Donati DGT Series User manual

Drive UNITS FOR CRANES
“DGT” Wheel Groups + “DGP” Offset Geared Motors
Endcarriages
for Single girder and Double girder Bridge Cranes
OPERATING MANUAL
INSTALLATION - USE - MAINTENANCE
KMAN19MG00

DONATI SOLLEVAMENTI S.r.l. - Via Quasimodo,17 - 20025 Legnano (MI) - Tel. [phone] - E: [e-mail]
2
CONTENTS
page
1. PRELIMINARY INFORMATION 4
1.1 Contents and recipients of the operating manual 4
1.2 Symbols: meaning and usage 4
1.3 Collaborating with users 5
1.4 Conformity to norms and regulations 5
1.5 Manufacturer’s liability and warranty 6
2. DESCRIPTION OF COMPONENTS AND TECHNICAL SPECIFICATIONS 7
2.1 “DGT” series drive units for cranes 7
2.1.1 Intended and proper usage 7
2.1.2 The range of drive units 7
2.1.3 Components on drive units 8
2.2 “DGT” series endcarriages for bridge cranes 9
2.2.1 Intended and proper usage 9
2.2.2 The range of endcarriages 9
2.2.3 Components on endcarriages 10
2.3 Technical specifications and operating conditions 11
2.3.1 Regulatory framework 11
2.3.2 Electrical power – Protection and insulation of electrical parts 11
2.3.3 Surface finish 11
2.3.4 Environmental conditions for standard usage 11
2.3.5 Noise emissions - Vibrations 11
2.3.6 Classification of “DGT” series drive units
3. SAFETY AND ACCIDENT PREVENTION MEASURES 12
3.1 Operator qualifications 12
3.2 General safety norms and regulations 13
3.3 Safety symbols and warning labels 13
3.4 Warnings inherent to residual risks 15
3.5 Safety devices and indications 16
3.5.1 Control devices 16
3.5.2 Safety and emergency devices 16
3.5.3 Identification nameplate and markings
17
4. HANDLING - INSTALLATION – SET-UP 18
4.1 General notes on the shipment 18
4.2 Packaging, transport and handling 18
4.2.1 Standard packaging 18
4.2.2 Transport 19
4.2.3 Lifting points and handling equipment 19
4.2.4 Handling 20
4.2.5 Removing the packaging 20
4.3 Installing “DGT” drive units and endcarriages 20
4.3.1 Setting up “DGT” drive units onto a crane beam 21
4.3.2 Setting up “DGT” endcarriages onto a bridge crane 24
4.3.3 Connections and electrical diagrams 25
4.4 Setup and preparation 26
4.4.1 Preliminary operations 26
4.4.2 Settings and operating tests 26
4.4.3 Testing the “DGT” drive units and endcarriages – getting ready for operation 27
4.5 Disabling the units 28
4.5.1 Storing the units and parts 28
4.5.2 Resetting up the units after storage 28

DONATI SOLLEVAMENTI S.r.l. - Via Quasimodo,17 - 20025 Legnano (MI) - Tel. [phone] - E: [e-mail]
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CONTENTS
page
5. OPERATION 29
5.1 Functions on “DGT” drive units and endcarriages 29
5.1.1 Intended and proper usage 29
5.1.2 Admissible and inadmissible loads 29
5.2 Operating conditions 29
5.2.1 Operating environment 29
5.2.2 Danger areas and exposed personnel 30
5.2.3 Lighting conditions in the work area 30
5.2.4 Operators 30
5.2.5 Load bearing capacities on “DGT” drive units and endcarriages 31
5.2.6 Driving operations 31
5.2.7 Safety devices 31
5.3 Safety measures and precautions 32
5.4 Counterindications 33
5.4.1 Improper and unintended usage – Foreseeable and unforeseeable improper usage 33
6. MAINTENANCE 34
6.1 Safety precautions 34
6.2 Qualifications for maintenance personnel 36
6.3 Maintenance program 39
6.3.1 Daily and periodic maintenance 39
6.3.2 Maintenance frequency and deadlines 40
6.3.3 Checking the operating efficiency of parts and components 41
6.3.4 Cleaning and lubrication 43
6.4 Setting the brake on the motors on “DGT” drive units and endcarriages 44
6.5 Disassembling the “DGP” drive motoreducer 47
6.6 Replacing parts and components 48
6.6.1 Replacing the brake on the motors on “DGT” drive units and endcarriages 48
6.6.2 Replacing the wheels on “DGT” drive units 49
6.7 Troubleshooting guide 50
6.7.1 Malfunctions and irregularities 50
6.7.2 Malfunctions on components and possible solutions 51
6.7.3 Personnel authorized to intervene in case of malfunctions 51
6.7.4 Disabling the units 51
6.8 Dismantling and disposing of the units 52
7. SPARE PARTS 52
8. CONTROL REGISTRY 53

DONATI SOLLEVAMENTI S.r.l. - Via Quasimodo,17 - 20025 Legnano (MI) - Tel. [phone] - E: [e-mail]
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1. – PRELIMINARY INFORMATION
1.1 Contents and recipients of the operating manual
•This technical publication, identified with the code KMAN19MG00, refers to the following products, hereinafter
also referred to as “components”:
•Drive units, comprising the “DGT” series Wheel Groups, in combination with the “DGP” series Offset
Geared motors;
•“DGT” series endcarriages for single girder and double girder bridge cranes;
designed, manufactured and introduced on the market by:
DONATI SOLLEVAMENTI S.r.l.
Via Quasimodo, 17 - 20025 Legnano (MI) - Italy
tel. [phone] - fax [phone]
e-mail: [e-mail] - www.donaticranes.com
•In relation to its "intended use," technical and functional specifications, performance characteristics and
installation, use and maintenance instructions, the manufacturer directs its attention at:
•the production plant or work site coordinator
•operators in charge of transport, handling and installation
•personnel charged with maintenance operations
•This operating manual must be kept under the care of a person responsible for the machinery’s operation, in an
appropriate location, so that it is always available for consultation in the best possible state of conservation.
•If this operating should go missing or become damaged, a replacement copy must be ordered directly from the
manufacturer, citing the code of this present operating manual.
•The manufacturer maintains the material and intellectual property rights to this publication
and forbids its dissemination and/or duplication, even partial, without its prior written
consent.
•Copyright© 2018 by DONATI SOLLEVAMENTI S.r.l.
1.2 Symbols: meaning and usage
•This operating manual makes use of various symbols to call the reader’s attention to and emphasize the
importance of certain safety considerations.
The table below provides a list of symbols used in the manual, and their related meaning.
SYMBOL MEANING EXPLANATION, RECOMMENDATIONS, NOTES
Danger
•Indicates danger with the risk of an accident, even death related.
•Failure to respect the safety instructions related to this symbol can
lead to extremely dangerous situations placing the unit’s operator
and/or persons exposed at risk!
•Abide strictly to all safety precautions indicated!
Warning
•Represents a warning notice for the possible deterioration of
components or the operator’s personal belongings.
•Important warning - pay maximum attention.
Caution
Note •Provides information or useful information on key functions.
•Visual control
•Take action
•An eye-shaped symbol tells the reader to:
a) proceed with a visual control check.
b) proceed with the operating sequence.
c) read or take note of a setting or measurement, check an
indication, etc.

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1.3 Collaborating with users
•This operating manual represents the state-of-the-art in technology at the time of the introduction to the market
of the components illustrated herein.
•Any integrations to this operating manual the manufacturer deems appropriate to send to users must be duly
conserved together with the original manual.
•The manufacturer is available to its customers to provide further information and to consider proposals for
improvements, so as to render this manual more responsive to the needs of users.
1.4 Conformity to norms and regulations
•The components illustrated in this publication have been designed and produced in conformity with current
legislation in Italy, adopting the following European Community Directives:
•Machinery Directive 2006/42/CE.
•Specifically, in relation to the obligations outlined in Machinery Directive 2006/42/CE, the “DGT” series Drive
Units and Endcarriages are:
•conceived and manufactured as per the “Essential Safety Requisites” cited in Attachment I;
•introduced onto the market, equipped with a Declaration of incorporation – Annexe IIB.
Facsimile of the Declaration of incorporation – Annexe IIB

DONATI SOLLEVAMENTI S.r.l. - Via Quasimodo,17 - 20025 Legnano (MI) - Tel. [phone] - E: [e-mail]
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1.5 Manufacturer’s liability and warranty
•In relation to the components illustrated herein and in reference to the indications outlined in this operating
manual, the manufacturer DONATI SOLLEVAMENTI S.r.l. declines any responsibility in the case of:
•usage contrary to Italian legislation on safety and accident prevention measures;
•wrongful preparation and setup of components in the worksite, and/or on structures and machinery the
components are set to operate on;
•faulty electrical line voltage specifications;
•failure to observe the instructions provided in this operating manual;
•non-authorized modifications or interventions on the product;
•installation on the part of non-qualified or ill-trained personnel.
•So as to avail itself of the warranty, as outlined in the certificate below, the buyer must meticulously observe the
prescriptions indicated in this operating manual, specifically:
•always operate within the product’s usage and performance limitations;
•always carry out constant and diligent maintenance, as outlined in this operating manual;
•entrust the use and operation of lifting equipment and machinery fitted with the “DGT” series drive units
and endcarriages to operators with proven experience and skills, and appropriately trained in their usage;
•make use of the manufacturer’s original spare parts exclusively.
•The usage designations and configurations foreseen for the “DGT” series sliding units and
beams are the ones admissible. Do not attempt to use these components disregarding the
indications provided.
•The instructions provided in this manual do not substitute, but summarize the obligations
stipulated under current legislation on accident prevention regulations.

DONATI SOLLEVAMENTI S.r.l. - Via Quasimodo,17 - 20025 Legnano (MI) - Tel. [phone] - E: [e-mail]
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2. – DESCRIPTION OF COMPONENTS AND TECHNICAL SPECIFICATIONS
2.1 “DGT” series endcarriages for cranes
2.1.1 Intended and proper usage
•The drive units for cranes comprise “DGT” series wheel groups in combination with “DGP” series offset
geared motors, are built specifically for handling lifting systems on rails, such as, for example, travelling cranes,
trolley cranes, wall-mounted cranes, etc. and/or related running trolleys, guaranteeing the precise alignment for
moving structures, control over high shifting speeds, while facilitating installation and maintenance.
•“DGT” series wheel groups and “DGP” series offset geared motors are modular components specifically
designed for drive units for cranes by manufacturers of machinery and industrial lifting and handling
installations.
•Running movements (forward and reverse) must be enabled electrically.
2.1.2 The range of Drive Units
•These drive units for cranes are designed and engineered based on the principle of modular components
which, in addition to the more common versions commercially available, when assembled to one other in relation
to the user’s requirements, allow for the fast and economical realization of multiple standard and special
configurations.
•DONATI drive units are configured in 6 production sizes, for which the basic components are:
•6 sizes of “DGT” series wheel groups (Ø 125, Ø 160, Ø 200, Ø 250, Ø 315 and Ø 400/400R)
•4 sizes of “DGP” series offset geared motors (DGP 0, DGP 1, DGP 2 and DGP 3)
•4 sizes of self-braking motors (motor 71, motor 80, motor 100 and motor 112)
Wheel Group configurations based on combinations between “DGT” Wheels and “DGP” Motoreducers
•The 6 production sizes for “DGT” series Wheel Groups cover the following operating limitations:
•Capacity of the lifting and/or traversing equipment:
•from 1000 to 40,000 kg
•Running speed:
•single speed, from 3.2 to 25 m/min;
•two-speed, from 12.5/3.2 to 80/20 m/min.
•The modular design of the basic components (wheels, reducers and motor) allows for two configurations of
“DGT” series drive units:
•Idle drive units (fig. 1a)
•Motor driven units (fig. 1b)
•The flexibility of the numerous fastening solutions adopted allow for assembly on a variety of mechanical frame
types, as well as easy integration with a number of accessories available on the market, such as, for example,
guide systems, or collision proof systems, whether mechanical, electrical or electronic, or speed control and
crane and trolley stop position systems.

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2.1.3 Components on Drive Units
•“DGT” series wheel groups:
The drive wheels Ø 125, Ø 160, Ø 200, Ø 250 and Ø 315 are carbon steel moulded. The wheels Ø 400 and Ø 400
R are cast-iron.
•All wheels revolve on radial bearings, permanently lubricated, with the exception of the larger capacity Ø
400 R wheel, which is fitted with roller bearings.
•They are available in either neutral (idle) operation or ready to be set up as drive units in combination with a
offset geared motors.
•In drive operation, the direct coaxial connection between the oscillating reducer’s exit shaft and the slotted
hub on the drive wheel ensures high safety standards and operating reliability.
•Wheels are available in a standard version with a double flange, and can be supplied, on request, in various
sliding band widths in relation to the type of traversing rail they are intended to slide on.
•Whether in idle or drive operation, the wheels are supported and contained within an electro-welded plated
frame which acts as a support box for the entire group, and as an joining element between the operating
head frame or trolley with which the wheel group is to be assembled.
•“DGP” series offset geared motors:
Reducers are designed as a “offset” type with a concave shaft, featuring parallel axes with two or three stages of
reduction, and permanent oil-bath lubrication.
•Engineered with cylindrical high resistance steel gears, featuring spiral toothing, thermically treated, entirely
supported on ball bearings.
•Sized to resist a lifetime of stress and wear, in accordance to the pertinent ISO service group.
•The connection between the reducer and sliding wheel is guaranteed by a slotted shaft connecting the holes
on both parts, while the reducer fastened to the wheel group makes use of a system comprising a reaction
arm fastened to the wheel group, and an elastic counter bearing with rubber buffers and a setscrew. The
entire reducer-wheel connection system guarantees both high quality sliding operation and maximum
duration over time with low maintenance, thanks to the elimination of rigid connections.
The electric motors are asynchronous, featuring a progressive start-up, with standard ventilation, self-braking with
axial shifting of the rotor guaranteeing a fast, reliable mechanical braking over time.
•Conical brakes are fitted with asbestos-free braking gaskets, featuring an extended braking surface.
•The brake block comprises a fan which ensures proper cooling for the brake and motor, shifting axially with
the motor shaft; the brake function is activated automatically in the case of a power outage.
•The connection between the motor and swinging reducer features a slotted joint contained within a coupling
housing, which also comprises, where required, a flywheel transferring progressive start-up and braking
drive motion.
Idle Drive Unit
fig. 1a
Powered Drive Unit
fig. 1b
“DGT” idle wheel group
Reaction arm
Self-braking motor
“DGT” drive
wheel group “DGT” oscillating reducer
Wheel gear motor connecting slotted shaft

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2.2 “DGT” series Endcarriages for bridge cranes
2.2.1 Intended and proper usage
•The endcarriages are designed for handling operations on rails on bridge cranes:
•at a running speed of from 3.2 to 25 m/min;
•at two running speeds, from 12.5/3.2 to 80/20 m/min;
operating on:
•single girder, with a capacity of up to 20,000 kg and gauge of up to 25 m;
•double girder, with a capacity of up to 40,000 kg and gauge of up to 27 m.
•The endcarraiges are equipped with drive units comprising “DGT” series wheel groups, which, in
combination with “DGP” series offset geared motors, guarantee:
•accurate alignments;
•control over high running speeds;
•easy installation and maintenance.
2.2.2 The range of endcarraiges
•The range of endcarriages for bridge cranes are designed in 6 production sizes corresponding to the
dimensions of the respective wheels, in 17 configurations based on 7 different wheel pitch lengths calibrated
in relation to the gauges and type of bridge crane they are combined with, i.e.:
•6 “DGT” series drive wheel group sizes:
(Ø 125, Ø 160, Ø 200, Ø 250, Ø 315 and Ø 400/400 R)
•17 configurations based on the wheel pitch:
(1800 mm; 2100 mm; 2400 mm; 2700 mm; 3300 mm; 3600 mm; 3900 mm)
Operating limitations for endcarriages on SINGLE GIRDER or DOUBLE GIRDER bridge cranes, in relation to span
Endcarriages are equipped with Drive Units, comprising “DGT” series Wheel Groups in combination
with “DGP” series Offset Geared Motors,as outlined in section 2.1.

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2.2.3 Components on travelling beams