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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