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Wheel Blocks
Compact wheel assemblies incorporating the crane wheel, bearings and housing into a practical unit for new installations, replacements and upgrades.
AC Crane Maintenance supplies, engineers, installs and supports crane wheel blocks, crane wheels and complete end carriage systems for overhead cranes, gantry cranes, new crane projects, replacements and modernisation applications.
From replacing worn wheel assemblies to manufacturing complete new end carriages for an existing crane, we look at the entire travel system — wheel loads, alignment, rail configuration, drives, bearings, motors, gearboxes, brakes and controls.
Wheel blocks and end carriages form a critical part of an overhead crane's long-travel system. Correct selection, installation and alignment directly affect how smoothly the crane travels and how the wheels, rails, bearings and drives wear.
Compact wheel assemblies incorporating the crane wheel, bearings and housing into a practical unit for new installations, replacements and upgrades.
Structural travel assemblies supporting the crane bridge and carrying the wheels, drives and associated components.
Replacement crane wheels, bearings and associated components selected around the crane load and existing travel arrangement.
Motors, gearboxes, brakes and drive arrangements configured around the required travel speed, duty and crane application.
Crane wheel blocks provide a compact and serviceable way of incorporating the wheel, bearings and housing into the crane travel system.
They can be used on new crane projects or considered when replacing worn, obsolete or expensive existing wheel assemblies.
Correct selection depends on far more than wheel diameter. The complete application must be considered before a replacement or new wheel block arrangement is selected.
AC Crane Maintenance can supply and install complete end carriage systems for new overhead cranes as well as replacement and modernisation projects on existing cranes.
End carriage systems configured around the bridge span, crane capacity, wheel loads and required travel performance.
Heavy industrial end carriage arrangements for double girder overhead crane systems.
Travel systems for suitable gantry and semi-gantry crane applications.
Application-specific end carriages for replacements, upgrades and specialised industrial crane projects.
A reliable travel system starts with understanding the complete crane. Selecting components from wheel diameter alone can create alignment, wear and drive problems later.
Safe working load and crane dead weight.
Bridge geometry and structural arrangement.
Calculated maximum loads at each wheel position.
Existing rail size, profile and condition.
Diameter, tread, flange and running arrangement.
Required long-travel operating speed.
Operating frequency and production requirements.
Motors, gearboxes, brakes and control method.
Mounting points, geometry and condition.
Dust, heat, moisture, outdoor and industrial conditions.
Replacing a worn wheel without understanding why it wore can leave the actual problem unresolved.
Excessive flange wear, repeated bearing failures, rail wear and a crane pulling to one side can indicate problems with wheel alignment, end carriage geometry, runway alignment, drive behaviour or a combination of factors.
AC Crane Maintenance can assess the travel system as a whole before recommending repairs or replacement components.
Heavy contact between wheel flanges and rail sides.
The bridge does not track consistently along the runway.
Bearings repeatedly fail or operate at excessive temperature.
Unusual wear patterns develop along the crane runway.
The travel drives work harder than they should.
Grinding, knocking or irregular crane movement.
A damaged wheel may be the result of another problem elsewhere in the crane travel system. Correcting the root cause can help prevent repeated component failure and unnecessary downtime.
Wheel geometry or end carriage alignment may force the crane against the rail.
Rail alignment and condition can influence tracking and wheel wear.
Wheel geometry and material must suit the application and rail arrangement.
Worn or damaged bearings can affect smooth wheel rotation and alignment.
Travel drive behaviour can contribute to poor tracking and mechanical strain.
The bridge and end carriage arrangement must work together as one system.
An older crane does not automatically require complete replacement. Where the existing crane girders and structural components remain suitable for continued service, the bridge structure can potentially be retained while the ageing travel system is replaced.
Subject to inspection, assessment and confirmation that the existing structure is suitable for the proposed continued service.
Where technically viable, retaining suitable existing girders can reduce the scope of a modernisation project while allowing worn, obsolete or problematic travel equipment to be replaced with a modern and serviceable system.
Replacing an existing Demag DRS wheel block does not necessarily mean the crane must remain tied to the same proprietary wheel-block arrangement.
Where technically suitable, AC Crane Maintenance can assess the existing crane and investigate a more cost-effective modern wheel block arrangement or complete replacement end carriage solution.
The objective is not to simply match a model number. We assess the actual crane, wheel loads, wheel diameter, rail, tread and flange arrangement, mounting geometry, travel speed, duty and drive requirements.
In some applications, repeatedly replacing expensive proprietary travel components may not be the most practical long-term solution.
The examples below are reference points for identifying common Demag DRS systems. Final replacement selection requires assessment of the actual crane and application.
| Existing System | Nominal Wheel Diameter | Published Max. Wheel Load* | AC Cranes Approach |
|---|---|---|---|
| DRS-M 160 | 160 mm | 7 t | Assess & engineer suitable alternative |
| DRS-M 200 | 200 mm | 10 t | Assess & engineer suitable alternative |
| DRS 250 | 250 mm | 16 t | Assess & engineer suitable alternative |
| DRS 315 | 315 mm | 22 t | Assess & engineer suitable alternative |
| DRS 400 | 400 mm | 30 t | Assess & engineer suitable alternative |
| DRS 500 | 500 mm | 40 t | Assess & engineer suitable alternative |
*Demag model names, nominal wheel diameters and published maximum wheel loads are shown for reference only. Demag and DRS are trademarks of their respective owner. AC Crane Maintenance is not representing alternative products as genuine Demag components or automatic direct replacements. Suitability must be established for each application.
The answer is not always to replace the entire crane. Depending on the condition and design of the existing system, different levels of modernisation may be possible.
Where the existing end carriage and wheel arrangement remain practical, worn wheels, bearings or associated components can be replaced.
KEEP THE EXISTING SYSTEMWhere proprietary or obsolete components have become impractical, a modern wheel block arrangement can be investigated and engineered where suitable.
MODERNISE THE COMPONENTSWhere the existing girders remain suitable, complete new end carriages and travel equipment can potentially be fitted while retaining the bridge structure.
MODERNISE THE TRAVEL SYSTEMCrane travel equipment must be selected around the actual operating environment. High wheel loads, frequent travel, harsh conditions and continuous production can place significant demands on end carriages, wheels and drives.
AC Crane Maintenance can provide travel solutions for suitable industrial, manufacturing, engineering and mining applications.
For new overhead crane projects, the travel system is selected as part of the complete crane design rather than as an isolated component.
Crane capacity, span, bridge weight, wheel loads, runway, travel speed, duty, motors, gearboxes, brakes and controls must work together as one system.
We work with the complete overhead crane. That means we can consider how the wheel blocks, end carriages, drives, bridge structure and runway interact instead of looking at one component in isolation.
Practical experience with overhead crane manufacturing, servicing, refurbishment and travel systems.
We understand that wheel and runway alignment can directly affect travel performance and component life.
AC Crane Maintenance is a registered Lifting Machinery Entity supporting industrial crane systems across South Africa.
We can support the project beyond component supply with installation, commissioning and ongoing crane maintenance.
AC Crane Maintenance supplies and supports crane wheel blocks, crane wheels and complete end carriage systems for industrial clients throughout South Africa.
We can assist with new crane projects, replacement components, end carriage upgrades, obsolete travel systems and complete crane modernisation projects.
Whether you need a replacement wheel block, new crane wheels, complete end carriages, an alternative to an existing proprietary system or a complete travel-system modernisation, send us the details of your crane and application.
AC Crane Maintenance (Pty) Ltd • LME 526 • South Africa
