IOMINI GRU SAS

“LIGHT CRANE SYSTEM”

INSTRUCTION MANUAL
INSTALLATION - USE - MAINTENANCE

File : IOMGRUCAN DOC. 200911-00

Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

“LIGHT CRANE SYSTEM” IDENTIFICATION DATA:

Manufacturer: Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI)

“Light crane system ” capacity :...250..kg., span : 2,1 m

Type:........KPS M B 20G................, Crane beam length : 2,6 m

Serial NO. :......180394............................ Year of manufacture :...2018

Manual code : IOMGRUCAN-ENG - Edizione 01 - 09.11 - Rev. 01.

“EC” marking : Affixed to the beam of the “ligth crane system”

CUSTOMER IDENTIFICATION DATA / INSTALLATION LOCATION:

Customer name and address :

Macchine installed at :

Place of installation :

ANNEXE:

 - Light crane system “EC” Declaration of Conformity

 - Assembly drawing
 - Drawing of suspensions runway/bridge crane
 - Drawing of suspensions bridge crane – detail
 - Drawing of suspensions runway – detail





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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

INDICE DEL CONTENUTO

1. - PRELIMINARY INFORMATION pag.. 4
- content and recipients of the manual pag.. 4
- key for reading the manual pag.. 4
- update of the manual - collaboration with the user pag.. 5
- adaptation to the Directives pag.. 5
- manufacturer's responsibility and warranty pag.. 5
2. - “LIGHT CRANE SYSTEM” pag.. 6
- intended use pag.. 6
- installation constraints pag.. 7
- the composition of the “Light crane system" pag.. 7
- technical information - employment criteria pag..11
3. - INSTALLATION INSTRUCTIONS pag..12
3.1 - PRELIMINARY INSTALLATION ACTIVITIES pag..12
- duties and responsibilities of the installer pag..12
- preparation of the installation site pag..13
- packaging, transport, unloading and handling pag..14
3.2 – MOUNTING THE “LIGHT CRANE SYSTEM” pag..16
- installation of the runways pag..16
- assembly the “Light crane system” pag..19
- assembly the trolley-hoist pag..22
- connection to the power supply network pag..22
- plate summary pag..23
3.3 – COMMISSIONING pag..24
- - adjustments, operation tests and crane test pag..24
3.4 – OTHER ACTIVITIES pag..28
- storage pag..28
- put back into service after storage pag..28
4. - USE AND MAINTENACE INSTRUCTIONS pag..29
4.1 – “LIGHT CRANE SYSTEM” FUNCTIONS pag..29
- intended use pag..29
- allowed and not allowed loads pag..30
- lifting accessories pag..30
4.2 - ENABLING pag..30
4.3 - OPERATIVITY pag..31
4.4 - DEACTIVATION pag..32
4.5 - WHAT TO DO ALWAYS! pag..33
- intended use, criteria and precautions for use pag..33
4.6 - WHAT NOT NEVER TO DO! pag..35
- unintended use, unauthorized use pag..35
-- foreseeable and unpredictable use pag..35
- contraindications for use pag..35
4.7 - MAINTENANCE pag..37
- ordinary / periodic maintenance pag..37
- periodicity and deadlines pag..40
4.8 - CLEANING – LUBRICATION pag..41
4.9 - TROUBLES AND REMEDIES pag..42
- main malfunctions or faults and possible remedies pag..42
- authorized personnel pag..42
- putting out of service pag..42
4.10 - DISPOSAL / SCRAPPING pag..42
5. - SPARE PARTS pag..43
6. - CONTROL REGISTER pag..43

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

1. - PRELIMINARY INFORMATION

Content and recipients of the manual

§ This technical publication, distinguished by the JOMGRUCAN-ENG - Edizione 01 - 09.11. - Rev. 01,
refers to "Light crane system" built by the company:

Iomini gru
Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI)
tel. 0331.880366 – fax. 0331.883410

§ It is related to their "intended use", their functional and performance technical characteristics and the
relative installation, use and maintenance instructions. It is aimed at:
• to the manager of the factory, the workshop, the site
• to operators involved in transport, handling and installation (as foreseen)
• to operators using the crane
• to the personnel in charge of maintenance
§ The manual must be kept by a responsible person for the purpose intended, in a suitable place, so that
it is always available for consultation in the best state of conservation.
§ In case of loss or deterioration, the replacement documentation must be requested, quoting the code of
this manual, directly to the manufacturer.

The manufacturer reserves the material and intellectual property of this publication
and forbids the disclosure and duplication, even partial, without prior written consent.

Key for reading the manual

§ Some symbols are used in this manual to draw the reader's attention and underline some particularly
important aspects of the discussion.
The following table shows the list and the meaning of the symbols used in the manual.

SYMBOL MEANNING EXPLANATION, ADVICE, NOTES

• Indicates a danger with risk of injury, even fatal.
• Failure to observe the instructions marked with this
DANGER symbol may result in a situation of serious danger to
the safety of the operator and / or exposed persons!
• Scrupulously comply with what is indicated!
• It represents a note of attention of possible
deterioration of the machine or another personal
CAUTION object of the operator.
• Important warning to pay close attention to.

ATTENTION • Indicates a warning or note about key features or

NOTE useful information.

A stylized eye can indicate to the reader that:

• VISUAL • It must proceed to a visual observation.
OBSERVATION
• It must proceed in the operating sequence
• ACTION TO BE
• It is required to read a measurement value, to
CARRIED OUT
check a signal, etc.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

Update of the manual - collaboration with the user

§ The manual reflects the state of the art when the “Light crane system” is placed on the market and is an
integral part of it.
§ Any changes, adjustments, improvements etc. that they were made to the cranes marketed
subsequently do not oblige the manufacturer to intervene on the material supplied previously nor to
consider the same and the related manual deficient and inadequate.
§ Any additions to the manual that the manufacturer deems appropriate to send to users must be kept
together with the manual of which they will be an integral part.
§ The manufacturer is available to his customers to provide further information and to consider
suggestions for improvement of this manual.
§ In case of transfer of the bridge crane in "canal" the primary user is invited to inform the manufacturer of
the new user's address so that it can be reached with any communications and / or updates deemed
indispensable.

Adaptation to the Directives

The “Light crane system” in the duct covered by this publication, are accompanied by the "CE"
Declaration of Conformity, are designed and produced in consideration and in order to meet all the
requirements imposed by the "Essential Safety Requirements" of the Community Directive
2006/42/EC, called the Machinery Directive. All the parts that make up the cranes are adequate to the
requirements of the Machinery Directive and the "CE" marking demonstrates its conformity.
Furthermore, the design and construction of the cranes is carried out in consideration of the requirements
imposed by all the Community Directives which involve the "CE" marking. In particular, electrical
equipment takes into account the Low Voltage Directive 2006/95/EC and the Electromagnetic
Compatibility Directive (EMC) 2004/108/EC.
This documentation, the original text of which is written in Italian, is written in consideration of the
harmonized standard EN ISO 12100 - 2nd part - chapter 6 and the requirements imposed by Directive
2006/42/EC, referred to the essential requirements of security 1.7.4 and 4.4.2. of Annex I

Manufacturer's responsibility and warranty

§ With reference to what is reported in this manual the IOMINI GRU company declines all responsibility
in case of:
* contrary use of the crane to the national laws on safety and accident prevention
* incorrect preparation of the building site and of the structures on which the crane is intended to operate
* voltage and power supply faults
* missing or incorrect compliance with the instructions provided in this manual
* unauthorized modifications to the machine
* use by untrained or unsuitable personnel
§ In order to benefit from the guarantee provided by the manufacturer, the customer must scrupulously
observe the instructions indicated in the manual and in particular:
* always operate within the limits of use of the machine
* always carry out a constant diligent maintenance
* use crane operators with proven skills for the purpose properly trained
* use only original spare parts specified by the manufacturer

* The intended use and configuration of the crane are the only ones allowed.
* Do not attempt to use the same in disagreement with the instructions provided.
* The instructions in this manual do not replace but summarize the obligations for
compliance with the current legislation on safety and accident prevention
regulations

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

2. – “LIGHT CRANE SYSTEM”

intended use
§ The single girder “Light crane system”, are made for the movement of goods inside the factory or in a
building site. The cranes lift the load vertically in space, using the hook of the lifting unit (electric or
manual chain hoist) and by means of accessories suitable for this operation.
§ The load can be moved manually, pushed, along the transverse and longitudinal axes of the bridge, by
means of hoist-carrying trolleys and bridge-holders sliding inside a special "profile" section bar.
§ The bridge cranes slide manually suspended on runways, also made of beam with special profile in
"canal", positioned at a height with respect to the ground, which therefore remains entirely free and
available for production activities. The runways are generally suspended from the supporting structure by
means of adjustable tie-rod suspensions and traverses with clamps (fig.1).
.

Legend:

1. main girder
2. hoist-holder translation unit ( hand-push trolley)
3. end caps with bumper
4. end-stop for travel limitation
5. bridge-holder sliding unit ( hand-push trolleys)
6. suspension brackets
7. spherical joint
8. Light crane system runways
9. joints
10. anticollision
11. threaded rod
12. level regulator
13. fixing crosspiece with clamps
14. lifting unit ( electric, manual or pneumatic chain hoist)
15. festoon electric system (if equipped with an electric hoist)

fig.1

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

Installation constraints
§ The “light crane system” and the relative runways are designed to be constrained, generally with
oscillating suspensions that avoid hyperstatic knots, to an existing structure (pillars, walls, ceilings, load-
bearing beams, trusses, machine bodies, etc.) through a system of brackets and tie-rods or with fixing
screws or, after verification, with expansion bolts or chemical bolts.

The customer is obliged to verify, directly or through specialized personnel in a

professionally competent and specifically appointed field, the suitability and adequacy
of the supporting structures, as well as the relative fixing surfaces of the suspensions,
which must guarantee the stability and safety of the cranes in all operating conditions,
withstanding the stresses and dynamic effects that derive from them.

The composition of the “Light crane system"

§ The “Light crane system” is used mainly to handle small loads of up to 1000 kg, as it can be manually
moved without excessive effort, generally using the electric or manual chain hoist as a lifting unit.
The hoist is suspended from the hoist trolley that runs inside the beam profile of the bridge.

§ The modular components, through a limited number of elements that make up the composition of the
“Light crane system”, for its simplicity, allows any non-professional installer to "assemble himself" with
ease and safety , multiple configurations of lifting systems included in the following limits of use:
• “Light crane system from 125 to 1000 kg, with suspension wheelbase and gauges up to 8 m.

§ These elements form the basis of a modular, easy-to-assemble modular system for rapid assembly.
The operations of installation, reconfiguration with the eventual integration of further elements and / or the
transfer of the realized systems are carried out, following the instructions contained in this manual and
acting only on bolted joints, thus excluding any welding operations.

§ The composition of the “Light crane system” is extremely simple being able to identify, the structure
constituted by the supporting beam, the lifting unit consisting of a chain hoist (electric or by hand), the
translating and sliding units formed from hoist and bridge-holder trolleys, a series of accessories (support
brackets, tie-rods, electrical system, etc.).

§ The structure and modular components: -ref. from -1- to -17- (fig.1)
• The structure of the single-girder “Light crane system” consists of a main beam -1-, made by a special
profile section (fig.2) in pressed or rolled steel sheet.
• In relation to the capacity and the span of the crane to be built, there are two construction sizes (P - G)
of a special profile section and the size (G) can also be made in reinforced (GR). They are available in
bars of lengths and cut-outs (from 2 to 8 m).
• The technical-dimensional features of the various elements in special profile are shown in the table
(fig.3)
• Inside the special profile, on the lower wings, the translation unit consisting in a hand-push trolley -2-
• At the end of the main beam, the closing covers -3- equipped with elastic rubber buffers, are bolted with
high strength bolts, with the function of limit switches towards the hoist-carrying trolley are positioned by
means of high-strength bolted joints. In the case of use with an electric hoist, fed with festooned cable
sliding inside the profile section of the beam, it is necessary, when the excessive accumulation of the
slides or of the nozzle trolleys at the end of the beam makes it appropriate, use the catch - run and field
limiters -4-.
• The beam is connected to and suspended from the sliding units made up of the bridge trolleys -5-, by
means of special suspension brackets -6- equipped with a spherical joint -7- and fixed to each other with
high strength bolts.

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• The runways -8-, are made up of the same types of special profiles that make up the main beam of
the bridge and are chosen in relation to the forces due to the loads to be moved and to the
suspension step.
• The head junctions, necessary to give an adequate and secure contiguity to the bars of the different
sections of the special profile elements constituting the runways, are made by high-strength bolted
joints that connect the junction pipes together -9- specially welded to the ends of the profiles
themselves.
• The welded pipes -9- also act, as in the case of the bridge beam, as a jointing element towards the
closing covers with buffer -3- which are positioned on the terminal ends of the special profiles
constituting the runways.
• To delimit or partialize any areas of use or influence of one or more bridge cranes in the runways,
along the runways, the stop-limiter for travel and field -4- can be used, which is fixed to the special
profiles of the runways by means of screws and related safety nuts.
• When several bridge cranes can operate on the same runway, an anti-collision system -10- must be
installed, mutually, between one crane and the other to avoid that, during the sliding, the cranes
themselves or their load transported. generating dangerous situations for exposed people. The length
of the anti-collision reciprocal devices -10- must be arranged in consideration of the bulkiness of the
transported masses and of the distance that must be imposed to the sliding carriages of the bridges.
This in relation to the range of the runway and the relative suspensions and due to the concentration
of the reactions on the wheels of the carriages acting on the runways themselves.
• The suspension of the runways are made with the use of the same brackets -6- that are used to
suspend the crane beam, while the spherical-male-female joints -7-, allow the oscillating connection,
through the threaded rod -11- and any flatness regulator -12-, between the suspension bracket and
the crosspiece with clamps fixing to the support structure -13-.
• In the construction of the structures, quality steels are used in order to ensure optimal safety
conditions and operational reliability of the entire lifting system.

§ Painting and surface treatments:

• All the parts that make up the metal structure of the bridge crane and the runways are subjected to a
mechanical brushing treatment, to remove any traces of oxidation and chemical degreasing of the
surfaces. The subsequent painting cycle involves the application of a thickness of anti-rust and a
finishing coat of anticorrosive enamel, yellow RAL 1007 to preserve the parts from atmospheric
agents and abrasions.
• On request, according to agreements (see order confirmation), "suspended" bridge cranes are
supplied subjected to SA 2 1/2 sandblasting cycle and with painting cycle with special colors and
varnishes.
• On request, suspension accessories and machined tool parts (brackets, tie rods, bolts, articulated
bulb heads, etc.) are protected against atmospheric agents by a galvanizing anodizing treatment of
"yellow zinc coating".

§ Translation and sliding units : -2- / -4-

• The translation and sliding units are made up of pushed trolleys, that, in relation to the section and
the size of special profile in “canal” used as well as the expected capacity, can be simple or double,
combined to each other to connecting crosspiece. Each pushed trolleys for “canal” is equipped with
four swivel steel wheels on ball bearings with a permanent lubrication. The carriages slide on the
lower wings of the same inside the profile in “canal” and are equipped with particular guide rollers to
avoid any sliding contacts between the edges of the beam slit and the trolley structure. The load-
bearing structure is made of press-formed sheet steel and offers the housing and relative holes to
allow, through a special carbon steel pin, the oscillating connection with the eyebolt of the hoist
and/or the articulated spherical heads of the bridge. The carriages are equipped with strikers that,
placed in contrast with the rubber buffers of the covers or of the stroke limiters, have the function of
delimiting the transversal and longitudinal movements ensuring maximum operational safety.

§ Lifting unit : -14-

• The light crane system with the profile “in canal” beam can be equipped with either an electric chain
hoist or a manual chain hoist.

The tackle’s/carriage’s descriptions and features, installed on the light crane system
are contained in relative instructions for use attached to this publication

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

§ Electrical system : -15-

• It’s realized to tackle’s power, when the same is in electric version, that slides transversely on the
bridge’s tackle with the carriage and longitudinally on bridge along the runways.
• The electrical supply system is realized to the use of festoon cable type of non-propagating flame,
generally of lat shape, sliding on special trolleys or slides that run along the entire length of bridge
beam and, when provided, of the runways, inserted inside the same special profile or on appropriate
binary.
• The supply line of the runways, in some cases very long lines, with bridge cranes mounted on the
same line, etc. can be made in "blind-trolley" with a trolley with a current roller of current outlet pulled
directly from the bridge.
• It’s provided the supply of a junction box that has been installed on terminal head on one of two
runways for the connection between the power line coming from the user-supplied
switch/disconnection, and the power festoon (or the “blind-trolley”) of the same runways. It can be
supplied a second junction box for request, for the special connection between the supply line of
runways and the tackle’s power festoon along the hoist of the bridge.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

PLANT LIGHT CRANE SYSTEM

fig.3

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

Technical Information – Employment criteria

§ Normative Requirements:
The design and construction of IOMINI GRU bridge cranes, in “light crane system” is made in
compliance with the following legislative/regulatory framework:
* Community directives:
Directive 2006/42/CE related to “Machines”.
Directive 2006/95/CE (ex 73/23/CEE) "Electrical equipment in low voltage".
Directive 2004/108/CE "Electromagnetic Compatibility ".
* Principal standards and rules considered:
EN ISO 12100:2005 parts: 1a and 2a “Basic concepts general principles of design”
EN 60204-32:2006 “Safety of the equipment about the lifting machines”
EN 60529:1992 “Grades of wrappers protection (codes IP)”
ISO 4301-1:1986 “Lifting devices. Classification. Generality”
FEM 1.001/98 “Calculation of lifting devices”
FEM 9.755/93 “Safe working periods”

§ Environmental conditions of employment:

Operating temperature: minimum -10 ° C; maximum + 40 ° C - Maximum relative humidity: 80%
§ Protections and insulation of electrical parts:
Junction boxes: IP54 protection - Voltage max. of insulation 500 V
Cables : CEI 20/22 - Voltage max. of insulation450/750 V

§ Electric power:
The IOMINI GRU “light crane system” is provided to be powered with electric current alternated
with three-phase voltage of: 400 V +/- 10% (min. 360 V; max. 440V) - 50Hz.

§ Employment criteria:
One of the necessary conditions to get the full functional correspondence of the “light crane system”,
to the service it is intended for as well as its optimal and long-lasting operation, consists in the right
choice of the machine model. This choice has to verify in according to the actual services requested
as well as the environmental conditions where the crane will have to operate.
For the choice about “the light crane system”, there are parameters that must be carefully considered,
which are:
• The flow rate: it must always be higher than the sum of the weights of the maximum load to lift and
the lifting accessories (balancers, pliers, suction cups, magnets, etc.).
• The functional dimensions: the height of the sliding beam of the trolley that determines the run of
the hoist’s hook, the gauge of the crane, the length of the runways and the step of the suspension
of the same, must be selected so as to ensure coverage functional of the space to be ensured in
consideration of the surrounding encumbrances.
• The nature of the cargo: delicate or not, it determines the choice about the most appropriate
speed thanks to its placement. In some cases is necessary to use two-speed hoists with a slow
positioning speed.
• The area of use: the “light crane system", as a type of light crane and with limited structure ,is
featured by, as its conception, intrinsic high elasticity that becomes even more evident when it is
used for movements with loads close to the maximum capacity and / or concentrated at the center
of the bays.
• The environment of use: the light cranes system " are provided for service inside and/or e/o
covered environment, repaired from the elements and in the absence of wind. In the case of use
on the outside, appropriate measures must be provided in relation to the surface treatment
(sandblasting-painting) as well as, in relation to their " dexterity ", the stopping of the parking
against the wind effect.
• The frequency of use: If the use is very high (frequent and/or repeated maneuvres With loads
coming at the maximum range o with the use on strokes of very long runways, the consequent
fatigue of the operator dued to the manual movements must be considered.

The correct evaluation of the above parameters indicated, can lead, if the same should
be close to the limit values, The need for the use of a crane with higher performance
features that, when will be downgraded, can be agree a major rigidity and less
translation and sliding efforts.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

3. - INSTALLATION INSTRUCTIONS

• The light cranes system, are delivered non assembled, in their principal part like
the suspensions, the raceways, the bridge, the electrical system and, the part of
the supply, the lifting unit. If the installation is not carried out by the manufacturer,
the purchaser must therefore proceed to the installation phases of light crane
system, following the instructions contained in the present chapter, possibly, the
assembly, and specialized installers.

3.1- PRELIMINARY INSTALLATION ACTIVITIES

Duties and responsibilities of the installer

• The installation of the light crane system, for importance of operation, can involve,
if not properly executed, serious risks to the safety of the exposed people both
during assembly and in the subsequent use of the crane. Therefore, if it is not
executed by the manufacturer, it must be entrusted to installers specialised in
installations of industrial plants. Lifting and elevation operations parts of crane
have to be effected by installers equipped with:
• personal protective equipment (e.g. helmet, gloves, safety belts, etc.) adequate
and suitable for
• equipment (e.g. forklift, scaffolding, etc.) suitable for the purpose
• And following a careful evaluation of these parameters:
• environmental characteristics of the workplace (e.g. trampling surface, etc.)
• height of the worktop in altitude with respect to the load plane
• dimensions and weight of the parts to be installed
• available spaces for moving parts to be installed

Before proceeding to the assembly of the parts and the installation of the light crane
system, the installer have make sure about the crane’s features, that they conform
what required and the use of which it is intended and in particular:

1. The range of the crane is  compared to the loads to be lifted.

2. The fastening structures (pillars, walls, ceilings, beams, trusses, machine bodies, etc.) have been
"Declared suitable" by the purchaser or by expert technicians, by the purchaser himself in charge.
3. The characteristics of the lifting unit (trolley/hoist), if not part of the supply, are compatible with those
of the bridge crane in "duct" in relation to:
• Range of hoist: it must be ≤ to the reach of the light crane system”.
• Weight of trolley/hoist: must be ≤ to the maximum required.
• Lifting/translating speed: must be ≤ with respect to the maximum permissible speeds.
• Dimensions/shape of the trolley/hoist: they must be ≤ to the maximum permissible.
• Reactions on the wheels of the trolley: they must be ≤ to the maximum permissible.

Following the installation activities about the light crane, it is the installer’s precise
task:

1. Conduct "commissioning" activities as described in paragraph 3.3;

2. Draw up the verbal of “Testing” and decide on the "suitability for use" about the light crane system

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Preparation of the installation site (curate by or in charge of the purchaser or installator)

Before the installation of the light crane system, executing these operations :

• Ensure the presence of the Declaration of suitability/adequacy of the support/fixing structures;

• Ensure the absence of obvious defects in the support/fixing structures; ( fig.4 )
• Check the suitability of the maneuver spaces available to the light crane system, especially if it
operates in areas where are others cranes or others machines;
• Verify the range of runways and structures when the crane is installed in addition to already existing
cranes and provide possible reciprocal anti-collision systems that confer to the crane adequate
distance;
• Verify the useless waste, which should be measured in at least three points of the shed (two close to
the ends and the last one in a central position);
• If the light crane system is equipped with electric hoist, verify the suitability and the correct operation
of the electric power mains:
1) correspondence of the voltage of the supply line with the voltage provided for the motors;
2) adequacy of the cable section of the power supply line;
3) presence and suitability of the grounding system;
• Prepare the masses for dynamic tests equal to: nominal flow for 1,1
• Prepare the masses for static tests equal to: nominal flow for 1,25
• Prepare the harness equipment and the lifting of masses for load tests;
• Verify the presence of signs that inform about the risks caused by crane handling;

• The fixing of the structures and the details of support and/or suspension through
bolts and plugs with expansion or chemical fixation, requires scrupulous
verification of suitability in relation to the type of support
• The verification of the suitability of these fastening are taken care and in charge of
the customer and they have to be conducting by expert technicals who decide the
feasibility and assume the relative responsibilities.

fig.4

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

Packaging, trasport, unloading and handling

At the reception of the supply check and make sure that:

• The shipping data (the recipient address, number of packaging, etc.) correspond to what is contained
in consignment documentations (delivery note and/or possible packing-list).
• The technical/legal documentation supplied with the light crane system includes:
• the manual of “Instructions for use” of the crane to be installed.
• the CE Declaration of Conformity or, alternatively, the Manufacturer's Declaration.
• the tackle’s/carriage’s instructions for use to be installed on the crane, if they are part of the supply.

Carry out a visual inspection of the goods before handling the load to make sure any
breakage or damage.

§ Packaging:

• The carpentry parts of the light crane system are generally supplied without packaging. The profile
bars in special profile can be supplied in loose packages or made of strat beams and, when
expected, the beam is equipped with wooden pinches.
• When necessary, the coupling point are indicated on the packages to facilitate handling during
transport and handling operations ( fig.5 ).
• A packaging is generally provided by cardboard boxes for the mechanical parts, the electric ones and
for the suspension accessories.
• The standard packaging is not waterproof against rain, is expected by land destinations and for
covered environment, but not by sea and for humid environment.
• Possible special waterproof packages can be prepared on request (in this case special instructions
will be delivered about their nature and disposal).
• The material, suitably conserved, can be stored for a period of about two years in covered
environments where the temperature is between -20 ° C and + 70 °c with relative humidity of 80%. A
specific package must be predisposed for different environmental conditions .
• Provide for the disposal of possible packages according to the regional laws on the subject in relation
to the nature of the same, after differentiated selection.
• To carry out the storage follow the instructions in Chapter 3.4 - OTHER ACTIVITIES-storage.

fig.5 fig.6

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§ Transport:

• The transport will be effected by qualified transporter able to guarantee the correct handling of the
transported material. The JOMINI GRU company assumes no responsibility in the case of transport
by the Customer or of transporters chosen by the same.
• Avoid overlying, during transport, weights and other possible parts of carpentry to the profiles in
special profile, which may be damaged ( fig.6 ).
• Provide a bounded and suitable area, with flooring or flat bottom, for unloading and ground mounting
of all the crane components. Open any packages from above and remove the various parts by lifting
them vertically after having them, if necessary, harness with care.
• Carry out a visual inspection of the goods to ascertain any breakage or damage.
• Check the integrity of the parts of the machine and that there is no shortage of accessories necessary
for installation (bolts, parts for the electrical system, etc.). Report the failings.
• Verify the documentation of the delivery note that identify, where necessary, alphabetically and/or
numerically each package, it shows the description, the quantity and specification, if necessary:
- the weight- the dimensions – the points of grip.
• Predispose the necessary unloading crane parts equipment taking account of the parameters
provided for each part or component (weight, dimensions, point of grip).
• Prepare adequate wooden cross of suitable dimensions to be placed below the carpentry packages
(canal, etc.) to move.
• For the unloading and handling of the crane and its parts don’t need special equipment
• The harness of the heavy packages can be carried out using chains, belts, ropes whose suitability
must be verified in relation to the load to be moved ( fig.7 ).
• The packages of mass less 30 kg don’t bear any indication of weight and can be handled by hand.
• Using suitable equipment lift the load vertically and move it in the area used for unloading taking care
to not cause fluctuations of the same during the displacement ( fig.8 ).

fig.7 fig.8

* In case of damage or missing parts, report the anomaly to the transporter, placing
a written reservation on the consignment note and giving a communication to
IOMINI GRU within eight days of receipt of goods.
* The IOMINI GRU company assumes no responsibility in the case of transport by
the Customer or of transporters chosen by the same.

* The horizontal structure of the structures guarantees maximum stability and must
be maintained at all stages of handling, transport and storage.
* It is prohibited to reverse or support the parts in a vertical position, except after
having suitably fixed them and/or having verified their stability.

Before having provided to unloading parts of light crane follow the instructions below
if it intends to proceed with the installation of the crane or see the instructions to
Chapter 3.4, if must carry out the storage.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

3.2 - MOUNTING THE “LIGHT CRANE SYSTEM”

Installation of the runways

• Before the installation runways suspensions of the light crane systems, being
necessary to the support structures and the fastening surfaces, are able to bear
the actions transmitted by the crane.
• The fixing must be made by the appropriate accessories (brackets, tie rods, bolts,
etc.) or, when expected and after having ascertained the suitability, by means of
expansion anchors or chemical fixation.

Suspensions and runways installation:

phase - 1 – run on the ground – on Work Bench

• Remove all the fixing components from the possible packaging and after having checked the integrity
and the functional and quantitative compliance, using the distinct of which Chapter 2 "The parts of the
light crane system" or the delivery note, place them on the Work Bench. When being part of supply,
perform the mounting of the clamping clamps (screw the nut on a few threads without tightening) on
the fixing bars ( fig.9 ). Insert in the appropriate seat on the cross (or on the suspension plate) the
female ball joint with threaded hole and, after having interposed the special spacers, insert the plug
that acts as a pin and tighten the safety locking nut moderately.
• After verifying the suitability of the threads and checking the length, assemble the threaded rods with
the relative nuts and washers and, when expected, with the flatness regulator ( fig.10 ).
• Assemble the suspension brackets inserting the female ball joint with the threaded hole in the special
seat and, after having interposed the appropriate spacers, insert the plug that acts as a pin without
fully tightening the self-locking nut for safety ( fig.11 ).
• Sometimes it can be expected, in particular when it comes to the need to contain the maximum
vertical footprint of the whole plant, the mounting on the suspension bracket of a spherical male joint
with a threaded portion in place of the female joint. In this case the function of the threaded fails and
the male joint must be screwed directly into the threaded hole of the female spherical joint mounted
on the crossbar. ( fig.12 ).
• Pull over without tightening the brackets clamping screw So that the two semi brackets are free to
divaricate to allow the introduction of the profile of the runways.

fig.9 fig.10

fig.11 fig.12

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Suspensions and runways installation:

phase - 2 – run at height, forklift and mobile scaffolding

• After having placed the suspension components ( crosses, straps and brackets ) on one pallet, raise
the same until reach the fixing fee of itself suspension, using the forklift and mobile scaffolding
properly chosen in relation to the height and the total mass to move.
• Operating from the plane at the height of the mobile scaffolding, provide to the fixing cross to the
structure tightening the clamps with a dynamometric wrench, with the appropriate nuts, according to
the tightening torque and according to the standard CNR UNI 10011/88 ( fig.13 ).
• Screw the threaded rod into the bore of the ball-head joint, checking that the threaded portion of the
rod, screwed on the body of the joint, is contained to the expected quota in the table ( fig.14 ).
• Assemble the suspension bracket on the tie rod by screwing the threaded bush of the ball-head joint
on the lower part of the threaded tie rod. Check that, even in this case, the threaded portion of the tie
rod, screwed into the body of the joint, is contained in the table ( fig.14 ). Fully tighten the anti-
unscrewing safety lock nut ( fig.15 ).
• After having assembled, in the same way as the description in the preceding points, all the threaded
suspensions, proceed to assemble the sections of the runways in special profile.
This operation can be effected by the using of a forklift or a mobile crane for lifting and by the using of
a mobile scaffolding for the mounting. The means must be appropriately chosen in relation to the
height and total mass to be handled.
• Place in barycentric equilibrium on a pallet and carefully sling the section of the profile using possibly
texting bands to avoid damaging the surface of the special profile, lift the same taking care to
unbalance not or to swing the mass dangerously, until to reach the connection dimension to the
suspension bracket.
• Connect the section of the runways with the corresponding brackets maintaining the profile
supported, from the lifting device (forklift or mobile crane) with which has been placed at altitude, as
long as there is not complete closure of the brackets and at the tightening of all the bolted joint,
without tightening too much to warp not the "channel" profile, which supports the runway. Then
remove the harnesses and lower the lifting medium releasing the suspended section of the special
profile.
• Proceed, with the same criterion, to the assembly of all the sections of profiles that make up the
runways connecting them, with the bolted joint through the pipes welded on the heads of the special
profile, taking care of respect the concomitances of the Numerations reported on the heads because
the sections were conjured during assembly and testing in the workshop (fig.16).

fig.13 fig.14

fig.15 fig.16

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• Carry out a verification of flatness of the runways using a level resting above the profile and, when
necessary, provide for the bubble by acting on the set threaded-joint with spherical head and/or,
when expected, on the flatness controller. Then ensure the final tightening of all the bolted joints,
taking care to cause not deformation of the profile .
In any planarity adjustment operations, check that the threaded portions in the grip of the tie rods
and/or in the male joints, inside the female sleeves, is always higher than delimited length by the
inspection hole.
• Mount the lids on one of the two ends of both runways, breaking free the other that will be used for
the insertion of head of the electric system to festoons, when expected, as well as the light crane
system

Runways electric power installation:

(if crane equipped of electrical utilities and if it’s part of supply)

§ The electric line power system that runs along the runways can, according to the cases, be made in
these three executions:
( 1 ) festoons sliding cable on slides within the same section of the runways in “special profile".
( 2 ) festoons Cable on carriages, sliding within track, parallel to the running road.
( 3 ) blind-trolley, placed laterally to runways, with power outlet.

§ Installation in executions ( 1 ) e ( 2 ):
• Exclusively in the case of ( 2 ) execution, sliding carriages in little binary, proceed to the assembly on
the running road of all the support and sliding components of the festoons, taking care to properly
counterweight the little binary to unbalance not the trim of runway in the special profile ( fig.17 ).
• Remove the cable and the trolleys or the slides from the possible packaging
• Insert the power cord into the slides or the cable trolleys so as to obtain a series of festoons of equal
width, and tighten it with the relative screws or saddles.
• Insert the slides or the carriages in the relatives sliding seats:
- profile of the beam rot in special profile of runways in the case of slides.
- appropriate binary places laterally to the runways in the case of carriages.
• Mount at the end of the runways, in the intended area, the junction box for connection to the power
line coming from the main switch.
• Connect the festoon power terminal to the clamp in the travel box.

§ Installation in execution ( 3 ):
• In the case of ( 3 ) execution, blind-trolley, proceed with the assembly of all the support components
of the power line on the runway according to the "special" instructions provided by the manufacturer
and attached to this publication, taking care to counterbalance the blind-trolley in an appropriate way
so as not to unbalance the layout of the “special profile” ( fig.18 ).

fig.17 fig.18

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

Assembly the “Light Crane System”

Mounting of bridge:
phase - 1 – run on the ground and on Work Bench

• Remove all the fixing components from the possible packaging and after having checked the
suitability and functional and quantitative response of it, using the distinct whose in Chapter 2 "the
parts of Light Crane System" or the delivery note, placed them on the Work Bench.
• Mount the suspension brackets inserting the complete spherical joint into the seat, male and female
and, after having interposed the appropriate spacers, insert the pin without completely tightening the
self-locking safety nut ( fig.19 ).
• Position the two suspension brackets on the beam of the bridge at a distance between them
corresponding to the measurement of the runways. Don’t tighten the joints but only fit the nuts so that
the brackets can easily be adapted to the gauge once the bridge is inserted in the runways ( fig.20 ).
• Remove the suspension pin from the sliding bridge carriages
• Insert the eyelet of the ball joint into the appropriate compartment of the carriage plate or into the
connecting crosspiece in case of use, respectively of a simple or double trolley and, after having
interposed the spacers, insert the pin and spread the edges of the safety pins ( fig.21 ).

fig.19 fig.20 fig.21

Mounting of bridge:
phase - 2 - run at altitude with forklift and mobile scaffolding

• The mounting operation in altitude can be effected by the using of a forklift or a mobile, for a lifting
operation and a mobile scaffolding for assembly.
The means must be chosen in relation to the height and the total mass to be moved.
• Position the barycentric balance on a pallet and carefully sling the bridge crane into a special profile
possibly using textile strips to avoid damaging the profile surfaces, lift it up taking care to unbalance
not or rock the mass dangerously, until reaching the connection altitude to the runways ( fig.22 ).

fig.22

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

• Operating for the trolleys centering from the height of the mobile scaffolding and making the
appropriate movements with the lifting device, insert the bridge carriages in the end of free profile of
runways, and put the corresponding closing cover in place ( fig.23 ).
• Tighten thoroughly the bracket fixing components, without deforming the slit of the profile where the
carriages slides, after having checked, if necessary arrested, the exact gauge in relation to the gauge
of runways
• When two or more bridge cranes are mounted on the same runways anti-collision devices must be
interposed between one crane and another ( fig.24 ) or, when expected, the field limiters ( fig.25 ).
In these cases, the relative supply systems must be set up so that they can flow and feed the cranes
completely independently of each other ( fig.26 ).

fig.23

fig.24

fig.25

fig.26

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

Mounting bridge electric power:

(if the crane is equipped with electrical utilities)

• The supply electric power of the possible electric hoist that runs, transversely to the runways, along
the bridge beam it is generally produced as standard with the use of a festooned flat cable sliding on
slides within the same section of the beam in special profile.
• In relation to supply system typology of runways, the bridge electric supply can be realized in blindo-
trolley, in this case the festoon supply of bridge achieved in flat cable connects itself directly to the
clamps of the trolley line in the blind-trolley that feeds the runways ( fig.27 ), or it can be made up, in
the case of in cable festoon line, of the supply cable itself of runways which, seamless, transits
directly from the runways to the beam of the light crane system ( fig.28 ).

fig.27 fig.28

• Remove the cable (when it’s not the same that feeds the runways) and the cable holder slides from
the possible packaging.
• Insert the supply cable into the cable holder slides in order to obtain a series of festoon of equal
width, and tightens it with the relative screws.
• Insert the slides in the relative sliding seat made up of the section of the beam in special profile.
• When the supply line of runways is realized in the blind-trolley, when expected, mount the junction
box for the connection with the supply line on the bridge beam, in areas designed for this purpose,
and, when expected, the towing arm of the trolley of current outlet with sliding skates.
• Connect the cable terminals, festooned comes from bridge and supply beam coming from the
runway, to the clamp contained in the junction box, if expected, placed on special profile beam of the
bridge.

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Assembly the trolley-hoist

Consult to also the instructions of use manual of chain hoist with trolley, attached to
this publication.

Assembly the trolley-hoist:

phase - 1 – run on the ground on a work bench

• Remove the forelock and slip the suspension pin of the holder hoist translation trolley.
• Insert the hoist suspension eyebolt in the appropriate compartment of the plate or in the connecting
cross in the case of use, respectively, of a simple or double trolley.
• Remount the pin, replace the forelock and divaricate on it the two lembs of safety ( fig.29 ).

Assembly the trolley-hoist:

phase - 2 – run at altitude with forklift and mobile scaffolding

• After having placed the hoist-trolley group on a pallet, lift to the same until to reach the entry head
altitude of the bridge using of the forklift and the mobile scaffolding adequately chosen in relation to
the height and the total mass to be moved.
• Operating from the height plan of the mobile scaffolding, insert the preassembled group to the
channel and put the closing cover in place, then tighten the fixing components ( fig.30 ).
• If the crane is equipped with electric hoist, execute the connecting of the cable supply line festooned
a sliding along the bridge beam in terminal of the electrical equipment hoist as described in the
instructions of use and maintenance manual attached.

fig.29 fig.30

Connection to the power supply network

If the crane is equipped with electrical utilities, the purchaser must prepared a general
line disconnector of magnetothermal type or protect with fuses and report its function
through special plate, install the switch in the immediate nearness of the crane, that it
will be connected to power supply network through certified plant in accordance the
law 46/90.

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Plate summary
§ Types of plates:
• manufacturer's nameplate and "CE" marking when required (*) -
• license plate.

§ Readability and storage of the plates

* The plates must ever being conserved readable relatively to all datas providing for periodically to their
clear.
So far as a plate deteriorates and / or has been not legible yet, also in only one of the informative
elements reported, it is recommended to request another one to the builder citing the data contained
at the presence manual and provide for its replacement.

(*)
When the Light Crane System is supplied without the lifting unit (hoist) the
plate crane data is devoiced of marking CE


The plates must being ever removed is absolutely forbidden to affix other plates on
the crane without the preventive authorization by the builder.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

3.3 - COMMISSIONING

Adjustments, operation testes and crane test

Preliminary controls on electric power (for crane equipped with electrical hoist)

• Verify that the voltage line corresponds to that provided for that for the crane operation
• Verify that the voltage value to clamps of junction box is within the limits of di +/- 10% of the nominal
value
• Proceed to the operation check verifying, in the way described below, the correct rotation sense of
motors:
• Operate for short distances, taking care of do not intervene possible switches, “up-down” hoist
buttons and check that the hook movements correspond with that indicated on the buttons.
• If the movement direction doesn’t correspond to indications of pushbutton, stop the movement and
reverse the two phase connection in the supply box placed on the crane.

If the rotation sense of the hoist motor is not accorded with the indicators of
pushbutton, the possible electric switches, when installed, don’t stop the movement, it
is therefore possible to determine dangerous situations

Adjustments: (for crane equipped with electrical hoist)

• Ensure that all operations, electrically controller, execute the required movement through relative
indicator of pushbutton.
• The automatic switches buttons are emergency devices that can’t be subjected to usual operation. If
exists this necessity, others buttons of additional switches for continuous service must being installed
arranged so that they act in advance of the security ones.
• Regular the switch of the lifting group. Consult to information about the manual’s instructions of
electrical hoist installed on the crane.
• The switch’s up position has been predetermined for allow the maximum possible race.
• The switch’s down must being regulated in order to the hook, in its lower point, be at least about 30
cm from the ground.
•
Consult to also manual’s instructions for use of the chain hoist with carriage, to this
publication attached.

Adjustments: (fro crane equipped with electrical hoist or hand hoist)

• Regular the race of translation movements or the anti-collision devices to avoid contacts or damages.
• Check the uniform sliding sensitivity of the trolley and the bridge throughout their excursion; verify the
absence of obstacles throughout the cover area from the service of crane.

• Ensure that the noises and/or abnormal vibrations are not heard and incorrect
movements of machine and its parts are not found during the movements
• Check the tightness of all bolted joints after the first lifting operations

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

Light crane system test- Suitability of work

• The light crane system is launched on market in consideration of that conducted

tests at the builder on similar prototypes subjected, in the structural parts
(suspensions, runways, bridge beam, etc.), to the control of suitability of themselves.
• The operation of test, described below, is related to verification compliance,
functional and performance, of the “light crane system”, installed in its place of use,
complete in throughout its parts (fixings, structure, lifting unit, lifting accessories, etc..).
• The crane installed test is take care and in charged of the final user and must being
conducted to the same specialized personnel (installer) that will be executed the
assembly, scrupulously following the instructions in this manual.
• The installer must perform the test and draw up a "Test report" and a certificate of
"Suitability for use".

§ After having executed the functional “empty” tests, execute the dynamic tests; they are effected with
masses of value corresponding to the capacity of the crane plate increased by the overload coefficient 1,1
(load equal to al 110% of the nominal value). Static tests are carried out with an overload coefficient 1,25
(load equal to 125% of the nominal value).

All proofs must being executed in absence of wind

Proceed with the “light crane system” test in this way:

§ “Empty” tests:

• Crane equipped with electrical hoist:

• enable the functions of the crane
• activate the general switch line
• put the emergency stop button of the pushbutton in the "traveling consensus" position
• press the "run / alarm" button, if available on the hoist pushbutton
• check the lifting operation pressing the "up and down" buttons of the pushbutton
(In the case of two-speed movements, verify its functionality)
• check the operation of the trolley and the push bridge by hand action
• check switches operations of all movements and of the friction device, when available

• Crane equipped with hand hoist:

• verification of the correct sliding of lifting chains and the maneuvering hoist by hand
• verification of the carriage operation and the push bridge by hand action
• verification of the switches operation of all the movements

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§ Dynamic proof:

• Crane equipped with electrical hoist:

• predispose adequate masses for load tests equal to: nominal flow x 1,1 and suitable equipment
for harnessing and lifting
• harness the load placing the hook on the vertical of the load of its to avoid oblique pulls
• put the harness slowly in tension to not generate rips
• execute the load proofs using the “slow” speed, if available
• lift slowly the load and verify that this happens without difficulties, abnormal noises, obvious
permanent deformations or sagging of the supporting structure and / or anchors are not heard
• repeat the test at maximum speed performing the previous controls
• verify the electric switches of “up and down” operation, when installed, and/or of the possible
friction device
• verify the brake function, checking that the mass is braked in adequate time and there aren’t load
slips, after having released the button
• verify the mechanical switches of “right and left” and “back and forth” moving the push mass
without bringing it to its maximum height (lift half a meter above the ground)
• first operate to slow speed, if available, and following at maximum speed
• verify the correct carriages lifting on the beam and ensure themselves that abnormal noises are
not heard, obvious permanent deformations or sagging of the supporting structure and / or
anchors
• verify the load limiter operation, if
• check the breaking and the stopping spaces during the lifting, translation and rotation
movements, verifying the stability of mass after having suspended the relative actions of
movements,

• Crane equipped with hand hoist:

• predispose adequate masses for load tests equal to: nominal flow x 1,1 and suitable equipment
for harnessing and lifting
• harness the load placing the hook on the vertical of the load of its to avoid oblique pulls
• lift the load and verify that this happens without difficulties, abnormal noises, obvious permanent
deformations or sagging of the supporting structure and / or anchors are not heard
• verify the brake function, checking that the mass is braked in adequate time and there aren’t load
slips
• verify the mechanical switches of “right and left” and “back and forth” moving the push mass
without bringing it to its maximum height (lift half a meter above the ground)
• verify the correct carriages lifting on the beam and ensure themselves that abnormal noises,
obvious permanent deformations or sagging of the supporting structure and / or anchors are not
heard
• check the breaking and the stopping spaces during the lifting, translation and rotation
movements, verifying the stability of mass after having suspended the relative actions of
movements,

Dynamic tests must be carried out under the most unfavorable load conditions, that is
combining the movements of lifting, translation and bridge sliding.

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§ Static proof:

• Crane equipped with electrical hoist:

• predispose adequate masses for load tests equal to: nominal flow x 1,25 and suitable
equipment for harnessing and lifting
• harness the load placing the hook on the vertical of the load of its to avoid oblique pulls
• put the harness slowly in tension to not generate rips
• execute the load proofs using the “slow” speed, if available
• lift slowly the load and verify that this happens without difficulties, abnormal noises, obvious
permanent deformations or sagging of the supporting structure and / or anchors are not heard
• stopped it in suspended position, for 10 minutes and not a less time, at a height of 10/20 cm
• verify that the suspended mass doesn’t fall down (the lifting brake and the load’s fiction/limiter
device, if installed, mustn’t slide) and are not found obvious permanent deformations or sagging
of the supporting structure and / or anchors are not heard

• Crane equipped with hand hoist:

• predispose adequate masses for load tests equal to: nominal flow x 1,25 and suitable
equipment for harnessing and lifting
• harness the load placing the hook on the vertical of the load of its to avoid oblique pulls
• lift the load and verify that this happens without difficulties, abnormal noises, obvious permanent
deformations or sagging of the supporting structure and / or anchors are not heard
• stopped it in suspended position, for 10 minutes and not a less time, at a height of 10/20 cm
• verify that the suspended mass doesn’t fall down (the brake mustn’t slide) and are not found
obvious permanent deformations or sagging of the supporting structure and / or anchors are not
heard

• Any movements of the mustn’t be activated during the statistic proofs

• The “light crane system” test must be repeated during the annual checks
• The annual checks results must be annotated on the control register (to be created
and drawn up by the customer).

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

3.4 – OTHER ACTIVITIES

Storage

Before proceeding to the storage verify that:

• There is no damage to the mechanisms, to the possible eletric power, to the lifting, translation and
sliding unit, to the supporting beam, to the canalines of runways and to the relative suspensions
accessories and avoid to scratch the surfaces of the structures.
• The materials are intended for indoor or outdoor installation, can be stocked until to a maximum
period of two years, in environment that owned there characteristics:
• protected from atmospheric agents
• relative humidity not higher than 80%
• minimum temperature - 20°C
• maximum temperature + 70°C
• Request storage procedures from the manufacturer for storage period higher than two years
• If these values should change during the storage, will be necessary execute several preliminary
controls before the starting of the crane (see the paragraph “Recovery after storage”).
• If the temperature exceeds or falls below the indicated values and the relative humidity is greater than
80% at the storage place predispose protections with barrier bags and hygroscopic salts for the
packages.
• For storage in outdoor areas provide:
• hooves from the floor for all the packages without pallets
• protect all packages with barrier bags and hygroscopic salts
• in the case of tha crane was been constructed to operate in outdoor, the carpentry parts don’t
require special protections; on the contrary, the parts worked on a machine tool (machined
surfaces, wheels, pins, etc.) must be protected with antioxidants (transparent paints, grease, etc.)
• Provide for delimiting the storage areas of the material.

Put back into service after storage

Before the starting of cranes that have suffered a long period of storage on site, is
necessary to execute these operations:

• Structure:
• remove traces of paint or lubricant from the structure and from the tracks
• clean the mating surfaces intended for assembly
• repair any structural damage (sculpted surfaces, peeling paint, etc.)
• Mechanisms:
• check for leaks and, if necessary, put back the lubricants levels
• verify the correct fixing of mechanisms to the structure
• check the integrity of the chain (clean and lubricate it), nuts and return spools, friction device or
load limiter
• remove traces of oxidation from the accessory sliding parts of the control elements
• lubricate bearings and unpainted mechanical parts (shafts, pins, joints, etc.)
• remove any residual water present in the concave parts
• Electrical equipment:
• remove any condensation from the motors and from the terminal blocks; dry with air jets
• check the integrity and functionality of the lifting brakes
• carefully clean the hoist brake surfaces removing traces of moisture and lubricants
• check the integrity and functionality of switches
• check the integrity of electric parts and components
• dry contactors contacts
• check the smoothness of festooned power lines
• carefully check the functionality of the control pushbutton

For all operations always use adequate personal protective accident prevention
devices ( D.P.I. = gloves, shoes, etc. )

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

4. - USE AND MAINTENANCE INSTRUCTIONS

4.1 – LIGHT CRANE SYSTEM FUNCTIONS

Intended use
§ Bridge cranes, single-girder version, of type “light crane system” are realized for the movements of
goods inside a plant or a building site.. The cranes slide vertically the load in space, through the lifting
hook unit (electric chain hoist or hand hoist) and by means of accessories for this operation.

§ The load can be moved manually, in push way, along the transverse and longitudinal axes of the
bridge, by means of hoist-carrying trolleys and and sliding deck-holders in a special section in special
profile.

§ The bridge cranes slide manually suspended on runways, also made of beam with special profile in
"canal" ", positioned above ground level which therefore remains entirely free and available for production
activities. The runways are generally hanging, to the supporting structure, thanks to the presence of
suspensions with adjustable tie rod and crosspiece with clamps.

§ The functions are realized through three principal movements:

• vertical: lifting the load through a electric chain hoist or hand hoist
• transversal: manual translation, by pushing the load, by moving the hoist-carrying trolley
• longitudinal: hand sliding, by pushing the load, through the crane carriages along the runways

§ These movements are activated by:

• Crane equipped with electrical hoist

pushbutton: pressing the UP or DOWN control keys for the LIFT movement
hand push : in RIGHT or LEFT direction for the TRANSLATION movement
hand push : in FORTH or BACK direction for the LIFT movement

• Up and down buttons of pushbutton activate the function when they are kept pressed and can be
of the type to "scale" in two steps the first one to control the "slow" speed the second one to
command the "fast".
• The STOP / EMERGENCY button on the pushbutton is generally mushroom-shaped, red color,
and activates the STOP function when it is pressed too much.
• To allow the operation about the tackle mounting on the crane is necessary to rotate the
STOP/EMERGENCY button clockwise and move it to the "up-turn" position of travel consent then
press, when available, the green march button.
• The control panel is suspended from the hoist and can be moved by the operator from the
ground, following the movement of carriage (RIGHT/LEFT) and/or the crane sliding
(FORTH/BACK).

• Crane equipped with hand hoist:

hand shooting : on the maneuvering chain to control the LIFT movement
hand push : in RIGHT or LEFT direction for the TRANSLATION movement
hand push : in FORTH or BACK direction for SLIDING movement

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Allowed and not allowed loads

§ The loads must be :
• Of shape, size, mass, balancing and temperature suitable to characteristics of place where they
have to be moved and compatible with the crane’s performance.
• Equipped with points of the grip and/or harnessed with accessories able to avoid the accidental
fall
• Stable and not subject to change their static or physical configuration during handling.

§ Movement of these loads is not permitted:

• whose weight, including any accessory, exceeds the capacity of the crane.
• having unbalanced masses respect to their center of gravity.
• with surfaces not sufficiently resistant to the pressure exerted by the grip
• that, are classified dangerous for their physico-chemical characteristics, which, for
example : flammable, explosive, radioactive materials, etc..
• harmful toxic materials or products, if not moved in appropriate safety containers,
such as for example: corrosive chemicals, with biological risks, etc.
• products or food substances loose, which can come into direct contact with parts
of the hoist or its lubricants.
• that can change their static and/or chemical physical configuration or their
barycentric during the movement
• equipped not with accessories referred to in the following point

Lifting accessories
§ Are generally allowed:
• Harnesses consisting of ropes and/or chains and/or bands in textile fiber
• Lifting accessories that are interposed between the load and the lifting hook such as: balancers,
pliers, suction cups, magnets and electromagnets, etc. The use of these accessories must be
conformed to the prescriptions provided by the manufacturer of the same.

§ The accessories that aren’t generally allowed :

• whose functional characteristics can cause dynamic over-stress to the crane
higher than those admissible or accidental overloads.
• that can collide with the light crane system
• that limit to free movement of the load
• that are connected with independent power lines

The owned weight of lifting accessories must be deducted by the “light crane system”
nominal flow.

4.2 - ENABLING

Before starting the operation activity with the crane, execute the following functions:

* check that the intensity of the crane service corresponds to that for which it was designed
* check that the crane range is equal or higher than the load to be lifted
* the useful lifting run of the hoist don’t be less than what necessary
* visually check the status of the entire suspended system conditions
* activate the supply line placing the main switch in “ON” position or “1”, if the bridge crane is equipped
with electrical hoist
* turn the STOP/EMERGENCY button, placing in “raised” of consensus of march position and press
subsequently the green “MARCH/ALARM” button.
* verify the crane operation, checking the movements described at 4.1 paragraph.
* Execute the preliminary controls a sas described at the chapter titled “HOW ALWAYS MAKE”

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4.3 - OPERATIVITY
§ Operating environment – it must have the following characteristics :
* temperature : min.: -10°C; max.: +40°C : relative humidity max. 80%
* use in cover environment : the crane is created to operate in a indoor environment and, not being
exposed in atmospheric agents, doesn’t require any special precautions.
* use in outdoor : the machine can be exposed in atmospheric agents during and after the using. It
will need to protect, where possible, the crane and its electric parts with sheds.
Protect the structure with anti-oxidants and lubricate the mechanisms to avoid oxidants.

The light crane system mustn’t be used in environments and areas:

* with highly corrosive and / or abrasive vapors, fumes or dusts (where this can’t be
avoided, intensify maintenance cycles).
* in of flames and/or heat presence higher than the permitted temperatures.
* In fire or explosion risks and where the use of explosion-proof and non-sparking
components is prescribed.
* in areas where strong electromagnetic fields are present that can generate
accumulation of electrostatic charges.
* in direct contact with loose food substances.

§ Lightning – the light crane system is not equipped with standard lightning.

The level of lightning environment must be such as to guarantee the operation of the
crane in the maximum possible safety in relation to the use for which is intended. In
the cases of maintenance operations located in not sufficiently illuminated areas or
parts of machine, is obligatory to acquire oneself with lightning portable system,
taking care of avoid shadows coins, that prevent or reduce the visibility of the point
where it’s going to operate or the surrounding areas
.

§ The operators are all they that, from time to time, effect the following phases on light crane system:
* the transport and the movement of parts
* the assembly, the installation, the regulations and the test
* the commissioning and use
* the cleaning, the maintenance and the repair
* the disassembly, the dismantling and demolition
* The operator must be suitable person of work and psychophysically able to attend to needs related to
the crane operation during all the operative phases and in particular during all harness and movement
phases.
* The operator in charge of using the light crane system, must place in a non-dangerous manner for its
same safety and or/ preventing and therefore avoiding to possible falls or dangerous movements of
load transported. He must follow the directions provided to obtain the major safety for itself and other
people during the use of machine, in particular have to scrupulously observe the instructions
contained in this manual.
* The operator mustn’t allow to anyone else to approach the crane during the use and
prevent its use by foreign personnel (especially to children under 16).
* The use of machine is forbidden to unauthorized or uninformed personnel.

§ The light crane system nominal flow, is clearly indicated be the plate affixed to it and it’s visible from
the maneuvering point.

• The limit of crane grip must never be exceeded although it is determined with ample
margins of security, therefore the light crane system must never be equipped with a
lifting device (hoist), having nominal flow higher than that of the crane itself.
* If the owned weight of the following lifting devices exceed 50 kg, must be deducted
from the crane's capacity.

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§ Maneuvers – it’s a good practice to perform a movement at time, because a maneuver can be started,
stopped and constantly followed by the operator just in this way, who will have to avoid to continuously
execute repeated insertions and disconnections even in the case of small movements.
* Taking the load with the crane hook and with the lifting accessories must happen carefully, gently,
without rips.
* Start the lifting operation placing the chains slowly in tension, until the load lift for a few centimeters,
stop the maneuver and verify the seal and the stability of the same.
* At the end of the movement, place the load carefully and break free the hoist hook.
* In hand translation and/or sliding maneuvers, the operator must always move the load pushing it and
never pulling it towards you

* Diligently and carefully operate, constantly following the maneuvers and visually
checking the balance of the mass
* Avoid abrupt maneuvers without having ascertained, after a short break, the
stability and the balance of the load. The “little rips” maneuvers are very dangerous
for the load stability cause of dynamic effects that are generated.
* Never lift with unbalanced plugs or omit to hook and ensure every harness
accessories expected or fixed the load with improvised and makeshift harnesses.

§ Lifting – the operator will have to pay attention to keep always the lifting chains taut, never placing the
hook on the ground or on the loads to be lifted. The banned chains can wrap around each other, form
several knots, damage themselves even seriously and create dangerous situations. The operator will
have to avoid effected oblique shoots always dangerous and badly controllable.

§ Bridge translation and light crane system sliding- avoid violent shocks between the trolley or crane
structure and the terminal bumpers, to not cause serious repercussions on the mechanical parts. The
stops or the switches devices are arranged in a position to allow complete travel when they are reached
at reduced speed and the braking distance as much as it’s higher the speed, consequently the operator
will have to slow down the carriage or the beam march of the light crane system” in proximity to the ends
of run.

§ Interlocks – if the crane is equipped with electrical hoist, the exclusion of the crane power supply
happens switching off the line switch (not included in the supply) or pressing the "Stop" button on the
control panel. En electric and/or mechanic interlock on the lifting prevents simultaneous command in the
two directions of rotation; the electric interlock placed on the lifting motor for slow or fast speed it prevents
a simultaneous feeding. The lack of tension causes the immediate blocking of all the movements of the
electric hoist.

4.4 - DEACTIVATION

To deactivate the light crane system, at the end of work, respect every following
provisions:

• place the bridge in a recovery position making sure of its stability, taking care that it can’t generate
dangers of impact or interference with surrounding structures and / or machines
• break free the lifting hook from the harnesses used to move the load
• raise the hook at a level not lower than 250 cm. by means that can’t create noise and danger to the
movement of people and things below the crane
§ In the case of the hand hoist use:
• ensure themselves that the maneuver’s chain doesn’t generate risks caused by dangers of
entanglement
§ In the case of electrical hoist use:
• stop all crane movements pressing the “STOP” button of pushbutton
• put the pushbutton in "not disturbe" position.
• remove the supply voltage to the light crane system placing the main switch lever in the "OFF" or
"0" position.

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4.5 – WHAT TO DO ALWAYS !

Intended use, criteria and precautions for use

The correct “light crane system” use allows to take full advantage of the services that
the same is able to supply with the total security. These potentials are guaranteed
only scrupulously keeping to the indications below:

• ALWAYS follow the indications and instructions reported to the “installation of use” manual and verify
the suitability crane’s components and parts.
• ALWAYS respect the instructions and warnings highlighted on the machine; the warning plates
exposed on the crane and on maneuvers areas, are accident preventions reports and they have to be
always perfectly readable.
• ALWAYS ensure themselves that the crane operates in protected environment by atmospheric
agents (rain, wind, snow, etc.), or, when intended for outdoor use , verify that have been installed the
appropriate protections (roofs, shelters, etc.).
• ALWAYS verify the compliance of the crane's performance in relation to the service for which it is
destined for ( work cycles - intermittent – time of use – load to be moved ).
• ALWAYS check the solidity of the structures that support the bridge crane and the suitability of
runways.
• ALWAYS verify that the lifting runway is placed to an altitude that doesn’t the operator to interfere
with the shape of the lifting unit and/or with the moving parts. In the case this can’t be possible,
provide for the fitting of appropriate shelters or signs in the area at risk ( fig.32 ).

fig.32

• ALWAYS before starting any maneuver, ensure themselves that the sliding crane zone (runways) be
free from obstacles.
• ALWAYS ascertain the adequacy of the conservation state (cleaning, lubrication) and crane
maintenance and its principal components (chains, block-hook, pushbutton, switches, wheels, etc.).
• ALWAYS verify, is equipped with electric utilities, the electric power suitability and function; in
particular check the correct connection precarious and dangerous connections. Check the correct
function of all the crane motors.
• ALWAYS test the emergency button function, if is equipped with electric utilities.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

• ALWAYS executes checks of chain, block hook, load limiter or friction device and pushbutton,
verifying it’s suitability and efficiency.
• ALWAYS ensure themselves that lifting hook isn’t consumed, damaged, without securities
(carabiner).
• ALWAYS verify the suitability and efficiency of used harnesses (ropes, chains, bands, etc.) in
particular check that don’t present lacerations, broken strands or unlubricated parts.
• ALWAYS ensure themselves have located the lifting (hoist and hook), on the perpendicular of the
load before having effected the harnesses and moved the same load.
• ALWAYS ensure correctly the load harnesses to the lifting, after having providing to equilibrate the
same load, before lifting pay the harnesses in tension with slow and confident harnesses
• ALWAYS make sure that the load don’t meet obstacles, during the movement operation (lifting,
sliding, translation).
• ALWAYS operate in the best conditions of lightning of the area and of visibility load.
• ALWAYS operate outside the operating range of the raised load.
• ALWAYS slowly and carefully execute the approach and positioning maneuvers pushing the load and
not pulling it towards yourself ( fig.33 ).
• ALWAYS, at the and of work, take the crane in the assigned position of “recovery” ready for the use,
taking care of placing the block-hook and the pushbutton, so that they don’t constitute collision
danger.

fig.33

• ALWAYS, before leaving the maneuvering point, activate the stopped command on pushbutton and e
turn off the crane main switch if equipped with electric utilities;
• ALWAYS proceed to remove the power supply voltage of the machine in case of inspections, repairs,
ordinary maintenance interventions if equipped with electric utilities;
• ALWAYS, for all functions, use suitable work clothing, in the respect of safety rules in work
environment;
• ALWAYS report following anomalies function (defective behavior, suspicion of breakage, uncorrected
movements and stranger noise) to the department manager and put the machine in inactive
conditions;
• ALWAYS respect the maintenance interventions program and check in, during each control, following
observations, especially, related to hook, chain, switches and brakes;

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

4.6 – WHAT NOT NEVER DO!

Unintended use, unauthorized use,

Foreseeable and unpredictable use
Contraindications for use

* The crane use for unauthorized maneuvers, its improper use and lack of
maintenance can involve risks of serious damages to the health and safety of the
operator and people exposed as well as to damage for work environment and to
compromise the functionality and the intrinsic safety of the machine.
* The action below describing, that obviously can’t cover the total arc of potential
“bad use” possibilities of “light crane system” and constitute nevertheless those
"reasonably" more predictable, and therefore are totally consider forbidden:

• NEVER use the bridge crane for the lifting and people transport ( fig.34 ).

fig.34

• NEVER lift loads while people are passing through the maneuvering area below
• NEVER transit, stop, operate and maneuver below the suspended load.
• NEVER allow the crane use to unqualified or less than 16 personnel.
• NEVER use the crane if the person isn’t psychophysically suitable.
• NEVER use the crane if equipped not with suitable work clothes or personal protection measures.
• NEVER operate without due attention during the lifting and translation maneuvers.
• NEVER put the hands on the spinning pucks, on moving chains, on the harnesses during the phase
of “tensioning” in the areas in contact with the load and between the hook and the harness.
• NEVER leave the suspended load unattended.
• NEVER lift loads higher than nominal flow and not apply masses higher than the same.
• NEVER use the crane for services that are different those for which it’s destined for, avoid it the use
for other operations like for example ceiling bleaching, lamp replacement, etc.
• NEVER lift unbalanced loads.
• NEVER swing the load or the hook during the translation.
• NEVER pay the chain in shooting diagonal position.
• NEVER use the crane to tow or drag.
• NEVER use the chain hoist like harness for the load.
• NEVER use the harness without having checked its suitability .
• NEVER use the chain like ground mass cable for welding machine.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

• NEVER use the load point as load bearing base.

• NEVER use the crane to to keep elements tied to the ground in tension.
• NEVER lift “driven” loads.
• NEVER after placing the load causing the ban of chains, continue the hook run,
• NEVER bump the bearing structures or other machines and systems with the load ( fig.35 ).

fig.35

• NEVER use two cranes at the same time to lift the same load, without having implemented adequate
security procedures.
• NEVER use the crane with two contemporary movements, wait for the completed movement stop
before starting with another.
• NEVER use the crane in unforeseen environmental conditions ( - 10°C +40°C; 80%).
• NEVER use the crane, or carry out maintenance operations on the same, in insufficient lightning and ,
visibility conditions.
• NEVER use the crane in areas where the use of is prescribed the use of explosion-proof components
• NEVER use, stop or place the crane at the end of work, in not protected environment by atmospheric
agents (rain, wind, snow, etc)
• NEVER continuously order out to the switches stops
• NEVER reach the areas of “end run” in full speed during the sliding bridge and the translation crane
movements.
• NEVER use the crane with the presence of a strong voltage drop on the supply network or with an
accidental lack of one of three phases, if is equipped with electric utilities.
• NEVER execute abrupt reversals during the lifting and translation operations.
• NEVER repeatedly set in motion the command buttons, if equipped with electric utilities.
• NEVER edit the functional/performance characteristics of the crane and/or of its components.
• NEVER edit, disrupt the adjustments of security devices (switch, load limiter/fiction device, etc.)
and/or cause tampering with the appliance.
• NEVER execute temporary repairs or recovery interventions incompliant with the instructions.
• NEVER use not original replacement parts or not recommended by the builder.
• NEVER entrust maintenances or repairs to uneducated personnel by the builder.
• NEVER abandon the crane to the end of work without being put in action the security procedures.
• NEVER effect ordinary maintenance operations, inspections or repairs without having put the crane
out of service and having activate the relative procedure.
• NEVER during the maintenance phases:
• use unsuitable means
• place stairs on the hoist or crane
• operate without personal protection means
• intervene without having removed the lifted load.
• NEVER use the crane if imperfectly conformed with its operation functions.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

4.7 - MAINTENANCE

§ The maintenance plan is composed by interventions of ordinary type, that provide inspections, controls
and checks directly conducted by the operator or specialized personnel assigned to the normal enterprise
maintenance and of periodic type that include the replacement, registration and lubrication operations
carried out by the educated staff for the purpose by the builder through specific courses or publications.

Ordinary/periodic maintenance

§ Ordinary maintenance :
* Is composed by the maintenance functions that can be directly execute by the operator assigned to
the use crane or by the specialized personnel, as prescribed in this publication and documentations
attached and that don’t require particular use of instruments and equipment.

The ordinary maintenance functions, that don’t require the use of particular and
special instruments and equipment, they are grouped in:

* Daily interventions, by the operator assigned to the crane use:

* general visual checks
* functional checks (motors test, switch, fiction device, vacuum brakes, buttons)
* chains and hooks conditions checks
* correct sliding of the bridge checks

* Weekly interventions, by the specialized staff :

* visual check of each mechanism and of possible leaks of lubricant
* functional check of full load brakes
* switch check and, if necessary, provide for the gearing of the relative machines
* the functionality and integrity of pushbutton and the relative cable check
* Monthly interventions, by the specialized staff :
* efficiency of chains and hook check
* trolley wheels usury of translation check
* check and cleaning of sockets/plugs connectors
* verification of the mobile carriages greasing of the festoon line e cables control
* efficiency and the integrity of the supply line and of its components verification
* efficiency and the state of conservation of the structure verification (painting, oxidations, etc.)


§ Periodic maintenance:
* Is composed by the maintenance functions that can be execute by the educated staff for the purpose
through this publication, related to registration checks, lubrication and following substitutions, related
to timings foreseen in the scheduled maintenance plan as reported in "Periodic maintenance
interventions" tables.

* Before the maintenance of mechanic and/or electric parts, is necessary to

deactivate the general disconnector and post a cartel on machine with the “machine
in maintenance” indication.
* The operations of periodic verification, control, repair, substitution must be
reported on the check register.

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For the single parts of the “light crane system”, pay attention to the following
instructions of periodic maintenance:

§ Structural elements, welds, pins and bolted joints:

• The metallic structure of the “light crane engine”, in addition to the normal alterations caused by the
environmental factors and measures of moving organs, can be subjected to , even inadvertently or
during the operative phases of movement, a impacts, contacts or slipping with other equipment or also
to anomalous stresses that can cause damages to carpentry frames, the welding and to pins.
Therefore the facilities, before perfect clear, must be periodically subjected to scrupulous controls for
per ascertain their suitability and if necessary pay remedy to following damages.
• The brackets consisted by plates and pins, that form hinged elements are subjected to usury as
mobile and oscillating elements subjected to grazing impact in the contact area. Provide to their
substitution when, during inspection, it should found an excessive usury.
• All screw pins, high strength plugs and little plugs must be disassembled and carefully checked every
year as well as the relative locations.
• Verify the tightening couple of the fixing bolts of the column or shelf, in compliant with the provided
couple of rule UNI 10011/88

Repair the facilities and the hinged elements or substitute them where event of:
• deformations : elongations, crushes, dents, bends
• usuries : consumed parts, section reductions, incisions, abrasions, corrosions, oxidations,
nicks, peeling paint
• breakages : welds cracks, cracks, cuts or incisions, broken parts
• section variations ≥ about 10%, or in diameter or thickness ≥ around 5 % compared
to the initial values

§ Wheels and guide rollers of the carriages in “canaline”:

• Verify the usury state of the rolling band of the wheels and the guide rollers
* Check the ball bearings, that have to be substituted where events of an excessive noise oror show up
excessive impacts, “pop-out”, difficulties or irregular rotation

Substitute the wheels and/or the guide rollers of the carriage in “canaline” when:
• The rolling diameter of the wheel presents a usury ≥ about 5 mm
• The rolling diameter of the guide roller presents a usury ≥ about 2 mm
• When can be necessary provided to the replacement also of one wheel, to obtain
the best functional guarantee and of duration is recommended to proceed to the
replacement of all carriages wheels

§ The carriage in “canaline” bumpers:

• Check that the ends stop are not deformed and with signs of subsidence in their fixing structures and
that the buffer is intact and well fixed to its support..

Replace the buffers when they show signs of breaking or permanent deformation, cuts,
abrasions, incisions

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§ Switches and mechanical anti collision:

• Enter of the conservation state and the correct intervention of mechanical switches
• Check the mechanical integrity of anti-collision mobile elements and verify tightening of fixing screws.

Replace the switches feedback or the anti-collision devices when present breakage or
permanent deformation signs.

§ The electric supply power:

• Verify the efficiency of festooned supply cable and that there aren’t stripping cuts, lacerations or other
alterations of protective girdle.
• Check the tightness of the conductors, of the power supply cable, to their terminals (in the junction
box) and, if necessary, provide to their correct tightening.
• Verify, the conductors and grounding connections efficiency, providing for a control and, if necessary,
for a fixing of the ground screws.
• Effect a checking of all the sealing gaskets of the covers and cable glands.
• Check the presence and the efficiency of the sign plates.

• Replace the electric component, when it comes to verify breakages, cuts and/or
incisions of the cable girdle, cable stripping, uncover conductors or when the
component isn’t able to offer sufficient guarantees of reliability

For the information about checks of all the structural, mechanical, electromechanical
components of the lifting and translation units, incorporate in “light crane system”,
consulate the relative documentation attached to this technical publication..

• Don’t hesitate to replace the part and/or the component in exam, when the same
isn’t able to offer sufficient guarantees of safety and reliability.
• Never make improvised or makeshift repairs.
• Exclusively use original replacement.

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Periodicity and deadlines

§ The periodicity of the maintenance operations, that are indicated in the following table, are related to a
“light crane system” subjected to a work service in normal conditions required by ISO 4301/88 law and
FEM 9.511 rules for M4 (1Am) group. If different working conditions exist, the frequency about the
maintenance interventions has to be augmented in relation to the usage group. If the “light crane system”
usage is normal and correct, its revision may happen after a period of employment about 10 years,
according the rule FEM 9.755 (S.W.P.).

Table of periodic interventions of controls and maintenance

Oggetto della verifica Periodic checks

Daily Monthly Quarterly  Annual

General visual
Visual controls checks General visual Usuries Annual
Inspections - tests Good checks inspections check test
operation

Readability
Visual inspections
Signals and pictograms signals and Capacity
integrity and clear
Cartels and plates pictograms,
plates and signals
check
cartels and plates

Structural elements Usury and

efficiency check
Welding Bolted/welded
Bolted joints joints check

Chain Efficiency and

Visual inspection
Fixing elements usury check

Visive inspection
Lifting hook Efficiency and
and carabiner
Referral sprocket check
usury check

Loading walnut Efficiency and

Chain guide usury check

Lifting adapter
Noisiness check
Translation adapter

Lifting adapter Translation Correct function

Funcional tests
adapter check

Lifting brake
Correct function Funcional tests
Translation brake check usury check
Rotation brake

Wheels and pinions

Usury check
Bearing - peans

Respingenti carrello Efficiency and

Visual inspection
Anticollisione gru usury check

Visual inspection
Electric power Correct function External Efficiency and
Pushbutton and cable check breakages usury check
Pushbutton/cable

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Functional
Friction device tests
Calibration check

Lifting switch Functional tests

Correct function Efficiency and
Translation switch check usury check
Roration switch
Verification of the Waste check
Cleaning and correct cleaning Lubrication
lubrication status e chains, hook and
lubrication mechanisms

NOTA:  the following operation must be reported on the “Check register”

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4.8 – CLEANING AND LUBRICATION

§ Cleaning and lubrication plan of the crane:

The clearing can be effected by not high specialized staff and it’s periodically
necessary to break free the structure and the mobile elements from accumulations of
dust and dirt and from sludge caused by excess lubricates.

* The clearing can be simply realized with the use of means, equipment and detergents or solvents
commonly used in general cleaning operations of industrial equipment not to existing particular
contraindications in relation to the products or materials use.

The accurate manage of the lubrication of the crane mechanisms is the necessary
condition to guarantee the effective response to the service what the same is destined
for, as well as its duration.

• The organs lubrication in movement is necessary to avoid the direct contact between the rolling
elements,
• The crane lubrication is very simple and can be effected by not high specialized staff, anyway
scrupulously complying with, the instructions contain in the present manual and effecting the checks
and the necessary additions, following the frequencies indicated on the table.
• The parts or components that must be periodically subjected to lubrication cycles, exclusively using
grease, are:
• the spherical ball joints of the suspensions
• the carriages or the cable holder sledges of the supply system
• the wheels and the guide rollers carriages of translation and sliding
• Furthermore, when the crane is supplied of the hoist completed, in the specific section of the “use and
maintenance” manual of the same attached to this publication, are indicated all intervention of
lubrication and all types of recommended lubricants. Anyway, the principal parts of the chain hoist
that must be periodically subjected to lubrication cycles are:
• chain, wot, and chain guide
• lifting adapter
• hook, sub-block or block

Table of periodic lubrication interventions – recommended lubricates

_________________________________________________________________________________________________________

COMPONENT LUBRICATION TYPE PERIODICITY

OIL GREASE
_________________________________________________________________________________________________________

- Wheels and rollers Agip Blasia GR MU3 3 Months

_________________________________________________________________________________________________________

- Beakers and junction Agip Blasia GR MU3 3 Months

_________________________________________________________________________________________________________

- Sledges and system carriages Agip Blasia GR MU3 3 Months

_________________________________________________________________________________________________________

- Wot and chains Agip Blasia GR MU3 3 Months

_________________________________________________________________________________________________________

- Thrust bearing Agip Blasia GR MU3 3 Months

* The lubricates, solvents and detergents are harmful/toxic products for the safety:
* if directly place with the epidermis they can generate irritations
* if inhaled they can cause serious intoxications
* if ingested they can cause the death
* Handle them with care using appropriate personal protective equipment (DPI), don’t
disperse them in the environment and arrange for their disposal in compliant with
the current regional legislative provisions in field of toxic/harmful waste.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

4.9 – TROUBLES AND REMEDIES

Main malfunctions or faults and possible remedies

§ In the columns of the following table are reported the principal conditions of the bad function,
reasonably foreseeable and the type of inconvenience, the potential cause of the failure and the possible
remedies.

Type of failure Possible causes of failure Possible remedy

The sliding movement of the • The entry of foreign body in the • Remove the foreign body from the “canaline”
hoist trolley holder or the “canaline” of the bridge or the
bridge trolley holder is runways beam
blocked • • sostituire il cuscinetto
Difficult sliding of the bridge • blockage of the “canaline” track • foresee the indoor clearing to the “canaline”
and/or of the carriage and/or • poor lubrication of the bearing • foresee to the lubrication track
of the electric system or sledges
sledges, that needs • scartamento inadeguato del • verify the gauge
excessive effort ponte
Unstable positioning of the • runway or bridge beam not • foresee to the living up of the runways of the
bridge or trolley sufficiently planar bridge beam

Authorized personnel
§ The personnel authorized to intervene in most cases of damage, or where not reported otherwise, is a
expert or authorized maintainer with a precise preparation about electric and mechanical parts.. Where
highlighted, the intervention of specialized personnel or specially educated or of technical personnel of
the builder is even necessary.

Putting out of service

§ In the case the repair of the “light crane system” couldn’t happen, proceed to the putting out of service
of the same, reporting its failure with the special sign; request the intervention from the assistance
service.

4.10 - DISPOSAL / SCRAPPING

When the “light crane system” and its components, as broken, worn out or come to
the end of the life foreseen by the builder, shouldn’t be used and not repairable, it’s
necessary to proceed to their scrapping.

* The scrapping of the crane must be effected with the use of suitable equipment chosen in relation to
the nature of the mean on which to intervene ( Ex. shears, blowtorch, hacksaw, etc. ).
* All components must be dismantled and scrapped, after having reduced them in little pieces so that
none of them can be reasonably reutilized.
* When the crane is scrapped is necessary to foresee the dismantling of its parts in differentiated way,
considering the different nature of the same (metals, oils and lubricants, plastic, tire, etc.) possibly
getting specialized enterprises in charge to the purpose and anyway in compliant with prescribed to
the law on the disposal of solid industrial waste scrapping.

Don’t try to reutilized the crane parts or its components that apparently may still seem
intact, when they, after controls and checks and replacement conducted by specialized
personnel or by the same builder, have been declared unsuitable.

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Iomini gru - Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI) – tel. 0331.880366 – fax. 0331.883410

5. – SPARE PARTS

* The IOMINI GRU “light crane systems” are designed and constructed so that not to
normally request, if correctly utilized and after a adequate maintenance as
described in the present manual, spare parts due to breakages and damages.
* Other parts subjected to usury (chain, hooks, brakes) can be deduced by the
relative documentations attached to the electric rope hoists or gear motors.

* Don’t hesitate to replace the part and/or the component in exam, when the same
can’t be able to offer sufficient safety guarantees and/or functional reliabilities.
* Don’t never effect improvised or makeshift repairs!

§ Where it was necessary to replace damaged parts is obligatory to exclusively utilized original
replaceable, directly request them to:

Iomini gru
Via Ragazzi del '99, 1/3 - 20022 Castano Primo (MI)
tel. 0331.880366 – fax. 0331.883410

6. – CONTROL REGISTER

§ In testimony of the correct conduction of all activities of control and maintenance of the “light crane
system”, as well keep track of any responsibility for the activities performed, as described in this
publication, it is recommended to carry out and draw up and keep for the foreseen life of the crane
(10 years) the special check register.

§ Report in the check register all foreseen operations contained in the plan of maintenance, on quarterly
and annual basis indicated “periodic maintenance interventions” on the table.

§ It will be care of the maintainer complete that register in every its part, reporting results and following
annotations in the special spaces.

§ The maintainer’s name and the day of the relative event, will be also clearly identifiable.

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