Data and dimensions

RS 400 wheel block system for wheel loads up to 18000 kg

Travel drives AF/AFW 08 – 12
KMF 80 – 100, KBF 80 – 140

41477144.eps

1198 EN 203 167 44 714 IS 845

 Manufacturer Mannesmann Dematic AG
P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0, Telefax (+49 2335) 927676
Internet http://www.dematic.com

General RS wheel block system

driven and non-driven

The Demag RS wheel block system is used wherever goods have to be transported
along straight lines. The connection holes in the wheel blocks provide the user with
many different possibilities for fitting the units to adjoining structures. All mechanical
and electrical components are also used in our end carriages. By using proven se-
ries-produced components, the user can be sure of the operational reliability of his
machinery, interchangeability without complicated conversion work and constant
access to spare parts. Demag RS wheel block systems have a wide range of applica-
tions and are used in materials handling and machinery installations.

Anti-friction bearings
The anti-friction bearings of RS 400 wheel blocks are suitable for temperatures from
-30 °C to +70 °C and normal ambient conditions. The bearings are sealed by cover
plates, lubricated for life and maintenance-free.

Drive unit with hollow-shaft gearbox

Basic data and dimensions for hollow-shaft gearboxes, squirrel-cage motors and
slip-ring motors are contained in this brochure.
Detailed data can be found in the following:
AF/AFW offset/hollow-shaft gearboxes
Data sheet 202 981 44, 714 IS 913.25.
KMF/KBF squirrel-cage brake motors, 2, 4, 8/2 and 12/2 poles
Data sheet 202 492 44, 714 IS 911.
SBA slip-ring rotor brake motors
Data sheet 202 515 44, 714 IS 913.20.
GDH DC motors with brake
Data sheet 202 566 44, 714 IS 914.
Cellular foam buffers
There are attachment holes in the wheel blocks for fitting buffers. This brochure con-
tains data showing the buffers corresponding to particular wheel blocks.
For determining the impact forces, see data sheet 202 574 44, 714 IS 883
Documentation accompanying products
Mounting, installation and operating instructions 206 285 44, 720 IS 845.
Component parts list
RS 400: 222 364 44, 721 IS 845
Price list
223 212 44, 711 IS 845
Design features
• Rapid fitting and removal without special tools.
• Many different connection possibilities.
• Fully developed attachment methods.
• Minimum maintenance.
• Optimally matched with Demag’s travel drive unit system.
203167k1.p65 1198

2
 Contents

1 Notes on application 5
1.1 Functions 5
1.2 Travel unit variants 6
1.2.1 Travel wheel type, diameter, wheel load 6
1.2.2 Horizontal load 6
1.2.3 Special design 6
1.3 Anti-friction bearings 7
1.3.1 Standard 7
1.3.2 Extreme conditions 7
1.4 Connection variants 8
1.5 Guide variants 8

2 Wheel block data 9

2.1 Permissible wheel loads perm. RM for
spheroidal graphite cast iron travel wheels 9
2.2 Permissible wheel loads perm. RST in kg
for all travel wheel types and connection variants 10
2.3 Permissible wheel loads perm. RM in kg
for Hydropur travel wheels F1 10
2.4 Correlation between travel wheel treads – rail head width
and special treads 10
2.5 Useful rail head width k1 10
2.6 Determining the group of mechanisms (FEM/DIN 15020) 11
2.7 Determining the stress factor group 11

3 RS wheel block dimensions, part nos. 12

4 Travel drive unit gearbox – motor combination selection 15

4.1 Travel motor operating cycles 15
4.2 Combination codes for determining motor and gearbox
for spheroidal graphite cast iron and polyamide travel wheels 16
4.3 Traction resistances and main characteristics of travel wheels
of spheroidal graphite cast iron, polyamide, Hydropur-elastomer 18
4.3.1 Traction resistances – Hydropur-elastomer travel wheels type F1 18

5 Connection variants 19
5.1 Top connection 19
5.1.1 Top connection – Direct connection to rolled section
Connection variant 6.1 19
5.2 End connection 20
5.2.1 End connection
Connection variant 6.3.3 20
5.2.2 Set nuts for wheel block 20
5.3 Side connection 21
5.3.1 Non-driven side connection
Connection variant 6.5 21
5.3.2 Mounting 21
5.4 Pin connection 22
5.4.1 Non-driven pin connection
Connection variant 6.6 22
5.5 Buffers 24
5.5.1 Standard buffers 24
203167k1.p65 1198

5.5.2 Hydraulic buffer 24

5.5.2 DPZ 160 buffers 25

3
 Contents

6 Guide arrangements 26
6.1 Guiding variants 26
6.2 Guide rollers 26

7 Drive variants 27
7.1 Individual drive unit 27
7.2 Central drive unit ZI 27
7.3 Central drive unit ZA 27
7.4 Universal shaft type F 28
7.5 Individual drive unit 28

8 Drive unit elements 29

8.1 Selection of drive shafts, shafts with coupling K1 29
8.2 Central drive unit ZI, version I with coupling K 29
8.3 Central drive unit ZI, version II with coupling K2 30
8.3.1 Instructions for fitting shaft, coupling 30
8.4 Central drive unit ZI, version III with coupling K 31
8.6 Dimensions, couplings K1, K2, part nos. 31
8.7 Shaft protection, single drive unit 33
8.8 Shaft protection, central drive unit 33
8.9 Torque arms 34
8.9.1 Torque arm variants 34
8.9.1.1 Connection with torque arm type D2 34
8.9.1.2 Connection with torque arm type D1 34
8.9.1.3 Data for connection to the supporting structure 35
8.9.2 Torque arm type D2, dimensions and part nos. 35
8.9.4 Torque arm type D1, AF/AFW 08 – 12 36

9 AF/AFW 08 – 12 travel drive data 38

9.1 Key values for input speed n = 2800 rpm, AF/AFW 08 – 12 38
9.2 Key values for input speed n = 1400 rpm, AF/AFW 08 – 12 39

10 AF/AFW 08 – 12 travel drive dimensions 40

10.1 AF 08 , model M 40
10.2 AF 10 – 12, model M 41
10.3 AFW 08, model M 42
10.4 AFW 10 – 12, model M 43

11 Shaft connection 44
11.1 Hollow-shaft design with splined shaft connection to DIN 5480 44
203167k1.p65 1198

4
 1 Notes on application

Under extreme operating conditions, the capacity and performance of component

parts and drive elements may be lower than specified in the tables. In such cases,
please confirm details with our office. The safety factors incorporated in working load
and drive torque data cover application examples as shown in section 1. If any doubt
exists concerning the safety of the application please contact us.

1.1 Functions According to its position and arrangement, the RS 400 wheel block with the various
travel drives and combined with the proven Demag drive units carries out the func-
tions of supporting, driving and guiding.

Supporting, driving and guiding Driving and guiding

40142744.eps

Supporting and driving

40142944.eps

40142844.eps
203167k1.p65 1198

5
 1.2 Travel unit variants
1.2.1 Travel wheel type, diameter, wheel load

Standard design RS 400: Wheel block housing material: weldable (similar to St 37-2)

41821644.eps 41821744.eps

Travel wheel type A1 B1

Flange-guided travel wheel Travel wheel without flange

Spheroidal graphite cast iron Spheroidal graphite cast iron

RS wheel block
diameter mm diameter mm

400 400 400

41821844.eps 41821944.eps

Travel wheel type D F1

Travel wheel with one flange Travel wheel without flange

Spheroidal graphite cast iron Hydropur

RS wheel block
diameter mm diameter mm

400 400 450

1.2.2 Horizontal load The max. horizontal load is 20% of the maximum wheel load

1.2.3 Special design

Special designs Travel wheel type G

Special travel wheel,

RS spheroidal graphite cast
The designs shown here travel wheel iron, Polyamide,
203167k1.p65 1198

are manufactured to dia. mm

order. Further variants
are possible.
400 Dimensions as agreed 41822044.eps

6
 1.3 Anti-friction bearings For use in temperatures from Bearings sealed by special sealing
1.3.1 Standard -30 °C to +70 °C and normal arrangement.
ambient conditions. Lubricated for life, maintenance-free.

41142044.eps

1.3.2 Extreme conditions

For use in temperatures from Bearings sealed by special sealing
-20 °C to +150 °C and in moist arrangement up to 150°C.
and dusty conditions. Lubricated for life, maintenance-free.

All bearings have the following

additional features:
- Metal cage
- Dimension stability
- High-temperature grease
41142044.eps
203167k1.p65 1198

7
 1.4 Connection variants
For the mounting configurations shown, there are sets For mounting methods not shown here, please contact us.
available which include all the parts required.

6.1 Top connection 6.6 Pin connection

Direct connection to rolled section. Fitted inside hollow sections or in crossmembers,
SET contains bolting parts and plugs. bogie links etc.
SET contains pins, spacer elements and plugs.

41822144.eps
41822444.eps

6.3.3 End connection

With thread, ready for direct connection.
SET contains weld-on part, bolting elements
and plugs.

41823444.eps

40171244.eps

6.5 Side connection

SET contains bolting parts, spacer tubes
and plugs.

41822344.eps

1.5 Guide variants

for all wheel block sizes

Standard designs Special designs

Examples
203167k1.p65 1198

Flanges Guide rollers

8 41823544.eps 41823644.eps
 2 Wheel block data

2.1 Permissible wheel loads perm. RM for spheroidal graphite cast iron travel wheels
Travel wheel types A1, B1, D
Group of Useful rail RS 400 - AF/AFW 08, 10, 12
mechanisms head width
Travel speed in m/min
FEM/DIN in mm
15 020 12,5 16 20 25 31,5 40 50 63 80 100 125 160

45 14808 14545 14283 13890 13497 13104 12711 12318 11925 11400 10745 10090

50 16453 16162 15870 15434 14997 14560 14123 13686 13250 12667 11939 11211

55 17778 17457 16977 16496 16016 15536 15055 14575 13934 13133 12332

1 Bm 60 17996 17472 16948 16424 15900 15201 14327 13453

65 17792 17224 16467 15521 14575

70 18000 17734 16715 15696

75 17909 16817

45 14808 14545 14283 13890 13497 13104 12711 12318 11925 11400 10745 10090

50 16453 16162 15870 15434 14997 14560 14123 13686 13250 12667 11939 11211

55 17778 17457 16977 16496 16016 15536 15055 14575 13934 13133 12332

1 Am 60 17996 17472 16948 16424 15900 15201 14327 13453

65 17792 17224 16467 15521 14575

70 18000 17734 16715 15696

75 17909 16817

45 14808 14545 14283 13890 13497 13104 12711 12318 11925 11400 10745 10090

50 16453 16162 15870 15434 14997 14560 14123 13686 13250 12667 11939 11211

55 17778 17457 16977 16496 16016 15536 15055 14575 13934 13133 12332

2m 60 17996 17472 16948 16424 15900 15201 14327 13453

65 17792 17224 16467 15521 14575

70 18000 17734 16715 15696

75 17909 16817

45 14808 14545 14283 13890 13497 13104 12711 12318 11925 11400 10745 10090

50 16453 16162 15870 15434 14997 14560 14123 13686 13250 12667 11939 11211

55 17778 17457 16977 16496 16016 15536 15055 14575 13934 13133 12332

3m 60 17996 17472 16948 16424 15900 15201 14327 13453

65 18000 17792 17224 16467 15521 14575

70 17734
16648 15459
75 17800

45 14808 14545 14283 13890 13497 13104 12711 12318 11925 11400 10745 10090

50 16453 16162 15870 15434 14997 14560 14123 13686 13250 12667 11939 11211

4m 55 17778 17457 16977 16496 16016 15536 15055 14575 13934 13133 12332

60 17996 17472 16948 16424

18000 15533 14527 13586 12616
³ 65 17885 16687

45 14808 14545 14283 13890 13497 13104 12711 12318 11925 11400 10745 10090

50 16453 16162 15870 15434 14997 14560 14123

5m 55 17778 17457 16977 16496

13586 12646 11828 11062 10272
60 15570 14562
18000 17927 16727
³ 65
203167k2.p65 1198

9
 2.2 Permissible wheel Connection variants (see pages 19 - 22)
RS
loads perm. RST in kg wheel block
Stress factor group
6.1, 6.3,
6.5, 6.6
for all travel wheel
B 1/ B 2 / B 3 18000
types and connection 400 B4 16000
B5/B6 14000
variants

RST = permissible load factors for steelwork and bolted connections to DIN 15 018.

2.3 Permissible wheel Travel wheel type RS Travel speed m/min

loads perm. RM in kg wheel block up to 40 up to 63 up to 80 up to 125 up to 160

for Hydropur travel F1 400 4200 4000 3900 on request

wheels F1
– Group of mechanisms as in 2.1
1 Bm
– Permissible ambient temperature in continuous operation –20 °C to +40 °C
– Permissible skewing angle 2‰
– Cyclic duration factor 40% CDF

2.4 Correlation between Special tread

Travel wheel Possible treads for extreme rail
travel wheel treads – diameter
Rail head width k Tread b1 ¹)
widths
mm mm
rail head width and mm Consider horizontal forces and
hardness of flange
special treads 400 45 - 75 80 400 dia., tread 81 - 105 mm

¹) Treads for other rail widths on request. Can be re-turned up to 45 mm.

2.5 Useful rail head DIN

Crane rail k1 = K - 2r1
abbreviation mm
width k1
A 55 45

536 Part 1 A 65 53

A 75 59

Note: For flat steel rails, the useful rail head width k1 = k (full width)
For railway type and rails with a similar camber k1 = k - 4/3 x r1

k1

r 1

k
b1
203167k2.p65 1198

10 41143844.eps
 2.6 Determining the group Load Definition Average daily operating time in hours
of mechanisms spectrum
£ 0,25 £ 0,5 £1 £2 £4 £8 £ 16 > 16
(FEM/DIN 15020) Mechanisms, or parts
thereof, usually subject to
1
light loads and - 1 Dm 1 Cm 1 Bm 1Am 2m 3m 4m
(light)
occasional maximum
loads

Mechanisms, or parts
thererof, usually subject
2
to light loads, but with a 1 Dm 1 Cm 1 Bm 1Am 2m 3m 4m 5m
(medium)
higher incidence of
maximum loads
Mechanisms, or parts
thererof, usually subject
3
to medium loads, and 1 Cm 1 Bm 1Am 2m 3m 4m 5m -
(heavy)
frequently to maximum
loads
Mechanisms, or parts
4
thererof, usually subject
(very 1 Bm 1Am 2m 3m 4m 5m - -
to maximum of almost
heavy)
maximum loads

2.7 Determining the stress Occasional, non- Regular use in Regular use in Regular use in
factor group Loading frequency
regular use with long
periods of non-use
intermittent
operation
continuous
operation
severe continuous
operation

Degree of stress Stress factor group

very light B1 B2 B3 B4

light B2 B3 B4 B5

medium B3 B4 B5 B6

heavy B4 B5 B6 B6
203167k2.p65 1198

11
 3 RS wheel block dimensions, part nos.

Travel wheel type

580
120
450

50
A1 2

R
R2
55 F8

240

150
130

35

15
105

50
200

222,5

190
23
40

35 F8 N65 Ø18,5 b1
59,5
Hub spline b2
to DIN 5480
40176544.eps

400
59,5 50
10
120

210

Ø78

12

M 20 59,5

40176344.eps 40147144.eps
2
Travel wheel type

B1 D F1
Ø400
Ø400

Ø450
222,5

b3
b2 b2
b1
Travel wheel without flange Travel wheel without flange
Spheroidal graphite cast iron b2 Hydropur
Single-sided flange travel wheel
40176644.eps Spheroidal graphite cast iron 40176844.eps 40176944.eps

Dimensions, part nos., weights

Wheel block cpl. part nos. / weights

RS
wheel block Travel wheel type
A1 B1 D F1
203167k3.p65 1198

Part no. 818 000 44 801 232 46 801 233 46 801 234 46
b1 80 - 100 -
400
b2/b3 140/- 120/- 130/40 140/-
Weight kg 154 136,5 145 144
12
 Hollow-shaft gearbox attached directly to the wheel
block with D1 torque arm
g
o
l9

l8
l2
l2
p1

240

240
Centre of Centre of
travel wheel travel wheel
200

200
190

190
p2
g3

k3 k2
40248244.eps 40248144.eps

Hollow-shaft gearbox attached to supporting Hollow-shaft gearbox attached to top of

structure with D2 torque arm supporting structure with D1 torque arm
l1 Only to be used with AF 10/12
l7 l8
m o l2
g
240

h4

h9
h1
h 10

h2

222,5
200

210
40176444.eps 40120644.eps

Attachment Dimensions in mm
RS
wheel block combinations All types AF A FW

Gearbox Motor g g3 h1 h2 h4 h9 h10 l2 m o l1 l8 k2 k3 l9 q1 q2

KBF 80 158 298 644 644 508

KBF 90 178 124 328 674 674 538

AF 08
104 160 98 230 - 475 229 bis 342 53 210 75
AFW 08 KBF 100 196 366 709 709 576
146
KBF 112 220 402 745 745 612

KBF 90 178 334 743 729 599

KBF 100 196 104 369 778 764 634

AF 10
400 137 200 127 297 290 560 206 bis 404 60 265 95
AFW 10 KBF 112 220 405 814 800 670
126
KBF 125 246 458 867 853 723

KBF 100 196 369 831 805 669

KBF 112 220 106 405 867 841 705

AF 12
173 250 160 360 290 623 204 bis 457 70 300 120
AFW 12 KBF 125 246 458 920 894 758
126
203167k3.p65 1198

KBF 140 274 550 1012 986 850

13
14
203167k3.p65 1198
 4 Travel drive unit gearbox – motor combination selection

4.1 Operating cycles The drive unit combinations specified on pages 16 and 17 are for a travel unit
working indoors at the rate of 40 cycles per hour, acceleration a » 0,10 m/sec² to
Travel motor a » 0,5 m/sec², depending on the load, with squirrel-cage motors (types KMF and
KBF) and a basic load of » 30% of the total load.
Loading corresponding to the groups of mechanisms 1 Bm to 3 m has been taken
into account.
The table gives the motor and gearbox data for the drive unit combinations.
If several drive units are used, the mass to be moved, m, must be divided by the
number of drive units.
For calculating the selection curve, a uniform load of 4 wheels, 2 driven, 1 motor
and a coefficient of friction of m = 0,2 is assumed for specifying the gearbox loading
limit.
It must be checked that the perm. gearbox loading limit perm. Rgearb. is not
exceeded.

Operating cycles of a Demag pole-changing travel motor

Speed

Time

a a
b c d e f g h1 g h2 g b c d e f g h1 g h2 g

Outward travel Return travel

41099644.eps

a = Acceleration with acceleration blocking d = Braking with time-lag controlled braking g = Break
b = Total acceleration e = Slow speed h1 = Correction 1
c = Fast speed f = Braking h2 = Correction 2

For combination with slip-ring brake motors, the acceleration on which calculations
are based is a » 0,2 m/sec2 (type SBA).
The procedure for determining the resistor units for these motors is simplified using
our selection tables (see data sheet 202 515 44).
For pole-changing motors, time-lag controlled braking must be provided.
The speeds specified are standard speeds. Due to different transmission ratios for the
different gearbox sizes and load variations, deviations from standard speed occur.
203167k4.p65 1198

15
 4.2 Combination codes for determining motor and gearbox for spheroidal graphite cast
iron and polyamide travel wheels, types A1, B1, C1, D

4.2.1 AF/AFW 08 - 12

AF 08 iact.
- 142 114 91,4 142 114 91,4 72,6 58,6 46,5 36,9 - 142 114 91,4 72,6 58,6 46,5 36,9 - 142 114 91,4 72,6
AFW 08 iact.

AF 10 iact.
180 140 113 180 140 113 90,6 73,2 58,1 46,1 36,4 180 140 113 90,6 73,2 58,1 46,1 36,4 180 140 113 90,6 73,2
AFW 10 iact.

AF 12 iact.
175 137 110 175 137 110 88,3 71,3 57,6 45,7 36,1 175 137 110 88,3 71,3 57,6 45,7 36,1 175 137 110 88,3 71,3
AFW 12 iact.

5/ 6,3/ 8/ 10/ 12,5/ 16/ 20/ 25/ 3,5/ 4/ 5/ 6,3/ 12,5/

v m/min 10 12,5 16 20 25 31,5 40 50 63 80 100
20 25 31,5 40 50 63 80 100 20 25 31,5 40 50

m per drive unit in kg

2000

4000
14
6000
1 10 16 3 4
8000
2 17
10000
5 8 9
12000
34
14000
5 13 6 7
16000
8 11 35 9 12
18000

20000
15 18 22 29 31 25 32
22000
20 24 21
24000
35
26000

28000
19 27 28
30000
22 26 30 24 25
32000
31 32
34000

36000

38000

40000
36 37 39 43 40
42000
45 44
44000

46000
41
48000

50000
46
52000
38
54000

56000

58000
42
60000
203167k4.p65 1198

16
 Gearbox/motor combination Gearbox loading limit for direct drive
No. Gearbox Motor CDF Output Speed with friction coefficient m = 0,2
% kW rpm
1 AF 08 KMF 80 A 2 40 0,65 2570 AF 08
2 AF 08 KMF 80 A 4 40 0,32 1350 i act Md perm. Rgearb.
Nm kg
3 AF 08 KMF 80 A 8/2 40/40 0,13/0,50 630/2710 all 3250 8282
4 AF 08 KMF 80 A 12/2 20/40 0,08/0,50 360/2770

5 AF 08 KMF 90 A 2 40 1 2510 AF 10
6 AF 08 KMF 90 A 8/2 40/40 0,20/0,80 590/2520 i act. Md perm. Rgearb.
Nm kg
7 AF 08 KMF 90 A 12/2 20/40 0,12/0,80 400/2650 all 6600 16820
8 AF 08 KMF 100 A 8/2 40/40 0,26/1,20 610/2620

9 AF 08 KMF 100 A 12/2 20/40 0,18/1,20 390/2640 AF 12

10 AF 08 SBA 100 B 2 40/ 2,5 2760 i act. Md perm. Rgearb.
Nm kg
11 AF 08 KBF 112 A 8/2 40/40 0,42/1,90 660/2650
all 13250 33760
12 AF 08 KBF 112 A 12/2 20/40 0,30/1,90 420/2620

13 AF 08 SBA 112 B 2 40 3,6 2825

14 AF 08 SBA 112 B 8/2 40/40 0,44/1,8 665/2780

Permissible wheel load perm. Rgearb.
15 AF 10 KMF 80 A 4 40 0,32 1350 resulting from the gearbox or shaft
16 AF 10 KMF 80 A 8/2 40/40 0,13/0,50 630/2710 loading limit
17 AF 10 KMF 80 A 12/2 20/40 0,08/0,50 360/2770 m = 0,2 for spheroidal graphite cast
iron
18 AF 10 KMF 90 A 2 40 1 2510
m = 0,23 for polyamide
19 AF 10 KMF 90 A 4 40 0,5 1350
m = 0,4 for Hydropur
20 AF 10 KMF 90 A 8/2 40/40 0,20/0,80 590/2520
perm. Rgearb. = MMG2 x 2
21 AF 10 KMF 90 A 12/2 20/40 0,12/0,80 400/2650 m x d x 9,81
22 AF 10 KMF 100 A 2 40 1,5 2460
If R max. > perm. Rgearb. a larger gearbox
23 AF 10 KMF 100 A 4 40 0,8 1350 must be selected.
24 AF 10 KMF 100 A 8/2 40/40 0,26/1,20 610/2620

25 AF 10 KMF 100 A 12/2 20/40 0,18/1,20 390/2640

26 AF 10 KBF 112 A 2 40 2,4 2600

27 AF 10 KBF 112 A 8/2 40/40 0,42/1,90 660/2650

28 AF 10 KBF 112 A 12/2 20/40 0,30/1,90 420/2620

29 AF 10 SBA 112 B 2 40 3,6 2825

30 AF 10 KBF 125 A 2 40 3,6 2510

31 AF 10 KBF 125 A 8/2 40/40 0,65/2,90 675/2600

32 AF 10 KBF 125 A 12/2 20/40 0,47/2,9 420/2630

33 AF 10 SBA 125 B 2 40 5,5 2840

34 AF 10 SBA 125 B 8/2 40/40 0,75/3,00 670/2860

35 AF 10 SBA 140 B 8/2 40/40 1,2/5,0 655/2870

36 AF 12 KMF 100 A 4 40 0,8 1350

37 AF 12 KBF 112 A 2 40 2,4 2600

38 AF 12 KBF 112 A 4 40 1,2 1360

39 AF 12 KBF 112 A 8/2 40/40 0,42/1,90 660/2650

40 AF 12 KBF 112 A 12/2 20/40 0,30/1,90 420/2620

41 AF 12 KBF 125 A 2 40 3,6 2510

42 AF 12 KBF 125 A 4 40 1,9 1380

43 AF 12 KBF 125 A 8/2 40/40 0,65/2,90 675/2600

44 AF 12 KBF 125 A 12/2 20/40 0,47/2,90 420/2630

203167k4.p65 1198

45 AF 12 SBA 125 B 2 40 5,5 2840

46 AF 12 SBA 140 B 2 40 9,5 2870

17
 4.3 Traction resistances and main characteristics of travel wheels of spheroidal graphite
cast iron, polyamide, Hydropur-elastomer

4.3.1 Traction resistances – Travel wheels with Hydropur-elastomer rims 94 ± 2 Shore " A "
Hydropur-elastomer travel
wheels type F1 Traction resistances of travel wheels depend largely on the deformation at
the point on which the wheel stands. In the case of Hydropur-elastomer
(anti-friction bearings)
wheels, the deformation varies as a function of load and time. The specific
traction resistances are stated correspondingly for 3 possible cases of oper-
ation:

Case A: Traction resistance in the travel wheel after several revolutions in

operation. Deformation from the rest state has been smoothed
out.

Case B: Traction resistance after being at rest for ten minutes under full
load (initial traction resistance).

Case C: Traction resistance after being at rest for two days under full load.

Travel wheel
RS wheel block Specific traction resistance in N/t
diameter in mm
Case A Case B Case C

400 450 64 115 210

203167k4.p65 1198

18
 5 Connection variants

5.1 Top connection For the mounting configurations shown, there are sets available which include all
the parts required.
Direct connection to rolled section. Set contains bolting parts, split sleeves and
plugs.
Part no. set: 818 191 44 N

5.1.1 Top connection

Direct connection to rolled section
Connection variant 6.1

580 Plate 12 x 100 x 170

400 210
300 120

12
Z max.21

240

400
440

Ø454
Ø400

O.K. Schiene

Split sleeve
350 12 x 30
Z
Self-locking bolt
M 20 x 60
140

40467444.eps

Self-locking bolt 41143044.eps

M 20 x 60

Plate contained in part no. 818 190 44.

230 +0,8

120 ±0,5

50 ±0,2

23
100

H 13

10
20,5
44

55

120 ±0,2
50 ±0,5 300 ±0,5 50 ±0,5 100 140
540 170
41142944.eps 40197044.eps

Bolts
RS Part no. ¹)
travel wheel S ET Size Tightening torque Nm

400 81819044 N M 20 x 60 554

¹) Part nos. include bolting parts, split sleeves and plugs.

203167k5.p65 1198

Mounting
Position the wheel block and tighten M 20 x 60 self-locking bolts with a tightening
torque of 554 Nm.
Drill open pre-drilled holes to 12H11 and secure with a 12 x 30 split sleeve. 19
 5.2 End connection Part no. 818 092 44
5.2.1 End connection
Connection variant 6.3.3 Y
590 Adjusting nut
540
300
400
300

3-6

260
440
41144344.eps

254
120

140

dia. 10 pre-drilled
263

Y
Split sleeve 12 x 30
Adjusting nut
Self-locking bolt 12
M20 x 60 40249944.eps

– Elements welded to supporting structure and bolted to wheel block.

– The parts are protected by welding primer.
– Torque arm type D 1 directly bolted to the wheel block.
– The side threaded holes for end connection arrangement are used to accommo-
date the adjusting nut. Position and fix the wheel block for end connection by turn-
ing the adjusting nuts.
5.2.2 Set nuts for RS wheel blocks
Threaded section
Size Part no. d5 H11 h1 m s1 Wheel block face
Attachment holes d2
M20 00461098 23 3,9 16 30 m
for set nuts
s1 h1
d5

Attachment holes d6
for buffer type S

41477144.eps 40127844.eps

The fully enclosed supporting structure of the wheel block has a large number of
attachment holes.
By inserting set nuts, the wheel block can be bolted to any supporting structure.

d2 d6
RS wheel block
203167k5.p65 1198

Part no. ¹) Size Part no. ¹) Size

400 00461098 23 M 20 00461098 23 M 20

1)
20 Part nos. include 1 set nut.
 5.3 Side connection Set contains bolting parts, spacer tubes and plugs.
Part no. set: 818 099 44
5.3.1 Non-driven side connection
Connection variant 6.5
Checking dimension 5+0,5

Mounting plate Upper bolted connection

Collared washer

Adjusting washer
Lower bolted connection
t
If mounting plate is thicker than 25 mm,
hollow section must be filled with 25 x
35 x 1 shims. Pay attention to checking
dimension 5+0,5.

41144444.eps 40178044.eps

RS Part no. ¹) Dimensions in mm Cheese Lock nut Supporting Weight

Through bolt Split sleeve
wheel block S ET a1 d l l1 t head screw DIN 980 ring kg

400 81809844 450 35 H11 235 55 25 M 24 x 300 M 24 x 90 M 24 35 x 30 25 x 35 x 1

1)
Part nos. include spacer tube, bolting parts, split sleeves and plugs

5.3.2 Mounting Bolt tightening torques in Nm

Bolt rows
RS wheel block
Upper Lower

400 M 24 710 M 24 710

203167k5.p65 1198

21
 5.4 Pin connection Fitted inside hollow sections or in crossmembers, bogie links, etc. Set contains
pins, spacer elements, plugs, adjusting washers and retaining rings.
Part no. set: 818 162 4
5.4.1 Non-driven pin connection
Connection variant 6.6

450 Drilling pattern 261

225 max. 240 Torque arm D1
Pin 55 x 290 (galvanized)
Supporting washer 55 x 63 x 3
3

D9
Ø55
55 F8

290
130

Width acc. to
application
Retaining ring 55 x 3
267
Adjusting washer
200

35 x 45 x 0,5, 100 units

Spacer plug 35,1 x 35

Top edge rail
110 41144544.eps

380 b1

Spacer
Spacer
Adjusting washer
under spacer Wheel block

Hollow section etc.

41125144.eps

– Suitable for fitting torque arm type D 2.

Bolted with set nuts, except where drive units are used with AF 08, AF 10 and
AF 12. In these cases, the supporting structure must be drilled with the appropriate
holes. The thread length must be min. 15 mm. Weld on reinforcing plate if neces-
sary.
203167k5.p65 1198

22
203167k5.p65 1198

23
 5.5 Buffers DPZ cellular foam buffer with tapped hole suitable for RS wheel block
5.5.1 Standard buffers l 1
Maximum masses
that can be buffered
(kg) at
V1 = 20 m/min

d1

d3

d2
V2 = 40 m/min
without w ti h
Buffer
l 3 counterpart buffer of
type
same type
V1 22500 V1 45000
DPZ 160

M
V2 6300 V2 12600
l 2
V1 34200 V1 68400
DPZ 210
V2 9900 V2 19800
40123644.eps

Weight
Part no.
Size
d1 d2 d3 l1 l2 l3 M 1)
[kg]
DPZ 160 160 155 M 12 150 55 40 M 12 1,7 811 098 44
DPZ 210 210 200 M 20 200 85 68 M 20 4,0 811 099 44

1)
Part nos. include cellular foam buffer, threaded pin and set nut.

RS wheel blocks are prepared at both ends for fitting Demag DPZ-type buffers with
locking internal threads. The buffer is connected to the wheel block with a threaded
pin, which is screwed into the tapped hole in the buffer to the required depth and a
set nut drawn into the wheel block. If the D1 torque arm and buffer are to be fitted to
one end face of the wheel block for reasons of design (see sketch), spacer rings are
required.

5.5.2 Hydraulic buffers

DPH hydraulic buffer

Standard mounting variant with adapter, threaded pin and set nut suitable for Mounting variant II
RS wheel block Foot or head position
Standard mounting variant with adapter
l2 l1
l3 H
d3
d2
M

415468401.eps 41546802.eps

Size Energy eff. Hydraulic buffer Adapter P in Part no.

consump- mass 3)
tion
mpU
Stroke Length Thread l3 d2 Weight M l l2
EpU [kg]
H l1 d3 [kg]
[Nm]
500
DPH 25 UNF
230 + 50,8 189 17 25,4 0,76 M 12 207 40 811 295 44
203167k5.p65 1198

adjustable 1¼-12
80000
54
DPH 80 UNF
780 + 76 246 23 38 2,1 M 12 267 40 811 296 44
adjustable 1¾-12
9500
3)
24 Part nos. include hydraulic buffer, nut, adapter, threaded pin and set nut
 Individual drive unit

DPZ 160 buffer

Torque arm type D11

l1

l1
S1

S1
Part no. 818 270 44

170
Spacer ring type E1 Buffering point Spacer ring type E1
150
40177644.eps

Buffer complete Dimensions in mm

S160 RS wheel block
Part no. ¹) Type l1 s1
100

81109844 DPZ 160 150 14

Top edge rail 400
81109944 ²) DPZ 210 200 14

1)
40185544.eps Part nos. include buffer, threaded pin, set nut
2)
Standard

Individual drive unit with

DPZ 210 buffer
S2

Torque arm type D1 S1 S2

l1

l1
S1

Spacer ring type E1 Buffering point Spacer ring type E1

Spacer ring type E2 Spacer ring type E2
40178244.eps

Spacer ring Dimensions in mm

RS wheel block Type Wheel block with Wheel block without
torque arm torque arm s1 s2
Part no. Part no.
E1 2 x 81804744 4 x 81804744 14 -
400
E2 1 x 81804644 1 x 81804644 - 21

Central drive unit

S2
S2

Torque arm
l 1 S1

type D1
l1
S1
203167k5.p65 1198

Spacer ring type E2 Spacer ring type E2

Spacer ring type E1 Spacer ring type E1
Buffering point
40249044.eps 25
 6 Guide arrangements

6.1 Guiding variants

Standard design Standard design Special design

Travel wheel
400
diameter d12

d 12
Rail camber
36
radius R6
R Wheel running

6
7
39,6

R
surface radius R7
Ratio
1,1
s R7/R6
Max. wheel load
s min = 1 mm 13500
in kg
41823744.eps 41818944.eps 41823644.eps 41142244.eps

s = minimum 1 mm, max.: 5 mm

between flange and rail perm. wheel load reduced by 25%

Flanges Guide rollers Travel wheel type G

• Guide rollers and torque arm cannot be fitted together on one end face.

6.2 Guide rollers

Guide rollers
Part no. 818 010 444
52
120
Set nut M20 Locking bolt
004 610 98 M20x45
50

342 085 44
Set nut M16
50 24 75

002 972 98
Locking bolt Top edge rail
M16x45
max.133 min.110 300 250 44 160 41450344.eps

Guide rollers
with buffer S 210
120 Guide rollers with spacer
for buffer S 160
Part no. 818 095 44 263
60

250 200
150
E1
E2
S 210

S 160
190
100

Top edge Top edge

rail rail
40248944.eps 40185444.eps

Guide rollers with buffer S 21 Spacer rings

RS wheel block Type Wheel block with Wheel block without
torque arm torque arm
Part no. Part no.
E1 4 x 81804744 5 x 81804744
400
E2 1 x 81804644 1 x 81804644
203167k6.p65 1198

Bolt size Tightening torque

M 16 330 Nm
M 20 500 Nm
26
 7 Drive variants

7.1 Individual drive unit Supporting structure

4 Type 1 Wheel block
Drive unit for all track gauges 2 Drive shaft
1 D2
3 Travel drive unit
4 Torque arm, type D2 for connection
to a supporting structure
5 Torque arm, type D1 for direct
6
connection to the wheel block
40119744.eps 6 Cover
7 Sealing ring
2 7 3 8 5 8 Shaft protection

40121344.eps

7.2 Central drive unit ZI For standard track gauges

1000 mm, 1400 mm, 2240 mm, 2800 mm, 3150 mm
ZI = drive inside and for all other track gauges up to 3150 mm.

1 4 3 1 1 Wheel block
2 Drive shaft
3 Travel drive unit
4 Torque arm
5 Coupling
6 Intermediate shaft
7 Sealing ring

7 2 5 6
Track gauge
40177744.eps

Economical solution for travel units with a track gauge of up to 3150 mm. The two
wheel blocks are driven with just one drive unit.

7.3 Central drive unit ZA For standard track gauges

1000 mm, 1400 mm, 2240 mm, 2800 mm, 3150 mm
ZA = drive outside and for all other track gauges up to 3150 mm.

1 Wheel block
2 Drive shaft
3 Travel drive unit
4 Torque arm
5 Coupling
6 Intermediate shaft
7 Sealing ring
4

3 7 1 2 5 6
203167k7.p65 1198

41087144.eps

Economical solution for travel units with a track gauge of up to 3150 mm. The two
wheel blocks are driven with just one drive unit.
27
 7.4 Universal shaft type F, Mounting example The universal shaft, of ST 52
dimensions material, makes it possible for
customers to fit various drive
Suitable for connecting drive elements elements. The shaft is provided
for hand chain, V-belt and chain drive at one end with an involute
units, universal joint shafts, etc. spline section fitting the travel
wheel and, at the other, a
turned end for connections
made by the customer, e.g.
keys, split pins or welded-on
parts.

40120144.eps

Mounting
The position of the universal shaft in the wheel block is fixed by the supplied retain-
ing rings.

For dimensions and part no. see table on page 32.

7.5 Individual drive unit

Torque arm Torque arm

type D1 type D1 type D2

Type A or D Type A or D Type F

Drive unit with direct connection, Drive unit for connection when fitted in a Drive unit with universal shaft for direct
AFW/AF gearbox attached to wheel hollow section, AFW/AF gearboxes can connection and fitting in a hollow sec-
block, arranged horizontally. be mounted at 4 x 90° intervals around tion. For external drives.
the shaft.
40143644.eps
203167k7.p65 1198

28
 8 Drive unit elements: shafts, couplings, torque arms,
shaft protection

8.1 Selection of drive shafts, 1) Mounting of shafts and coupling

shafts with coupling K1 Track gauge arrangement only for RS 400 -
AF 08
Drive Track gauge
G shafts are no drive shafts! Drive Shaft
Length I for shaft type G with deviating type G
standard track gauge.

Shaft Coupling Shaft

type D type K type G
Shaft Coupling Shaft
type D 4) type K type D 5)

41125444.eps 41631444.eps

Travel A FW / A F Individual drive unit Central drive unit

wheel Individual Universal Central Coupling Hub Washer Retaining
RS
hub shaft shaft shaft K spline clip
spline 08 10 12 A or D F D1400 2240 3150
N50 81101944 81102444 81105844
- - 81811644 81815644 81170344 N45 81815844 -
¹) 3) 3) 3)
400 N65 81813344
- N65 - 81815744 81815744 81179844 81192744 81192744
81170444 N65 - 81833344
- - N65 81815744 81815744 81179844 2) 81192744

2) Shorten part no. 81192744 by 910 mm.

3) Shorten part nos. 81101944, 81102444, 81105844 by 143 mm.
4) Drive shaft
5) Intermediate shaft

Travel wheel Travel wheel Length l

RS wheel block
type hub spline in mm
400 - AF 08 A1, B1, D N 65 x 2 Track gauge minus 783
400 - AF 10/12 A1, B1, D N 65 x 2 Track gauge minus 450

8.2 Central drive unit ZI,

Variants for connecting the torque arms as for individual drive units
version I with coupling K
Track gauge X
Retaining clip

Sealing Shaft Coupling Shaft

ring type D type K type G Cover

40141344.eps 41145344.eps

– Shafts type G from table section 8.1 are available for standard track gauges. Di-
mensions as shown in table on page 31.
– For arrangements with non-standard track gauges, the standard shafts in table of
section 8.1 can be shortened by the customer (length “l” according to table
203167k8.p65 1198

section 8.1).
– Shafts with travel wheel hub spline N65 x 2 can be ordered for the track gauge
required. Order length “l” is given in table, section 8.1.
29
 8.3 Central drive unit ZI, Side X Track gauge Side Y
version II with
coupling K2

Seal- Shaft Coupling Shaft Coupling Shaft

ing type D type K2 H type K2 type D 40120044.eps
ring
Shaft type H (to be supplied by the customer)
Drill with coupling K2.
Nominal diameter d2
corresponds to

d2
nominal diameter d4
of coupling K2
l

For dimensions see chapters 8.3.1 and 8.6 40249544.eps

For non-standard track gauges up to max. 3150 mm.

Direct connection and connection to hollow section.
Central intermediate shaft type H to be supplied by the customer.

8.3.1 Instructions for fitting shaft,

coupling Side X Side Y
Retaining ring

D D
Retaining ring Supporting washer 41145644.eps

Shaft D must be fitted on the Y side such that the shaft end is located in the wheel
block without retaining ring. The supporting washer must always be positioned be-
tween retaining ring and travel wheel.

Selection of shaft D, coupling K2, supporting washer

A F/ A FW Shaft Coupling Supporting washer
RS wheel block
12 D K2
400 N 65 818 157 44 811 516 44 343 485 99

Selection of shaft type H

m in.
RS wheel block d2 h9 l (m m )
track gauge
400, AF12 70 Track gauge minus 906 1092
203167k8.p65 1198

Shaft material:
– Strength at least as for St 50 i.e. s fmin = 300 N/mm²,
s bwmin = 250 N/mm²
– Shafts with diameter d2h9 are commercially available as drawn material.
30
 8.4 Central drive unit ZI,
version III with
Track gauge
coupling K
Drive
Shaft F

Sealing Shaft Coupling Tube Supporting washer

ring type D type K

41145244.eps

Selection of shaft D, shaft F, coupling K, supporting washer, tube

RS A F/ A FW Shaft Shaft Coupling Supporting washer Tube length Min. track gauge
wheel block 12 D F Typ K
mm mm
400 N 65 81815744 81813344 81170444 1 x 34348599 Track gauge - 873 1033

For special track gauge from 3150 to 10000 mm

8.6 Dimensions,
Coupling K1 Coupling K2
couplings K1, K2
Part nos. l2
l1
d3 d3
Shaft H 1 2 Shaft D
d3

d2
d1

d2
d4

d1
l3 5
l1 l2
l
l
Part nos. include coupling (2) and
“Connex” heavy-duty split sleeve (1).
40177944.eps 40122644.eps

Coupling K1
RS Travel wheel Gearbox Dimensions in mm
Part no.
wheel block hub spline A F/ A FW d1 d2 d3 l l1 l2

400 N 65 x 2 08/10/12 64,6 H11 80 8 125 55 55 81170444

Coupling K2
RS Travel wheel Gearbox Dimenisons in mm Part no. Weight
wheel block hub spline A F/ A FW d1 d2 d3 d4 l l1 l2 l3 kg
203167k8.p65 1198

400 N 65 x 2 12 64,6 H11 100 14 H12 70 G7 160 30 65 93 81151644 5,5

31
 Shaft design
Gearbox
Shaft Dimensions in mm
RS Part no. ¹) AFM, AF, AFW
type Track Weight
gauge Retaining ring kg
Type Hub spline
d1 l l1 l2 l3 l4 l5 l6 DIN 983

N 65/ N 50/
81811644 A/D 08 477 119,2 260,2 285,2 379,5 50 x 2 58 x 2 8
N 45 ²)
81815744 A/D - 10/12 N 65 548 235,2 313,2 343,2 385,2 412 450,5 58 x 2 65 x 2,5 13
400 81813344 F N 65 80f8 329 85 231 58 x 2 65 x 2,5 8,85
81179844 1400 - N 65 950 22,9
G
81192744 3150 N 65 2700 65,2

1)
Part nos. include retaining rings
2)
Stepped shaft for single or central drive

Type A/D Type F

Centre of wheel block l 6 Centre of wheel block
Mitte Radblock

d1
l1
l1
l2
l6
l3
l
l

40197344.eps 40178344.eps

Type A/D Centre of wheel block Type G

Mitte Radblock l5

l1 l

l2
These shafts may only be used as connecting
l3
shafts and not as drive shafts.
l4
l5
l

40241644.eps 40141744.eps
203167k8.p65 1198

32
 8.7 Shaft protection, single drive unit

Sealing ring Shaft protection

Centre RS 400 End AF 08

40178144.eps 41145044.eps 41800344.eps

Shaft protection for use in ambient temperatures up to max. 80 °C.

RS Shaft protection Sealing ring

Shorten tube of shaft protection wheel block Part no.
818 035 44 by 30 mm. Part no. ¹) for spline

For shaft 818 116 44 with AF 08 400 81821944 W 65 81804544

use sealing ring 818 044 44.
1)
Part nos. include shaft protection and sealing ring

8.8 Shaft protection, central drive unit

Tube 1 Tube 2

RS 400 AF 10/12

41823844.eps

Shaft protection part nos. RS Gearbox Track gauge Shaft protection cpl. Tube 2 ²)
wheel block A F/ A FW Part no.

10 653
1400 80009846
12 602

10 1493
400 3) 2240
12 1442
80009946
10 unshortened
3150
12 2352
203167k8.p65 1198

2)
Shorten to length specified.
3)
Shaft protection for RS 400 with AF 08 on request.

33
 8.9 Torque arms Connection of AF/AFM hollow-shaft gearboxes via torque arm D 2 to the side of
8.9.1 Torque arm variants any supporting structures
– can be fitted to the right and left hand side of the wheel block
8.9.1.1 Connection with
– 4 mounting positions by rotating around the shaft at 90° intervals
torque arm type D2 Type D2

Important! Supporting
structure
The oil level depends
on the mounting posi-
tion. The gearbox
must be fitted in the
mounting position as
ordered.
40119744.eps

8.9.1.2 Connection with

Mounting variant I
torque arm type D1
Direct connection of AF/AFM hollow-shaft gearboxes to the wheel block by
means of torque arm type D 1
– can be mounted on either side in the flat, horizontal position
– connection of the torque arm to both end faces of the wheel block possible
– the top edges of the torque arm and drive unit are lower than the upper connection face of the
wheel block

A Type D1

40222144.eps

View A
Possibilities for fitting
torque arm

40119844.eps

Mounting variant II
Connection of AF/AFM hollow-shaft gearboxes to the top of the supporting
structure by means of torque arm typ D 1
– can be mounted on either side in the vertical position
(torque arm can be used as template for drilling holes in supporting structure)

Type D1
203167k8.p65 1198

Supporting structure
40222044.eps
34
 8.9.1.3 Data for connection to
the supporting structure

AF/AFW 10/12 Attention! Gearbox Torque arm Mounting screws Drilling pattern
Part no. Tighten-
torque arm f1
Size Q ty ing d H11 h1 h2 h4 q4 u
connection torque
±0,3
h2

q4 AF 08/
81120844 20 230 99 36 ±10
d AFW 08
AF 10/
81121044 M 16 4 300 Nm 18,5 65 60 297 72,5 42,5 ±12
AFW 10
88
AF 12/
81121244 360 74,5 40,5 ±12
h4

AFW 12
h1

Bolt quali-
f1 ty 10.9
u DIN 933

Washer
Set nut DIN 6916
quality 8 40140244.eps

8.9.2 Torque arm type D2,

dimensions and part nos.

Gearbox AF 08; AFW 08 Part no. 811 208 44 1 Lock nut VM 16,
12 3 4 5 6 DIN 980-8
82 163 2 Washer 17x45x6, DIN 6340
3-4 Spring element 17x45x10
7

60 135
5 Washer 17x30x4,
20 45

DIN 6916-HV
63
17

6 Socket head screw M16x90,

145

DIN 912-10.9
60

39
Tightening torque 200 Nm
Ø17

65 49,5 25
135
41037944.eps

Gearbox AF 10; AFW 10 Part no. 811 210 44 1 Lock nut VM 20,
1 23 4 5 6 DIN 980-8
80 152 2 Washer 21x50x6, DIN 6340
10

44 115 3-4 Spring element 21x50x23,5

5 Washer 21x37x4,
63

84

DIN 6916-HV
6 Socket head screw M20x130,
230
88

22

DIN 912-10.9
45
Tightening torque 300 Nm
60

Ø17

65 47,5 25
160
41038044.eps

Gearbox AF 12; AFW 12 Part no. 811 212 44 1 Lock nut VM 20,
2 4 6 DIN 980-8
1 3 5
76,5 152 2 Washer 21x50x6, DIN 6340
10

44 115 3-4 Spring element 21x50x20

5 Washer 21x37x4,
63

84

DIN 6916-HV
12
230

6 Socket head screw M20x130,

88

22

45 DIN 912-10.9
60

Ø17

Tightening torque 300 Nm

203167k8.p65 1198

7 Split pin 12x45, DIN 1481

65 30 25
125
7
160
41038144.eps 35
 8.9.4 Torque arm type D1 For direct connection to the end faces of the wheel block or to the top of end con-
AF/AFW 08-12 nection elements or purpose-built supporting structures.
AF/AFW gearboxes must be attached to the torque arm either in an exactly horizontal
or an exactly vertical position. The spacers in the clamping bolt connection are cor-
respondingly arranged to this effect. It must be ensured that a plastic cushioning
washer is placed on both sides of the gearbox eye.
In the case of supporting structures purpose-built by the customer, the position of the
torque arm is determined by dimension Z.

l3 l2
l1
Tensioning screw
= =
a4

Tightening torques in Nm

Bolt size Clamping bolt Locking screw

d1 M 16 200 330
a1

z
a9

M 20 300 500
a2
a5
a3

Centre of
d3
wheel block
l6
wheel block
Centre of

d4
Detail torque arm
to wheel block connection
l4
a8

Split pin
s1

Set nut
a7

Locking screw
l5
l7

20176244.eps 41143944.eps

RS Part no. 1)
Torque arm Dimensions in mm
wheel block
for AF/AFW
gearbox
a1 a2 a3 a4 a5 a6 a7 a8 a9 d1 d2 d3 d4
81807544 08 - 60 10 - 38
400 81802044 10 198 165,5 15,5 24 24 - 0 0 21 - 22
13 48,3
81802544 12 70 - -

Clamping bolt Locking screw Weight kg

Dimensions in mm

l1 l2 l3 l4 l5 l6 l7 s1 s2 s3 z
229 85 183 186 220 336,5 - M 16 x 190 6,5
120 206 84,2 - - 187 315,2 14 - - 189,5 M 20 x 190 M 20 x 45 5,5
204 85 183 193 183 314 - M 20 x 220 6,2
203167k8.p65 1198

36
203167k8.p65 1198

37
 9 AF/ AFW 08 - 12 travel drive data

9.1 Key values for input speed n = 2800 rpm, AF/ AFW 08 - 12

Gearbox AF 08 / AFW 08 Gearbox AF 10 / AFW 10 AF 12 / AFW 12

Input speed 2800 rpm Input speed 2800 rpm

80 90
80
90 100
90
Motor frame sizes Motor frame sizes 100 112
100
which can be fitted which can be fitted 112 125
112
125 140
(125) 1)
(140) 1)

PN2 PN2 PN2

n2 MN2 M G2 n2 MN2 M G2 MN2 M G2
i nom. i act. kW i nom. i act. kW i act. kW
rpm Nm Nm rpm Nm Nm Nm Nm
2) 2) 2)

140 20 142 2,5 1240 3250 180 16 180 3,8 2290 6600 175 5,2 3110 13500

125 22,4 130 2,8 1240 3250 160 18 164 4,0 2260 6600 160 5,6 3080 13500

112 25 114 3,2 1240 3250 140 20 140 5,2 2480 6600 137 10,2 4730 13500

100 28 104 3,5 1240 3250 125 22,4 128 5,6 2430 6600 125 10,8 4630 13500

90 31,5 91,4 4,0 1230 3250 112 25 113 6,0 2300 6600 110 11,4 4270 13500

80 35,5 83,6 4,2 1200 3250 100 28 105 6,0 2140 6600 102 12,8 4470 13500

71 40 72,6 4,2 1050 3250 90 31,5 90,6 7,0 2160 6600 88,3 14,4 4330 13500

63 45 67,5 4,9 1120 3250 80 35,5 84,3 7,2 2070 6600 82,1 15,0 4200 13500

56 50 58,6 5,0 1000 3250 71 40 73,2 7,3 1800 6600 71,3 17,1 4170 13500

50 56 53,6 5,7 1040 3250 63 45 66,9 8,4 1920 6600 66,3 17,4 3950 13500

45 63 46,5 5,9 935 3250 56 50 58,1 8,8 1730 6600 57,6 20,0 3930 13500

40 71 42,3 6,7 960 3250 50 56 53,1 9,8 1780 6600 52,7 20,6 3700 13500

35,5 80 36,9 5,9 740 3250 45 63 46,1 10,3 1610 6600 45,7 23,5 3680 13500

31,5 90 33,3 7,6 870 3250 40 71 41,9 11,5 1640 6600 41,6 24,4 3460 13500

28 100 29,1 7,1 705 3250 35,5 80 36,4 12,6 1560 6600 36,1 28,0 3440 13500

25 112 26,4 7,6 690 3250 31,5 90 33,6 13,3 1520 6600 31,5 30,9 3310 13500

22,4 125 23 7,1 555 3250 28 100 28,9 14,3 1400 6600 28,7 29,0 2840 13500

20 140 20,8 7,6 540 3250 25 112 26,7 15,1 1370 6600 25 31,4 2680 13500

18 160 18,2 8,2 510 3250 22,4 125 22,8 16,4 1270 6600 22,6 29,0 2240 13500

16 180 16,8 8,2 475 3250 20 140 20 17,4 1180 6600 20,5 29,0 2030 13500

14 200 14,4 9,4 460 3250 18 160 18,7 18,6 1190 6600 17,9 31,4 1920 13500

11,2 250 16 180 16,3 19,9 1100 6600 15,8 37,3 1950 13500

9 315 14 200 14,5 22,1 1090 6600 14,3 36,3 1770 13500

8 355
203167k9.p65 1198

MG2 = Max. permissible gearbox limit torque

1) The torques must be checked carefully for the motors in
inom. = Rated gearbox transmission ratio brackets.
n2 = Gearbox output speed 2) PN2 for AFW gearboxes is lower by a factor 0,98.
iact. = Actual gearbox transmission ratio
PN2 = Rated gearbox output
38 MN2 = Rated gearbox torque
 9.2 Key values for input speed n = 1400 rpm, AF/ AFW 08 - 12

Gearbox AF 08 / AFW 08 Gearbox AF 10 / AFW 10 AF 12 / AFW 12

Input speed 1400 rpm Input speed 1400 rpm

80 90
80 90 100
Motor frame sizes 90 Motor frame sizes 100 112
which can be fitted 100 which can be fitted 112 125
112 125 140
(125) 1) (140) 1)

PN2 PN2 PN2

n2 MN2 M G2 n2 MN2 M G2 MN2 M G2
i nom i act. kW i nom. i act. kW i act. kW
rpm Nm Nm rpm Nm Nm Nm Nm
2) 2) 2)

140 10 142 1,3 1240 3250 180 8 180 2,1 2480 6600 175 3,3 3920 13500

125 11,2 130 1,4 1240 3250 160 9 164 2,3 2480 6600 160 3,3 3880 13500

112 12,5 114 1,6 1240 3250 140 10 140 2,5 2480 6600 137 5,5 5070 13500

100 14 104 1,7 1240 3250 125 11,2 128 2,8 2480 6600 125 5,9 5070 13500

90 16 91,4 2,0 1240 3250 112 12,5 113 3,2 2480 6600 110 6,8 5070 13500

80 18 83,6 2,2 1240 3250 100 14 105 3,5 2480 6600 102 7,2 5070 13500

71 20 72,6 2,5 1240 3250 90 16 90,6 4,0 2480 6600 88,3 8,5 5070 13500

63 22,4 67,5 2,7 1240 3250 80 18 84,3 4,3 2480 6600 82,1 9,0 5070 13500

56 25 58,6 3,1 1240 3250 71 20 73,2 5,0 2480 6600 71,3 10,4 5070 13500

50 28 53,6 3,4 1240 3250 63 22,4 66,9 5,3 2420 6600 66,3 10,7 4850 13500

45 31,5 46,5 3,8 1190 3250 56 25 58,1 5,8 2300 6600 57,6 12,2 4820 13500

40 35,5 42,3 4,2 1210 3250 50 28 53,1 6,2 2240 6600 52,7 12,6 4540 13500

35,5 40 36,9 3,8 950 3250 45 31,5 46,1 6,6 2080 6600 45,7 14,5 4520 13500

31,5 45 33,3 4,9 1110 3250 40 35,5 41,9 7,3 2070 6600 41,6 15,0 4240 13500

28 50 29,1 4,5 900 3250 35,5 40 36,4 7,9 1970 6600 36,1 17,1 4220 13500

25 56 26,4 4,9 880 3250 31,5 45 33,6 8,4 1920 6600 31,5 18,9 4070 13500

22,4 63 23 4,5 710 3250 28 50 28,9 8,9 1770 6600 28,7 18,5 3630 13500

20 71 20,8 4,9 690 3250 25 56 26,7 9,4 1720 6600 25 20,1 3420 13500

18 80 18,2 5,3 650 3250 22,4 63 22,8 10,3 1600 6600 22,6 18,5 2860 13500

16 90 16,8 5,3 600 3250 20 71 20 10,9 1490 6600 20,5 18,5 2590 13500

14 100 14,4 6,0 590 3250 18 80 18,7 11,8 1500 6600 17,9 20,1 2450 13500

11,2 125 16 90 16,3 12,5 1390 6600 15,8 23,2 2490 13500

9 155 14 100 14,5 13,9 1380 6600 14,3 23,3 2260 13500

8 180

MG2 = Max. permissible gearbox limit torque

203167k9.p65 1198

inom. = Rated gearbox transmission ratio 1) The torques must be checked carefully for the motors in
n2 = Gearbox output speed brackets.
iact. = Actual gearbox transmission ratio 2) PN2 for AFW gearboxes is lower by a factor 0,98.
PN2 = Rated gearbox output
MN2 = Rated gearbox torque 39
 10 AF/AFW 08 - 12 travel drive dimensions

10.1 AF 08, model M

q c4 o

q4 l5 z3 g1

l4 g4
p2
d4

y3
p1

h5
h4

h3
h1
s3

h2
q1
g2
k1 for hollow-shaft design
see page 44

41071544.eps

Size Model M
Gearbox Motor d4 g g1 g2 g4 h1 h2 h3 h4 h5 k k1 l4 l5 o p1 p2 q q1 q4 s3 y3 z3
KBF 80 A 158 220 337 514 285 82
Pg16 54
KBF 90 A 178 240 347 544 315 92
M
AF 08 KBF 100 A 18 196 274 24 160 98 358 230 356 579 155 73,5 74 348 100 38 213 5 99 104
209
KBF 112 A 220 298 368 615 369 Pg21 60 111
KBF 125 A 246 322 381 668 420 123

203167k9.p65 1198

40
 10.2 AF 10 - 12, model M

q c4 o

q4 l5 g1
g5
l4

l6 z3 g4
p2
d4

y3

h4
p1

h3

h5
h1
s3

h2
q1 g2

k1 for hollow-shaft design

see page 44

41072044.eps

Size Model M
Gearbox Motor d4 g g1 g2 g4 g5 h1 h2 h3 h4 h5 k k1 l4 l5 l6 o p1 p2 q q1 q4 s3 y3 z3
KBF 80 A 158 220 406 565 285 82
Pg16 54
KBF 90 A 178 240 416 595 315 92
KBF 100 A 196 274 M 425 630 348 104
AF 10 22 25 45 200 127 452 297 207,5 22,5 73 37,5 125 51 261 7,5 72,5
KBF 112 A 220 298 274 437 666 369 Pg21 60 111
KBF 125 A 246 322 450 719 420 123
KBF 140 A 274 366 464 811 512 Pg29 75 139
KBF 90 A 178 240 499 641 315 92
Pg16 54
KBF 100 A 196 274 508 676 348 104
M
AF 12 KBF 112 A 22 220 298 32 55 250 160 568 360 520 712 255 26,5 77 33 369 158 55 307 8,5 74,5 111
346 Pg21 60
KBF 125 A 246 322 533 765 420 123
KBF 140 A 274 366 547 857 512 Pg29 75 139
203167k9.p65 1198

41
 10.3 AFW 08, model M

q4 l5 k
e4 g4

l4
d4

p2

h4
h5
h1

h3
h2
for hollow-shaft
design see page 44
q1
k1 g2

o
y3 z3 c4 q6 q7
s3

k3
g

g3
x3
g1

k4
20
°

q5

41073444.eps 41072544.eps

Size Model M
Gearbox Motor d4 e4 g g1 g2 g3 g4 h1 h2 h3 h4 h5 k k1 l4 l5 o p2 q q1 q4 q5 q6 q7 s3 x3 y3 z3
KBF 80 A 158 220 337 613 285 103 82
Pg16 54
KBF 90 A 178 240 347 643 315 113 92
AFW 08 KBF 100 A 18 18 196 274 204 200 24 160 98 358 230 356 678 155 73,5 37,5 348 38 176,5 5 99 70 210 75 130 104
KBF 112 A 220 298 368 714 369 Pg21 142 60 111
KBF 125 A 246 322 381 767 420 152 123
203167k9.p65 1198

42
 10.4 AFW 10 - 12, model M

q4 k
l4 l5 g5

l6 g4
d4

p2

h4
h1

h3
h5
h2
for hollow-shaft
design see page 44
q1 e1

k1 g2

y3
o
s3

z3 c4 q6 q7
x3
g1

k3
g
g

g3

k4
20
°
q5

41073444.eps 41073044.eps

Size Model M
Gearbox Motor d4 g g1 g2 g3 g4 g5 h1 h2 h3 h4 h5 k k1 l4 l5 l6 o p2 q q1 q4 q5 q6 q7 s3 x3 y3 z3
KBF 80 A 158 220 406 703 285 103 82
Pg16 54
KBF 90 A 178 240 416 733 315 113 92
KBF 100 A 196 274 425 768 348 130 104
AFW 10 22 268 250 25 45 200 127 452 297 207,5 22,5 36 37,5 51 224,5 7,5 72,5 80 265 95
KBF 112 A 220 298 437 804 369 Pg21 142 60 111
KBF 125 A 246 322 450 857 420 152 123
KBF 140 A 274 366 464 949 512 Pg29 173 75 139
KBF 80 A 158 220 489 774 285 103 82
Pg16 54
KBF 90 A 178 240 499 804 315 113 92
KBF 100 A 196 274 508 839 348 130 104
AFW 12 22 340 315 32 55 250 160 568 360 255 26,5 43 33 55 273 8,5 74,5 80 300 120
KBF 112 A 220 298 520 875 369 Pg21 142 60 111
KBF 125 A 246 322 533 928 420 152 123
KBF 140 A 274 366 547 1020 512 Pg29 173 75 139
203167k9.p65 1198

43
11 Shaft connection

11.1 Hollow-shaft design with

splined shaft connection
to DIN 5480

AF/AFW 08 - 12

l3 +0,1
Flange bearing l4 1) K1 s H13
connection
Measuring
surface
arrangement Dm

d2 h12
Me

d3
41825244.eps

Measuring
Splined shaft 2) Checking dimension
Gearbox d2 h12 d3 k1 l3 l4 1) R s rollers diameter
DIN 5480 Me
DM
W 45 x 2 x 21 37,5 40 48,75 -0,03
AF/AFW 08 155 157 36 1,85
W 50 x 2 x 24 39,5 42 54,07 -0,035
4
AF/AFW 10 W 65 x 2 x 31 55 58 207,5 209,8 42,5 57,5 2,15 68,882 -0,04
W 65 x 2 x 31 3) 55 3) 58 257,3 42,5 2,15 68,882 -0,04
AF/AFW 12 255
W 85 x 3 x 27 72 75 257,8 40,5 2,65 6 91 -0,04

1)
Only together with RA/RN wheel set
2)
Flank-centred
3)
Only together with RS 400 wheel block

Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter Subject to alteration
Printed in Germany PDF/0699