Payne Pallet Retriever User manual

09/2012RARVERSION5
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MACHINENo.xxxx
LEVERCONTROLS&FULLGUARDS
OPERATORSMANUAL
DerehamRoad,Beeston,KingsLynn,NorfolkPE322NQ,UK
Telephone:+44(0)1328700138Fax:+44(0)1328701879
www.paynepalletinverters.co.uk
ORIGINALPALLETRETRIEVER

09/2012RARVERSION52
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CONTENTS
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INTRODUCTION
CONTENTS2
CONTENTSCONTINUED3
SAFETYPRECAUTIONS4
PRODUCTDESCRIPTION5

INSTALLATION
HANDLING6
MACHINEINSTALLATION7
GUARDINSTALLATION8
CONNECTION9
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OPERATION
PRE‐USE&STARTUPPROCEDURE10
OPERATORSMANUAL11
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MAINTENANCE
MAINTENANCESCEDULE12
LUBRICATION13
OILCHANGEPROCEDURE14
OILCHANGEPROCEDURECONTINUED15
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TECHNICAL

FLOWDIVERTERVALVE16

09/2012RARVERSION53
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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
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SPECIFICATIONS
SPECIFICATION25
OILDATASHEET26
OILDATASHEETCONTINUED27
GREASEDATASHEET28
GREASEDATASHEETCONTINUED29
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ATTACHEDDOCUMENTS
DRAWINGS,ECCONFORMITY,SERVICEAGREEMENT,WARRANTY 
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CONTENTS
CONTINUED

09/2012RARVERSION54
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SAFETYPRECAUTIONS
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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.
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Themachineisfittedwitharunbutton,whichMUSTbereleasedinallpossibleemergencysitua‐
tions,disablingthemachine.
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ThefollowingguidelinesMUSTbeobeyedandthemachineoperatedinstrictaccordancewith
theoperatorsmanual:
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• Onlyfullyauthorisedpersonnelmayoperatethismachine.
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• Onlyfullyauthorised,suitablyqualifiedpersonnelmaycarryoutmaintenanceoperations
onthismachine.
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• ThemachineMUSTonlybeoperatedwhentheareawithinthefixedguardsisclear.
Nobodymayenterthisareawiththemachineinoperation.
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• Atnopointmayanyperson/personsentertheareaunderthemachinebody.
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• ThemachineMUSTonlybeoperatedwithinthemaximumloadcapacityforwhichitwas
designed.

• AllloadsMUSTbelocatedsecurelyinthemachine,withtheleadingedgeplacedagainst
thefixedrearwall.
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• TheelectricalsupplyMUSTbeisolatedandsuitablylockedoff,whencarryingoutany
maintenancetasks.

• DoNOTtamperwithoralterthemachineinanyway.
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• CorrectpersonalprotectiveandsafetyequipmentMUSTbeusedatalltimesandin
accordancewithgovernmenthealthandsafetyandsitespecificguidelines.
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09/2012RARVERSION55
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PRODUCTDESCRIPTION
LEVERCONTROLS
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TheRetrieverisdesignedfortheefficientexchangingof
palletsfromaload.
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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.
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Thelevercontrolsforthismachineareaffixedtotheguards.
A“RUN”startbuttonisfittedtothecontrolpanel,ensuring
theoperatorstandsattherequiredsafedistancewhilstthe
machineisrunning.
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Themachineisfittedwithauniqueidentification
plateattachedtotheframe.Onthisplateisstamped
themodeltype,machineserialnumber,yearof
manufactureandmaximumpermissiblemachine
load.Thisinformationshouldbequotedinevery
communicationwithus,enablingustodealwith
yourqueriesaseffectivelyaspossible.

09/2012RARVERSION56
Fig. 1 Transportation support
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HANDLING
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ThereisonlyonemethodofliftingthePalletRetriever:
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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.
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
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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7
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MACHINEINSTALLATION
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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
• Correctelectricalsupply

NOTE:ATTHISPOINTTHEFLOORSHOULDBECHECKEDTOADEPTHOFATLEAST200mmFOR
UNDERGROUNDOBSTRUCTIONS,WHICHCOULDHINDERINSTALLATION.

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• Ensurethefloorisfreeofobstructionsordebriswhichcouldhindertheplacementofthe
palletretriever.

• Placethemachineonlevelground,initsintendedfinalposition,ensuringthereisenough
spacetoaccesstheelectricalpaneldoor.

• Withthemachinelocated.useasuitabledrilland20mmdrillbittodrillthefloorateachof
the6floorattachmentpointsoftheframetoadepthof160mm(SeeFig3).

• Usingasuitablemallet,locatethe6xM20flooranchorboltssecurelyintoplace.Usinga
30mmspannerorratchet,securethemachinetothefloorboltsusingtheappropriatefix‐
ings.
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

09/2012RARVERSION58
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GUARDINSTALLATION
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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).
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• 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.
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• 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.

• Using4xM8fastenersattachthetwinhandleblockassemblyintherecessedareaonthe
relevantreturnguard.Ifnotalreadyattached,locateandsecuretheholdtorunpushbut‐
tonusing2xattachmentscrews.
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• Usingthe5.5mcontrolcablesandrelevantcableconnectingkits,connectthetwin
handleblocktothespoolvalveassembly.

• Attachthebottomplatefortherecessedcontrolpanelusing2xM8fasteners,theplate
hasacutoutenablingthecontrolcablestopassthrough.
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• locatethe2xcontrolleversinthetwinhandleassembly.Usinga13mmspannersecurethe
M10lockingnutsinplace.

• Routethecontrolandelectricalcableswithinthecabletrays.Securethecablestothetrays
usingtheclipsandtiesprovided.

• Markoutanddrillthefloorforeachattachmentpositionoftheguardfeet
(12mmx100mmindepth).
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• Locatethe16xM12floorboltsforthefixedguardingsecurelyintotheground.

• Oncetheguardsarealigned,tightenallguardpanelfasteners.

09/2012RARVERSION59
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
CONNECTION
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SAFETY:THEFOLLOWINGSHOULDONLYBECARRIEDOUTBYAFULLYQUALIFIEDELECTRICIAN.
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• Connectthemachinetoanadjacentsuitablyratedelectricalsupply.
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• 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.
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• 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10
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PRE‐USE&STARTUPPROCEDURE
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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.
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• 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.
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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
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StartupProcedure:

• Turntheelectricalisolatoron(locatedontherearpanel).
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• PresstheRUNstartbuttonandensurethatthemotorstartscorrectlyandrunssmoothly
throughout.

• WiththeRUNbuttondepressedchecktheclampingoperationofthemachinetableby
movingtheclampleverupanddownonthecontrolpanel.

• WiththeRUNbuttonstillpressedcheckthemachinesInvertandreturn
operationswork,bymovingtheInvertandreturnleverupanddownonthe
controlpanel.

• EnsurethemachineshutsdownwhentheRUNbuttonisreleased

• Followtheoperatinginstructionsgivenonthefollowingpages.