DRF200

Assembly instructions
DRF 200 friction wheel travel drive with travel motor
120914 en GB 214 395 44 719 IS 913.92

Original assembly instructions
Manufacturer
Demag Cranes & Components GmbH
Forststrasse 16
40597 Düsseldorf, Germany
www.demagcranes.com
info@demagcranes.com
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DRF 200 friction wheel travel drive and important information if you ever have to contact the manufacturer or his rep‐
resentative.
Owner
Where in use
Size
Serial number
Travel drive no.
Year of manufacture
Operating voltage
Control voltage
Frequency
Wiring diagram number

Tab. 1
Further documents are available for sub-assemblies/components in addition to these assembly instructions. If required, the
corresponding documents are supplied or can be ordered separately, even if special designs or additional options differing
from these assembly instructions are ordered.
Documents 1) Order no.

Demag DC-Pro 1 - 25 chain hoist
203 525 44
Demag DCS-Pro 1 - 10 chain hoist
KBK classic (steel, powder-coated) 202 976 44
KBK trailing cable 202 617 44
Technical data/catalogues DEL conductor line 202 673 44
DKK conductor line 202 540 44
DCL conductor line 203 387 44
Fittings + C-rail overview 201 752 44
Cellular foam buffer 202 607 44
Operating instructions/component DC-Pro 1 - 15 chain hoist 214 741 44
parts DRF current collector bracket 206 630 44
ZNA, ZBA, ZBF motors 214 228 44
Assembly – Adjustment – Dimensions
KBA, KBF motors 214 318 44
DRF 200 friction wheel travel drive 222 572 44
Z 63/Z 71 motor 222 856 44
Spare parts
ZBF 80 motor 222 864 44
KB 71 - 140 motor 217 039 44
Tab. 2
The metric system is used in this document and all figures are shown with a comma as the decimal separator.
214 395 44/120914
2 1) The documents can be ordered from the relevant Demag office.

Table of contents
1 General........................................................................................................................................................................ 5
1.1 DRF 200 friction wheel travel drive ............................................................................................................................. 5
1.2 Symbols/signal words.................................................................................................................................................. 5
1.3 Information on the assembly instructions .................................................................................................................... 5
1.4 Liability and warranty................................................................................................................................................... 5
1.5 Copyright ..................................................................................................................................................................... 6
1.6 Use of spare parts ....................................................................................................................................................... 6
1.7 Definition of personnel................................................................................................................................................. 6
1.8 After-sales service ....................................................................................................................................................... 7
2 Safety .......................................................................................................................................................................... 8
2.1 General........................................................................................................................................................................ 8
2.2 Safety signs on the equipment .................................................................................................................................... 8
2.3 Intended use................................................................................................................................................................ 8
2.4 Hazards that can be caused by the DRF 200 friction wheel travel drive..................................................................... 9
2.5 Responsibility of the owner ....................................................................................................................................... 10
2.6 Operating personnel requirements............................................................................................................................ 11
2.7 Personal protection equipment.................................................................................................................................. 11
2.8 Regular inspections................................................................................................................................................... 11
3 Technical data ........................................................................................................................................................... 12

3.1 Design overview ........................................................................................................................................................ 12
3.2 Travel speed, motor size and maximum permissible total displaceable load............................................................ 13
3.2.1 General...................................................................................................................................................................... 13
3.2.2 ZBF motor ................................................................................................................................................................. 13
3.2.3 KBF motor ................................................................................................................................................................. 13
3.3 Motor key data........................................................................................................................................................... 14
3.3.1 ZBF motor ................................................................................................................................................................. 14
3.3.2 KBF motor ................................................................................................................................................................. 14
3.4 Dimensions................................................................................................................................................................ 15
3.5 Transport, packing and storage................................................................................................................................. 17
4 Technical description................................................................................................................................................. 18
4.1 Design ....................................................................................................................................................................... 18
4.2 Motor ......................................................................................................................................................................... 18
4.3 Trolley........................................................................................................................................................................ 18
4.4 Runway ..................................................................................................................................................................... 19
4.5 Trolley for KBK crane construction kit ....................................................................................................................... 20
4.6 Link bar...................................................................................................................................................................... 20
4.7 Load bar .................................................................................................................................................................... 20
4.8 Disengaging device ................................................................................................................................................... 21
4.9 Buffer fitting ............................................................................................................................................................... 21
4.10 Power supply lines .................................................................................................................................................... 22
5 Assembly ................................................................................................................................................................... 23
5.1 General assembly information................................................................................................................................... 23
5.2 Safety instructions for assembly................................................................................................................................ 23
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5.3 Tightening torques..................................................................................................................................................... 24

5.4 Installation procedure ................................................................................................................................................ 25
5.5 Preparing for installation............................................................................................................................................ 25
5.6 Trolleys ...................................................................................................................................................................... 26 3
5.7 Link bar...................................................................................................................................................................... 30
5.8 Load bar .................................................................................................................................................................... 31
5.9 Connecting the electric equipment ............................................................................................................................ 31
6 Putting into service for the first time .......................................................................................................................... 32

6.1 Safety instructions when putting into service for the first time................................................................................... 32
6.2 Inspection regulations ............................................................................................................................................... 32
6.3 Checks on entering service, handover ...................................................................................................................... 33
7 Operation................................................................................................................................................................... 34
7.1 Safety instructions for operation................................................................................................................................ 34
7.2 Switching on .............................................................................................................................................................. 34
7.2.1 Checks when starting work ....................................................................................................................................... 34
7.2.2 Function checks ........................................................................................................................................................ 35
7.3 Operation................................................................................................................................................................... 35
7.3.1 General...................................................................................................................................................................... 35
7.4 Taking the equipment out of operation...................................................................................................................... 36
7.4.1 Taking the equipment out of service when faults occur ............................................................................................ 36
7.4.2 Taking the equipment out of service at the end of the shift ....................................................................................... 36
7.4.3 Taking the equipment out of service for maintenance and repairs............................................................................ 36
8 Maintenance/repair.................................................................................................................................................... 37
8.1 Safety instructions for maintenance and repair work ................................................................................................ 37
8.2 Basic maintenance requirements .............................................................................................................................. 38
8.3 Maintenance schedule .............................................................................................................................................. 39
8.4 Maintenance work ..................................................................................................................................................... 40
8.4.1 Oil lubrication............................................................................................................................................................. 40
8.4.2 Grease lubrication ..................................................................................................................................................... 40
8.4.3 Brake ......................................................................................................................................................................... 41
8.4.3.1 General...................................................................................................................................................................... 41
8.4.3.2 Checking and adjusting brake air gap s1 ................................................................................................................... 42
8.4.3.3 Replacing the brake disc ........................................................................................................................................... 44
8.4.4 Friction wheel drive ................................................................................................................................................... 46
8.4.4.1 Removing and installing the friction wheel ................................................................................................................ 46
8.4.4.2 Removing and installing the suspension fork and suspension.................................................................................. 47
9 Malfunctions/warnings ............................................................................................................................................... 48
9.1 Safety instructions for malfunctions/warnings ........................................................................................................... 48
10 Disassembly/disposal ................................................................................................................................................ 49
10.1 General...................................................................................................................................................................... 49
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4
1 General
1.1 DRF 200 friction wheel travel drive

You have purchased a Demag quality product.
This DRF 200 friction wheel travel drive was manufactured to European standards and regulations in accordance
with state-of-the-art engineering principles. The EC Machinery Directive requirements are satisfied.
1.2 Symbols/signal words

Important safety information and instructions are marked by corresponding symbols and signal words in these in‐
structions.
Safety instructions and information must be followed. Exercise particular caution to ensure that accidents, injuries
and damage are avoided in such cases.
Locally applicable accident prevention regulations and general safety regulations must also be followed.
The following symbols and instructions warn against possible injuries or damage and are intended to assist you in
your work.
DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
WARNING
This symbol indicates a possibly hazardous situation which might result in serious injury or death.
CAUTION
This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage.
Operating hazard for the machine.

● This 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.
1.3 Information on the assembly instructions

These assembly instructions are designed to provide the owner and operator with useful instructions for transport‐
ing, installing, putting into service, operating and maintaining our DRF 200 friction wheel travel drive. These as‐
sembly instructions are an integral part of the installation.
Persons entrusted with the various types of work must know and comply with the safety regulations and the as‐
sembly instructions.
The installation may only be operated by personnel who are fully familiar with the assembly instructions. In partic‐
ular, they contain the "Safety" section and the relevant safety instructions in the working sections of these assem‐
bly instructions.
The assembly instructions must be available to operating personnel at all times in order to prevent operating er‐
rors and to ensure smooth and trouble-free operation of our products. They must be kept in the immediate vicinity.
1.4 Liability and warranty

All information included in these instructions has been compiled on the basis of the relevant regulations, state-of-
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the-art engineering principles and our many years of experience.

These instructions must be read carefully before starting any work on and with the DRF 200 friction wheel travel
drive, especially before it is put into service for the first time. The manufacturer assumes no liability for any dam‐
age which results from the following: 5
● non-compliance with the instructions,
● inappropriate use,
● untrained personnel,
● unauthorised conversions,
● technical modifications.
Wearing parts are not subject to liability for defects.

We reserve the right to incorporate technical modifications within the scope of improving the operating character‐
istics and further development of the product.
1.5 Copyright
These instructions are only intended to be used by the people who work with or on the DRF 200 friction wheel
travel drive.
Any and all content, texts, drawings, images and any other information are protected within the sense of copyright
law and are subject to further industrial rights. Any misuse is an offence.
No part of this documentation, in whole or in part, may be reproduced, distributed, shown in public or used in any
other way without specific prior consent. Infringements are an offence resulting in obligatory compensatory dam‐
ages. Further rights reserved.
All industrial rights reserved.
1.6 Use of spare parts

We urgently recommend that only spare parts and accessories approved by us be used. Only then can we ensure
the safety and normal service life of the installation.
Spare parts not approved by us may cause unpredictable hazards, damage, malfunctions or complete failure of
the DRF 200 friction wheel travel drive.
The use of unauthorised spare parts may render null and void any claims for warranty, service, damages or liabili‐
ty against the manufacturer or his appointed personnel, dealers and representatives.
1.7 Definition of personnel

The manufacturer is the person 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 is not considered to
be the manufacturer provided the name of the manufacturer (as in 1.) appears on the equipment;
3. imports the equipment into the country and places it on the market for the first time or
4. exports equipment to another member state of the European Union and hands it over direct to a user in that
country.
Owner
Owners (employer, company) are defined as persons who own the machine and who use it as intended or allow it
to be operated by suitable and trained persons.
Operating personnel/operator
Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper‐
ate the machine. This person must be trained by the owner in accordance with the tasks to be performed.
Trained person
Trained persons are defined as persons who have been instructed and trained for the tasks assigned to them and
on the possible hazards resulting from inappropriate conduct. Personnel must be informed about the required pro‐
tective devices, protective measures, relevant regulations, codes of practice, accident prevention regulations and
operating conditions and must provide verification of their competence. This person must be trained by the owner
in accordance with the tasks to be performed.
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Specialist personnel
Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks,
such as installation, setting-up, maintenance and fault elimination. This person must be trained by the owner in
accordance with the tasks to be performed.
6
Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of
electric machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. This person must be
trained by the owner in accordance with the tasks to be performed.
Experienced technician
Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐
cient knowledge in the field of the machine. They must be familiar with the relevant national industrial safety regu‐
lations, codes of practice, accident prevention regulations, directives and generally accepted engineering stand‐
ards enabling them to judge the safe operating condition of machines.
Assigned expert engineer (in the Federal Republic of Germany according to BGV D8, Section 23, for determining
the S.W.P.)
An assigned expert 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 to
carry out a general overhaul of the machine.
Authorised expert engineer (according to BGV D6, Section 28 in the Federal Republic of Germany)
In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorised expert engi‐
neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers’ Mu‐
tual Insurance Association.
1.8 After-sales service

If you have any questions on our products or need technical information, please contact our after-sales service.
Please keep the serial or order number (see test and inspection booklet, load capacity plate on the crane) for any
correspondence or spare part orders. Specifying this data ensures that you receive the correct information or the
required spare parts.
The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found
on the Demag Cranes & Components GmbH homepage at www.demagcranes.com/Contact
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7
2 Safety
2.1 General
The "Safety" chapter provides an overview of all important safety aspects for optimum protection of personnel as
well as safe and trouble-free operation.
When it is placed on the market, the DRF 200 friction wheel travel drive is built according to generally accepted
engineering standards and is considered to be safe to operate. It may may still be a cause of danger if it is not
used correctly or as intended by suitably trained personnel.
Knowledge of the contents of the assembly instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the DRF 200 friction wheel travel drive safely
and reliably.
Any conversions, modifications or additions to the DRF 200 friction wheel travel drive are prohibited unless ap‐
proved by Demag in writing.
2.2 Safety signs on the equipment

Any pictograms, signs or labels on the machine must be obeyed and
must not be removed. Pictograms, signs or labels that are damaged or
no longer legible must be replaced immediately.
Fig. 1 Example: capacity plate
2.3 Intended use

The DRF 200 friction wheel travel drive may only be used as intended and in compliance with the requirements
for the owner and the following limitations as specified in these assembly instructions. Any other use may result in
a danger to life and limb and/or cause damage to the DRF 200 friction wheel travel drive and/or load.
● The support superstructure for the DRF 200 friction wheel travel drive must be 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 permitted load includes the load and any load
handling attachment.
● The DRF 200 friction wheel travel drive may only be installed, used, operated, maintained and removed by
trained personnel when it is in perfect working order. Personnel must meet the requirements according to
 "Operating personnel requirements", Page 11.
● Intended use includes compliance with the safety instructions as well as any other instructions on assembly
and disassembly, commissioning, function and operation, maintenance and fault elimination as well as compli‐
ance with the instructions on the installation safety devices, any possible remaining hazards and protection
against hazards.
● The DRF 200 friction wheel travel drive may only be used subject to the permissible technical data,  "Techni‐
cal data", Page 12.
● The DRF 200 friction wheel travel drive must be maintained regularly and appropriately by trained personnel in
line with the specified deadlines and checked according to  "Maintenance schedule", Page 39. Wearing
parts must be replaced in good time.
● UVV/BGV D8, Section 23 (2) and BGV D6 (1) guidelines must be not be ignored.
No liability for inappropriate use
The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐
ceptable according to these assembly instructions. In particular, the manufacturer assumes no liability for damage
due to inappropriate or any other prohibited use of the DRF 200 friction wheel travel drive in the sense of the "In‐
214 395 44/120914
tended use" section.
8
No liability for structural modifications
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the DRF 200 friction wheel travel drive to devices or equipment that do not
belong to our scope of delivery, or the installation or use of third-party accessories, equipment or sub-assemblies
that are not approved by the manufacturer.
Depending on the type and scope of the DRF 200 friction wheel travel drive, it may be necessary to have an in‐
spection carried out by an expert engineer before it is handed over to the owner.
2.4 Hazards that can be caused by the DRF 200 friction wheel travel drive
The DRF 200 friction wheel travel drive has been subjected to a risk assessment. The design and execution
based on this analysis corresponds to state-of-the-art engineering principles. However, residual risks remain.
The DRF 200 friction wheel travel drive operates with high electric voltage.
DANGER
Live components
Danger to life and limb.
Electric energy may cause very severe injuries. Danger of death caused by electric current if the insulation or
individual components are damaged.
– Switch the machine 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 equipment. Check to ensure that
the components to be replaced are de-energised.
– Do not remove any safety equipment or render it inoperative by modifications.
WARNING
Crushing hazard
There is a risk of injury due to parts of the body being crushed/sheared or clothing or hair becoming entangled.
Protection must be provided if the DRF 200 friction wheel travel drive is suspended at a height within normal
reach.
WARNING
Suspended load. Falling parts.
Danger to life and limb from falling parts.
The track ends must be provided with elastic buffers.
WARNING
Danger to life and limb if the operating and maintenance instructions are not followed.
Required tests and inspections must be carried out.
In the course of the annual inspection, the trolley must be checked for:
– deformation or cracks,
– chipping or wear of the travel wheels,
– completeness of all parts,
– correct adjustment of the DRF 200 friction wheel travel drive.
Certain work and practices are prohibited when using the machine as they may involve danger to life and limb
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and result in lasting damage to the machine. Observe the safety instructions in the sections:
●  "Assembly", Page 23
●  "Putting into service for the first time", Page 32
9
●  "Operation", Page 34
●  "Maintenance/repair", Page 37
2.5 Responsibility of the owner

Information on safety at work refers to the regulations of the European Union that apply when the DRF 200 friction
wheel travel drive is manufactured. The owner is obliged to ensure that the specified industrial safety measures
comply with the latest rules and regulations and to observe new regulations during the entire service life of the
DRF 200 friction wheel travel drive. Local industrial safety legislation and regional regulations and codes of prac‐
tice applicable at the site of operation of the DRF 200 friction wheel travel drive must be observed outside the
European Union.
General safety, accident prevention and environmental protection regulations that apply where the DRF 200 fric‐
tion wheel travel drive is in operation must be observed and complied with in addition to the safety instructions
contained in these assembly instructions.
The owner and any personnel authorised by him are responsible for correct operation of the DRF 200 friction
wheel travel drive and for clearly defining responsibilities for installation, operation, maintenance and cleaning.
The assembly instructions must be followed in full and without any limitations.
Special local conditions or applications may lead to situations which are not considered in these assembly instruc‐
tions. In such cases, the required safety 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 equipment. The assembly instructions must, if required, be supplemented by the owner
with instructions relating to organisation of work, working procedures, authorised personnel, supervising and re‐
porting obligations, etc. For further information, see  "Safety instructions for operation", Page 34.
Furthermore, the owner must ensure that
● any further working and safety instructions resulting from the risk assessment of the workplaces at the installa‐
tion are specified in operating procedures.
● personnel who work with or on the installation are provided with appropriate first-aid equipment. Personnel
must be trained in the use of the first-aid equipment.
● the assembly instructions are always kept available in the immediate vicinity of the installation for installation,
operating, maintenance and cleaning personnel.
● personnel are trained in accordance with the work to be performed.
● the installation is only operated when in safe and proper working order.
● safety devices are always kept freely accessible and are checked regularly.
● national regulations for the use of cranes and lifting appliances are observed.
● any specified regular checks and inspections are carried out on time and are documented.
The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these
instructions at a suitable place where they can be easily seen.
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10
2.6 Operating personnel requirements
Only authorised and trained personnel may work on the installation. The personnel must have received instruction
on the installation functions and any hazards that may occur.
Every individual given the task of working on or with the installation must have read and understood the instruc‐
tions before any work starts.
Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with
the installation.
Age and job-specific regulations relevant at the place where the installation is operated must be observed for the
selection of any personnel.
Personnel are obliged to report to the owner without delay any changes to the installation that impair safety.
For independent operation (operator) or maintenance (trained maintenance fitter) of the installation, the owner
may only employ persons
● who are at least 18 years of age,
● who are mentally and physically suitable,
● who have been instructed in the operation and maintenance of the installation and who have proven their quali‐
fication to the owner in 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 assessment:
● Protective clothing, closely fitting working clothes (low tear strength, no loose sleeves, no rings or any other
jewellery, etc.);
● Safety shoes to protect against falling parts and against slipping;
● Safety helmet to be worn by everybody in the danger zone.
2.8 Regular inspections

The owner of the installation may be obliged to carry out regular inspections by national industrial safety legisla‐
tion and regional regulations. In Germany, this is specified by the accident prevention regulations for winches,
hoists and towing devices (BGV D8) and the accident prevention regulations for cranes (BGV D6), for example.
These specify that
● the installation must be inspected before it is put into operation,
● the installation must be inspected regularly.
The owner is obliged to ensure that the installation complies with the latest rules and regulations and to observe
new regulations at all times.
If no comparable inspection regulations or requirements apply at the place where the installation is operated, we
recommend compliance with the above-mentioned regulations.
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11
3 Technical data
3.1 Design overview
Fig. 2
Item Designation Item Designation

A For straight travel B For travel on curved tracks
1 Load trolley 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 trolley 5 Tractor trolley
6 Dished washer stack 6 Dished washer stack
7 DRF 200 7 DRF 200
8 Curve travel guide arm
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Tab. 3
12
3.2 Travel speed, motor size and maximum permissible total displaceable load
3.2.1 General
● Friction wheel travel drive without a motor weighs 12 - 14 kg.

● Motor duty factor 40% CDF or 40/20% CDF for pole-changing motors.
● Calculated with a travel resistance of 160 N/t.
● Permissible tangential force ≤ 1500 N.
● Only for operation on dry horizontal tracks. Operation on inclined tracks or damp running surfaces on request.
● Motors for other voltages and frequencies, KBF motors with microspeed unit or motors for frequency inverter
operation on request.
3.2.2 ZBF motor
1 travel speed 2 travel speeds

Load ca‐ Possible travel Travel drive Brake iges Possible travel Travel drive Brake iges
pacity speeds speeds
[kg] [m/min] [m/min]
1500 10/40 ZBF 63 A8/2 B004 43,7
1800 40 ZBF 63 A2 B004 43,7
2000 8/31,5 ZBF 63 A8/2 B004 55,1
2200 10/40 ZBF 71 A8/2 B004 43,7
16 ZBF 63 A4 B004 55,1
2300
31,5 ZBF 63 A2 B004 55,1
6,3/25 ZBF 63 A8/2 B004 68,9
2500 8/50 ZBF 80 A12/2 B020 34,6
12,5/50 ZBF 80 A8/2 B020 34,6
2800 8/31,5 ZBF 71 A8/2 B004 55,1
12,5 ZBF 63 A4 B004 68,9 5/20 ZBF 63 A8/2 B004 84,6
3000
25 ZBF 63 A2 B004 68,9
16 ZBF 80 A4 B020 54,6
3200
25 ZBF 80 A2 B020 67,0
3400 31,5 ZBF 80 A2 B020 54,6 6,3/25 ZBF 71 A8/2 B004 68,9
10 ZBF 63 A4 B004 84,6 6,3/40 ZBF 80 A12/2 B020 43,7
3500 20 ZBF 63 A2 B004 84,6 10/40 ZBF 80 A8/2 B020 43,7
50 ZBF 80 A2 B020 34,6
4/25 ZBF 80 A12/2 B020 67
4000
6,3/25 ZBF 80 A8/2 B020 67
4200 40 ZBF 80 A2 B020 43,7 5/20 ZBF 71 A8/2 B004 84,6
5/31,5 ZBF 80 A12/2 B020 54,6
4500
8/31,5 ZBF 80 A8/2 B020 54,6
Tab. 4
3.2.3 KBF motor
1 travel speed 2 travel speeds

Load capacity Possible travel speeds Travel drive iges Load capacity Possible travel speeds Travel drive iges
[kg] [m/min] [kg] [m/min]
1710 40 KBF 71 A 2 44,4 1750 8/31,5 KBF 71 A 8/2 56
2170 31,5 KBF 71 A 2 56 1990 10/40 KBF 71 B 8/2 44,4
2230 16 KBF 71 A 4 56 2200 6,3/25 KBF 71 A 8/2 68,8
2740 25 KBF 71 A 2 68,8 2530 8/31,5 KBF 71 B 8/2 56
2800 12,5 KBF 71 A 4 68,8 2710 5/20 KBF 71 A 8/2 85,9
3390 20 KBF 71 A 2 85,9 3180 6,3/25 KBF 71 B 8/2 68,8
3450 10 KBF 71 A 4 85,9 3930 5/20 KBF 71 B 8/2 85,9
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Tab. 5
13
3.3 Motor key data
3.3.1 ZBF motor
Size PN nN IN for 50 Hz, 3 ~ 2) IA/IN cos φN

230 V 400 V 500 V
[kW] [rpm] [A] [A] [A]
ZBF 63 A 2 B004 0,26 2630 1,30 0,76 0,61 3,40 0,78
ZBF 63 A 4 B004 0,13 1370 0,75 0,43 0,34 3,70 0,62
0,06 675 1,20 0,66 0,53 1,40 0,59
ZBF 63 A 8/2 B004
0,25 2745 1,70 0,95 0,76 2,65 0,71
0,09 675 1,40 0,76 0,61 1,60 0,61
ZBF 71 A 8/2 B004
0,34 2785 1,80 1,00 0,80 3,50 0,73
ZBF 80 A 2 B020 0,50 2630 2,30 1,30 1,10 3,50 0,87
0,13 630 2,10 1,20 0,96 1,25 0,64
ZBF 80 A 8/2 B020
0,50 2790 2,50 1,40 1,10 4,50 0,73
0,06 415 2,70 1,50 1,20 1,00 0,71
ZBF 80 A 12/2 B020
0,50 2790 2,50 1,40 1,20 4,50 0,73
Tab. 6
Size MN MA/MN MH Jmot A MOpHrs Weight

[Nm] [Nm] [kgm2] [1/h] [Nm] [kg]
ZBF 63 A 2 B004 0,94 3,20 550
2,50 12
ZBF 63 A 4 B004 0,91 3,30 720
0,00461 1,3
0,85 2,20 1,70 720
ZBF 63 A 8/2 B004 12,5
0,87 2,10 1,50 550
1,25 2,70 620
ZBF 71 A 8/2 B004 2,50 0,00692 1,8 13
1,15 2,60 500
ZBF 80 A 2 B020 1,80 2,90 4,20 500 18,5
1,95 2,10 3,50 620
ZBF 80 A 8/2 B020
1,70 2,60 4,00 0,01275 500 3,3
19,5
1,40 2,40 3,00 620
ZBF 80 A 12/2 B020
1,70 2,60 4,00 500
Tab. 7
3.3.2 KBF motor
Size PN nN IN for 50 Hz, 3 ~ 2) IA/IN cos φN

230 V 400 V 500 V
[kW] [rpm] [A] [A] [A]
KBF 71 A 2 0,26 2550 0,90 3,20 0,83
KBF 71 A 4 0,13 1340 0,57 2,45 0,65
0,04 640 0,76 1,25 0,71
KBF 71 A 8/2 On request On request
0,20 2650 0,62 3,55 0,80
0,06 660 1,20 1,15 0,55
KBF 71 B 8/2
0,30 2750 1,10 3,55 0,70
Tab. 8
Size MN MA/MN MH Jmot A MOpHrs Weight

[Nm] [Nm] [kgm2] [1/h] [Nm] [kg]
KBF 71 A 2 0,97 3,1 2,5 3,8 940 1,4 9,6
KBF 71 A 4 0,93 2,8 2,1 3,8 1080 1,4 9,6
0,60 3,2 1,7 1400
KBF 71 A 8/2 3,8 1,1 9,6
0,72 2,5 1,5 600
0,87 4,4 2,5 1250
KBF 71 B 8/2 3,9 1,6 11,0
1,05 3,1 2,7 500
214 395 44/120914
Tab. 9
14 2) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
3.4 Dimensions
DRF 200 with ZBF motor
Fig. 3

214 395 44/120914
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 KBK III
Tab. 10
15
Trolley for DRF 200
Fig. 4

A) Trolley for straight travel as tractor trolley B) Trolley with curve travel guide arm as tractor trolley
Tab. 11
214 395 44/120914
16
3.5 Transport, packing and storage
Safety instructions
WARNING
Falling parts
Risk of injury from falling parts during transport, loading and unloading operations.
– Do not step under the suspended load. Keep a sufficient safety distance.
– Cordon off a large area around the working zone.
WARNING
Damage caused during transport
The DRF 200 friction wheel travel drive may be damaged or destroyed by inappropriate transport.
Attach lifting and handling equipment only at the correspondingly marked points.
Scope of delivery
If special designs or additional options are ordered or the latest technical modifications are incorporated, the ac‐
tual scope of supply may differ from the data and information as well as from the illustrations described here. If
you have any questions, please contact the manufacturer.
Transport inspection
● Check the delivery immediately on receipt to ensure that it is complete and examine it for any damage caused
in transit.
● If any transport damage is visible from the outside, do not accept the delivery or only on condition. Note the
scope of damage in the shipping documents/delivery note of the forwarding company. Lodge a claim.
● 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, the accessories and the trolleys are shipped in cardboard packing.
If no agreement has been made on the return of the packing material, separate the materials according to type
and size and make them available for further use or recycling.
Environmental protection:
● Always dispose of packing materials in an environmentally compatible way and according to locally applicable
disposal regulations.
● If required, utilise the services of a recycling company.
Storage
Until they are installed, the equipment and accessories must be kept closed and may only be stored under the
following conditions:
● Do not store outdoors.
● Store in dry and dust-free places, relative air humidity: max. 60%.
● Do not expose to aggressive media.
● Protect against direct sunlight.
● Avoid mechanical vibrations.
● Storage temperature: -25 to +70 °C.
● Avoid strong temperature fluctuations (condensation).
● Oil all bare machine parts (rust protection).
● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
214 395 44/120914
protection.
● If stored in a damp location, the equipment must be packed tight and protected against corrosion (use desic‐
cant).
17
4 Technical description
4.1 Design
The friction wheel with HydroPUR tyre is driven via a gearbox and electric motor.
The gearbox of the DRF 200 is a 3-stage spur wheel gearbox. The gearbox housing is designed in such a way
that it can be fitted direct to the relevant trolleys.
The motor shaft features a tapered opening. The pinion bonded into the tapered opening transfers the motor tor‐
que to the gearbox.
4.2 Motor
The drive is an electric motor. The equipment is designed in accordance with the VDE regulations. The type of
enclosure is IP 55. Refer to the relevant motor operating instructions for further details.
4.3 Trolley
The trolley has been specially developed as a tractor trolley for the
DRF 200 friction wheel travel drive.
The drive unit has been developed as a component particularly for I-
beam girders and box-section girders that have parallel flanges for
flange thicknesses from 10 mm to 30 mm. The flange width range from
82 mm to 300 mm (100 mm - 300 mm for travel on curved tracks) is
covered by load bar pins on four different lengths; fine adjustment 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 radius.
Lateral guidance of the trolley on the girder section is ensured by by
two polyamide guide rollers on each trolley side cheek.
Fig. 5
Tilting of the trolley caused by acceleration and braking is prevented by anti-tilt rollers. A certain amount of play is,
however, necessary in order to avoid positive guidance. The special design of the deep-drawn side cheek en‐
sures that the trolley has both an anti-derailment feature as well as an integral drop stop.
The use of a guide arm for travel on curved tracks enables the trolley to travel through a horizontal curve radius of
approx. 800 mm and a vertical gradient radius of approx. 2000 mm.
The maximum travel speed in both horizontal and vertical curves must not exceed 10 m/min. For curve-negotiat‐
ing trolleys, we recommend the use of a pole-changing motor and selection of the lower speed for travel on
curved track.
In this case, the anti-tilt guide rollers are not fitted in the trolley side cheek. The function of these rollers is then
provided by the anti-tilt guide rollers of the curve travel guide arm.
214 395 44/120914
18
4.4 Runway
Item Designation
A) Hatched areas with primer coat only
Tab. 12
WARNING
Overload
Danger to life and limb if the trolley is subjected to an
overload.
The load capacity of the hoist unit must not exceed the
load capacity of the trolley.
When selecting a track, we recommend you specify the special profile

sections (see  "Trolley for KBK crane construction kit", Page 20) of
our Demag KBK crane construction kit. They are characterised by their
low deadweight. The cold-rolled track sections feature a smooth run‐
ning surface and offer the advantage of simple power supply by means
of trailing cables or integrated conductor lines.
I-beam girders and box-section girders that have parallel flanges can al‐
so be used tracks.
Fig. 6
In the interest of good travel characteristics, we recommend the use of much larger curve radii, see  Tab. 13,
Page 19.
● Wear of the travel wheels is highly dependent on the curve radius. The force required to move the load may
be much higher on small curve radii in connection with heavy loads.
● The travel wheels and guide rollers may display increased wear in installations featuring intensive 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 to obtain an even and regular curve. Ready-made curved sec‐
tions are available for our special track.
Travel on I-beam tracks must in no way be obstructed by protruding suspension pins, bolt heads, clamping plates
and butt straps, etc. These types of obstruction can be avoided by using our special track section.
In unclean environments, the running surface of the track should be cleaned regularly and should be free of oil
and grease.
Resilient buffers should be mounted at the level of the travel wheel axle at the ends of tracks to prevent the trolley
from derailing (see  "Buffer fitting", Page 21).
The running surfaces of rails and for friction wheel travel drives on crane girders and runways must only be given
a primer coat of 40 µ in the area of the wheels, see (A)  Fig. 6, Page 19. Travel characteristics would be im‐
paired by a top coat.
Curve radii
Minimum medium horizontal curve radius

Flange width b [mm] ≥ 100 < 200 < 300
Curve radius Rhor min [mm] > 800 > 850 > 900
Minimum medium vertical curve radius (gradient radius)
Flange thickness t [mm] 10 - 19 20 - 25 28 - 30
Curve radius Rvert min [mm] > 2000 > 2500 > 3000
Tab. 13
214 395 44/120914
19
4.5 Trolley for KBK crane construction kit
Fig. 7

A) KBK II-L, KBK II, KBK II-R B) KBK III
Tab. 14
DRF 200 friction wheel travel drives transmit the output of the travel motor, which is specially developed for the
crane construction kit, via a spring-mounted friction wheel to the bottom flange of KBK rails. The wide friction
wheel should be used for KBK II, and the narrow friction wheel for KBK III. DRF 200 mounting components can be
relocated to vary the position of the spring assembly and motor as required. Contactor control and timed mechani‐
cal braking, or timed mechanical braking elements in the control pendant are required if pole-changing travel
drives are used.
4.6 Link bar

Two different lengths of link 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 long link bar (l = 270 mm) is required for travel
on curved tracks. The long link bar is available for travel on horizontal curve radii up to R = 800 mm and there is a
second bar for travel on radii up to R = 2000 mm.
4.7 Load bar

The tractor trolley can also be used as a load trolley when a load bar is used. Load and tractor trolleys are availa‐
ble in variants for travel on straight and curved tracks.
The load bar pin is retained on the trolley by a load bar and distance sleeve that corresponds to the flange width.
The load bar (see  "Load bar", Page 31) is suitable for attaching a DC 1 or DC 2 chain hoist. The maximum
permissible safe working load of the load trolley is 270 kg for non-guided loads which are allowed to swing freely.
214 395 44/120914
20
4.8 Disengaging device
The counterweight is used to manually relieve the pre-tension of the
dished washer stack.
The trolley and drive can be pushed along the track by hand when the
tension on the dished washer stack is released.
Fig. 8
4.9 Buffer fitting
Fig. 9

A) Buffer fitted to steelwork, buffered against flat steel 1 M12 set nut
B) Buffer fitted to the trolley via flat steel 2 Threaded pin
Tab. 15
Bore holes are provided on the end 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 tech‐
nical data" document  Tab. 2, Page 2.
The buffer must be attached to a trolley for travel on curved tracks on the opposite side to that of the curve travel
guide arm. A fitted buffer may collide with the track when the trolley travels through a gradient radius. In this case,
we recommend fitting the buffer to the end of the track as a stationary buffer. The impact with the stationary buffer
is then absorbed via the rail section on the trolley.
214 395 44/120914
21
4.10 Power supply lines
Fig. 10 Example of a current collector arrangement on a DRF 200 trolley
Power supply is provided via a specially developed current collector system.

The DEL current collector system is suitable for travel through horizontal and vertical curves in the specified per‐
mitted radius range.
The DCL current collector profile is suitable for travel through horizontal 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 trailing cable.
The current collector bracket and/or current collector tube can be bolted to the trolley using the corresponding
bore holes in the side cheek.
Limit switches and proximity switches can be attached to the trolley using a C-rail.
For further information on DEL, DCL and DKK power supply lines, the trailing cable and the C-rail, see  Tab. 2,
Page 2.
214 395 44/120914
22
5 Assembly
5.1 General assembly information

These instructions enable owners to install, re-install or replace DRF 200 friction wheel travel drives themselves.
The owner must appoint a coordinator who is authorised to issue instructions before assembly work commences.
Despite detailed information, errors cannot be excluded when the installation is assembled by the customer. For
this reason, we recommend that this work be carried out by our trained specialists or by persons authorised by
us.
The wiring of DRF 200 friction wheel travel drives complies in all respects with current DIN VDE and accident pre‐
vention regulations.
Unauthorised intervention and modifications eliminate compliance with these regulations.
DANGER
Live components
It must be possible to switch off the power supply by means of a device to disconnect the power supply (e.g.
mains connection or isolating switch with a padlock).
DRF 200 friction wheel travel drives are supplied with power from an AC power network. The voltage and fre‐
quency of the AC power network must match the data specified on the rating plate.
5.2 Safety instructions for assembly
DANGER
Incorrect assembly
Incorrect installation may result in severe injury and/or damage to property. Therefore, this work may only be
carried out by 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 clearance before starting assembly work.
– Secure and fence off the working and danger zone.
– If an elevating work platform is used for assembly, only use appropriate attachments for the lifting of per‐
sons which ensure that work is carried out in a safe and stable position.
– Only suitable, tested and calibrated tools and accessories may be used for assembly or disassembly work.
– Wear protective clothing.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any unneeded machine or installation parts and tools in such a
way that there is no risk of them falling.
– Fit components appropriately. Comply with specified bolt tightening torques. Incorrectly fitted components
may fall and cause severe injuries.
– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐
ments must be fulfilled. The electrode holder and earth must be connected to the same assembly when
welding work is carried out. Otherwise serious damage may be caused to the hoist.
– Customer-specific regulations must be observed.
DANGER
Live components
214 395 44/120914

Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐
nel", Page 6) in compliance with the safety regulations.
23
Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐
tected against unauthorised or accidental restoration of the power supply by means of a padlock.
Mechanical safety
All bolted connections must be correctly tightened.
Self-locking nuts must not be replaced by other types of nut. Self-locking nuts must be replaced when they have
been tightened and untightened five times. The clamping torque of a self-locking nut must not be lower than the
loosening torque specified by EN ISO 2320.
A sufficiently secure connection can only be guaranteed by tightening to the specified tightening torque.
Bolted connections must not be lubricated as otherwise the specified tightening torque values will be too high.
Check to ensure that pin connections are correctly fitted.
All assembly work must be completed in accordance with the assembly instructions. Operation with defective or
damaged DRF 200 friction wheel travel drives results in a high risk of accidents with personal injuries and dam‐
age to the installation and is, therefore, strictly prohibited.
Any change or modification which prejudices safety must be reported to the nearest person responsible immedi‐
ately. Repairs may only be carried out by experienced technicians.
Ensure that all attachment points are freely accessible for inspections and servicing or that free access can be
provided.
Protective earth conductor
The protective earth conductor in insulated leads and cables must be coloured green and yellow along its entire
length.
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 DIN 6798). It must be possible to disconnect each individual connection.
Protective earth conductors must not carry any current in normal operation.
The same number of protective earth connection points must be provided as electric power infeed and outfeed
points.
Continuity of the PE conductor connection must be checked.
Mains connection switch
A mains connection switch must always be provided for the mains power supply line to the installation. The mains
connection switch must be arranged to disconnect all poles of your hoist unit from the mains supply.
Ensure that the mains connection switch is installed in an easily accessible position in the vicinity of your hoist
unit and that it is clearly marked.
Isolating switch
If two or more lifting appliances are fed from a common supply line, each one should be provided with an isolating
switch. This makes it possible to carry out maintenance work on individual units, without affecting operation of the
rest of the system.
Power supply line
The power supply line/cable to be used depends on the motor size, see the "Key motor data" section.
5.3 Tightening torques

Tightening torques [Nm]
Gearbox housing 15
ZBF 63/71 motor/gearbox 15
ZBF 80 motor/gearbox 80
Hub/output shaft 45
Friction wheel/hub 70
Suspension/gearbox housing 70
Suspension fork/suspension 270
Tab. 16
CAUTION
Loose connections
214 395 44/120914
Loose connections are a danger to life and limb and a risk of damage to the machine.
Metal nuts featuring a locking element (self-locking nuts) must not be replaced by normal nuts.
24
5.4 Installation procedure
1. Unpack and dispose of the packing material in an environmentally compatible way  "Transport, packing
and storage", Page 17.
2. Check the delivery is complete  "Transport, packing and storage", Page 17.
3. Release air from the friction wheel travel drive  "Preparing for installation", Page 25.
4. Assemble the DRF 200 with trolley.
5. Attach the hoist unit.
6. Connect to the power supply  "Connecting the electric equipment", Page 31.
7. Carry out checks before putting the unit into operation for the first time  "Putting into service for the first
time", Page 32.
8. The equipment is ready for operation  "Operation", 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 included in the
supply. If this is not done, the friction wheel travel drive may leak due to the overpressure that is created.
Adjusting the dished washer stack
Friction wheel with HydroPUR tyre 3)

Contact pressure FP max.
3900
[N]
Stack consisting of 38 dished washers, single washers ar‐
Dished washers ranged alternately L = 91,2 mm.
Order no. 339 757 99 (31,5 x 16,3 x 1,5)
Adjustment length 4) L [mm] 76
Tab. 17
Fig. 11
214 395 44/120914
3) HydroPUR is a low-wearing hydrolysis-resistant polyurethane.

4) Adjustment length applies to the specified spring length LO. Modify accordingly to correct for different dimensions. 25
5.6 Trolleys
Trolley for straight travel
Fig. 12

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
Tab. 18
214 395 44/120914
26
Max. flange thickness t [mm] 30
Max. web thickness s [mm] smax = flange width - 60 mm
￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭
Flange width b [mm] 82 - 130
Load bar l [mm] 222
Load trolley Item 1 4 x 26,9 x 2,65 x 25,5
Spacer sleeve Item 1 2 x 26,9 x 2,65 x 25,5
Tractor trolley
Item 2 2 x 26,9 x 2,65 x 43
Position of the distance washers (4 mm distance washer). Required number of distance washers for straight tracks.
From - 82 86 90 94 98 102 106 110 114 118 122 126
Flange width
To 82 86 90 94 98 102 106 110 114 118 122 125 130
inside 0 0 1 1 2 2 3 3 4 4 5 5 6
Left side cheek
Number of washers for outside 7 7 6 6 5 5 4 4 3 3 2 2 1
Right side each load bar pin inside 0 1 1 2 2 3 3 4 4 5 5 6 6
cheek outside 7 6 6 5 5 4 4 3 3 2 2 1 1
Weight [kg] 8
￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭
Load bar l [mm] 280
Tractor trolley
Item 2 2 x 26,9 x 2,65 x 68
From - 132 136 140 144 148 152 156 160 164 168 172 176 180 184
Flange width
To 132 136 140 144 148 152 156 160 164 168 172 176 180 184 188
inside 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7
Left side cheek
Number of washers for outside 16 16 15 15 14 14 13 13 12 12 11 11 10 10 9
Right side each load bar pin inside 0 1 1 2 2 3 3 4 4 5 5 6 6 7 7
cheek outside 16 15 15 14 14 13 13 12 12 11 11 10 10 9 9
Weight [kg] 8,3
￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭
Load bar l [mm] 338
Tractor trolley
Item 2 2 x 26,9 x 2,65 x 97
From - 190 194 198 202 206 210 214 218 222 226 230 234 238 242
Flange width
To 190 194 198 202 206 210 214 218 222 226 230 234 238 242 246
inside 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7
Left side cheek
cheek outside 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1
Weight [kg] 8,6
￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭
Load bar l [mm] 396
Tractor trolley
Item 2 2 x 26,9 x 2,65 x 126
From - 248 252 256 260 264 268 272 276 280 284 288 292 296 300
Flange width
To 248 252 256 260 264 268 272 276 280 284 288 292 296 300 304
inside 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7
Left side cheek
214 395 44/120914

cheek outside 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1
Weight [kg] 8,9
Tab. 19
27
Trolley with curve travel guide arm
Fig. 13

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
Tab. 20
214 395 44/120914
28
Max. flange thickness t [mm] 30
Max. web thickness s [mm] smax = flange width - 70 mm
￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭
Load bar l [mm] 222
Tractor trolley
Item 2 2 x 26,9 x 2,65 x 43
From 100 102 106 110 114 118 122 126
Flange width
To 102 106 110 114 118 122 125 130
inside 2 3 3 4 4 5 6 6
Left side cheek
Number of washers for outside 5 4 4 3 3 2 2 1
Right side each load bar pin inside 3 3 4 4 5 5 6 6
cheek outside 4 4 3 3 2 2 1 1
Weight [kg] 8,9
￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭
Load bar l [mm] 280
Tractor trolley
Item 2 2 x 26,9 x 2,65 x 68
From - 132 136 140 144 148 152 156 160 164 168 172 176 180 184
Flange width
To 132 136 140 144 148 152 156 160 164 168 172 176 180 184 188
inside 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7
Left side cheek
cheek outside 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1
Weight [kg] 9,2
￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭
Load bar l [mm] 338
Tractor trolley
Item 2 2 x 26,9 x 2,65 x 97
From - 190 194 198 202 206 210 214 218 222 226 230 234 238 242
Flange width
To 190 194 198 202 206 210 214 218 222 226 230 234 238 242 246
inside 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7
Left side cheek
cheek outside 16 15 15 14 14 13 13 12 12 11 11 10 10 9 9
Weight [kg] 9,5
￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭￭
Load bar l [mm] 396
Tractor trolley
Item 2 2 x 26,9 x 2,65 x 126
From - 248 252 256 260 264 268 272 276 280 284 288 292 296 300
Flange width
To 248 252 256 260 264 268 272 276 280 284 288 292 296 300 304
inside 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7
Left side cheek
214 395 44/120914

cheek outside 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1
Weight [kg] 9,8
Tab. 21
29
Trolley suspension
Fig. 14
Flange thickness t [mm] 10 13 16 19 22 25 28 30

Number of washers, item (1)  Fig. 14, Page 30 0 1 2 3 4 5 6 7
Order no. 340 542 44
Bolt length, item (2)  Fig. 14, Page 30 [mm] 45 50 55 65
Order no. 300 250 44 300 251 44 300 252 44 300 253 44
Tab. 22
Adjusting the curve travel guide arm

The position of the lower anti-tilt guide roller must be adjusted to the given flange thickness by means of a slot.
The roller must be secured in such a way that an optimum play of approx. 1 mm is achieved. The curve travel
guide arm must not bind at any point 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 when the pre-tension in the dished washer stack has been relieved by means of a disengaging de‐
vice.
5.7 Link bar
Fig. 15

A) KBK I, II-L, II, II-H link bar, short for straight travel B) KBK I, II-L, II, II-H link bar, long for travel on curved tracks
C) KBK III link bar, not for curved tracks D) KBK III link bar, for curved tracks
Tab. 23
214 395 44/120914
The two trolleys connected for travel on a curved track must be arranged in such a way that the curve travel guide
arms are aligned towards the link bar, see  Fig. 2, Page 12.
30
5.8 Load bar
Ø20
Ø26
26
44
60
R16
122,5
245
285
Fig. 16
WARNING
Overload
Danger to life and limb due to an overload.
The maximum permissible safe working load is 270 kg for non-guided loads which are allowed to swing freely.
5.9 Connecting the electric equipment

Mains connection
First check to ensure that the voltage and frequency specified 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 supply power, the protective earth conductor line must be specially marked. If
it is mounted on insulators, it is sufficient to mark the insulators.
Friction wheel travel drive
The motors are connected in star when they leave the factory. Connect the friction wheel travel drive in accord‐
ance with the wiring diagram.
214 395 44/120914
31
6 Putting into service for the first time
6.1 Safety instructions when putting into service for the first time
WARNING
Safe operation of the installation is not yet ensured when it is first put into operation.
The installation may only be put into operation if it has been installed/assembled according to the assembly in‐
structions.
– Machines may only be put into operation by qualified personnel.
– Check installation/operation of the safety devices before commissioning.
– Check to ensure that the mains voltage and frequency match the details specified on the rating plate.
– Move the trolleys by hand and check that they can be moved without resistance by hand over the entire
length of the track section (if fitted).
– Ensure sufficient working clearance before starting assembly work.
– Wear protective equipment.
Only trained personnel may be employed when the installation is first put into operation since:
● it may be necessary to render safety devices or features inoperative when adjustments or function checks are
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 regulations
Compliance with all inspection regulations is essential to ensure safe operation of the installation.
Required tests and inspections must be carried out.
All inspections must be arranged and documented by the owner at the specified intervals/points of time.
– Inspection in accordance with relevant national regulations, e.g. UVV/BGV D6 for cranes; UVV/BGV D8 for
winches, hoists and towing devices in Germany.
The owner is responsible for ensuring that power-driven hoists are inspected by an expert engineer before
they are first put into service and before they are put into service again after major modifications have been
carried out. This also applies to manually operated or semi-powered hoists that have a load capacity of
more than 1000 kg.
– Adjustment, maintenance and inspection activities and inspection deadlines including specifications con‐
cerning the replacement of parts/assemblies prescribed in the assembly instructions must be observed.
This work may only be carried out by specialist personnel.
214 395 44/120914
32
6.3 Checks on entering service, handover
WARNING
Unauthorised operation
Danger to life and limb if the installation is operated without previous inspection.
The installation may only be put into service if it has been checked according to the accident prevention regula‐
tions.
By means of suitable measures carried out by the owner or on his behalf, the owner must ensure that the load
handling attachments and machinery ready for operation function in complete safety before they are first put into
service. The specified measures must allow for the static and dynamic features of the installation.
The following checks must be carried out when the installation enters service:
● The supporting structure must be in good condition and the load capacity of the hoist unit must be checked.
● Safety devices must 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 be checked to ensure that it is used as intended in all possible
applications, in each case with the maximum permissible load. Operation of the safety devices must be checked
(e.g. by lifting an overload). At the same time, the behaviour of the hoist unit must be checked when it is not used
correctly.
Various checks of the installation must be carried out before it is handed over:
● Check to ensure it is suitable for operation
● Acceptance inspection
Any test and inspection records that might be required can be compiled as soon as safe operation is ensured.
The test and inspection records (test and inspection booklet; observe relevant national regulations) must be hand‐
ed over when the installation is handed over.
The installation may be used as intended after it has been handed over.
214 395 44/120914
33
7 Operation
7.1 Safety instructions for operation
WARNING
Incorrect operation
Risk of injury due to incorrect operation.
Incorrect operation may result in severe injury or damage to property. The equipment may only be operated by
authorised and instructed personnel in compliance with all accident-prevention and safety regulations. National
regulations for the use of cranes and lifting appliances must be observed and followed.
– The owner must arrange for operating personnel to be trained.
WARNING
Risk of burns
Risk of burns from contact when the DRF 200 friction wheel travel drive is in operation.
Do not touch hot motor housings.
WARNING
Non-compliance with operating regulations/industrial safety regulations
Danger to life and limb if relevant regulations are disregarded.
Machinery may only be operated in compliance with relevant national operating regulations, e.g. BGV D6 for
cranes in Germany.
– If required, apply a copy of the relevant operating regulations, part no. 214 748 44, at a suitable place
where operators can read them at any time (e.g. at the mains connection switch).
The installation must not be put into operation or must be taken out of service immediately if any defects or irregu‐
larities relating to operating safety and reliability or function are detected.
Safety devices must not be rendered inoperative or modified contrary to their intended use.
Ensuring safe operation
Special local conditions or special 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 safe operation have been clarified and implemented in agreement with Demag or other relevant bodies.
In the event of a stoppage (e.g. if defects regarding safe and reliable operation are detected, in emergency situa‐
tions, in the event of operating malfunctions, for repairs and maintenance purposes, if damage is detected or after
finishing work), the operator must carry out all prescribed safety measures or observe that they are automatically
carried out.
Work on electric equipment may only be carried out by qualified electricians.
7.2 Switching on
7.2.1 Checks when starting work

Before starting work, the operator must be satisfied that the installation is in safe and correct operating condition.
Ensure that nobody is endangered by operation of the installation before switching it on or putting it into operation.
If the operator notices persons who may be exposed to a risk to their health or personal safety by operation of the
installation, he must stop operation immediately and may not resume operation until the persons are outside the
danger zone.
If there are any defects which endanger safe and reliable operation, the installation must be taken out of service
without delay. Defects relevant to safety in this sense are, for example:
● Damage to electric devices, cables or insulation,
● Delayed operation or failure of brakes and safety devices,
214 395 44/120914
● Missing covers or housing parts or

● Damage to load-bearing parts.
34
Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay.
This also applies if damage occurs to parts of machinery or equipment which makes an immediate stoppage nec‐
essary.
If the installation has been stopped by an emergency stop due to safety-relevant defects, it must be secured
against being returned to operation until an experienced technician is satisfied that the cause of the hazard situa‐
tion has been eliminated and that operation of the installation is possible without any hazard.
Before starting work:
● Wear protective equipment.
● Ensure that nobody is present in the danger zone of the equipment.
7.2.2 Function checks

Instructions for users where the BGV D06 accident prevention regulations apply:
In accordance with BGV D06, the crane operator must also check operation of the emergency-stop device when
he or she starts work. This does not apply to slipping clutches used as an emergency-stop device which do not
need to be checked when work begins (BGV D06, Section 30).
The following main functions of the machine must be checked before work begins:
● Emergency-stop device,
● Check control cable and control pendant housing for damage,
● Function of the brake.
7.3 Operation
7.3.1 General
WARNING
Overload
Higher loads than those specified on the load capacity plate must not be handled.
– Do not exceed the maximum permissible load capacity of the hoist.
– Only use load handling attachments which are adequately dimensioned.
– Only use load handling attachments for their intended purpose.
Important information for operation

Observe the following during operation:
Safety during operation
– Take the installation out of service immediately if functional defects or irregularities are detected.
– The operator is obliged to check the DRF 200 friction wheel travel drive for any visible damage at least once
per shift and to report any damage immediately.
– Do not render safety devices inoperative.
– Do not approach limit stops in normal operation, e.g.: emergency-stop devices (emergency limit switches),
emergency limit stop devices (slipping clutch or emergency limit switch), track and limit buffers to stop move‐
ment of the crab or crane, hook assembly or bottom block against limit stops. Continuously approaching
these limits may result in severe damage.
– Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing, parts of the
body or hair becoming entangled.
214 395 44/120914
35
7.4 Taking the equipment out of operation
7.4.1 Taking the equipment out of service when faults occur
DRF 200 friction wheel travel drives must be switched off immediately in the event of the following faults:
● If electric devices and cables as well as parts of the insulation are damaged.
● Brake and safety device failure.
7.4.2 Taking the equipment out of service at the end of the shift
The following measures must be taken when finishing work or leaving the working area:
● Move the unloaded installation into its resting position.
● Actuate the emergency stop.
● Switch the installation power supply off at the mains connection or isolating switch.
The installation must be disconnected from the power supply when finishing work or leaving the working area.
However, if the installation is continuously connected to the power supply, the following must be considered:
● 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 lightning strikes.
● The power-supply line and the electric cabling and wiring must be checked with particular care and at shorter
intervals.
7.4.3 Taking the equipment out of service for maintenance and repairs
1. Switch off the mains connection switch or isolating switch before commencing maintenance work.
2. Secure the mains connection switch with a padlock to prevent unauthorised or accidental re-connection to
the supply.
3. Only carry out maintenance work on the installation when the load has been removed.
4. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.
5. Observe the relevant accident prevention regulations, instructions concerning intended use and statutory
regulations for operation and maintenance.
6. Observe relevant safety regulations when repairing electric equipment.
214 395 44/120914
36
8 Maintenance/repair
8.1 Safety instructions for maintenance and repair work

The following sections contain a description of maintenance work that is necessary for optimum and uninterrupted
operation of the equipment.
DANGER
Live components
WARNING
Risk of burns
Risk of burns from contact after the DRF 200 friction wheel travel drive has been in operation.
Do not touch hot motor housings. Allow the motor to cool down before performing any maintenance or repair
work.
WARNING
Inappropriate maintenance work
Danger to life and limb. Risk of material damage.
Maintenance and repair work may only be carried out by authorised, instructed personnel ( "Definition of per‐
sonnel", Page 6) in compliance with the safety regulations.
– 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.
– Only suitable, tested and calibrated tools and accessories may be used for maintenance work.
– Only use approved spare parts, see also  "Use of spare parts", Page 6.
– Wear protective clothing.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any unneeded machine or installation parts and tools in such a
way that there is no risk of them falling.
– Fit components appropriately. Comply with specified bolt tightening torques. Incorrectly fitted components
may fall and cause severe injuries.
– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐
ments must be fulfilled. The electrode holder and earth must be connected to the same assembly when
welding work is carried out. Otherwise serious damage may be caused to the hoist. Trolleys must not be
welded or drilled.
– Customer-specific regulations must be observed.
CAUTION
Loose connections
Loose connections are a danger to life and limb and a risk of damage to the machine.
Metal nuts featuring a locking element (self-locking nuts) must not be replaced by normal nuts.
214 395 44/120914
37
CAUTION
Risk of injury.
Oils and lubricants may pose a health hazard.
Contact with these media may result in serious damage to health (poisoning, allergies, skin irritations, etc.).
CAUTION
Risk of injury.
Leaking oils and lubricants are hazards due to the increased risk of slipping.
Spilt oils and lubricants must be absorbed immediately by means of sawdust or oil absorbent and disposed of in
an environmentally compatible way.
8.2 Basic maintenance requirements
General information on maintenance/repairs
The specified inspection and maintenance intervals ( "Maintenance schedule", Page 39) apply to normal
DRF 200 friction wheel travel drive operating conditions. Under normal operating conditions, friction wheel travel
drives are almost maintenance-free.
All wearing parts must be checked in the course of the annual inspection.
For single-shift operation and medium duty, a general overhaul should be carried out by an experienced techni‐
cian authorised by the manufacturer after 8–10 years of use.
If routine maintenance reveals that the intervals are too long, they should be adapted to the specific operating
conditions.
Pay attention to the following when working on machinery or machine equipment:
1. Wear personal protection equipment.
2. Before starting any maintenance work, switch off the mains connection switch and protect it against unau‐
thorised or accidental re-connection to the power supply by locking it with a padlock.
3. Only carry out maintenance work on the DRF 200 friction wheel 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. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.
6. Observe the relevant accident prevention regulations, instructions concerning appropriate use and statutory
regulations for operation and maintenance.
7. Observe the relevant safety regulations when repairing electric equipment.
8. Reinstall safety devices as required by relevant regulations and check them for correct operation after finish‐
ing maintenance work.
Maintenance work which is not possible from the ground may only be carried out from work stands or platforms.
The danger zone below the DRF 200 friction wheel travel drive must be fenced off if there is a risk of falling ob‐
jects.
Instructions for maintenance work in the course of operation
If maintenance work has to be carried out on the DRF 200 friction wheel travel drive in the course of operation,
special safety precautions must be taken depending on the operating situation. In each individual case, the owner
or the person assigned by him must check whether the maintenance work may be carried out in the course of
operation without risk of personal injury and, taking into account the local conditions, must implement all necessa‐
ry safety precautions.
214 395 44/120914
Replace damaged or deformed spring clip fasteners and split sleeves.

Defective bolted connections must be replaced.
Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly
manner.
38
After finishing maintenance work
Re-install safety devices as required by relevant regulations and check them for correct operation after finishing
maintenance work.
8.3 Maintenance schedule

Activity Before first putting 3 months after ini‐ Before starting Every 6 months During the annual
into operation tial commission‐ work inspection
ing
Check operation of the brake X X X
Check brake displacement, adjust as required X X
Check connections and attachment bolts on the friction
X X
wheel
Check tapered surface of output shaft and hub/friction
X X
wheel
Check friction wheels for cracks and wear X X
Check dished washer stack,
X X
correct L dimension adjustment, as required
Check power supply line
For conductor lines:
Check insulators, conductor rails, connectors and expan‐
sion joints X X
For current collectors:
Check sliding contacts and travel rollers for wear and con‐
tact pressure.
Remove dust and production residue from the friction wheel
X
travel drive
Clean the air vent screw X
Check the friction wheel travel drive for leaks, check shaft
X
seals
Check electric switchgear and wiring X X
Check and apply or supplement corrosion protection, as re‐
X
quired
Oil change Every 4 years
Tab. 24
Despite detailed information, errors cannot be excluded when the installation is maintained by the customer. For
this reason, we recommend that this work be carried out by our trained specialists or by persons authorised by
us.
214 395 44/120914
39
8.4 Maintenance work
8.4.1 Oil lubrication
General information on oil lubrication
Under normal operating conditions, the lubricant must be changed after 10000 hours of service. The lubricant
should, however, be changed at least every 4 years.
Under exceptional operating conditions, e.g. high ambient temperatures, we recommend that the oil should be
changed at shorter intervals.
Oil change
Drain the old oil at operating temperature.
To do this, first remove the air vent screw at the top of the gearbox and then the plug at the bottom, and the oil will
run out.
For each oil change, we recommend that the gearbox is filled and flushed with oil of the same viscosity.
The flushing oil should have a viscosity of 46 – 68 mm2/s at 40° C. The quantity of flushing oil used should be
approximately twice that specified for lubrication. Switch the motor on and allow the gears to run without any load
for a few minutes and then drain the flushing oil. Repeat this operation several times, also in alternate directions
of rotation, to ensure that all remains of the old lubricant are drained together with the flushing oil. Refer to the
data plate on the friction wheel travel 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.g. BP ENERGOL GR-XP 220, Esso Spartan EP 220, SHELL
Omala oil 220, Mobilgear 630 or Aral Degol BG 220.
At higher or lower ambient temperatures, the type of oil used should be adapted to the specific conditions.
Required oil quantity 0,7 l Order no.

2,5 l pack 472 900 44
1,0 l pack 472 902 44
Tab. 25
8.4.2 Grease lubrication
General information on grease lubrication

If the gearbox is filled with grease, we recommend that this should be changed after 10000 hours of service. The
grease should, however, be changed at least every 4 years.
Grease change
Open the gearbox and clean it thoroughly with commercially available cleaning agent. Subsequently fill the hous‐
ing with fresh grease. The required quantity of grease is specified on the gearbox data plate.
Grease quality
For ambient temperatures of approx. -10 °C to +50 °C, a low-viscosity gear grease with a dripping point of approx.
150 °C and a worked penetration of 380 to 430 1/10 mm should be used, DIN 51502 GP 00F, e.g. BP Energrease
HT EP 00, SHELL special low-viscosity gear grease H, Esso Fibrax EP 370 or Aralub FD 00.
Required grease quantity 0,9 kg Order no.

0,2 kg pack 472 918 44
Tab. 26
214 395 44/120914
40
8.4.3 Brake
8.4.3.1 General
DANGER
Inappropriate maintenance work
Danger to life and limb. Risk of material damage.
Check brake air gap s1 at certain intervals and adjust it, as required.
If the brake is not adjusted, it will no longer release after further wear. If the motor then operates against the
applied brake, the brake and motor may be damaged.
Apart from wear, the brake is virtually maintenance-free.

The organic/mineral brake lining is designed in such a way that worn surface particles are only given off as mini‐
mal abrasion. This built-in regeneration of the brake lining surface ensures that the braking characteristics remain
constant. To ensure the brake 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 brake coil).
Brake size B004 B020

Remaining thickness b min 5 6
Adjusting angle α1 120° 120°
Tab. 27
When the brake has been adjusted several times, the remaining thickness bmin of the brake disc must be checked.
The guide pins feature an easily visible mark (x) which clearly indicates the minimum dimension. The brake rotor
must be replaced when this mark is exceeded. A maintenance and spare parts set is available to do this.
The air gap must be adjusted when the max. permissible value s1 has been reached, (however, immediately if the
brake no longer releases).
For DRF units fitted with KBF motors, see "KBA, KBF motor assembly instructions"  Tab. 2, Page 2.
214 395 44/120914
41
8.4.3.2 Checking and adjusting brake air gap s1
Fig. 17
Item Designation Item Designation Item Designation

1 Fan cover retaining bolts 5 Armature plate 9 Magnet assembly
2 Fan cover 6 Brake disc 10 Feeler gauge
214 395 44/120914
3 Retaining ring 7 Collared pin 11 End cap

4 Fan wheel 8 Hexagon nuts 12 Stop plate
Tab. 28
1. Unscrew the four retaining bolts (1) of fan cover (2).

42
2. Remove fan cover (2) from the motor.
3. Remove retaining ring (3) from the shaft.
4. Remove fan wheel (4) from the shaft.
5. Check the remaining thickness of brake disc (6), see  Tab. 27, Page 41.
If the edge of armature plate (5) has reached mark (x) on collared pin (7), brake disc (6) must be replaced,
see  "Replacing the brake disc", Page 44.
6. Check the brake air gap.
Brake air gap s1min = 0,35 mm - s1max = 1,2 mm
Tighten magnet assembly (3) with the three hexagon nuts (8) uniformly until the air gap is zero. Subsequent‐
ly loosen the three hexagon nuts (8) by angle α1, see  Tab. 27, Page 41.
Measure air gap s1 using feeler gauge (10) at three points around the circumference. If the measured value
is within the specified range, the motor can be re-assembled. If this is not the case, adjust again as required.
7. Press fan wheel (4) onto the shaft and secure it with retaining ring (3).
Check to ensure that the retaining ring is correctly fitted. Ensure the retaining ring clicks correctly into place.
8. Re-attach fan cover (2) to the motor with a tightening torque of 6,2 Nm.
214 395 44/120914
43
8.4.3.3 Replacing the brake disc
RD BU
A) B)
RD BU BU
RD BU
Fig. 18

1 Terminal box cover 5 Armature plate 9 End cap
2 Hexagon nuts 6 Brake disc 10 Brake springs
214 395 44/120914
3 Magnet assembly 7 Distance springs 11 Magnet assembly connecting cable

4 Stop plate 8 Collared pin
Tab. 29
44
Proceed as follows to replace the brake, see also  "Checking and adjusting brake air gap s1", Page 42:
● Unscrew the four retaining bolts of the fan cover.
● Remove the fan cover from the motor.
● Remove the retaining ring from the shaft.
● Remove the fan wheel from the shaft.
1. Remove terminal box cover (1).
Unscrew hexagon nuts (2) and remove magnet assembly (3).
2. Remove stop plate (4), armature plate (5), brake disc (6) and distance springs (7). Check collared pins (8)
and the braking surface of end cap (9) for signs of wear.
Defective parts and components and parts close to failure must be replaced.
3. If collared pins (8) or end cap (9) have to be replaced, proceed as follows:
Screw collared pins (8) out of end cap (9) and remove end cap (9) from the shaft. New collared pins (8) must
be screwed into end cap (9) with the correct tightening torque:
B004 brake = 2,3 Nm
B020 brake = 4 Nm
Push end cap (9) back onto the shaft.
4. Install brake disc (6).
Mark ("I") and bore hole (b) on stop plate (4) must be aligned with the terminal box when armature plate (5)
is fitted.
5. 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 secure it with hexagon nuts (2). Tighten magnet as‐
sembly (3) with the three hexagon nuts (2) uniformly until the air gap is zero. Subsequently loosen the three
hexagon nuts (2) by angle α1, see  Tab. 27, Page 41.
Measure air gap s1 using a feeler gauge at three points around the circumference, see also  "Checking
and adjusting brake air gap s1", Page 42. If the measured value is within the specified range, the motor can
be re-assembled.
Pull connecting cable (11) of magnet assembly (3) back into the terminal box, connect it and re-attach termi‐
nal box cover (1).
Arrangement of brake springs (10)

Motor Brake torque Quantity of brake springs Spring arrangement, see
[Nm] Red (RD) Blue (BU)  Fig. 18, Page 44
ZBF 63 A … B004 1,3 3 - A)

ZBF 71 A … B004 1,8 - 6 B)
ZBF 80 A … B004 3,3 3 - A)
Tab. 30
Proceed as follows for the further steps, see also  "Checking and adjusting brake air gap s1", Page 42:
● Press the fan wheel onto the shaft and secure it with the retaining ring.
● Re-attach the fan cover to the motor with a tightening torque of 6,2 Nm.
214 395 44/120914
45
8.4.4 Friction wheel drive
8.4.4.1 Removing and installing the friction wheel
Fig. 19

1 Friction wheel 2 Hexagon bolts 3 Hub
Tab. 31
1. To 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 45 Nm.
Ensure the tapered connection is dry when new parts are installed.
Install friction wheel (1) and tighten the three hexagon bolts (2) to a tightening torque of 70 Nm.
214 395 44/120914
46
8.4.4.2 Removing and installing the suspension fork and suspension
Fig. 20

1 Suspension fork 3 Hexagon bolt suspension
2 Hexagon bolt 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 bolts (3) for the suspension to a tightening torque of
70 Nm. The bore holes of suspension fork (1) and eye bolt (4) are used to attach a trolley load bar.
214 395 44/120914
47
9 Malfunctions/warnings
9.1 Safety instructions for malfunctions/warnings
WARNING
Inappropriate fault elimination
Danger to life and limb. Risk of damage to the machine.
Faults may only be eliminated by qualified instructed personnel ( "Definition of personnel", Page 6) in compli‐
ance with the safety regulations.
DANGER
Live components
WARNING
Risk of burns
Risk of burns from contact after the DRF 200 friction wheel travel drive 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 actuating the emergency stop without delay if malfunctions
occur that result in an immediate danger of personal injury, damage and/or an operating hazard.
2. Switch the installation off at the mains connection switch or isolating switch and secure it against switching
on again.
3. Inform the person responsible at the location about the malfunction.
4. Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per‐
sonnel.
Conduct after a malfunction is eliminated
WARNING
Check for correct assembly
Before reconnecting the power supply, ensure that
– Malfunction and cause of malfunction have been eliminated.
– All safety devices have been fitted properly and are in perfect condition and working order.
– Nobody is present in the danger zone of the equipment.
214 395 44/120914
48
10 Disassembly/disposal
10.1 General
WARNING
Before disassembly, follow the safety instructions in  "Maintenance/repair", Page 37 of these operating in‐
structions.
Unless a return or disposal agreement has been concluded, separated components must be recycled after proper
removal:
● Scrap any remaining 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 materials are subject to special disposal
regulations and may only be disposed of by certified companies.
National disposal regulations must be considered regarding environmentally friendly disposal. Further information
can be obtained from corresponding local authorities.
214 395 44/120914
49
Original Ident. number / Language
Declaration for fitting partly completed machinery 19962044 / EN
according to Machinery Directive 2006/42/EC, Annex IIB Issue Page
1217 1/ 1
Hereby we,

Forststrasse 16, 40597 Düsseldorf, Germany
declare that the electric travel drive for driving Demag trolleys
Demag DRF 200 travel drive

supplied as partly completed machinery is intended to be incorporated into machinery and its
initial bringing into service is prohibited until the machinery* into which this partly completed
machinery is to be incorporated has been declared in conformity with all relevant provisions of
EC Machinery Directive 2006/42/EC.

(* insofar as this machinery is subject to the scope of application)
Basic requirements of the EC Machinery Directive, insofar as they are relevant for the scope of
delivery, are met by application of the following harmonised standards or C standard drafts:
EN 14492-2 Cranes - Power driven winches and hoists -
Part 2: Power driven hoists
e
EN 60204-32 Safety of machinery - Electrical
equipment of machines - Part 32:
Requirements for hoisting machines
pl The safety objectives of Low Voltage Directive 2014/35/ЕU are achieved
The product additionally complies with the following relevant directives/provisions:
EU EMC Directive 2014/30/EU
The special technical documentation according to Annex VII Part B of Directive 2006/42/EC has
am
been compiled and will be made available to authorised national authorities by the designated
authorised representative in response to a justified request.
Authorised representative for technical documentation
Hans-Jörg Böttcher, Demag Cranes & Components GmbH, Forststrasse 16, 40597 Düsseldorf,
Germany
Düsseldorf, 13.07.2018
S
ppa. Thomas Wiesmann i.V. Franz Schulte

Head of Plant Wetter Knowledge Centers &
Core of Lifting
Industrial Equipment
XENGLIFR
Subject to change. No liability for errors or omissions

214 395 44/120914
51
The current addresses of our sales offices, subsidiaries and agencies worldwide can be
found on the homepage
www.demagcranes.com

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

www.demagcranes.com
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany) Subject to change. Not liable for errors or omissions.

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Assembly instructions

DRF 200 friction wheel travel drive with travel motor

120914 en GB 214 395 44 719 IS 913.92

Travel drive no.

Wiring diagram number

Documents 1) Order no.

2 1) The documents can be ordered from the relevant Demag office.

3 Technical data ........................................................................................................................................................... 12

5.3 Tightening torques..................................................................................................................................................... 24

6 Putting into service for the first time .......................................................................................................................... 32

1.1 DRF 200 friction wheel travel drive

1.2 Symbols/signal words

Operating hazard for the machine.

1.3 Information on the assembly instructions

1.4 Liability and warranty

the-art engineering principles and our many years of experience.

Wearing parts are not subject to liability for defects.

1.6 Use of spare parts

1.7 Definition of personnel

1.8 After-sales service

2.2 Safety signs on the equipment

Fig. 1 Example: capacity plate

2.3 Intended use

tended use" section.

2.5 Responsibility of the owner

2.7 Personal protection equipment

2.8 Regular inspections

3.1 Design overview

Item Designation Item Designation

● Friction wheel travel drive without a motor weighs 12 - 14 kg.

3.2.2 ZBF motor

1 travel speed 2 travel speeds

3.2.3 KBF motor

1 travel speed 2 travel speeds

Size PN nN IN for 50 Hz, 3 ~ 2) IA/IN cos φN

Size MN MA/MN MH Jmot A MOpHrs Weight

3.3.2 KBF motor

Size PN nN IN for 50 Hz, 3 ~ 2) IA/IN cos φN

Size MN MA/MN MH Jmot A MOpHrs Weight

DRF 200 with ZBF motor

Item Designation Item Designation

Item Designation Item Designation

When selecting a track, we recommend you specify the special profile

Minimum medium horizontal curve radius

Item Designation Item Designation

4.6 Link bar

4.7 Load bar

4.9 Buffer fitting

Item Designation Item Designation

Fig. 10 Example of a current collector arrangement on a DRF 200 trolley

Power supply is provided via a specially developed current collector system.

5.1 General assembly information

5.2 Safety instructions for assembly

Danger to life and limb.

5.3 Tightening torques

5.5 Preparing for installation

Releasing air from the friction wheel travel drive

Adjusting the dished washer stack

Friction wheel with HydroPUR tyre 3)

3) HydroPUR is a low-wearing hydrolysis-resistant polyurethane.

Trolley for straight travel

Item Designation Item Designation

Right side each load bar pin inside 0 1 1 2 2 3 3 4 4 5 5 6 6 7 7

Item Designation Item Designation