MAGNUM DOOR LOADER PRODUCT AND OPERATIONS MANUAL DOCUMENT NUMBER 17-301
Eff. S/N LM-6915
Release 0
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Norfield Industries P.O. Box 459 Chico, CA 95927 SERVICE: (530) 891-4214 PARTS: (800) 824-6242
Serial No: Date Sold:
Norfield Industries is the name that represents Quality, Reliability, Support, Innovation and True Customer Service. We have been dedicated to providing quality products and excellent customer service for more than 40 years. Norfield Industries has earned a reputation in the pre-hanging industry for setting standards for reliable machinery, full technical support, machine parts, full line industrial woodworking tools and supplies and a team of customer care representatives to support you! Our factory-trained technical personnel are ready to assist you on the telephone or in your shop.
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Table of Contents INTRODUCTION ........................................................................................................................................ 4 SAFETY INFORMATION........................................................................................................................... 5 LABEL AND D EFINITIONS ............................................................................................................................ 5 MUST READ SAFETY INFORMATION! ........................................................................................................... 6 SPECIFICATIONS .................................................................................................................................... 8 INSTALLATION.......................................................................................................................................... 9 1.1 SHIPPING DAMAGE AND SHORTAGES .......................................................................................... 9 1.2 INSTALLATION ................................................................................................................................. 9 1.3 POSITIONING .................................................................................................................................. 10 1.4 LEVELING........................................................................................................................................ 11 1.5 INSTALLING LOADER BASE PLATES ...................................................................................................... 12 1.6 INSTALL THE CONTROL STAND ............................................................................................................. 13 1.7 ELECTRICAL ................................................................................................................................... 13 1.8 CHECK MOTOR ROTATION.................................................................................................................... 14 BEFORE YOU BEGIN............................................................................................................................... 15 2.1 ADJUST O UTFEED HEIGHT................................................................................................................... 15 2.2 ADJUST THE DOOR ON SENSOR ............................................................................................................. 16 OPERATING THE MAGNUM DOOR LOADER .................................................................................... 17 3.1 LOADING A DOOR STACK ..................................................................................................................... 17 3.2 FEEDING A DOOR INTO THE MAGNUM .................................................................................................. 17 MAINTENANCE........................................................................................................................................ 18 4.1 MAINTENANCE ............................................................................................................................... 18 4.2 GENERAL MAINTENANCE COMMENTS ...................................................................................... 18 TROUBLESHOOTING.............................................................................................................................. 19 5.1 INPUT AND OUTPUT LIGHTS ................................................................................................................ 19 5.2 SYMPTOM SOLUTION MATRIX .............................................................................................................. 20 SERVICE DOCUMENTS .......................................................................................................................... 24 PRE-INSTALLATION............................................................................................................................... 45 WARRANTY .............................................................................................................................................. 48
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INTRODUCTION
INTRODUCTION Congratulations on your purchase of your Norfield Industries Magnum Door Loader. You can be assured that this machine was constructed and assembled to a set of rigid specifications by trained workers who take pride in the quality of their work. To safely operate this machine it is vital that you read and understand all safety and operator instructions. The Norfield Industries Magnum Door Loader is designed to work with the Signature Series Magnum Door Machine, or in conjunction with most other vertical door machines not supplied by Norfield Industries. It provides an economical solution for feeding doors on edge eliminating the need to lift, turn and feed each door. Prior to shipment from our factory each Norfield machine is put through a series of tests and inspections to insure that you are provided with the highest quality product for your business. In order for this machine to provide you with a long period of continuous and trouble free service, it is necessary that it be properly installed, operated, and maintained. We urge you to study the contents of this manual and be guided by the suggestions herein. We strongly recommend that a periodic review of the contents of this manual be made to maintain a high level of competency when operating this machine.
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INTRODUCTION SAFETY INFORMATION
STOP! Protect Yourself This manual contains information that is important to the safe operation of your Norfield equipment.
LABEL AND DEFINITIONS Danger indicates an imminently hazardous situation, which if not avoided, WILL result in death or serious injury. Warning indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. Caution indicates a potentially hazardous situation which, if not avoided MAY result in minor or moderate injury. It may also be used to alert against unsafe practices. Caution without the safety alert symbol indicates a potentially hazardous situation which, if not avoided may result in property damage (i.e. not personal injury).
Notice indicates important information that if not followed may CAUSE damage to the equipment.
Mandatory Action conveys an action step that should be taken to avoid the hazard.
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INTRODUCTION
MUST READ SAFETY INFORMATION!
Read and understand the operator's manual before using this machine. Failure to follow proper operating instructions could result in death or serious injury.
Do not operate this machine unless all guards are in place and working correctly. If any guards or hazard labels are missing or damaged call Norfield's Service department immediately and request a replacement at 800-824-6242. Only trained personal that have read and understand the operator's manual and all the safety precautions may operate this machine. This machine, when in operation, produces wood chips and dust. The operator and all persons in the work area MUST wear approved eye protection with permanently attached, rigid plastic side shields. These safety glasses must conform to ANSI Z87.1 standards and will have "Z87" printed on the lens. This machine, when in operation, produces a noise level greater than 85dB. The operator and all persons in the work area MUST wear approved hearing protection. OSHA has determined that a noise level in excess of 85dB average in 8 hours can cause permanent hearing damage. We recommend that hearing protection be worn even if the decibel level is below 85dBA. Certain types of wood dust can cause allergic reactions, Sawdust has been determined to be a Group A carcinogen by the International Agency for Research on Cancer (IARC). A dust collection system or an approved personal dust mask MUST be used during the operation of this equipment. This machine has moving parts that loose clothing and long hair can become entangled in. Take care not to become caught between the work material and the feed mechanisms or any other moving components. Inspect the machine at the beginning and end of each shift for damaged or cracked components such as, but not limited to, saw blades, router bits, drill bits, and boring bits.
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INTRODUCTION
MUST READ SAFETY INFORMATION! (CONTINUED)
Never leave this machine unattended while it is in operation. Make sure that all electrical and air is in the off position when the machine is not in use or is unattended and that any cutting blades have come to a complete stop.
Do not attempt to clean material from this machine until all the cutting blades have come to a complete stop. Even when the machine has been turned to the off position it may take up to several minutes for the blades to coast-down to a complete stop.
Before beginning any service repairs, general maintenance, or adjustments you MUST follow proper Lockout Tag-Out procedures. OSHA regulation 1910.147 establishes a minimal lockout tag-out procedure to assist employers in development of their own procedures.
Woodworking machinery is inherently dangerous, common sense and good safety practices are your best defense against injury.
If you have any questions regarding the correct operation of the machine and safety procedures in this manual call the Norfield Industries Service Department at 800-824-6242.
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INTRODUCTION
SPECIFICATIONS
Electrical Requirements: AC Line 208 220/240 440/480
Phase 3Φ 3Φ 3Φ
Hertz 60Hz 60Hz 60Hz
Air Requirements: Approximate Weight: Space requirements(W x L x H):
Machine Capabilities: Door Width Door Height Door Thickness Infeed Height Outfeed Height Maximum Stack Height Maximum Stack Weight
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Amperage 15A 15A 10A
None
1800 lbs. 8' x 7'10" x 6'
1'6" to 4'0" 4'6" to 9'0" 1-1/8" to 2-1/4" 12" Above Floor 16" to 20" Above Floor 48" Including Pallet 2800 lbs.
INSTALLATION
SECTION 1 I N S TA L L AT I O N 1.1 SHIPPING DAMAGES & SHORTAGES Before and after the crated machine is unloaded from the truck the create should be inspected for any signs of damage. If suspected damage is found it must be noted on the bill of lading and signed by the driver and the person receiving the shipment. After the machine has been uncrated inspect it and all other contents of the crate for shipping damage. In the event that damage has occurred in transit notify the freight carrier and Norfield Industries immediately. Inspect the complete shipment against the packing slip to make sure all items listed are accounted for. If any shortages are noticed, the freight carrier and Norfield Industries should be notified immediately. While any shortages, other than back orders, or freight damages are the complete responsibility of the freight carrier, Norfield Industries desires to be notified so that the replacement of lost or damaged parts can be expedited. 1.2 INSTALLATION The information in this section refers to the installation and setup of the Norfield Magnum Door Loader. Since the purchase of this machine does not include a start-up by a field technician, it will be necessary to follow these instructions as closely as possible to insure proper operation. In the unlikely event that you have a problem during this process, you may contact the Norfield Service Department, at (800) 824-6242, for technical assistance. 1. Uncrate the machine. Remove the top and sides of the crate. Remove the plastic cover and the box of miscellaneous parts. Inspect the machine for loose or damaged parts. Inventory the box parts. 2. Remove all of the straps, bolts and shipping restraints that attach the machine to the crate base. 3. With the control stand still in the shipping position, insert the forks of a forklift into the lifting brackets as far as possible and lift the machine out of the crate. Figure 1-1 shows your Magnum Door Loader as it should look when it comes out of the crate. The two lifting brackets are used to lift the machine out of the crate and place it in position. In the event it is necessary to lift the machine from the other side, the lifting brackets can be turned around and mounted facing the other direction. Figure 1-1
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I N S TA L L AT I O N 1.3 POSITIONING With the use of a forklift move the machine to its permanent position within your shop. This space should have been predetermined and electrical power should be installed prior to the machines arrival. To complete the installation and setup of your new Magnum Door Loader the following list of tools will be necessary. •
Hex key wrench set from 1/8” – 5/16”.
•
Open end wrench sizes, 7/16”, 9/16”, (2) 3/4”, 1 1/8”, 1 1/2”, or, 2 adjustable wrenches that will cover the same sizes.
•
Side cutters
•
Tape measure.
1. Place the machine at the infeed end of the Magnum (or other vertical door machine) and align the vertical edge of the roller tray with the front face of the Magnum frame. See figure 1-2. 2. Dimension (A) is the dimension between the Magnum frame and the Magnum Door Loader frame. The recommended distance is 18”. However, this dimension can be as small as 12” or as large as needed to meet floor space requirements. If dimension (A) is to be larger then 30” an additional support roller will be needed. 3. If you will be handling doors shorter then 6’ 8” the maximum length of dimension (A), with out additional support, will be less then 30”.
Figure 1-2
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INSTALLATION
4. Remove the lifting brackets. Remove the bolts from both ends of one of the lifting brackets and carefully lift it off the machine. 5. Remove the bolts from the lifting bracket mount and remove it. Repeat the process for the other lifting bracket. See figure 1-2. 6. If there is a chance that you will move the machine again, the lifting brackets should be stored in a safe place. In the event that you need to move a Norfield Magnum Door Loader and the lifting brackets can not be located, they can be ordered from Norfield Industries. The parts necessary are, (2) 6850-130 lift bracket, (2) 6850-039 lift bracket mount, (8) ½” x 4 ½” bolts, (4) ½” x 1” bolts, and (8) ½” nuts. 1.4 LEVELING 1. To level the frame. Loosen the lock nuts on the four one-inch diameter leg bolts. Level the long frame tubes from front to back. 2. The side closest to the door machine should be approximately 3/16” higher then the side furthest from the door machine. (This will be discussed further in Section 2.)
Figure 1-3
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1.5 INSTALLING LOADER BASE PLATES During the course of normal operation the door stacks being loaded onto the Norfield Magnum Door Loader may impact the vertical wear strips with sufficient force to move the machine and cause misalignment with the door machine. Installation of the four loader base plates will minimize this effect.
Figure 1-4
After the installation and setup procedure has been completed carefully lift each corner of the machine until the leveling bolts are high enough to slide the loader base plates under the leveling bolts. Then let the bolt down into the center hole, as shown in Fig.1-4. This can be done using a 3 or 4 ft. long piece of 2 x 4 or another suitable pry bar. CAUTION: DO NOT, AT ANY TIME, PLACE ANY PART OF YOUR BODY BETWEEN EITHER THE LEVELING BOLT, OR THE BASE PLATE, AND THE FLOOR! Install concrete anchor bolts or studs through the two smaller holes in the loader base plates and bolt the plates securely to the floor. Check that the machine is still level.
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INSTALLATION 1.6 INSTALL THE CONTROL STAND 1. Install the control stand. Unbolt the control stand from its shipping position. Carefully move the control stand into the operating position and install the four bolts. See fig. 1-5. 2. Before tightening the mounting bolts, adjust the control stand support legs so that the control stand mounts are flat against the frame. 3. Tighten the control stand mounting bolts and all six support leg lock nuts. 4. Attach the wire loom to the tie bases on the frame with the tie wraps provided.
Figure 1-5
1.7 ELECTRICAL 1. When wiring the machine, follow all local electrical and safety codes as well as the National Electric Code (NEC) and Occupational Safety and Health Act (OSHA). 2. Before connecting any electrical power to the main electrical enclosure, be sure that the characteristics labeled on the enclosure match those of your service. Refer to the drawing 6850-001 in Appendix A of this manual. 3. The electrical connection point is located in the upper right corner inside of the main electrical cabinet. 4. Route the incoming electrical power such that it comes in low along the long frame tube. It should not be above the frame tube until it is inside the control stand. See Fig. 1-6 for electrical connections.
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INSTALLATION
Figure 1-6
1.8 CHECK MOTOR ROTATION 1. When you are confident that all of the electrical connections are correct, close the main electrical cabinet door and tighten the screws. 2. Turn the disconnect switch to the “On” position, reset the E-stop button. 3. Look through the window in the control panel, you should see a number of the lights on. 4. Check to see that the Run light is on, Refer to figure 5-1. 5. If the Run light is on, rotate the tilt control in the up direction briefly (less then 1-sec.) and note the direction of rotation of the motor fan. (This may require two people.) 6. The correct motor rotation is clockwise facing the fan end of the motor. 7. If the Run light does not come on, refer to the troubleshooting section of this manual. NOTE: SUSTAINED OPERATION WITH THE INCORRECT MOTOR ROTATION WILL DAMAGE THE PUMP AND PUMP SHAFT SEAL.
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BEFORE YOU
BEGIN
SECTION 2 BEFORE YOU BEGIN The information in this manual refers to using the Magnum Door Loader with the Norfield Magnum. While the Norfield Magnum Door Loader is designed to work with most vertical door machines currently on the market, Norfield can not guaranty compatibility with any machine not made by Norfield 2.1 ADJUST OUTFEED HEIGHT 1. The outfeed side of the Magnum Door Loader should be 3/16� higher then the other side, refer to section 1.4. This will cause the door to outfeed at a slightly upward angle. 2. Set the Magnum infeed bed to the height you would normally use for your standard undercut. 3. Loosen the lock nuts and adjust the tilt stop pads so the door rolls out of the Magnum Door Loader and on to the Magnum infeed bed smoothly. See Figure. 2-1. 4. When the door is on the Magnum infeed bed it should be slightly above the rollers on the Magnum Door Loader. Tilt up a few inches and down again to confirm that the tilt stop pads contact the stops simultaneously. 5. Tighten the lock nut.
Figure 2-1
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BEFORE YOU BEGIN 2.2 ADJUST THE DOOR ON SENSOR The Door On Sensor consists of two elements. The emitter at the top of the mount post and the receiver at the bottom. See Figure 2-1. 1. The receiver should be adjusted, using the long slots in the mount plate, so the door stops ¼” – ½” out from the white wear strip of the Magnum. If there is not enough adjustment in the slots, it will be necessary to move the machine to compensate. Note: The emitter and receiver need to point at each other and the receiver needs to display both the amber and red lights. This should cause input light 9, on the controller, to be on.
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OPERATING
THE
MAGNUM DOOR LOADER
SECTION 3 O P E R AT I N G T H E M A G N U M D O O R L O A D E R The following procedure will assist the operator in loading the machine for the first time. It assumes that that the power is on and that the machine stack is unloaded and in the down position. 3.1 LOADING A DOOR STACK 1. Turn the Tilt knob to the "Up" position and continue holding the knob until the tilt frame is in the full upright position. NOTE: THE MACHINE WILL ONLY ROTATE WHEN THE KNOB IS HELD IN EITHER THE UP OR DOWN POSITION. 2. Press and release the green AUTO START button. This will automatically move the forks in the down direction until they are fully down. 4. Load a door onto the forks. The door stack should be as close as possible to the white wear strips on the tilt frame and must hang over the fork on the operator side at least 8� but not more then 18�. 5. Turn the TILT knob to the down position and hold it until the tilt frame is in the full down position. 6. Press and release the green AUTO START button. The light in the AUTO START button will come on and the forks will move the door stack in the up direction until the top door breaks the photo eye light beam. The top door should now be in line with the magnum infeed table. 3.2 FEEDING A DOOR INTO THE MAGNUM After following the above procedure the machine will be in the automatic mode (green light still on) and waiting for the operator to begin. Please note that this machine will move without warning when a door is removed from the door stack and loaded into the Magnum, at any time the automatic mode can be canceled by turning either of the two positioning knobs located on the control panel. 1. Pull the top door off the loader and onto the magnum infeed bed. 10 seconds after the door clears the photo sensor the machine will automatically position the next door to be loaded. 2. Continue feeding doors from the stack into the Magnum. 3. After the last door is removed from the loader the forks will automatically return to the full down position. 4. Turn the Tilt knob to the "Up" position and continue holding the knob until the tilt frame is in the full upright position.
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MAINTENANCE
SECTION 4 MAINTENANCE 4.1 MAINTENANCE It is the machine owner's responsibility to insure that the machine is properly maintained and that personal is adequately trained to safely perform the maintenance function. A program of routine and preventive maintenance that is strictly adhered to will keep expensive "down time" to a minimum and give maximum life to the machine. Please read and use the following checklist for daily, weekly and monthly procedures. For your convenience, these lists are duplicated in a "checklist" format so they can be copied and kept near the machine available for the operator or maintenance personnel. Always lock and tag out the electrical power source to the machine before starting inspection or performing maintenance. 1. Using an air hose blow all motors off 2-3 times daily. 2. using a stiff brush clean gears and gear racks on elevator mechanism at the end of each shift, DO NOT LUBRICATE! 3. Wipe vertical posts on elevator clean at the end of each shift. 4. Once a week check the oil level in the hydraulic pump. 5. Once a month remove door edge rollers and clean the roller I.D. and shaft O.D. with a non-oil based solvent (Electrical/Electronic Contact Cleaner), wipe dry. DO NOT LUBRICATE! 6. The oil in the hydraulic pump should be changed every 5 years. Replace with Norfield 10wt turbine oil. 4.2 GENERAL MAINTENANCE COMMENTS 1. A clean machine is essential for superior performance and reduced maintenance. 2. Unless directed otherwise never use oil, silicon, or graphite to lubricate any bearing surface or chrome slide rod. Any substances such as those mentioned above will collect fine sawdust and dirt particles that will wear the bushings very quickly. If any assembly is binding and you have kept everything clean, the problem is most likely that the parts are in misalignment or have become excessively worn.
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TROUBLESHOOTING
SECTION 5 TROUBLE SHOOTING 5.1 INPUT & OUTPUT LIGHTS As the machine sequences the output and input lights on the controller turn on and off. These lights can be an invaluable troubleshooting tool. As an example, if you press the Auto Start Button and the Auto Start Light on the controller does not come on when the button is held down, then the controller is not getting the start input, and the machine will not cycle. Taking a close look at the Auto Start Button is warranted. To assist you in determining the cause of a problem when it occurs, we have labeled and identified all inputs and outputs of the controller module. The labeling is on the control panel and the lights should be clearly visible through the window on the operator control panel.
Figure 5-1
Inputs 00 through 04 are from the switches on the control panel and these input lights are on only when the switch is operated. Inputs 05 through 09 are from the position sensors and these input lights are normally on. Input lights 05 through 09 are off when the respective motion is at its limit. As an example, the Tilt Full Down light will be off when the machine is tilted fully down. Outputs 00 through 05 control all of the machine functions. As an example, when output light 02 is on the hydraulic pump should be running.
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TROUBLESHOOTING 5.2 SYMPTOM SOLUTION MATRIX Symptom
Probable Cause
Machine does not index correctly There is no input from the Index Full Down Sensor (Input light 06 is off). Machine does not index down. There is no input from Index Down Switch (Input light 03 stays off when knob is turned).
There is input from the Tilt Full Down Sensor (Input light 06 is on).
Machine does not index up
There is no input from the Index Full Up sensor (Input light 07 is off) There is no input from Index Up Switch. (Input light 02 stays off when knob is turned)
There is no input from Door On Sensor (Input light 09 is off).
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Solution
Index is already down all the way. Index Full Down Sensor cable is disconnected. Index Full Down Sensor or cable needs to be replaced. Index Down Switch is defective. Machine is not tilted all the way down. Tilt Full Down Sensor is out of adjustment. Tilt Full Down Sensor cable is disconnected. Tilt Full Down Sensor or cable is defective. Machine is already indexed up all the way. Index Full Up Sensor cable is disconnected. Index Full Up Sensor or cable is defective. Index Up Switch is defective.
Door On Sensor is blocked or out of adjustment (Light receiver displays a green light and not the red or yellow). No power to light receiver (No lights on receiver). No power to light emitter (No green light on emitter).
TROUBLESHOOTING Symptom
Probable Cause
Solution
Machine does not tilt up There is no input from the Tilt Full Up Sensor (Input light 05 is off)
Machine does not tilt up.
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There is no input from Tilt Up Switch. (Input light 00 stays off when knob is turned) There is an input from the Tilt Up switch (Input light 00 is on). There is an output from Pump Start (Output light 02 is on) and the Hydraulic Pump does not run. There is an input from the Tilt Up switch (Input light 00 is on). There is an output from Pump Start (Output light 02 is on) and the Hydraulic Pump does run. There is an input from the Tilt Up switch (Input light 00 is on). There is an output from Pump Start (Output light 02 is on), the Hydraulic Pump runs and there in an output from Tilt Up (Output light 00 is on).
Machine is already tilted up all the way. Tilt Full Up Sensor cable is disconnected. Tilt Full Up Sensor or cable is defective. Tilt Up Switch is defective.
Motor Overload has tripped. Motor Starter is defective.
Hydraulic Pump is low on oil.
The Hydraulic Valve is defective.
TROUBLESHOOTING Symptom Machine does not tilt down
Probable Cause
There is no input from the Tilt Full Down Sensor (Input light 06 is off)
Machine does not tilt down.
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There is no input from Tilt Down Switch. (Input light 01 stays off when knob is turned) There is an input from the Tilt Down switch (Input light 01 is on). There is an output from Pump Start (Output light 02 is on) and the Hydraulic Pump does not run. There is an input from the Tilt down switch (Input light 01 is on). There is an output from Pump Start (Output light 02 is on) and the Hydraulic Pump does run. There is an input from the Tilt Down switch (Input light 01 is on). There is an output from Pump Start (Output light 02 is on), the Hydraulic Pump runs and there in an output from Tilt Down (Output light 01 is on).
Solution Machine is already tilted down all the way. Tilt Full Down Sensor cable is disconnected. Tilt Full Down Sensor or cable is defective. Tilt Down Switch is defective.
Motor Overload has tripped. Motor Starter is defective.
Hydraulic Pump is low on oil.
The Hydraulic Valve is defective.
TROUBLESHOOTING Symptom Probable Cause Machine will not perform automatic operations When the Auto Start Button is pushed, nothing happens. (Input light 04 stays off when Auto Start Button is pushed)
Machine will not automatically index doors.
Machine will not automatically return when the last door is removed in the auto mode.
Solution Auto Start Switch is defective.
Machine is not tilted all the way down. Tilt Full Down Sensor is out of adjustment. Tilt Full Down Sensor cable is disconnected. Tilt Full Down Sensor or cable is defective. Index Full Up Sensor cable is When the Auto Start Button is disconnected. pushed, input light 04 comes Index Full Up Sensor or cable on but not the light in the Auto is defective. Start Button. Door On Sensor is blocked or out of adjustment. (Light receiver displays a green light and not the red or yellow) No power to light receiver. (No lights on receiver) No power to light emitter. (No green light on emitter) Index Full Up Sensor cable is disconnected. The green light in the Auto Index Full Up Sensor or cable Start Button is on, input 07 (Index Full Up) is on and input is defective. light 09 (Door On Sensor) is off. Machine is already tilted up all the way.
Machine will not auto down when tilted up.
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Machine is tilted up, green light on Auto Start Button will Tilt Full Up Sensor cable is not come on, input light 05 disconnected. (Tilt Full Up) is on. Tilt Full Up Sensor or cable is defective.
SERVICE DOCUMENTS
SECTION 6 S E RV I C E D O C U M E N T S
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SERVICE DOCUMENTS
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SERVICE DOCUMENTS
BASE ASSEMBLY ITEM PART #
PART DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
LOADER BASE SENSOR TARGET 2” CLAMP COLLAR PIVOT BEARING 1-8 NC HHCS x 2-1/2” (LEVELING BOLT) 1-8 NC JAM NUT 5/8-11 SHCS x 2” 5/8” LOCK WASHER 5/8-11 NC HEX NUT ACE MC1202-3 SHOCK ABSORBER ¼-20 NC SHCS x 2-1/4” ¼” LOCK WASHER ¼-20 NC HEX NUT PHOTO EYE BRACKET (TOP) ALLEN BRADLEY 60-2657 SENSOR BRACKET ALLEN BRADLEY 42EF-R9MNB-F4 PHOTO EYE EMITTER ALLEN BRADLEY 42EF-R9MPB-F4 PHOTO EYE RECEIVER PHOTO EYE BRACKET (BOTTOM) PHOTO EYE MOUNT 8-32 NC BHCS x ½” #8 FLAT WASHER #8 LOCK WASHER 8-32 NC HEX NUT ¼” FLAT WASHER ALLEN BRADLEY 872DH4CP12D4 ALLEN BRADLEY 871A-BRN12 SENSOR BRACKET 10-24 BHCS x 3/8” TUBE CLAMP (DBL) 5/16-18 NC SHCS x 1-3/4” ACE 250-0038 LOCK NUT
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6850-112 6850-131 ***** 6850-108 ***** ***** ***** ***** ***** 12-528 ***** ***** ***** 6850-020 11-933 11-958 11-957 6850-021 6850-109 ***** ***** ***** ***** ***** 11-1116 11-1146 ***** 16-105 ***** 12-529
QTY 1 1 1 2 4 4 * * * 2 * * * 1 2 1 1 1 2 * * * * * 3 3 * 4 * 2
SERVICE DOCUMENTS
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SERVICE DOCUMENTS
TILT ASSEMBLY ITEM PART #
PART DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
TILT FRAME TILT FRAME STOP 1-8 NC REDI-THREAD x 6” 1-8 NC JAM NUT LOVEJOY U75 ¾” COUPLING w/KEY WINSMITH 913MWN SPEED REDUCER DAYTON 2N916 MOTOR DAYTON 6K233 MAGNETIC DISC BRAKE BALL SCREW BS&A R1105-3 FLANGE MOUNT BS&A PR1105-2 BALL NUT 7/16-14 NC SHCS x 1-3/4” BS&A B20-01 PRELOAD BEARING GEAR RACK 3/8-16 NC HHCS x 1” 3/8” LOCK WASHER SWECO S-25-20-1-1/8-A HYDRAULIC CYLINDER WEAR STRIP ¼-20 NC FHCS x ¾” ¼-20 NC FHCS x ½” ROLLER TRAY ¼-20 NC FHCS x ¾” ¼” FLAT WASHER ¼” LOCK WASHER ¼-20 NC HEX NUT 5/16-18 HHCS x ¾” 3/8-16 BHCS x ¾” LIFT FRAME ROLLER TRAY MOUNT 3/4” Ø SHOULDER BOLT x 3” ROLLER 5/8-11 NC JAMB NUT ROLLER MOUNT 5/16” LOCK WASHER 5/16-18 HHCS x 1” 3/8” FLAT WASHER 3/16” Ø COTTER PIN x 2-1/2” 3/16” SQUARE KEY x 7/8” LG.
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6850-107 6850-024 9517-600 ***** 12-627 15-168 15-167 15-048 6850-016 12-587 12-586 ***** 12-628 6850-100 ***** ***** 16-111 6850-023 ***** ***** 6850-111 ***** ***** ***** ***** ***** ***** 6850-105 ***** 6850-022 ***** 6850-110 ***** ***** ***** ***** 9072-088
QTY 1 2 2 4 1 1 1 1 1 1 1 4 1 2 4 4 2 2 10 4 1 2 2 2 2 4 2 1 3 3 3 2 4 4 4 8 2
SERVICE DOCUMENTS
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SERVICE DOCUMENTS
LIFT ASSEMBLY ITEM PART#
PART DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
LIFT FRAME GEAR SHAFT 1” Ø SPLIT COLLAR ½-13 NC HHCS x 1-1/2” BUSHED BLOCK SPUR GEAR 1/4” SQUARE KEY x 1-1/4” LG. TORRINGTON CRS-32 CAM FOLLOWER SPACER 7/8-14 NF HEX NUT ½-20 NF HEX NUT ½” LOCK WASHER ½-13 SHCS x 1” SLIDE MOUNT PLATE LIFT FRAME SLIDE ¼-20 FHCS x ¾” McGILL CFL-1-1/4-S CAM FOLLOWER SPACER ½” FLAT WASHER
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6850-104 6850-015 ***** ***** 0023-101 8030-001 9073-125 12-629 6850-019 ***** ***** ***** ***** 6850-013 6850-014 ***** 12-147 9013-025 *****
QTY 1 1 2 4 2 2 2 4 4 4 2 2 4 2 2 4 2 2 4
SERVICE DOCUMENTS
31
SERVICE DOCUMENTS
HYDRAULIC ASSEMBLY ITEM PART#
PART DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
PGL-25-3000S GAUGE ¼-20 SHCS x 2-1/2” PARKER 2202P-4-4 BRASS ELBOW BARNES 2620290 MANIFOLD ADAPTER DENISON A4D0132070302B1W0181 VALVE HYDRAULIC POWER SUPPLY HYDRAULIC TUBE #4 TUBE CLAMP (DBL) HYDRAULIC HOSE #1 MODIFIED “L” FITTING SWECO S-25-20-1-1/8-A HYDRAULIC CYLINDER HYDRAULIC HOSE #2 AEROQUIP 2033-6 TEE FITTING HYDRAULIC TUBE #3 HYDRAULIC TUBE #2 HYDRAULIC TUBE #1 AEROQUIP 206209-6-6 “L” FITTING AEROQUIP 2062-6-6 “L” FITTING 10-24 SHCS x 1-1/4” 5/16-18 NC HHCS x 1” 5/16” LOCK WASHER 5/16” FLAT WASHER 5/16-18 NC HEX NUT 3/16” Ø COTTER PIN x 2-1/2”
32
16-013 ***** 21-072 16-090 16-091 16-088 6850-126 16-105 6850-127 6850-132 16-111 6850-128 16-097 6850-125 6850-124 6850-123 16-108 16-096 ***** ***** ***** ***** ***** *****
QTY 1 4 1 1 1 1 2 4 2 4 2 2 2 1 2 1 1 1 4 4 4 4 4 8
SERVICE DOCUMENTS
33
SERVICE DOCUMENTS
ELECTRICAL ENCLOSURE ITEM
PART#
PART DESCRIPTION
QTY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
6850-122 13-585 6850-028 6850-029 11-1558 11-1561 11-1694 11-752 11-695 ***** ***** 6850-120 6850-121 ***** 11-1005 6810-020 ***** 6850-026
CONTROL CABINET STAND CHROME HANDLE ALUMINUM CONTROL PANEL CONTROL PANEL OVERLAY ALLEN BRADLEY 800FPMT44 E-STOP BUTTON ALLEN BRADLEY 800FP-LF3 ILLUM. PUSHBUTTON ALLEN BRADLEY 800FP-SB32 SELECTOR SPRECHER & SCHUH LFS2-E-6-175I SWITCH HANDLE SPRECHER & SCHUH LA2-G3194 SWITCH END SHAFT ¾-10 NC HH BOLT x 2-1/2” ¾-10 NC JAM NUT CONTROL STAND CONNECTOR (SHOWN) CONTROL STAND CONNECTOR (NOT SHOWN) 3/8-16 NC SHCS x ¾” ALLEN BRADLEY 1761-L16BWA MICRO PLC ELECTRICAL ENCLOSURE WINDOW ¼-20 BHCS x 1” ELECTRICAL ENCLOSURE
1 2 1 1 1 1 2 1 1 2 2 1 1 4 1 1 6 1
34
SERVICE DOCUMENTS
35
SERVICE DOCUMENTS
CONTROL PANEL ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
36
PART# 6850-122 11-1005 ***** 6810-009 11-1071 11-960 11-969 11-887 11-741 11-1160 11-1567 11-1566 11-1567 11-1560 6850-028 6850-029 6850-027 11-1568 11-1566 *****
PART DESCRIPTION CONTROL STAND ALLEN BRADLEY 1761L16BWA 16 POINT MICRO PLC DIN RAIL x 5-1/2” LG. SPACER ALLEN BRADLEY 1492-WG4 GROUNDED TERMINAL ALLEN BRADLEY 1492-EA35 TERMINAL ANCHOR ALLEN BRADLEY 1492-EB3 TERMINAL BARRIER ALLEN BRADLEY 1492-W4 TERMINAL BLOCK ALLEN BRADLEY 1492-CJ610 TERMINAL JUMPER ALLEN BRADLEY 1492-PP3 TERMINAL SEPARATOR ALLEN BRADLEY 800F-ALP LATCH ALLEN BRADLEY 800FX10V CONTACT BLOCK NO ALLEN BRADLEY 800F-ALP LATCH ALLEN BRADLEY 800F-X01 CONTACT BLOCK NC CONTROL PANEL CONTROL PANEL OVERLAY CONTROL ENCLOSURE ALLEN BRADLEY 800F-N3G LAMP MODULE GREEN ALLEN BRADLEY 800FX10V CONTACT BLOCK NO DIN RAIL x 7” LG.
QTY 1 1 1 1 1 2 1 22 1 1 3 4 1 1 1 1 1 1 1 1
SERVICE DOCUMENTS
37
SERVICE DOCUMENTS
ELECTRICAL PANEL ITEM
PART#
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
6850-025 11-960 11-887 11-741 11-969 11-055 11-938 11-696 11-619 11-992 11-1157 11-1124 11-1067 11-1154 11-1158 11-881 11-1121 11-145 11-936 11-1168 ***** *****
38
PART DESCRIPTION
QTY
ELECTRICAL PANEL ALLEN BRADLEY 1492-EA35 TERMINAL ANCHOR ALLEN BRADLEY 1492-W4 TERMINAL BLOCK ALLEN BRADLEY 1492-CJ610 TERMINAL JUMPER ALLEN BRADLEY 1492-EB3 TERMINAL BARRIER ILSCO AU-0 TERMINAL LUG SPRECHER & SCHUH LA7-63-1753 3 POLE SWITCH SPRECHER & SCHUH LA2-G2853 EXTENSION MODULE ACME TA-2-81212 TRANSFORMER ALLEN BRADLEY 100C09D10 CONTACTOR ALLEN BRADLEY 193ED1DB MTR PROTECTOR (208V/230V) ALLEN BRADLEY 193EA1EB MOTOR PROTECTOR (460V) ALLEN BRADLEY 1492-CB1G010 CIRCUIT BREAKER MINARIK AC212B-0.4 SPEED CONTROLLER (208V/230V) MINARIK AC214T-0.4 SPEED CONTROLLER (460V) ALLEN BRADLEY 1492-CB2H010 CIRCUIT BREAKER ALLEN BRADLEY 1492-CB3H100 CIRCUIT BREAKER IDEC RH2BU-12V RELAY IDEC SH2B-05 RELAY SOCKET AC TECH 844-110 EPM DIN RAIL x 4-1/2” LG. DIN RAIL x 7” LG.
1 2 14 1 1 1 1 3 1 1 1 1 2 1 1 1 1 1 1 1 1 1
SERVICE DOCUMENTS
39
SERVICE DOCUMENTS MAGNUM DOOR LOADER ELECTRICAL SCHEMATIC (208V/230V) ITEM
PART NO.
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
11-938 11-752 11-696 11-1121 11-992 11-1157 16-088 11-055 11-881 11-619 11-1154 11-1067 11-1558 11-1560 11-1568 15-167 15-168 11-1567 11-958 11-871 11-1694 11-1566 11-1567 11-933 11-1561 11-1148 11-1147 11-1116 15-048 11-957 11-1005 16-091 11-145 11-936 11-1169 11-1566 11-1426 11-1448
S&S LA7-63-1753 3 POLE SWITCH S & S LFS2-E-6-175I HANDLE ASSEMBLY S & S LA2-G2853 EXTENSION MODULE AB 1492-CB3H100 CIRCUIT BREAKER AB 100C09D10 CONTACTOR AB 193ED1DB MOTOR PROTECTOR 3.2-16A HYDRAULIC PUMP GRAINGER #4F685 ILSCO AU-0 TERMINAL LUG AB 1492-CB2H010 CIRCUIT BREAKER ACME TA-2-81212 TRANSFORMER MINARIK AC212B-0.4 SPEED CONTROLLER AB 1492-CB1G010 CIRCUIT BREAKER AB 800FP-MT44 E-STOP 40MM MUSHROOM, 22MM AB 800F-X01 CONTACT BLOCK N.C. AB 800F-N3G LED MODULE, GRN DAYTON MOTOR 2N916 WINSMITH GEAR BOX 3JH52 AB 800F-ALP LATCH, PLASTIC AB 42EF-E1EZB-F4 PHOTO EYE EMITTER AB 899D-F4AC-5 SENSOR CABLE AB 800FB-SB32 SWITCH, 3 POS, SPRING RTN,BLK AB 800F-X10 CONTACT BLOCK N.O. AB 800F-ALP LATCH, PLASTIC AB 60-2657 PHOTO EYE BRACKET AB 800FP-LF3 ILLUMINATED PUSH BUTTON AB 889D-R4AC-2 SENSOR CABLE AB 889D-R4AC-5 SENSOR CABLE AB 872C-DH4CP12-D4 PROXIMITY SENSOR N.C. DAYTON 6K233 BRAKE AB 42EF-R9-MPB-F4 PHOTO EYE RECEIVER AB 1761L16BWA 16 POINT MICRO PLC HYDRAULIC VALVE IDEC RH2BU-12V RELAY IDEC SH2B-05 RELAY SOCKET MULTICOMP P6KE12A DIODE AB 800FX10V CONTACT BLOCK NO AB 1492-WFB4 FUSE HOLDER BUSSMAN GMA250MA
40
QTY. 1 1 3 1 1 1 1 1 1 1 1 2 1 2 1 1 1 3 1 1 2 4 1 2 1 2 4 4 1 1 1 1 1 1 1 1 1 1
SERVICE DOCUMENTS
41
SERVICE DOCUMENTS MAGNUM DOOR LOADER ELECTRICAL SCHEMATIC (440V)
ITEM
PART NO.
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 36
11-938 11-752 11-696 11-1121 11-992 11-1124 16-088 11-055 11-881 11-619 11-1158 11-1067 11-1558 11-1560 11-1568 15-167 15-168 11-1567 11-958 11-871 11-1694 11-1566 11-1567 11-933 11-1561 11-1148 11-1147 11-1116 15-048 11-957 11-1005 16-091 11-145 11-936 11-1169 11-1566 11-1426 11-1448
S&S LA7-63-1753 3 POLE SWITCH 1 S & S LFS2-E-6-175I HANDLE ASSEMBLY 1 S & S LA2-G2853 EXTENSION MODULE 3 AB 1492-CB3H100 CIRCUIT BREAKER 1 AB 100C09D10 CONTACTOR 1 AB 193EA1EB MOTOR PROTECTOR 1.6-5.0A 1 HYDRAULIC PUMP GRAINGER #4F685 1 ILSCO AU-0 TERMINAL LUG 1 AB 1492-CB2H010 CIRCUIT BREAKER 1 ACME TA-2-81212 TRANSFORMER 1 MINARIK AC214T-0.4 SPEED CONTROLLER 1 AB 1492-CB1G010 CIRCUIT BREAKER 2 AB 800FP-MT44 E-STOP40MM MUSHROOM,22MM 1 AB 800F-X01 CONTACT BLOCK N.C. 2 800F-N3G LED MODULE, GRN 1 DAYTON MOTOR 2N916 1 WINSMITH GEAR BOX 3JH52 1 AB 800F-ALP LATCH, PLASTIC 3 AB 42EF-E1EZB-F4 PHOTO EYE EMITTER 1 AB 899D-F4AC-5 SENSOR CABLE 1 AB 800FP-SB32 SWITCH, 3 POS, SPG RTN,BLK 2 AB 800F-X10 CONTACT BLOCK N.O. 4 AB 800F-ALP LATCH, PLASTIC 1 AB 60-2657 PHOTO EYE BRACKET 2 AB 800FP-LF3 PUSH BUTTON,FLUSH,ILLUM,GRN 1 AB 889D-R4AC-2 SENSOR CABLE 1 AB 889D-R4AC-5 SENSOR CABLE 4 AB 872C-DH4CP12-D4 PROXIMITY SENSOR N.C. 4 DAYTON 6K233 BRAKE 1 AB 42EF-R9-MPB-F4 PHOTO EYE RECEIVER 1 AB 1761L16BWA 16 POINT MICRO PLC 1 HYDRAULIC VALVE 1 IDEC RH2BU-12V RELAY 1 IDEC SH2B-05 RELAY SOCKET 1 MULTICOMP P6KE12A DIODE 1 AB 800F-X10 CONTACT BLOCK, NO 1 AB 1492-WFB4 FUSE HOLDER 1 BUSSMAN GMA250MA 1
42
QTY.
SERVICE DOCUMENTS
43
SERVICE DOCUMENTS
HYDRAULIC SCHEMATIC ITEM
PART#
PART DESCRIPTION
1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
16-013 21-072 16-090 16-091 16-088 6850-126 16-105 6850-127 6850-132 16-111 6850-128 16-097 6850-125 6850-124 6850-123 16-108 16-096
PGL-25-3000S GAUGE PARKER 2202P-4-4 BRASS ELBOW BARNES 2620290 MANIFOLD ADAPTER DENISON A4D0132070302B1W0181 VALVE HYDRAULIC POWER SUPPLY HYDRAULIC TUBE #4 TUBE CLAMP (DBL) HYDRAULIC HOSE #1 MODIFIED “L” FITTING SWECO S-25-20-1-1/8-A HYDRAULIC CYLINDER HYDRAULIC HOSE #2 AEROQUIP 2033-6 TEE FITTING HYDRAULIC TUBE #3 HYDRAULIC TUBE #2 HYDRAULIC TUBE #1 AEROQUIP 206209-6-6 “L” FITTING AEROQUIP 2062-6-6 “L” FITTING
44
QTY 1 1 1 1 1 2 4 2 4 2 2 2 1 2 1 1 1
P R E -I N S T A L L A T I O N
APPENDIX A
45
P R E -I N S T A L L A T I O N
46
P R E -I N S T A L L A T I O N
47
WARRANTY
Phone: 800-824-6242
Web: www.norfield.com
Parts Replacement Policy The following will explain Norfield Industries policy for handling warranty claims. Our "Limited Warranty" is stated below for your reference. Our warranty covers the replacement of defective parts; however, the labor to replace the parts on the machine is not included. Upon notification of a warranty claim, Norfield will either refer the customer to a regional repair facility or replacement parts will be shipped from the factory. Parts shipped from the factory will be invoiced to the customer's account until the warranty claim is verified. To obtain verification, the defective parts must be returned to Norfield within thirty (30) days from the date of the claim for inspection. Before returning the defective parts, please contact Norfield to obtain a "Return Material Authorization Number". All parts manufactured by Norfield and found to be defective will be given appropriate credit. All parts not manufactured by Norfield are covered by their respective manufacturer's warranty and will be sent to the original manufacturer for credit. When, and if, credit is issued to Norfield, we will in turn issue credit to your account.
Limited Warranty Norfield warrants any and all such parts manufactured by them against defects in material or workmanship for a period of one-year from date of purchase. Norfield's liability under this warranty shall be limited to replacing free of charge, F.O.B. Chico, California, any parts proved to be defective within the period of the warranty. Norfield will not be responsible for transportation charges or consequential damages. Norfield will not in any case or under any circumstances be liable or responsible for any injuries to persons or property suffered as a result of the use or operation of the machine, or losses or costs resulting from any period of non-operation for any reason. Parts which are claimed to be defective, but show tangible evidence of abuse or negligence will not be replace on a no-charge basis. Norfield reserves the right, at its own discretion without notice and without making similar changes in machinery previously manufactured, to make changes in material, design, finish and/or specifications. Any changes, alteration or installation of additional equipment to this machine without first obtaining written consent from Norfield may void this warranty. Determination of the effect of any alteration on this warranty is left to the discretion of Norfield. Norfield makes no written or implied warranty with respect to electrical equipment, including motors or other purchased components used in the manufacture of the machine. All such parts are covered by their respective manufacturer's warranty. We do endeavor, at all times, to purchase only those components manufactured by responsible manufacturers which we have found to be reputable in their handling or warranties. Norfield expressly disclaim any warranty, expressed or implied, other than those which are expressly made in this limited warranty.
48