Payne Pallet Retriever User manual

09/2012RARVERSION5

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

OPERATION
PRE‐USE&STARTUPPROCEDURE10
OPERATORSMANUAL11

MAINTENANCE
MAINTENANCESCEDULE12
LUBRICATION13
OILCHANGEPROCEDURE14
OILCHANGEPROCEDURECONTINUED15

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.

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.

• 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.

• Atnopointmayanyperson/personsentertheareaunderthemachinebody.

• 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.

• 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.

• 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.

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:

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.




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.



• 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).

• 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.

• 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.

• 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.

• 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).

• 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.

• 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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.

• 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


StartupProcedure:

• Turntheelectricalisolatoron(locatedontherearpanel).

• 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.

09/2012RARVERSION511
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

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
mid‐position.
• StilldepressingtheRUNbutton,presstheleft‐handleverupwardsuntiltheloadhasbeen
inverted,thenallowthelevertoreturntomid‐position.

• StilldepressingtheRUNbutton,presstheright‐handleverupwardsuntiltheloadhasbeen
fullyunclamped,thenallowthelevertoreturntomid‐position.

• Replacetheoriginalpalletfromtheload.

• DepresstheRUNbuttonwithonehandandwiththeotherhandpresstherighthandlever
downuntiltheloadisfullyclamped,thenallowittoreturntomid‐position.

• StilldepressingtheRUNbutton,presstheleft‐handleverdownwardsuntiltheloadisfully
re‐inverted,thenallowthelevertoreturntomid‐position.

• StilldepressingtheRUNbutton,presstheright‐handleverupwardsuntiltheloadisfully
unclampedandonceagainallowthelevertoreturntomid‐position.Removetheloadfrom
themachine.Shutdownmachineattheelectricalpanelwhennotinuse.
RUN Clamp/unclamp
Invert/return
Fig. 2

09/2012RARVERSION512



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)

Annually:

• Visuallyexaminethemachineforobviousdeformities,payingparticularattentionto:

i.Frame,bodyandtables(cracksanddeformation)
ii.Hoses,valvesandmanifolds(leaksorperishing)
iii.Electricalpanel,includinglatchesandhinges
iv.Electricalcables,insulation,conduitandclamps
v.Rubberbuffers(wearandperishing)
vi.Slidingtablerollers

• Ensureallguardpanelsaresecureandfreefromdamage
• Cleanthemotorcasingandfins
• Renewthehydraulicoilandsuctionfilter(seepages14&15)

SAFETY:INTHEUNLIKLEYEVENTOFANYMACHINEMALFUNCTION,STOPANDREPORT
IMMEDIATELY.

SAFETY:REPLACEALLGUARDPANELSREMOVEDDURINGANYMAINTENANCEOPERATIONS&
ENSUREALLSAFTEYDEVICESARERE‐INSTATED.

09/2012RARVERSION513
LUBRICATIONPOINT



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.
Fig. 3, Table slides
Fig. 4, Pivot points

09/2012RARVERSION514



OILCHANGEPROCEDURE










• Placeasuitableemptycontainer,sufficienttoholdapprox60litresofoil.

• Usinga24mmspannerorratchet,unscrewthetopofthereturnfilterandcarefullyremove
thefilterelement.

• Removetheoilfromthetankintothecontainerthroughthereturnfiltersocket,usinga
suitableoiltransferpump. 

NOTE:ALTHOUGHTHEWHOLEHYDRAULICSYSTEMCONTAINS60LITRESOFOILONLY
40LITRESWILLBEINTHETANKITSELF.

• Renewthefilterelementandrefitthetopofthereturnfilter.

• RemovetheM8screws(Fig5)fromthetanktoplidandliftoffcarefully.Thestrainerfilter
willbefoundattachedtothepumpassembly.


• Removethestrainerfilterbyturningitanti‐clockwise.

• Replacethestrainerfilterwiththenewfiltercomponent.
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 A/R
60 litre container Oil absorbent pads A/R
Fig. 5, Hydraulic oil tank

09/2012RARVERSION515



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.

• Runthemachineforapproximately5minutestocirculatetheoilandremoveanyairthat
mayhaveenteredthesystemduringtheoilchangeprocedure.

• Re‐checkthehydraulicoillevelandexaminethemachineforanyoilleaks.

• Topupthemachineiftheoillevelhasdropped.


SAFETY:DISPOSEOFWASTEOILCORRECTLY,WITHANAUTHORISEDCOMPANYIN
ACCORDANCEWITHLOCALAUTHORITYGUIDELINES.

09/2012RARVERSION516
Fig. 6 Flow diverter valve



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. 7 Hydraulic drawing

09/2012RARVERSION517
ItemComponentPartNo.
1Motor/pumpassemblyE‐EMA‐4KW
2PressuregaugeH‐PG‐4000BTM
1
2
Fig. 8



COMPONENTS
PUMPASSEMBLY

09/2012RARVERSION518
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
6
4
3
2
1
5
Fig. 9
Fig. 9.1



COMPONENTS
PUMPASSEMBLY(INTERNAL)

09/2012RARVERSION519



COMPONENTS
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
Fig. 10 (Front of control panel)
1
2
3
Fig. 10.1 (Handle block, located behind control panel)

09/2012RARVERSION520
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
Fig. 11
1
3
2
4
SYSTEM PRESSURE
CLAMP PRESSURE



COMPONENTS
SPOOLVALVEASSEMBLY