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Related Manuals for Payne Pallet Retriever
Summary of Contents for Payne Pallet Retriever
- Page 1 MACHINE No. xxxx LEVER CONTROLS & FULL GUARDS OPERATORS MANUAL www.paynepalletinverters.co.uk Dereham Road, Beeston, Kings Lynn, Norfolk PE32 2NQ, UK Telephone: +44 (0) 1328 700138 Fax: +44 (0) 1328 701879 09/2012 RAR VERSION 5 ...
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Page 2: Table Of Contents
CONTENTS INTRODUCTION CONTENTS 2 CONTENTS CONTINUED 3 SAFETY PRECAUTIONS 4 PRODUCT DESCRIPTION 5 INSTALLATION HANDLING 6 MACHINE INSTALLATION 7 GUARD INSTALLATION 8 CONNECTION 9 OPERATION PRE‐USE & START UP PROCEDURE 10 OPERATORS MANUAL 11 MAINTENANCE MAINTENANCE SCEDULE 12 LUBRICATION ... -
Page 3: Contents Continued
CONTENTS CONTINUED COMPONENTS PUMP ASSEMBLY 17 PUMP ASSEMBLY (INTERNAL) 18 CONTROL PANEL 19 VALVE ASSEMBLY 20 TABLE ROLLERS 21 FLOW DIVERTER VALVE 22 TURNOVER RAM 23 CLAMP RAM 24 SPECIFICATIONS SPECIFICATION 25 OIL DATA SHEET 26 OIL DATA SHEET CONTINUED 27 GREASE DATA SHEET 28 GREASE DATA SHEET CONTINUED 29 ATTACHED DOCUMENTS DRAWINGS, EC CONFORMITY, SERVICE AGREEMENT, WARRANTY ... -
Page 4: Safety Precautions
SAFETY PRECAUTIONS SAFETY: THE MACHINE IS TO BE USED ONLY IN ACCORDANCE WITH SAFTEY GUIDELINES AND IS NOT TO BE USED FOR ANY OTHER PURPOSE THAN ORIGINALLY INTENDED. The machine is fitted with a run button, which MUST be released in all possible emergency situa‐ tions, disabling the machine. The following guidelines MUST be obeyed and the machine operated in strict accordance with the operators manual: • Only fully authorised personnel may operate this machine. • Only fully authorised, suitably qualified personnel may carry out maintenance operations on this machine. ... -
Page 5: Product Description
PRODUCT DESCRIPTION LEVER CONTROLS The Retriever is designed for the efficient exchanging of pallets from a load. The machine is loaded at a floor level, with either fork or pallet truck. It then tips the load through 95 degrees, ena‐ bling the pallet to be easily exchanged. The load is then returned to its original orientation and removed from the machine. The lever controls for this machine are affixed to the guards. A “RUN” start button is fitted to the control panel, ensuring ... -
Page 6: Handling
HANDLING There is only one method of lifting the Pallet Retriever: The machine MUST only be unloaded and loaded with the use of a suitably rated fork lift truck and a competent, qualified driver. The retriever must be in the position illustrated (Fig 1). With the transportation supports placed under the machine frame. NOTE: If the machine is to be set down before it reaches it final desti‐ nation, it is important that the transport supports are kept in position, as it will be difficult to move the machine once removed. Fig. 1 Transportation support The supports should be set down near each corner of the frame (Fig 1). When the machine is in its desired final position, remove the supports before attaching the machine to the floor. SAFETY: CARE MUST BE TAKEN WHILST MANEUVERING THE EQUIPMENT AROUND OBJECTS AND PEOPLE TO AVOID DAMAGE/INJURY. 09/2012 RAR VERSION 5 ... -
Page 7: Machine Installation
MACHINE INSTALLATION Tools Required: Materials: 13mm spanner M8 fixings x 14 19mm spanner M12 through bolts x 22 30mm spanner M20 through bolts x 6 Suitable heavy mallet Cable clips and ties Drill, 12 & 20mm SDS drill bits Before installation, ensure the following items are made available: • A suitably rated forklift (5000kg) • A level floor Also ensure the presence of: • A fully qualified electrician • A fully qualified forklift driver • Suitable floor space for the machine •... -
Page 8: Guard Installation
GUARD INSTALLATION NOTE: THE HOLES FOR ASSEMBLY ARE PRE DRILLED IN THE GUARD FRAMES, ENSURE THE GUARDS ARE IN THE CORRECT ORIENTATION BEFORE COMMENCING ASSEMBLY. • Place the 5.5m lever control cables at the front of the machine (be careful not to trap these while assembling the guards). • Locate the guard panels, electrical box and cable trays in their respective positions (see lay‐ out drawing). There are 8 panels in total, including two which make up the front returns. • Loosely assemble the guards as per plan using 12 x M8 fasteners to secure between panels. Fit the cable trays to the guards as this will help with alignment (there are 4 attachment lugs for the cable trays located on each guard panel). NOTE: DO NOT TIGHTEN THE GUARD PANELS DOWN AT THIS POINT. ... -
Page 9: Connection
CONNECTION SAFETY: THE FOLLOWING SHOULD ONLY BE CARRIED OUT BY A FULLY QUALIFIED ELECTRICIAN. • Connect the machine to an adjacent suitably rated electrical supply. • Switch the electrical isolator on, at the electrical panel (see below). NOTE: POSITION CAN VARY DEPENDING ON SPECIFICATION. • Start the machine by pressing the RUN button. • check for the correct clockwise rotation of the motor. If necessary, change the motor con‐ nections to reverse the polarity. 09/2012 RAR VERSION 5 ... -
Page 10: Pre-Use & Start Up Procedure
PRE‐USE & START UP PROCEDURE Pre‐use Inspection: • Visually inspect the machine for any obvious deformities or irregularities. • Ensure there are no oil leaks and the hydraulic oil level is correct on the tank sight glass. • Ensure the area under the body is free from debris using a long handled broom, never en‐ ter the area under the body at any time. • Ensure any load placed in the machine is correctly located against the fixed rear wall and sliding side table. SAFETY: ALWAYS ENSURE THERE ARE NO PERSONS PRESENT WITHIN THE GUARDED AREA PRIOR TO STARTING! SAFETY: NEVER START UP THE MACHINE IF ANY OF THE ABOVE CRITERIA ARE NOT MET ... -
Page 11: Operators Manual
OPERATORS MANUAL • Ensure any load placed in the machine is correctly located against the fixed rear wall and sliding side table. SAFETY: ALWAYS ENSURE THERE ARE NO PERSONS PRESENT WITHIN THE GUARDED AREA PRIOR TO STARTING! • Depress the RUN button (Fig 4) with one hand and with the other hand press the right‐ hand lever downwards until the load is fully clamped, then allow the lever to return to its ... -
Page 12: Maintenance Scedule
MAINTENANCE SCHEDULE SAFETY: BEFORE CARRYING OUT ANY MAINTENANCE OPERATION ENSURE THE MACHINE IS IN ITS DEFAULT (AT REST) POSITION AND THAT THE ELECTRICAL ISOLATOR ON THE MAIN CON‐ TROL PANEL IS SWITCHED OFF AND LOCKED. Weekly: • Grease all lubrication points including: i. Table slides (Page 13) ii. Body centre pin (Page 13) Monthly: • Check the hydraulic oil level at the tank sight glass, replenish with correct grade oil if necessary (See specifications page) ... -
Page 13: Lubrication
LUBRICATION GREASING POINTS Lubricate all grease points shown below (Fig 3 & 4) in accordance with the maintenance schedule on the previous page. NOTE: It is important to use the correct grade of grease (see specification page). SAFETY: DISPOSE OF WASTE GREASE AND SOILED RAGS CORRECTLY AND IN ACCORDANCE WITH LOCAL AUTHORITY GUIDELINES. LUBRICATION POINT Fig. 3, Table slides Fig. 4, Pivot points 09/2012 RAR VERSION 5 ... -
Page 14: Oil Change Procedure
OIL CHANGE PROCEDURE Tools Required: Materials Required: Part No. 13mm spanner Oil suction filter H-F-SE1320 24mm spanner Return filter element H-F-2012 Oil transfer pump Pegasus 32 oil 60 litre container Oil absorbent pads ... -
Page 15: Oil Change Procedure Continued
OIL CHANGE PROCEDURE CONTINUED • Examine the tank lid seal for deterioration, signs of perishing or damage and replace the seal if necessary. At this point drain any excess oil from the motor/pump assembly. • Carefully refit the complete tank top lid assembly. • Refill the hydraulic tank through the filler breather with Mobil Pegasus 32 grade oil until it reaches the top mark on the sight glass. Fill the tank carefully, to prevent a build up of air in the system. NOTE: THE OIL LEVEL MAY DROP A SMALL AMOUNT AFTER THE MACHINE HAS BEEN RUN FOR THE FIRST TIME, THIS IS NORMAL AS THE OIL HAS TO FILL THE HYDRAULIC SYSTEM. • Re‐fit the tank filler/breather cap. •... -
Page 16: Technical
TECHNICAL FLOW DIVERTER VALVE NOTE: NO ADDITIONAL ADJUSTMENT TO THE FLOW DIVERTER VALVE SHOULD BE REQUIRED. 1. The flow diverter valve acts only on the return operation of the machine. It is a 2 position valve with no neutral. It operates by switching flow from the turnover ram back to the hy‐ draulic reservoir tank. • When the body is reaching the end of travel the plunger is depress by means of an adjustable buffer (located on side of body). NOTE: This buffer should not be adjusted as it may cause the machine to malfunction. • The plunger operates the valve which in turn diverts the feed from the turnover ram back into the hydraulic tank, thus disabling the ram. Fig. 6 Flow diverter valve Fig. 7 Hydraulic drawing 09/2012 RAR VERSION 5 ... -
Page 17: Components
COMPONENTS PUMP ASSEMBLY Fig. 8 Item Component Part No. 1 Motor/pump assembly E‐EMA‐4KW 2 Pressure gauge H‐PG‐4000 BTM 09/2012 RAR VERSION 5 ... -
Page 18: Pump Assembly (Internal)
COMPONENTS PUMP ASSEMBLY (INTERNAL) Fig. 9 Fig. 9.1 Item Component Part Number 1 11cc hydraulic pump H‐P‐11CC 2 Strainer filter H‐F‐SE1320 3 Filler filter H‐F‐1163.40 4 LS252 motor bell housing H‐EM‐B/HOUS 5 Return filter replacement element H‐F‐2012 6 Flexible coupling (inside bell housing) H‐EM‐P/COUP 09/2012 RAR VERSION 5 ... -
Page 19: Control Panel
COMPONENTS CONTROL PANEL Fig. 10 (Front of control panel) Fig. 10.1 (Handle block, located behind control panel) Item Component Part No. 1 10mm control lever H‐CCL‐M10 2 5.5 meter control cable H‐CCWNS‐5.5 3 Twin handle block H‐CCHA‐WA 4 Cable connecting kit (cable to handle block) H‐CC‐GPS 09/2012 RAR VERSION 5 ... - Page 20 COMPONENTS SPOOL VALVE ASSEMBLY CLAMP PRESSURE Fig. 11 SYSTEM PRESSURE Item Component Part No. 1 Flow speed control valves (clamp rams) H‐V‐SCV‐06S 2 Inline relief valve H‐V‐06INLINE 3 Double spool valve H‐V‐SPL‐SD5/2 4 Cable connecting kit (cable to valve) H‐CCF‐TP50 09/2012 RAR VERSION 5 ...
- Page 21 COMPONENTS TABLE ROLLERS Fig. 12 Item Component Part No. 1 Sprung roller 6” R‐SR‐6X1.5 09/2012 RAR VERSION 5 ...
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Page 22: Flow Diverter Valve
COMPONENTS FLOW DIVERTER VALVE Fig. 13 Item Component Part No. 1 Plunger operated flow diverter H‐V‐SV80 09/2012 RAR VERSION 5 ... -
Page 23: Turnover Ram
COMPONENTS TURNOVER RAM & HYDRO TANK 1&2 Fig. 14 Item Component Part No. 1 Turnover Ram H‐RAM‐PR0007REV 2 Ram seal kit (turnover ram) H‐RS‐GM‐90/50 3 Speed control valves (turnover ram) H‐V‐SCV‐06S 4 Return filter pressure indicator H‐F‐RFI 5 Return filter assembly H‐F‐1211.341 6 Filler/filter H‐F‐1163.40 7 Tank sight glass H‐SG‐FLT‐221 09/2012 RAR VERSION 5 ... -
Page 24: Clamp Ram
COMPONENTS CLAMP RAM 1&2 Fig. 15 Item Component Part No. i. Clamp ram for 5’1 inverter SI0004 ii. Clamp ram for 5’7 inverter SI0005 1 iii. Clamp ram for 6’1 inverter SI0006 iv. Clamp ram for 6’7 inverter SI0007 v. Clamp ram for 7’1 inverter SI0008 2 Replacement seal kit H‐RS‐GM‐50/30 09/2012 RAR VERSION 5 ... -
Page 25: Specification
SPECIFICATION Type Original pallet retriever 95 degree Lever control c/w full guards Manufactured xxxx Beeston Kings Lynn, Norfolk, UK General data Minimum operating temperature (˚c) ‐18 Maximum noise level (Db) <74.8 Finish Blue c/w black guards Mechanical data Oil capacity (litre) 60 Oil pump capacity (cc) 11 Hydraulic system pressure (psi) 2000 Load capacity (kg) ... -
Page 26: Oil Data Sheet
OIL DATA SHEET Pegasus 32 Hydraulic and Circulatory Fluid: Pegasus 32 is a high quality hydraulic and circulatory fluid manufactured from solvent refined mineral oils and incorporating an extremely high performance additive system. Specifically developed to meet or exceed the very stringent performance specifications demanded by ma‐ jor original equipment manufacturers. Primarily recommended where maximum equipment protection is required when the severest of opera‐ tional conditions are to be encountered. Performance Benefits: Extremely sophisticated additive system meets the highest performance requirements of current equip‐ ment manufacturers of both static and mobile plant. Excellent anti wear protection dramatically reduces mechanical abrasion even under the most severest of operational conditions, greatly reducing the frequency and level of maintenance requirements. Corrosion, foam and oxidation inhibitors produce an extremely stable lubricant even under the most ardu‐ ous of working conditions, greatly extending fluid life and substantially reducing maintenance costs. Health and Safety: ... - Page 27 OIL DATA SHEET Pegasus 32 Hydraulic and Circulatory Fluid: Performance Specifications: Hydraulic Standards: Din 51524 Part 2 (HLP) ISO 11158 HM Sperry Vickers I‐286‐S (Industrial) AFNOR NF E 48‐603 (HM) Denison Filterability TP 02100 Typical Performance Data: Oxidation Stability ASTM‐D943 1000 Hours Time to TAN 2.0 mgKOH/g Load Carrying Capability ...
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Page 28: Grease Data Sheet
GREASE DATA SHEET Proteus 000EP, 00EP, 0EP, 1EP, 2, 2EP, 2M, 3 Lithium Soap Greases: A range of premium quality multi purpose greases, manufactured from Lithium‐12‐Hydroxy Stearate Soap dispersed in solvent refined mineral base stocks, fortified with selected compounds to inhibit corrosion and oxidation. The grades highlighted with EP signifies the inclusion of specially selected soluble extreme pressure additives, and in the case of Proteus 2M the addition of micronised Molybdenum Disulphide has been added to enhance its operational characteristics. This highly versatile range of greases are recommended for a variety of applications including automotive, industrial and off‐highway plant for bearings, steering and chassis fittings, grease cups, water pump bear‐ ings and grease lubricated universal joints. These grades may also be used to advantage over a wide range of other industrial applications from small high speed bearings operating under high unit pressure and load, as well as centralised lubricating sys‐ tems. As well as the ability to provide continuous pumpability over wide temperature ranges, they exhibit ... - Page 29 GREASE DATA SHEET Proteus 2EP Lithium Soap Grease: Typical Physical Characteristics: 2EP Appearance Medium fibred grease Colour Bottle Green Worked Penetration (IP50) 265/295 NLGI Classification 2 Dropping Point (IP132) ...
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