GORBEL G-Force Q2 Series Instruction manual

G-Force®
Q2and iQ2Series
®
Date
Month Year
Gorbel® Dealer
Rev C released: 12/2020
Gorbel® Customer Order No. / Serial No.
Original manual released: 06/2020
IMPORTANT!
DO NOT DESTROY
OR DISCARD.
Default Settings for your G-Force®unit:
AP SSID: G-Force AP Order Number
AP Password: Order Number
Installation,
Operation, &
Maintenance
Manual

TABLE OF CONTENTS
Safe Hoist Operating Guidelines...........................................................................................................................................3
Warnings & Introduction.....................................................................................................................................................5-6
Correct G-Force® Installation Orientation.............................................................................................................................7
G-Force® Main Assembly Component Description ..............................................................................................................8
Installation
Step 1 - Unpacking the G-Force®.....................................................................................................................9
Step 2 - Pre-Assembly / Tools Required...........................................................................................................9
Step 3 - Actuator Assembly Installation ............................................................................................................9
Step 4 - Coil Cord Installation .........................................................................................................................10
Step 5A - In-Line Slide & Force Sensing Slide Handle Installation.....................................................................11
Step 5B - Remote Mounted Slide Handle Installation .........................................................................................11
Step 5C - Suspended Pendant Handle Installation .............................................................................................13
Step 5D - Remote Mounted Pendant Handle Installation....................................................................................14
Step 5E - 1320 Lb. In-Line Slide or Remote Mounted Handle Installation..........................................................15
Step 5F - 1320 Lb. Suspended Pendant Handle Installation ..............................................................................16
Step 5G - 1320 Lb. Air Hose Installation (Option) ...............................................................................................17
Step 5H - Remote Mount Force Sensing Slide Handle Installation.....................................................................18
Step 5I - Remote Mount Force Sensing Hub Handle Installation ....................................................................19
Step 6 - Electrical Power Connection..............................................................................................................20
Step 7 - Initial Power-Up .................................................................................................................................20
Step 8 - Float Mode and Final Steps .........................................................................................................21-22
Step 9 - Expansion I/O Block Mounting Instructions (Option).........................................................................23
Lift Functionality ..................................................................................................................................................................24
Controls Interface Features.................................................................................................................................................27
Program Mode
Overview & Basic Features ..................................................................................................................................28
Menu and Sub-Menu Selections...........................................................................................................................30
Program Mode Menus and Explanations ..............................................................................................................30
Troubleshooting
Basic Troubleshooting ..........................................................................................................................................47
LED Status Chart..................................................................................................................................................49
Technical Specifications......................................................................................................................................................50
Wire Rope Inspection, Maintenance, & Replacement.........................................................................................................51
Slack Spring Adjustment.....................................................................................................................................................58
Recommended Spare Parts Kits.........................................................................................................................................59
Dual Handle Set Up Instructions .........................................................................................................................................60
G-Force® HMI Visualization................................................................................................................................................62
Appendix A: AP Field Customization Instructions ...............................................................................................................81
Appendix B: AP VNC Viewer Install Instructions .................................................................................................................84
Appendix C: AP Connection QuickStart Guide....................................................................................................................86
Appendix F: PC IP Address Set Up for Wired Connections ................................................................................................88
Limited Warranty .................................................................................................................................................................90
CE Declaration of Conformity..............................................................................................................................................91
Inspection and Maintenance Schedule ...............................................................................................................................92
2

SAFE HOIST OPERATING GUIDELINES
General
There is no one single factor that is more important for minimizing the
possibility of personal injury to the operator and those working in the area,
or damage to property, equipment, or material than being familiar with the
equipment and using Safe Operating Practices.
Hoists/trolleys are designed for lifting and transporting of material only.
Under no circumstances, either during initial installation or in any other use,
should the hoist be used for lifting or transporting personnel.
No operator should be permitted to use the equipment who is not familiar
with its operation, is not physically or mentally fit, or has not been schooled
in safe operating practices. The misuse of hoists can lead to certain
hazards which cannot be protected against by mechanical means; hazards
which can only be avoided by the exercise of intelligence, care, and
common sense.
Safe Operating Practices also involve a program of periodic inspection and
preventative maintenance (covered in a separate section). Part of the
operator’s training should be an awareness of potential
malfunctions/hazards requiring adjustments or repairs, and bringing these to
the attention of supervision for corrective action.
Supervision and management also have an important role to play in any
safety program by ensuring that a maintenance schedule is adhered to,
and that the equipment provided for the operators is suitable for the job
intended without violation of one or more of the rules covering safe
operating practices and good common sense.
The Safe Operating Practices shown are taken in part from the following
publications:
•American National Standard Institute (ANSI)
•Safety Standards for Cranes, Derricks, Hoists
•ANSI B30.2 - Overhead and Gantry Cranes
•ANSI B30.16 - Overhead Hoists
Do’s and Don’ts (Safe Operation of Hoists)
The following are Do’s and Don’ts for safe operation of overhead
hoists. A few minutes spent reading these rules can make an
operator aware of dangerous practices to avoid and precautions to
take for his own safety and the safety of others. Frequent
examinations and periodic inspections of the equipment as well as a
conscientious observance of safety rules may save lives as well as
time and money.
DON’TS - HOISTS
1. Never lift or transport a load until all personnel are clear and do
not transport the load over personnel.
2. Do not allow any unqualified personnel to operate hoist.
3. Never pick up a load beyond the capacity rating appearing on
the hoist. Overloading can be caused by jerking as well as by
static overload.
4. Never carry personnel on the hook or the load.
5. Do not operate hoist if you are not physically fit.
6. Do not operate hoist to extreme limits of travel of cable without
first checking for proper limit switch action.
7. Avoid impact between two hoists or between hoist and end stop.
Do not tamper with or adjust any parts of the hoist unless
specifically authorized to do so.
8. Never use the load cable as a sling.
9. Do not divert attention from load while operating hoist.
10. Never leave a suspended load unattended.
11. Do not use limit switch(es) for normal operating stop(s). These
are safety devices only and should be checked on a regular
basis for proper operation.
12. Never operate a hoist that has an inherent or suspected
mechanical or electrical defect.
13. Do not use load cable as a ground for welding. Never touch a
live welding electrode to the load cable.
14. Do not jog controls unnecessarily. Hoist motors are generally
high torque, high slip types. Each start causes an inrush of cur-
rent greater than the running current and leads to overheating
and current failure, or burnout, if continued to excess.
15. Do not operate hoist if load is not centered under hoist.
16. Do not operate hoist if cable is twisted, kinked, or damaged.
17. Do not remove or obscure label.
18. Do not permanently activate operator present sensor.
19. Do not dis/reassemble components while the hoist is energized,
‘Hot-Swapping’of components is strongly discouraged.
DO’S - HOISTS
1. Read and follow manufacturer’s instruction, installation, and
maintenance manuals. When repairing or maintaining a hoist,
use only manufacturer’s recommended parts and materials.
2. Read and follow all instruction and warning information on or
attached to a hoist.
3. Remove the hoist from service and thoroughly inspect and
repair, as necessary, if unusual performance or visual defects
(such as peculiar noise, jerky operations, travel in improper
direction, or obviously damaged parts) are noticed.
4. Establish a regular schedule of inspection and maintain records
for all hoists with special attention given to hooks, load cables,
brakes, and limit switches.
5. Check operation of brakes for excessive drift.
6. Never lift loads over people, etc.
7. Check for damaged hooks and load cable.
8. Keep load cable clean and well maintained.
9. Check the load cable for improper seating, twisting, kinking,
wear, or other defects before operating the hoist.
10. Make sure a load clears neighboring stockpiles, machinery, or
other obstructions when raising, lowering, or traveling the load
11. Center hoist over the load before operating.
12. Avoid swinging of load or load hook when traveling the hoist.
13. Be sure the load attachment is properly seated in the saddle of
the hook. Balance load properly before handling. Avoid hook tip
loading.
14. Pull in a straight line, so that neither hoist body nor load cable
are angled around an object.
15. Take up slack slowly.
16. Know the hand signals for hoisting, cross travel, and crane
travel if working with cab-operated hoists or cranes. Operators
should accept signals of only those persons authorized to give
them.
3

G-FORCE®OPERATIONAL GUIDELINES
All operators should read the G-Force® Installation and Operation Manual before
operating the unit. Please follow the instructions contained in this manual for your
safety and the optimum trouble-free operation of your G-Force®.
0
Maximum
Trolley Saddle is
Read and follow all
instructions and warning
information on or attached
to the G-Force®.
Check Wire Rope for
improper seating, twisting,
kinking, wear or defects
before operating.
Center G-Force® over the
load before lifting a load.
Do not end or side load.
Avoid swinging of load or
load hook when traveling
with the G-Force®.
Check the coil cord for
improper seating, twisting,
kinking, wear or defects
before operating.
The operator’s hand should
not leave the handle grip at
any time the G-Force® is in
use (excluding Float Mode).
Float Mode – press the
G-Force® button with only the
load weight hanging from the
unit. Applying additional force
will cause unit to drift.
The wire rope should never be
>15°out of vertical while the
G-Force® is in use. The G360
must be level at all times.
Do not impact the
G-Force® into end stops
repeatedly or at a speed
faster than a normal
walking pace.
Maximum Trolley Saddle or
the G-Force® with standard
in-line slide handle is 14’.
What is
Trolley
Saddle?
The
distance
from
bottom of
wheels to
floor.
Questions about G-Force®?
Call your local Gorbel®
distributor or Gorbel®
Customer Service at
[phone].
The maximum available
wire rope travel for the
G-Force® is 11’.
For H5 duty cycle, the
maximum working stroke
is 8’.
11’
?
4

WARNINGS
IMPORTANT SAFETY INSTRUCTIONS
WARNINGS
1. All operators should read the G-Force® Installation and Operation Manual before operating the
unit.
2. Check wire rope for improper seating, twisting, kinking, wear, or defects before operating.
3. Center the G-Force® over the load before lifting. DO NOT end or side load the G-Force®. End or
side loading will seriously reduce the life of the wire rope and lead to premature failure. The wire
rope should never exceed an out of vertical angle greater than 15° under any circumstances.
4. Avoid swinging of load or load hook when traveling with the G-Force®.
5. Check the coil cord for improper seating, twisting, kinking, wear, or defects before operating. Any of
the described conditions will seriously reduce the life of the coil cord and lead to premature failure.
6. Press the G-Force® logo button for Float Mode feature with only the load weight hanging from the
unit. Additional external forces applied to the load during initiation of Float Mode will result in the load
drifting.
7. Do not repeatedly impact the 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® Inside Sales for alternative end stop options.
8. The G-Force® does not meet “wash-down” environment requirements. The G-Force® does not
meet “explosion proof” requirements.
9. Ensure that the slide handle is supported properly in remote mounted handle applications by
mounting the slide handle at both the top and bottom mounting points (diagram D, page 23).
10. Do not mount any objects to the G-Force® slide handle grip (i.e. switches). Additional objects may
interfere with the travel of the sliding handle grip and affect the overall speed and functionality of the
unit.
11. Do not mount any load bearing components to the blue housing of the G-Force® slide
handle, pendant handle, or actuator assembly.
12. Do not dis/reassemble components while hoist is energized (i.e. No ‘Hot-Swapping’).
TOOLING INTEGRATION GUIDELINES
1. All tooling must be retained to the G360™ assembly utilizing the M16 thread and locking pin
provided. The locking pin is optional on Slide Handle and Wire Rope Swivel assemblies if proper
inspection and maintenance procedures are followed.
2.
Do not mount anything to the G-Force® handle housing. Use supplied brackets, valves, and
switches whenever possible.
3.
In-line tooling must always be centered directly under the hand controller.
4.
Tooling design which does not keep the tooling level; and balanced in both the loaded and
unloaded condition may induce a bending force on the handle and/or collector assembly which
may reduce the life and/or performance of the handle and/or collector assembly
5.
Do not mount anything to the sliding portion of the G-Force® hand controller.
6.
Do not alter or add conductors to the G-Force® coil cord.
7.
Use only Gorbel’s slide on air hose (slides over coil cord) to supply air power to end effector tooling.
Gorbel cannot guarantee performance or functionality of other methods of supplying air power to end
effector tooling.
8.
All cables used in a remote mounted handle configuration must be properly clamped and/or strain-
relieved to prevent premature failure of the G-Force® or customer tooling.
5

INTRODUCTION
Thank you for choosing a Gorbel® G-Force® Q2/iQ2 Intelligent Lifting Device (ILD)** to solve your
material handling needs. The G-Force® is a servomotor driven, high speed, ergonomic materials handling
device. The innovative design and heavy-duty construction of the G-Force® will provide a superior quality
product that will offer years of long-term value. A Gorbel® G-Force® will provide many years of
dependable service by following the installation and maintenance procedures described herein.
** U.S. Patent No’s: 5,865,426, 6,622,990, 6,386,513, & 6,886,812, Other Patents Pending
Dimensions contained in this installation manual are for reference only and may differ for your
particular application.
WARNING
WARNING
Only competent erection personnel familiar with standard fabrication practices should be employed to
install the G-Force® because of the necessity of properly interpreting these instructions. Gorbel is not
responsible for the quality of workmanship employed in the installation of this hoist according to these
instructions. Contact Gorbel, Inc., at 600 Fishers Run, P.O. Box 593, Fishers, New York 14453,
1-585- 924-6262, for additional information if necessary.
WARNING
Equipment described herein is not designed for, and should not be used for, lifting, supporting, or
transporting humans. Failure to comply with any one of the limitations noted herein can result in serious
bodily injury and/or property damage. Check Federal, State and Local regulations for any additional
requirements.
WARNING
Gorbel Inc. authorizes use of wire rope only as supplied by Gorbel for any G-Force® equipment. Use of
other than Gorbel supplied wire rope shall void Gorbel’s warranty of the product.
WARNING
Prior to installation, consult a qualified structural engineer to determine if your support structure is
adequate to support the loadings created during normal operation of the G-Force®.
WARNING
Reference American Institute of Steel Construction (AISC) Manual of Steel Construction (9th edition), Part
5, Specification for Structural Joints using ASTM A325 or A490 Bolts (section 8.d.2) for proper procedure
to follow when using any torque tightening methods.
WARNING
Do not field modify the G-Force® actuator or handles in any way. Any modification, without the written
consent of Gorbel, Inc., will void warranty.
WARNING
The jog switch buttons are for system maintenance and load testing only, and should not be manipulated
during normal operation of the G-Force®. Operation of the jog switch buttons during normal operation
increases the risk of personal injury to the operator.
6

CORRECT G-FORCE® INSTALLATION ORIENTATION
In-Line Slide Handle Remote Mounted Slide Handle
Remote Mounted Pendant Handle Suspended Pendant Handle
WARNING
The G-Force® was designed and fully life tested in the installation orientations shown above. Any
modification to the installation orientation of the G-Force® without the written consent of Gorbel, Inc.
Engineering will immediately void the warranty.
WARNING
As a normal safety precaution, check for obstructions in the crane and G-Force® travel.
WARNING
To Reduce the Risk of Electric Shock Do Not Expose to Rain, Use Indoors Only, Store Indoors Only.
WARNING
Maximum Operational Ambient Temperature 50°C (122°F).
7

G-F ORCE® MAIN ASSEMBLY COMPONENT DESCRIPTION
Prior to installing the G-Force® it is a good idea to familiarize yourself with the main components.
Standard Assembly: The G-Force® consists of three (3) main assemblies and they are as
follows:
1) Actuator (diagram 1): The actuator assembly contains
the lifting power transmission of the G-Force®. The drive
assembly of the actuator consists of the servomotor with
failsafe brake, gearbox, main drum pulley, and controls.
The actuator assembly also contains the upper and lower
limit switches. See the Lift Functionality section (page
25) and Controls Interface Features section (page
28) for additional details.
2) Coil Cord Assembly (diagram 2): The coil cord assembly
carries signals from the handle to the actuator assembly
which will include lift speed, lift direction and emergency
stop. Do not restrain coil cord to any foreign objects. Do
not hang or strain relief additional cable or festooning from
the
.
3) Handle (diagram 3): The handle is the main interface between the
operator and the lifting device. See the Lift Functionality section
(page 25) and Controls Interface Features section (page 28) for
additional functionality located at the handle. The Gorbel® slide
handle can accommodate either a Gorbel® load hook or tooling
(supplied by others). Tooling must meet the guidelines set forth by
Gorbel, Inc (see Tooling Integration Guidelines on page 3). Improper
tooling integration will result in degraded performance and premature
failure of the G-Force®.
The Q2 and iQ2 G-Force® Actuators are only compatible with Q2
and iQ2 Handles and vice-versa. This hardware is NOT backward
compatible with prior generation units.
*Image depicts an inline Slide Handle. Certain applications may be
more appropriate for use with an inline Force Sensing Handle. Contact
your Gorbel® G-Force® Dealer for more information.
Diagram 2. Standard Coil
Cord Assembly.
Diagram 3. In-line Slide
Handle* and Pendant Handle.
WAWARNING
The quick disconnects on the coil cord are keyed. The
connector must be aligned correctly before it threads into
place.
WARNING
The unique serial number for this unit can be found on the front cover of this manual, the bottom of
the actuator assembly, and the handle. Always have this serial number available during all
correspondence regarding your G-Force or when ordering repair parts.
WARNING
Do not field modify the G-Force in any way. Any modification, without the written consent of Gorbel
Inc, will void warranty.
TIP: The G-Force® comes in 4 Capacities. The 2 largest capacities, 660 lbs. & 1320 lbs. (300kg &
600 kg) are identical in terms of Hardware and Software internal to the Actuator.
Diagram 1. Actuator Assembly
8

INSTALLATION
STEP 1 - UNPACKING THE G-FORCE®
1.1 Carefully remove all items from the box.
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® Inside
Sales or After the Sales Service (ATSS) immediately at [phone] or (585) 924-
6262.
STEP 2 - PRE-ASSEMBLY / TOOLS REQUIRED
2.1 Read this entire Operator’s Manual before beginning installation of the G-Force®.
2.2 Tools and materials (by others) typically needed to install/assemble a G-Force® are as follows:
• 5mm Allen wrench • 19mm hex socket
• 8mm Allen wrench • Plastic cable tie straps
• 2.5mm Allen wrench • Ladders/man lifts
• 6mm Allen wrench (1320 lb. only) • 10mm wrench
• 14mm wrench or hex socket • Snap ring pliers
• 3mm Allen wrench
STEP 3 - ACTUATOR ASSEMBLY INSTALLATION
3.1 The standard G-Force® will come with the wheels
pre-assembled to the actuator trolley (diagram 3A).
When a Gorbel® G-Force® is to be used on a
non-Gorbel® bridge system, a universal adapter trolley is
required (diagram 3B). Note: The customer must provide
two (2) hoist trolleys when the unit will run in a
non-Gorbel® bridge system.
3.2 Ensure the power cord from the actuator is facing the
festooning side of the bridge/monorail. Remove the end
stop from the bridge and install the G-Force® actuator into
the track. Immediately reinstall the end stop. Verify that
the G-Force® trolley wheels are correct for the style and
capacity track that the unit is being installed on by rolling
the actuator assembly along the full length of the bridge to
ensure that the travel is smooth throughout.
Diagram 3A. Standard Actuator Assembly.
Diagram 3B. Standard Actuator Assembly
with Universal Adapter Trolley.
WARNING
DO NOT lift the actuator by grabbing the blue plastic end covers. To lift the actuator, grab the handle
slots in the trolley.
TIP: Packing list can be found in plastic pocket attached to shipping box.
9

STEP 4 - COIL CORD INSTALLATION
Note: G-Force® units, standard in-line or remote mounted, that are ordered from the
factory will be shipped with the coil cord assembled to the actuator wear ring and the
coil cord footer, creating the coil cord assembly (diagrams 4A and 4B). In addition,
units ordered with air power will have a 1/4” ID nycoil air hose coil cord assembled
onto the coil cord assembly (not shown).
4.1 Verify the coil cord assembly is correct. There are two coil cord
assemblies: standard and double length. The standard coil cord assembly
is used on systems with a trolley saddle up to 14’ (4.27m) and will measure
approximately 8.3” (211.46mm) in length. The double length coil cord
assembly is used on systems with a trolley saddle greater than 14’
(4.27m) and will measure approximately 16.4” (415.93mm) in length.
4.2 Feed the wire rope from the actuator assembly through the center of the
coil cord assembly.
4.3 Use the actuator assembly hardware to fasten the coil cord assembly to
the actuator (diagram 4C). Adjust the coil cord in the clamps so that the
coil cord connector is conveniently located on the proper side of the
actuator assembly. Note: The orientation of the coil cord must be correct
so that the connector is located properly (diagram 4DC). There should
be no need for adjustment of the coil cord clamps if coil cord is aligned
as shown.
4.4 Thread the coil cord connector into the actuator connector (diagram 4C).
4.5 Assure that the coils of the coil cord are
centered around the wire rope when
properly installed.
4.6 Use the 16mm shoulder bolt and M12
jam-nut to retain the coil cord footer to the
thimble in the wire rope. Note: The
shoulder bolt and jam-nut will be used to
retain the handle or collector in the next
step.
4.7 If applicable, connect air hose coil cord to supply line from
the actuator assembly. The air hose coil cord is provided
with two (2) ¼” NPT male swivel fittings located at both ends of
the air hose.
Diagram 4A. Standard Coil
Cord Assembly.
Diagram 4B. Double
Length Coil Cord
Assembly.
4.8 For standard in-line slide handle or in-line force sensing handle
installation, go to Step 5A, page 12.
For remote mounted slide handle installation, go to Step 5B, page 12.
For suspended pendant handle installation, go to Step 5C, page 14.
For remote mounted pendant handle installation, go to Step 5D, page 15.
For 1320 lb. in-line slide or remote mounted handle installation, go to Step 5E, page 16.
For 1320 lb. suspended pendant handle installation, go to Step 5F, page 17.
For remote mounted force sensing handle installation, go to Step 5H, page 19.
For remote mounted force sensing hub handle installation, go to Step 5I, page 20.
CAUTION
The connectors on the coil cord are keyed. The connector must be
aligned correctly before it threads into place.
TIP: This step is best completed once the actuator has been installed into the bridge system.
Diagram 4C. Coil Cord Assembly
Installation at the Actuator (Bottom
view/black center not shown).
10

STEP 5A - IN-LINE SLIDE & IN-LINE FORCE SENSING HANDLE INSTALLATION
5A.1 Ensure the wire rope is still fed through the center
of the coil cord. Hold the slide handle just below
the coil cord.
5A.2 Center the coil cord footer between the ears of
the slide handle swivel. Note: Make sure the fin
of the coil cord footer is on the opposite side of
the slide handle connector.
5A.3 Remove the 16mm shoulder bolt from the coil
cord footer and wire rope and allow the coil cord
footer and wire rope to slide down into the slide
handle swivel.
16 mm Shoulder Bolt
Slide Handle Connector
Wire Rope
Coil Cord Footer
M12 Jam Nut
**COIL CORD
HAS BEEN
REMOVED FOR
CLARITY
5A.4 Once the wire rope, coil cord footer and slide handle
swivel are aligned, replace the 16mm shoulder bolt, thereby capturing
the wire rope, coil cord footer and slide handle (diagram 5A1).
5A.5 Thread the coil cord connector into the slide handle connector (diagram
5A1).
5A.6 Thread the M12 jam nut onto the 16mm shoulder bolt.
5A.7 Check that the coils of the coil cord are centered around the wire rope
when properly installed.
5A.8 Optional: Install the hook or tooling using the retaining nut and lock
washer. The included flat washer is unnecessary in this application. Use
the open pilot hole on the Slide Handle Retaining Nut and a #21 drill bit
Diagram 5A2. Slide
Handle with Optional Pin.
to drill a hole completely through the threads of the hook and the opposite side of the nut. Hammer
the included M4x36mm spring into the hole until it is flush with the surface of the nut (diagram 5A2).
5A.9 Continue to Step 6 on page 21.
STEP 5B - REMOTE MOUNTED SLIDE HANDLE INSTALLATION
5B.1 Ensure the wire rope is still fed through
the center of the coil cord. Hold the
G360™ swivel just below the coil cord
assembly.
5B.2 Center the coil cord footer between the
ears of the G360™ swivel. Note: Make
sure the fin of the coil cord footer is on the
opposite side of the G360 connector.
5B.3 Remove the 16mm shoulder bolt from the
coil cord footer and wire rope and allow
the coil cord footer and wire rope to slide
down into the G360 swivel.
**COIL CORD HAS BEEN
REMOVED FOR CLARITY
G360 Swivel
STRAIN-RELIEF CL AMP - MUST BE USED
TO PREVENT DAMAGE TO G360.
Diagram 5A1. Slide Handle,
Shoulder Bolt and Coil Cord
Diagram 5B1.
G360, Shoulder
Bolt, and Coil
Cord
11

2x M16 Hex Head Cap
2x M16
2x M16
STEP 5B - REMOTE MOUNTED SLIDE HANDLE INSTALLATION (CONTINUED)
5B.4 Once the wire rope, coil cord footer
and G360™ swivel are aligned,
replace the 16mm shoulder bolt
thereby capturing the wire rope, coil
cord footer and G360™ swivel
(diagram 5B1, page 12).
5B.5 Thread the coil cord connector into the
G360™ connector (diagram 5B1,
page 12).
5B.6 Thread M12 jam nut onto the 16mm
shoulder bolt.
5B.7 Check that the coils of the coil cord
are centered around the wire rope
when properly installed.
Diagram 5B2. Tooling Installation.
2X M16 Hex
x 30mm Lg.
Head Cap Screw
2X M16
Lockwasher
5B.8 A pilot hole is provided for the locking pin. Attach tooling to
G360™ utilizing M16 thread. The tool bolt/rod thread should be
beyond pilot hole of shaft when fully engaged. Using a #21 drill
bit, drill through the tool bolt/rod thread and out the other side of
G360™ shaft. Hammer pin into place thereby locking tooling to
G360™ (diagram 5B2).
Slide Handle,
Remote Mounted
Configuration
2X M16
Flatwasher
Remote
Mount Slide
5B.9 Assemble the remote mounted slide handle inside the remote mount
bracket using the hardware provided (diagram 5B3). Note: This step is
best completed on a workbench prior to mounting handle to tooling.
WARNING
Remote mounted G-Force® handles must be mounted at both
the top and bottom of the handle assembly. Failure to mount the
remote mounted handle at top and bottom can result in poor
performance and/or premature component failure.
5B.10 Attach the remote mounted handle with bracket to the tooling. Assure
that the mounting arrangement does not affect the operating function
of the slide handle.
Handle
Bracket
Diagram 5B3. Remote
Mounted Slide Handle,
Exploded View.
5B.11 Connect the extension cable from the G360™ to the remote mounted slide handle. Securely clamp
the remote mount coil cord extension cable to the tooling as needed.
CAUTION
All cables used for a remote mounted handle configuration must be properly clamped and/or strain-
relieved to prevent premature failure of the G-Force or customer tooling.
CAUTION
Take care to avoid looping excess cable at locations where the loop could catch on foreign objects.
5B.12 Continue to Step 6 on page 21.
12

STEP 5C - SUSPENDED PENDANT HANDLE INSTALLATION
5C.1 Assure that the coils of the pendant handle coil cord are
centered around the pendant handle wire rope.
5C.2 Remove the eyebolt from suspended pendant cable
assembly using the threaded connector.
5C.3 Thread the eyebolt into the bottom of the actuator
assembly as shown (diagram 5C1).
5C.4 Reattach the suspended pendant cable assembly to the
eyebolt via the threaded connector.
5C.5 Adjust the suspended pendant cable assembly so that
there is a service loop in the wiring cable and there is
no tension in the wire cable.
5C.6 Thread the cable assembly connector into the actuator
connector (diagram 5C1).
5C.7 Remove the cotter pin and clevis from the wire rope
swivel assembly.
Diagram 5C1. Assembly of Suspended Pendant
Cable Assembly to Bottom of Actuator Assembly.
5C.8 Optional: Install the hook or tooling with the washer, lock washer and nut
in the orientation shown (diagram 5C2) then use the pilot hole and a #21
drill bit to drill through the hook threads, a minimum of 36mm deep. Use a
hammer to insert the M4x36mm spring pin into the hole until it is flush
with the surface of the swivel assembly (diagram 5C3).
5C.9 Reinsert the clevis and cotter pin capturing the wire rope thimble in the
swivel assembly (diagram 5C3).
5C.10 Continue to Step 6 on page 21.
Note: On suspended pendant equipped systems, the wire rope swivel
assembly must be installed before AC power is applied to the system
or a limit switch error will occur (501 / 11000 error codes). To clear
this fault you will have to (must be done in this order):
1. Install wire rope swivel assembly or other weighted device on
wire rope.
2. Disconnect AC power from the system (using the e-stop will
not work).
3. Reconnect the AC power and wait approximately one minute
for system to power on completely.
Diagram 5C2. Hook
installation.
STEP 5D - REMOTE MOUNTED PENDANT HANDLE INSTALLATION
5D.1 Ensure the wire rope is still fed through the center of the coil cord. Hold the
G360 swivel just below the coil cord.
5D.2 Center the coil cord between the ears of the G360 swivel. Note: Make sure the fin of the coil cord footer
is on the opposite side of the G360 connector.
5D.3 Remove the 16mm shoulder bolt from the coil cord footer and wire rope and allow the coil cord footer and
wire rope to slide down into the G360™ swivel.
Actuator Connector
Eyebolt With Hexnut
Threaded Connector
Cable Assembly
Connector
Suspended Pendant
Cable Assembly
Diagram 5C3. Cotter
Pin, Clevis, Wire Rope
Swivel Assembly, and
Wire Rope Thimble
13

STEP 5D - REMOTE MOUNTED PENDANT HANDLE INSTALLATION (CONTINUED)
5D.4 Once the wire rope, coil cord footer and
G360™ swivel are aligned, replace the
16mm shoulder bolt thereby capturing
the wire rope, coil cord footer and
G360™ swivel (diagram 5D1).
5D.5 Thread the coil cord connector into the
G360™ connector (diagram 5D1).
5D.6 Thread the M12 jam nut onto the 16mm
shoulder bolt.
5D.7 Check that the coils of the coil cord are
centered around the wire rope when
properly installed.
5D.8 A pilot hole is provided for the locking pin.
Attach tooling to G360™ utilizing M16
thread. The tool bolt/rod thread should be
beyond pilot hole of shaft when fully
engaged. Using a #21 drill bit, drill
through the tool bolt/rod thread and out
the other side of G360 shaft. Hammer pin
into place, thereby locking tooling to
G360 (diagram 5D2).
16 mm Shoulder Bolt
**COIL CORD HAS BEEN
REMOVED FOR CLARITY
Wire Rope
Coil Cord Footer
M8 Jam Nut
G360 Swivel
STRAIN-RELIEF CLAMP - MUST BE
USED TO PREVENT DAMAGE TO G360
5D.9 Attach the pendant handle bracket directly
to the tooling. Assure that the mounting
arrangement does not affect the operating
function of the pendant handle. Note: If
necessary, a collar clamp mounting bracket
option can be used to attach the pendant
handle to the tooling (diagram 5D3).
5D.10 Connect the extension cable from the
G360™ to the remote mounted pendant
handle. Securely clamp the remote mount
coil cord extension cable to the tooling as
needed.
5D.11 Continue to Step 6 on page 21.
CAUTION
All cables used in a remote mounted handle configuration must be
properly clamped and/or strain relieved to prevent premature failure of
the G-Force or customer tooling.
CAUTION
Take care to avoid looping excess cable at locations where the loop
could catch on foreign objects.
Diagram 5D1. G360™, Shoulder Bolt and Coil Cord.
CLAMP COLLAR
REMOTE
MOUNTED
PENDANT
HANDLE
Diagram 5D3. Remote
Mounted Pendant Handle
with Collar Clamp Mounting
Bracket (option)
Diagram 5D2. Tooling Installation
14

STEP 5E - 1320 LB. INLINE SLIDE & REMOTE MOUNTED HANDLE INSTALLATION
5E.1 With the actuator hanging from the rail or other supported
structure, thread the free end of the wire rope through the
coil cord assembly so it hangs below the coil cord
mounting plate and attach the wear ring to the wear ring
bracket (inside actuator wire rope opening), using the
supplied hardware (diagram 5E1).
5E.2 Thread the connector on coil cord into mating connector
on the underside of the actuator.
5E.3 Grab the free end of the wire rope and loop it up towards
the underside of the actuator, ensuring there are no twists
or kinks in the rope. Feed the U-bolt through the wire
rope thimble and insert the U-bolt into the appropriate
holes in the reinforcement plate. Using supplied hexnuts,
securely tighten U-bolt to the plate (diagram 5E2).
2X 65112
2X 03370
2X 79150
2X 79150
2X 65032
83253
65032
WEAR RING
(76764)
2X 03370
2X 65028
COIL CORD
79150
WIRE ROPE ASSEMBLY
5E.4 Attach the plate to the underside of the actuator using
the supplied cap screws, lockwashers, and spacers as
shown and ensure hardware is now completely
tightened. (If an air hose is being installed, leave
hardware loose for now.)
5E.5 While holding the handle or G360™, loop the pulley
through the wire rope and slip the pulley and side
spacers down between the plates (diagram 5E3, page
17).
5E.6 Align the holes in the plates with the spacers and the
bearings, insert the pulley pin, and install the snap ring
on the pulley pin.
5E.7 Using the supplied cap screws and lockwashers, attach
the coil cord mounting plate to the top of the handle or
G360™.
Diagram 5E1. Assembly of Wire Rope to
1320 lb. Actuator Assembly.
Diagram 5E2. Attaching U-bolt and
Reinforcement Plate to Actuator Assembly.
5E.8 Attach the coil cord connector to the mating connector in the top of the handle or G360™ and use
the supplied cap screw to attach the strain relief clamp to the side plate so there is a small service
loop at the connector.
5E.9 Continue to Step 6 on page 21.
4X 83260
83252
4X 00195
4X 83236
2X 01355
4X 02158
83265
NOTE: COIL CORD AND ASSOCIATED COMPONENTS
NOT SHOWN FOR CLARITY
15

STEP 5F - 1320 LB. SUSPENDED PENDANT HANDLE INSTALLATION
5F.1 With the actuator hanging from the rail or other
support structure, thread the free end of the wire
rope through the coil cord assembly, so it hangs
below the coil cord mounting plate and attach the
wear ring to the wear ring bracket (inside actuator
wire rope opening) using the supplied hardware
(diagram 5E1, page 16).
5F.2 Grab the free end of the wire rope and loop it up
towards the underside of the actuator, ensuring there
are no twists or kinks in the rope. Feed the U-bolt
through the wire rope thimble and insert the U-bolt
into the appropriate holes in the reinforcement plate.
Using supplied hexnuts, securely tighten the U-bolt
to the plate (diagram 5E2, page 16).
4X 65018
4X 65052
83255 (PULLEY)
83261 (BEARING)
65086 (SNAP RING)
2X 83259
2X 2001.12
83258
5F.3 Attach the plate to the underside of the actuator using the supplied cap screws, lockwashers and
spacers as shown and ensure hardware is completely tightened. (If an air hose is being installed,
leave hardware loose for now).
5F.4 Insert eyebolt at the end of the pendant cable into the threaded hole on the reinforcement plate
and tighten. Thread the coil cord connector into mating connector on the underside of the
actuator.
5F.5 While holding the G360™, loop the pulley through the wire rope and slip the pulley and side
spacers down between the plates (diagram 5E3).
5F.6 Align the holes in the plates with the spacers and the bearing, insert the pulley pin, and install the
snap ring on the pulley pin.
5F.7 Using the supplied cap screws and lockwashers, attach the coil cord mounting plate to the top of
the G360™.
5F.8 Continue to Step 6 on page 21.
Diagram 5E3. Attaching Wire Rope
to Pulley.
16

STEP 5G - 1320 LB. AIR HOSE ASSEMBLY INSTALLATION (OPTIONAL)
5G.1 The air hose assembly comes attached to the wear ring and coil cord mounting plate. Once the
handle installation is complete, the air hose should be installed.
5G.2 Remove two of the screws and lockwashers holding the reinforcement plate to the underside of the
actuator (leaving the spacers in place) and insert them through the air hose bracket and reattach to
the underside of the actuator. Tighten all hardware.
5G.3 At the handle or G360™, insert the male swivel fitting at the end of the air hose into the female
end of the elbow in the footer and tighten.
5G.4 Connect the bulkhead fitting on the underside of the actuator to shop air and check for leaks.
17

STEP 5H - REMOTE MOUNT FORCE SENSING SLIDE HANDLE INSTALLATION
5H.1 Follow Steps 5B.1 through 5B.7 on
pages 12 and 13 to install G360™.
5H.2 Bracket must be sized to fit the handle
it will be holding and rigid enough to
resist the forces exerted on it
(diagram 5H1).
5H.3 Using the included M16 hardware,
fasten both ends of the handle to the
bracket. Attach bracket to tooling if
necessary.
5H.4 Connect cable from G360™ to handle
top. Clamp the cable to tooling to
prevent it from being snagged.
5H.5 Continue to Step 6 on page 21.
Note: The system cannot support two Force
Sensing Handles running simultaneously
on one G-Force®. If dual handles are
required, one Force Sensing Handle and
one traditional handle is a supported
configuration.
Diagram 5H1. Force Sensing Slide Handle bracket sizes.
Note: Due to the nature of the Force Sensing Slide Handle, excessive
twisting of the grip may be interpreted as intended motion. For best
results, only push and pull the handle grip while avoiding twisting
(diagram 5H3).
Note: To avoid damaging the handle, do not apply more than 200 lbs (90 kg)
to the grip or handlebars.
Note: Remote handles must be mounted rigidly in order to function
correctly. For slide handles, the mounting holes on the tooling must be
aligned to avoid any binding of the handle and the bolts at each end of
the handle must be tightened enough to prevent motion but not induce
binding. The included rubber washers must be mounted between the
handle and tooling to prevent binding. Additionally, the handle must be
captured via the
.
Note: Do not attach anything to the grip of the Slide Force Sensing Handle as
performance will be degraded.
Note: Changing the orientation of the handle (tilting) while the system is live may be
interpreted as intent to move. It is recommended that the handle remains vertical
at all times during use.
Note: When taring the handle, care must be taken not to apply force to the grip or
handlebars as subsequently removing the force will be interpreted as intent to
move.
Note: For optimal performance, re-taring the handle periodically may be necessary.
The interval will depend on usage.
Diagram 5H2. Remote handle
mounting dimensions
Diagram 5H3. Proper use
of Force Sensing Handle
grip
18

STEP 5I - REMOTE MOUNT FORCE SENSING HUB HANDLE INSTALLATION
WARNING
This handle is only intended for remote mount
applications and must not be used for transmitting
lifting loads.
5I.1 Follow Steps 5B.1 through 5B.7 on pages
12 and 13 to install G360™.
5I.2 Mount Hub body to tooling rigidly to resist
forces exerted on it. Optional mounting plate
74136 is available. See diagram 5I1 for
dimensions for mounting directly totooling.
5I.3 Attach handlebars to Hub. Handlebar kit
(74630) is available or handlebars may be
fabricated (by others). Optional handlebar
mounting plate 74138 (with clamp collars)
or 74141 (plain for modification by
integrator) are available. See diagram 5I2
for dimensions for fabricating a custom
solution.
Diagram 5I1. Mounting handlebar and mounting plate.
5I.4 Connect cable from G360™ to handle top. Clamp the cable to
tooling to prevent it from being snagged.
5I.5 Continue to Step 6 on page 21.
Note: The system cannot support two Force Sensing Handles
running simultaneously on one G-Force®. If dual handles are
required, one Force Sensing Handle and one traditional
handle is a supported configuration.
Note: Handlebars and attachments for Remote Force Sensing
Hub Handles must not exceed 25 lb (11.3 kg). For
optimal performance, handlebar assemblies should be
as light as possible. Handlebar weight in excess of 10
lbs. (4.5 kg) will detract from net capacity of the G-Force®.
Note: For optimal performance and to reduce the risk of
damaging the handle, handlebars on Remote Force
Sensing Hub Handles should not exceed 24” (0.6m) (12”
or 0.3m in either direction) in width or 24” (0.6m) from the
face of the handlebar mounting plate (diagram 5I3).
Diagram 5I2. Mounting plate dimensions.
Note: To avoid damaging the handle, do not apply more than 200 lbs. (90 kg) to the grip or handlebars.
Note: Remote handles must be mounted rigidly in order to function correctly. For Hub handles, the
back of the handle body must be securely fastened to the tooling.
Note: When taring the handle, care must be taken not to apply force to the grip or handlebars as
subsequently removing the force will be interpreted as intent to move.
Note: For optimal performance, re-taring the handle periodically may be necessary. The interval will
depend on usage.
Diagram 5I3. Handlebar dimensions.
Diagram 5I2. Mounting plate
dimensions
19

STEP 6 - ELECTRICAL POWER CONNECTION
STANDARD
6.1 Prior to final wiring, inspect the entire system to ensure that all connections are seated and
strain relieved properly, and are without kinks or bends. Verify the following connections:
a) Coil cord to handle or G360™ collector
b) Coil cord to actuator assembly
c) Extension cables (if included)
6.2 Connect a 220 VAC single-phase power source through a disconnect switch (by others) to the
festooned power cabling (not provided with G-Force®).
WARNING
If your system displays drive faults 7219 and 4005 either when it powers on or when you attempt to
lift or lower a load it means the AC power is too low. Even though the specification is 220 VAC +/-
10%, the power available at the system may be very close to the low end of the specification
because of its proximity to the power source. The closer to the nominal 220 VAC you are supplying to
the system the less likely you’ll experience any problems related to the AC voltage.
6.3 After verifying the disconnect switch is turned OFF, follow local Electrical Codes to terminate the
end of the festooned power cable at the G-Force®.
STEP 7 - INITIAL POWER-UP
7.1 Turn on the disconnect switch (by others) to apply power to the G-Force®. When power is
detected, “POWER ON” is displayed on the OLED.
7.2 Disengage the emergency stop (E-STOP ENGAGED) button located on the face of the handle.
7.3 During the system power up the OLED at the handle will display “G-FORCE INITIALIZING”. If you
are using a Force Sensing Handle, after power is applied to the system and the unit has booted,
fault 11009 will usually be displayed indicating that the handle needs to be tared. Please refer to
the Programming Section,
7.4 Once the system is on-line and ready, G-FORCE READY TO LIFT will be displayed on the OLED.
7.5 • Standard Operation - Slide Handle Configuration: Grasp the handle grip to run the unit up
and down. Do this several times to get a feel for the unit. The OLED displays RUN MODE
HANDLE.
• Standard Operation - Pendant Handle Configuration: Depress the up and down levers to
run the unit up and down. Do this several times to get a feel for the unit. The OLED displays
RUN MODE PENDANT.
See the Lift Functionality section on page 25 for complete details on handle operation.
7.6 Finally, test the operation of any special tooling that may have been integrated to the G-Force®.
TIP: Do not connect main power until all assembly is complete.
TIP: The operator should always keep their hand under the operator present sensor on the
slide handle while operating the unit in standard mode. If the hand is frequently moved away
from the operator present sensor it will result in jerky movement from the unit.
TIP: Gorbel, Inc., does not provide integrated tooling for the G-Force®.
All tooling related questions should be directed to the tooling manufacturer or supplier.
20