21120244_en_gb_120213 eudr-bas ai

8/13/2019 21120244_EN_GB_120213 EUDR-Bas AI

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Assembly instructionsDemag EUDR-Bas trolley

Standard-headroom monorail hoist trolley

EUDR-Bas 3 - 5 - 10

130212 en GB 211 202 44 719 IS 813

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Original assembly instructions

Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your

Demag EUDR-Bas trolley and important information if you ever have to contact the manufacturer or his representative.

Owner

Where in use

Range

Serial number

Tab. 1

Further documents are available for the trolley in addition to these assembly instructions. The documents are supplied as nec‐

essary or can be ordered separately.

Documents1 Order no. Classification

Spare parts lists

Spare parts lists for Demag hoist unitFDR-Bas 3 - 5 - 10 217 066 44 721 IS 813

EU-/EK-/EZDR-Bas 3 - 5 - 10 217 088 44 721 IS 813

Technical data

EUDR-Bas 3 - 10 technical data 203 739 44 714 IS 813

Assembly and operating instructions

EUDR-Bas 3 - 10 operating instructions 211 203 44 720 IS 813

FDR-Bas 3 - 10 assembly instructions 211 211 44 719 IS 813

Bas control assembly instructions 211 205 44 719 IS 813

MT-Bas cylindrical-rotor motor assembly instructions 211 196 44 719 IS 951

Demag test and inspection booklet for cranes and hoist units On application 720 IS 100

Tab. 2

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

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Table of contents

General........................................................................................................................................................................5EUDR-Bas 3 - 5 - 10 trolley.........................................................................................................................................5

Information on the assembly instructions ....................................................................................................................5Symbols/signal words..................................................................................................................................................5

Terms and definitions ..................................................................................................................................................6

Safety ..........................................................................................................................................................................8

General........................................................................................................................................................................8

Safety signs.................................................................................................................................................................8

Intended use................................................................................................................................................................8

Hazards that can be caused by the machine ..............................................................................................................9

Assembly personnel requirements............................................................................................................................10

Personal protection equipment..................................................................................................................................10

Inspection regulations ...............................................................................................................................................10Technical data ...........................................................................................................................................................11

Operating conditions .................................................................................................................................................11

Weights .....................................................................................................................................................................11

Dimensions................................................................................................................................................................11

Track girder requirements .........................................................................................................................................11

Runway .....................................................................................................................................................................11

Travel unit..................................................................................................................................................................12

EUDR-Bas 3 - 5 - 10 wheel loads .............................................................................................................................12

Travel motor ..............................................................................................................................................................12

Design and function...................................................................................................................................................13

Design .......................................................................................................................................................................13

Travel motor ..............................................................................................................................................................13

Transport, packing, storage.......................................................................................................................................14

Safety instructions .....................................................................................................................................................14

Transport inspection..................................................................................................................................................14

Packing......................................................................................................................................................................14

Storage......................................................................................................................................................................14

Installation and putting into operation for the first time ..............................................................................................15


EUDR-Bas trolley assembly ......................................................................................................................................17

Overview ...................................................................................................................................................................17

Fit the trolley connecting beam to the rope hoist (on electrical equipment cover) .................................................... 18

Fit the trolley connecting beam to the rope hoist (gearbox side)............................................................................... 19

Punch marks for adjustment to the sides of the runway............................................................................................20

Fit the side of the trolley with the travel motor on the trolley connecting beams of the rope hoist ............................ 21

Adjust and secure trolley side with travel motor ........................................................................................................21

Place the side of the trolley without travel motor on the trolley connecting beam ..................................................... 21

Insert the threaded rods ............................................................................................................................................22

Place the trolley on the runway girder and adjust the second half of the trolley ....................................................... 23

Install the drive shaft .................................................................................................................................................24

Buffer installation on the runway ...............................................................................................................................25

Connecting the electrical equipment .........................................................................................................................25Operation...................................................................................................................................................................26

Operation of the monorail trolley ...............................................................................................................................26

Maintenance .............................................................................................................................................................27


1

1.1

1.21.3

1.4

2

2.1

2.2

2.3

2.4

2.5

2.6

2.73

3.1

3.2

3.3

3.4

3.4.1

3.4.2

3.4.3

3.4.4

4

4.1

4.2

5

5.1

5.2

5.3

5.4

6

6.1

6.2

6.2.1

6.2.2

6.2.3

6.2.4

6.2.5

6.2.6

6.2.7

6.2.8

6.2.9

6.2.10

6.3

6.47

7.1

8

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Regular inspections...................................................................................................................................................28

Maintenance schedule ..............................................................................................................................................28

Check travel wheels ..................................................................................................................................................29

Oil change .................................................................................................................................................................29

Malfunctions ..............................................................................................................................................................30


Conduct when malfunctions occur ............................................................................................................................30

Conduct after malfunctions have been eliminated ....................................................................................................30

Malfunctions, causes and remedy.............................................................................................................................31

Index...........................................................................................................................................................................................32

8.2

8.3

8.4

8.5

9

9.1

9.2

9.3

9.4

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1 General

1.1 EUDR-Bas 3 - 5 - 10 trolley

You have purchased a Demag Cranes & Components product.This Demag trolley was manufactured in accordance with the relevant standards and regulations and satifies the

regulations.

These assembly instructions describe the trolley for the Demag EUDR-Bas standard-headroom monorail-travel‐

ling hoist. The trolleys of the following ranges are described:

● EUDR-Bas 3

● EUDR-Bas 5

● EUDR-Bas 10

The following data always apply for all three ranges. Any differences for individual ranges are specially marked.

1.2 Information on the assembly instructionsThese assembly instructions are designed to provide the owner with appropriate instructions for safe and correct

operation and for maintenance. These assembly instructions are an integral part of the trolley.

Operation of the complete EUDR-Bas standard-headroom travelling hoist is described in the operating instruc‐

tions, 211 203 44.

1.3 Symbols/signal words

Important safety information and instructions in these assembly instructions are marked by corresponding sym‐

bols and signal words.

Safety instructions and information must be followed. Follow these instructions with care to avoid any accidents,

injuries or damage.

Any 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 warning symbol indicates an immediate danger that can result in severe injuries or death.

– Follow these instructions at all times and be particularly careful and cautious.

WARNING

This warning symbol indicates a possibly dangerous situation that might result in severe injuries or death.


CAUTION

This warning symbol indicates a possibly dangerous situation that might result in medium or slight injuries or ma‐terial damage.


Operating hazard for the machine

● This symbol indicates information on the appropriate use of the machine.

● Failure to follow these instructions may result in malfunctions, damage or pollution of the environment.

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1.4 Terms and definitions

Manufacturer The manufacturer is the person who

1. manufactures machinery under his or her own name and places it on the market for the first time;

2. resells machinery made by other manufacturers under his or her own name, whereby the reseller is not con‐

sidered to be the manufacturer, provided the name of the manufacturer (as defined in 1.) appears on the

equipment;

3. imports machinery into a market and places it on the market for the first time, or

4. exports machinery to another state and hands it over direct to a user in that country.

Owner

Owners (employer, company) are defined as persons who own a machine and who use it as intended or allow it

to be operated by suitable and trained persons.

Operating personnel/machine operator

Operating personnel or machine operators are defined as persons entrusted by the owner of a machine with oper‐

ation of the equipment. The operating personnel must be trained by the owner in accordance with the tasks to beperformed.

Trained person

Trained persons are defined as persons who have been instructed and trained for the tasks assigned to them andon 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. Trained personnel must be trained by the

owner in accordance with the tasks to be performed.

Specialist personnel

Specialist personnel are defined as persons assigned by the owner of a machine to carry out special tasks suchas installation, setting-up, maintenance and fault elimination. Specialist personnel must be trained by the owner

before any work is carried out on or with the machine.

Qualified electrician

Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of

electrical 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. Qualified electricians 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 machines. They must be familiar with the relevant national industrial safety regula‐tions, codes of practice, accident prevention regulations, directives and generally accepted engineering standards

enabling them to judge the safe operating condition of machines.

Assigned expert engineer

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

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.

Design limit

For selection of the crane, the size is defined in accordance with the application and the customer specifications.The design limits of the crane must not be exceeded.

Rope hoist

Rope hoists are systems used for lifting and moving loads, such as cranes, crabs and travelling hoist units, rail

systems.

Crab or travelling hoist

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A crab or travelling hoist is a mobile crane assembly for changing the situation of the lifting rope (on the load at‐

tachment side). Depending on the type, the crab/travelling hoist carries one or several return sheaves for the lift‐

ing rope or directly the hoist unit. The crab/travelling hoist travels along a runway girder.

Travel unit

The travel unit is part of the travelling hoist. It transports the rope hoist along one or two girder rails by means of

driven travel wheels.

Partly completed machinery

Partly completed machinery is a combination of parts/components that are almost a machine, but which cannot

provide a certain function without additional parts.

Partly completed machinery is integrated into other machines or into other partly completed machinery to form acomplete machine together with them.

The EUDR-Bas trolley is partly completed machinery.

Complete machine

A complete unit of connected parts that are equipped with a drive system, of which at least one moves and which

are assembled for a particular application.The EUDR-Bas travelling hoist is a complete machine.

Assembly instructions

Documentation supplied by a manufacturer of partly completed machinery/component. The assembly instructions

describe the installation of the scope of delivery in a larger assembly.

Operating instructions

Documentation supplied by the manufacturer of a complete machine which describes operation of the machine/

installation (of the complete scope of delivery).

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2 Safety

2.1 General

The “Safety” chapter provides an overview of all important safety aspects for optimum protection of personnel aswell as safe and trouble-free operation of the machine.

At the time of its development and manufacture, the machine was built according to generally accepted engineer‐

ing standards and is considered to be safe to operate. The machine 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 machine safely and reliably.

Any conversions, modifications or additions to the machine are prohibited unless approved by Demag in writing.

These assembly instructions describe operation of one hoist. The use of several travelling hoists on one runway

girder or tandem operation of cranes is not included in these assembly instructions.

2.2 Safety signs

Any pictograms, signs or labels on the trolley must be obeyed and must not be removed. Pictograms, signs or

labels that are damaged or no longer legible must be replaced immediately.

2.3 Intended use

The trolley is intended to be installed in an existing installation. These assembly instructions describe how the trol‐

ley is fitted to a FDR-Bas rope hoist and how the trolley is installed on the girder rail. These assembly instructions

do not describe operation of the complete installation.

The following documents must be considered for the intended use of the entire installation:

● Trolley assembly instructions

● EUDR-Bas rope hoist operating instructions, 211 203 44.

● FDR-Bas rope hoist assembly instructions, 211 211 44.

● DST-Bas control pendant assembly instructions, 211 204 44.

● Bas control system assembly instructions, 211 205 44.

● Duties of the owner to operate installations/machinery, regional regulations.

The installation is used as intended with reference to the above documents and the following limitations. Any oth‐

er use may result in a danger to life and limb and/or cause damage.

● The trolley is only intended for installation on a FDR-Bas rope hoist and on a suitable runway girder.

● The trolley may only be installed, operated, maintained and removed when in perfect working order by trained

personnel in accordance with the relevant safety and accident prevention regulations.

● Intended use also includes compliance with the safety instructions as well as any other instructions on assem‐bly/disassembly, commissioning, function/operation, maintenance/fault elimination as well as compliance with

the instructions on safety devices, protection against hazards and any possible remaining hazards.

● The trolley may only be used subject to the permissible technical data, "Technical data", Page 11.

● The trolley must be maintained regularly and appropriately by trained personnel in line with the specified dead‐

lines and checked according to the maintenance schedule ( "Maintenance schedule", Page 28). Wearing

parts must be replaced in good time in accordance with the frequency and intensity of use.

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 in accordance with the entire installation and these assembly instructions. In particular, the manufacturer

assumes no liability for damage due to inappropriate or any other prohibited use of the machine in the sense of the "Intended use" section.

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 machine to devices or equipment that do not belong to our scope of de‐

livery, or the installation or use of third-party accessories, equipment, sub-assemblies or spare parts that are not

approved by the manufacturer.

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Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by an

expert engineer before it is handed over to the owner.

The machine is designed for operation indoors and at temperatures ranging from - 10° C to + 45° C. At extreme

temperatures and in aggressive atmospheres, the owner must implement special measures after consulting De‐mag.

2.4 Hazards that can be caused by the machine

DANGER

Live components

Danger to life and limb.

Electrical energy may cause very severe injuries. Danger to life caused by electrical 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 electrical 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.

DANGER

Assembly work on partly completed machinery


The machine is supplied broken down into sub-assemblies and is assembled at the owner's premises.

Situations may occur during assembly that offer a high risk of potential hazards.

– Assembly work may only be carried out by qualified personnel in accordance with regional safety regula‐tions.

– Co-ordinate all assembly work and appoint a supervisor, particularly for any activities in which loads arelifted.

– Use suitable lifting equipment to lift any loads that weigh more than 20 kg; do not exceed the permissible

load capacity.

– Personal safety equipment must be used.

– Carry out assembly work in accordance with the operating and assembly instructions.

WARNING

Crushing hazard

Body parts can be crushed when loads are lifted or lowered.

Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered.

WARNING

Suspended load. Falling parts.

Danger to life and limb if lifted loads are dropped.

Keep out of the danger zone at all times.

– Keep a sufficient safety distance.

– Never step under a suspended load.

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2.5 Assembly personnel requirements

Only authorised and trained personnel may work on the trolley. The personnel must have received instruction onany hazards that may occur.

Every individual given the task of installing or maintaining the trolley must have read and understood the assem‐

bly instructions before any work on the trolley starts.

Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with

the trolley.

Age and job-specific regulations relevant at the place where the machine is operated must be observed for theselection of any personnel.

Personnel are obliged to report to the owner without delay any changes to the machine that impair safety.

For independent assembly or maintenance of the trolley, 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 machine and who have proven their qualifi‐

cation to the owner in this respect.

2.6 Personal protection equipment

When work is carried out on or with the machine, the following is recommended to be worn according to the own‐

er's risk 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.

● Gloves for handling the wire rope.

● Safety helmet to be worn by everybody in the danger zone.

2.7 Inspection regulations

Notes on inspections in accordance with:

● Local accident prevention regulations for winches and hoists.

● JB/T 9008.1-2004 “Electric wire rope hoists, Part one: Types and basic parameter, specification”

● JB/T 9008.2-2004 “Electric wire rope hoists, Part two: Testing method”

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3 Technical data

3.1 Operating conditions

Ambient temperature range -10 to +45 °CMax. air humidity 85 %

Max. altitude/air pressure 1000 m above sea level

Tab. 3

Safe operation is only possible under the conditions specified above. Please contact the manufacturer for any

other operating conditions.

3.2 Weights

Range H12 H20

EUDR-Bas 3 trolley 146 153

EUDR-Bas 5 trolley 200 206EUDR-Bas 10 trolley 373 384

Tab. 4

3.3 Dimensions

Refer to the EUDR-Bas technical data for dimensions, 203 739 44.

3.4 Track girder requirements

3.4.1 Runway

43328844.eps

Fig. 1

The running surfaces must only be given a primer coat.

Minimum requirements for runways:

● Permissible deviations in dimension and shape of the track girder according to DIN EN 10034.

See EUDR-Bas technical data (203 739 44) for track girder dimensions and permissible wheel loads.

● Hoist travel on track beams must in no way be obstructed by protruding suspension bolts, screw heads, buttstraps, clamping plates, etc.

● Track gradients should not exceed 2%.

● Limit stops must be fitted at both ends of the runway.

● Track joints must be clean and smooth. Bolted joints must be outside the travel area of the travel wheels (ob‐

serve maximum web thickness).

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● The running surface of the track girder must only be given a primer coat of 40 µ in the area of the wheels.

Travel characteristics would be impaired by a top coat ( Fig. 1, Page 11).

● Rails and track beams should be kept clean; oil, grease, ice and dirt on the running surfaces will cause travelwheels to skid.

3.4.2 Travel unit

The trolleys are infinitely adjustable to various flange widths, "EUDR-Bas trolley assembly", Page 17 see also

EUDR-Bas technical data 203 739 44.

Do not use the monorail hoist to pull free, pull or drag loads on the ground. The monorail crab must never run

against the buffer stops at full speed, as otherwise damage to the hoist unit or even accidents may occur.

3.4.3 EUDR-Bas 3 - 5 - 10 wheel loads

Refer to the EUDR-Bas technical data for travel wheel dimensions and wheel loads, 203 739 44.

3.4.4 Travel motor

Refer to the EUDR-Bas technical data for travel motor data, 203 739 44.

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4 Design and function

4.1 Design

1

2

3

4

5

6789

Fig. 2

1 Guide roller

2 Trolley side without travel motor

3 Travel wheel4 Travel motor

5 Trolley side with travel motor

6 Threaded rod (opposite the motor side)

7 Trolley connecting beam (connection to the

rope hoist)

8 Drive shaft

9 Threaded rod (motor side)

4.2 Travel motor

A Demag MT-Bas brake motor with a separately controlled brake is used as the travel motor. The travel motor is

of 8/2-pole design.

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5 Transport, packing, storage

5.1 Safety instructions

WARNING

Risk of injury from falling parts


Secure components during transport. Do not step under the suspended load.

CAUTION

Inappropriate transport

The machine may be damaged.

Lift loads only at the marked lifting points. Only use suitable hoisting equipment which has sufficient load capaci‐

ty.

5.2 Transport inspection

● Check that the delivery is complete and for transport damage immediately upon receipt.

● If any transport damage is visible from the outside, only conditionally accept the delivery. Note the scope of

damage in the shipping documents/delivery note of the forwarding company and lodge a claim.

● Lodge a claim for any defects that are not immediately detected as soon as they are discovered, since claims

for damages may only be asserted within the relevant claim notification periods.

5.3 Packing

If no agreement has been made on the return of the packing material, separate the materials according to typeand size and make it 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.

5.4 Storage

Until they are installed, the machine and accessories must be kept closed and may only be stored under the fol‐

lowing 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 °C to +55 °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

protection.

● If stored in a damp location, the machine must be packed tight and protected against corrosion (desiccant).

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6 Installation and putting into operation for the first time


WARNING

Dangerous electric current


Work on electrical equipment may only be carried out by qualified specialist personnel in compliance with thesafety regulations.

– Before starting work, switch off the electrical supply and secure against restoration.

WARNING

Danger of falling load, crushing hazard

Danger of falling load if parts move in an uncontrolled way during assembly or insertion. Crushing hazard if per‐

sons are present in the area where the load is moving.

The EUDR-Bas unit may only be assembled after the sequence of work has been agreed:

– Specify responsibilities.

– Agree sequence of work with everybody involved.

– Fence off the working area at a generous distance.

– Maintain safety distance.

Only use suitable lifting equipment for assembly.

– Only lift parts weighing more than 20 kg with lifting equipment.

Only use tested and sufficiently dimensioned lifting equipment for lifting.

– Always use the specified lifting points to lift the parts.

– Avoid any measures that may result in a risk of personal injury. – Nobody may be present in the area in which the parts move.

Special information for assembly

a) b)

Fig. 3 Example of safe assembly

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a) Protection for the working area

b) Example of a suitable working platform

WARNING

Risk of injury if incorrectly assembled

Incorrect installation can lead to severe injury and/or damage to property.

Therefore, this work may only be carried out by authorised, instructed personnel who are familiar with the princi‐

ple of operation of the machine in compliance with all safety regulations:

– Ensure sufficient working clearance before starting assembly work.

– Make the working and danger zone safe ( Fig. 3, Page 15).

– If a lifting appliance is used for assembly, only use appropriate attachments for the lifting of persons which

ensure that work is carried out in a safe and stable position ( Fig. 3, Page 15).

– First check that the voltage and frequency specified on the data plates match the owner's mains power sup‐

ply. – All clearance dimensions and safety distances (see approval drawing) must be checked before putting the

unit into operation.

– Work may need to be carried out in the danger zone when the unit is put into operation.

– In the course of putting the unit into operation, it may be necessary to render safety devices or features

temporarily inoperative.

– 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. – The electrode holder and earth must always be connected to the same assembly when welding work is car‐

ried out as otherwise serious damage may be caused to the machine.

– Attach the trolley and rope hoist only at the appropriate connecting points.

– Only carry out installation work when all requirements regarding the installation location are met "Operat‐

ing conditions", Page 11.

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6.2 EUDR-Bas trolley assembly

6.2.1 Overview

1

2

3

4

5

6

7

8

Fig. 4

EUDR trolley

1 EUDR trolley

2 Cross-travel motor

Electrical equipment

3 Electrical equipment enclosure (only for CC de‐sign)

FDR-Bas

4 Gearbox

5 Bottom block

6 Return sheave

7 Hoist motor

8 Electrical equipment cover with geared limitswitch

- Control pendant

CAUTION

Loose connections

Loose connections are a danger to life and limb.

Tighten the connections to the tightening torques and use threadlocker as specified below.

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The runway girders must be aligned properly before fitting the cross-travel units, therefore, the dimensional ac‐

curacy of the runways must be checked before fitting, "Track girder requirements", Page 11.

6.2.2 Fit the trolley connecting beam to the rope hoist on electrical equipment cover)

1

2

34

67

910

8

5

Fig. 5

1 Trolley connecting beam

2 Washer

3 Sleeves

4 Plate5 Bolt

6 Washer

7 Bolt

8 Seal

9 Cover 10 Bolt

Assembly sequence:

1. Unscrew four bolts (10) of the electrical equipment cover and remove cover (9).

2. Remove seal (8).

3. Remove four screws (5).

4. Remove two bolts (7) and washers (6).

5. Remove plate (4).

6. Remove two sleeves (3).

7. Insert trolley connecting beam (1) and four washers (2), ensure the trolley connecting beam is installed in the

right direction.

8. Insert two sleeves (3) through washers (2) and the bore holes of trolley connecting beam (1).

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9. Fit plate (4), insert two bolts (7) with washers (6) and tighten them.

Tightening torque of bolts 7):

DR-Bas 3: 60 Nm

DR-Bas 5: 104 Nm

DR-Bas 10: 104 Nm

10. Insert and tighten four screws (5).


DR-Bas 3: 85 Nm

DR-Bas 5: 130 Nm

DR-Bas 10: 130 Nm

11. Install seal (8).

12. Fit cover (9) and secure with four bolts (10).

Tightening torque of bolts 10): 41 Nm

6.2.3 Fit the trolley connecting beam to the rope hoist gearbox side)

15

4

3

2

Fig. 6

1 Bolt

2 Trolley connecting beam

3 Washer

4 Sleeve

5 Washer

Assembly sequence:

1. Remove two bolts (1) and washers (5).

2. Remove two sleeves (4).

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3. Insert trolley connecting beam (2) and four washers (3), ensure the trolley connecting beam is installed in the

right direction.

4. Insert two sleeves (4) through washers (3) and the bore holes of trolley connecting beam (2) and secure withtwo bolts (1) and washers (5).


DR-Bas 3: 60 Nm

DR-Bas 5: 104 Nm

DR-Bas 10: 104 Nm

6.2.4 Punch marks for adjustment to the sides of the runway

2/1 4/1

Fig. 7 Punch marks on the trolley connecting beams for 2/1 and 4/1 reeving arrangements

Adjust both sides of the trolley to ensure that they are symmetrically aligned with the centre of gravity and thatthey match the width of the bottom flange of the runway girder. The trolley connecting beams of the rope hoist are

provided with punch marks for this adjustment.

WARNING

Risk of errors in assembly

Danger if the trolley is incorrectly adjusted.

The centre of gravity of the standard-headroom travelling hoist will vary depending on its rope reeving arrange‐

ment. For this reason, the trolley connecting beams have different punch marks for 2/1 and 4/1 reeving arrange‐ments. The load will be unequally distributed on the trolley if the wrong marks are used.

– Ensure that the correct punch mark is used for the relevant reeving arrangement when the trolley is adjus‐

ted, Fig. 7, .

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6.2.5 Fit the side of the trolley with the travel motor on the trolley connecting beams of the rope hoist

1. Secure the rope hoist in mounting position A (motor on the side) for assembly.

2. Raise the side of the trolley with the travel motor and place sliding section (1) on trolley connecting beams

(3) of the rope hoist.

1

2

3

a

Fig. 8 Distance a for 4/1 reeving (example), use other punch mark

for 2/1 reeving arrangements

6.2.6 Adjust and secure trolley side with travel motor

Distance a between the relevant punch mark on the trolley connecting beam ( "Punch marks for adjustment to

the sides of the runway", Page 20) and the side of trolley sliding section (1) depends on the width of the runway

girder.

EUDR-Bas 3 a = (b - 46 mm) / 2

where b = width of the runway girder[mm]UDR-Bas 5 a = (b - 58 mm) / 2

EUDR-Bas 10 a = (b - 66 mm) / 2

Tab. 5

Example for EUDR-Bas 5:

Width b of the runway girder (lower flange) = 200 mm, distance a to be set = (200 mm - 58 mm) / 2 = 71 mm

1. Align the side of the trolley with the travel motor at distance a, Fig. 8, .

2. Secure the side of the trolley with grub screw (2) following alignment, Fig. 8, Page 21.

Tightening torque MA = 41 Nm

3. Apply Loctite 290 threadlocker inside the bore hole and allow it to harden.

6.2.7 Place the side of the trolley without travel motor on the trolley connecting beam

1. Place the side of the trolley without travel motor on the opposite side of the trolley connecting beam to match

the side of the trolley with travel motor, Fig. 9, Page 22.

Do not yet adjust the side of the trolley to distance a.

● First adjust the side of the trolley in such a way that the minimum distance between the sides of the trolley is

wider than the width of the runway girder to ensure that the trolley can be placed on the runway girder from

below.

2. Secure the side of the trolley by tightening grub screw (3), Fig. 9, Page 22.

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6.2.8 Insert the threaded rods

The two halves of the trolley must be connected by threaded rods at each end.

1. Insert threaded rod through the bore hole in the trolley flange on one side of the trolley.

2. Screw two nuts (1) onto threaded rod (2) between the sides of the trolley.

3. Insert threaded rod through the flange bore hole on the other side of the trolley.

4. Screw two nuts (1) onto both ends of the threaded rod and tighten them evenly against the sides of the trol‐

ley.

1

2

3

4

Fig. 9

5. Counter-tighten the nuts against each other on both sides of the trolley flange on the already adjusted side of

the trolley (with travel motor).


6. Repeat the process for the second threaded rod at the other end of each half of the trolley.

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6.2.9 Place the trolley on the runway girder and adjust the second half of the trolley

1. Raise the trolley with suitable lifting equipment until it is just below runway girder (2).

2. Align the trolley with the runway girder in such a way that the trolley can be placed on the runway girder from

below.

3. Raise the trolley further until travel wheels (1) are above the lower flange of the runway girder.

4. Move the trolley on the motor side up to guide rollers (3).

5. Loosen grub screw (4).

4

1

2

3

a

5

Fig. 10 Distance a for 4/1 reeving (example), use other punch

mark for 2/1 reeving arrangements

6. Tighten outside nut (5) on the threaded rod to move the side of the trolley opposite the travel motor against

the runway girder until distance a is reached between the side of the trolley sliding section and the punch

mark, Fig. 10, . Caculation of distance a Tab. 5, Page 21.

7. Tighten grub screw (4), Fig. 10, Page 23.


8. Apply Loctite 290 threadlocker inside the bore hole and allow it to harden.

9. Counter-tighten nuts (5) against each other on both sides of the trolley flange (on the side opposite the travel

motor). Fig. 10, Page 23.


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6.2.10 Install the drive shaft

1. Insert drive shaft (1) through the sleeves of both sides of the trolley from the motor side.

2. Secure drive shaft (1) with pin (2) and nut (3) on the side opposite the travel motor.

Tightening torque MA = 7,3 Nm

12 3

Fig. 11

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6.3 Buffer installation on the runway

43365544.eps

2

b 7

1

Fig. 12

1 Buffers

2 Buffer complete

Range b7 [mm]

DR-Bas 3 120

DR-Bas 5 137,5

DR-Bas 10 171

Tab. 6

Buffers must be fitted at both ends of the runway.

6.4 Connecting the electrical equipment

DANGER

Live components


All wiring and connection work may only be carried out by an instructed and qualified electrician according to thespecifications.

A circuit diagram must be compiled for connection of the Demag rope hoist.

The wiring of the Demag machine complies in all respects with current local regulations. Unauthorised interven‐

tion and modifications may result in infringement of these regulations.

Refer to the control assembly instructions 211 205 44 for further information on electrical connection.

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7 Operation

7.1 Operation of the monorail trolley

These assembly instructions describe assembly of the hoist unit on the EUDR-Bas trolley and assembly of thetrolley on the runway girder.

● Operation of the hoist unit including the travel drive is described in the EUDR-Bas operating instructions,

211 203 44.

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8 Maintenance


The following sections contain a description of maintenance work that is necessary for optimum and uninterruptedoperation of the machine.

WARNING

Risk of injury.

Incorrect maintenance work may result in severe injury or damage to property.

Maintenance work may only be carried out by authorised and instructed specialist personnel in compliance with

all safety regulations.

DANGER

Live components

Electric current may cause danger to life and limb.

Work on electrical equipment may only be carried out by qualified personnel in compliance with the safety regu‐

lations.

Always:

1. Wear personal protection equipment.

2. Fence off the working area.

3. Before starting work, switch off the machine and secure it against switching on again.

4. Switch off the power supply at the mains connection or isolating switch. Check that the system is de-ener‐

gised.

5. Ensure that there is sufficient freedom of movement.

6. Parts of the body can be crushed when working on the machine. Secure the machine/machine parts against

unintended movement and work with the utmost care and caution.

7. Keep the working area clean and tidy. Loose parts or tools left lying around may cause accidents.

8. Reinstall safety devices as required by relevant regulations and check them for correct operation after finish‐ing maintenance work.

9. Only use genuine Demag spare parts.

CAUTION

Lubricants/oils

Risk of injury resulting from contact with the body/skin. Oils and lubricants are a health hazard.

Contact with these media may result in serious damage to health (poisoning, allergies, skin irritation, etc.)

– Pay attention to the manufacturer's safety data sheets and instructions.

CAUTION

Risk of injury. Risk of slipping.

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.

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8.2 Regular inspections

Hoists and cranes must be inspected by an experienced technician at least once a year. Regular inspectionsmainly consist of a visual inspection and a function check which should include a check to determine the condition

of components and equipment regarding damage, wear, corrosion or other alterations and a check to determinethe integrity and efficiency of safety devices.

It may be necessary to remove parts in order to inspect wearing parts.

Load-bearing media and suspensions must be inspected along their entire length, including those parts which

cannot normally be seen. A function and brake test with a load (test load that is close to the maximum permissible

load capacity) must be carried out.

Updating the test and inspection booklet

● The owner must arrange for all inspections to be carried out and documented in the hoist or crane test and

inspection booklet.

8.3 Maintenance schedule

The specified inspection and maintenance intervals apply to normal operating conditions. If routine maintenance

reveals that the intervals are too long, they should be shortened according to the specific operating conditions.

Check during operation

Activity See section Before the

unit is first

put into oper‐

ation

Before start‐

ing work

Every 6

months

Once per

year

Check all connections (bolts, weld seams etc.) KD 2) X

Check travel wheels "Check travel wheels",

Page 29 X

Check securing elements (clips, bolts, etc.) for

tight fit and corrosionKD 2) X

Check and apply or supplement corrosion pro‐

tection, as requiredKD 2) X

Change oil in cross-travel gearbox Every 8 - 10 years, "Oil change", Page 29

Check condition of all buffers KD 2) X

Check travelling hoist power supply. Check

sliding contacts and travel rollers for wear and

sliding contacts for contact pressure of current

collectors

according to local regulations

X

Tab. 7

WARNING

Danger due to incomplete maintenance.

Danger to life and limb since safe operation of the machine is not ensured.

– Carry out all specified maintenance work appropriately and in time.

– Please contact Demag Customer Service for any work that you cannot carry out yourself.

– Make sure that the entries in the test and inspection booklet of the crane installation are complete.

2) The inspection may only be carried out by Demag Customer Service or by authorised specialist personnel.28 2 1 1

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8.4 Check travel wheels

d

Fig. 13

Travel wheels must be checked for wear every year, permissible wear must not exceed 4% of the rated diameter.

Travel wheel dia. d

Rated diameter [mm] Wear limit [mm]

100 96

125 120

160 153,6

Tab. 8

Travel wheels must be replaced if their diameter is less than the wear

limit.

8.5 Oil change

The travel gearbox is filled with the required quantity of lubricant before leaving the factory. In normal cases, it is

not necessary to change or supplement it.

Oil leaks/loss of oil in the course of operation may cause damage to or total failure of the machine. If this occurs,

stop the machine and notify Service.

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Index

A

Assembly instructions 7

Assigned expert engineer 6

C

Complete machine 7

D

Design limit 6

E

Electrical equipment 17

EUDR trolley 17

Experienced technician 6

Expert engineer 6

F

FDR-Bas 17

G

Guide roller 13

M

Machine operator 6Maintenance 27

Manufacturer 6

O

Operating instructions 7

Operating personnel 6

Owner 6

P

Partly completed machinery 7

Q

Qualified electrician 6

R

Rope hoist 6

S

Signal words 5

Specialist personnel 6

Symbols 5

T

Trained person 6

Travelling hoist 7

Travel motor 13

Travel wheel 13

Trolley 7

Trolley beam 13

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34 2 1 1 2 0 2 4 4_

e n / C N

Notes

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35 2 1 1 2 0 2 4 4_

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Notes

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The current addresses of the sales of fices and the subsidiaries and agencies worldwide

can be found on the Demag Cranes & Components homepage at

www.demagcranes.com/Contact