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]
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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

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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

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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

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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.

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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

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2.3 Technical specifications and operating conditions
2.3.1 Applicable norms and regulations
•The following norms and technical principles have also been taken into consideration in the design and
manufacturing of “DGT” series endcarriges for bridge cranes:
•EN ISO 12100/2010 “Fundamental concepts on general engineering principles”
•EN 60529/97 “Degrees of protection for casings (IP Codes)”
•ISO 4301-1/88 “Classifications for lifting equipment”
•ISO 8306/85 “Tolerances for travelling girders”
•FEM 1.001/98 “Calculations for lifting equipment”
•FEM 9.511/86 “Classifications for mechanisms”
•FEM 9.683/95 “Options for lifting and traversing motors”
•FEM 9.755/93 “Safety work periods”
2.3.2 Electrical power – Protection and insulation of electrical parts
•The motors on the Drive Units are designed to be powered through three-phase alternating current: 400 V -
50Hz. in accordance with IEC 38-1.
•Drive Unit motors: Protection IP55 (motor) - IP23 (brake); class “F” insulation.
•Limit switch: minimum protection IP65; max. Insulation voltage 500 V
2.3.3 Surface finish
•Finishing on the bodywork on the “DGT” series Drive units and Endcarriages and protection from
atmospheric and environmental agents (dust, gas, etc.) is guaranteed by a special paintwork finish which applies
a chrome and lead free primer coat of 40 microns in thickness of yellow enamel RAL 1002; surfaces are
previously prepared with SA 2 degree metallic sanding in accordance with SVENSK STANDARD SIS 055900.
The finish is oven dried for 40 min. at a temperature of 60-80°C.
•The special waterproof paintwork finish adopted for electro-mechanical parts (swinging reducer and self-braking
drive motor), obtained using an electrostatic process and the complete sealing of parts, guarantees their
inalterability over time and constant high performance characteristics, even in particularly hostile environments.
2.3.4 Environmental conditions for standard usage
•Operating temperature: minimum - 10°C; maximum + 40°C
•Maximum relative humidity: 80% - Maximum altitude 1000 m above sea level.
•Standard Drive units and Endcarriages for bridge cranes must be installed in a well aerated working
environment, free of corrosive vapours (acidic vapours, saline mists, etc.), and are designed to operate in a
covered environment, protected from atmospheric elements.
It is forbidden to operate the “DGT” series Drive units and Endcarriages in a potentially
explosive environment, i.e. in which the use of anti-explosive components is mandatory.
2.3.5 Noise emissions - Vibrations
•Noise emission levels emanating from the Drive units and Endcarriages during traversing operations, whether
empty or fully loaded, are in all cases inferior to a value of 80 dB (A), as measured at a distance of 1 m and 1.6
m from the ground.
•The incidence of environmental characteristics such as the transmission of sound through metallic structures,
reflection caused by combined machinery and surrounding walls, are not taken into consideration in the value
indicated.
•Vibrations produced by the Drive units and Endcarriages during traversing operations are not considered
dangerous for the health and wellbeing of personnel operating the lifting equipment on which the units are
installed.
•Excessive vibrations can be caused by a malfunction, which must be immediately pointed out and eliminated so
as to safeguard the reliability of components.

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3. – SAFETY AND ACCIDENT PREVENTION MEASURES
•“DGT” series drive units and endcarriages are engineered and manufactured based on the most advanced
technical know-how, and are designed to be operated safely.
•Dangers for personnel operating the equipment can be totally eliminated and/or notably reduced only if the
components are used in accordance with the instructions outlined in this operating manual, by authorized and
specially trained and prepared personnel.
In relation to installation, use and maintenance tasks to be carried out on “DGT” series drive
units and endcarriages, operating personnel are responsible for the following operations:
•Incorporating components in assembling lifting equipment (crane, trolley, etc.).
•Completion of component and missing parts (electrical controls) in conformity with directives stipulated by
current legal norms and regulations in force
•Setup and assembly of components, and managing its operation;
•Performing operations of a different nature on components, specifically in relation to maintenance, controls and
repairs, of any and all parts, before the machine’s start-up, during its operation or even after its shutdown.
•Personnel must be absolutely informed regarding potential dangers inherent in conducting work operations,
both in relation to operating the equipment and the correct use of safety devices on the machine.
•Personnel must also carefully observe all safety norms and regulations contained in this section of the operating
manual, in order to prevent potentially dangerous situations.
3.1 Operator qualifications
•The table below outlines professional operator profiles with related pictograms, so as to better define the field of
intervention and consequent responsibilities for each OPERATOR, provided by specific training and
qualifications, as required for every type of intervention.
PICTOGRAM OPERATOR PROFILE
GENERIC OPERATOR
Generic operator:
Personnel qualified to perform only tasks which do not imply technical
interventions on the “DGT” drive units and/or endcarriages, such as, for
example: transport, reception of goods, storage, usage, etc.
MECHANICAL MAINTENANCE
PERSONNEL
Mechanical maintenance personnel:
Personnel qualified to intervene on components under normal conditions, as
well as carry out normal adjustment on machine parts, ordinary
maintenance interventions and simple mechanical repairs.
ELECTRICAL MAINTENANCE
PERSONNEL
Electrical maintenance personnel:
Personnel qualified to intervene on components under normal conditions, and
responsible for normal interventions on electrical parts, settings, including
simple electrical maintenance and repairs.
MECHANIC
Mechanic:
Technician specialized in carrying out complex and extraordinary operations of
a mechanical nature, such as, for example, assembling “DGT” drive units
and/or endcarriages onto lifting equipment.
ELECTRICIAN
Electrician:
Technician specialized in carrying out complex and extraordinary operations of
an electrical nature, such as, for example, incorporating “DGT” drive units
and/or endcarriages onto lifting equipment.

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3.2 General safety norms and regulations
•Before installing and operating the “DGT” drive units and/or endcarriages:
•Carefully read and understand this operating manual;
•Know what safety devices are available and know their location (e.g. endstrokes);
•Some tasks which need to be carried out on components in operation (e.g. setting the limit switches) expose
operators to potentially dangerous situations; operators must therefore carefully observe the following:
•Personnel must be authorized and specifically trained on operating procedures, dangerous situations which
may arise, and on correct procedures to prevent and avoid such dangers.
•If operating personnel is required to remove the cover on the motor drive terminals, due to specific technical
maintenance, inspections or repairs, they must immediately replace the safety guards at the end of such
operations.
•Personnel must ascertain that, at the end of any intervention on machine components, no tools, foreign
objects or mechanical parts are forgotten inside.
•For their own personal safety and whenever possible before work operations, personnel conducting
maintenance, inspections and repairs must enact all required preventive safety measures, specifically
checking that the “DGT” drive units and/or endcarriages have been:
•set in stop mode (no power or movement) and in a stationary position;
•disabled (power cut off);
•subjected to preventive measures (warning signs, blocking devices, etc.) so as to avoid accidental or
unforeseen start-ups.
•Electrical maintenance personnel intervening on live electrical components must proceed with extreme
caution.
3.3 Safety symbols and warning labels
•This operating manual uses signals and pictograms to highlight or call the reader’s attention to dangerous
situations resulting from residual risks or actions which must necessarily be conducted according to safety
procedures indicated in this manual.
DANGER AND WARNING SYMBOLS USED
SYMBOL MEANING
DANGER: LIVE ELECTRICAL PARTS
Warning label indicating live electrical parts affixed to electrical
equipment (e.g. covers on motor terminals) and any live structure or
component.
GENERIC DANGER
Warning: generic danger
(completed with a caption indicating the type of danger)
DANGER: WATCH YOUR HANDS!
Warning: danger to upper limbs from mechanical parts in motion
(e.g. wheels, beam girder, etc.)
DANGER: WATCH YOUR FEET!
Warning: danger to lower limbs from mechanical parts in motion
(e.g. wheels, beam girder, etc.)
DANGER OF GETTING CAUGHT UP
IN MOVING PARTS
Warning: danger of getting caught up and being dragged by
moving parts (e.g. wheels, beam girder, etc.)
DANGER: OVERHEAD LOADS
Warning: danger from overhead loads in motion during installation
and maintenance phases.

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WARNING SYMBOLS USED TO INDICATE ACTIONS WHICH ARE FORBIDDEN
SYMBOL MEANING
DO NOT REMOVE THE PROTECTIONS
It is forbidden to remove protective devices on the machine in
motion or when it is powered on.
DO NOT CONDUCT MANOEUVRES
It is forbidden to conduct manoeuvres during maintenance
operations on moving parts.
DO NOT TOUCH
It is forbidden to touch, mishandle, disable or extract devices
and/or components.
NO ACCESS
During technical interventions, access to non-authorized
personnel is forbidden.
WARNING SYMBOLS USED TO INDICATE OBLIGATIONS
SYMBOL MEANING
CONSULT THE MANUAL
Consult the manual when this symbol appears preceding or
within an indication (instructions, adjustments, maintenance, etc.),
OPERATORS MUST WEAR GLOVES
Operating personnel must wear safety gloves.
OPERATORS MUST WEAR A HELMET
Operating personnel must wear safety protective helmets.
OPERATORS MUST WEAR SAFETY
FOOTWEAR
Operating personnel must wear safety non-slip footwear.
OPERATORS MUST WEAR A SAFETY
HARNESS
Operating personnel must wear safety harnesses when working
at altitudes with a risk of falling.
SYMBOLS USED FOR SAFETY INDICATIONS
SYMBOL MEANING
SUPPLEMENTAL LIGHTING
Supplemental lighting is recommended for interventions in
which this label appears.

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3.4 Warnings inherent to residual risks
•After having carefully considered the dangers present in all operating phases for “DGT” drive and/or
endcarriages, the following measures have been adopted so as to eliminate, as far as possible, risks for
operators and/or limit or reduce risks deriving from dangers which cannot totally be eliminated at their source.
However, in spite of all the precautions adopted on the machine, the following residual risks remain; these
risks can be eliminated or reduced through the following preventive measures:
RISKS DURING OPERATION
DANGER / RISK CAUTION / WARNING OBLIGATION / PREVENTION
Risks from the danger of becoming
ensnared and/or crushed, following
contact with the beams and/or
wheels in motion, where such
components are accessible to
operators.
•Warning! Exposure to moving
parts can create dangerous
situations.
•Caution!
Do not touch moving
Beams and/or Wheels.
•Ascertain that the rail/wheel
contact area is > 2.7 mabove the
walking area.
•For quotas < 2.7 m, enact
special technical measures.
RISKS DURING MAINTENANCE
DANGER / RISK CAUTION / WARNING OBLIGATION / PREVENTION
Risk of electrocution when
performing maintenance on electrical
motors without cutting off electrical
power first.
•Caution! Do not intervene on
electrical motors without cutting
off electrical power first.
•Caution! Do not restart the
motors without replacing the
covers on the terminals.
•Entrust electrical maintenance
operations to qualified personnel
only.
•Perform controls on electrical
equipment as required by norms.
•After controls, replace the covers
on the terminals.
Risks from the danger of becoming
ensnared, crushed and/or exposed
to falling loads during inspections,
adjustments and maintenance on
Beams and/or Wheels.
•Warning! Exposure to moving
parts can create dangerous
situations.
•Caution! Do not intervene on
moving parts
•Caution! Access to non-
authorized personnel is
forbidden.
•Entrust maintenance operations
to qualified personnel only.
•Make use of suitable personal
safety devices and equipment
when carrying out adjustments on
parts and components.

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3.5 Safety devices and indications
3.5.1 Control devices
•“DGT” drive units and endcarriages are supplied without command and control
devices, which must be provided by the buyer incorporating these components onto
an industrial lifting or handling system.
•“DGT” drive units and endcarriges must not be operated before they have been
incorporated, in conformity with indications outlined in Machinery Directive
2006/42/CE, and a “CE Marking” has been affixed, as shown here, on the whole of
the lifting or handling system they are assembled onto.
3.5.2 Safety and emergency devices
“DGT” drive units and endcarriages are equipped with the following devices:
1. Brakes (fig. 3): mechanical, negative type,
incorporated in the drive motors (self/braking) for
forward / reverse manoeuvres.
The brakes intervene automatically in case of a
electrical power failure, and are sized to stop the
maximum load the “DGT” drive units and
endcarriages can move in total safety and in the
shortest time possible, at the maximum travelling
speed.
fig. 3
2. Limit switches (fig. 4)
a) Electrical: rotating, shaft-cross type, when included; equipped with sensitive micro-switches which, by
activating the auxiliary circuit, limit the lengthwise stroke of the running beams in forward/reverse
manoeuvres. For “DGT” drive units and endcarriages with two operating speeds, in addition to the stop
function in both directions, electrical limit strokes also ensure a pre-slowdown function, switching from “high”
speed to “low” speed;
b) Mechanical: provided as standard equipment, comprising shock absorbing buffers in hard rubber, sized to
absorb forces from kinetic energy generates by the travelling of the bridge crane, in an eventual accidental
strike, i.e. in case the electrical limit strokes fail to work.
Positioning of “DGT” limit strokes 1, 2 and 3:
limit stroke arm fastened by 4 screws ( x ) on the wheel support
Positioning of “DGT” limit strokes 4, 5 and 6:
limit stroke fastened by 2 lower screws ( x ) on the wheel support
fig. 4
•The electrical limit switches, when included, are not connected!
•It is obligatory to install and connect the electrical limit switch before setting up and
operating the “DGT” drive units and endcarriages, checking to make certain they intervene
correctly, as outlined at section 4.4 “Setup and Preparation”.

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3.5.3 Identification nameplate and markings
•“DGT” drive units and endcarriages are equipped with the following identification nameplates (fig. 5):
•nameplate on “DGT” drive unit (fig.5a) or endcarriage (fig.5b), containing:
•manufacturer’s logo, name and address;
•specific weight of the wheel group or beam girder;
•type, serial number and code of the wheel group or beam girder;
•year of manufacture.
•identification nameplate on the “DGP” offset geared motors, containing (fig.5c):
•manufacturer’s logo, name and address;
•specific weight of the motoreducer;
•type, serial number and code of the motoreducer;
•year of manufacture.
•identification nameplate on the self-braking motor, containing (fig.5d):
•manufacturer’s logo, name and address;
•specific weight of the motoreducer;
•type, serial number and code of the motor;
•year of manufacture.
•typical electrical specifications for the motor (power, absorption, etc.);
•CE marking for the following European Community Directives:
•Low Voltage Directive 2014/35/UE;
•Electromagnetic Compatibility Directive 2014/30/UE.
fig. 5
•Readability and conservation of identification nameplates:
•Identification nameplates must be cleaned periodically so that they are legible at all times and properly display
information for all personnel.
•If a nameplate becomes deteriorated and/or is no longer legible, even if only partially, a replacement should
be requested from the manufacturer, citing the information contained in this operating manual or on the
original nameplate.
Since “DGT” drive units and endcarriages are considered incomplete machinery,
i.e. designed to be assembled onto other machinery, they bear no “CE Marking,” in
accordance with mandatory requirements outlined in Machinery Directive
2006/42/CE.

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4. - HANDLING - INSTALLATION – SETUP
4.1 – General notes on the shipment
•“DGT” drive units and endcarriages are, as far as is possible, shipped pre-assembled in their
main parts.
•The Buyer can proceed with installation phases (incorporating the units onto industrial lifting
or handling equipment) by following the instructions contained in this section of the
operating manual, entrusting such tasks to qualified personnel.
•Due to the delicate and important nature of the operations described in this section, serious
risks for the health and safety of personnel can be incurred if such operations are carried out
inappropriately during the installation and use of the industrial lifting or handling equipment
on which the components are assembled.
•As such, these operations must be performed by professionally trained and qualified
personnel specialized in the construction and/or assembly of lifting systems, with special
expertise in electromechanics, and equipped with personal safety and accident prevention
working equipment conforming to current legislative ordinances on matters related to safety
and accident prevention in the workplace, after having carefully read this operating manual.
On reception of the shipment, check to make certain that:
•The documentation provided with the components, attached to this operating manual, comprises the
Manufacturer’s Declaration – Annexe IIB.
•The packaging, if part of the shipment, is in good condition, and does not present damages.
In case of damage or missing parts, notify the shipping company of the irregularity, annexing a
written statement to the accompanying document and notifying DONATI SOLLEVAMENTI S.r.l.
of the mishap within eight days of receiving the goods.
4.2 Packaging, transport and handling
Before carrying handling operations on the
“DGT” drive units and endcarriages, read the following:
4.2.1 Standard packaging
•To facilitate handling and assembly operations, components are generally shipped separately or in carton boxes,
on appropriately bound pallets. Special protections or packagings are therefore excluded from the shipment.
•In some cases, components can be packed in a crate or wooden case.
•When materials are shipped on pallets, they are generally covered and protected against dust with a plastic film
wrapping.
•Swinging gearmotors and related accessories are generally shipped inside carton boxes, which, depending on
the mass being handled, may or may not be equipped with pallets.
•Standard packagings are not provided with protection against rain, and are foreseen for destinations via ground
and not sea shipments, for covered and non humid environments.
•Packages, suitably conserved, can be stored for a period of around two years in a covered environment in which
the temperature is comprised between - 20°C and + 60°C with a relative humidity of 80%.
Any special packaging, waterproofed and/or for destinations shipped by sea, can be
appropriately prepared at the Buyer’s request.

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4.2.2 Transport
•Entrust all transport operations to qualified personnel, capable of guaranteeing a correct handling of materials;
•During transport operations, the manufacturer recommends avoiding the following:
•do not place onto the components other packages which may cause damage;
•do not place the beam girders on the wheels, placing them onto wooden blocks instead (fig. 6);
•do not tilt or overturn pallets, crates/cases or boxes containing the materials, so as to prevent dangerous
oscillations and ensure constant stability.
DONATI SOLLEVAMENTI S.r.l. declines all responsibility for transport operations performed by
the Buyer or shipping companies appointed by the Buyer.
4.2.3 Lifting points and handling equipment
•To ensure safe handing operations, in relation to the configuration foreseen, the “DGT” drive units or
endcarriages and related accessories are fitted with the following lifting points:
A. “DGT” drive units, comprising the wheel groups and related “DGP” offset geared motors:
1. “DGT” wheel groups are fitted with special holes for handling purposes, situated in the upper section of
the wheel bearing flanges, which enable lifting using a transverse bar of suitable diameter, and a lifting
accessory (slinging the group using two chains or straps) - (fig. 7).
The wheel groups weight less than 30 kg and as such can be handled manually.
2. “DGP” offset geared motors, which are always provided separately from wheel groups or running beams,
when their weight exceeds 30 kg and cannot be handled manually must be lifted using suitable straps fitted
like a “noose” in the gearmotor connection area (fig. 8).
3. The handling operations outlined at points 1 and 2 must be performed using lifting machinery (a bridge or
jib crane, etc.), adopted in relation to the weight of the mass indicated on the packaging being handled.
4. If the packagings are placed onto pallets, the pallet must be handled using a fork lift or transpallet, adopted
in relation to the weight being handled, whereas individual packagings (if they cannot be handled manually)
must be lifted using lifting equipment and related accessories, as outlined below.
B. “DGT” drive units, comprising the beam girder cover and “DGP” offset geared motors:
1. The beam girders can be handled using a fork lift or lifting machinery (a bridge or jib crane, etc.) equipped
with suitable straps fitted like a “noose”. Lifting equipment adopted must be selected in relation to the mass
indicated on the packaging and employed so as to ensure proper balancing. (fig. 9).
2. For handling “DGP” offset geared motors, proceed as outlined at points A2 and A3.
fig. 6 fig. 7
fig. 8 fig. 9

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4.2.4 Handling
For handling operations on “DGT” drive units or endcarriages, proceed as follows:
•Prepared a suitable demarcated area, with a flat level flooring, for unloading and storing the materials.
•Depending on the type of shipping packaging and indications illustrated at point 4.2.3, prepare the necessary
equipment for unloading and handling the various packagings, taking into consideration their weight, dimensions
and lifting elements.
•No special tools are required.
•Any packages with accessories weighing less than 30 kg can be handled manually.
•Secure and lift all components with care in the unloading area, avoiding dangerous oscillations and unbalancing
of the loads being moved.
•Once the handling operations have been completed, check the packages to make certain they have not been
damaged.
All materials must be handled with care, using suitable transport and lifting equipment, so as to
avoid generating dangerous risks due to a loss of stability.
4.2.5 Removing the packaging
•Open the packagings and remove the various parts using suitable equipment in relation to their weight and lifting
points (see point 4.2.3).
•Check to make certain all materials in the shipment are whole and that no parts and/or accessories are missing.
Promptly notify the manufacturer of any damage or missing parts.
•To store the materials, follow the instructions outlined at section 4.5.1 “Storing the units and parts”.
Dispose of all packaging materials following the indications prescribed by local ordinances in
relation to their nature (wood, plastic, carton) and differentiating the materials for recycling
purposes.
4.3 – Installing “DGT” drive units and endcarriages
•The installation of “DGT” drive units and endcarriages, in their various configurations,
refers to the process of “incorporating” the components into a more complex assembly.
•Specifically, two types of “incorporating” processes can be adopted:
1. Incorporating the “DGT” drive units onto a crane beam (sect. 4.3.1)
2. Incorporating the “DGT” drive units onto a bridge crane (sect. 4.3.2)
Before proceeding with “incorporating” the “DGT” drive units and beams, carry out the
following controls:
•check that the performance specifications of the components are suitable for the type of service required
(capacity, speed, ISO/FEM classification, dimensions of sliding rail, available space, etc.).
•check that no damage has resulted to component during transport operations.
•if the component has been stored in a humid or tropical location for en extended period of time, check the
brakes, and if necessary, remove the gluing on the brake surfaces.
•use grease to lubricate the drive shaft that will be joined to the offset geared motor and wheel.