GORBEL RETROFIT II Instruction manual

IMPORTANT!
DO NOT DESTROY
Installation, Operation,
& Maintenance Manual
Month Year
Gorbel®Dealer
Date
RETROFIT II
TRACTION DRIVE
Gorbel®Customer Order No. / Serial No.
®
Issued: 12/2010
Revised: 07/2022

TABLE OF CONTENTS
Introduction........................................................................................................1
Installation
Step 1- Pre-Assembly...................................................................................................... 2
Step 2- Installation and Drive Assembly Instructions ................................................... 2-3
Step 3A - Electrification Installation (Standard Drive)...................................................... 4
Step 3B - Electrification Installation (Variable Frequency Control Drive) ..................... 4-5
Step 4- Limit Switch Installation ................................................................................... 6-8
Step 5- Endstop/Tagline Installation................................................................................ 9
Step 6- Shut Down Procedures..................................................................................... 10
Step 7- Final Steps ........................................................................................................ 10
Safety Warnings and Precautions................................................................... 10
Troubleshooting Guide .................................................................................... 11
Trunnion Roller Replacement.......................................................................... 11
Crane Operator Instructions............................................................................ 12
General Operating Suggestions...................................................................... 12
Limited Warranty ............................................................................................. 13
Appendix A: Securex Friction Torque Limiter Type C&T Installation.............. 14
Maintenance Schedule.................................................................................... 22
Lubrication Schedule....................................................................................... 22
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INTRODUCTION
Thank you for choosing a Gorbel® Retrofit II to solve your material handling needs. The innovative design and
heavy-duty construction of a Retrofit II added to an existing jib will provide a superior quality product that will offer
years of long term value. All Gorbel® cranes are pre-engineered for powered hoist operation. The hoist weight
allowance is 15% of the crane capacity (for example, a crane rated for 1000 pounds allows for a 1000-pound live
load plus 150 pounds for the weight of the hoist). There is also an allowance of 25% of the crane capacity for
impact caused by hoist use. Gorbel® Free Standing Jib Cranes will provide many years of dependable service by
following the installation and maintenance procedures described herein.
Dimensions contained in this installation manual are for reference only and may differ for your particular
application.
Normal safety precautions: These include, but are not limited to:
• Checking for obstructions in crane rotation
• Checking that all bolts are tight and have lockwashers
• Making sure that endstop is in place
• Making sure that festooning cannot be snagged or pinched
For additional safety precautions see page 12.
WARNING
Only competent erection personnel familiar with standard fabrication practices should be employed to assemble
these cranes because of the necessity of properly interpreting these instructions. Gorbel is not responsible for the
quality of workmanship employed in the installation of a crane according to these instructions. Contact Gorbel, Inc.,
at 600 Fishers Run, P.O. Box 593, Fishers, New York, 14453-0593, 1-800-821-0086, for additional information if
necessary.
WARNING
Equipment described herein is not designed for, and should not be used for, lifting, supporting or transporting
humans. Failure to comply with any one of the limitations noted herein can result in serious bodily injury and/or
property damage. Check State and Local regulations for any additional requirements.
WARNING
Consult a qualified structural engineer to determine if your support structure is adequate to support the loads
generated by anchor bolt force, overturning moment, or axial load of your crane.
WARNING
Crane cannot be utilized as a ground: A separate ground wire is required. For example, systems with 3-phase
power require 3 conductors plus one ground wire.
WARNING
Reference American Institute of Steel Construction (AISC) manual of Steel Construction (9th edition), Part 5,
Specification for Structural Joints using ASTM A325 or A490 bolts (section 8.d.2) for proper procedures to follow
when using any torque tightening method.
WARNING
Do not field modify crane in any way. Any modifications without the written consent of Gorbel, Inc. will void
warranty.
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INSTALLATION
STEP 1 - PRE-ASSEMBLY
1.1 Read entire manual before installing the Retrofit II.
1.2 Check packing list to ensure no parts have been lost prior to initiating assembly of the
Retrofit II.
1.3 Tools and materials (by others) typically needed to assemble Retrofit II:
• Ladders/man lifts
• Hand tools
• Torque wrench
STEP 2 - INSTALLATION AND DRIVE ASSEMBLY INSTRUCTIONS
2.1 Take main frame assembly and place it between the side plates of the head assembly
(diagram 2A, page 3).
2.2 Measure 1” down from the bottom edge of the top plate of the mast to the top of main
frame assembly. Measure 2-1/4” from mast face to inside edge of main frame assembly.
2.3 Mark hole positions from main frame assembly onto head assembly side plates. Holes
should be in line and run parallel to mast face.
2.4 Drill three (3) Ø1-1/16” holes in each side plate.
2.5 Mount main frame assembly between side plates using Ø1” bolts, lockwashers and hex
nuts provided.
2.6 Insert drive mounting frame into spring tension frame using Ø1” pivot rod and cotter pin to
secure the assembly.
2.7 Insert spring pressure rod assembly into main frame assembly. Secure with cotter pin.
2.8 Attach drive mounting frame and spring tension frame (assembled in Step 2.6) to the main
frame using the Ø1” pivot rod and hardware.
2.9 Tighten the hardware to compress springs after “0” clearance is taken up. Compress
spring 1/2” to 1”. If slippage occurs, additional compression may be needed. Do not
allow coils of spring to bind.
2.10 Mount electrical enclosure (if applicable) to side plate and connect power, motor and
control connections according to the electrical print included. A minimum of two (2) button
pendant (by others) with on/off to operate mainline contactor is required to rotate jib in the
clockwise and counterclockwise directions.
2.11 If electrical was not ordered with a fuse block or a fusible disconnect switch, some type of
fused protection must be provided between power supply and electrical enclosure.
TIP: Packing list can be found in plastic pocket in hardware box.
TIP: The reducer and motor are already mounted to the drive mounting frame as shown in
diagram 2B, page 3.
TIP: Be sure safety nuts are in place on all springs before tightening.
TIP: Be sure all power is off before wiring.
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STEP 2 - INSTALLATION AND DRIVE ASSEMBLY (CONTINUED)
Diagram 2A. Frame Installation.
Diagram 2B. Retrofit II.
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STEP 3A - ELECTRIFICATION INSTALLATION (STANDARD DRIVE)
JIB DRIVE CONTROLLER
Jib rotation control is by magnetic reversing starters. For troubleshooting and general
informattion, a brief summary is included below. Other controllers may be available. See the
appropriate enclosed insert for any optional equipment where applicable.
SINGLE SPEED OPERATION
Single speed operation utilizes the drive ratio of the reducer and the ratio of the drive to driven
sprockets to produce the standard jib rotation speed. These ratios are determined by the crane
parameters (span, capacity, indoor, outdoor, etc.).
Materials typically contained within the electrical enclosure are as follows:
• Mainline Fuseblock
• Branch Fusing (Hoist)
• Control Transformer
• Terminal Strip
• Reversing Starters
• Thermal Overloads
• Mainline Contactor
STEP 3B - ELECTRIFICATION INSTALLATION
(VARIABLE FREQUENCY CONTROL DRIVE)
JIB DRIVE CONTROLLER
The drive controller for the jib drive is pre-programmed at Gorbel for single speed, two speed, or
three speed operation. For troubleshooting and general information, a brief summary of how the
drive controller is designed to be used is included below. No additional programming is required.
All options utilize an adjustable speed controller.
SINGLE SPEED OPTION
This option utilizes the drive ratio of the reducer and the ratio of the drive to driven sprockets to
produce the standard jib rotation speed. These ratios are determined by the crane parameters
(span, capacity, indoor, outdoor, etc.). The drive controller is then programmed for the motor to
operate at normal speed (60 Hz).
TWO SPEED OPTION
This option varies the motor speed to determine the desired jib drive speeds. The motor
controller is then programmed for the motor to operate at two different percentages of full speed
based on the desired speeds specified by the customer at the time the order is placed.
WARNING
The drive controller drive must only see its own internal voltage and not be connected to an external voltage source.
Allowing 24 or 120 control voltage to go through the drive will PERMANENTLY DAMAGE the internal controls!
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STEP 3B - ELECTRIFICATION INSTALLATION
(VARIABLE FREQUENCY CONTROL DRIVE) (CONTINUED)
THREE SPEED OPTION
This option is similar to the two speed option listed above. The motor controller is programmed
for the motor to operate at three different percentages of full speed based on the desired speeds
specified by the customer at the time the order is placed.
DRIVE CONTROLLER PROGRAMMING
Gorbel pre-programs a number of parameters in the drive controller prior to shipment. The
remaining parameters are left at the factory default settings. All parameters are stored on the
EPM module. These parameters are as follows:
Preset speeds 2 & 3 are used only if required for two or three speed drives.
Parameter 50 contains the fault history of the last eight (8) faults with the most recent first.
Pressing the “Mode” button three times will access this parameter.
Deceleration time: The deceleration time is factory set at 4 seconds. This can be adjusted to a
shorter time period with the following warning. If the deceleration time is set to too short a time
period, the drive controller will shut down and show an alarm. This is the result of the jib crane
having too much inertia for the reducer and motor to stop in such a short time. If this occurs,
increase the deceleration time.
WARNING
Do not remove or install the EPM module while power is applied to the drive controller. After removing power from
the drive controller, wait three (3) minutes before removing the EPM module for the capacitors to discharge.
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NOTE: The two or three speed options listed above consist of two or three pre-set speeds, they are not
infinitely variable during use.
Parameter # Name - SCL/SLM Drive Name - SCF Drive New Value - (Setting)
1Line Voltage Line Voltage High or Low (see manual) - (01)
4Stop Method Stop Method Ramp to stop - (03)
5Standard Speed Source Standard Speed Source Preset speed - (02)
10 TB-13A Function Select TB-13A Function Select Run reverse - (06)
11 TB-13B Function Select TB-13B Function Select Preset speed - (04)
12 TB-13E Function Select TB-13C Function Select Preset speed - (04)
17 Rotation Rotation Forward and Reverse - (02)
19 Acceleration Acceleration 4 seconds
20 Deceleration Deceleration 4 seconds
23 Minimum Frequency Minimum Frequency 0 Hz
24 Maximum Frequency Maximum Frequency 60 Hz
26 Motor Overload Motor Overload As required (see manual)
31 Preset Speed 1 Preset Speed 1 As required (0-60 Hz)
32 Preset Speed 2 Preset Speed 2 As required (0-60 Hz)
36 Preset Speed 3 Preset Speed 3 As required (0-60 Hz)

STEP 4 - LIMIT SWITCH INSTALLATION
If applicable, install limit switches per the following instructions and diagram 4A on page 8.
The limit switches are designed to shut off the power to the rotation drive motor in a clockwise or
counterclockwise direction and are not intended to serve as a spotting function.
Two limit switches are mounted on the channel attached to the main frame. Each switch has an
adjustable roller-type lever arm and is actuated by a limit switch ramp that must be attached to
the mast pipe. The limit switch ramps must be field located, by the installer, to shut off power at
the desired clockwise and counterclockwise points. The switches (optional) are pre-wired into
the control panel of the jib crane and require no additional electrical hook-up.
SWITCH ADJUSTMENT:
After the jib crane has been erected and the safety channel, with the two limit switches, has been
installed, the switch set-up is as follows:
1. Loosen the hex socket screw that locks the adjustable lever arm in position.
2. Loosen the lock pin hex nut that fastens the lever arm assembly to the limit switch.
3. Rotate the lever arm until it is perpendicular to the face of the mast pipe and then rotate it an
additional 15° away from the side that will contact the limit switch ramp (15° counterclockwise
for the upper limit switch and 15° clockwise for the lower limit switch). The additional 15° will
prevent jamming of the lever arm when the lever arm contacts the limit switch ramp.
4. Adjust the roller so that it has a 1/8” maximum clearance to the face of the mast pipe.
5. Retighten both the hex socket screw and the lock pin hex nut.
6. Rotate the jib crane 360° and check to see if the roller comes in contact with the mast pipe.
If the roller contacts the mast pipe, increase the clearance between the roller and the pipe
until it does not.
7. Repeat this procedure for the second limit switch.
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STEP 4 - LIMIT SWITCH INSTALLATION (CONTINUED)
RAMP INSTALLATION:
Two rotation limits can be established, one in the clockwise direction and one in the counter-
clockwise direction. The lower switch will be the clockwise rotation limit switch and the upper
switch will be the counterclockwise rotation limit switch. Do not reverse the functions of the
upper and lower limit switches. Reversing the functions may cause the limit switch lever arm
to hit the limit switch mounting bracket.
Clockwise Rotation Limit Switch Ramp Installation:
1. Place the jib in its’ clockwise limit position.
2. Position a limit switch ramp, with the beveled edge facing the switch lever arm roller, on the
mast pipe to the left of the lower switch.
3. Slide the limit switch ramp along the surface of the mast pipe, into the roller lever arm
causing the lever arm to move. Stop moving the ramp when an audible click is heard from
the switch.
4. Drill and tap two (2) 1/4”-20 holes in the mast pipe centered in the two slots in the limit switch
ramp.
5. Secure the limit switch ramp to the mast pipe using the (2) tapped holes and the 1/4”-20
hardware provided.
6. Adjust the limit switch ramp location to compensate for over travel (see the over travel
adjustment instructions on page 8.
Counterclockwise Rotation Limit Switch Ramp Installation:
1. Place the jib in its’ counterclockwise limit position.
2. Position a limit switch ramp, with the beveled edge facing the switch lever arm roller, on the
mast pipe to the right of the upper switch.
3. Repeat Steps 3 through 6 from “Clockwise Rotation Limit Switch Ramp Installation”
instructions.
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STEP 4 - LIMIT SWITCH INSTALLATION (CONTINUED)
Over Travel Adjustment Instructions:
All cranes will experience some over travel, after power to the drive is shut off, due to inertia of
the load acquired during rotation. The amount of over travel is dependent on the application and
the size of the jib crane. In order to accurately compensate for over travel, it is necessary to test
the rotation performance of the jib under full load and determine the actual over travel.
1. With the hoist at the end of the boom, lift a capacity load up one half the distance from the
floor to the hoist.
2. Push the “ON” button to power controls.
3. Start rotating jib crane in the direction of the previously installed limit switch ramp. It is
important to give the jib crane enough
starting distance before the ramp to
accelerate to full speed.
4. When the limit switch reaches the
desired rotation limit position, the lever
arm will contact the ramp and the
power to the motor will be shut off.
Allow the jib crane to come to a full
stop.
5. Measure the distance between the
beveled edge of the ramp and the
centerline of the roller on the switch
arm.
6. Loosen the 1/4”-20 hardware holding
the limit switch ramp to the mast pipe
and slide the ramp towards the lever
arm roller the distance measured in
Step 5.
7. Retighten the 1/4”-20 hardware to hold the limit switch ramp into place on the mast pipe.
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Diagram 4A. Limit Switch Installation