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860-7104-19 DTB Operation Manual
OPERATION
MANUAL
Engineered Lifting Systems and Equipment, Inc. DBA Gorbel Canada
T (800) 263-9823 | F (519) 669-9047 | www.gorbel.com
275 Union Street | Elmira, ON N3B 3P1 | Canada
Original Instructions
Restuff-it
Models:
DTB2, DTB4, DTB5,
DTB6, DTB7, DTB8,
DTB9, DTB10, DTB11
Loader
TM
1
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Summary of Contents for GORBEL Restuff-it DTB2
- Page 1 Engineered Lifting Systems and Equipment, Inc. DBA Gorbel Canada T (800) 263-9823 | F (519) 669-9047 | www.gorbel.com 275 Union Street | Elmira, ON N3B 3P1 | Canada OPERATION Original Instructions Restuff-it Loader MANUAL Models: DTB2, DTB4, DTB5, DTB6, DTB7, DTB8,...
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Page 2: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS ........... 2 CONNECT CONVEYORS 1 AND 2 ....... 29 MACHINE SPECIFICATIONS ........3 CONNECT CONVEYOR TO CE DECLARATION OF CONFORMITY ....4 REMOTE PANEL ........... 30 INTRODUCTION ............. 5 CONNECT POWER TO REMOTE PANEL .... 30 MANUFACTURER INFORMATION ...... -
Page 3: Machine Specifications
MACHINE SPECIFICATIONS Thank you for purchasing a Restuff-it Unloader from Engineered Lifting Systems & Equipment, Inc. DBA Gorbel Canada (ELS). ® This manual contains valuable safety and operation information. Ensure operators read the SAFETY and OPERATING sections of this manual prior to operating your new machine. -
Page 4: Ce Declaration Of Conformity
CE DECLARATION OF CONFORMITY 01-13-2023 CE Declaration of Conformity Hereby, Gorbel Inc., declares that this material handling equipment is in compliance with the essential requirements and other relevant provisions listed below. ----------------------------------------------------------------------------------------------------------------------------------------------- EMC Directive: 2014/30/EU Standard EN 61000-6-4:2007 +A1 :2011 Electromagnetic compatibility (EMC) –... -
Page 5: Introduction
INTRODUCTION MANUFACTURER INFORMATION Thank you for purchasing a Restuff-it Unloader. This manual Engineered Lifting Systems & Equipment, Inc. DBA Gorbel ® provides safety and operation information for the machine. Canada (ELS) 275 Union Street, Elmira, ON Canada N3B 3P1 When maintained and operated properly, the unit is designed to provide many years of reliable service. -
Page 6: Warranty Policy
WARRANTY POLICY d) Any incidental, indirect, special or consequential damages. e) Wear items. Engineered Lifting Systems & Equipment, Inc. DBA Gorbel ® SHIPPING: It is the responsibility of the customer to inspect all Canada (ELS) warrants their equipment, when shipped, and their... -
Page 7: Notice To All Operators
NOTICE TO ALL OPERATORS • NEVER operate this equipment without completing daily inspection checklist. • NEVER operate machine if safety devices have been altered KNOW YOUR EQUIPMENT or disabled. • NEVER operate a potentially defective machine. Operators of this unit must be familiar with its principal parts and •... -
Page 8: Reasonably Foreseeable Misuse
REASONABLY FORESEEABLE MISUSE • Do not operate machine with persons on the machine base. • Do not use machine in a wet environment. • Do not drive machine on unstable surface, off the side of Do not operate above design capacities. dock plate or over holes. -
Page 9: Iso Graphical Symbols Legend
ISO GRAPHICAL SYMBOLS LEGEND (For warning labels on the Destuff-it Restuff-it machines) SYMBOL OR LABEL DEFINITION This is the safety alert symbol. It is used to alert to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid a possible injury or death. The addition of this symbol to a DANGER or WARNING safety label indicates that an electrical hazard exists, which will result in personal injury if the instructions are not... - Page 10 ISO GRAPHICAL SYMBOLS LEGEND (For warning labels on the Destuff-it Restuff-it machines) SYMBOL OR LABEL DEFINITION AREA SCANNER LABEL REAR SCANNER FAULTS (RIGHT / REVERSE / LEFT) REVERSE SCANNER BYPASS RECOMMENDED ZERO POINT TURN RECOMMENDED FORWARD SCANNER FRONT SCANNER FAULTS (RIGHT / FORWARD / LEFT) E0604R1 BATTERY CHARGER...
- Page 11 ISO GRAPHICAL SYMBOLS LEGEND (For warning labels on the Destuff-it Restuff-it machines) SYMBOL OR LABEL DEFINITION POWER ON FAULT REMOTE STOP RUN AND JOG CONVEYOR RESET START 860-7104-19 DTB Operation Manual...
- Page 12 MACHINE OVERVIEW 860-7104-19 DTB Operation Manual...
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Page 13: Machine Overview
MACHINE OVERVIEW Power Supply Operator Platform Connection Remote Panel Pivoting Conveyor (Mobile or Anchored) Drive Panel Middle Conveyor Lockable Casters Battery Rear Conveyor Remote Section Conveyor (additional conveyor sections are optional) Rear Area Scanner (optional) Control Panel Pressure Sensing Safety Mats (two on both sides of machine) Lifting Points (two on both sides of machine) LED Light Strips (on both masts) Rotary Handle (on both sides of machine) - Page 14 UNLOADING THE MACHINE 860-7104-19 DTB Operation Manual...
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Page 15: Unloading The Machine
UNLOADING THE MACHINE ONLY AUTHORIZED PERSONNEL SHOULD DRIVE THE 6. Ensure your weight is on operator sensing mat when standing RESTUFF-IT on operator platform. 1. Remove all packing materials and tether straps. Roll out remote section and conveyor (if applicable). 2. - Page 16 FACILITY POWER SUPPLY 860-7104-19 DTB Operation Manual...
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Page 17: Facility Power Supply
FACILITY POWER SUPPLY All electrical installations and connections are to be made by ONLY AUTHORIZED PERSONNEL SHOULD CONNECT qualified installation personnel and adhering to national and local POWER SUPPLY TO THE REMOTE PANEL. PERSONNEL codes. MUST ALWAYS FOLLOW PROPER PROCEDURES AND WEAR APPROPRIATE PPE. -
Page 18: Phasing
PHASING After connecting power supply to the Remote Panel, phasing must be verified. If phasing is correct, the LED Status on the Phasing Monitor Device (PMD) will be green and the White Power Light on the door of the Remote Panel will turn on. If phasing is reversed, the White Power Light on the door of the Remote Panel will not turn on. - Page 19 MACHINE COMPONENTS 860-7104-19 DTB Operation Manual...
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Page 20: Machine Components
MACHINE COMPONENTS Modular front belt, middle belt, powered rear conveyor REMOTE PANELS Mounted in Stand (Anchored) Mounted in Remote Section (Mobile) 860-7104-19 DTB Operation Manual... -
Page 21: Control Panel
CONTROL PANEL REMOTE PANEL White Power ON Light E-Stop Button E-Stop Button AC Power ON Light Green START Button Fault Light Ground Fault Red LED Indicator Remote Stop Light Ground Check Green LED Indicator Conveyor Start/Stop Selector Switch (if equipped) Control Panel OPERATOR PLATFORM Control Panel... -
Page 22: Emergency Stop (E-Stop) Buttons
EMERGENCY STOP (E-STOP) BUTTONS There are 5 E-Stop buttons on each unit. E-Stop buttons are located on the control panel, drive panel, remote panel and both sides of front pivoting conveyor. Pressing an E-Stop button will stop all machine motion immediately. Rotate E-Stop buttons gently to release. -
Page 23: Batteries
BATTERIES service life is expected when proper charging and storage procedures are followed. Batteries (2) 120VAC power cord Battery Charger Step-down Transformer BATTERY GAUGE A battery gauge is also provided on control panel to show state of charge. Battery Charge Level Indicator Hour Meter (Belt Run Time) Battery meter has 10 LEDS to show battery condition. -
Page 24: Battery Chargers
BATTERY CHARGERS B) NOCO GENIUS® GENPRO (IF SO PROVIDED) If machine uses a NOCO Genius® GENPRO10X2 Battery A) XANTREX TRUECHARGE (IF SO PROVIDED) ® Charger model 10amp x 2 (12V): If machine uses a Xantrex TrueCharge 2 Battery Charger ® model TC2024 (20A, 24VDC): WARNING: SHOCK HAZARD Truecharge 2 Battery... -
Page 25: Rotary Handle
SENSORS Operator Sensing Mat ROTARY HANDLE Sensing Edge (when equipped) Pressure Sensing Safety Mats Use rotary handle for conveyor UP/DN or to steer when travelling. Area Scanners (when equipped) Gripping rotary handle releases brake allowing side to side front conveyor motion. Rotating rotary handle moves platform and/or pivoting conveyor up and down. -
Page 26: Operator Controls
OPERATOR CONTROLS D - Machine Travel - Turn selector switch to move machine forward or backwards. Hold selector switch in position to maintain travel in desired direction. CONTROLS ON PIVOTING CONVEYOR E - Machine Rotate - Turn selector switch to rotate unit either clockwise or counterclockwise. -
Page 27: Fault Codes
FAULT CODES PIVOTING CASTOR AND DRIVE WHEELS Three lights of selector switches (B, D, E) flash and beep to Each unit is equipped with one steel dual swivel caster and two announce a fault. Codes are as follows: urethane drive wheels. One Flash/Beep Sensor fault Objects putting pressure on the mats... - Page 28 STARTING THE MACHINE 860-7104-19 DTB Operation Manual...
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Page 29: Starting The Machine
STARTING THE MACHINE Ensure front conveyor legs are raised 3 inches off the ground. If this step is not followed, damage will occur IMPORTANT: Only persons who are appropriately trained and to the flex conveyor. It is recommended that two people qualified with the safe operation and service of this machine connect conveyor to machine. -
Page 30: Connect Conveyor To Remote Panel
CONNECT POWER TO REMOTE PANEL CONNECT CONVEYOR TO REMOTE PANEL Method 1: Method 1: Suspended Power Drop (connected to cable in post in the Remote Section) Ensure power supply from the building is OFF. Connect Remote Panel to facility’s power supply with Meltric Connector at the end of the post in the Remote Section. - Page 31 START-UP SEQUENCE Stand on operator platform. 1. Turn facility fused disconnect to ON position. 7. Press green START button on pivoting conveyor. Button will illuminate green when started. Wait 20 seconds for PLC to 2. Verify all 5 E-Stops are released (by rotating clockwise). start.
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Page 32: Quick Start Guide With Conveyor
QUICK START GUIDE WITH CONVEYOR WARNING: DO NOT operate the Restuff-it machine without 10. To start conveyor, rotate the Belt Motion Control Switch (D). proper authorization. Failure to avoid this hazard could Check that the conveyor belt direction is moving according to result in serious injury. - Page 33 FLEXIBLE CONVEYOR (when provided) 860-7104-19 DTB Operation Manual...
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Page 34: Flexible Conveyor
FLEXIBLE CONVEYOR Adjust Speed Control dial on each Conveyor Control Box to suit handling of product size/weight. To start conveyor, rotate Belt Motion selector switch on Ensure Conveyor Start/Stop Selector switch (located on pivoting conveyor towards the front of the machine. remote panel if equipped) is turned to ON. - Page 35 PREVENTIVE MAINTENANCE NOTE: Conveyors should be started and allowed to run for a few mintues to warm up O-Rings. This will ensure efficient product transfer. After starting flex conveyor, ensure ALL rollers are Daily Maintenance turning. Manually turn any rollers that are slipping to get each Keep conveyor clean and free of debris, dirt and grease started.
- Page 36 CASCADING BELT CONVEYOR (when provided) 860-7104-19 DTB Operation Manual...
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Page 37: Cascading Belt Conveyor
CASCADING BELT CONVEYOR 3. Connect strain relief cable to Restuff-it 1. Bring conveyor into position near Restuff-it machine. Connect hitch to ball on Restuff-it 4. Attach any additional conveyor (optional). 2. Connect plug to receptacle. 860-7104-19 DTB Operation Manual... - Page 38 5. Select direction of product to be transferred. NEVER overload conveyors. 6. To start conveyor, rotate the RUN control selector switch on NEVER allow motors to continue to run under a jammed product. pivoting conveyor towards the front of the machine. NEVER unplug conveyors with the power on.
- Page 39 OPERATING THE MACHINE 860-7104-19 DTB Operation Manual...
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Page 40: Operating The Machine
OPERATING THE MACHINE OPERATOR RESPONSIBILITIES FOR MAINTENANCE Serious injury could result from using a Restuff-it machine that is This section provides necessary information needed to operate not properly maintained or kept in good working condition. the Restuff-it machine. It is important for all users to read and understand this section prior to operating the machine. -
Page 41: Restuffing Best Practices
RESTUFFING BEST PRACTICES DRIVING INSTRUCTIONS ALWAYS ensure clearance of obstructions before driving unit LOADING CONTAINER (BOTTOM OF THE BOX WALL) toward dock. • Keep pivoting conveyor at waist height allowing product When entering the truck, ALWAYS drive the machine with the to fall into place (using gravity as main energy source). -
Page 42: Restuffing Modes
DOCK FLOOR BELT STATUS LED INDICATORS • Plan workflow to eliminate unnecessary wait times. Organize Belt status LED indicators are located on left and right-hand sides dock floor. Organize work so physical demands and work of front conveyor, facing operator. LED changes colour depend- pace increase gradually. - Page 43 helpful for heavy packages. Packages must be minimum size of MODE 1 - NEVER STOP 8” long x 4” wide x 4” high. Belts always run. Packages never stop at end of conveyor. LED constantly shows AMBER, then GREEN when product Machine sensors never stop the product.
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Page 44: Daily Operation Checklist
INSPECTING THE MACHINE DAILY OPERATIONS DESTUFF-IT RESTUFF-IT CHECKLIST [Operator’s Daily/Pre-Shift Inspection Form] Unit #: Department: Date: Operator’s Name: No. of Hours on Machine: ITEM # INSPECT CHECK FOR PASS FAIL Electrical Cables and Damaged connectors or latches. Check for kinked, worn, or Connectors damaged electrical cables. -
Page 45: Transportation And Storage
TRANSPORTATION AND STORAGE 860-7104-19 DTB Operation Manual... -
Page 46: Transporting The Machine
TRANSPORTING THE MACHINE The Restuff-it utilizes a sealed hydraulic system to facilitate proper and efficient operation. There are no special precautions or requirements surrounding this system prior to movement with a This section provides necessary information needed to safely forklift. transport the Restuff-it machine within a warehouse operation. -
Page 47: Preventing Battery Rundown (For Long Term Storage)
PREVENTING BATTERY RUNDOWN (FOR Step 2 - Remove the 4 thumb screw knobs and washers that secure the guard over top of the batteries. Remove the guard LONG TERM STORAGE) and place it on the machine in a safe place. Reinstall the thumb screws and washers to prevent them from being lost. -
Page 48: Safe Handling
SAFE HANDLING Do not operate machine: • Unless trained and authorized. • Unless operator manual is read and understood. • Unless mentally and physically capable of following machine instructions. • Under the influence of alcohol or drugs. • While using a cell phone or other types of electronic devices. •... - Page 49 OPTIONS 860-7104-19 DTB Operation Manual...
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Page 50: Options
OPTIONS Depending on the options you choose to be included in your Restuff-it unit, your machine may have the following features: SENSORS The Restuff-it machine may use a forward sensing edge switch to stop forward travel if the machine impacts an object. The machine will stop driving forward and the conveyor belts will shut off. -
Page 51: Network Integration
NETWORK INTEGRATION SAFETY GUARD RAILS If your machine has Network Integration, the Remote, Control and Drive Panels will appear different. The Network cable will be integrated in the panels and will connect to an ethernet port at the Rear Conveyor. Ethernet Connection SIDE GUIDES STANDARD OPERATOR PLATFORM... -
Page 52: Spanish
SPANISH 860-7104-19 DTB Operation Manual... -
Page 53: Guía Rápida De Inicio Yfuncionamiento
GUÍA RÁPIDA DE INICIO Y FUNCIONAMIENTO ADVERTENCIA: NO opere la máquina Destuff-it™ o Restuff-it™ sin la los tapetes laterales deben ser reiniciados. Gire hacia atrás debida autorización. El no obedecer esta advertencia puede ocasionar el botón de Movimiento de las Bandas (D), sosténgalo por segundos, lesiones graves. -
Page 54: Descargando Su Máquina
DESCARGANDO SU MÁQUINA 6. Asegúrese de que su peso se encuentre sobre del tapete de detección del operador cuando se encuentre sobre la plataforma NOTE: SOLAMENTE PERSONAL AUTORIZADO PUEDE del operador. CONDUCIR LA MAQUINA RESTUFF-IT™. 1.Retire todo el material de embalaje y las correas de sujeción. Manualmente mueva la sección remota y la banda transportadora (si corresponde) fuera del camión.
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