Installation & Operational Manual Model D6120-40
Contents
1. Nonetheless grease zerks are provided on the ends of the actuator These grease paths allow grease to come down and escape from the shaft seal area flushing debris away from the shaft seal The purpose of this is to improve the life of the seal as well as aid in keeping the shaft greased for easy removal during servicing Perkins recommends greasing these points once every 6 months or as necessary for your environmental conditions Bleeding air from the Actuator Air does not usually get trapped inside the actuator but it does happen on occasion BLEED particularly with initial installations For this PORTS reason the actuator has 4 bleed ports located atop it Cracking the plug loose slightly will allow trapped air to escape Perkins recommends this be performed only as necessary Lifter motion that is very erratic is usually a sign of trapped air The lifter should be run several times up and down first as this usually clears any trapped air without having to use the bleed ports Make sure the bleed ports are fully tightened when complete L Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 24 of 42 www perkinsmfg com Perkins Single Lifter Hydraulics Schematic ROTARY MOVEMENT GRIPPER CYLINDER gt 2 PERKINS D63575 ADJ FLOW CONTROL i fa f PERKINS D63580 A TF p P O CHECK VALVE E 5 Iil a o SS N d PERKINS2. Installation amp Operational Manual Model D6120 40 27k Dumping Gripper Arm Lifter Protected by US Patents 6 921 239 amp 7 273 340 Perkins Manufacturing Company 800 882 5292 _Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 1 of 42 www perkinsmfg com gt D6120 40 27k Gripper Arm Lifter Specifications Typical Mounting Application iperaorcompatse MO Weight Capacity 400 Ibs Dump Angle 45 degrees from the horizon Mounting Height ground level to top of mounting 38 up to 42 plate Approximate Unit Weight not counting 185 Ibs packaging Hydraulic Package Tap In Tap Inkits are sold separately are sold Tap Inkits are sold separately Perkins regularly makes product improvements Specifications are subject to change without notice Actual pressure required to lift a load can vary Do not lift more than the recommended amount printed on the cart by the cart manufacturer or damage or injury may result See Warranty page enclosed in this manual for full details of coverage Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 2 of 42 www perkinsmfg com Overall Dimensions Perkins regularly makes product improvements Dimensions are subject to change without notice V Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAwa
3. ROMEOVILLE IL PART D72114 Perkins Manufacturing Company www perkinsmfg com Creators of the TuckAway Cart Lifter Protective Safety Labeling DO NOT PAINT OVER THIS LABEL NO PINTAR ENCIMA DE ESTA ETIQUETA THIS EQUIPMENT IS RATED FOR 3 000 PSI MAX RECOMMENDED PRESSURE SETTINGS CAN BE FOUND IN THE INSTRUCTION MANUAL 400 LB MAX LOAD RATING EL EQUIP TIENE UNA CAPACIDADO NOMINAL MAXIMA DE 3000 PSI PARA SABER CUAL ES LA REGULACION DE PRESION RECOMENDADA CONSULTE EL MANUAL DE INSTRUCCIONES CAPACIDAD DE CARGA MAXIMA 400 LB CAUTION STAY CLEAR DURING OPERATION PRECAUCION MANTENASE ALEJADO CUANDO ESTA EN FUNCIONAMIENTO NOTE RUNNING THE LIFTER TOO FAST OVERLOADING THE LIFTER COLLISIONS WITH THE LIFTER MODIFYING THE LIFTER OR NEGLECTING TO MAINTAIN THE LIFTER VOIDS THE WARRANTY 708 482 9500 2008 PERKINS MFG CO WWW PERKINSMFG COM ATENCION PARA MANTENER LA GARANTIA DE EL LEVANTADOR LUBRIQUE SEMANALMENTE OPERE ENTRE 6 8 SEG POR CYCLO PRECAUCION MANTENGASE ALEJADO MIENTRAS ESTA EN FUNCIONAMIENTO NUNCA OPERE EL LEVANTADOR HACIA ARRIBA CUANDO LA PLACA EMPACADORA ESTA ABAJO O BAJANDO CALL 708 482 9500 PERKINS MFG ROMEOVILLE IL PART D72115 800 882 5292 Revised 11 7 2013 Page 42 of 42 TWO YEAR LIMITED WARRANTY BEFORE ANY WARRANTY CAN BE ALLOWED ON ANY NEW EQUIPMENT THE APPLICABLE REGISTRATION FORM MUST BE FILED WITH PERKINS MANUFACTURING COMPANY PERKINS MANUFAC
4. 9 Installation of this equipment requires welding painting grinding torching and working with high pressure hydraulic systems The appropriate safety equipment should be used at all times amp Always follow OSHA specified lock out procedures while working with a truck amp Cart lifters weigh on average between 185 to 300 Ibs Do not lift the lifter onto the mounting plate by hand Always use proper lifting equipment amp Always use a chain or strap to secure the lifter in the upright position during the installation process Unsecured lifters may fall suddenly causing injury amp The truck to which the lifter is to be installed should be empty of waste Torching and welding can ignite the contents of the truck and cause a fire 9 Do not weld on the truck unless a ground is in place and the battery is disconnected 9 Do not open loosen any hydraulic lines unless the system is off and depressurized amp Always double check hydraulic fittings and hoses for tightness prior to reactivating the pump amp Always relocate lights that need to be moved due to the position of the cart lifter to a clear and unobstructed area clearly visible to drivers 9 All painting of the truck lifter after installation is complete should be done with proper ventilation and per local regulations Do not paint over caution and warning labels amp If there are any questions about the proper installation or use of the cart lifter not covered in
5. For shipping purposes Remove to operate 48 D63596 Connector 6mo 6mo 49 D63575 One Way Adjustable Flow Control Valve 45 deg Elbow 6mo 8mt Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 39 of 42 www perkinsmfg com V 27k Actuator Parts Guide n Pa Ga Pome 2 ARG e The F k d b a 4 ACA i t i i T d x i a Me d W PORT P1 2X Housing P1 inner Housing P2 outer 4 D73060 4 Piston Sleeve Bearing Retainer 6 D63238 1 Splined Driver Hub Retaining Disc 8 D62006 Bolt FHCS 13x 1 1 4 9 D62014 Grease Zerk D63238 106 2 Port plug 4 SAE bleed ports 11a Sold as Bearing Thrust Washer Kit D73060 3 Bushing Sold as Wiper Seal 2b 27k Seal Kit Cup Seal Shaft 12c D73060 1 Cup Seal Piston Sleeve Cup Seal Piston Sleeve no energizer m N m e e NIN mo amp O ring Seal Housing B U Ring Housing m N oa O ring Seal Housing Cup Seal Piston Sleeve Cup Seal Piston Sleeve no energizer 3 D63238 9 O ring Seal Adapter gt m m VIN m N h Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 40 of 42 www perkinsmfg com Quick Rebuild Kit Sometimes a lifter is damaged by collision although the actuator and mounting parts are usually not dama
6. is not as desired you may switch the hoses to reverse the handle s operation Connect one long hose from the hand valve s IN port to the diverter valve s P port or if performing a dual installation to port P1 or P2 Connect the last long hose from the hand valve s OUT port to a tank line Note See photo of tank line connection on following page for more details Make sure all the hoses have been routed neatly The hoses must be protected from rubbing or pinching If performing a double installation repeat this process for the second lifter L Perkins Manufacturing Company Creators of the TuckAway Cart Lifter www perkinsmfg com 800 882 5292 Revised 11 7 2013 Page 18 of 42 Tapping into the Tank Line There are two ways to run the oil back to tank Perkins does not suggest allowing the return oil to get pushed back into the packer control valve because this generates back pressure and heat Recommended Method Locate the return line coming off the packer control valve and find a suitable large fitting as shown in the photo below Remove this fitting and drill and tap into it to fit an adapter or tee for a double installation to allow the oil to flow back into the return line Be sure to clean the fitting of metal shavings before returning it to the system PACKER BLADE CONTROL VALVE RETURN LINE SRE es FROM HAND VALVE S cib Alternative Method
7. or missing parts hardware should be attended to immediately to avoid risk of further damage to the lifter damage to the cart or injury to the operator Operating a cart lifter that is not properly maintained is hazardous Step 1 Bring the TuckAway lifter out of the storage position and into the pick up position by pulling up on the hand valve handle until the faceplate is just shy of vertical to facilitate easy cart engagement Step 2 Roll a loaded cart to the lifter and position the upper bar of the cart on the upper saddle of the lifter or in a position where the lifter will engage the bar once it starts it s motion It is not necessary to lift the cart onto the upper saddle Step 3 Look and make sure no one is in the area of the lifter or cart then operate the hand valve by pulling up on the handle The lifter will rotate and engage the cart and raise it to 45 degrees above the horizon Safety Note The hand valve operates like a deadman switch Releasing the handle at any time will stop motion of the lifter Normal operation may be resumed by operating the handle again Step 4 At the operator preference the cart may be shook back and forth to help discharge the contents of the cart by moving the hand valve back and forth rapidly Shaking the cart is not harmful to the lifter however cart damage can result if the lifter soeed is too great Make sure the speed adjustment of the lifter is set slow enough to allow for safe cart s
8. that the packer body be mounted to a chassis and the truck is empty and parked on a smooth and level a surface when this mounting height is determined A cart lifter which has been positioned too low may kick carts away before successfully engaging them CNP ARR AOUR G ARI A cart lifter which is mounted too high will make it difficult for the operator to latch the cart at all causing the operator to have to lift the cart onto the latch A good mounting height will make latching carts effortless with no lifting or holding the cart in place Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 7 of 42 www perkinsmfg com Positioning the Mounting Plate 35 39 22 25 1 2 1 6 ph The mounting plate may be positioned as low as 39 and as high as 42 as needed The mounting plate itself should be vertical and level Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 8 of 42 www perkinsmfg com L Reinforce the Mounting Plate UNSUPPORTED MOUNTING PLATE Dimensions shown above are an example only and will vary from truck to truck ADDED ANGLED SUPPORT STRUCTURE PLATE Perkins Manufacturing Company Creators of the TuckAway Cart Lifter www perkinsmfg com When the mounting height is determined the lifter s mounting plate frequent
9. the manual it is recommended to call Perkins at 800 882 5292 Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 5 of 42 www perkinsmfg com gt Installation Tips Do not mount the lifter to a refuse body which is not already mounted to a chassis Chassis heights can vary and this will affect the final installed height of the cart lifter Tack weld only until all positions and clearances are verified to work well for your application Always work on a smooth level surface with an empty truck Residential Only Installation A residential only installation is when the cart lifter will be mounted to the truck and the truck will not be used for collecting commercial containers such as 1 thru 10 yard containers A residential only installation is very straightforward and simple and very little customization required Therefore a residential only installation may take only 4 6 hours The D6120 40 27k is a Gripper Arm Style Cart Lifter JZ 10 3 4 Z ROS I i i 0 X AltA Cm Perkins Manufacturing Company Creators of the TuckAway Cart Lifter www perkinsmfg com The first consideration when installing any Gripper Arm style cart lifter is to make sure the unit has space to store under the load sill Some trucks have a hopper shape that does not accept a Gripper Arm style cart lifter so it may be necessary to use a different cart lift
10. the wide variety of trucks changes made by the OEM as well as the possibility of other aftermarket parts especially on used trucks the fittings you need to make these connections may not be included in your kit and will have to be purchased separately The Perkins Diverter Valve Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 17 of 42 www perkinsmfg com Ordinarily the diverter valve s port P will feed the lifter But if you have two lifters then you will use the Perkins Double Diverter Valve It s the same valve except port P is plugged and a 50 50 splitter valve is mounted on top In this case ports P1 and P2 will feed the lifters an equal amount of flow each Making the Hose Connections PORT P1 amp P2 USE FOR DOUBLE INSTALLATIONS PLUG PORT P IF USING P1 amp P2 ADDED 50 50 _ SPLITTER FOR DOUBLE INSTALLATIONS SINGLE DIVERTER VALVE PORT P USE FOR SINGLE INSTALLATIONS All the primary valves are now in place for a typical installation The tap in kit would have come with 2 short hoses and 2 long hoses single installation or 4 short and 4 long for double installation Connect one short hose from the lifter s left side to the hand valve port A Connect another short hose from the lifter s right side to hand valve port B Note If the handle s operation
11. D63519 f i a 2 SPOOL HAND VALVE e N A BUILT IN PO CHECK OUT IN PERKINS D63237s DIVERTER VALVE lt L o i ay Pe n PACKER BLADE m CONTROLS A bas Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 25 of 42 www perkinsmfg com V Perkins Double Lifter Hydraulics Schematic ROTARY MOVEMENT ROTARY MOVEMENT GRIPPER GRIPPER CYLINDER CYLINDER PERKINS D63575 PERKINS D63575 gt 2 ADJ FLOW CONTROL ADJ FLOW CONTROL H 3 E 3 g PERKINS D63580 PERKINS D6 P O CHECK VALVE P O CHECK VALVE 2 SPOOL HAND VALVE V 2 SPOOL HAND VALVE V ER e BUILT IN PO CHECK HR BUILT IN PO CHECK OUT Li PERKINS D63411s DIVERTER VALVE W 50 50 SPLITTER B ha PACKER BLADE CONTROLS AT D L Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 26 of 42 www perkinsmfg com Operating the Lifter Operating Instructions The recommended cycle is 3 4 seconds to travel up and 3 4 seconds to travel down This cycle time is based on the safe and smooth movement that the plastic cart can be swung about at without risking damage to the cart or injury to the operator Therefore operating the lifter faster than this time will void the warranty It is recommended that the lifter be visually inspected on a daily basis to ensure that there is nothing obviously in need of repair Broken
12. Manufacturing Company 800 882 5292 Revised 02 13 2015 Creators of the TuckAway Cart Lifter Page 36 of 42 www perkinsmfg com Exploded Parts View Lifter Portion RH Idler Arm Weldment RH Driver Arm Weldment Faceplate Weldment 4 D69630 LH Driver Arm Weldment LH Idler Arm Weldment 6 D69567 Center Rubber Strip Bolt FHCS 3 8 16 x 1 GR8 Zinc Plate 8 D62468 Bolt FHCS 5 16 18 x 1 Zinc Plate 9 D62081 Locknut 13 GR8 Zinc Plate 1 dia Self lubricated bushing Part of arm assemblies Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 37 of 42 www perkinsmfg com V Grabber Arms View Latch Portion m Linkage Arm Weldment LH Grabber Arm Weldment Rubber Pad RH Gripper Arm Weldment Cylinder Modified CC52099 Actuator Flange 515583 HHCS Bolt 5 16 18 x 3 4 Pivot Pin Bolt FHCS 3 8 16 x 1 1 2 Gr 8 Zinc Plated 10 5 16 Split Lockwasher 11 Self Lubricated Bushing x 1 2 12 Bolt 1 2 13 x 1 13 Long Pin Short Pin Self Lubricated Bushing x 3 4 Self Lubricated Bushing x 1 Flat Washer 3 8 8 3 8 16 Locknut PlRPl Pl RiP Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 38 of 42 www perkinsmfg com Exploded Parts View Hydraulic Fittings Adapter 6mo 6mt 45 deg Elbow 6ft 6mt 46 D63431 Reducer 6ft 8mt Cap 8ft
13. On some trucks it is not possible to tap into a return line fitting It some instances everything is hard piped and there are no fittings to tap into If this is the case the return lines may be feed into the T port of the Perkins Diverter Valve This tends to create some backpressure in the system but otherwise does work Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 19 of 42 www perkinsmfg com L Adjusting the Speed Single Diverter D63237s Double Diverter D63411s This valve s adjustment controls the flow going to the lifter The flow controls the speed of the lifter A typical 27k rotary lifter requires 3 5 gpm to achieve a 6 8 second cycle time To adjust turn off the system and loosen the locking nut Turn the adjustment screw clockwise all the way in This will stop flow to the lifter completely From this position make counter clockwise adjustments turn at a time When the correct position is found tighten the locking nut to hold the adjustment in place Troubleshooting the Diverter Valve Adjusting the Perkins Hydraulics CAUTION ADJUST THIS VALVE WITH THE HYDRAULIC PUMP OFF OR VALVE DAMAGE COULD OCCUR ADJUSTMENT SCREW Replacement Parts D63477 Seal Kit D63565 Adjustment Screw To convert a Single Diverter to a Double D63236 50 50 Splitter comes with mounting hardware This diverter valve does not affect li
14. TURING COMPANY warrants its ROTARY cart lifters to be free from defects in material and workmanship under normal use for a period of two 2 years from the date of delivery to the first purchaser This warranty covers all ROTARY cart lifters shipped after May 1 2011 This warranty is expressly limited to the repair or replacement of any component or part of any ROTARY cart lifter unit manufactured by PERKINS which is proven to PERKINS satisfaction to have been defective in material or workmanship This warranty shall not obligate PERKINS to bear the cost of labor or transportation charges in connection with the repair or replacement of defective parts and it shall not apply to a product upon which repairs or alterations have been made unless authorized in writing by PERKINS Any improper use substitution of parts not approved by PERKINS modifications other than those done at the factory or as authorized in writing by the factory or any alteration or repair by others in such a manner which in PERKINS judgment materially and adversely affects the product shall void this warranty Periodic maintenance is required to maintain warranty Please refer to the maintenance section of the service manual for instructions PERKINS makes no warranty of products manufactured by others and supplied by PERKINS the same being subject to warranties if any of their respective manufacturers PERKINS shall not assume any liability for any incidental consequentia
15. age is not covered by warranty Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 28 of 42 www perkinsmfg com Adjusting the Lifter Other Adjustments Make sure all hardware is firmly tightened If any hardware loosens they may be affixed with Blue Loc tite type 242 thread locker Perkins uses anti sieze lubrication on the shafts of the actuator when applying the driver bearing hubs This typically does not wash away and helps in reducing corrosion This makes removing the driver bearing hubs off the splines easier in the future When rebuilding a lifter reapply a fresh coating of anti sieze on the splines There is a wide variety of carts some of which do not meet ANSI standards Customers may experience engagement issues with some particular brands of carts and in circumstances like these spacers can be added behind the upper saddle or behind the lower stop to extend them out from the faceplate This helps certain brands sizes of carts to lock to the lifter better If you experience any difficulties with the cart type you have please call Perkins at 800 882 5292 to discuss the problem and Perkins will advise the best solution to meet your needs Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 29 of 42 www perkinsmfg com V Reassembling the Faceplate to the Actuator After a major tear down reassembling the
16. an be compromised It may be necessary to add custom structure reinforcements where the lifter is to be mounted V www perkinsmfg com Perkins Manufacturing Company Creators of the TuckAway Cart Lifter 800 882 5292 Revised 11 7 2013 Page 11 of 42 Add the Sill Extension Bumper kit With the notches in the sill extension cut out cap off the exposed ends and mount the mounting plate using the correct mounting height as previously described It may be necessary to add customized pieces to bolster the support of the mounting plate on top or below the plate At this point the lifter may stick out above or beyond the extension sill That is normal Note The size and shape of the bumper extension can vary depending on your fabrication preferences Perkins does offer pre made bumper extension kits sold separately CA1084 single lifter offset to the right CA1085 single lifter center mounted CA1086 double lifter installation Now we add the rest of the supporting structure Like in the residential only install it is necessary to bring the load sill up to match to the top of the mounting plate and or top of the bumper extension Contact with commercial containers can easily crush the cart lifter To protect it install a bumper extension over the OEM supplied sill extension The bumper should be sized and positioned so that contact with a commercial container is not possible Perkins Manufacturi
17. and free of charge It contains detailed instructions for rebuilding based on a complete tear down Also within the manual is a complete parts listing To receive a copy of the actuator manual simply call Perkins at 800 882 5292 Flushing the Actuator Because the oil displacement of the actuator is nearly equal to the displacement of the hoses the oil inside the actuator does not fully dispel to the system and get filtered with each use Only a percentage of the oil dispels Because of this it is possible to have build up of particles over time which can lead to premature wear especially in dirty oil conditions Perkins recommends flushing the oil in the actuator to the system to allow for complete filtration once every 6 months This will help ensure the actuator has a very long lifespan To flush the oil turn off depressurize the system and connect a hose from one bleed port to the other Tighten the fittings restart the pump Run the hand valve back and forth several times holding the handle down for about a minute each time This ensures any particles have completely exited the actuator BYPASS HOSE USING THE 4 BLEED PORTS Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 23 of 42 www perkinsmfg com Flush the Debris from the Shaft Seal Area The actuator does not need greasing as it is GREASE ZERK self lubricated naturally from the internal hydraulic oil
18. anty Do not operate the lifter unless the area around it is clear of personnel This means do not touch the lifter while it is in operation and do not stand or sit under near the lifter while it is moving Lifters have pinch points which can cause serious injury Stay clear at all times TuckAway lifters can hang very low to the ground at certain points of their lift cycle It is the operator s responsibility to move the lifter to a safe position while going down the road such as putting the lifter all the way up or fully into the storage position Lifters left hanging low risk bottoming out on the street which will cause serious lifter damage Damage caused by bottoming out is not covered by warranty Lifters of all kinds can be struck by utility poles walls other vehicles backed into earthen hills etc It is the operator s responsibility to position the cart lifter in a safe position prior to coming close to any other foreign object If the lifter is damaged by collision the damage will not be covered by warranty If the lifter is installed in such a way that the lifter or cart can make contact with the packer blade then it is critical to pay attention and make sure the lifter is not operated when the packer blade is down or coming down If the truck is equipped to dump commercial containers the lifter must be stored all the way down prior to engaging the commercial container or the cart lifter may be crushed by the container This dam
19. e left side of the actuator with the arrow pointed away from the actuator and that the valve is adjusted properly Try turn adjustments until the lifter returns to ground level smoothly Lifter drifts out of position when not in use Make sure the PO Check valve is installed If it is and the lifter still drifts remove the PO check and remove and clean the cartridge If the valve is damaged replace it If the problem does not seem to be the PO check the hand valve may have internal leakage Replace the hand valve seals and or spool as needed If the problem persists then the actuator may be leaking internally Check for internal leakage by running the lifter up and holding the hand valve while reading a pressure gage If the pressure falls then the actuator is leaking internally and should be rebuilt with a new seal kit Lifter is in good condition latch is adjusted but lifter still breaks carts In this case the lifter is most likely being operated too fast or the carts are overweight Excessively hard shaking of the carts by the operators can also lead to cart damage Train your operators to operate the lifters properly Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 34 of 42 www perkinsmfg com Making a Warranty Claim SERIAL NUMBER PLATE LOCATION For complete warranty coverage details please see the warranty page at the end of this manual If you sus
20. er model in these cases Find the mounting height you will need to mount your cart lifter at as instructed on the following pages Measure from this point down 10 to check and see if the D6120 40 27k is the right model for this application If there is interference with a light panel the panel may be trimmed at the customer s preference Relocate lights if necessary If your truck does not have room to mount a D6120 40 27k Gripper Arm call Perkins at 800 882 5292 for help selecting a different model 800 882 5292 _Revised 11 7 2013 Page 6 of 42 Mark Your Centerlines Begin by selecting whether the installation will be centered on the truck or offset or a double installation Draw a centerline on the truck s loading sill A centered installation will place the lifter directly centered on the centerline of the truck An offset installation will place the lifter 17 from the center of the truck usually to the curb side as shown in the picture at right A double installation will place a lifter 17 to the left and 17 to the right of the truck s centerline A typical offset installation Determine the Mounting Height The mounting height is critical to the proper function of any cart lifter The ideal location for the upper hook is 34 off the ground when the lifter is positioned so that the faceplate is 5 degrees tilted back from vertical as shown in the diagram at left It is important
21. fting power weight capacity Only check this valve if your lifter stops moving or moves to fast or too slow Maintaining the Diverter Valve The valve requires no periodic maintenance If a problem is thought to exist in the diverter valve turn the system off and check the cartridge by unscrewing either of the large caps from the ends and removing the cartridge The cartridge may then be cleaned and inspected Flush the valve out to remove any contaminants return the cartridge and reinstall L Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 20 of 42 www perkinsmfg com Adjusting the Lifting Capacity 2 spool Hand Valve D63519 valve only This valve directs the flow to the lifter to make it move up or down It features a deadman stop Release the handle and the lifter should stop moving The valve has a built in pressure relief valve To increase the lifting capacity loosen the locking nut and turn the adjusting screw clockwise It is recommended to use a pressure gauge to achieve the right setting Raise the lifter until it stops and continue to pull the handle Note the pressure on the gauge and adjust the screw accordingly When the pressure is correct retighten Note The setting for the D6120 40 27k is approximately the locking nut 2000 psi to lift 400 Ibs Replacement Parts D63127 Seal Kit D63192 Spring Kit D63672 Ca
22. ge 13 of 42 Mixed Commercial amp Residential Installation Example Note the Bumper Extension fully protects the cart lifter from contact with the commercial container The elephant ears and container locks have been shifted back and material added The reverse lights have been relocated in this installation so they would not be obscured by the lifter placement Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 14 of 42 www perkinsmfg com V Non Perkins Hydraulics Hydraulic Oil The most important component of any hydraulic system is the oil Perkins cart lifters use standard seal materials and should therefore be compatible to most grades of hydraulic oils operating in typical weather conditions for most of North America However the condition of the oil is an important consideration that should not be overlooked Hydraulic oil may be dirty contaminated lost its viscosity burned up or have too high a concentration of absorbed water and or air While these things are unlikely to cause an immediate performance issue with your cart lifter these issues can lead to premature wear and tear in the longer term Perkins would like to take this opportunity to remind you to check the quality of your hydraulic oil periodically and make sure it meets your standards Oil that is maintained in good condition will help your equipment last longer Non Perkins Controls Some customers wi
23. ged in this type of accident Perkins offers a kit for the easy ordering of the necessary parts to quickly restore the lifter to good operation By ordering the Perkins part number D6080r 27k you will receive a partially assembled assortment of parts including the faceplate shell and all other pieces forward of the actuator As shown below everything is included minus the shaded components USE YOUR EXISTING ACTUATOR AND PARTS INCLUDED IN THE REBUILD KIT Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 41 of 42 www perkinsmfg com V Perkins provides each finished cart lifter with ANSI specified caution labels They are clearly placed directly on the machine for easy viewing by the operators Should the cart lifter ever be re painted or if the labels are damaged beyond recognition it is advised to replace the labels immediately to help keep your crew Safe OHSA requires these labels to be in clear sight on the machine at all times Responsibility to maintain proper caution and warning labels is the responsibility of the end user Large Safety Label D62474 Small English Label D72114 Small Spanish Label D72115 ATTENTION TO MAINTAIN WARRANTY ON DUMPER LUBRICATE WEEKLY OPERATE IN AN 6 8 SEC CYCLE CAUTION STAND CLEAR WHILE OPERATING NEVER OPERATE DUMPER TO FULL UP POSITION WHILE BLADE IS IN DOWN MOTION CALL 800 882 5292 PERKINS MFG
24. haking if you plan to regularly shake the cart Step 5 Lower the cart by reversing the hand valve handle pushing down until the cart is safely returned to the ground and the lifter has disengaged the cart Step 6 Remove the empty cart and repeat the process as needed Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 27 of 42 www perkinsmfg com gt Safe Operating Tips Always follow your company s safety policy during the use of this lifter including use of proper clothing personal protective gear reflective clothing etc Remember you are operating the lifter on a public road alley among moving traffic Always be aware of your surroundings and watch for cars and pedestrians Do not lift anything with the lifter other than ANSI approved carts which are in good condition Non approved carts may not lock properly causing them to fall from the lifter which can cause damage or injury and will void the warranty Do not use the lifter for any purpose other than lifting a cart Lifters are not meant as steps they are not to be used to help lift a commercial container or used to crush breakdown an item Doing so can cause serious damage or injury and will void the warranty Speeding up the lifter beyond the recommended cycle time of 6 8 seconds and or adjusting the relief valve to pick up weights heavier than 400 Ibs can lead to damage or injury and will void the warr
25. ing properly Check the arrow printed on the valve body The valve should be installed so the arrow points away from the actuator Adjust clean or replace the adjustable flow control valve as needed Cart lifter will not pick up the weight The cart may be overweight If the cart is obviously very heavy and hard to move try removing a few items from the top to lighten the load The hand valve relief pressure setting may be set too low Check and adjust the pressure using a pressure gage Note the pressure being delivered and adjust accordingly If adjusting the hand valve s relief does not bring the pressure up to where it should be then the truck s relief pressure setting may be set too low Try adjusting the truck s relief valve see manufacturer s instructions on how to do this for your vehicle In cases of older equipment the hand valve may be in need of replacement or repair If all pressures are set properly and the hand valve works then the actuator may have internal leakage Test for internal leakage by running the lifter all the way up and dead head the lifter up Note the pressure gage and see that the pressure stays constant as the hand valve is held depressed If the pressure falls you may have internal leakage and the actuator should be repaired rebuilt with new seals Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 31 of 42 www perkinsmfg com Lifte
26. l direct or indirect damage loss or delay of any kind including but not limited to the loss of profits product or time PERKINS warrants any service parts it may sell for a period of ninety 90 day from the date of delivery for replacement only The warranty item must be returned to PERKINS for evaluation upon its request The cost of labor to replace such part shall be the responsibility of the owner PERKINS does not warrant any used parts PERKINS whose policy is one of continuous improvement reserves the right to improve its products through changes in design or materials as it may deem desirable without obligation to incorporate such changes in products of prior manufacture THE ABOVE WARRANTY SUPERCEDES AND IS IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES INCLUDING WITHOUT LIMITING ANY IMPLIED WARRANTIES OF MERCHANABILITY OR FITNESS FOR A PARTICULAR PURPOSE NO EMPLOYEE OR ANY OTHER REPRESENTATIVE OF PERKINS IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR TO GRANT ANY OTHER WARRANTY ANY LEGAL ACTION CONERNING THIS WARRANTY OR THE PRODUCT INVOLVED INCLUDING WITHOUT LIMITING ANY ARBITRATION OR ADMINISTRATIVE PROCEEDING SHALL BE GOVERNED BY THE LAWS OF THE STATE OF ILLINOIS WHICH SHALL BE APPLIED AS THE CHOICE OF LAW
27. lifter can be made simple when you remember to make matching marks on the teeth and driver hubs However if this is forgotten the correct position can be discovered by this method below Rotate the actuator to the fully up position as shown in the diagram Install the faceplate assembly so that the face is 45 degrees above the horizon Each tooth offers separation of 12 8 degrees so if you use the wrong tooth it should be readily obvious and easily correctible INSTALL FACEPLATE WITH MOTOR UP AND FACEPLATE AT 45 ABOVE THE HORIZON TURN ACTUATOR ALL THE WAY UP UNTIL IT STOPS ima Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 30 of 42 www perkinsmfg com V Troubleshooting Guide Lifter operation is erratic lifter does not move smoothly When the lifter does not move smoothly there is typically air in the system This is usually an issue after the initial installation or a recent repair where the hydraulic lines may have been opened Bleed air out of the system by loosening a fitting very slightly and running the hand valve to create flow Excess air should bleed out of the opening in the fitting Retighten when complete done In rare instances the flow may be too low This would also be noticeable if the lifter was also very slow Try adjusting the diverter valve to increase the flow Another possibility is the adjustable flow control D63575 not function
28. llations this is the result of having the pressure and tank lines reversed Check and make sure that the pressure line goes to the IN port and the tank line goes to the OUT port Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 32 of 42 www perkinsmfg com Hand valve is leaking oil This is typically caused by worn or damaged seals Install new seals with part number D63217 In some cases the spool itself is worn If so replace the hand valve Unable to achieve 1950 psi at the hand valve The truck s pressure setting may be too low Adjust the truck pressure according to the manufacturer s instructions If pressure cannot be increased further it may be necessary to install a soeed up switch which will rev the engine higher during peak need to deliver the desired pressure Note that speed up switches will increase fuel consumption Unable to achieve over 1400 psi The truck pressure is too low If adjustments do not help the pump may be bad or underpowered Contact your truck manufacturer Lifter breaks the lower bars of carts First make sure there is no damage to the lifter Replace damaged components as needed Check adjustment of plunger assembly and threaded rod assembly Check function of plunger Adjust as needed On new installations check the mounting height It is common for brand new lifters to break lower bars if the lifter is installed too lo
29. ly ends up being higher than the original load sill This is normal and requires the addition of a supporting structure It is necessary to fully support the mounting plate to provide a rigid base for the cart lifter An unsupported mounting plate can easily deform through normal use in a short period of time Failure to fully support the mounting plate can lead to rapid premature failure of the cart lifter Perkins recommends adding steel structural tube across the entire length of the load sill This tube becomes the new load sill The tube should be at least thick and sized to allow the top of the support to mate to the top of the mounting plate Do not extend the support tube above the mounting plate top edge The size needed will vary from installation to installation use what best suits your needs Note Simply adding gussets to the back of the mounting plate does not provide adequate support The reinforcement should cover the entire rear of the plate and be welded fully 800 882 5292 Revised 11 7 2013 Page 9 of 42 Residential Only Installation Example iia a ie eat A typical example of a center positioned residential only installation Note the mounting plate is fully supported After the cart lifter and supports are tack welded in place move the cart lifter by hand up and down carefully making sure there are no interferences Double check the gripper arm height to the ground If e
30. nd tank and pointing towards the front of the truck and all hoses are neatly routed for a clean look and best hose protection Perkins Manufacturing Company 800 882 5292 Creators of the TuckAway Cart Lifter www perkinsmfg com Revised 11 7 2013 Page 16 of 42 Locate and Connect the Diverter Valve PACKER BLADE DIVERTER VALVE PRESSURE LINE CONTROL VALVE The diverter valve is designed to accept full system flow continuously divert a portion of that flow to the lifter s and pass the remaining flow on to the packer control valve The amount of flow that is diverted is adjustable so the same valve that feeds one lifter can also be adjusted to feed two lifters Adding the Perkins diverter valve to your system will slow down your packer cycle by several seconds whether you are actively using the lifters or not However this is usually an acceptable tradeoff since the Perkins diverter valve doesn t generate much backpressure or heat and it allows you to use the packer and the lifters simultaneously With the system off and depressurized find the pressure line that feeds the packer valve and disconnect it Connect this pressure line to the IN port of the Perkins diverter valve Connect the OUT port of the diverter valve back to the packer control valve where the pressure line originally was The fittings to do this will vary from truck to truck The Perkins Tap in Kit generally gives you the required fittings but due to
31. ng Company 800 882 5292 Creators of the TuckAway Cart Lifter www perkinsmfg com L Revised 11 7 2013 Page 12 of 42 Moving the Container Locks At this point the bumper extension is now sticking out past the OEM supplied sill extension by X inches This dimension might typically be about 3 or 4 Measure this dimension The distance the extension has shifted out is the distance the container locks must be extended Carefully torch the elephant ear and container locks right off the truck Reposition the container locks and elephant ears back on the truck at the same height and spacing but shifted back to the rear of the truck The shift distance X is equal to the amount the bumper extensions went past the OEM supplied extension sill X Add filler material as a spacer to take up the gap created by shifting the locks It may be necessary to reconstruct the container lock backing bars to make them have a smaller gap Customized pieces of steel are used thoughtout this step and are not provided by Perkins Prior to fully welding make sure a commerical container will properly lock up to the container locks in their new position Double check that a commerical container cannot make contact with the lifter If everything is satisfactory weld fully gt Perkins Manufacturing Company 800 882 5292 Creators of the TuckAway Cart Lifter www perkinsmfg com Revised 11 7 2013 Pa
32. pect that failure of the lifter to operate is due to a defect please take a moment to locate the serial number of your lifter Warranty cannot be honored on lifters or individual pieces unless a serial number is provided Since the tag is frequently lost damaged or painted over it is a good idea to note ROUTE TESTED DRIVER APPROVED the serial number in this manual at the time of installation 737 Oakridge Drive Romeoville IL 60446 At right is an example of the serial number plate 708 482 9500 800 882 5292 It will be stamped with a model number and serial number Once you have the number please call Perkins Manufacturing at 800 882 5292 for additional instructions Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 35 of 42 www perkinsmfg com Q gt Exploded Parts View Base Actuator Portion Rear Mounting Plate Front Mounting Weldment Pivot Pin Weldment Bolt FHCS 5 16 18 x 1 Zinc Plate Idler Lug Weldment 6 D63238 20k 27k Hub 12 pt Flange Bolt 5 8 11 x 1 5 D72042 Bolt HHCS 13 x 2 GR8 O e D62405 Bolt HHCS 13 x 2 GR8 pA 1 1 2 2 2 2 2 ES Botl HHCS 5 8 11 x 1 GR8 2 z Bolt HHCS 1 13 x 1 2 Bolt FHCS 5 8 11 x 1 Zinc Plate pA Locknut 5 16 18 GR8 Plate Bolt HHCS 13 x 1 1 2 D62458 Split Lockwasher 5 8 D62006 Bolt FHCS 14 13 x 11 4 Perkins
33. r operates slowly Check the flow adjustment on the diverter valve Use a flow meter to make sure each lifter receives approximately 3 5 gom Adjust diverter as needed following instructions in the manual Engine idle may be too low to provide adequate flow Following the manufacturer s instructions adjust the engine idle Remember increasing engine idle will increase fuel consumption The hand valve may be faulty Check clean and or replace as needed The truck s pump may be faulty unable to deliver the desired flow Contact your truck manufacturer In rare instances debris within the oil may be clogging the diverter valve Check and clean the valve as needed Lifter operates too fast Check diverter valve adjustment screw Adjust in to lower the flow delivered to the lifters Engine idle speed may be too high Adjust per the manufacturer instructions Diverter valve is leaking oil Worn or Damaged seals within the diverter will cause external leaking Rebuild the valve using D63477 divert valve spring kit Hand valve lever sticks does not return to center A worn or broken spring on the spool will cause the handle to fail to return to center This is dangerous since this means the deadman stop feature is not working Check and replace the spring with part number D63192 If the spring is not the problem check and clean the hand valve of any rust corrosion and debris in or around the spool or the external parts On new insta
34. rtridge Kit Troubleshooting the Hand Valve This valve does not affect lifter speed Only adjust this valve if the lifter won t pick up the desired weight or if a chattering noise is heard Don t be fooled Containers full of water concrete rocks dirt wet grass of other materials can easily weigh far more than the capacity of the lifter Just because the lifter doesn t pick up that heavy cart doesn t mean the lifter needs adjustment If there is doubt try weighing the container in question Maintaining the Hand Valve This valve requires no periodic maintenance If a problem is traced to the hand valve turn the system off and remove the cartridge Clean and inspect the cartridge Make sure the handle returns to center on it s own If it doesn t it may need a spring kit Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 21 of 42 www perkinsmfg com There are usually multiple relief valves within the same system They must be set at least 100 psi apart from each other or they will chatter Adjusting one valve to be set differently than another should eliminate the problem Example Pump relief valve 2000 psi packer relief valve 1900 psi lifter relief valve 1650 psi Maintaining the PO Check Valve PO Check Valve D63580 The valve locks the oil from escaping unless the hand control is activated This locks equipment in position and prevents drifting
35. th new trucks may choose to use hydraulic controls provided by the OEM As long as the GPM and pressure settings used match the specifications required then the lifter should operate fine Perkins cart lifters do not require special Perkins valves to operate In other cases a Perkins cart lifter may be replacing a competitive lifter for which controls are already installed Again Perkins cart lifters should work just fine with competitive equipment as long as the GPM and pressure settings are adjusted within the specified ranges Lifter Speed The cycle time of the lifter is very important for safe operation Perkins suggests a complete cycle time of 6 8 seconds 3 4 seconds up and 3 4 seconds down Faster cycle times may be dangerous Running a lifter too fast can damage the cart or make a cart break loose off the lifter and fall resulting in damage and or injury The speed of the cart lifter is determined by the rate of oil gom going to the unit Typical lifters with a 27k actuator will require approximately 3 5 gpm in order to meet this speed A gauge is recommended but not needed to determine proper lifter soeed Counting the cycle time using a stop watch is adequate to determine proper flow rate Running a lifter too fast will void the warranty Weight Capacity The maximum amount of weight that can be lifted is limited by the pressure relief valve The settings must be determined with a pressure gauge The D6080 27k requires 1650 psi
36. to lift a 400 Ib load Place a pressure gauge after the hand valve and run the actuator until it stops continue activating the handle and note the pressure on the gauge Adjust the relief valve according to the manufacturer s instructions Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 15 of 42 www perkinsmfg com Locate the Hand Valve Assembly A suitable location for the hand valve assembly should be found on the side of the truck It s placement should not interfere with any existing truck components The handle should be a comfortable distance from the ground typically about 48 high so that repeated ergonomics is easy to use and safe The Perkins hand valve assembly comes with a mounting bracket which may be welded directly to the side of the truck Typically the hand valve s handle will point to the back of the truck and the ports A amp B which feed the lifter will be pointing to the ground This position should allow the operator holding the handle to still be within arm s reach of the cart that is being lifted This keeps the steps back and forth to a minimum for best efficiency Tack weld the valve bracket in place temporarily until all the hoses have been routed V Perkins Hydraulic Installation Note the hoses feeding the lifter are pointing straight down The hoses Sold Separately leading back to the pressure supply a
37. verything appears satisfactory the lifter s mounting plate and supports may be welded fully The mechanical portion of the installation is complete Perkins Manufacturing Company 800 882 5292 _Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 10 of 42 www perkinsmfg com Mixed Commercial amp Residential Installation When performing a commercial installation the same procedure of the residential installation must be followed with these additional steps Recess The Cart Lifter When a truck is provided with commercial container locks the OEM will usually add an extended bumper over the original load sill To mount a cart lifter to a truck like this you must recess the cart lifter by cutting a notch in the extended load sill Cut a notch that will leave a 2 gap on either side of the lifter Do not cut into the original load sill The original load sill is a structural member of the tailgate and must not be severed or the structural integrity of the tailgate will be compromised leading to distortion and failure EXTENDED LOAD SILL ORIGINAL LOAD SILL TOP VIEW OF TRUCK LOAD SILL ORIGINAL LOAD SILL p 172 TRUCK CENTERLINE LIFTER CENTERLINES 17 JE NOTCH SIZED TO LEAVE 2 GAP ON EACH SIDE OF LIFTER EXTENDED LOAD SILL NOTCH SIZED TO LEAVE 2 GAP ON EACH SIDE OF LIFTER Note Be careful not to cut into the original load sill or else the structural integrity of the tailgate c
38. w Remove the lifter and remount at the correct height Lifter breaks upper bar of carts The upper bar of the cart is typically broken when the cart is lifted while it is excessively loaded or while the lifter is operated too quickly Adjust the speed of the lifter to bring the cycle time to 6 8 seconds Make sure the pressure is set no higher than 1950 psi Make sure the lifter is not damaged Bent or broken lifter parts can contribute to cart damage Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 33 of 42 www perkinsmfg com Lifter drops carts A common problem is the lower latch is not adjusted correctly or the latch is damaged or unable to move freely Check clean and grease the parts as necessary to achieve free motion of the latch and appropriate latch timing Make sure the upper hook is not damaged and make sure the lower stop is in place Some customers have been known to remove the lower stop but this leads to dropping carts and latch damage Carts which are damaged or have missing lower bars will obviously not latch properly and should be repaired or replaced Some carts do not meet ANSI standards Measure the problem cart and see that the bar to bar spacing is within 14 15 Lifter slams down to the ground or comes down too quickly On the way down the lifter can get ahead of the oil and free fall Check that the adjustable flow control is mounted to th
39. when equipment is idle It also acts as a safety in the event of a broken hose the valve stops the movement of the equipment This valve is not adjustable This valve requires no periodic maintenance If a problem is traced back to the PO check turn off the system and remove the cartridge Clean and inspect for damage Replace cartridge if needed flush the valve rebuild and install Maintaining the Adjustable Flow Control L www perkinsmfg com Perkins Manufacturing Company Creators of the TuckAway Cart Lifter Adjustable Flow Control Valve D63575 The valve is located on the left hand side port of the rotary actuator It s purpose is to restrict oil coming out of the actuator when the lifter is moving back down By restricting the oil the lifter is prevented from getting ahead of the oil and slamming into the ground This valve only works in one direction so adjusting it does not affect the speed of the upwards direction The valve has a small arrow stamped into its body The arrow should point away from the actuator If the lifter comes down too quickly try turning this valve in clockwise turn at a time until the down direction is smooth and under control 800 882 5292 Revised 11 7 2013 Page 22 of 42 Servicing the Perkins Helical Rotary Actuator Perkins Helical 27k Actuator D73060 Common Parts Seal Kit D73061 1 Shaft D73060 2 The manual for the actuator is provided separately
40. y Cart Lifter Page 3 of 42 www perkinsmfg com Glossary of Terms Cart Types ANSI Type B carts ANSI Type C Carts ANSI Type D Carts ANSI Type G Carts US Style two bar European type Diamond Type Automated Collection carts with a Using an upper lip for Having a rounded body dimension of 14 lifting Height to ideal for gripper arms to 15 bar to bar ground varies with size clasp around Spacing of cart Note Some ANSI Type B carts are also Type G compatible but some carts particularly older designs are not This affects gripper arm type of lifters that rely on grasping the cart around it s body If using a gripper arm type of lifter check your carts and see if they have rounded corners look for approximately 6 radius If so they are likely ANSI Type G compatible Key Hydraulic Components i Vn 2 a gt j e m LS p Sew Ye t A Diverter Valve Hand Valve PO Check Valve 50 50 Splitter Double Diverter Valve Adjustable Flow Control Helical Rotary Actuator Valves are sold separately or as part of a tap in kit The valves are shown for reference identification purposes only Your specific installation may require other equipment not shown gt Perkins Manufacturing Company 800 882 5292 Revised 11 7 2013 Creators of the TuckAway Cart Lifter Page 4 of 42 www perkinsmfg com Installation Safety Please read this manual prior to installing repairing or using this cart lifter
Download Pdf Manuals
Related Search