Perkins D6120-27k Series Installation And Operational Manual
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Perkins D6120-27k Series Installation And Operational Manual

Perkins D6120-27k Series Installation And Operational Manual

Dumping gripper arm lifter
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Installation & Operational Manual
Model D6120-27k Series
Dumping Gripper Arm Lifter
Protected by US Patents 6,921,239 & 7,273,340
Perkins Manufacturing Company
800-882-5292
Revised:8/1/22
Creators of the TuckAway
Cart Lifter
Page 1 of 59
®
www.perkinsmfg.com

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Summary of Contents for Perkins D6120-27k Series

  • Page 1 Installation & Operational Manual Model D6120-27k Series Dumping Gripper Arm Lifter Protected by US Patents 6,921,239 & 7,273,340 Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 1 of 59 ® 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 A NOTE ABOUT WEIGHT CAPACITY Please note that the advertised weight capacity of our Perkins lifters is typically 400 lbs, which includes our standard lifters equipped with our standard 27k rotary actuator. That figure of 400 lbs exceeds the marked capacity of the bin.
  • Page 4 Overall Dimensions – D6120-37 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 3 of 59 ® www.perkinsmfg.com...
  • Page 5 Overall Dimensions – D6120-37 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 4 of 59 ® www.perkinsmfg.com...
  • Page 6 Overall Dimensions – D6120-40 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 5 of 59 ® www.perkinsmfg.com...
  • Page 7 Overall Dimensions – D6120-40 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 6 of 59 ® www.perkinsmfg.com...
  • Page 8 Overall Dimensions – D6120-47 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 7 of 59 ® www.perkinsmfg.com...
  • Page 9 Overall Dimensions – D6120-47 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 8 of 59 ® www.perkinsmfg.com...
  • Page 10 Overall Dimensions – D6120-51 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 9 of 59 ® www.perkinsmfg.com...
  • Page 11 Overall Dimensions – D6120-51 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 10 of 59 ® www.perkinsmfg.com...
  • Page 12 Overall Dimensions – D6120-57 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 11 of 59 ® www.perkinsmfg.com...
  • Page 13 Overall Dimensions – D6120-57 Perkins regularly makes product improvements. Dimensions are subject to change without notice. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 12 of 59 ® www.perkinsmfg.com...

  • Page 14: Glossary Of Terms

    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. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway...

  • Page 15: 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 17: Installation Tips

    Relocate lights if necessary. If your truck does not have room to mount a D6120-27k Gripper Arm, call Perkins at 800- 882-5292 for help selecting a different model. Perkins Manufacturing Company 800-882-5292...
  • Page 18 Grip Arm Mounting Height Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 16 of 59 ®...
  • Page 19 Positioning the Mounting Plate * The mounting plate itself should be vertical and level. All D6120 gripper arms must be between 24”-26” Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 17 of 59 ® www.perkinsmfg.com...
  • Page 20 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 21 Double check the gripper arm 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:8/1/22...
  • Page 22 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 23 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 24 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.
  • Page 25 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:8/1/22...
  • Page 26 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.
  • Page 27 (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...
  • Page 28 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 29 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 30 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 31 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 32 Adjusting the Perkins Hydraulics Adjusting the Speed Adjustable Flow Control Valve: D63575 LEFTHAND: 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.
  • Page 34 “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:8/1/22...
  • Page 35 #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 39 (pushing down) until the cart is safely back on 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:8/1/22 Creators of the TuckAway...
  • Page 40 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:8/1/22...
  • Page 41 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 42 Replacing Idler Arms Instructions for D6120-37 Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 40 of 59 ® www.perkinsmfg.com...
  • Page 43 Replacing Idler Arms Instructions for D6120-40, -47, -51, -57 Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 41 of 59 ® www.perkinsmfg.com...
  • Page 44 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:8/1/22 Creators of the TuckAway...

  • Page 45: 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:8/1/22 Creators of the TuckAway...
  • Page 46 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 47 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:8/1/22...
  • Page 48 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:8/1/22...

  • Page 49: 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 50 Bolt HHCS ½-13 x 1 ¾” D62458 Split Lockwasher 5/8 D62006 Bolt FHCS ½-13 x 1 1/4 D62008 SAE Flatwasher ½” x 1.06 Zinc Plated Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 48 of 59 ®...
  • Page 51 D62004 Flat Washer 3/8 D62080 3/8-16 Locknut D72208 Locknut Thin 1-8 D72209 HHCS 1-8 x 9 D72490 Self-lubricating Bearing D73066 Actuator Flange (Cut) Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 49 of 59 ® www.perkinsmfg.com...
  • Page 52 1” dia. Self-lubricated bushing *Part of arm assemblies D62080 3/8-16 locknut D62030 Locknut 5/16”-18 GR8 Plate D63239-9 External O-ring Seal (not shown, mounted under driver arm hub) Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 50 of 59 ®...
  • Page 53 RH Idler Arm Weldment -57 D69672 RH Driver Arm Weldment -57 D69671 LH Driver Arm Weldment -57 D69674 LH Idler Arm Weldment -57 Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 51 of 59 ® www.perkinsmfg.com...
  • Page 54 D62004 Flat Washer 3/8 D62080 3/8-16 Locknut D72208 Locknut Thin 1-8 D72209 HHCS 1-8 x 9 D72490 Self-lubricating Bearing D73066 Actuator Flange (Cut) Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 52 of 59 ® www.perkinsmfg.com...
  • Page 55 * For shipping purposes. Remove to operate. D63596 Connector #6mo - #6mo D63575 One-Way Adjustable Flow Control Valve D63663 45 deg. Elbow - #6mo - #8mt Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 53 of 59 ®...
  • Page 56 #6 HYDRAULIC HOSE ASSY X 40" long Hose – D6120-57 D63517 #6 Hydraulic hoses assembly x 32'' LONG D69676 #6 HYDRAULIC HOSE ASSY X 40" long Perkins Manufacturing Company 800-882-5292 Revised:8/1/22 Creators of the TuckAway Cart Lifter Page 54 of 59 ®...
  • Page 58 Sometimes a lifter is damaged by collision, although the actuator and mounting parts are usually not damaged 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.
  • Page 59 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 61 If any issues occur, please contact service immediately. Perkins Manufacturing Company 800-882-5292 Revised:8/1/22...
  • Page 62 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 63 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 64 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 65 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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