Donati GRL Series User manual

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

USE AND MAINTENANCE MANUAL FOR JIB CRANE
GRL SERIES
I
INDICE DEL CONTENUTO
1PRELIMINARY INFORMATION.........................................................................1
1.1 Manual contents and recipients ................................................................................................ 1
1.2 Symbols: meaning and use ....................................................................................................... 1
1.3 Collaboration with the user........................................................................................................ 2
1.4 Regulatory compliance............................................................................................................... 2
1.5 Manufacturer’s liability and warranty ....................................................................................... 2
2DESCRIPTION OF THE MACHINE AND TECHNICAL INFORMATION...........4
2.1 The jib cranes with manual/electric rotation............................................................................ 4
2.1.1 Intended use - Expected use - Intended purpose .................................................................4
2.1.2 Installation restrictions...........................................................................................................4
2.1.3 The composition of the jib cranes..........................................................................................4
2.2 Technical information and service conditions ........................................................................ 7
2.2.1 Regulatory reference framework ...........................................................................................7
2.2.2 Protection and insulation of electrical parts...........................................................................7
2.2.3 Electrical supply.....................................................................................................................7
2.2.4 Ambient use conditions .........................................................................................................7
2.2.5 Noise - Vibration....................................................................................................................7
2.2.6 Use criteria and operating conditions....................................................................................8
2.2.7 Electrically rotated GRL: characteristics and technical data .................................................9
3SAFETY AND ACCIDENT PREVENTION .......................................................13
3.1 Authorised operator qualifications ......................................................................................... 13
3.2 General safety regulations....................................................................................................... 14
3.3 Safety signs............................................................................................................................... 14
3.4 Warnings on residual risks...................................................................................................... 15
3.5 Safety devices and instructions.............................................................................................. 16
3.5.1 Control devices....................................................................................................................16
3.5.2 Safety and emergency devices for GRL..............................................................................16
3.5.3 Warning and notice devices - Signage summary................................................................16
4HANDLING - INSTALLATION - COMMISSIONING.........................................18
4.1 General notes for delivery........................................................................................................ 18
4.2 Packaging, transport and handling......................................................................................... 19
4.2.1 Standard packaging.............................................................................................................19
4.2.2 Transport .............................................................................................................................20
4.2.3 Handling...............................................................................................................................20
4.2.4 Removal of the packaging and/or checking of the crane parts ...........................................21
4.3 Jib crane installation ................................................................................................................ 21
4.3.1 Installer duties and responsibilities......................................................................................21
4.3.2 Preparation of the installation site .......................................................................................22
4.3.3 Assembly of the column (foundation plate, counterplate, column)......................................23
4.3.4 Assembly of the thrust bearing, arm and gear motor..........................................................27
4.3.5 Assembly of the electrical system .......................................................................................28
4.3.5.1 Electrical connections..................................................................................................... 29
4.3.6 Assembly of the trolley/hoist................................................................................................31
4.4 Commissioning ......................................................................................................................... 33
4.4.1 Preliminary tests - Adjustments and operating tests...........................................................33
4.4.2 Acceptance test of the jib crane - Suitability for use............................................................34
Static test:........................................................................................................................................ 35

USE AND MAINTENANCE MANUAL FOR JIB CRANE
GRL SERIES
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4.5 Decommissioning ..................................................................................................................... 35
4.5.1 Storage and preservation of parts ...................................................................................... 35
4.5.2 Resetting after storage ....................................................................................................... 36
5OPERATION AND USE OF THE JIB CRANE .................................................37
5.1 Functions of the jib crane ........................................................................................................ 37
5.1.1 Intended use - Expected use - Intended purpose............................................................... 37
5.1.2 Permitted loads, unpermitted loads.................................................................................... 38
5.1.3 Lifting accessories .............................................................................................................. 38
5.2 Operating conditions ................................................................................................................ 39
5.2.1 Operating environment ....................................................................................................... 39
5.2.2 Danger zones and exposed persons.................................................................................. 39
5.2.3 Work area lighting............................................................................................................... 39
5.2.4 Operator.............................................................................................................................. 40
5.2.5 Jib crane capacity............................................................................................................... 40
5.2.6 Manoeuvres: lifting, trolley traverse and arm rotation......................................................... 40
5.2.7 Safety devices..................................................................................................................... 41
5.3 Activating the jib crane............................................................................................................. 41
5.4 Deactivating at the end of work............................................................................................... 42
5.5 Use criteria and precautionary measures .............................................................................. 43
5.6 Use contraindications............................................................................................................... 44
5.6.1 Unintended and unpermitted use - Predictable and unpredictable incorrect use............... 45
6JIB CRANE MAINTENANCE ...........................................................................47
6.1 Safety precautionary measures............................................................................................... 47
6.2 Qualification of personnel assigned to maintenance............................................................ 49
6.3 Maintenance plan ...................................................................................................................... 53
6.3.1 Daily and routine maintenance ........................................................................................... 53
6.3.2 Frequency and deadlines for maintenance interventions................................................... 54
6.3.3 Test of part and component efficiency................................................................................ 55
6.3.4 Cleaning and lubricating the jib crane ................................................................................ 57
6.4 Troubleshooting........................................................................................................................ 58
6.4.1 Main causes of malfunctions or faults and possible solutions............................................ 58
6.4.2 Personnel authorised to intervene in the event of a failure ................................................ 58
6.4.3 Decommissioning ............................................................................................................... 58
6.5 Disassembly, disposal and scrapping.................................................................................... 58
7SPARE PARTS.................................................................................................59
8CONTROL BOOKLET......................................................................................59

USE AND MAINTENANCE MANUAL FOR
JIB CRANE - GRL SERIES
1
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. [phone] - Fax [phone]
E-mail: [email protected]
www.donaticranes.com
It is related to their “intended use”, their functional technical specifications and performance and the relative
installation, use and maintenance instructions. It is addressed to:
•the manager of the plant, garage or job site
•operators assigned to transport, handling and installation
•operators assigned to use of the jib crane
•personnel assigned to maintenance
The manual must be kept by a person in charge of doing so, in a suitable place, so that it is always available
for consultation in the best possible conditions.
If it is lost or deteriorates, replacement documentation must be requested directly from the manufacturer,
quoting the code of this manual.
The manufacturer reserves the right to the material and intellectual property of this
publication and forbids its dissemination and duplication, including partial, without
prior written consent.
1.2 Symbols: meaning and use
Certain symbols are used in this manual to call the reader’s attention and underline some particularly
important aspects.
The following table shows the list and meaning of the symbols used in the manual.
SYMBOL
MEANING
EXPLANATION, RECOMMENDATIONS AND NOTES
Hazard
• Indicates a hazard with the risk of an accident, including fatal.
• The failure to comply with the instructions marked with this
symbol may result in a seriously hazardous situation for the
operator’s and/or exposed persons’ safety!
•Carefully follow the instructions!
Warning
• Represents a warning note of a possible deterioration of the
jib or a personal item of the operator.
•Important warning to pay attention to.
Warning Note
•Indicates a warning or a note on key functions or useful
information.
• Visual
observation
•Actions to
perform
• A stylized eye may indicate to the operator that:
a) He/she needs to make a visual inspection.
b) He/she must proceed with the operating sequence.
c) A measurement value needs to be read, a warning needs to
be checked, etc.

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JIB CRANE - GRL SERIES
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1.3 Collaboration with the user
The manual reflects the state of the art at the time the machine was placed on the market and is an integral
part of the machine.
Any supplements to the manual that the manufacturer considers appropriate to send to the users must be
kept together with the manual.
The manufacturer is available to its customers to provide additional information and to consider proposals
for improvement in order to make the manual closer to the needs for which it was prepared.
If the jib crane is sold, the main user is asked to deliver, along with the crane, this manual and the relative
attached documentation (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.
fig. 1 Example of CE Certificate
fig. 2 Example of UKCA Certificate
In addition, the GRL series jib cranes are in compliance with the following directives:
•Low Voltage Directive 2014/35/EU;
•Electromagnetic compatibility directive 2014/30/EU.
1.5 Manufacturer’s liability and warranty
In terms of the contents of this manual the company shall not be held liable in the following cases:
•use of the jib crane not in compliance with national laws on safety and accident prevention
•incorrect selection or set-up of structures on which the crane will be installed

USE AND MAINTENANCE MANUAL FOR
JIB CRANE - GRL SERIES
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•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
To be able to use the warranty, the customer must scrupulously follow the instructions indicated in this
manual, and in particular:
•always operate within the limits of use of the jib crane
•always perform a constant and diligent maintenance
•assign use of the machine to operators with a proven capacity, adequately instructed for the
purpose
•only use the original spare parts indicated by the manufacturer
•The intended use and the configurations of the jib are the only ones allowed.
Do not try to use it ignoring the provided instructions.
•The instructions contained in this manual do not replace but summarise the
obligations to comply with current accident prevention laws.

USE AND MAINTENANCE MANUAL FOR
JIB CRANE - GRL SERIES
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2 DESCRIPTION OF THE MACHINE AND TECHNICAL
INFORMATION
2.1 The jib cranes with manual/electric rotation
2.1.1 Intended use - Expected use - Intended purpose
The jib cranes, with manual/electric rotation, in “Column” version - GRL series are created to locally handle
goods inside a plant, on a loading dock or along with operating stations.
Jib cranes perform three operations:
•they lift the load vertically in space, via a hook on the lifting unit, generally composed of a manual
or electric chain hoist and using accessories suitable for this operation;
•they traverse the load in space, with the assistance of an electric or manual hoist holder trolley,
which runs along the radial axis of the crane arm;
•they rotate the load in space, around the constrained axis of the arm, through a manual push
action of the load using the circular area below, limited by the rotation radius of the arm.
2.1.2 Installation restrictions
The “Column-mounted” - GRL series jib cranes, are generally designed to be attached to the ground,
the column is self-bearing and can be anchored to the ground with stay bolts, on a specific foundation plinth
or, in special cases after verifying the feasibility, also with expansion bolts or chemical anchoring.
•The user must verify, either directly or through personnel specialised in the matter,
the suitability of the anchoring surfaces which must ensure the stability and safety
of the crane in all operating conditions, withstanding the stress and dynamic
effects induced by the overturning moment and the lifting type and speed.
2.1.3 The composition of the jib cranes
The composition of the jib crane is relatively simple: the metalwork structure, lifting unit composed of a
hoist (electric or manual), the traverse unit formed by hoist holder trolley (electric or by pushing) and a
series of accessories (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.
Column: Made of press-forged steel sheet welded to the tubular structure with polygonal section it allows
high rigidity and stability for the crane; it is fixed to the base with a base plate and a system of bolts or stay
bolts. In the upper part a pair of plates supports the crane arm and allows it to rotate (fig. 3).
Rotating arm: The arm, turning around its axis on thrust bearing, is composed of a weight-bearing beam
for travel of the hoist holder trolley and is created for capacities from 125 to 2,000 kg and jibs up to 7 m
(fig. 4).Made using a laminated double T-beam form: the hoist carrying trolley runs on the lower flanges of
the T-beam. The beam is self-bearing with cantilever, therefore it does not have support bolts. Allows
optimal use of the available overhead space due to the absence of bolts. The crane can be used in
combination with electric or mechanical push-trolleys.

USE AND MAINTENANCE MANUAL FOR
JIB CRANE - GRL SERIES
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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. The electrical system is built using a flame retardant type generally flat cable with festoons,
sliding on specific trolleys.
Foundation frame with stay bolts:
Upon request, supplied for fixing the column itself to the base (foundation plinth) (fig. 6).
Counterplate with chemical bolts:
Upon request, supplied for fixing the column itself to the floor (fig. 7).
Finishing:
Protection of the metalwork structure from inclement weather and environmental agents (dust, gases, etc.)
is guaranteed by treatments performed using the application of yellow (std RAL1007) enamel, after
preparing the surfaces with metallic sandblasting.
Lift and traverse unit:
The manually or electrically rotated jib cranes can be equipped with a hoist with relative trolley in both
electric and manual version.
For the dimension specifications, weights and maximum reactions allowed on the trolley wheels see the
relative table in the “Technical specifications” in paragraph 2.2.
fig. 5

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JIB CRANE - GRL SERIES
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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.
•The base components, columns and arms, thanks to their extreme compactness can be assembled
together so as to guarantee the maximum use of the hook run and, thanks to their minimum lateral
encumbrance, allow the optimal use of the area where the jib crane operates.
•The construction uses the most evolved technology based on high industrialisation production
processes and allows the creation of completely reliable and technically innovative machines
through economies of scale.
Arm electric rotation device:
Formed by a gear motor (fig. 8) fixed vertically in the upper part of the arm, made with a motor of epicycloid
type, with gears in a thermally treated oil bath and self-braking conical brake motor.
The pinion protruding from the gear motor is coupled with a toothed thrust bearing attached to the column.
Progressive starting and braking are ensured by a frequency variator (inverter).
Electric safety limit switch (fig. 9) on the rotation movements, installed, if necessary, to delineate the rotation
field of the arm of the crane.
Working on the auxiliary circuits at low voltage, it is a worm screw type with two thresholds of intervention
both in right rotation and left and also carries out the emergency function in safety if there is any fault or
malfunctioning of the first threshold of intervention.
fig. 8
fig. 9
fig. 6
fig. 7