Perkins D6220b-27k Installation And Operational Manual
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Perkins D6220b-27k Installation And Operational Manual

Perkins D6220b-27k Installation And Operational Manual

Hydraulic cart lifter
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Installation & Operational Manual
Model D6220b-27k
Hydraulic Cart Lifter
Perkins Manufacturing Company
800-882-5292
Revised: 8/12/21
Creators of the TuckAway
Cart Lifter
®
www.perkinsmfg.com

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Summary of Contents for Perkins D6220b-27k

  • Page 1 Installation & Operational Manual Model D6220b-27k Hydraulic Cart Lifter Perkins Manufacturing Company 800-882-5292 Revised: 8/12/21 Creators of the TuckAway Cart Lifter ® www.perkinsmfg.com...
  • Page 2 Warranty 2 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: Overall Dimensions

    Overall Dimensions Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/12/21 Creators of the TuckAway Cart Lifter Page 2 ® www.perkinsmfg.com...

  • Page 4: 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:8/12/21 Creators of the TuckAway...

  • Page 5: 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 7: Installation Tips

    Therefore, a residential-only installation may take only 4-6 hours. The D6220b-27k is a TuckAway® Style Cart Lifter The first consideration when installing any TuckAway® style cart lifter is to make sure the unit has space to store under the load sill.
  • Page 8 Upper hook mounting height 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:8/12/21 Creators of the TuckAway...
  • Page 9 Positioning the Mounting Plate * The mounting plate may be positioned as low as 36” and as high as 40”, as needed. The mounting plate itself should be vertical and level. Perkins Manufacturing Company 800-882-5292 Revised:8/12/21 Creators of the TuckAway...
  • Page 10 Dimensions shown above are an example only and will vary from truck to truck Perkins recommends adding steel structural tube across the entire length of the load sill. This tube becomes the new load sill.
  • Page 11 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:8/12/21...
  • Page 12 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 13 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 14 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:8/12/21 Creators of the TuckAway Cart Lifter Page 12 ®...
  • Page 15 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:8/12/21...
  • Page 16 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 D6220b-27k requires 1550 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 17 (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.
  • Page 18 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 19 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 20 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 21 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 22 “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. Perkins Manufacturing Company 800-882-5292 Revised:8/12/21...
  • Page 23 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:8/12/21 Creators of the TuckAway...
  • Page 25 #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...
  • Page 26 Perkins Single Lifter Hydraulics Schematic Perkins Manufacturing Company 800-882-5292 Revised:8/12/21 Creators of the TuckAway Cart Lifter Page 24 ® www.perkinsmfg.com...
  • Page 27 Perkins Double Lifter Hydraulics Schematic Perkins Manufacturing Company 800-882-5292 Revised:8/12/21 Creators of the TuckAway Cart Lifter Page 25 ® www.perkinsmfg.com...
  • Page 28 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:8/12/21...
  • Page 29 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:8/12/21...
  • Page 30 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 31: 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:8/12/21 Creators of the TuckAway...
  • Page 32 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 33 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:8/12/21...
  • Page 34 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:8/12/21...

  • Page 35: 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 800-882-5292 Revised:8/12/21...

  • Page 36: Exploded Parts View

    Exploded Parts View Perkins Manufacturing Company 800-882-5292 Revised:8/12/21 Creators of the TuckAway Cart Lifter Page 34 ® www.perkinsmfg.com...
  • Page 37 Perkins Manufacturing Company 800-882-5292 Revised:8/12/21 Creators of the TuckAway Cart Lifter Page 35 ® www.perkinsmfg.com...

  • Page 38: Parts List

    EXTERNAL HUB SEAL O-RING D63074 ADAPTER #6MT - #6MO D62008 SAE FLATWASHER 1/2 X 1.06 OD ZINC PLATED D62405 BOLT HHCS 1/2-13 X 2, GR8, Zinc Plated Perkins Manufacturing Company 800-882-5292 Revised:8/12/21 Creators of the TuckAway Cart Lifter Page 36 ®...
  • Page 39 D76796 STEEL LATCH WELD D72109 SPRING-LOWER LATCH (Rev A) D72113 LABEL - PERKINS LOGO, diamond cut, 4'' long x 2 1/2'' high, solid color (not a gradient) D72589 LABEL - ''CAUTION'' FOR D6220-TYPE MODELS D72590 LABEL - ''CAUTION'' FOR D6220-TYPE MODELS - SPANISH...
  • Page 40 * For shipping purposes. Remove to operate. D63431 Reducer - #6ft - #8mt D63581 45 deg. Elbow - #6ft - #6mt D63074 Adapter #6mo - #6mt Perkins Manufacturing Company 800-882-5292 Revised:8/12/21 Creators of the TuckAway Cart Lifter Page 38 ®...
  • Page 42 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 44 If any issues occur, please contact service immediately. Perkins Manufacturing Company 800-882-5292 Revised:8/12/21...
  • Page 45 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 46 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 47 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 48 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.

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