MANUAL PALLETIZER

CONTAINER AUTOMATION SYSTEMS P. O. BOX 2850 CUMMING, GA 30028

Phone: (678) 947-5656 Fax: (678) 947-5655

24-HOUR HOTLINE SERVICE: (678)-947-4544

WORK ORDER # 0000

CUSTOMER - LOCATION

CERTIFICATE OF ORIGIN

THIS IS TO CERTIFY THAT ALL CONSTRUCTION OF THIS EQUIPMENT WAS

UNDERTAKEN IN THE UNITED STATES, AND THAT ALL COMPONENT PARTS WERE SOURCED THROUGH US SUPPLIERS OR THEIR US

REPRESENTATIVES.

EQUIPMENT IDENTIFICATION: CAS Manual Palletizer Project Number: 0000

SIGNATURE: Ryan Grovijohn, President DATE: October 14, 2014

1. SHIPPING/UNLOADING INSTRUCTIONS

2. SYSTEM LAYOUT/SAFETY INTRUCTIONS

3. OPERATION REQUIREMENTS

4. OPERATION INSTRUCTIONS

5. PARTS LISTING

6. PNEUMATIC CIRCUIT SCHEMATIC

7. TROUBLESHOOTING

8. MANUAL PALLETIZER MAINENANCE SCHEDULE

9. RECOMMENDED OPTIONAL HAND CART FOR PALLET

REMOVAL

(33” Outside Fork Dimension Low Profile Unit)

1. SHIPPING/UNLOADING INSTRUCTIONS

CAS MANUAL PALLETIZER, MODEL PML

(SHIPPING/UNLOADING INSTRUCTIONS)

1. Remove operating manual and review accordingly.

2. Remove machine from truck using a fork lift with forks long enough to position

them under hand card removable cross member secured to the base of the frame

with two removable pins at the pallet entry area.

3. Remove the shipping brackets under the machine deck holding deck to frame of

the machine and store as noted on ensuing page.

4. The Manual Palletizer can be relocated in plant as needed by utilizing the

transport bar and hand cart. Both these items can be stored under the deck when

not in use.

5. Once manual palletizer is setting on the plant floor, remove banding securing

forks, etc. to the unit.

6. With transport two wheel cart pin inserted into bottom of transport cross bar,

move manual palletizer to location to be used on line. Remove two wheel cart

and transport cross bar and store in location removed from under deck. Then

place, if unit is so optionally equipped, the 2 ea. 5’ gravity sections of

conveyor inside forks in elevator. Place 2 each 10’ sections outside the

elevator gravity frame sections for pallet accumulation. Bolt gravity roller

deck inside elevator to floor to secure it in place and use 4 bolts on 4 x 4”

manual palletizer frame to secure it in location on floor. Securing the gravity

conveyor inside deck and manual palletizer is needed due to using gravity

conveyor. This prevents palletizer or conveyor from moving resulting in forks

coming down on gravity conveyor or side frames coming down on top of gravity

conveyor as unit is tilting up

7. Connect 90 to 110 psi (7 bar) clean/dry, non-lubricated air supply using ½”

(12mm) ID hose.

8. Unit is now ready to operate (see Operating Instruction in Section 4 of this

manual).

SHIPPING BRACKET REMOVAL FOR STORAGE

A) Remove the 4 – ½” x 1” HexHeadCapScrew on the unit’s trunion mount

B) Tilt unit to up position, turn main air supply to off (locked out position)

C) Remove the 4 – ½” x 1” HexHeadCapScrew on the unit’s base frame

D) Invert shipping brackets, mount the trunion bracket to base frame bracket.

E) Install and tighten the 2 – ½” x 1” HexHeadCapScrew.

Bracket will be marked, “this side up for storage”.

E) Storage location of shipping brackets, mobility cross member & cart

MOBILITY BRACKET STORAGE LOCATION

MOBILITY CART

REMOVAL OF SPACERS OPTION

A) With the unit tilted in the down position, lock out air supply

B) With a minimum of 2 people, one on each end, remove four 3/8” fine

threaded bolts and gently roll the spacer block toward the lower side of

the palletizer deck.

C) Spacer now can be removed from unit on the lower side of the deck.

D) Repeat for other side, store spacers in a flat position in a controlled

environment.

INSTALLATION OF SPACERS OPTION

A) With the unit tilted in the down position, lock out air supply.

B) Measure the stationary side panels from inside to inside.

(Approximately 56 ½”) Measure the size of the bundle width you are

changing over to. (Example 48”) Add ½” to this measurement. Need

to always have a clearance of ½” total. ( Example now is 48 ½”)

Subtract 5 5/16” from the 56 ½” = 50 7/8” (These are the two spacers)

This leaves you with 50 7/8”- 48 ½” = 2 3/8”.

C) With a minimum of 2 people, one on each end, pick up a spacer and

place it on a cloth on the lower end of the palletizer. The spacer has a

top, bottom, left and right side, make sure the orientation is correct.

D) Roll the space block into position and install the four 3/8” fine

threaded bolts with lock and flat washers, 2 on the roller band end / 2 on

the bottom.

2. SYSTEM LAYOUT/SAFETY INSTRUCTIONS

RECOMMENDEDOPTIONAL SAFETY

MESH GUARD

3. OPERATION REQUIREMENTS

AIR PREPARATION

The filter/regulator fitted to this equipment is a 3/8” (10mm) bore, self-relieving type with a lockable dump valve. Set air pressure at 60 – 110 psi (4 ½ - 8 bar) for system operation.

NOTES: The dump valve exhausts all regulated equipment to atmosphere when it is operated. Periodically drain any collected water from the bowl and clean the filter element. To remove the bowl, turn off the air supply, push the bowl upwards, turn it through 45 degrees (anti-clockwise) and gently pull down. If palletizer is equipped with Signode Pneumatic bander gun, an oiler will be installed in line to bander gun only. Set oiler to drip no more than 1 drip per minute as bander gun is depressed as if tightening a band.

AIR LINE FILTER REGULATOR WARNING: IF YOUR UNIT HAS A PLASTIC BOWL 1. DO NOT use plastic bowl units without a bowl guard installed.* Plastic bowl units

are sold only with bowl guards to minimize the danger of flying fragments in the event of bowl failure. If this unit is in service without a bowl guard installed, manufacturer’s warranties are void, and the manufacturer assumes no responsibility for any resulting loss. (*EXCEPT F00, F08 MODEL)

2. DO NOT install the unit where it will be subjected to temperatures higher than 125ºF

(52ºC). 3. DO NOT install the unit where it will be subjected to pressures higher than 150 psig

(10.3 bar). 4. CAUTION: Certain compressor oils, household cleaners, chemicals, solvents, paints

and fumes will attack plastic bowls and can cause plastic bowl failure. See manufacturer’s list shown elsewhere on this sheet. Do not use near these materials.

5. WHEN BOWL becomes dirty, replace bowl or wipe only with a clean, dry cloth. 6. DO NOT install on a compressed air line where the compressor is lubricated with, or

the air contains, a material that will attack plastic bowls. 7. DO inspect plastic bowls to detect crazing, cracking, damage or other deterioration.

Immediately replace any crazed, damaged or deteriorated bowl with a metal bowl or a new plastic bowl and bowl guard.

8. IF A UNIT HAS BEEN IN SERVICE AND DOES NOT HAVE A BOWL

GUARD, ORDER ANOTHER ONE AND INSTALL BEFORE PLACING BACK IN SERVICE.

SOME OF THE MATERIALS THAT WILL ATTACK POLYCARBONATE PLASTIC BOWLS: Acetaldehyde Benzyl alcohol Cyclohexanone Acetic acid (conc.) Brake fluids Cyclohexene Acetone Bromobenzine Dimethyl formamide Acrylonitrile Butyric acid Diozane Ammonia Carbolic acid Ethane tetrachloride Ammonium fluoride Carbon disulfide Ethyl acetate Ammonium hydroxide Carbon tetrachloride Ethyl ether Ammonium sulfide Caustic potash solution Ethylamine Anaerobic adhesives and Caustic soda solution Ethylene chlorohydrin sealants Chlorobenzene Ethylene dichloride Antifreeze Chloroform Ethylene glycol Benzene Cresol Formic acid (conc.) Benzoic acid Cyclohexanol Freon (refrig. and propell)

Page 2 of 3

AIR LINE FILTER REGULATOR (Continued) Gasoline (high aromatic) Phenol Tetrahydronaphthalene Hydrazine Phosphorous hydroxy chloride Thiophene Hydrochloric acid (conc.) Phosphorous trichloride Toluene Methylene chloride Phosphoric acid Turpentine Methylene salicylate Pyridine Xylene and others Milk of lime (CaOH) Sodium hydroxide Nitric acid (conc.) Sodium sulfide Nitrobenzene Styrene Nitrocellulose lacquer Sulfuric acid (conc.) Perchlorethylene Sulphur chloride TRADE NAMES OF SOME COMPRESSORS OILS, RUBBER COMPOUNDS AND OTHER MATERIALS THAT WILL ATTACK POLYCARBONATE PLASTIC BOWLS: Atlas “Perma-Guard” Kano Kroil Sinclair oil “Lily White” Buna N Keystone penetrating oil #2 Some Loctite Compounds Cellulube #510 and #250 Marvel Mystery Oil Stillman #269-75 (polyurethane) Crylex #5 cement Minn. Rubber 366Y Stillman #SR-513 (neoprene) *Eastman 910 National Compound #N11 Stauffer Chemical FYRQUEL #150 Garlock #98403 (polyurethane) “Nylock” VC 3 Tannergas Haskel #568-023 Parco #1306 Neoprene Telar Hilgard Co’s hil phene Petron PD287 Tenneco anderol #495 and Houghton and Co. oil #1120, Prestone #500 oils #1130 & #1055 Pydraul AC Titon Houtosafe 1000 Sears Regular Motor Oil Zerex We cannot possibly list all harmful substances, check with a Mobay Chemical or General Electric office for further information on polycarbonate plastic. IMPORTANT MAINTENANCE INSTRUCTIONS FOR FILTERS: 1. BEFORE SERVICING THIS UNIT, READ THIS ENTIRE PRODUCT

INFORMATION SHEET. If your unit has a plastic bowl, note the special warning information that applies.

2. DEPRESSURIZE UNIT BEFORE REMOVING GUARD AND/OR BOWL. 3. If it is a plastic bowl unit, inspect daily to detect crazing, cracking, damage or other

deterioration. Immediately replace any crazed, cracked, damaged or deteriorated bowl with a new metal bowl or a new plastic bowl and bowl guard.

4. A. If unit has filter element, clean periodically by removing from filter, tapping on

surface, and blowing off with air blowgun.

Page 3 of 3

AIR LINE FILTER REGULATOR (Continued) B. If unit has soft cloth element, replace with a new one at least every six months, or

sooner if it looks dirty or causes excessive pressure drop 10 psig (0.7 bar) or more at rated flow.

5. A. If unit is equipped with a manual petcock, drain bowl at least once per work shift.

B. If unit is equipped with a float in the bowl, clean the bowl each time the element is cleaned or change by turning the bowl upside down and tapping onto tabletop. Blow clean with blow gun.

6. If bowl seal is crazed, cracked or otherwise damaged or deteriorated, replace with

manufacturer’s approved seal. 7. On plastic bowl units, reinstall bowl guard before pressurizing.

4. OPERATION INSTRUCTIONS

OPERATING INSTRUCTIONS MANUAL PALLETIZER

SAFETY NOTE: This unit is to be operated by properly trained and duly

authorized personnel only. The operator must stay by the “tilt” switch during

movement of the palletizer in order to reverse its direction of movement should an

emergency occur. It is the responsibility of the operator to ensure that no personnel

or equipment will be injured or damaged by operation of the palletizer.

INSTALLATION:

The unit is to be installed on firm level ground with adequate access for manual pallet

truck and the operator.

A clean, dry (i.e. not oiled) static air supply at 90 to 110 PSI (6.2 to 8 BAR) nominal

pressure is required to operate the palletizer, connected via the 3/8” (9.4mm) BSP fitting

on the side of the filter regulator unit (1). Rigid piping, if used, must not be continuous,

as allowance for accidental movement of the palletizer has to be made.

MOBILITY SYSTEM:

The palletizer is capable of being moved to the required position by means of the twin-

wheel “Tug” unit provided, in conjunction with the heavy-duty pallet rollers fitted at the

rear of the base frame.

The tug unit engages into a socket on the underside of the detachable crossbeam mounted

onto the base frame (held in position by retaining pins). This crossbeam must be

removed prior to use of the palletizer.

The palletizer should be moved in the loading position only, i.e. with the hod tilted.

When in position, the floor jacking bolts should be adjusted to ensure level operation of

the palletizer, taking into account local floor level conditions.

PALLETIZING OPERATION:

1. With the hod in the vertical position, load an empty pallet into the open

side of the palletizer and position the pallet on the forks (as shown on

drawing PML-S2-M). This operation should be undertaken using a

manual pallet truck (not fork lift), to avoid damaging the deck and sliding

deck cover of the unit.

2. Move to the side of the palletizer, check the Pal/Depal switch (2) that is set to

palletize mode. Then operate the tilt switch (3). As the hod tilts into the

loading position, the forks and pallet will elevate automatically to the full top

loading position. Note, if the curtain does not get to or drops back down from

this position during this tilt operation, it may be necessary to adjust tip over

speed or to check tip switch located on side frame of unit. Curtain must be all

the way up prior to this switch being made.

Operating Instructions CAS Manual Palletizer Page 2 of 3

3. If palletizer is equipped with dual bander reels, manually insert bands

into two provided bander install rods located on tilt cylinder. Slide rods

with bands attached through side of palletizer slot and through pallet board

opening to other side of elevator. Remove bands from opposite side of rods,

slide band up side of pallet, over top roller of elevator and clamp off band

with dual hand clamps provided. Remove two rods and restore in holder

provided.

4. Commence loading and continue until the available space if filled on the

layer. Some bottles may require the use of side or bottom spacers to

center/contain bottles on the skid in optimum pattern. Consult factory if you

feel this is required as a change part for your specific application for design

recommendations. If sample bottles are provided prior to order placement,

you machine may have been provided with spacers for your specific

application for either the sides or bottom row. Side spacers usually are only

required for the first 2 full layers. The 3rd

layer can be recycled back to the

layer being built by going to side of manual palletizer and pulling straight up

on board. The added weight of layers continues to hold this layer of bottles in

position. If bottom row of bottles requires spacing up to center layer on skid,

then a spacer per layer is required. Once load is banded, these light weight

spacers either fall out inside the elevator to be collected and reused or can be

manually removed from the layers once pallet is removed from the elevator if

4 banding versus 2 band system is being used.

5. After each layer, lower the pallet by pressing the foot pedal (4) until the load

moves down, leaving sufficient space for the next layer. Place a layer tray in

position and recommence loading.

6. Continue the loading cycle until the pallet load is complete. If unit is

equipped with dual bander reel system/signode pneumatic bander gun, remove

bands from clamp at this time and tighten bands securely at this time. Use

either plastic pull ties or use optional signode bander gun to provide bond seal.

7. Restore the hod to the vertical position next by operating the tilt switch (3).

8. Using a manual pallet hand truck, remove the completed load, and position a

new pallet in the unit to repeat process.

REGULATION OF PALLETIZER UNIT MOVEMENT:

To ensure smooth surge-free operation, the facility to regulate airflow in the pneumatic

circuit is provided.

Operating Instructions Manual Palletizer Page 3 of 3

The palletizer is factory tested and properly adjusted prior to delivery, but in the event

adjustment becomes necessary to balance movement of the tilt up and down cylinders to

each other, this is controlled by flow restrictors fitted to tilt cylinder inlet ports.

Adjustment MUST be made to both tilt cylinders until problem corrected.

Controls are provided for tilt up and down slow start/stop of cycle and speed during

middle tip cycle of the rod side cylinders. These flow controls are located behind rear

curtain machine frame guard. Normally once set for your specific load range, these flows

should not be to be adjusted. See pneumatic diagram part of this manual for specific

switch operation.

The elevator curtain rodless cylinder behind the rear machine frame is not adjustable on

the cylinder. All pipework and fittings are sized to provide the optimum, balanced

operating speeds. Make sure sizes are not changed or modified in any way.

STRAPPING SYSTEM (Optional)

The palletizer may be fitted with strap guidance and tensioning brackets, together with

retaining clamps. Some units may also have optional dual bander reels to supply banding

material versus just cut lengths being threaded through the above guidance system.

This clamp band guide system is designed to be used in conjunction with a plant free

standing bander reel or with optionally provided dual bander reel integrated kit onto

palletizer. Either way, this system allows 2 straps to be applied to the load prior to

removal of load from elevator. A separate strap-sealing gun or plastic pull clips are

required to secure the load on completion of packing prior to tilting load to upright

position. A 3rd

and 4th

optional band clamp kit can also be applied if purchased

accordingly. These, however, must be precut and threaded through guidance system by

hand on a pallet load basis.

The strapping material should be threaded through the guidance brackets as shown on the

next page for a two-band setup. This will provide the required tension to strap during the

loading process.

The strapping material is to be passed beneath the pallet, to the retaining clamps

positioned opposite – ensuring enough material is available to allow the load to be

securely strapped on completion.

If four straps are used, the same principle applies, with the straps running vertically

across the loading aperture of the palletizer.

SPACER BLOCKS (OPTIONAL)

The palletizer may be fitted with optional adjustable sides that adjust from 56” down to

48” wide. This will aid in palletizing non-standard size units and box/cartons.

Please see the installation instructions in section 1 of this manual for proper setup.

OPTIONAL DUAL BANDING REEL KIT 

 

BANDING REELS WILL ACCEPT STRAPPING 

WITH THE FOLLOWING SPECIFICATIONS: 

 

Strapping Width – 3/8” to 3/4” 

Coil Width – 3” and 6” 

Coil ID – 16”  

OPERATING PROCEDURE IF PALLETIZER USED WITH SELECTOR SWITCH IN DEPALLETIZER MODE.

NOTE: THIS UNIT IS TO BE OPERATED BY PROPERLY TRAINED AND DULY AUTHORIZED PERSONNEL ONLY. THE OPERATOR MUST STAY BY THE “TILT” SWITCH DURING MOVEMENT OF THE PALLETIZER IN ORDER TO REVERSE ITS DIRECTION OF MOVEMENT SHOULD AN EMERGENCY OCCUR. If unit is purchased as a palletizer, but you wish to use it in depal mode to raise the forks, use the following procedure:

1. With the hod in the tilted over position, move to the side of depalletizer. Check the pal/depal switch (2) to ensure it is correctly set to the depal mode, then compress foot pedal to raise layer to desired position. Note, as palletizer only unit incorporates a rodless cylinder vs. air motor to drive lanes, the lift capacity of forks is limited to a a few layers of bottles.

2. Commence unloading etc. until the complete layer of containers has been

removed or desired result achieved. If required, continue to raise the pallet by pressing the foot pedal (4) until the load moves up to the desired level.

3. Once depal function is complete, restore the hod to the palletizer position by

turning the select switch to “pal” (2). When the tilt switch (2) is turned, the empty/partially empty pallet will descend to floor level as the hod tilts or prior to actuating the tilt switch (2) by manually using the foot pedal at this time.

5. PARTS LISTING

CONTAINER AUTOMATION SYSTEMS PO BOX 2850 CUMMING, GA 30028 PHONE 678-947-5656 FAX 678-947-5655

CAS # Description QtyM5010-2 Carriage Cylinder, 63mm Bore, 2390mm Stroke 1M5011-2 Carriage Cylinder Seal Kit 1M5016-2 Tilt Cylinder Seal Kit, 100mm Bore 1M5012-3 Tilt Cylinder, 100mm Bore, 1550mm Stroke 1M5014-1 Trunion/Tilt Cylinder 1M5070 Rod End/Tilt Cylinder, 100m (Standard) 1M5023 Pivot Bearing/Tilt 1M5024 Bearing for Carriage 1M5025 Pressure Gauge, 160 psi 1M50262 Main Regulator 1M50272 Air Shut-Off Valve 1M5028 Modular Sleeve Bracket for Regulator 1M5029 Modular Sleeve Bracket for Filter 1M50302 Air Filter Coalescing 1M50313 Filter Cartridge 1M5032 Brass Bushing for Trunion 1M5064 Air Valve 1M5033 Switch Body for Tilting 1M5034 Switch Base 1M5035 OR Valve 1M5036 AND Valve 1M5065 Limit Switch Valve for carriage up/down & tilt down 1M5038 Foot Switch 1M5040 Needle Valve 1M5041 Check Valve 1M5042 Hose Sleeve (per foot) 1M5043 Banding Reels 1M5044 Toggle Clamp 1M5046 Side Skins for Elevator 1M5047 B-Line Troley 1M5019 Curtain Assembly 1M5020 Curtain Only, 27" Fork Spacing, 56" Wide 1M5061 Curtain Only; 37" Fork Spacing, 56" Wide 1

M5069 Curtain Only, 27" Fork Spacing, 48" Wide 1

M50691 Curtain Only, 27" Fork Spacing, 40" Wide 1

M5072 Switch Valve for Tilting 1

M5073 Switch Valve for Tilting 1

M5074 Inline Check Valve 1

CAS Manual Palletizer Parts List

6. PNEUMATIC CIRCUIT SCHEMATIC

7. TROUBLESHOOTING

MANUAL PALLETIZER TROUBLESHOOTING GUIDE – PNEUMATICS

PNEMATIC SYSTEM IS NON-LUBRICATED

Caution: During adjustments made to the pneumatic board, unit must be in the vertical position.

PROBLEM SOLUTION

Unit is erratic or sluggish Unit tilts down too slow Unit tilts down too fast Unit sets too hard at the bottom Unit tilts up too slow Unit tilts up too fast

Check air PSI – must maintain 90 PSI, pressure too high or low will prevent optimum operation. A. Increase NV3 1/8” turn counterclockwise until desired speed is acquired. B. Increase NV1 1/8” turn counterclockwise until desired speed is acquired. A. Decrease NV3 and NV1 turn clockwise until desired speed is acquired. A. Adjust limit down K bracket forward to make switch before unit sets down A. Increase NV4 1/8” turn counterclockwise until desired speed is acquired. A. Increase NV4 turn clockwise until desired speed is acquired. B. Fine adjustment may be required on NV4 if unit sets too hard at the top unload position. C. Adjust limit L bracket forward to make limit switch before unit sets up.

8. MAINENANCE SCHEDULE

MANUAL PALLETIZER MAINTENANCE SCHEDULE

Bi-Monthly: 1. Inspect air system trap for moisture, bleed off as necessary. 2. Inspect coalescing air filter indicator. If green then filter is ok. If red, filter needs to

be changed. 3. Inspect air lines, especially external, for cuts, knicks, etc. 4. Inspect roller blind for cuts, sluggish operation. Clean back metal surface of

palletizer with cleaner. An optional cost of silicone base polish can be applied to curtain surface for optimum curtain free movement.

5. Check brake operation on optional bander reels for proper operation in releasing banding as elevator forks move downward.

6. Clean elevator interior plastic side sheets with cleaner to remove foreign dirt, etc. 7. Monitor tip over and tip up timing/speed to ensure slow/smooth operation. Adjust

flow controls as required (located behind rear desk guard of machine). 8. Check forks for squareness to blind (use square). This ensures straight pallet build

pattern. 9. Check/add as required mineral oil to optional bander gun oiler (if bander gun

equipped). 10. Check for air supply pressure setting of 90 to 110 psi on main regulated air supply on

machine. Adjust as required. After 6 weeks of operation: 1. Grease the 2 lower bearings on pivot pins. 2. Check all bolts and screws for tightness.

9. RECOMMENDED OPIONAL HAND CART FOR PALLET REMOVAL