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GORBEL 150 BX G-Force Installation, Operation & Maintenance Manual

Bx series, lbs. capacity maximum
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™
150
lbs.
CAPACITY MAXIMUM
®
1 1 5 5 0 0 / / 3 3 0 0 0 0 / / 3 3 8 8 0 0 l l b b s s . .
B B X X S S e e r r i i e e s s
Gorbel® Dealer:________________________________
Serial Number: _________________________________
Gorbel® Customer Order No.: ____________________
Date: _________________________________________
I I n n s s t t a a l l l l a a t t i i o o n n , ,
O O p p e e r r a a t t i i o o n n , ,
& & M M a a i i n n t t e e n n a a n n c c e e
U.S. PATENT NO'S:
5,865,426, 6,386,513,
& 6,886,812
OTHER PATENTS
PENDING
M M a a n n u u a a l l
™

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Summary of Contents for GORBEL 150 BX G-Force

  • Page 1 1 1 5 5 0 0 / / 3 3 0 0 0 0 / / 3 3 8 8 0 0 l l b b s s . . B B X X S S e e r r i i e e s s Gorbel® Dealer:________________________________ Serial Number: _________________________________ Gorbel® Customer Order No.: ____________________ Date: _________________________________________...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Safe Hoist Operating Guidelines ..............2-4 Introduction .

  • Page 3: Safe Hoist Operating Guidelines

    SAFE HOIST OPERATING GUIDELINES General Do not operate hoist to extreme limits of travel of cable There is no one single factor that is more important for minimizing without first checking for proper limit switch action. the possibility of personal injury to the operator and those working Avoid sharp contact between two hoists or between hoist and in the area, or damage to property, equipment, or material, than end stops.
  • Page 4 Do not repeatedly impact the BX G-Force® into the end stops. This condition will seriously reduce the life of the Controls and could lead to premature failures. If the unit impacts the end stop more than 10 times in a single shift, contact Gorbel® Customer Service for alternative end stop options. WARNING The BX G-Force®...
  • Page 5 Please follow the instructions contained in these manuals for your safety and for optimum trouble-free operation of your G-Force®. When repairing or maintaining a G-Force®, use only Gorbel® recommended parts and materials. Check Wire Rope for Center G-Force...

  • Page 6: Introduction

    The innovative design and heavy-duty construction of the G-Force® BX ILD will provide a superior quality product that will offer years of long-term value. A Gorbel® G-Force® BX ILD will provide many years of dependable service by following the installation and maintenance procedures described herein.

  • Page 7: Correct G-Force® Installation Orientation

    The BX G-Force® was designed and fully life tested in the installation orientation shown above. Any modification to the installation orientation of the BX G-Force® without the written consent from Gorbel, Inc. Engineering will immediately void the warranty. Please contact the factory if a modification to the installation orientation shown above is desired.

  • Page 8: Lift Functionality

    LIFT FUNCTIONALITY Standard Operation: The Gorbel® G-Force® BX ILD is a servomotor driven, high speed, ergonomic materials handling device. When the device is in the standard operational mode, the sliding handle of the hand controller commands the z-axis direction and speed of the lift (reference Diagram A). The handle has a center neutral position and can slide up and down to provide up and down speed commands to the control system.

  • Page 9: Controls Interface Features

    (and balanced) on the end of the wire rope, while the handle can be remote mounted. The tooling must be attached to the end of the wire rope with a swivel assembly (supplied by Gorbel, Inc.). Failure to mount the tooling with a swivel assembly can result in premature failure of both the wire rope and the coil cord.
  • Page 10 2. Speed Control Adjustment: The 10 position Speed Control adjustment switch allows the operator to adjust the speed of the lifting device with a small flathead screwdriver. 3. Power Up Diagnostic Mode: When the “E-stop” button is released and power is applied to the lift, the servo motor controller goes into a power up diagnostic mode test.

  • Page 11: Technical Specifications

    TECHNICAL SPECIFICATIONS BX Series 150 lbs. 300 lbs. 380 lbs. Maximum Capacity (Load & Tool) 150 lbs. 300 lbs. 380 lbs. Max Lifting Speed 240 fpm 120 fpm 86 fpm Unloaded (feet per minute) Max Lifting Speed 200 fpm 100 fpm 71 fpm Fully Loaded (feet per minute) Max Float Mode (Option) Lifting...

  • Page 12: Installation

    Diagram 1A. 150# BX series shipped components. Diagram 1B. 300/380# BX series shipped components. 1.2 Verify that all components listed on the packing slip are included. 1.3 If any items are missing or were damaged during shipping, please contact Gorbel® Customer Service immediately. ®...

  • Page 13: Step 2 - Pre-Assembly

    STEP 2 - PRE-ASSEMBLY 2.1 Read entire installation manual before beginning installation of the G-Force® BX ILD. 2.2 Tools and materials typically needed to install/assemble a G-Force® BX ILD are as follows: • Hand tools • Plastic cable tie straps •...

  • Page 14: Step 3A - Handle-Coil Cord Installation (Remote Mount Standard Units)

    Diagram 3B. Coil Cord to Actuator assembly. STEP 3A - HANDLE-COIL CORD INSTALLATION (STANDARD REMOTE MOUNTED) TIP: This step is best completed on a workbench, prior to installation of the Actuator into the bridge system. 3A.1 Attach the wire rope Swivel assembly directly to the end tooling (reference Figure I3, page 67). 3A.2 Remove the Cotter and Clevis Pin from the Swivel assembly.

  • Page 15: Step 3B - Handle-Coil Cord Installation (Remote Mount Float Mode Units)

    3A.10 Assure that the coils of the Remote Mount Coil Cord are centered around the wire rope when properly installed. When the proper alignment of the Remote Mount Coil Cord has been achieved, finish clamping the hardware to fix the Remote Mount Coil Cord in place (reference Diagram 3B, page 13). 3A.11 Attach the Standard Remote Mount Handle to the Tooling, being sure to mount at both the top and bottom of the Remote Mount Handle assembly (reference Figure I3, page 67).

  • Page 16: Step 4 - Installing The Actuator Assembly

    Trolleys when being installed in a Gorbel® Bridge system. The customer must provide two (2) Hoist Trolleys when the unit will run in a non-Gorbel® Bridge system. 150# G-Force® BX ILDs can also be supplied with an Actuator Adapter Trolley, similar to that of the 300 and 380# units.

  • Page 17: Step 6 - Air Connection (Option)

    3/8” ID Nycoil air hose integrated into the full length of the Coil Cord. The Coil Cord is provided with two (2) Male fittings located at both ends of the air hose. Gorbel also provides both mating Female fittings for 3/8” ID air hose.

  • Page 18: Step 9 - Float Mode (Option)

    TIP: Gorbel® Customer Service is available from 7am to 7pm Eastern Time Monday - Thursday and 7am to 5pm Eastern Time Friday. 10.1 Please contact the Gorbel® factory (585-924-6262) of any of the following occur. DO NOT ATTEMPT TO REPAIR UNIT YOURSELF. •...
  • Page 19 Unexpected Hardware Configuration 1. Mode switch does not match jumper or software configuration. 2. Handle pulled in during power up. 3. Power interruption during operation. Note: If any of the above listed problems persist, contact Gorbel® Customer Service. 4/04-Rev. S ®...

  • Page 20: Wire Rope Inspection, Maintenance, Replacement Criteria & Replacement Instructions

    WIRE ROPE INSPECTION 1) Frequent Inspection The operator or other designated person should visually inspect all ropes at the start of each shift. These visual observations should be concerned with discovering gross damage, such as listed below, which may be an immediate hazard: (a) distortion of the rope such as kinking, crushing, unstranding, birdcaging, main strand displacement, or core protrusion;...
  • Page 21 5) Rope should be maintained in a well-lubricated condition. Gorbel recommends using Chain and Cable Penetrating oil for lubrication. Lubricant applied as part of a maintenance program shall be compatible with the original lubricant. Lubricant applied shall be of the type that does not hinder visual inspection. Immediately after inspection, lubricant shall be applied before rope is returned to service.
  • Page 22 WIRE ROPE REPLACEMENT INSTRUCTIONS TIP: Wire rope replacement is to be performed by qualified maintenance personnel only. Note: All referenced drawings below are for a 150# unit. The procedure remains the same regardless of capacity. 1) Depress the Emergency Stop (E-Stop) button on the Handle. Disconnect power from the unit. 2) Remove the Covers from the Actuator assembly.
  • Page 23 17) Feed the new wire rope assembly, Stop Sleeve terminated end first, through the following path: a) Through the Nylon Insert (Item #2, Figure A1, page 24) at the bottom of the Actuator Frame. b) Over the top of the Idler Pulley going counter-clockwise. c) Clockwise around the Main Drum Pulley (Item #2, Figure A6, page 27).
  • Page 24 29) Reconnect power to the unit. 30) Release the Emergency Stop button on the Handle and grasp the operator present switch. Run the unit up and down several times to assure proper operation. 31) Continue normal operation. ® 4/04-Rev. S...

  • Page 25: Appendix A - 150# Bx Actuator Assembly Drawings

    APPENDIX A - 150# BX ACTUATOR ASSEMBLY DRAWINGS Figure A1 (bottom) & Figure A2 (top). 150# BX Actuator Assembly. 4/04-Rev. S ®...
  • Page 26 Figure A3 (bottom) & Figure A4 (top). 150# BX Actuator Assembly. ® 4/04-Rev. S...
  • Page 27 Figure A5. 150# BX Actuator Assembly. 4/04-Rev. S ®...
  • Page 28 Figure A6. 150# BX Actuator Assembly. ® 4/04-Rev. S...
  • Page 29 Figure A7 (bottom) & Figure A8 (top). 150# BX Actuator Assembly. 4/04-Rev. S ®...
  • Page 30 Figure A9 (bottom) & Figure A10 (top). 150# BX Actuator Assembly. ® 4/04-Rev. S...
  • Page 31 Figure A11 (bottom) & Figure A12 (top). 150# BX Actuator Assembly. 4/04-Rev. S ®...
  • Page 32 Figure A13. 150# BX Actuator Assembly. ® 4/04-Rev. S...
  • Page 33 Figure A14. 150# BX Actuator Assembly. 4/04-Rev. S ®...

  • Page 34: Appendix B - 300/380# Bx Actuator Assembly Drawings

    APPENDIX B - 300/380# BX ACTUATOR ASSEMBLY DRAWINGS Figure B1 (bottom) & Figure B2 (top). 300/380# BX Actuator Assembly. ® 4/04-Rev. S...
  • Page 35 Figure B3 (bottom) & Figure B4 (top). 300/380# BX Actuator Assembly. 4/04-Rev. S ®...
  • Page 36 Figure B5. 300/380# BX Actuator Assembly. ® 4/04-Rev. S...
  • Page 37 Figure B6. 300/380# BX Actuator Assembly. 4/04-Rev. S ®...
  • Page 38 Figure B7 (bottom) & Figure B8 (top). 300/380# BX Actuator Assembly. ® 4/04-Rev. S...
  • Page 39 Figure B9 (bottom) & Figure B10 (top). 300/380# BX Actuator Assembly. 4/04-Rev. S ®...
  • Page 40 Figure B11 (bottom) & Figure B12 (top). 300/380# BX Actuator Assembly. ® 4/04-Rev. S...
  • Page 41 Figure B13. 300/380# BX Actuator Assembly. 4/04-Rev. S ®...
  • Page 42 Figure B14. 300/380# BX Actuator Assembly. ® 4/04-Rev. S...

  • Page 43: Appendix C - Bx Standard Handle Assembly Drawings

    APPENDIX C - BX STANDARD HANDLE ASSEMBLY DRAWINGS Figure C1 (bottom) & Figure C2 (top). Standard Handle Assembly. 4/04-Rev. S ®...
  • Page 44 Figure C3. Standard Handle Assembly. ® 4/04-Rev. S...
  • Page 45 Figure C4. Standard Handle Assembly. 4/04-Rev. S ®...
  • Page 46 Figure C5 (bottom) & Figure C6 (top). Standard Handle Assembly. ® 4/04-Rev. S...
  • Page 47 Figure C7 (bottom) & Figure C8 (top). Standard Handle Assembly. 4/04-Rev. S ®...
  • Page 48 Figure C9 (bottom) & Figure C10 (top). Standard Handle Assembly. ® 4/04-Rev. S...
  • Page 49 Figure C11 (bottom) & Figure C12 (top). Standard Handle Assembly. 4/04-Rev. S ®...
  • Page 50 Figure C13. Standard Handle Assembly. ® 4/04-Rev. S...

  • Page 51: Appendix D - Bx Float Mode Handle Assembly Drawings

    APPENDIX D - BX FLOAT MODE HANDLE ASSEMBLY DRAWINGS Figure D1 (bottom) & Figure D2 (top). Float Mode Handle Assembly. 4/04-Rev. S ®...
  • Page 52 Figure D3 (bottom) & Figure D4 (top). Float Mode Handle Assembly. ® 4/04-Rev. S...
  • Page 53 Figure D5 (bottom) & Figure D6 (top). Float Mode Handle Assembly. 4/04-Rev. S ®...
  • Page 54 Figure D7 (bottom) & Figure D8 (top). Float Mode Handle Assembly. ® 4/04-Rev. S...
  • Page 55 Figure D9 (bottom) & Figure D10 (top). Float Mode Handle Assembly. 4/04-Rev. S ®...
  • Page 56 Figure D11. Float Mode Handle Assembly. ® 4/04-Rev. S...

  • Page 57: Appendix E - Bx Coil Cord Assembly - Schematic Drawings

    APPENDIX E - COIL CORD ASSEMBLY - SCHEMATIC DRAWINGS Figure E1. Coil Cord Assembly Standard - Float Mode. 4/04-Rev. S ®...
  • Page 58 Figure E2. Air Coil Cord Assembly Standard - Float Mode. ® 4/04-Rev. S...
  • Page 59 Figure E3. Remote Mount Coil Cord Standard - Float Mode. 4/04-Rev. S ®...
  • Page 60 Figure E4. Air Remote Mount Coil Cord Standard - Float Mode. ® 4/04-Rev. S...

  • Page 61: Appendix F - Controls Schematic Drawings

    APPENDIX F - CONTROLS SCHEMATIC DRAWINGS Figure F1. Remote Load Cell Assembly. 4/04-Rev. S ®...
  • Page 62 Figure F2. BX Controls Schematic. ® 4/04-Rev. S...

  • Page 63: Appendix G - Overall G-Force® Reference Dimension Drawings

    APPENDIX G - OVERALL G-FORCE® REFERENCE DIMENSIONS Figure G1. BX G-Force® 150# Overall Dimensions. 4/04-Rev. S ®...
  • Page 64 Figure G2. BX G-Force® 300/380# Overall Dimensions. ® 4/04-Rev. S...

  • Page 65: Appendix H - Bx G-Force® Handle Reference Dimension Drawings

    APPENDIX H - BX G-FORCE® HANDLE REFERENCE DIMENSIONS Figure H1. BX G-Force® Handle Detail Dimensions. 4/04-Rev. S ®...

  • Page 66: Appendix I - Component Layout Drawings

    APPENDIX I - COMPONENT LAYOUT DRAWINGS Figure I1. 150# Standard Inline Component Layout. ® 4/04-Rev. S...
  • Page 67 Figure I2. 300/380# Standard Inline Component Layout. 4/04-Rev. S ®...
  • Page 68 Figure I3. Standard Remote Mount Component Layout. ® 4/04-Rev. S...
  • Page 69 Figure I4. Float Mode Remote Mount Component Layout. 4/04-Rev. S ®...

  • Page 70: Recommended Spare Parts List

    77084 Lower Limit/Slack Switch, 150, 300, & 380# 77559 Offset Idler Pulley, 150, 300, & 380# 72190 Controls Assembly, MLD-114 78010 BX G-Force® Universal Miscellaneous Hardware Kit Contact Gorbel® Customer Service for Spare Parts pricing and availability. ® 4/04-Rev. S...

  • Page 71: Limited Warranty

    Cancellations: If it becomes necessary for the purchaser to cancel this order wholly or in part, he shall at once so advise Gorbel in writing. Upon receipt of such written notice all work will stop immediately. If the order entails only stock items, a flat restocking charge of 15% of the purchase price will become due and payable by Purchaser to Gorbel.

  • Page 72: Inspection And Maintenance Schedule

    CABLE ASSEMBLY, THEREFORE CAUSING PREMATURE UNIT FAILURE. KEEP ROTATION OF HANDLE TO LESS THAN 360 DEGREES. ® 600 Fishers Run, P.O. Box 593 Fishers, NY 14453-0593 Phone: (800) 821-0086 Fax: (800) 828-1808 E-Mail: info@gorbel.com http://www,gorbel.com © 2004 Gorbel Inc. All Rights Reserved ® 4/04-Rev. S...

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