Assembly instructionsDemag EKDR-Bas trolleyLow-headroom monorail trolleyEKDR-Bas 3 - 5 - 10

241111 en GB 211 200 44 719 IS 813

Original assembly instructions

Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of yourDemag EKDR-Bas trolley and important information if you ever have to contact the manufacturer or his representative.

OwnerWhere in useRangeSerial 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. ClassificationSpare parts lists Spare parts list for Demag trolley EU-/EK-/EZDR-Bas 3 - 5 - 10 217 088 44 721 IS 813Further documentsEKDR-Bas 3 - 10 technical data 203 736 44 714 IS 813EKDR-Bas 3 - 10 operating instructions 211 201 44 720 IS 813FDR-Bas 3 - 10 assembly instructions 211 211 44 719 IS 813Bas control assembly instructions 211 205 44 719 IS 813Demag 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.2 211

200

44/2

4111

1

Table of contents

General........................................................................................................................................................................ 5EKDR-Bas 3 - 5 - 10 trolley ......................................................................................................................................... 5Information on the assembly instructions .................................................................................................................... 5Symbols/signal words.................................................................................................................................................. 5Terms and definitions .................................................................................................................................................. 5Safety .......................................................................................................................................................................... 8

General........................................................................................................................................................................ 8Safety signs................................................................................................................................................................. 8Intended use................................................................................................................................................................ 8Hazards that can be caused by the machine .............................................................................................................. 9Assembly personnel requirements .............................................................................................................................. 9Personal protection equipment.................................................................................................................................. 10Inspection regulations ............................................................................................................................................... 10Technical data ........................................................................................................................................................... 11

Operating conditions ................................................................................................................................................. 11Weights ..................................................................................................................................................................... 11Dimensions................................................................................................................................................................ 11Track girder requirements ......................................................................................................................................... 12Runway ..................................................................................................................................................................... 12Travel unit.................................................................................................................................................................. 12EKDR-Bas 3 - 5 - 10 wheel loads.............................................................................................................................. 12Travel motor .............................................................................................................................................................. 12Design and function................................................................................................................................................... 13

Design ....................................................................................................................................................................... 13Arrangement of assemblies....................................................................................................................................... 13Travel motor .............................................................................................................................................................. 13Transport, packing, storage....................................................................................................................................... 14

Safety instructions ..................................................................................................................................................... 14Transport inspection.................................................................................................................................................. 14Packing...................................................................................................................................................................... 14Storage...................................................................................................................................................................... 14Installation and putting into operation for the first time.............................................................................................. 15

Safety instructions ..................................................................................................................................................... 15EKDR-Bas trolley assembly ...................................................................................................................................... 17Overview ................................................................................................................................................................... 17Fit the trolley connecting beam to the rope hoist (on electrical equipment cover) .................................................... 18Fit the trolley connecting beam to the rope hoist (gearbox side)............................................................................... 19Fit the side of the trolley with the travel motor on the trolley connecting beams ....................................................... 20Insert the threaded rods ............................................................................................................................................ 21Place the trolley on the runway girder and adjust it to the track width ...................................................................... 21Install the drive shaft ................................................................................................................................................. 22Installing counterweights ........................................................................................................................................... 23Buffer installation on the runway ............................................................................................................................... 24Connecting the electrical equipment ......................................................................................................................... 24Operation................................................................................................................................................................... 25

Operation of the monorail trolley ............................................................................................................................... 25Maintenance.............................................................................................................................................................. 26

Safety instructions ..................................................................................................................................................... 26Regular inspections................................................................................................................................................... 26

11.11.21.31.42

2.12.22.32.42.52.62.73

3.13.23.33.43.4.13.4.23.4.33.4.44

4.14.24.35

5.15.25.35.46

6.16.26.2.16.2.26.2.36.2.46.2.56.2.66.2.76.2.86.36.47

7.18

8.18.221

1 20

0 44

/241

111

3

Maintenance schedule .............................................................................................................................................. 27Check travel wheels .................................................................................................................................................. 28Change gearbox oil ................................................................................................................................................... 28Malfunctions .............................................................................................................................................................. 29

Safety instructions ..................................................................................................................................................... 29Conduct when malfunctions occur ............................................................................................................................ 29Conduct after malfunctions have been eliminated .................................................................................................... 29Malfunctions, causes and remedy............................................................................................................................. 30

Index........................................................................................................................................................................................... 31

8.38.48.59

9.19.29.39.4

4 211

200

44/2

4111

1

1 General

1.1 EKDR-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 theregulations.

These assembly instructions describe the trolley for the Demag EKDR-Bas low-headroom monorail-travellinghoist. The trolleys of the following ranges are described:● EKDR-Bas 3● EKDR-Bas 5● EKDR-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 instructions

These assembly instructions are designed to provide the owner with appropriate instructions for safe and correctoperation and for maintenance. These assembly instructions are an integral part of the trolley.

Operation of the complete EKDR-Bas travelling hoist is described in the operating instructions, 211 201 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 inyour 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.– Follow these instructions at all times and be particularly careful and cautious.

CAUTION

This warning symbol indicates a possibly dangerous situation that might result in medium or slight injuries or ma‐terial damage.– Follow these instructions at all times and be particularly careful and cautious.

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.

1.4 Terms and definitions

Manufacturer

211

200

44/2

4111

1

5

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 theequipment;

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 itto be operated by suitable and trained persons.

Operating personnel/machine operatorOperating 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 personTrained 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 andoperating conditions and must provide verification of their competence. Trained personnel must be trained by theowner in accordance with the tasks to be performed.

Specialist personnelSpecialist 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 ownerbefore any work is carried out on or with the machine.

Qualified electricianQualified electricians are defined as persons who, owing to their technical training, knowledge and experience ofelectrical machines as well as knowledge of the relevant valid standards, codes of practice and regulations, areable to assess the tasks given to them and to identify and eliminate potential hazards. Qualified electricians mustbe trained by the owner in accordance with the tasks to be performed.

Experienced technicianExperienced 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 standardsenabling them to judge the safe operating condition of machines.

Assigned expert engineerAn assigned expert engineer is defined as an experienced technician specifically assigned by the manufacturer todetermine the remaining duration of service (service life) of the machine (S.W.P. = safe working period) and tocarry out a general overhaul of the machine.

Authorised expert engineerIn 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 limitFor 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 hoistRope hoists are systems used for lifting and moving loads, such as cranes, crabs and travelling hoist units, railsystems.

Crab or travelling hoistA 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 unit6 21

1 20

0 44

/241

111

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

Partly completed machineryPartly completed machinery is a combination of parts/components that are almost a machine, but which cannotprovide 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 EKDR-Bas trolley is partly completed machinery.

Complete machineA complete unit of connected parts that are equipped with a drive system, of which at least one moves and whichare assembled for a particular application.The EKDR-Bas travelling hoist is a complete machine.

Assembly instructionsDocumentation supplied by a manufacturer of partly completed machinery/component. The assembly instructionsdescribe the installation of the scope of delivery in a larger assembly.

Operating instructionsDocumentation supplied by the manufacturer of a complete machine which describes operation of the machine/installation (of the complete scope of delivery).

211

200

44/2

4111

1

7

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 usedcorrectly or as intended by suitably trained personnel.

Knowledge of the contents of the assembly instructions is one of the requirements necessary to protect personnelfrom 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 runwaygirder 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 orlabels 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 instructionsdo not describe operation of the complete installation.

The following documents must be considered for the intended use of the entire installation:● Trolley assembly instructions● EKDR-Bas rope hoist operating instructions, 211 201 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 withthe 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 27). Wearingparts must be replaced in good time in accordance with the frequency and intensity of use.

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

No liability for structural modificationsThe 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 notapproved by the manufacturer.

8 211

200

44/2

4111

1

Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by anexpert 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 extremetemperatures 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 componentsDanger to life and limb.Electrical energy may cause very severe injuries. Danger to life caused by electrical current if the insulation orindividual 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 machineryDanger to life and limb.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 are

lifted.– 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 hazardBody 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.

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.

211

200

44/2

4111

1

9

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 withthe 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 operation (machine operator) or maintenance (maintenance fitter) of the machine, the ownermay 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”

10 211

200

44/2

4111

1

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 anyother operating conditions.

3.2 Weights

Range H12 H20 H30EKDR-Bas 3 trolley 156 164 170EKDR-Bas 5 trolley 210 215 224EKDR-Bas 10 trolley 402 412 426

Tab. 4

3.3 Dimensions

Refer to the EKDR-Bas technical data for dimensions, 203 736 44.

211

200

44/2

4111

1

11

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 EKDR-Bas technical data for track girder dimensions and permissible wheel loads, 203 736 44.● Hoist travel on track beams must in no way be obstructed by protruding suspension bolts, screw heads, butt

straps, 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).● 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 12).● Rails and track beams should be kept clean; oil, grease, ice and dirt on the running surfaces will cause travel

wheels to skid.

3.4.2 Travel unit

The trolleys are infinitely adjustable to various flange widths, "EKDR-Bas trolley assembly", Page 17 andEKDR-Bas technical data 203 736 44.

Do not use the monorail hoist to pull free, pull or drag loads on the ground. The monorail crab must never runagainst the buffer stops at full speed, as otherwise damage to the hoist unit or even accidents may occur.

3.4.3 EKDR-Bas 3 - 5 - 10 wheel loads

Refer to the EKDR-Bas technical data for travel wheel dimensions and wheel loads, 203 736 44.

3.4.4 Travel motor

Refer to the EKDR-Bas technical data for travel motor data, 203 736 44.

12 211

200

44/2

4111

1

4 Design and function

4.1 Design

1

2 3 4 5 6

789

Fig. 2

1 Guide roller2 Trolley side without travel motor3 Travel wheel4 Drive shaft5 Travel motor

6 Trolley side with travel motor7 Counterweights8 Trolley connecting beam (connection to the

rope hoist)9 Threaded rod

4.2 Arrangement of assemblies

The trolley is designed to be used on IPB girders, the width of the trolley is adjusted during assembly.

The rope hoist is installed on the side of the trolley. Counterweights are fitted on the side of the trolley oppositethe rope hoist.

4.3 Travel motor

A Demag MT-Bas brake motor with a separately controlled brake is used as the travel motor. The travel motor isof 8/2-pole design.

211

200

44/2

4111

1

13

5 Transport, packing, storage

5.1 Safety instructions

WARNING

Risk of injury from falling partsDanger to life and limb.Secure components during transport. Do not step under the suspended load.

CAUTION

Inappropriate transportThe 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 material according to type andsize 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).

14 211

200

44/2

4111

1

6 Installation and putting into operation for the first time

6.1 Safety instructions

WARNING

Dangerous electric currentDanger to life and limb.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 hazardDanger 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 EKDR-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

211

200

44/2

4111

1

15

a) Protection for the working areab) Example of a suitable working platform

WARNING

Risk of injury if incorrectly assembledIncorrect 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.

16 211

200

44/2

4111

1

6.2 EKDR-Bas trolley assembly

6.2.1 Overview

1

2

3

4

5

6

3

7

8

Fig. 4

EKDR-Bas trolley1 EKDR trolley2 Cross-travel motor3 CounterweightElectrical equipment4 Electrical equipment enclosure (only for CC de‐

sign)

FDR-Bas5 Gearbox6 Bottom block7 Hoist motor8 Electrical equipment cover with geared limit

switch- Control pendant

CAUTION

Loose connectionsLoose connections are a danger to life and limb.Tighten the connections to the tightening torques and use threadlocker as specified below.

211

200

44/2

4111

1

17

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 12.

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

21

345678910

Fig. 5

1 Trolley connecting beam2 Washers3 Bolts4 Cover5 Seal

6 Bolts7 Washers8 Bolts9 Plate10 Sleeves

Assembly sequence:

1. Unscrew four bolts (3) of the electrical equipment cover and remove cover (4).

2. Remove seal (5).

3. Remove four screws (8).

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

5. Remove plate (9).

6. Remove two sleeves (10).

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

8. Insert two sleeves (10) through washers (2) and the bore holes of trolley connecting beam (1).

18 211

200

44/2

4111

1

9. Fit plate (9), insert two bolts (6) with washers (7) and tighten them.Tightening torque of bolts (6):DR-Bas 3: 60 NmDR-Bas 5: 104 NmDR-Bas 10: 104 Nm

10. Insert and tighten four screws (8).Tightening torque of bolts (8):DR-Bas 3: 85 NmDR-Bas 5: 130 NmDR-Bas 10: 130 Nm

11. Install seal (5).

12. Fit cover (4) and secure with four bolts (3).Tightening torque of bolts (4): 41 Nm

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

345 12

Fig. 6

1 Bolts2 Washers3 Sleeves

4 Washers5 Trolley connecting beam

1. Remove two bolts (1) and washers (2).

2. Remove two sleeves (3).

211

200

44/2

4111

1

19

3. Insert trolley connecting beam (5) and four washers (4), ensure the trolley connecting beam is installed in theright direction.

4. Insert two sleeves (3) through washers (4) and the bore holes of trolley connecting beam (5) and secure withtwo bolts (1) and washers (2).Tightening torque of bolts (1):DR-Bas 3: 60 NmDR-Bas 5: 104 NmDR-Bas 10: 104 Nm

6.2.4 Fit the side of the trolley with the travel motor on the trolley connecting beams

1. Secure the rope hoist with fitted trolley connecting beams in mounting position (motor below) for assembly.

2. Raise side of the trolley (1) with the travel motor and place sliding sections (2) on trolley connecting beams(4).

1

2

34

Fig. 7

3. First adjust the distance between the two halves of the trolley in such a way that the minimum distance issignificantly wider than the width of the runway girder to ensure that the trolley can be placed on the runwaygirder from below.

4. Secure the fitted side of the trolley on both sides with grub screws (3).

20 211

200

44/2

4111

1

6.2.5 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 (2, 3) onto threaded rod (1) 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 (2, 3) onto both ends of the threaded rod and tighten them evenly against the sides of thetrolley.

12223

Fig. 8

5. Counter-tighten nuts (3) against each other on both sides of the trolley flange on the fixed side of the trolley.Tightening torque MA = 171 Nm

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

6.2.6 Place the trolley on the runway girder and adjust it to the track width

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

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

3. Raise the trolley further until travel wheels (2) are above the lower flange of the runway girder.

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

5. Loosen grub screws (4) on sliding section (5) on both sides of the trolley.

6. Loosen nuts (7) on both sides of the trolley.

7. Adjust distance a between guide rollers (3) using nut (6) in such a way that 2 mm of play remains on eachside between runway girder (1) and the guide rollers.Calculation for adjustment of distance a [mm]:a = b + 4 mmwhere b = width of the runway girder[mm]

211

200

44/2

4111

1

21

Example:Width of the runway girder = 200 mm, a = b + 4 mm = 204 mm

1

a

2

7 6 5

4

3

Fig. 9

8. Tighten grub screws (4) on both sides of the trolley.Tightening torque = 41 Nm

9. Apply Loctite 290 threadlocker to the threads of the grub screws and allow it to harden.

10. Counter nuts (6) and (7) against each other on both sides of the trolley.Tightening torque = 171 Nm

6.2.7 Install the drive shaft

1. Insert drive shaft (4) through the sleeves below driven travel wheels (3) from the travel motor side.

2. Secure drive shaft (4) with pin (1) and nut (2) on the side opposite the travel motor.Tightening torque = 7,3 Nm

1 2 43

Fig. 10

22 211

200

44/2

4111

1

6.2.8 Installing counterweights

Counterweights are fitted on the opposite side of the trolley when the rope hoist is installed on one side.

The quantity of required counterweights depends on the size of the trolley and on the width of the trck girder,see EKDR-Bas technical data 203 736 44.

1. Place the required quantity of counterweights on both trolley connecting beams (5) opposite the rope hoist.

2. Secure each counterwight (2) with bolt (4), washer (3) and nut (1).

1

5 4 3 2

Fig. 11

211

200

44/2

4111

1

23

6.3 Buffer installation on the runway

43358744.eps

2

b7

1

Fig. 12

1 Buffers2 Buffer complete

Range b7 [mm]DR-Bas 3 120DR-Bas 5 137,5DR-Bas 10 171

Tab. 5

Buffers must be fitted at both ends of the runway.

6.4 Connecting the electrical equipment

DANGER

Live componentsDanger to life and limb.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.

24 211

200

44/2

4111

1

7 Operation

7.1 Operation of the monorail trolley

These assembly instructions describe assembly of the hoist unit on the EKDR-Bas trolley and assembly of thetrolley on the runway girder.● Operation of the hoist unit including the travel drive is described in the EKDR-Bas operating instructions,

211 201 44.

211

200

44/2

4111

1

25

8 Maintenance

8.1 Safety instructions

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 withall safety regulations.

DANGER

Live componentsElectric 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 againstunintended 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/oilsRisk 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 inan environmentally compatible way.

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

26 211

200

44/2

4111

1

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 whichcannot normally be seen. A function and brake test with a load (test load that is close to the maximum permissibleload 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 maintenancereveals that the intervals are too long, they should be shortened according to the specific operating conditions.

Check during operation

Activity See section Before theunit is first

put into oper‐ation

Before start‐ing work

Every 6months

Once peryear

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

Check travel wheels "Check travel wheels",Page 28 X

Check securing elements (clips, bolts, etc.) fortight fit and corrosion KD 2) X

Check and apply or supplement corrosion pro‐tection, as required KD 2) X

Change oil in cross-travel gearbox Every 8 - 10 years, "Change gearbox oil", Page 28Check condition of all buffers KD 2) X

Check travelling hoist power supply. Checksliding contacts and travel rollers for wear andsliding contacts for contact pressure of currentcollectors

according to local regulations

X

Tab. 6

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.211

200

44/2

4111

1

27

8.4 Check travel wheels

D

43358544.eps

Fig. 13

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

Travel wheel dia. dRated diameter [mm] Wear limit [mm]100 96125 120160 153,6

Tab. 7

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

8.5 Change gearbox oil

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

28 211

200

44/2

4111

1

9 Malfunctions

9.1 Safety instructions

WARNING

Risk of injury.Incorrect elimination of malfunctions may result in severe injury or damage to property.Malfunctions may only be eliminated by authorised and instructed specialist personnel in compliance with allsafety regulations.

DANGER

Live componentsElectric 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.

9.2 Conduct when malfunctions occur

Always:

1. Bring the machine to an immediate standstill by actuating the emergency stop without delay if malfunctionsoccur that result in an immediate danger of personal injury, damage and/or an operating hazard.

2. Disconnect the machine from the power supply and secure the machine against reconnection.

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.

9.3 Conduct after malfunctions have been eliminated

WARNING

Putting into operation againDanger to life and limb.Before switching on again, check 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 machine.

211

200

44/2

4111

1

29

9.4 Malfunctions, causes and remedy

Fault Cause RemedyA Cross travel not functioning 1 Thermal contact of cross-travel motor ac‐

tiveAllow cross-travel motor to cool down

2 Check cross-travel inverter see electrical equipment, 211 205 443 Brake of cross-travel motor does not re‐

leaseBrake or control defective,inform Service

B Crab only travels at slow speed 1 Crab/crane in blocked area (by-passcontrol) 3)

Leave the blocked area

2 Incorrect fast-to-slow limit switch/areaswitch setting

Adjust appropriately

3 Incorrect parameter settings Inform ServiceC Lifting and cross travel not possible, long

travel is possible, switching noises of thecrab electrical equipment main contactor canbe heard.

1 Crab circuit breaker has tripped Switch circuit breaker on again, 211205 44

2 400 V voltage missing Measure voltage3 Connector loose Check 400 V plug-in connections for tight

fit4 Broken conductor in the power supply

linesInform Service

Tab. 8

3) Optional30 211

200

44/2

4111

1

Index

A

Assembly instructions 7Assigned expert engineer 6

C

Complete machine 7Counterweights 13

D

Design limit 6Drive shaft 13

E

EKDR trolley 17Electrical equipment 17Experienced technician 6Expert engineer 6

F

FDR-Bas 17

G

Girder 13Guide roller 13

M

Machine operator 6Manufacturer 5

O

Operating instructions 7Operating personnel 6Owner 6

P

Partly completed machinery 7

Q

Qualified electrician 6

R

Rope hoist 6

S

Signal words 5Specialist personnel 6Symbols 5

T

Threaded rod 13

Trained person 6Travelling hoist 6Travel motor 13Travel wheel 13Trolley 7Trolley beam 13Trolley side 13

211

200

44/2

4111

1

31

The current addresses of the sales offi ces and the subsidiaries and agencies worldwide can be found on the Demag Cranes & Components homepage atwww.demagcranes.com/Contact

Reproduction in whole or in part only with prior consent of Demag Cranes & Components Subject to change. Not liable for errors or omissions.