Perkins D6780-27k Installation & Operation Manual
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Perkins D6780-27k Installation & Operation Manual

Perkins D6780-27k Installation & Operation Manual

Hydraulic cart lifter
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Table of Contents

Installation & Operational Manual
Model D6780-27k & D6785-27k
Hydraulic Cart Lifter

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Table of Contents
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Summary of Contents for Perkins D6780-27k

  • Page 1 Installation & Operational Manual Model D6780-27k & D6785-27k Hydraulic Cart Lifter...
  • Page 2 Warranty 3-years *** 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.
  • Page 3 Warranty 3-years *** 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.
  • Page 4 D6780 Overall Dimensions Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 3 ®...
  • Page 5 D6785 Overall Dimensions Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 4 ®...

  • Page 6: Glossary Of Terms

    Control 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. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com...

  • Page 7: Installation Safety

    Do not paint over caution and warning labels.  If there are any questions about the proper installation or use of the cart lifter not covered in the manual, it is recommended to call Perkins at 800-882-5292. Perkins Manufacturing Company...
  • Page 9 (usually to the curb side) as shown in the picture at right. A double installation will place a lifter 17 ½” to the left and 17 ½” to A typical offset installation. the right of the truck’s centerline. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com...
  • Page 10 A good mounting height will make latching carts Upper hook mounting height effortless with no lifting or holding the cart in place. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com...
  • Page 11 Positioning the Mounting Plate * The mounting plate may be positioned as low as 40 5/8” and as high as 43 3/4”, as needed. The mounting plate itself should be vertical and level. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com...
  • Page 12 Support Mounting Plate Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 10 ®...
  • Page 13 Double check the hook height to the ground. If everything 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: 7/6/2021...
  • Page 14 Note: Be careful not to cut into the original load sill or else the structural integrity of the tailgate can be compromised. It may be necessary to add custom structure reinforcements where the lifter is to be mounted. Perkins Manufacturing Company 800-882-5292...
  • Page 15 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 –...
  • Page 16 Double check that a commerical container cannot make contact with the lifter. If everything is satisfactory, weld fully. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com...
  • Page 17 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: 7/6/2021...
  • Page 18 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 D6780-27k requires 1650 psi to lift a 400 lb 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.
  • Page 19 (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 &...
  • Page 20 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.
  • Page 21 The Perkins Diverter Valve 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.
  • Page 22 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.
  • Page 23 Adjusting the Perkins Hydraulics 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.
  • Page 24 Note the pressure on the gauge and adjust the screw accordingly. When the pressure is correct, retighten the locking nut. Note: The setting for the D6780-27k is approximately 1650 psi to lift 400 lbs. Replacement Parts: D63127 – Seal Kit D63192 –...
  • Page 25 If the lifter comes down too quickly, try turning this valve in clockwise ¼ turn at a time until the down direction is smooth and under control. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com...
  • Page 27 #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...
  • Page 28 Perkins Single Lifter Hydraulics Schematic Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 26 ®...
  • Page 29 Perkins Double Lifter Hydraulics Schematic Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 27 ®...
  • Page 30 Step 4: 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 5: Remove the empty cart and repeat the process as needed. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021...
  • Page 31 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 damage is not covered by warranty. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021...
  • Page 32 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.
  • Page 33 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. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com...

  • Page 34: Troubleshooting Guide

    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: 7/6/2021...
  • Page 35 On new installations, 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...
  • Page 36 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: 7/6/2021...
  • Page 37 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: 7/6/2021...

  • Page 38: Making A Warranty Claim

    At right is an example of the serial number plate. 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...
  • Page 39 Exploded Fitting Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 37 ®...
  • Page 40 Faceplate Exploded View Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 38 ®...
  • Page 41 Base Portion Exploded View Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 39 ®...
  • Page 42 Full Exploded View Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 40 ®...

  • Page 43: Parts List

    SAE FLATWASHER 1/2 X 1.06 OD ZINC PLATED D42024 Plastic Bearing, 5/8'' ID X 3/8 THIN LOCKNUT 5/8-11 Distorted Thread, Grade 8, Zinc-plated D75573 D78814 FIBERGLIDE BUSHING 5/8 DIA X 5/8 Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 41...
  • Page 44 DRIVE SCREW #6-3/8 PLATED D72163 LABEL - GREASE POINT, REV B D72219 12pt Flange Bolt 5/8-11 x 1 1/2 LG, ZINC PLATED *Parts for D6785-27k **Parts not Shown Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021 Creators of the TuckAway Cart Lifter www.perkinsmfg.com Page 42...
  • Page 46 Protective Safety Labeling 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.
  • Page 48 If any issues occur, please contact service immediately. Perkins Manufacturing Company 800-882-5292 Revised: 7/6/2021...
  • Page 49 Safety Labeling and Training Requirements Perkins provides safety labeling on all outgoing product per ANSI regulations, seen below. It is the responsibility of owner of this product to maintain the safety labels, keep them clear & visible to all users, and replace the safety labels when they become worn or missing.
  • Page 50 If you believe your Perkins lifter has suffered from a failure that could be covered by warranty, immediately lock out any equipment that has failed per OHSA guidelines.
  • Page 51 If Perkins shipped the wrong item(s), the incorrect item(s) may be returned within 30 days of receipt of the item by contacting Perkins for a return authorization (RGA#). The item(s) must be shipped within 2 weeks of the return authorization. Perkins will pay the return freight and waive the restocking fee.
  • Page 52 PERKINS warrants any service parts it may sell for a period of ninety (90) day from the date of delivery for replacement only. The item being replaced must be returned to PERKINS for evaluation upon its request.

This manual is also suitable for:

D6785-27k

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