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Summary of Contents for Donati GRL Series
- Page 1 JIB CRANE 360° MANUAL AND ELECTRIC CONTINUOUS ROTATION –GRL SERIES - USE INSTRUCTIONS - INSTALLATION - USE - MAINTENANCE MARCH 2022 KMAN60MG00 Translated from the original instructions in Italian...
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Page 3: Table Of Contents
USE AND MAINTENANCE MANUAL FOR JIB CRANE GRL SERIES INDICE DEL CONTENUTO PRELIMINARY INFORMATION ................. 1 Manual contents and recipients ....................1 Symbols: meaning and use ....................... 1 Collaboration with the user ......................2 Regulatory compliance....................... 2 Manufacturer’s liability and warranty ..................2 DESCRIPTION OF THE MACHINE AND TECHNICAL INFORMATION ... - Page 4 USE AND MAINTENANCE MANUAL FOR JIB CRANE GRL SERIES Decommissioning ........................35 4.5.1 Storage and preservation of parts ..................35 4.5.2 Resetting after storage ....................... 36 OPERATION AND USE OF THE JIB CRANE ..........37 Functions of the jib crane ......................37 5.1.1...
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Page 5: Preliminary Information
1 PRELIMINARY INFORMATION 1.1 Manual contents and recipients This technical publication, marked with the code KMAN60MI00, refers to the “Jib crane, with manual/electric rotation, “Column” type - GRL series. DONATI SOLLEVAMENTI S.r.l. Via Quasimodo, 17 - 20025 Legnano (MI) Tel. +39 0331 14811 - Fax +39 0331 1481880 E-mail: dvo.info@donaticranes.com... -
Page 6: Collaboration With The User
(declarations, diagrams, test logbook, etc.). 1.4 Regulatory compliance The GRL series jib cranes are designed and constructed in consideration of the “Essential Health and Safety Requirements” of Annex 1 of Machinery Directive 2006/42/EC and are put on the market with the CE marking and CE Declaration of Conformity - as per Annex II A of the same Directive. - Page 7 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES • defects in voltage and the mains supply • no or incorrect compliance with the instructions provided in this manual • unauthorised modifications to the machine • use by personnel who are not trained or not suitable...
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Page 8: Description Of The Machine And Technical Information
(tie-rods, foundation plinth, electrical system, etc.). The GRL series crane is composed of a column with polygonal section attached via stay bolts or bolts to the specifically dimensioned base and of a rotating arm situated on the column itself. - Page 9 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES fig. 3 fig. 4 Electrical system: It is intended for the electrical input of the hoist and/or trolley (if electric) which slides along the arm of the crane. It has a connector block, situated on the top of the crane, for the connector between the line and the festooned cable.
- Page 10 The concept and construction: • The 360° rotating jib cranes of the GRL series are built based on the concept of modular components which, assembled to each other based on commercial needs, as well as the standard versions always available in the warehouse, they allow fast and economic creation of many standardised and special configurations.
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Page 11: Technical Information And Service Conditions
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 2.2 Technical information and service conditions 2.2.1 Regulatory reference framework In the designing and construction of the manually rotated jib cranes, the following standards and main technical rules have been taken into consideration: •... -
Page 12: Use Criteria And Operating Conditions
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 2.2.6 Use criteria and operating conditions One of the necessary and indispensible conditions to obtain the complete operating compliance of the jib crane, for the use it is intended for, as well as excellent and long-lasting operation of the same, consists of the correct selection of the machine model. -
Page 13: Electrically Rotated Grl: Characteristics And Technical Data
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 2.2.7 Electrically rotated GRL: characteristics and technical data... - Page 14 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES Fixing systems for jib cranes...
- Page 15 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES Counterplates for fixing the following pillar-mounted cranes to the floor with chemical bolts: GRL • M16 chemical bolts - minimum floor thickness 170mm The fixing of the pillar with chemical bolts requires a scrupulous check of suitability in relation to the type of support flooring.
- Page 16 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES • M12 chemical bolts - minimum floor thickness 140mm The fixing of the pillar with chemical bolts requires a scrupulous check of suitability in relation to the type of support flooring. The suitability checks are the responsibility of the user and must be carried out by expert, qualified technicians who will evaluate the feasibility and formally undertake the relative responsibilities.
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Page 17: Safety And Accident Prevention
JIB CRANE - GRL SERIES 3 SAFETY AND ACCIDENT PREVENTION The GRL series rotating jib cranes and relative accessories were designed and built based on the most modern technical knowledge and can be used safely. The hazards for assigned personnel can be completely eliminated and/or significantly reduced only if the crane is used in accordance with the instructions contained in this documentation by authorised and specifically instructed personnel, in possession of sufficient preparation. -
Page 18: General Safety Regulations
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 3.2 General safety regulations Before putting the jib crane into service, it is necessary to: • Carefully read the technical documentation; • Become informed on the operation and positioning of the emergency stop devices;... -
Page 19: Warnings On Residual Risks
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 3.4 Warnings on residual risks After having carefully considered the hazards present in all of the jib crane operating phases, measures have been adopted that are necessary to eliminate, as much as possible, the risks for operators and/or to limit or reduce the risks resulting from hazards that cannot be completely eliminated at the source. -
Page 20: Safety Devices And Instructions
11 fig. 10 3.5.3 Warning and notice devices - Signage summary The GRL series jib cranes are equipped with the following warning and notice devices. Plates present on the machine: • manufacturer’s logo. (fig. 12a) •... - Page 21 The plates must never be removed and it is absolutely prohibited to affix other plates on the crane without prior authorisation from DONATI SOLLEVAMENTI S.r.l.
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Page 22: Handling - Installation - Commissioning
4 HANDLING - INSTALLATION - COMMISSIONING 4.1 General notes for delivery • The GRL series jib cranes are delivered unassembled, in their main parts including the column, arm, electrical system and, if it is part of the supply, the lifting unit. •... -
Page 23: Packaging, Transport And Handling
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 4.2 Packaging, transport and handling Before handling the jib crane and its accessories you should know that: 4.2.1 Standard packaging • The metalwork parts of the jib crane (column and arm) are generally supplied with packaging, hooking points are present on the columns to make it easier to move them during installation operations (fig. -
Page 24: Transport
DONATI SOLLEVAMENTI S.r.l. shall not be held liable for transports made by the customer or shippers chosen by the customer. 4.2.3 Handling To move the jib crane, proceed as follows: •... -
Page 25: Removal Of The Packaging And/Or Checking Of The Crane Parts
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 4.2.4 Removal of the packaging and/or checking of the crane parts • In the case of packaged parcels, open the packaging and extract the various parts using suitable equipment chosen in relation to their weight and grip points. -
Page 26: Preparation Of The Installation Site
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES fig. 17 Following the jib crane installation activities, the installer must: 1. Conduct the “Commissioning”, activities as described in paragraph 4.4; 2. Draft the “Acceptance test” report and approve the jib crane “Suitable for use”;... -
Page 27: Assembly Of The Column (Foundation Plate, Counterplate, Column)
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES fig. 20 fig. 19 4.3.3 Assembly of the column (foundation plate, counterplate, column) • The column can be anchored to the ground in the following manners: using the foundation frame with stay bolts embedded in a plinth formed in reinforced concrete. - Page 28 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES fig. 22 fig. 21 fig. 24 fig. 23 Positioning of the counterplate with chemical bolts: To ensure the hold of the fixing operate as follows: a) Check that the inclination of the surface where the counterplate is to be fitted is within the tolerances shown in fig.
- Page 29 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES fig. 25 Pillar assembling: On a foundation frame (plinth): 1) When the plinth has solidified, remove the protection of the bolt threading and check that the high nuts unscrew without forcing, then remove them and the washers.
- Page 30 After the first lifting operations it is advisable to check nut tightening again, to take up any play due to settlement of the plinth. Donati Sollevamenti SRL shall not be held liable for any fixings other than those indicated in fig. 28 e fig. 29.
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Page 31: Assembly Of The Thrust Bearing, Arm And Gear Motor
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 4.3.4 Assembly of the thrust bearing, arm and gear motor To assemble the arm, in the case of a thrust bearing already fixed on the column proceed as follows: 1) Check that the teeth of the thrust bearing have been carefully greased and that the upper and lower surfaces of the same are perfectly clean. -
Page 32: Assembly Of The Electrical System
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES fig. 36 fig. 37 fig. 39 fig. 38 4.3.5 Assembly of the electrical system To assemble the electrical system proceed as follows: 1) Extract the cable, trolleys and other electric components from the packaging 2) Insert the power supply cable 1 in the slides 3 (fig. -
Page 33: Electrical Connections
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES fig. 42 fig. 41 fig. 40 fig. 44 fig. 45 fig. 43 fig. 46 4.3.5.1 Electrical connections • Never make the electrical connections with the voltage on • Never make temporary connections or jump or makeshift connections •... - Page 34 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES Rotating collector ring control After carrying out the assembly as shown in the previous paragraph, make the connection as follows: 1. Connect the shortest cable to terminals L1-L2-L3 of the rotation equipment integrated in the gear motor (fig.
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Page 35: Assembly Of The Trolley/Hoist
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES Contact settings: 1. Set the cam for contact SQ5A to limit the RIGHT rotation as needed. 2. Set the cam related to the emergency contact SQ5B immediately after the intervention of contact SQ5A. - Page 36 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES fig. 54 Electrical connections of the lifting unit (trolley/hoist): To connect the festoon power line cable in the lifting unit electrical equipment connector block, see the trolley/hoist “User instructions”, attached to this publication •...
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Page 37: Commissioning
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 4.4 Commissioning 4.4.1 Preliminary tests - Adjustments and operating tests Perform the following tests before commissioning the crane: • Check the suitability of the electrical system: Check that the line voltage and frequency, shown on the respective motor plates, correspond to those required for operation. -
Page 38: Acceptance Test Of The Jib Crane - Suitability For Use
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 4.4.2 Acceptance test of the jib crane - Suitability for use • The jib crane is put on the market considering the acceptance tests conducted at the manufacturer on similar prototypes subjected to testing of their suitability on the structural parts (columns, shelves, arms, etc.). -
Page 39: Static Test
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES • perform the same tests also for the trolley traverse movements and arm rotation, checking the operation of the limit switches without bringing the load to the maximum height (lift to a metre from the ground). -
Page 40: Resetting After Storage
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES • If during the entire storage period, these values do not comply with what is indicated, it will be necessary to perform some preliminary tests before putting the crane into service (see paragraph 4.5.2) •... -
Page 41: Operation And Use Of The Jib Crane
5.1 Functions of the jib crane 5.1.1 Intended use - Expected use - Intended purpose The jib cranes, with manual/electric rotation - GRL series are created to locally handle goods inside a plant, on a loading dock or along with operating stations. -
Page 42: Permitted Loads, Unpermitted Loads
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES • • When the electric movements of the crane are controlled by remote control the pushbutton panel is not restricted by the crane, the operator thus must always pay utmost attention during manoeuvres without ever losing sight of the work area and the handled load in order not to compromise his safety and/or that of any exposed persons. -
Page 43: Operating Conditions
5.2.3 Work area lighting The GRL series jib cranes are not equipped with their own lighting system. Consequently, the workplace of the operator assigned to use the crane must be adequately lighted and ensure maximum visibility. -
Page 44: Operator
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 5.2.4 Operator The operators are all of those who carry out the following activities on the jib crane on a time-to-time basis: • transport, handling, assembly, installation, adjustments and the acceptance test •... -
Page 45: Safety Devices
The lifting, traverse and rotation limit switches limit the maximum vertical and horizontal travel of the load. They are emergency devices and not suitable as operating stops. • The safety devices, when excluded from the DONATI SOLLEVAMENTI S.r.l. supply must be installed by the customer. •... -
Page 46: Deactivating At The End Of Work
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 5. Put the “emergency stop” red mushroom head button in start consensus 6. Activate all of the functions by pressing the “start” button, if available 7. Check the operation of the safety devices by checking the movements as described in the paragraph 5.1 –... -
Page 47: Use Criteria And Precautionary Measures
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 5.5 Use criteria and precautionary measures • The correct use of the jib crane makes it possible to fully use the performance that is able to provide in completely safe conditions. -
Page 48: Use Contraindications
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES • ALWAYS use suitable personal protection equipment (PPE, gloves, etc.) for all operations • ALWAYS report any operating anomalies (defective behaviour, suspected breakage, incorrect movements and noise that is not normal) to the department head and put the machine in non- working conditions. -
Page 49: Unintended And Unpermitted Use - Predictable And Unpredictable Incorrect Use
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 5.6.1 Unintended and unpermitted use - Predictable and unpredictable incorrect • NEVER use the jib crane to lift and transport people (fig. 61). • NEVER use the jib crane to lift and transport people (fig. 57). - Page 50 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES • NEVER use the crane in unpermitted environmental conditions or, if installed outdoors, in harsh, unfavourable and/or dangerous environmental conditions (strong wind, heavy rain, etc.) - (fig. 65). • NEVER use or work on the crane in insufficient lighting and/or visibility conditions.
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Page 51: Jib Crane Maintenance
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 6 JIB CRANE MAINTENANCE 6.1 Safety precautionary measures The accident prevention measures contained in this paragraph must always be strictly complied with during maintenance, in order to avoid personal injury and damage to the crane. - Page 52 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES Avoid the use of flammable or toxic solvents (petrol, ether, alcohol, etc.). Avoid prolonged contact with solvents and inhalation of their fumes. Specifically avoid use near open flames. Always ensure, before starting the crane, that the personnel assigned to maintenance is at a safe distance (no longer above ground) and that tools and materials have not been left on the crane.
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Page 53: Qualification Of Personnel Assigned To Maintenance
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 6.2 Qualification of personnel assigned to maintenance To be able to adequately perform maintenance of the jib crane, the personnel assigned to maintenance must: • know the current laws related to accident prevention during the work performed on the machines with motor transmission and be able to apply them •... - Page 54 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES knowledge of the measurement and test methods to determine the actual state of the crane and hoist conditions (testing of: brakes, wear on chain and hook wear, wheel wear, anomalous noise, etc.)
- Page 55 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES Mechanical technician • Typical technical activities: mechanical adjustments of safety devices, calibrations and acceptance tests (annual load tests) routine maintenance operations after replacement of complex mechanical components and/or those which are critical for safety purposes (anchoring components, arm, gear motors, motors, etc.)
- Page 56 “MACHINE MAINTENANCE”. For any problems which should arise or to order spare parts contact the DONATI SOLLEVAMENTI S.r.l. Technical Assistance Service...
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Page 57: Maintenance Plan
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 6.3 Maintenance plan The maintenance plan includes all ordinary type operations, that entail inspections, tests and checks conducted by the operator assigned to use of the crane and/or qualified personnel assigned to normal company and periodic type maintenance which include replacement, setting and lubrication operations performed by technical personnel instructed for the purpose through specific courses or publications. -
Page 58: Frequency And Deadlines For Maintenance Interventions
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 6.3.2 Frequency and deadlines for maintenance interventions The frequency of the following operations refers to a jib crane used in normal operating conditions and are valid up to service group M5 (standard ISO 4301/86) or 2m (FEM 9,511 rule). If the use of the jib crane is normal and correct for a daily 8 hour shift, the following overhaul may be performed after a use period of approximately 10 years (FEM 9,755 - S.W.P. -
Page 59: Test Of Part And Component Efficiency
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 6.3.3 Test of part and component efficiency The following instructions should be scrupulously complied with for the single parts of the jib crane: Annual test of the efficiency of the structural elements, welding, pins and bolted joints (fig. - Page 60 USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES Quarterly check of the efficiency of the wheels (paragrafo 6.3.2): • Check the wear of the rolling band of the wheels • Check the ball bearings. They need to be replaced if there is excessive noise or if they have excessive friction, “tugging”, difficult and/or irregular rotation...
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Page 61: Cleaning And Lubricating The Jib Crane
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 6.3.4 Cleaning and lubricating the jib crane • Cleaning can be performed by personnel who is not highly specialised. • It is periodically necessary to keep the following parts clean: ... -
Page 62: Troubleshooting
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 6.4 Troubleshooting 6.4.1 Main causes of malfunctions or faults and possible solutions The columns of the table below show the main malfunction conditions that can be reasonably predicted and the type of problem, potential cause of the fault and possible solutions. -
Page 63: Spare Parts
USE AND MAINTENANCE MANUAL FOR JIB CRANE - GRL SERIES 7 SPARE PARTS • The jib cranes have been designed so they do not normally need spare parts due to FAULTS OR BREAKAGE, if they are used correctly and following adequate maintenance as described in this manual. - Page 65 Le immagini riportate sono di proprietà della Donati Sollevamenti S.r.l., pertanto ne è vietata la riproduzione, divulgazione ed utilizzo senza esplicito permesso. Donati Sollevamenti S.r.l. declina ogni responsabilità per errori di stampa o inesattezze e si riserva di cambiare, aggiornare o modificare le informazioni presenti in qualunque momento e senza alcun preavviso.
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