DFW-L-E travel units

with DRS 112 to 200

150414 enGB 203 321 44 714 IS 845.1

 Contents

Page
1 Product description 3
1.1 Application 3
1.2 Modular travel unit system 3
1.3 Corrosion protection and paint finish 3
1.4 Documentation 3
2 Design and installation notes 4
2.1 Steel superstructure 4
2.2 Possible mounting arrangements 4
2.3 DRS wheel block system 5
2.4 Track gauge adjustment 5
2.5 Wind drift safety device 6
2.6 Optimising speeds 6
3 Type code 7
3.1 Type designation 7
3.2 Information for ordering 7
4 Data and dimensions 8
4.1 DFW-L-E / S travel unit 8
4.2 DFW-L-E / O travel unit 10
5 Fittings for DFW-L-E travel units 12
5.1 Derailment protection fitting complete with buffer 12
5.2 Guide roller fitting complete with buffer 12
5.3 Connecting plates for DFW-L-E / S 13
5.4 Bolted and welded connecting plates for DFW-L-E / O 14
5.5 Torque brackets 15
5.6 Buffers and spacer elements 15
5.7 Roller guide arrangement 15
6 Order form for DFW-L-E travel units 16

DFW-L-E / S Wheel block fitting

Threaded pin set Connecting plate elements Geared motor

Steel
superstructure
Terex MHPS GmbH

Torque bracket

Buffers
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Buffer adapter and

Buffers Wheel block HT connection Cover plate Spacer element Driven wheel bolt
only for outdoor operation block only for DFW-L-E 112
non-driven
1x for Ax<=500 mm
2x for Ax>500 mm 20332001.eps
2
 1 Product description

1.1 Application DFW-L-E travel units are used for travel applications for crane and hoist steelwork
and related mechanical engineering structures.

1.2 Modular travel unit Compact DFW-L-E rail-mounted travel units can be connected direct to load-
bearing structures. Two wheel systems are installed in the torsionally rigid box
system section:
a driven wheel block to which a geared brake motor can be fitted,
and a non-driven wheel block.
The travel unit beam, which is designed on the basis of the latest findings in the
field of steel superstructures, displays excellent travel characteristics, even at
high loads due to tight tolerances resulting from differences in the runway gauge,
skewing and misalignment, for example.
Specially matched travel motors ensure that the travel unit starts and stops
smoothly with favourable speed/torque characteristics, both with and without a
load.

We offer the following mounting combinations to meet your design needs:

Connection
Travel units with a side crane girder connection (standard)
Travel units with a top crane girder connection

Travel unit/travel wheel

DRS 112, 125, 160, 200 mm wheel block
Maximum wheel loads up to 10000 kg
2000, 2500, 3150, 4000 mm wheel bases

Travel drive (drives optionally fitted to the right or left-hand side)

AM offset gearbox
ZBF travel motor
MA torque bracket

Buffers
DPZ/DPZ-R cellular foam buffers

1.3 Corrosion protection Pre-treatment of structural steel parts in a shot-blasting unit (degree of rust
removal Sa2,5 to DIN EN ISO 12944-2).
and paint finish
RAL 1004 golden yellow top coat (60 m coat thickness)
Other finish coat colours are also available, on request.
Other corrosion protection measures on request.

1.4 Documentation Travel unit

Operating instructions 214 362 44
Component part list 222 735 44

DRS wheel blocks, gearboxes, travel motors and buffers

Demag DRS wheel block system Volume 1 1) 203 352 44
Geared motors 203 151 44
Terex MHPS GmbH
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1) Required for specifying the travel units 3

 2 Design and installation notes

2.1 Steel superstructure The steel superstructure of the travel unit is specified to HC3/S3 according to
EN 150011/EN13001 as standard. This applies for hoist unit types and duty types
> HD1 with lifting speeds up to 20 m/min. Other classifications on request.
Special features of the steel superstructure include:
Rugged design thanks to rigid, enclosed box-section profile. Precisely welded
diaphragm plates reinforce the connection area.
Precise position of the travel wheel axes in relation to the connecting surfaces
thanks to machining in a NC machine tool.
Easy assembly and good accessibility. Reliable high-tension bolted connection
to the connecting structure.
Optimum travel characteristics and, if required, reliable replacement of the
wheel blocks thanks to reproducible connection geometry of the wheel block for
reproducible geometry of the travel unit without the need for special tools.
Tight tolerances for tracking errors, skewing and alignment errors are achieved
by simple assembly of the precision-machined end carriage connection
surfaces.

Steel superstructure with top connection to the

crane girder

Steel superstructure with side connection to the

crane girder

20332002.eps

2.2 Possible mounting The connecting structure can be attached to the travel unit:
arrangements flush with the bottom edge (side crane girder connection),
flush with the top edge (side crane girder connection),
raised (side crane girder connection),
lowered (side crane girder connection),
top-mounted (top crane girder connection)
Terex MHPS GmbH

flush with bottom edge flush with top edge raised lowered top-mounted
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4
 2.3 DRS wheel block Wheel blocks feature:
system Positive travel wheel/shaft connection resulting from the splined shaft section.
Fast and simple assembly and replacement with commercially available tools.
High wheel loads and long service life due to anti-friction bearings that are
sealed against dust and lubricated for life.
Simple adjustment of track gauge by re-arranging spacer elements between the
wheel block and the inside of the end carriage.
Greatly reduced wear on travel wheels (wear indicator) and crane runway
rails as a result of the self-lubricating effect of spheroidal-graphite cast iron
compared with steel.
Low-noise running due to high self-damping effect of the travel wheel material.

Travel wheel profile

Dimensions in mm Max. wheel loads 2)

d1 d2 b2 max brad Standard brad 1) [kg]

112 132 80 60 47,60 3500

d2
d1

125 150 80 60 47,60 5000

160 188 89 65 47,60,65 7000

200 230 101 65 65 10000

bschiene
brad

b2

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2.4 Track gauge The track gauge can be changed by means of replaceable spacer elements and
by adjusting the threaded pins.
adjustment
d1 Spacer elements

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

112 6

125 4
2, 3 and 5
160 6

200 10

Spacer elements Threaded pin

X Z

Z
Terex MHPS GmbH

X
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1) Other treads on request

2) Maximum wheel loads with linear contact (flat rail to DIN 1014 or A-type rail to DIN 536) depending on
the FEM group, useful rail width and long-travel speed, see catalogue 203 352 44 section 2.6.5.

5
 2.5 Wind drift safety According to relevant accident prevention regulations (e.g. UVV, BGV D6
Section 14.1 (VBG 9), cranes must be designed in such a way that their power-
device driven travel and turning motions can be braked and unwanted crane movements
prevented. According to relevant accident prevention regulations (e.g. UVV 18.2
BGV D6 Section 30.6 (VBG 9)), the crane operator must ensure that cranes that
are exposed to the wind are locked in stormy weather and at the end of work.
Depending on the surface area exposed to the wind, one or two wind drift safety
devices are required per crane.
A manually operated wind drift safety catch should preferably be employed
depending on accessibility.

2.6 Optimising speeds Optimum handling rates can only be achieved by selecting the right operating
speeds. This is determined by the average speed resulting from the individual
motions.

125
100
80
63
50
Travel speed in 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 of span in m
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Terex MHPS GmbH

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 3 Type code

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

Crane girder connection

Wheel base ekt

Travel wheel diameter d1

Single-girder crane

Overhead travelling cranes

Demag travel unit

3.2 Information for The following information is needed:

ordering Travel unit type: E = single-girder crane

Travel wheel diameter or wheel block size / wheel base:

112 / 2000, 2500
125 / 2000, 2500, 3150, 4000
160 / 2000, 2500, 3150, 4000
200 / 2000, 2500, 3150, 4000
(Other wheel base dimensions on request)

HT bolt centre distance for DFW-L-E/S: Ax

Crane girder connection: S side

O top

Travel wheel tread: See section 2.3

Travel wheel tread: A guide flange on both sides

(See section 2.6.3 of catalogue 203 352 44 for other travel wheel treads)

Drive arrangement looking at bolted connecting plate:

L - 1 left-hand travel unit
R - 1 right-hand travel unit
RL - 2 travel units arranged as a pair (on right
and left)

Number of drives per travel unit:

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

Drive shaft diameter: 30, 35, 45 or 50

Buffer DPZ: 70, 100, 130, 160

DPZ-R 100, 160
Terex MHPS GmbH

Derailment protection: see section 5.1

DFW-L connecting plate: Bolted connecting plate, see section 5.3

The scope of delivery of a DFW-L-E travel unit includes:

Travel unit
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Connecting plate with attachment bolts, washers

Optional accessories:
- Buffers
- Horizontal guide rollers. 7
 4 Data and dimensions

4.1 DFW-L-E / S travel unit

ekt

A Ax

100 standard buffer height

B

Ay1
65 250

Ay2
Ay3

h1
95
M10

21

h12
d1
A 51,5 a5 a4

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Dimensions in mm

d1 brad ekt Gearbox Ax Ay1 Ay2 Ay3 a4 a5 b3 b4 b8

2000 A10 150 - 136

112 max. 60 280 - 20 71,5 70
2500 A20 95 150 135

2000 138

2500 280
-
A10
125 max. 60 3150 A20 95 150 - 77,5 70
A30 500 140

280 100 for

4000 220 DPZ100
500
120 for
2000 DPZ130 158

2500 280
95 150 220 150 for
A20 DPZ160
160 max. 65 3150 A30 - 88 85
A40 500 150 for 160
DPZ-R100
280
Terex MHPS GmbH

4000 150 220 290 160/240 for

500 DPZ-R160
2000 183

2500 280

A30
200 max. 65 3150 150 220 290 - 105,5 95
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A40 500 185

280
4000
500

8
 The scope of delivery of a DFW travel unit includes: travel unit, connecting plate with attachment bolts and buffer.
brad - See section 2.3 for standard travel wheel treads; other travel wheel treads on request.
Travel unit weight with DRS, without connecting plate, motor and gearbox.

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

Travel Crane
unit girder
b9
b3 b4
Y

HAP
h7

Travel wheel centre

67,5 1 DFW-L-E 112
67,5 1 DFW-L-E 125
82,5 1 DFW-L-E 160
92,5 1 DFW-L-E 200

h9
brad
b8 20

20332010.eps 20332011.eps

Dimensions in mm Weight
b9 h1 h7 h9 h12 HAP L in kg

244 13 2190 131

12 149 22,5 308
247 14 2690 164

281 2220 164

285 2720 214

162,5 42,5

15 289 15 308 3370 281

232,5 359 30 4220 400

353 2275 222

357 2775 284

217 32 308

15 361 17 3425 368

Terex MHPS GmbH

294 441 39 385 4275 510

440 2340 300

442 2840 383

15 277 42 20 385 3490 486

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444

4340 586

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 4.2 DFW-L-E / O travel unit
Illustration: bolted connection

L
ekt

100 standard buffer height

A
B

X 65 250

95
M10

A B d1

h12
a5 a4

Bx1
By1

Bx2

20332012.eps

Dimensions in mm
d1 brad ekt Gearbox Bx1 Bx2 By1 a4 a5 b3 b4 b8 b10

2000 A10 136

112 max. 60 360 360 56 20 71,5 70 22
2500 A20 135
100 for
2000 138
A10 DPZ 100
125 max. 60 2500 A20 360 440 44 - 77,5 70 55
A30 120 for 140
3150 DPZ 130
2000 150 for 158
A20
160 max. 65 2500 A30 470 470 64 DPZ 160 - 88 85 65
A40 160
3150 150 for
DPZ-R100
2000 183
470 or 560 470 or 560 160/240 for
2500 A30
200 max. 65 See page See page 85 DPZ-R160 - 105,5 95 73
3150 A40 185
14 14
4000
Terex MHPS GmbH
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 The scope of delivery of a DFW travel unit includes: travel unit, connecting plate with attachment bolts and buffer.
brad - See section 2.3 for standard travel wheel treads; other travel wheel treads on request.
Travel unit weight with DRS, without connecting plate, motor and gearbox.

Illustration: bolted connection

For bolted connection

for bolted and welded connection

View X Section A-A Section B-B
b3 b4 b10
h25

h24

h7

brad b8

20332013.eps

Dimensions in mm
Weight in kg
h7 h12 h24 h25 L

244 13 259 281 2190 131

247 14 262 284 2690 164

281 296 318 2220 164

285 15 300 322 2720 214

289 304 326 3370 281

353 371 393 2275 222

357 17 375 397 2775 284

361 379 401 3425 368

440 455 477 2340 300

442 457 479 2840 383

20
444 459 481 3490 486

444 459 481 4340 586

Terex MHPS GmbH
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 5 Fittings for DFW-L-E travel units

5.1 Derailment protection fitting complete with buffer

DFW Part no. b11 b12 c1 c2
Standard buffer height

112 652 888 44 130

75 120
125 652 892 44 140
95
160 652 895 44 170
85 122
200 652 885 44 190
c1
100

c2

b11

b12

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5.2 Guide roller fitting complete with buffer

DFW Part no. b13

112 652 889 44

Standard buffer height

30 - 70
125 652 893 44

160 652 896 44 30 - 80

200 652 886 44 40 - 90

100

b13
Terex MHPS GmbH

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 5.3 Connecting plates for DFW-L-E / S
Non-countersunk connecting plates

d3

Ay1

Ay2

Ay3

HAP
Ay4

Ay
Ax 20

BAP
20332018.eps

DFW Part no. Dimensions in mm Weight

d1 ekt Ax Ay1 Ay2 Ay3 Ay4 Ay BAP HAP d3 d4 in kg
2000 95 1)
112
2500 810 706 44 - 182,5
280 375 17,9
2000, 2500, 3150
4000 810 778 44 150 220 265 308
125 95
3150 658 199 44 - 182,5 28,8
500 600
4000 811 283 44 35,6
220 - 265 21 -
2000, 2500, 3150 810 778 44
280 375 17,9
4000 655 031 44 150 220 290 335 385
160
3150 811 283 44 95 150 220 265 308
500 600 35,6
4000 655 033 44
2000, 2500, 3150, 4000 655 031 44 280 150 220 290 335 375 385 17,9
200
3150, 4000 655 033 44 500 600 35,6

Countersunk connecting plates

Ay1
d3

d4

Ay2

Ay3

HAP
Ay4

Ay

Ax 2,5 0,5

BAP 20
20332019.eps

DFW Part no. Dimensions in mm Weight

d1 ekt Ax Ay1 Ay2 Ay3 Ay4 Ay BAP HAP d3 d4 in kg
2000 95 1)
112
2500 810 265 44 - 182,5
280 375 17,9
2000, 2500, 3150
Terex MHPS GmbH

4000 959 347 44 150 220 265 308

125 95
3150 658 198 44 - 182,5 28,8
500 600
4000 811 285 44 35,6
220 - 265 21 50,1
2000, 2500, 3150 959 347 44
280 375 17,9
4000 655 032 44 150 220 290 335 385
160
3150 811 285 44 95 150 220 365 308
500 600 35,6
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4000 655 034 44

2000, 2500, 3150, 4000 655 032 44 280 150 220 290 335 375 385 17,9
200
3150, 4000 655 033 44 500 600 35,6

1) Do not use bore holes for this combination 13

 5.4 Bolted and welded connecting plates for DFW-L-E / O

Connecting plates

Bx2

Bx1
By1

d3

B
H
G

E T

20332020.eps

DFW Bu in mm Part no. Dimensions in mm Weight

in kg
d1 Bx1 Bx2 By1 E F G H T A B d3

112 200 or 300 652 789 44 360 56 40 112 120 460 140 17 8,8
360
125 200 or 300 652 823 44 440 44 73 138 150 540 170 12,1
150
160 200 or 400 652 856 44 64 83 168 177 22 200 15,2
470 470 570 21
200 or 400 653 749 44 16,5
200 85 91 198 210 230
400 or 500 652 879 44 560 560 360 660 18,3

Bu - width of the lower crane girder flange Terex MHPS GmbH

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 Welded connecting plates

B
H
F

E T

20332021.eps

DFW Bu Part no. Dimensions in mm Weight

in mm in kg
d1 E F H T A B

112 200 or 300 652 791 44 40 120 360 140 6,1

15
125 200 or 300 652 825 44 73 150 540 170 8,6
150
160 200 or 400 652 858 44 83 177 18 200 12,8
570
200 or 400 653 750 44 14,5
200 91 210 15 230
400 or 500 652 881 44 360 660 12,8

Bu - width of the lower crane girder flange

5.5 Torque brackets Torque brackets are used together with AM offset gearboxes, ZBF cylindrical-rotor
motors and DRS wheel blocks with pin connection for standard cranes.
See catalogue 203 352 44 for data, dimensions and ordering
Torque bracket Section 4.1
See catalogue 203 151 44 for data, dimensions and ordering
Offset gearboxes
Cylindrical-rotor motors

5.6 Buffers and spacer Buffers with a high energy absorption capacity are required to prevent any critical
deformation in structural steelwork resulting from travel units colliding with each
elements other or with stops at the end of a track.
Terex MHPS GmbH

See catalogue 203 352 44 for data, dimensions and ordering

Buffers and spacer elements Section 4.4

5.7 Roller guide The horizontal guide rollers must be considered together with the DRS wheel
block. Information on the roller guide arrangement must be specified in the order
arrangement
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for the travel unit.

See catalogue 203 352 44 for data, dimensions and ordering
Roller guide arrangement Section 4.6

15
6 Order form for DFW-L-E travel units

From company: Date:

Mr./Ms.: Phone:

Department: Fax:

Address:

Order data Wheel block size: 112 125 160 200

Wheel base: 2000 2500 3150 4000
Crane girder connection: S O
Bolt centre distance Ax: 280 500
Travel wheel tread
Standard DRS 112: 47 55 60
Standard DRS 125: 47 55 60
Standard DRS 160: 47 55 60 65
Standard DRS 200: 55 65
Special: ______ mm (please specify)
Travel wheel tread: A - guide flange on both sides
B - no flange
D - flange on one side
Other:
Drive arrangement: Pair of travel units Single travel unit
R/L- right/left Left Right
Number of drives: 1 2 0
Drive shaft diameter: 30 35 45 50
Roller guide arrangement: Yes No
Derailment protection: Yes No
Buffer: DPZ 100 130 160
DPZ-R 100 160x160 160x240
Connecting plate
DFW-L-E: Bolted connecting plate for crane girder connection
Finish coat: RAL1004 golden yellow Other:_________
Accessories: Horizontal guide rollers

Terex MHPS GmbH

PO Box 67 58286 Wetter (Germany)
Phone +49 (0 )2335 92-0
Fax +49 (0 )2335 92-7676
Printed in Germany

www.demagcranes.com

Reproduction in whole or in part only with prior consent of Terex MHPS GmbH, 58286 Wetter (Germany) Subject to change. Not liable for errors or omissions.