DEMAG DRF 200, Assembly Instructions Manual

Page 1: ...Assembly instructions DRF 200 friction wheel travel drive with travel motor 120914 en GB 214 395 44 719 IS 913 92...

Page 2: ...al designs or additional options differing from these assembly instructions are ordered Documents 1 Order no Technical data catalogues Demag DC Pro 1 25 chain hoist Demag DCS Pro 1 10 chain hoist 203...

Page 3: ...size and maximum permissible total displaceable load 13 General 13 ZBF motor 13 KBF motor 13 Motor key data 14 ZBF motor 14 KBF motor 14 Dimensions 15 Transport packing and storage 17 Technical descri...

Page 4: ...service for maintenance and repairs 36 Maintenance repair 37 Safety instructions for maintenance and repair work 37 Basic maintenance requirements 38 Maintenance schedule 39 Maintenance work 40 Oil l...

Page 5: ...s symbol indicates information on the appropriate use of the machine This symbol in the operating instructions indicates all warnings which if not complied with may result in mal functions or damage 1...

Page 6: ...erson who 1 manufactures the equipment under his or her own name and places it on the market for the first time 2 resells other manufacturers equipment under his or her own name whereby the reseller i...

Page 7: ...ert engineer is defined as an experienced technician specifically assigned by the manufacturer to determine the remaining duration of service service life of the machine S W P safe working period and...

Page 8: ...designed to accommodate loads resulting from operation of the hoist unit The maximum safe working load is the load capacity specified on the capacity plate This must not be exceeded The maximum permit...

Page 9: ...e off and secure it against restoration of the power supply before any maintenance cleaning or repair work is carried out Switch the power supply off before any work is carried out on the electric equ...

Page 10: ...y measures must be defined and implemented by the owner Necessary measures may also relate for example to the handling of hazardous materials or tools and the provision wearing of personal protection...

Page 11: ...this respect 2 7 Personal protection equipment When work is carried out on or with the installation the following protective equipment is recommended to be worn according to the owner s hazard assess...

Page 12: ...1 Load trolley 2 Load bar 2 Load bar 3 DC chain hoist 3 DC chain hoist 4 KBK I II L II II H link bar short for straight travel 4 KBK I II L II II H link bar long for travel on curved tracks 5 Tractor...

Page 13: ...4 6 12 5 50 ZBF 80 A8 2 B020 34 6 2800 8 31 5 ZBF 71 A8 2 B004 55 1 3000 12 5 ZBF 63 A4 B004 68 9 5 20 ZBF 63 A8 2 B004 84 6 25 ZBF 63 A2 B004 68 9 3200 16 ZBF 80 A4 B020 54 6 25 ZBF 80 A2 B020 67 0 3...

Page 14: ...5 0 87 2 10 1 50 550 ZBF 71 A 8 2 B004 1 25 2 70 2 50 0 00692 620 1 8 13 1 15 2 60 500 ZBF 80 A 2 B020 1 80 2 90 4 20 0 01275 500 3 3 18 5 ZBF 80 A 8 2 B020 1 95 2 10 3 50 620 19 5 1 70 2 60 4 00 500...

Page 15: ...r Fig 3 Item Designation Item Designation A DRF 200 with ZBF 63 71 motor B Narrow version with ZBF 63 71 motor only for KBK III C DRF 200 with ZBF 80 motor D Narrow version with ZBF 80 motor only for...

Page 16: ...Trolley for DRF 200 Fig 4 Item Designation Item Designation A Trolley for straight travel as tractor trolley B Trolley with curve travel guide arm as tractor trolley Tab 11 16 214 395 44 120914...

Page 17: ...Lodge a claim for any defects as soon as they are detected since claims for damages may only be asserted within the relevant claim notification periods Packing DRF 200 friction wheel travel drives th...

Page 18: ...nt can be achieved by means of spacer rings The trolley has only one polyamide travel wheel on each side to ensure that the unit can travel on curved tracks and to enable transfer to a gra dient radiu...

Page 19: ...ve operation Displacement between the rails and gaps at the joint must be avoided Any displacement between the rails should be ground flat if required I beam tracks should be bent with the utmost care...

Page 20: ...bar are available to connect the tractor trolley to the load trolley see also the KBK classic technical data document Tab 2 Page 2 The short link bar l 130 mm is sufficient for straight travel the lon...

Page 21: ...nd surfaces of the trolley side cheeks to attach a rail for the buffer fitting Various types of buffer or different buffer sizes can be bolted to the middle of this rail see also Cellular foam buffer...

Page 22: ...rizontal curves The minimum permitted radius for this system depends on the enclosure material and the conductor cross section Power supply for travel along straight tracks can also be provided by a t...

Page 23: ...y authorised instructed personnel who are familiar with the principle of operation of the DRF 200 friction wheel travel drive in compliance with all safety regulations Ensure sufficient working cleara...

Page 24: ...ngth The protective earth conductor must not be connected to mounting bolts or screws Protective earth connections must be protected against accidental loosening e g by using serrated lock washers to...

Page 25: ...eration Page 34 5 5 Preparing for installation Releasing air from the friction wheel travel drive Replace the plug screw at the highest point of the friction wheel travel drive with the vent screw inc...

Page 26: ...aight travel Fig 12 Item Designation Item Designation A Load trolley max load capacity 270 kg 1 Spacer sleeve for load trolley or tractor trolley B Tractor trolley 2 Spacer sleeve for tractor trolley...

Page 27: ...side cheek inside 0 1 1 2 2 3 3 4 4 5 5 6 6 7 7 outside 16 15 15 14 14 13 13 12 12 11 11 10 10 9 9 Weight kg 8 3 Flange width b mm 190 246 Load bar l mm 338 Spacer sleeve Load trolley Item 1 4 x 26 9...

Page 28: ...guide arm Fig 13 Item Designation Item Designation A Load trolley max load capacity 270 kg 1 Spacer sleeve for load trolley or tractor trolley B Tractor trolley 2 Spacer sleeve for tractor trolley Ta...

Page 29: ...7 outside 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 Weight kg 9 2 Flange width b mm 190 246 Load bar l mm 338 Spacer sleeve Load trolley Item 1 4 x 26 9 x 2 65 x 79 5 Tractor trolley Item 1 2 x 26 9 x 2 65 x 79...

Page 30: ...along the track push the trolley along the entire track by hand to check that it does not bind This check can only be carried out before the dished washer stack of the drive has been pre tensioned or...

Page 31: ...ified on the rating plate match your mains supply The protective conductor marked green yellow in the supply line must be connected to the green yellow earth ter minal If conductor lines are used to s...

Page 32: ...e carried out work may need to be performed in the danger zone when the installation is first put into operation 6 2 Inspection regulations WARNING Non compliance with operating and maintenance regula...

Page 33: ...be complete and effective Clearances and safety distances must be maintained The emergency stop device must be checked by actuating the emergency stop When the unit is first put into operation it must...

Page 34: ...applications may lead to situations which were not known when this chapter was written In this case the owner must ensure safe operation or take the installation out of service until meas ures for saf...

Page 35: ...k control cable and control pendant housing for damage Function of the brake 7 3 Operation 7 3 1 General WARNING Overload Danger to life and limb Higher loads than those specified on the load capacity...

Page 36: ...ed The installation is not protected against unauthorised or accidental switching on and therefore it is not pro tected against unintended movements Damage may be caused by an electric surge if lightn...

Page 37: ...d danger zone If an elevating work platform is used for maintenance work only use appropriate attachments for the lifting of persons which ensure that work is carried out in a safe and stable position...

Page 38: ...travel drive when the load has been re moved 4 Ensure that there is sufficient freedom of movement Keep the working area clean and tidy Loose parts or tools left lying around may cause accidents 5 St...

Page 39: ...stack correct L dimension adjustment as required X X Check power supply line For conductor lines Check insulators conductor rails connectors and expan sion joints For current collectors Check sliding...

Page 40: ...drive for the required quantity of oil Oil grades For ambient temperatures of approx 10 C to 50 C a gear oil of 220 mm2 s at 40 C with mild high pressure additives should be used DIN 51502 CLP 220 e...

Page 41: ...releases reliably air gap s1 must be regularly checked and adjusted as required Brake air gap s1min 0 35 mm s1max 1 2 mm The brake disc can be freely turned when the brake is released power applied to...

Page 42: ...n Item Designation 1 Fan cover retaining bolts 5 Armature plate 9 Magnet assembly 2 Fan cover 6 Brake disc 10 Feeler gauge 3 Retaining ring 7 Collared pin 11 End cap 4 Fan wheel 8 Hexagon nuts 12 Stop...

Page 43: ...ee hexagon nuts 8 uniformly until the air gap is zero Subsequent ly loosen the three hexagon nuts 8 by angle 1 see Tab 27 Page 41 Measure air gap s1 using feeler gauge 10 at three points around the ci...

Page 44: ...Designation Item Designation Item Designation 1 Terminal box cover 5 Armature plate 9 End cap 2 Hexagon nuts 6 Brake disc 10 Brake springs 3 Magnet assembly 7 Distance springs 11 Magnet assembly conn...

Page 45: ...Push distance springs 7 onto collared pins 8 Position brake springs 10 in magnet assembly 3 for arrangement of the brake springs see Tab 30 Page 45 Slide magnet assembly 3 over collared pins 8 and se...

Page 46: ...replace friction wheel 1 unscrew the three hexagon bolts 2 2 The tightening torque of hub 3 must be checked and if necessary re tightened before friction wheel 1 is installed The tightening torque is...

Page 47: ...t suspension fork 4 Eye bolt Tab 32 1 Install suspension fork 1 with hexagon bolt 2 2 Tighten hexagon bolt 2 to a tightening torque of 270 Nm 3 On both sides of the friction wheel tighten hexagon bolt...

Page 48: ...has been in operation Do not touch hot motor housings Allow the motor to cool down before eliminating the fault Conduct when malfunctions occur 1 Bring the installation to an immediate standstill by...

Page 49: ...ining metallic material Dispose of plastic elements for recycling Separate and dispose of any other components by material type Electric scrap electronic components lubricants and other auxiliary mate...

Page 50: ...f machinery Electrical equipment of machines Part 32 Requirements for hoisting machines The safety objectives of Low Voltage Directive 2014 35 U are achieved The product additionally complies with the...

Page 51: ...214 395 44 120914 51...

Page 52: ...tter Germany Subject to change Not liable for errors or omissions The current addresses of our sales offices subsidiaries and agencies worldwide can be found on the homepage www demagcranes com Demag...