.5

• End plate variant: Standard, variant for Italy, USA or for guide rol-
lers
See section 6.1
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• DFW-L-E/S mounting plate: with countersunk bore holes,

with non-countersunk bore holes
See section 6.2

• DFW-L-E/O mounting plate: bolted type, welded type 7

See section 6.3
 4 DFW-L-E/S end carriages

4.1 Data and dimensions

ekt a3

A B

(Standard buffer height)

Ax
S

X a9

Ay1
Ay2
a 12 d4 d3
h 18
h 21

Ay3

h1
h 19

h8

h 17

100
h 20

h 12

h 23
a10 a11 21 d1

A 51,5 a8 a7 a4

B 4 4
i - Number of securing bolts for torque
bracket

20332009.eps

Dimensions in mm

d1 bwheel ekt Gearbox Ax Ay1 Ay2 Ay3 a3 a4 a7 a8 a9 a10 a11 a12 b2 b3 b4 b8

2000 A10
150 - 672
112 max 60
A20
280 - 93 203 145 - 79 50 80 71,5 70 135
2500 95 150 922

2000 617 138

A10
2500 867 -
A20
140
3150 1192
125 max 60 280 95 150 - 108 233 175 77,5 58,5 80 77,5 70
2000 617 138

2500 A30 106 867 92

for 140
3150 DPZ100 1192

2000 126 575 158

280 for
2500 A20 DPZ130 825 -
160
3150 500 158 1135
160 max 65 95 150 220 135,5 for 288 220 97,5 75 89 88 85
2000 DPZ160 575 158
A30
280
2500 A40
825 110
160
3150 500 1135

2000 542 183

280
2500 792
A30
200 max 65
A40
150 220 290 168 353 275 140 120 105 101 105,5 95
3150 1072 185
500
4000 1497
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 The supply of a DFW end carriage includes: End carriage, mounting plate with securing bolts and buffer
bwheel – standard travel wheel tread see item 2.3; other travel wheel treads on request
End carriage weight without mounting plate, motor and gearbox
Assignment of end carriages: For SWL – span, see standard overhead travelling cranes brochure 203 317 44
(crane selection tables and wheel loads/mass forces/forces resulting from running at an angle/buffer forces/dead loads of the crane)

View X Section A-A Section B-B Detail Y

b3 b4 S b9 End carriage Main girder

Y

h13
h7

Travel wheel
67,5 ± 1 DFW-L-E 112
h10
h22

67,5 ± 1 DFW-L-E 125

centre
82,5 ± 1 DFW-L-E 160
92,5 ± 1 DFW-L-E 200
bwheel

h9
b2 b8 20

20332010.eps 20332011.eps

Dimensions in mm Number Weight

b9 d3 d4 h1 h7 h8 h9 h10 h12 h13 h17 h18 h19 h20 h21 h22 h23 L S i kg

243 2204 7 113

12 18,5 M8 149 215 22,5 24 14 308 42 40 60 10 - 9,5 - 4
247 2704 9 153

281 2224 8 152

285 - 2724 10 4 202

289 3374 12 269

15 21 M8 162,5 250 42,5 28 15 308 47,5 40 68,5 41 9 9
281 2224 8 152

285 10 2724 10 6 202

289 3374 12 269

353 2280 8 195

357 - 2780 10 4 257

361 3430 12 341

15 30 M 10 217 320 32 31 17 308 63 55 90 56 10 10
353 2280 8 195

357 12 2780 10 6 257

361 3430 12 341

440 2336 8 300

442 2836 10 380

15 35 M 10 277 400 42 35 20 385 80 75 115 70 10 10 15 6
3486 462
444 12
4336 586
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 5 DFW-L-E/O end carriages

5.1 Data and dimensions

Figure: Bolted connection

L
a3
ekt
B

(Standard buffer height)

A

X a9
a12 d4 d3
h18
h21

h8

h17
h19

100
h20

h12

h23
a10 a11 d1
B a8 a7 a4
A
i - Number of securing bolts for torque bracket Si Sa
Bx1
By1

Bx2

20332012.eps

Dimensions in mm

d1 bwheel ekt Gearbox Bx1 Bx2 By1 a3 a4 a7 a8 a9 a10 a11 a12 b2 b3 b4 b8 b9 b10

max 2000 A10 672

112 360 360 56 93 203 145 - 79 50 80 71,5 70 135 12 22
60 2500 A20 922

2000 617 138

A10
2500 867 -
A20 140
max 3150 1192
125 360 440 44 108 106 233 175 77,5 58,5 80 77,5 70 15 55
60 2000 617 138
for
2500 A30 DPZ 867 92
100 140
3150 1192
126
2000 for 575 158

2500 A20 DPZ 825 -

130 160
max 3150 1135
160 470 470 64 135,5 158 288 220 97,5 75 89 88 85 15 65
65 2000 575 158
for
A30 DPZ
2500 825 110
A40 160 160
3150 1135

2000 542 183

470 470
2500 or or 792
max A30
200 560 560 85 168 353 275 140 120 105 101 105,5 95 15 73
65 3150 A40 1072 185
s. s.
S16 S16
4000 1497
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 The supply of a DFW end carriage includes: End carriage, mounting plate with securing bolts and buffer
bwheel – standard travel wheel tread see item 2.3; other travel wheel treads on request
End carriage weight without mounting plate, motor and gearbox
Assignment of end carriages: For SWL – span, see standard overhead travelling cranes brochure 203 317 44
(crane selection tables and wheel loads/mass forces/forces resulting from running at an angle/buffer forces/dead loads of the crane)

Figure: Bolted connection

For bolted connection

For bolted and welded connection

View X Section A-A Section B-B

b3 b4 b10

S b9
h25

h24

h7

h22

h10
bwheel b8
b2

20332013.eps

Dimensions in mm Number Weight

d1 d3 d4 h7 h8 h10 h12 h17 h18 h19 h20 h21 h22 h23 h24 h25 L S Sa Si i in kg

243 258 280 2204 7 113

112 18,5 M8 215 24 14 42 40 60 10 - 9,5 - 4 4 4
247 262 284 2704 9 153

281 296 318 2224 8 152

285 - 300 322 2724 10 4 202

289 304 326 3374 12 269

125 21 M8 285 28 15 47,5 40 68,5 41 9 9 4 4
281 296 318 2224 8 152

285 10 300 322 2724 10 6 202

289 304 326 3374 12 269

353 371 393 2280 10 195

357 - 375 397 2780 10 4 257

361 379 401 3430 12 341

160 30 M10 320 31 17 63 55 90 56 10 10 4 4
353 371 393 2280 10 195

357 12 375 397 2780 10 6 257

361 379 401 3430 12 341

440 455 477 2336 10 300

442 457 479 2836 10 380

200 35 M10 400 35 20 80 75 115 70 10 10 15 4 4 6
444 459 481 3486 12 462

444 459 481 4336 12 586

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 6 DFW-L-E end carriage attachments

6.1 End plates

Standard version (buffer height = 100 mm)

DFW-L-E 112 DFW-L-E 125 DFW-L-E 160 DFW-L-E 200

652 771 44 652 798 44 652 832 44 652 865 44

169
60

134
60
109

410
87

328
266
229

77

73
85
86

65 70 85 95
130 138 158 185

20332012.eps

Variant for Italy (buffer height = 0,6 x travel wheel diameter)

Due to the application of the EC Machine Directive 98/37/EC

in Italy, the buffer height of 100 mm has been adapted to our
standard.
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 Variant for USA (buffer height = 100 mm; with derailment guard)

DFW-L-E 112 DFW-L-E 125 DFW-L-E 160 DFW-L-E 200

652 770 44 652 800 44 652 833 44 652 866 44

60

432
87

459
373
346
276

301
229
263
120

120

122
122

58
54
46

46

34 50 54 62
75 75 85 85

65 70 85 95

130 138 158 185

20332014.eps

Variant for guide rollers (buffer height = 100 mm)

DFW-L-E 112 DFW-L-E 125 DFW-L-E 160 DFW-L-E 200

652 769 44 652 831 44 652 864 44 652 868 44

158 185

138
130
134

169
208

283
109

160
87
142
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 6 DFW-L-E end carriage attachments

6.2 Bolted mounting plates for DFW-L-E/S end carriages

Bolted mounting plates with non-countersunk bore holes

B = h13 Standard mounting plate

Ay1
d3

Ay2

Ay3

Ay4

B
Ay
Ax ±0,2 20

20332018.eps

DFW Part no. Dimensions in mm Weight

d1 ekt 1) Ax Ay1 Ay2 Ay3 Ay4 Ay A B d3 d4 in kg

112 2000, 2500

810 706 44 280 95 150 - - 182,5 375 17,9
125 2000, 2500, 3150
308
160 2000, 2500 810 778 44 280 95 150 220 - 265 375 17,9
21 -
160 3150 811 283 44 500 95 150 220 - 265 600 35,6

200 2000, 2500 959 823 44 280 150 220 290 - 335 375 17,9
385
200 3150, 4000 959 824 44 500 150 220 290 - 335 600 35,6

1) The open bore holes dia. 21 mm in the bolted mounting plate are closed with plugs

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 Bolted mounting plates with countersunk bore holes

20332019.eps

DFW Part no. Dimensions in mm Weight

d1 ekt 1) Ax Ay1 Ay2 Ay3 Ay4 Ay A B d3 d4 in kg

112 2000, 2500

810 265 44 280 95 150 - - 182,5 375 17,9
125 2000, 2500, 3150
308
160 2000, 2500 959 347 44 280 95 150 220 - 265 375 17,9
21 -
160 3150 811 285 44 500 95 150 220 - 265 600 35,6

200 2000, 2500 959 722 44 280 150 220 290 - 335 375 17,9
385
200 3150, 4000 959 720 44 500 150 220 290 - 335 600 35,6

1) The open bore holes dia. 21 mm in the bolted mounting plate are closed with plugs
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 6 DFW-L-E end carriage attachments

6.3 Bolted and welded mounting plates for DFW-L-E/O

Bolted mounting plates

Bx2

Bx1
By1

d3

B
H
G

E T

203 320 20.eps

DFW Bu Dimensions in mm Weight

Part no.
d1 in mm Bx1 Bx2 By1 E F G H T A B d3 in kg

112 200 oder 300 652 789 44 360 360 56 150 40 112 120 22 460 140 17 8,8

125 200 oder 300 652 823 44 360 440 44 150 73 138 150 22 540 170 12,1

160 200 oder 410 652 856 44 470 470 64 150 83 168 177 22 570 200 15,2
21
200 oder 410 653 749 44 470 470 85 150 91 198 210 22 570 230 16,5
200
410 oder 500 652 879 44 560 560 85 360 91 198 210 22 660 230 18,3

Bu - Width of crane girder flange, bottom

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 Welded mounting plates

B
H
F

E T

203 320 21.eps

DFW Bu Dimensions in mm Weight

Part no.
d1 in mm E F H T A B in k g

112 200 oder 300 652 791 44 150 40 120 15 360 140 6,1

125 200 oder 300 652 825 44 150 73 150 15 540 170 8,6

160 200 oder 410 652 858 44 150 83 177 18 570 200 12,8

200 oder 410 653 750 44 150 91 210 15 570 230 14,5
200
410 oder 500 652 881 44 360 91 210 15 660 230 12,8

Bu - Width of crane girder flange, bottom

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 6.4 Torque brackets In standard cranes, the torque brackets are used in conjunction with AM offset gear-
boxes, ZBF cylindrical rotor motors and DRS wheel blocks with pin connection.
For data, dimensions and ordering, see catalogue 203 352 44
• Torque brackets section 4.1
For data, dimensions and ordering, see catalogue 203 355 44
• Offset gearboxes
• Cylindrical rotor motors

6.5 Buffers and spacers Buffers with high buffering forces are required to avoid hazardous deformations of the
supporting structure in the event of end carriage collisions or when running against
the end stop at the runway end.
For data, dimensions and ordering, see catalogue 203 352 44
• Buffers and spacers sections 4.4

6.6 Guide rollers The horizontal guide rollers always have to be considered in conjunction with the
DRS wheel block. When ordering the end carriage, information on the guide rollers is
required.
For data, dimensions and ordering, see catalogue 203 352 44
• Guide rollers section 4.6

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 7 Order form for DFW-L-E end carriages

From company: Date:

Ms./Mr.: Telephone:

Department: Telefax:

Address:

Order data: Wheel block size: 112 125 160 200

Wheel base: 2000 2500 3150 4000

Connection of main girder: S O

Travel wheel tread:

Travel wheel type: A flange on both sides B without flange

D flange on one side Others:

Drive arrangement: L- left R- right RL - right or left

Number of drives: 0 1 2

Drive shaft diameter: 30 35 45 50

Guide rollers (standard): yes no

Buffers: 100 130 160

Version: Standard USA

DFW-L-E/S mounting plate: Countersunk Non-countersunk

DFW-L-E/O mounting plate: Bolted Welded

Protection against corrosion: RAL1004 golden yellow Others:

Paint finish: RAL1007 daffodil yellow Others:

Classification: H2 B3 (indoor operation) Others on request

# = Modifications compared to previous issue
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 Printed in Germany Basse/131005/5H

Demag Cranes & Components GmbH

P.O. Box 67 · D-58286 Wetter
Telephone (+49/2335) 92-0 · Telefax (+49/2335) 927676
www.demagcranes.com

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.