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860-7200-18 DTU DTB Service & Maintenance Manual
SERVICE AND
MAINTENANCE
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
Destuff-it
Model: DTU
Restuff-it
Model: DTB
Unloader
TM
Loader
TM
1
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Summary of Contents for GORBEL Destuff-it DTU
- 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 SERVICE AND Destuff-it Unloader Model: DTU MAINTENANCE Restuff-it Loader MANUAL Model: DTB...
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Page 2: Table Of Contents
TABLE OF CONTENTS DIAGNOSTICS TABLE OF CONTENTS ���������������������������������������������� 2 MACHINE SPECIFICATIONS ������������������������������������ 3 SAFETY RELAY DIAGNOSTIC CHART ������������������ 44 CE DECLARATION OF CONFORMITY ��������������������� 4 FAULT CODES ��������������������������������������������������������� 45 INTRODUCTION �������������������������������������������������������� 5 REPAIRS MANUFACTURER INFORMATION ���������������������������� 5 WARRANTY POLICY ������������������������������������������������� 6 BELT CONFIGURATION LAYOUTS ������������������������... -
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 LOCKOUT/TAGOUT PROCEDURES KNOW THE EQUIPMENT Follow safe lockout/tagout procedures� For complete procedures, refer to Lockout/Tagout Section� Operators of this unit must be familiar with its principal parts DESTUFF-IT STANDARD SERVICE and have a thorough understanding of its control functions and movements�... -
Page 8: 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 9: 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 10: 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 11: 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 12 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 13 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 860-7200-18 DTU DTB Service & Maintenance Manual...
- Page 14 MACHINE OVERVIEW 860-7200-18 DTU DTB Service & Maintenance Manual...
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Page 15: Machine Overview
MACHINE OVERVIEW Power Supply Operator Platform Connection Remote Panel Pivoting Conveyor (Mobile or Anchored) Drive Panel End of Travel Sensor Middle Conveyor Lockable Casters Battery Rear Conveyor (Gravity Skate Wheels for Destuff-it™ or Powered Belt for Restuff-it™) Remote Section Conveyor (additional conveyor sections are optional) Rear Area Scanner (optional) -
Page 16: Lockout And Tagout
LOCKOUT AND TAGOUT 860-7200-18 DTU DTB Service & Maintenance Manual... -
Page 17: Safety Lockout/Tagout Procedure
SAFETY LOCKOUT/TAGOUT PROCEDURE AC and DC Disconnect Switches Power Drop Connector AC Battery Charger Plug Destuff-it Main Electrical Connector ONLY TRAINED AUTHORIZED PERSONNEL SHALL CONDUCT LOCKOUT PROCEDURES IMPORTANT: against the safety block and prevents it from lowering any Only persons who are appropriately trained further�... - Page 18 wait 15 minutes to ensure the lights and indicators are out on Fig. 5 the VFD and to allow the DC bus capacitors to discharge� Fig. 7 time, date, machine being serviced, and reason for the lock out� 4� Lockout and tag the AC cord plug for the battery charger (located at rear of Destuff-it, under the rear conveyor).
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Page 19: Removing The Lockouts
10� Stand on the operator platform� Press the Green Start button It is now safe to service the Destuff-it machine. on the side of the front pivoting conveyor� Wait for 20 seconds until the PLC starts� REMOVING THE LOCKOUTS 11� Remove Hydraulic Lockout: Use the rotary handle control Check that all guards have been re-installed and there are no to raise the front conveyor to its highest position�... -
Page 20: Components
COMPONENTS 860-7200-18 DTU DTB Service & Maintenance Manual... -
Page 21: Control Panel
CONTROL PANEL E-Stop Button CONTROL PANEL (CASE) Fuses Terminals Relays Safety Relay CONTROL PANEL (DOOR) PLC (Programmable Logic Controller) Analog Output Modules PLC Inputs PLC Outputs NOTE: If your machine has network integration, the Control Panel will appear different. Please see Appendix. 860-7200-18 DTU DTB Service &... -
Page 22: Remote Panel
REMOTE PANEL White Power ON Light E-Stop Button Green Start Button Conveyor Start/Stop Selector Switch (if equipped) Ground Check Green LED Ground Fault Red LED Meltric Connector REMOTE PANEL (CASE) Fuses Ground Fault/Monitor Relay Relays PMD (Phase Monitor Relay) 480V to 120VSEC Transformer 24VDC Power Supply Circuit Breakers REMOTE PANEL (DOOR) -
Page 23: Drive Panel
DRIVE PANEL E-Stop button AC Disconnect switch DC Disconnect switch DRIVE PANEL (CASE) Fuses VFDs (Variable Frequency Drives) Relays PMD (Phase Monitor Relay) Hydraulic Pump Overload Relay Battery Charger Contactor Hydraulic Pump Contactor Main Contactor Conveyor Motor - 2 & 3 Overload Relays DRIVE PANEL (DOOR) Drive Relays Drive Motor Fuses... -
Page 24: Electrical Systems
ELECTRICAL SYSTEMS The Destuff-it machine uses 3 electrical systems: 24VDC, 120VAC and 3 Phase - 480VAC. 24VDC Circuits The Destuff-it machine contains two maintenance free, 12-volt AGM batteries wired in series to power the drive system and PLC control circuits with 24VDC� There is an AC charger in the base of the machine, which charges and maintains the charge on the bat- teries�... - Page 25 *Note: In Canadian versions of the machine, a 600V to 480V step down transformer mounted on the remote panel, is used to con- vert the operating voltage to 480VAC for the machine. Power Mode There are two power modes for the Destuff-it: AC mode and DC mode�...
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Page 26: Control Devices
CONTROL DEVICES VFD: The VFD (Variable Frequency Drive) controls the conveyor motors� One VFD controls the front conveyor and the other controls the middle and rear conveyor motors (if equipped with a Control Device: The PLC (Programmable Logic Controller) is powered 3rd conveyor)�... -
Page 27: Operator Platform Mat
OPERATOR PLATFORM MAT The operator platform mat contains a sensor mat which detects the presence of a person on the operator platform� The mat senses pressure from the weight of a person and sends a 24VDC signal to the PLC when there is sufficient weight to activate it. The mat circuit is normally Open circuit�... -
Page 28: Sensors
SENSORS base of the machine� On the top of each display/head is the black memory module� The memory module contains the software for the scanner and connects to a power/logic output harness� The Front Sensing Edge Switch scanner body and display are connected with a dedicated cable� The Destuff-it machine may use a forward sensing edge switch to The scanner lens and ledge must be kept clean for the scanner to stop forward travel if the machine impacts an object�... -
Page 29: Rotary Handle
ROTARY HANDLE the machine� Only use Isopropyl alcohol to clean the ends of the fiber optic cables to prevent blurring the ends. The rotary control handle provides the PLC with input information Handle position sensors to control driving and steering the Destuff-it as well as controlling On each rotary handle are 2 proximity switches which sense that the functions of raising/lowering/pivoting the front conveyor and the rotary handle is being rotated in one direction or the other�... - Page 30 HAND PRESENT SENSOR Programming Keyence Sensor Amplifier 860-7200-18 DTU DTB Service & Maintenance Manual...
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Page 31: Hydraulic System
HYDRAULIC SYSTEM up/down and brake/brake hold� When a solenoid is activated by the PLC, a light on the coil wire on top of the solenoid turns ON� The SV1 solenoid has a Red pushbutton on the top, which if The hydraulic system of the Destuff-it is comprised of a hydraulic necessary, will manually open the valve manually and allow the pump/power unit, hydraulic manifold with solenoid valves and operator platform to lower if the red button is pushed�... -
Page 32: Access Under Floor Plates
ACCESS UNDER FLOOR PLATES 1� To remove floor plates, remove the four screws (as shown). 2� Move the plate only slightly to access the mat connector plug and disconnect it� 3� The plate can now be fully removed to access the motor and wheel�... -
Page 33: Maintenance
MAINTENANCE 860-7200-18 DTU DTB Service & Maintenance Manual... -
Page 34: Area Scanner Cleaning Procedure
AREA SCANNER CLEANING PROCEDURE 3� With a clean, damp, soft cloth, reach under the platform to clean the scanner� You need to wipe the lens and ledge as shown below. (Figure 2 – Rear scanner shown. Front scanner IMPORTANT: Only persons who are appropriately trained and is similar�) qualified with the safe operation and service of this machine 4�... -
Page 35: Lubrication Points
LUBRICATION POINTS LOCATION: Pivoting Conveyor (Modular Belt) GREASE ITEM PART INTERVAL FITTING TYPE Bearings for Head and NLGI 2 grease such as Every 2,000 hours Straight 0�04 oz Tail Shafts Castrol MP NLGI 2 grease such as Idler Bearings (2) Every 2,000 hours Straight 0�04 oz... - Page 36 Head shaft bearing (left, front corner of front pivoting conveyor) Head shaft bearing (right, front corner of front pivoting conveyor) Tail shaft bearing (left, rear corner of front pivoting conveyor) Idler bearing (left, rear corner of front pivoting conveyor) Tail shaft bearing (right, rear corner of front pivoting conveyor) Idler bearing (right, rear corner of front pivoting conveyor) 860-7200-18 DTU DTB Service &...
- Page 37 Drive bearings (left side of front pivoting conveyor, 3 in total Drive bearings (left side of front pivoting conveyor, 3 in total beneath holes in cover plates) beneath holes in cover plates) Transition plate bushing (remove 7 screws to remove top plate Drive bearings (right side of front pivoting conveyor, 3 in total and middle plate)�...
- Page 38 LOCATION: Middle Conveyor GREASE ITEM PART INTERVAL FITTING TYPE Drive and Idler Shaft NLGI 2 grease such as Every 2,000 hours Straight 0�04 oz Bearings (4) Castrol MP LOCATION: Rear Conveyor (Modular Belt) GREASE ITEM PART INTERVAL FITTING TYPE Drive and Idler Shaft NLGI 2 grease such as Every 2,000 hours Straight...
- Page 39 Idler shaft bearing under cover plate of middle conveyor Drive shaft bearing under cover plate of middle conveyor (right side of machine) (right side of machine) Idler shaft bearing under cover plate of rear conveyor Drive shaft bearing under cover plate of rear conveyor (left side of machine, front corner of rear conveyor) (left side of machine, rear corner of rear conveyor) Idler shaft bearing beneath cover plate of rear conveyor...
- Page 40 Under middle conveyor 8.1 8.4 Under floor plates 9.5 9.6 LOCATION: Rear Conveyor (Gravity Wheel) GREASE ITEM PART INTERVAL FITTING TYPE NLGI 2 grease such as 5.8 6.2 Caster on support frame Every 1,000 hours Straight See notes Castrol MP NOTES Apply grease to the wheel and swivel bearings�...
- Page 41 LOCATION: Operator Platform (Left Mast) GREASE ITEM PART INTERVAL FITTING TYPE Caster oil such as Molub- Spray entire Cylinder Lift Chain Every 1,000 hours None Alloy Chain Oil 22 Spray chain NOTES Remove Lexan cover and spray entire chain with platform fully raised� LOCATION: Middle Conveyor Support GREASE ITEM...
- Page 42 LOCATION: Base Frame GREASE ITEM PART INTERVAL FITTING TYPE NLGI 2 grease such as Drive Wheel Bearings Every 1,000 hours Straight Thin layer Castrol MP NLGI 2 grease such as Front Caster Every 1,000 hours None Thin layer Castrol MP NOTES Remove floor plates to access drive motors, wheel bearings and the two grease nipples on the casters.
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Page 43: Diagnostics
DIAGNOSTICS 860-7200-18 DTU DTB Service & Maintenance Manual... -
Page 44: Safety Relay Diagnostic Chart
SAFETY RELAY DIAGNOSTIC CHART INDICATOR CONDITION POSSIBLE CAUSES OR SOLUTION STATUS Power LED ON Waiting for manual reset: Fault LED OFF • EDM (External Device Monitoring) contacts not closed� Check PLC Module will not reset Ch 1 LED flashing outputs to safety mat reset relay - check relay & connections Ch 2 LED flashing •... -
Page 45: Fault Codes
FAULT CODES Fault light will flash and audible alarm with sound in sequence to identify type of fault� One Flash/Beep Sensor fault Objects blocking the step mats Remote sensor Remote panel conveyor selector set to STOP Two Flashes/Beeps Overload fault� Each belt conveyor and hydraulic pump have overload devices located in Drive Panel�... -
Page 46: Repairs
REPAIRS 860-7200-18 DTU DTB Service & Maintenance Manual... -
Page 47: Belt Configuration Layouts
BELT CONFIGURATION LAYOUTS M1220GX24X1KIT - Front Conveyor Belt Repair 24” w x 1” Lg Griptop M1220GX30X1KIT - Middle and Rear Conveyor Belt Repair 30” w x 1” Lg Griptop Rod Removal Tool (Part # H010702262): Do not use a hammer and punch to remove rods to avoid damage to links. -
Page 48: Replacing The Front Conveyor
REPLACING THE FRONT CONVEYOR MODULAR BELT IMPORTANT: Only persons who are appropriately trained and qualified with the safe operation and service of this machine should be allowed to carry out operation, installation, service or maintenance� Trained personnel must follow all applicable codes, laws and standards, both national and local, when conducting any servicing or maintaining of the machine and associated equipment�... - Page 49 8� Before joining the new belt ensure that the sprocket spacing 6� Use the rod removal tool (part # H0102262) to partially is correct on all three shafts� Some shafts have metal remove a rod from the top of the belt� Grab the end of the retaining rings which lock the sprockets in place, on the shaft�...
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Page 50: Belt Tension
10� Re-install all the lower conveyor guards, covers and the 11� Check the machine is clear of all tools and items used front conveyor motor fan guard cover� Use a small amount of during the repair� Remove the Lockouts for the AC and lubricant (White Lithium grease) on the bearing in the center DC disconnect switches and all the connectors�... -
Page 51: Replacing The Front Sensing Edge Strip Switch
REPLACING THE FRONT SENSING EDGE 3� Place wood blocking between the floor and underside of STRIP SWITCH the operator platform� Ideally the platform should be about 12 inches off the floor to allow room to work. Ensure that The front sensing edge strip switch is designed to prevent the blocking does not obstruct the front or left edge of the the machine from travelling forward in the event the Destuff-it platform where the cable for the sensor edge switch is... - Page 52 residue or coating� DO NOT spray lubricant in the channel� terminal strip ports they were removed from earlier� It makes This won’t allow the new sensor strip to stay firmly in the no difference which wire goes to either of the two respective channel, once it is installed�...
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Page 53: Levelling The Operator Platform
LEVELLING THE OPERATOR PLATFORM 2� With the machine ON, raise the operator platform enough (about 8 inches) to slide a floor jack underneath the right side of the platform� Set the jack to its lowest height� Lower Tools required: Measuring tape, 14mm (9/16”) wrench, floor jack, the platform down so it rests on the floor jack. -
Page 54: Replacing The Hydraulic Brake
REPLACING THE HYDRAULIC BRAKE 3� Remove the white plastic transition plate between the rear and middle conveyor belts� Support the rear conveyor section from above (must be sufficient to hold the weight). Ideally a winch or crane should be used as the rear conveyor will need IMPORTANT: Only persons who are appropriately trained and to be moved sideways somewhat, to allow room to access qualified with the safe operation and service of this machine... - Page 55 5� Place rags or absorbent material over the battery cover plate Brake Disc Alignment/Setup to catch any hydraulic fluid spills. Disconnect the hydraulic IMPORTANT: In order for the new brake to obtain a long hose at the left side of the brake� Cover the end of the hose service life, the correct set up of the brake and brake disc to prevent fluid leakage and debris from entering the hose.
- Page 56 12� With the machine started, one person turns off the brake release switch and another person cycles the brake while the first person watches it open and close. Use the brake release switch� Verify a small gap (1/16”) appears between the underside of the caliper disc plate and the top of the lower brake pad�...
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Page 57: Replacing The Hydraulic Fluid
REPLACING THE HYDRAULIC FLUID (Extreme caution should be exercised when draining hot lubricant to prevent possible injury or spills). IMPORTANT: Only persons who are appropriately trained and 6� Remove the pump and tank from the machine on to a work qualified with the safe operation and service of this machine bench. -
Page 58: Transportation And Storage
TRANSPORTATION AND STORAGE 860-7200-18 DTU DTB Service & Maintenance Manual... -
Page 59: Transporting The Machine
TRANSPORTING THE MACHINE or requirements surrounding this system prior to movement with a forklift� This section provides necessary information needed to safely OPERATOR RESPONSIBILITIES FOR transport the Restuff-it machine within a warehouse operation� SAFE TRANSPORTATION It is not intended to cover normal operation and use which are covered under other sections of this manual�... -
Page 60: Preventing Battery Rundown
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 61: 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 62: Appendix
APPENDIX 860-7200-18 DTU DTB Service & Maintenance Manual... -
Page 63: Control Panel (With Network Integration)
CONTROL PANEL (WITH NETWORK INTEGRATION) CONTROL PANEL (FRONT) E-Stop CONTROL PANEL (CASE) Fuses Terminals Relays Safety Relay CONTROL PANEL (DOOR) PLC (Programmable Logic Controller) Analog Output Modules PLC Inputs PLC Outputs 860-7200-18 DTU DTB Service & Maintenance Manual... -
Page 64: Remote Panel (With Network Integration)
REMOTE PANEL (WITH NETWORK INTEGRATION) REMOTE PANEL (FRONT) White Power ON Light E-Stop Button Green START Button Ground Fault Red LED Ground Check Green LED Meltric Connector REMOTE PANEL (CASE) Fuses PMD (Phase Monitor Relay) 24VDC Power Supply PLC (Program Logic Control) 480V to 120VSEC Transformer Ground Fault/Monitor Relay Relays... -
Page 65: Drive Panel (With Network Integration)
DRIVE PANEL (WITH NETWORK INTEGRATION) DRIVE PANEL (FRONT) E-Stop button AC Disconnect switch DC Disconnect switch DRIVE PANEL (CASE) Fuses VFDs (Variable Frequency Drives) Relays PMD (Phase Monitor Relay) Hydraulic Pump Overload Relay Battery Charger Contactor Hydraulic Pump Contactor Main Contactor Conveyor Motor - 2 &...
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GROUND CHECK KEEPS BLINKING AND HAS CLICKING NOISE OFF THE DFGC