LOCKER INSTALLATION

MANUAL MODEL # TL3

•Compatible with All Rear Loader Commercial Trucks

•Hydraulic Cylinder Provides Strong Grip

•Near-Silent Operation Increases Operating Hours

•Maintenance is a snap with grease zerk fittings

Revised: 5/22/2001

Table of contents

Page General Information

Introduction 1 Service Information 1 Warranty Claims 2 Warranty Procedure 2

Mechanical Installation Installation Preparation 3 Know Your Hardware 3 Locker Installation 4 Locker installation 4-B Fig. 1-1 Mounting Height 5 Fig. 1-2 Locker Mounting Configuration 5

Hydraulics Hydraulic Package 6 Fig. 2-1 Hydraulic Schematic 7 Locker Package 7 Hydraulic Adjustments 8 Fig. 2-2 Locker/Truck Hydraulics 9 Fig. 2-3 Diverter Valve, Single Locker 10 Fig. 2-4 Diverter Valve, Dual Lifter 10 Fig. 2-5 Hand Valve Assembly 11 Fig. 2-6 Return Line Elbow/Tee Assembly 12 Fig. 2-7 Repairing the Hydraulic Cylinder 13

Operating Instructions and Safety Operation 14 Safety 14

Maintenance Maintenance 15 Fig. 3-1 Lubrication Chart 15 Fig. 3-2 Exploded View 16 Fig. 3-3 Parts List 17

Trouble Shooting Guide (Four-Page Supplement)

Trouble Shooting Guide

Welcome to the world of Perkins Manufacturing. Congratulations on your purchase of the LOCKER. Your new LOCKER is the pinnacle of commercial waste collection technology currently available. We want you to be satisfied with our product. Please read through this manual carefully. It is meant to guide you ,through the installation process and can answer most of your questions. Be sure that before operating the lifter all personnel have read and understand the operational and safety guidelines found in this manual.

Perkins Quality Service

1 1

1-708-482-9500 Perkins Mfg. Company or 423 East Elm Avenue 1-800-882-5292 La Grange, IL 60525

1-708-354-5878

Check out our web-site!

WWW.TUCKAWAY.COM

All the latest information on most any Perkins cart lifters can be

found here. You can also leave E-mail messages or questions

Customer Satisfaction is our

#1 Priority!

Page 1

Extending Your Dollar - Perkins Warranty Service

Each Perkins cart lifter is assigned a serial number. This number will be required when making warranty claims, so please keep this number in a safe place.

Model No.__________________________ Serial No. __________________________ Actuator Serial No.__________________

Warranty Claims Procedure If you suspect a broken item falls under protection of our warranty, please call Perkins Manufacturing to receive a RGA number (Return Goods Authorization) before you ship the item. Please have the Serial Number, Model Number and Part Number ready when you call. You will need the serial number of the locker to receive the RGA number. We will ship you the new parts via UPS and temporarily invoice you. In return, please UPS the parts to us with the RGA number printed clearly on the outside of the box and on the shipping papers. Incoming parts will be refused without the RGA number. Once we receive the parts, we will determine the warranty status. If the parts are defec-tive, you will be issued credit for the part and the invoice for the new parts will be canceled. If you require the part to be shipped by means other than UPS ground, you will be responsible for any additional freight costs.

Page 2

Warranty Your locker is backed by Perkins' 1-year warranty, which is our promise to repair or replace (at our option) any part that proves to have been defective. Your warranty does not cover parts that are damaged by abuse or neglect, or that have been modified by personnel other than Perkins' own service technicians. Using the locker without adhering to the operational and safety guidelines can void this warranty. Perkins will be free of any liability resulting from misuse of our products.

Installation Preparation

1 Proper installation measurements depend on the height of the empty truck. Empty hopper completely of all waste materials.

2 Be sure there are no flammable materials or liquids near the installation area or in the truck’s hopper.

3 Park the truck on a smooth, level surface.

4 Check the truck's electrical system (lights, horn, etc.) for proper operation, note anything not working prior to installation.

5 Unpack the locker and inspect it for any damage that may have occurred during shipping.

6 Review the chart below to familiarize yourself with Perkins’ hardware setup to help make installation run smoothly.

Know your Hardware

Page 3

DIVERTER

VALVE

HAND VALVE

CYLINDER DOUBLE P.O. CHECK VALVE*

50/50 SPLITTER

HOSES (4)

ASSORTED FIT-TINGS

HOSE CLAMPS (5)

LOCK VALVE

Locker Installation

1 Cut the elephant ears vertically, about 1/8 of the inch shorter that the sill or container attachment of the truck grind and clean the edge for better welding.

2 Using “C” clamp or Vise Grips attach the Locker assembly to the pre cut edge of the elephant ear with the Locker on the closed position and the plate touching the sill. You should have 90 degrees angle between the elephant ear and the Locker Plate. Before you tack or weld on the place check the following dimen-sions: Fig. a Fig. b 1. The bottom of the locker assy. Must be at least 2” lower that the top of the sill (see Fig. a) 2. The bosses of Locker must be approximately 1/16” separated from the edge of the elephant ear (Fig b)

3 Mark the location on the Locker, where lug assembly will be welded. This location will vary depending on the truck. In most cases when you do not have clearance problems we recommend to install it on the center of the Locker plate. If you don’t have clearance, you can locate it on the top or bottom, according to your needs. In any of this cases you must check the following: 1. The lug assembly must be at exactly 90 degrees angle to the edge of the Locker (see Fig. c) 2. The outer edge of the lug assembly must be at the outer edge of the Locker (see Fig. c) Clamp it and

weld it in place. Fig. c

4 Installing the cylinder and cylinder supports: Insert the rod end of the cylinder into the lugs at the Locker plate using one of the cylinder pins. At the other end of the cylinder insert the support assembly with an-other cylinder pin. With the Locker all the way closed and the cylinder all the way open, attach the sup-port assembly to the body of the truck. Weld the plate support and then install the support assembly. Tack weld and check for proper function (open and close by hand). At the bottom of the hand valve you will see a 50/50 splitter connected to port “A” and a “tee” fitting connected to port “B”. Using the pro-vided hoses connect ports on 50/50 splitter to the head port of each cylinder and the “tee” fitting to the rod port of each cylinder.

Page 4

SAFETY FIRST As a part of the Locker hydraulic system and for a safety purposes Perkins has implemented the

new locking valve. This valve allows the winch or kick bar to operate only when the Locker is fully closed. To install the Locking valve De-pressurize hydraulic system for kick bar and/or winch disconnect hydraulic hose out of the valve port (the port on kick bar valve has to be the one that pushes the kick bar up and the port-on winch valve has to be the one that pulls the winch). Connect the locking valve as show in Fig. d, (fitting may vary) Using the provided hoses connect the port marked “R” to the rod port of one of the cylinders, and port marked “H” to the head port of the same cylinder, tight connections and test, the kick bar or winch, they won’t move unless the locker is closed.

Page 4-B

5 Measure the horizontal distance from the container locks to the original sill. Once the CA is added, the container locks must still be this distance away from the edge of the CA or they will not lock up contain-ers. Torch off the container locks and move them out until their relation to the CA is the same as it was to the original sill. Add extension plates and supports where needed. See Fig 1-1

6 Tack weld hand valve mounting bracket to the side of the truck in a horizontal position. The handle of the valve must be protected from accidental activation. This can be helped by placing the valve so that the handle does not extend rearward past the elephant ear, or hang below the elephant ear. Also, the hand valve must be close enough to allow the included hoses to reach the lifter unit. (Fig. 2-2)

7 Connect 175” hose # D63535 from the port marked “out” on the hand valve to the truck’s return line as shown in Fig. 2-3.

8 De-pressurize the truck hydraulic system and disconnect the hose leading to the main packer valve. Con-nect the diverter valve as shown in fig. 2-3 (The fittings required might vary).

9 Connect 175” hose # D63535 from Diverter Valve port “P” to Hand Valve port marked “IN”.

10 Weld hose clamps in position shown in Fig. 2-2 (One clamp assembly # D63014).

11 Grease Locker and test with an empty container. Make any hydraulic adjustments is necessary.

Fig 1-1

Locker Dimensions

Rear End Configurations Fig. 1-2

SINGLE CENTER INSTALLATION

SINGLE OFFSET INSTALLATION

DOUBLE INSTALLATION

Page 5

Page 6

HYDRAULIC PACKAGE

The hydraulic equipment included in each kit is as follows: FLOW DIVERTER VALVE One (1) Flow Diverter Valve This valve takes 50 GPM input from main packer pressure line and diverts zero up to eight GPM to the cart lifter system, and sends the remaining flow to the packer blade. Both packer and lifter (s) can be operated simultane-ously. The diverter valve should be mounted on the top of the truck, right next to the Packer Control Valve. Please check your trouble-shooting guide for reference on flow required for your lifter. HAND VALVE Single installation: one (1) hand valve This directional 4-way hydraulic control valve is a three position valve which allows pressure flow into either of it’s out-going ports, and then reverses the flow direction by moving the handle to the opposite direction. It has a capacity to withstand full pressure in its return port with a built-in relief valve. Releasing handle stops all lifter motion. 50/50 Splitter This valve distributes equal amount of oil to the two cylinders so they work in sequence. Lock Valve Is intended so kick bar or winch hook won’t operate unless the Locker is fully closed. HOSE CLAMP SET Single installation: five (5) hose clamps Dual installation: ten (10) hose clamps FITTINGS 1 Elbow (tap-in), 1 Elbow (pressure in to diverter valve) 2 straight fittings to adapt diverter valve in to main pressure line NOTE: the two straight fittings may differ depending on the truck model. DECALS One (1) UP-DOWN One (1) CAUTION WIRE TIES Five (5)

Hydraulic Circuit Schematic Fig. 2-1

Page 7

LOCKER PACKAGE LOCKER ASSEMBLY All models are assembled with the best quality workmanship. Lifters are primed and painted yellow. If other color is desired (by customer request), you must let us know at the time of or-der. (Rush orders will be primer only). CYLINDERS The lifter comes with two cylinders. CHECK VALVE When you purchase a Perkins Locker, you should also get two check valves. This valve is a safety device that will prevent incidental motion of the cylinders when the pump is off and when containers are dumped . (Check valves are assemble with cylinders)

VALVELOCK

PACKER

PUSH BAR

VALVE

WINCHVALVE

VALVE

VALVEDIVERTER

FLOW

TANK

VALVELOCK

PUSH BARCYLINDER

DIVIDER

WINCH

VALVE

PUMPRELIEF

50/50

VALVECHECK

CHECKVALVE

PUSH BARCYLINDER

LOCKERCYLINDER

CYLINDERLOCKER

DIRECTIONALCONTROLVALVE

TANK

TANK

Page 8

Diverter Valve (also see Fig 2-3) Problem: Dumper runs too fast or too slow. Open the Adjustable Flow Control 100%. Insert a flow meter between diverter valve and hand valve. Loosen locking nut on diverter. Turn in adjusting screw (clockwise) until flow to the lifter stops. Turn screw out (counter-clockwise) in 1/2-turn increments until flow reaches 3 GPM (per lifter).

Hand Valve (also see Fig. 2-5) Locker Pressure Adjustment Insert a pressure gauge between port A of hand valve (pressure inlet) and the locker inlet pressure line (Bottom port of cylinder). Cycle the locker to full close position and check pressure. The gauge should read 1200 PSI. If not, adjust the pressure by loosening the locknut on the relief valve located inside the hand valve under a hex cap. Screw the valve in to increase pressure and out to decrease pressure.

Replacement Seal Kit PN# D63127 Replacement Spring Kit PN# D63197

Locker valve Safety feature to stop the winch when locker is not Close. No adjustment needed.

Hydraulic Adjustments

Fig. 2-3

Diverter Valve Setup

On most trucks, this fitting must be removed from the circuit, drilled & tapped with a 3/8-18 NPT hole,

and fitted with Elbow # D63550 as shown. In the case of a double lifter system, use a tee, PN # D63416 instead.

Remember to flush the shavings before re-installing the fitting, or your hydraulic components could be dam-

aged. The entire unit can then be re-inserted into original location. NOTE: The exact type of fitting that will

be tapped into will vary from truck to truck. In some instances, an additional fitting must be added.

Page 10

Fig. 2-4 Hand valve assembly

D63586

Page 11

Fig. 2-6 Return Line Elbow / Tee

The large fitting shown is typicallylocated on the main packer valve return line, as shown in Fig. 2-1. On most trucks, the fitting must be removed from the circuit, drilled & tapped with a 3/8-18 NPT hole, and fitted with El-bow # D63550 as shown. In the case of a double lifter system, use a tee, PN # D63416 instead. Remember to flush the shavings before re-installing the fitting, or your hydraulic components could be damaged. The entire unit can then be re-inserted into original location. NOTE: The exact type of fitting that will be tapped into will vary from truck to truck. In some instances, an additional fitting must be added

Page 12

Repairing the Cylinder Occasionally, hydraulic cylinders may become worn or damaged. In order to serve customers’ needs, Perkins has

made available the following parts for repair of our product.

Please take great care in restoring hydraulic components. Perkins will not assume liability for products repaired by

people other than qualified Perkins’ technicians.

The following are a list of available spare parts for hydraulic cylinders:

Rebuilt/repaired cylinders or other replacement parts may be available on special request as stock allows.

Page 13

Description Part Number

Seal kits (all replaceable seals included) CALL

Shaft/Piston CALL

Clevis end CALL

Operating Instructions Operation 1. Start engine 2. Cycle Locker to check for leaks and purge air from lines (first time only). 3. Pull hand valve to close Locker and grasp container 4. Hold hand valve in active position while Locker is in close motion. Letting go of the lever will stop the Locker automatically.

5. Once container is locked and container is back on the ground , reverse the Locker by pushing down on hand valve.

6. Locker will now return to open and release the container. 7. Replace the empty container with loaded container and repeat process. Safety 1. Always keep hands away from Locker while it is in operation. 2. Never reach into the hopper while the Locker is in operation. 3. Be sure all persons are clear of the Locker before operating it.

4. Check to be certain the hand valve is in a neutral position when the Locker is not in use. 5. Never try to lift empty container that are in need of repair. 6. Inspect the Locker daily for worn hoses, leaks, and cracks. 7. Do not use the Locker to push container loaded in place. 8. Do not use The Locker to carry containers with the truck in motion.

Page 14

Maintenance

Lubricate the locker's grease zerks once per week or as needed during heavy usage.

Fig. 3-1 Lubrication Guide

Page 15

You will find (4) grease fittings on your locker similar to this one. They can be found located on the Hinge point. They will accommodate standard size greasing nipples. See Fig. 3-2 for exact locations. The zerks are covered with plastic caps, part number D63029. Replace caps as necessary to help keep internal components free of grime.

Pag

e 16

L

ocke

r E

xplo

ded

Vie

w

F

ig. 3

-2

#

PAR

T #

D

ESC

RIP

TIO

N

QTY

#

PAR

T #

D

ESC

RIP

TIO

N

QTY

1

D

6201

4

GR

EASE

FTG

. STR

.1/8

4

2

C

A106

4

GR

IPP

ER

AS

SY

R.H

. 1

3

C

A103

9

GR

IPP

ER

AS

SY

L.H

. 1

4

C

A106

1 C

YLIN

DE

R

2

5

D75

819

LU

GS

CYL

IND

ER

8

6

7

C

A103

4

PIN

LIF

E EN

D

2

8

D62

013

RO

LL P

IN ¼

X 2

8

9

C

A104

1

PIN

GR

IPP

ER

2

10

D62

062

FLAT

WAS

HE

R S

AE P

LATE

4

11

*

CA1

045

S

IDE

SU

PP

OR

T P

LATE

2

12

*

CA1

078

LOC

KE

R C

AU

TIO

N L

AB

EL

2

*

=

NO

T S

HO

WN

13

* D

6301

1 E

LBO

W 9

0 #6

MT-

#6M

O

1

14

* D

6301

4

CLA

MP

SET

#8

7

15

* D

6307

4 A

DP

T. S

TR.#

6MT-

#6M

O

2

16

* D

6309

2 AD

PT.

STR

. #20

MT-

#20M

O

1

17

* D

6309

5 A

DP

T. S

TR.#

16M

T-#2

0MO

1

18

* D

6310

6 E

LBO

W 9

0 #6

MT-

#6FT

2

19

* D

6313

8 TE

E

2

20

*

D63

430

AD

PT.

STR

.#8M

T-#6

MO

2

21

*

D63

526

ADP

T.ST

R. #

12M

T-#2

0MO

2

22

*

D63

589

TE

E

1

23

* D

6359

5 50

/50

SPLI

TTER

VAL

VE

1

24

* D

6375

8

HO

SE

AS

SY

#8

X 20

0” L

ON

G

2

25

* D

6381

7

LOC

K V

ALV

E

1

26

* D

6910

4

HO

SE

AS

SY

#6

X 60

” LO

NG

6

27

*

D74

411

GU

SS

ET

MTG

PLA

TE

4

L

OC

KE

R P

AR

TS

KE

Y #

TL

3

Fig

. 3-3

D

ate:

03.

22,

200

2

Page

17

P E R K I N S

Trouble Shooting Guide

P E R K I N S

MANUFACTURING COMPANY

Perkins Manufacturing – Locker Trouble Shooting Guide

Symptom Possible Causes Solution

a. Locker operation is very erratic.

1. Air is trapped in the system. 2. Low flow in the system.

1. Bleed all air from lifter hydraulic system.

2. Increase flow from the diverter valve.

b. Locker open’s with

Container 1. Broken hose 2. Locker system hydraulic pressure is too low. 3. Faulty hand valve. 4. Cylinder leaking internally (bypassing oil) 5. Faulty check valve

1. Replase damaged hoses 2. Check and adjust pressure on

hand valve. 3. Replace or Rebuilt hand valve 4. Rebuild or send to Perkins for re-

build. 5. Replace check valve

c. Locker operates slowly. 1. Adjustment screw is closed to far in the diverter valve. 2. Engine idle is too low. 3. Faulty hand valve. 4. Faulty truck hydraulic pump. 5. Trash in the diverter valve.

1. Adjust the drive screw on the di-verter valve to increase the flow in to the lifters.

2. Adjust engine idle. 3. Replace hand valve. 4. Check the truck maintenance

manual. 5. Carefully clean all components

and the orifice of the diverter valve, or replace.

d. Locker operates fast. 1. Adjustment screw is open to far

out. 2. Engine idle is too high.

1. Adjust the drive screw on the di-verter valve to decrease the flow in to the lifter.

2. Adjust the engine idle.

e. Diverter valve is leaking oil around cartridges.

1. Worn or damaged seals on car-tridge valves.

2. Replace seal kit for diverter valve (replacement seal kit P/N D63477).

f. Hand valve lever sticks in the up or down position.

1. Worn or broken spring center device.

2. Trash or rust in or around the hand valve shift spool. 3. Pressure (in) and tank (out) ports are hooked up backwards.

1. Install spring center kit (replacement spring kit P/N D63192).

2. Disassemble and clean spool and housing.

3. Make sure all hoses are plumbed according to the hydraulic

schematic.

Perkins Manufacturing Co. Chicago (HQ office) • 423 E. Elm Av., La Grange, IL 60525 • ph: 708.354.5303, 800.882.5292 • fx: 708.354.5878

Symptom Possible Causes Solution

g. Hand valve is leaking oil around the shift spool.

1. Worn or damaged seals. 2. Worn spool.

1. Install hand valve seal kit (replacement seal kit P/N D63217).

2. Replace hand valve. h. Not able to set pressure set-

tings of rotary type units to 1,950 p.s.i.

1. Truck settings are between 1,500 and 1,700 p.s.i.

1. Need to install a pressure speed up switch (customer must request).

i. Not able to set pressure set-tings of cylinder type units to 1,200 p.s.i.

1. Truck pressure is lower than 1,400 p.s.i.

1. Call the manufacturer.

j. Locker speed must be 5 to 6 sec. cycle time.

1. Flow setting may not be set at 7.0 g.p.m.

1. Adjust Perkins diverter valve to 7.0 g.p.m. If operated w/ other, call Perkins for alternatives.

l. One gripper closing before the other.

1. Dirt in 50/50 splitter 2. Damaged 50/50 splitter 3. Locked gripper

1. Carefully clean components 2. Replace 50/50 splitter 3. Grease and move manually until

gets free or replace gripper.

P E R K I N S

MANUFACTURING COMPANY

Perkins Manufacturing – Lifter Trouble Shooting Guide

Perkins Manufacturing Co. Chicago (HQ office) • 423 E. Elm Av., La Grange, IL 60525 • ph: 708.354.5303, 800.882.5292 • fx: 708.354.5878