Manual - V E S T I L D O
Contents
1. Inner Seal Cylinder Head al ie iy r za nji Step 10 Replace the seals then perform steps 1 through 9 in reverse order to reassemble the cylinder and to refasten it to the pallet truck Copyright 2013 Vestil Manufacturing Corp Page 31 of 51 Rev 0213 EPT Manual doc Instructions for Changing the Throttle Assembly Estimated time 30 minutes Necessary tools 5mm Allen wrench Philips blade screwdriver Small Regular flat blade screwdriver AWARNING Only trained authorized personnel should perform maintenance on this equipment Lead acid batteries present hazards to the person s working on with or in the vicinity of them To minimize the risk of serious personal injury read every one of the instructions and DO NOT proceed with maintenance unless you understand each of them e Lock out all potential energy sources i e battery before attempting this installation according to OSHA lockout tagout procedures 29 CFR 1910 147 turn off the unit and remove the key DO NOT work on with or in the vicinity of the battery UNLESS you are wearing personal protective equipment particularly a face shield Batteries contain sulfuric acid and produce explosive gases A battery explosion could result in loss of eyesight or serious burns DO NOT smoke near the battery or expose the battery to sparks or flames Charge batteries ONLY in clean dry and well ventilated locations DO NOT lay tools or anything metallic on top of a batte2. Label 206 Label 220 ISO 32 150 SUS HYDRAULIC OIL OR NON SYNTHETIC TRANSMISSION FLUID ACEITE HIDRAULICO O LIQUIDOS DETRANSMISION NO SINTETICOS KEEP CLEAR MANTENGASE SETENIR A HUILE OU LIQUIDE HYDRAULIQUE NON SYNTH TIQUE Ba WHEN IN USE ALEJADO CUANDO SE DISTANCE LORS DU VESTIL MANUFACTURING CORPORATION Phone 260 6657586 wrew vestiloom ESTA OPERAN DO FONCTIONN EM ENT VESTIL MANUFACTURING CORPORATION Angola Indiana USA Phone 280 645 7588 sales valil come wee vas com eyo Rev CDA Label 527 Only trainged authorized persons should operate this device Improper operation might result in serious personal injuries sustained by the truck operator and or bystanders Operators must observe the following satety enhancing practices BEFORE operating inspect mast carriage forks deck cable chain wheels and brakes for damage DO NOT use if damaged ALWAYS walk travel path before using truck to identify hazards Y DO NOT contact electrical lines or overhead objects with device or load Y DO NOT travel up down inclines if an alternate route is available Y DO NOT travel over debris ONLY travel with forks deck in lowest position appropriate for conditions ALWAYS center and evenly distribute loads on forks deck ALWAYS secure load to forks deck ONLY drive or operate truck functions from operator position DO NOT exceed maximum rated load capacity DO NOT allow people to ride on device DO NOT
3. See p 25 Batteries and Charger Troubleshooting If the unit does not operate 1 Charge the unit overnight 2 Check all of the wiring connections to make sure they re both mechanically and electrically sound Give particular attention to the connections with the battery terminals and to the motor A fully charged lead acid battery in nominal condition at room temperature should store 12 65 Volts When battery voltage drops to 11 9 Volts the battery is considered fully discharged If you need to check the voltage turn off the charger and then wait at least 1 2 hour before checking the baitery s voltage If the charger fails to charge the batteries check the output fuse on the bottom of the charger Verify the fuse is good with an onmmeter or by visual inspection The output fuse is 10Amp 250 Volt GDA 10A If the fuse is good plug the charger in and check the lights next to the fuse Red Power On Yellow Charging Green Full Charge Green Flashing Batteries are not connected to charger Verify that the on off toggle switch is in the ON position With the charger connected to the battery read the output voltage of the battery charger Depending on the battery voltage the reading should be within the range of 26V to 29V DC Copyright 2013 Vestil Manufacturing Corp Page 46 of 51 Rev 0213 EPT Manual doc Instructions for Adding Quencharcs Estimated time 15 minutes Tools Required Regular flat bla
4. charger s AC cord into an 115VAC power source AC charger cord e EPT 45 s the AC cord is tucked inside the battery box on the right side circled in the second photo below Plug this end into a standard 115 volt outlet and charge batteries for at least 8 hours The charger will not overcharge the batteries so leaving the unit plugged in overnight or over a weekend is ok However the charger should only be used indoors When the charge cycle completes disconnect the AC cord from the outlet and reinstall the tray EP T 30 s Storing the EPT Unload the lifter then return it to the designated storage location NOTICE A proper storage location is one where the unused lifter will not 1 Interfere with or obstruct traffic or other operations 2 Be exposed to corrosive chemicals or water either as a consequence of weather or of worksite conditions Copyright 2013 Vestil Manufacturing Corp Page 22 of 51 Rev 0213 EPT Manual doc TROUBLESHOOTING AWARNING Before performing any corrective action described in the following table block the drive wheel off of the ground Contact Vestil for problems at time of installation or for any problems not addressed below Problem Unit does not respond to movement controls does not move either forward or in reverse Unit will not charge Unit will not go forward reverse works belly switch just kills unit does not go forward and faults out Unit will not
5. horquillas platatorma cuando este elevada con carga o sin carga NO deje el equipo desantendido HASTA que este completamente cargado Y descargado NO modifique el equipo de ninguna manera VESTIL MANUFACTURING CORPORATION Phone 260 665 7586 www vestil com MATIERES CORROSIVES Label 208 T 8 S Equipment Company Ph 219 665 9521 Fax 21 91665 1339 New area code 260 in 2002 295 Copyright 2013 Vestil Manufacturing Corp Page 51 of 51
6. in the unpacking process to clear the area 3 Lift the EPT off of the pallet using either a hoist or a forklift with a capacity of at least 2 000 pounds Always apply the proper hoisting procedures or forklift operation practices you learned during your training program To remove the EPT from the shipping pallet using a hoist EPT 2 45 models Remove the battery box a Disconnect the power cable from the socket on top of the EPT housing circled in photo 1 below Unfasten the box from the EPT frame by unscrewing the bolt in the center of the flange the bolt is shown in photograph 2 next page Copyright 2013 Vestil Manufacturing Corp Page 3 of 51 Rev 0213 EPT Manual doc b Connect the sling to both hook points on the EPT 1 on each side the picture below only shows the hook point on the right side then lift the unit no more than 6 8 inches above the pallet The EPT will tilt towards the control yoke Additionally it may swing from side to side once free of the pallet if you did not properly position the hoist above the center of the sling Stabilize the suspended truck with one hand and stand safely to the side while operating the hoist All Models Securely connect the sling hooks to the hook points see photographs below lift the EPT a few inches off of the pallet direct the EPT away from the pallet and then lower it until it is entirely supported by the ground Hook point EPT 45 To lift the EPT
7. lift loads over people DO NOT permit people to walk beneath the forks deck when raised loaded or unloaded DO NOT leave unattended UNTIL fully lowered AND unloaded DO NOT modify device in any way Solo personas entrenadas y aulorizadas deben operar este equipo La operaci n inadecuada podria resultar en da os serios al operario del cami n y o a los transeuntes Los operarios deben observar y seguir las siguientes pr cticas de seguridad ANTES de usar inspeccione el m stil el equipo las horguillas plataforma cable cadena ruedas y frenos por dados NO use si se observan da os SIEMPRE camine el trayecto de viaje antes de usar el cam n para identificar riesgos Y NO toque las lineas el ctricas u objectos altos con el dispositivo o la carga NO viaje en inclinaciones de subida y bajada si hay otra ruta alternativa Y NO viaje sobre desechos Label 4295 SOLO viaje con las horguillas platatorma en la posici n de descenso m s apropiada DANGER gt SIEMPRE centre y distribuya las cargas uniformemente en las horquillas plataforma CORROSIVE MATERIAL SIEMPRE asegure la carga a las horquillas plataforma lt PELIGRO SOLO conduzca u opere las functiones del cami n desde la posici n del operario MATERIAL CORROSIVO NO exceda la capacidad m xima tasada de carga NO permita que la gente viage en el equipo NO eleve las cargas sobre la gente NO permita que la gente camine debajo de las
8. may need to lift the edge of the cover over the tabs with a flat blade screwdriver Push the larger end of the spring into the pocket and position the top of the spring around the nub Photos 12 and 15 Copyright 2013 Vestil Manufacturing Corp Page 34 of 51 Rev 0213 EPT Manual doc Step 8 Install the bushings onto the throttle wheel shaft Notice that the bushing must be installed as shown the drawing to the right of Photo 16 below This end onto wheel shaft Step 10 To fasten the tiller assembly to the handle first insert the assembly aligning tabs circled in Photo 19 NOTE Tabs underneath the switch cover Photo 19 into the slots in the handle tongue shown in photos 20 and 21 and identified with arrows in the magnified view An Exploded Parts Diagram appears on the next page 19 NOTE In order to show the aligning tabs the switch cover does not appear in this picture Magnified view of Handle Tongue point to aligning tab slots Copyright 2013 Vestil Manufacturing Corp Page 35 of 51 Rev 0213 EPT Manual doc Fic 2 EXPLODED PARTS VIEW OF BELLY SWITCH He Me ae VIEW OF BELLY SWITCH MECHANISM AS Step 11 Press and hold the switch cover then slide the assembly down the handle tongue The tab slot of the switch cover must wrap around the tabs on both sides of the handle Tab slot na the switch ki cover Step 12 Make sure that the wires tuck securely inside the tiller han
9. operator of an EPT equipped with a properly installed rider platform EPT DO NOT attempt to lift an unevenly distributed load Always center and evenly distribute the load on the forks DO NOT operate the EPT on surfaces ramps or grades angled more than 4 degrees DO NOT leave the EPT unattended while it supports a load Always fully lower the forks and then completely disengage the skid or pallet Complete the parking storing procedure described in Storing the EPT on p 22 DO NOT modify the pallet truck without first receiving written authorization from Vestil Unauthorized modifications may make the EPT unsafe to use NOTICE To maximize the service life of the EPT and to prevent damage e Always store the machine in a secure dry location where it will not interfere with traffic or other activities e Maintain the product as suggested in Maintenance amp Inspections on p 49 50 REMOVING THE PALLET TRUCK FROM THE SHIPPING PALLET The pallet truck is shipped in ready to use condition However it must first be removed from the shipping pallet before it can be used for the first time AWARNING DO NOT attempt to drive the pallet truck off of the pallet it might tip over and cause bodily injuries or property damage To minimize the risk of injury to yourself or other persons perform the following steps to remove the machine from the shipping pallet 1 Remove all packing material 2 Inform all personnel not participating
10. studs 8 10mm Nuts go CEVI KN LEVA TVE k y Ae ii ili Step 6 Once the old battery charger is removed the replacement charger can be installed The new charger is attached to a mounting bracket blue in the photograph below so that it can install onto the 4 mounting studs Install the new charger with the pigtail electrical cord facing downwards and the LED s facing upwards EJ k pl 4 i k i b i i Ja AAA Kai a FUE Step 7 Secure the new charger in position by winding the nuts back onto the mounting studs Feed the wires labeled POS and NEG into the battery compartment following the same path noted in Step 4 Copyright 2013 Vestil Manufacturing Corp Page 45 of 51 Rev 0213 EPT Manual doc Step 8 Connect the POS wire to the red positive post then connect the NEG wire to the negative terminal Reconnect the positive cable to the positive post and fasten it with the corresponding nut On the other side reconnect the negative cable to the negative post and then fasten the connection with the post nut BLACK Negative Terminal Connection to negative post shown below RED Positive Terminal Step 9 Plug this end into a standard 115 volt outlet and charge batteries for at least 8 hours The charger will not overcharge the batteries so leaving the unit plugged in overnight or over a weekend is ok However the charger should only be used indoors
11. 4104 EPT 30 4104 Flow Control Valve 5LMRN 4105 EPT 30 4105 Solenoid Valve 4106 EPT 30 4106 CheckValve 4107 EPT 30 4107 Bolt 4108 EPT 30 4108 90 x 3 1 O Ring gt Z o S 4109 EPT 30 4109 Pick Up Tube 4110 EPT 30 4110 Breather 4111 EPT 30 4111 Hydraulic Fluid Reservoir 4112 EPT 30 4112 Intake Strainer S 4113 EPT 30 4113 Pump Retaining Bolt O Z o Z o 4114 EPT 30 4114 Hydraulic Gear Pump o Z o 4115 EPT 30 4115 Return Tube 4116 EPT 30 4116 Relief Valve O Z o Z S Copyright 2013 Vestil Manufacturing Corp Page 15 of 51 Rev 0213 EPT Manual doc FIG 7 EPT 45 MAIN HOUSINGS AND SUPPORTING STRUCTURE item No PartNo 1001 1001 1002 1002 EPT 45 1013 2 Complete Stabilizing Wheel Assembly EPT 45 1014 Wheel Axle 1014 Item No PartNo Description EPT CORD Battery ChargerCord__ Copyright 2013 Vestil Manufacturing Corp Page 16 of 51 Rev 0213 EPT Manual doc FIG 9 EPT 45 CYLINDER AND FUSE PANEL 3200 3007 3300 3008 3009 Item No PartNo Description ItemNo PartNo Description Copyright 2013 Vestil Manufacturing Corp Page 17 of 51 Rev 0213 EPT Manual doc FIG 10 EPT 45 FORK AND CARRIAGE ASSEMBLIES tem No PartNo Description HemNo PartNo Description EPT 45 2004 Roll Pin Roll Pin 2014 EPT 45 2014 Clevis Lock Nu
12. If the wheels stick or grind when rotated contact Vestil to request replacement bushings za a s A mr W ve j JN y X 1 MORATA v A xd j OS smo 4 i u ai z 1 gt i i Copyright 2013 Vestil Manufacturing Corp Page 33 of 51 Rev 0213 EPT Manual doc Step 5 The red belly switch cover connects to the throttle assembly via a tab on each side one of which is circled in Photo 9 To remove the switch cover lift an edge with a flat blade screwdriver then push the cover over the tab Next disengage the tab on the other side You should now be able to separate the cover from the rest of the assembly kan Dir T RA aii Step 6 A spring rests in a seat molded into the inner surface of the switch cover see Photo 11 The top of the spring fits over a molded nub see Photo 12 Confirm that both solder joints are intact and that the two wires green and pink in Photo 13 are securely attached to the switch as shown below Also verify that the belly switch actuator moves freely between the actuated position pressed and the inactive position released The switch activator should click as it moves between positions lf the switch is stuck or if you notice any other broken or missing components contact Vestil to discuss replacement options Solder Connections Step 7 To reconstruct the throttle assembly first press the switch cover until it snaps into place over the tabs see Photo 14 You
13. Rev 0213 EPT Manual doc VESTIL MANUFACTURING CORP 2999 North Wayne Street P O Box 507 Angola IN 46703 Telephone 260 665 7586 or Toll Free 800 348 0868 Fax 260 665 1339 www vestilmfg com e mail sales vesiil com EPT SERIES ELECTRIC PALLET TRUCKS OPERATION AND MAINTENANCE MANUAL Receiving instructions After delivery IMMEDIATELY remove the packaging from the product in a manner that preserves the packaging and maintains the orientation of the product in the packaging then inspect the product closely to determine whether it sustained damage during transport If damage is discovered during the inspection immediately record a complete description of the damage on the bill of lading If the product is undamaged discard the packaging NOTES 1 Compliance with laws regulations codes and non voluntary standards enforced in the location where the product is used is exclusively the responsibility of the owner end user 2 VESTIL is not liable for any injury or property damage that occurs as a consequence of failing to apply either a Instructions in this manual or b Information provided on labels affixed to the product Neither is Vestil responsible for any consequential damages sustained as a result of failing to exercise sound judgment while assembling installing using or maintaining this product TABLE OF CONTENTS PAGE TABLE OF FIGURES Safety Principles Fig 1A EPT Main Body Components Product Introduc
14. Seal Ring 4304 EPT 30 4304 O Ring 4305 EPT 30 4305 O Ring 4401 EPT 30 4401 4402 EPT 30 4402 Hydraulic Hose 4403 EPT 30 4403 4300 EPT 30 4300 Seal Kit EPT 30 amp 45 Copyright 2013 Vestil Manufacturing Corp Page 7 of 51 Rev 0213 EPT Manual doc FIG 3 EPT 30 MODELS DRIVE WHEEL ASSEMBLY ltem No Part No Description ltem No Part No Description Not EPT 30 45 DBA Drive Brake Assembl 20 m sa ne PA 3300 EPT 30 DWA Complete Drive Wheel 3016 EPT 30 3016 Key Assembly includes Motor 3001 EPT 30 3001 24VDC 700W Drive Motor 3017 EPT 30 3017 Pinion Gear Bearing 3002 EPT 30 3002 Woodruf Key 3018 EPT 30 3018 Cap 3003 EPT 30 3003 Motor Adaptor Ring 3019 EPT 30 3019 Cap Screw 3004 EPT 30 3004 5x 16 Dowel Pin 3020 EPT 30 3020 M6 x 15 Cap Screw 3005 EPT 30 3005 M6 x 15 Cap Screw 3021 EPT 30 3021 Motor Retainer Cap Screw 3006 EPT 30 3006 6mm Washer 3022 EPT 30 3022 Drive Gear Drive Wheel Wheel 3024 EPT 30 3024 Motor Shaft Pilot Bearing EPT 30 MTR BLT M6 1 0 x 185mm Motor Bolt _ Copyright 2013 Vestil Manufacturing Corp Page 8 of 51 Rev 0213 EPT Manual doc FIG 4A EPT 30 MODELS FORK AND CARRIAGE 1002 4003 TURI ms 1019 pe aii Item No Part No Description Item No Part No Description 1001 EPT 30 1001 Fork Assembly 1012 EPT 30 1012 2 Push Rod Pin H
15. al items like rings bracelets necklaces and watches BEFORE beginning to work on the battery The battery can produce energy sufficient to weld jewelry to metal underlying skin could be severely burned Keep fresh water and soap nearby in case battery acid contacts skin clothing or eyes Immediately rinse any skin that has been contacted by acid If acid gets in your eyes rinse them thoroughly with eye wash After rinsing the affected area notify your supervisor about the incident DO NOT expose the unit or the charger to rain or other adverse conditions ALWAYS return the unit to its designated storage location when you finish using it The designated storage location should offer protection from the elements and should not interfere with or obstruct traffic Replace defective cords or wires immediately Routinely check the water level in the battery Make sure the battery charger is unplugged from the 115V source BEFORE driving the unit Operating the pallet truck when battery voltage is low can cause premature motor contact failure Turn off power to the pallet truck and remove the key Purpose To repair a leaking cylinder or to replace a damaged cylinder with a new cylinder Step 1 Remove the black plastic cover by lifting it as shown below then disconnect the black battery cables from the negative post with 13mm wrench negative terminal identified with a white arrow in Photol below Next disconnect the red cables from the positive te
16. an produce energy sufficient to weld jewelry to metal underlying skin could be severely burned Keep fresh water and soap nearby in case battery acid contacts skin clothing or eyes Immediately rinse any skin that has been contacted by acid If acid gets in your eyes rinse them thoroughly with eye wash After rinsing the affected area notify your supervisor about the incident DO NOT expose the unit or the charger to rain or other adverse conditions ALWAYS return the unit to its designated storage location when you finish using it The designated storage location should offer protection from the elements and should not interfere with or obstruct traffic Replace defective cords or wires immediately Routinely check the water level in the battery Make sure the battery charger is unplugged from the 115V source BEFORE driving the unit Operating the pallet truck when battery voltage is low can cause premature motor contact failure Turn off power to the pallet truck and remove the key Purpose To repair or replace a malfunctioning Forward Reverse Contactor Step 1 Remove the Main Body Housing by unfastening the two 2 screws on either side of the housing as shown in photo 1 then remove the yellow cover With the cover removed the electrical components si Motor Controller are visible as shown in the second photograph to the right Molex Connector Step 2 Locate the Forward Reverse Contactor FRC pointed to in phot
17. ded screw driver PURPOSE lf the pallet truck operates normally but stops running when the horn is activated then devices that suppress electrical noise called Quencharcs should be added Each electrical coil for example the horn raise lower buttons generates noise which interferes with normal motor operation AWARNING Only qualified personnel should work on this equipment READ ALL INSTRUCTIONS BEFORE PROCEEDING To minimize the risk of serious personal injury read every one of the instructions and DO NOT proceed with maintenance unless you understand each of them Lock out all potential energy sources before attempting this installation according to OSHA lockout tagout procedures 29 CFR 1910 147 turn off the unit and remove the key DO NOT work on with or in the vicinity of the battery UNLESS you are wearing personal protective equipment particularly a face shield Batteries contain sulfuric acid and produce explosive gases A battery explosion could result in loss of eyesight or serious burns DO NOT smoke near the battery or expose the battery to sparks or flames Charge batteries ONLY in clean dry and well ventilated locations DO NOT lay tools or anything metallic on top of a battery Remove personal items like rings bracelets necklaces and watches BEFORE beginning to work on the battery The battery can produce energy sufficient to weld jewelry to metal any underlying skin could be severely burned Keep fresh water a
18. demanding standards for quality safety and durability Vestil Manufacturing Corp recognizes the critical importance of workplace safety Each person who might participate in operation or maintenance of the product must read this manual Read the entire manual and fully understand the directions BEFORE using or performing maintenance on the cart If you do not understand an instruction contact Vestil for clarification Failure to adhere to the directions in this manual might lead to serious personal injury or even death Vestil is not liable for any injury or property damage that occurs as a consequence of failing to apply the safe operation and maintenance procedures explained in this manual or that appear on labels affixed to the product Furthermore failure to exercise good judgment and common sense may result in property damage serious personal injury or death and also are not the responsibility of Vestil This manual applies the hazard identification methods suggested for instruction manuals by the American National Standards Institute ANSI In accordance with ANSI guidelines for hazard identification language this manual classifies personal injury risks and situations that could lead to property damage with SIGNAL WORDS These signal words announce an associated safety message The reader must understand that the signal word chosen indicates the seriousness of that hazard according to the following convention AA DANGER Identifies a hazardo
19. dle then press the assembly and handle together Do not crush wires between the two parts as they come together Fasten the assembly to the handle with the three 5mm Allen head bolts removed in Step 1 Copyright 2013 Vestil Manufacturing Corp Page 36 of 51 Rev 0213 EPT Manual doc Instructions for Changing the Motor Controller Estimated time reguired 30 minutes Tools Required 2x 14mm wrench open face Philips head screwdriver 8mm wrench or adjustable crescent wrench AWARNING Only trained authorized personnel should perform maintenance on this equipment Lead acid batteries present hazards to the person s working on with or in the vicinity of them To minimize the risk of serious personal injury read every one of the instructions and DO NOT proceed with maintenance unless you understand each of them e Lock out all potential energy sources before attempting this installation according to OSHA lockout tagout procedures 29 CFR 1910 147 turn off the unit and remove the key DO NOT work on with or in the vicinity of the battery UNLESS you are wearing personal protective equipment particularly a face shield Batteries contain sulfuric acid and produce explosive gases A battery explosion could result in loss of eyesight or serious burns DO NOT smoke near the battery or expose the battery to sparks or flames Charge batteries ONLY in clean dry and well ventilated locations DO NOT lay tools or anything metallic on top of a bat
20. e forks should immediately stop moving Reset the E stop 5 Drive the EPT in reverse at low speed and while driving press the belly switch The machine should immediately move in the opposite direction for 3 seconds and then stop Reset the control yoke 6 Drive the EPT in both the forward and reverse directions for a few seconds 7 Testthe horn see Fig 1 p 9 8 Verify that the control yoke automatically returns to the vertical position when released see Operation Step 3 on this page JAWARNING Only use the pallet truck if all mechanisms function normally If a malfunctions occurred park the stacker in a safe location tag it Out of Service and then report the malfunctions to maintenance personnel Operation Step 1 Turn on the power See Power callout box on p 9 Step 2 Pull the red E Stop button up to disengage the service brake Step 3 Tilt the control yoke to the drive position 2 which is shown in the photograph to the right 1 lt Neutral NOTE The EPT uses magnetic brakes which engage when the handle is in or near either of the neutral positions 1 and 3 gi 2 Drive The yoke is designed to automatically return to neutral position 1 after the handle is released therefore the brakes will engage automatically 3 Neutral as well Step 4 Rotate the movement control wheel in the appropriate direction to move either forward or in reverse See Movement Controls text box and the co
21. e pin see Photo 9 and collect the bushings If the pin requires encouragement to move use a flat punch and hammer uu vaj Remove Snap Ring Bushings Upper retaining bracket Copyright 2013 Vestil Manufacturing Corp Page 29 of 51 Rev 0213 EPT Manual doc Step 5 The cylinder is now completely disconnected from the EPT frame remove the disconnected cylinder To install a new cylinder perform steps 1 through 4 in reverse order with the replacement cylinder To repair the cylinder follow the remaining steps Step 6 Separate the piston rod from the barrel To loosen the rod immobilize the cylinder in a vise and use a flat punch and a hammer to tap the cylinder head in a counterclockwise direction see Photos 10 8 11 Once the cylinder head loosens you should be able to rotate it by hand to withdraw it from the barrel see Photo 12 cua Retaining pin opening in piston rod Step 7 With a small screwdriver remove the Seal and the O Ring from the piston both of which are identified in Photo 13 Copyright 2013 Vestil Manufacturing Corp Page 30 of 51 Rev 0213 EPT Manual doc Step 8 Remove the bushings from the top of the cylinder rod see Photo 16 Note In the photograph one bushing has already been removed Slide the cylinder head off of the piston rod i PISTON ROG Step 9 Remove the internal seal photo 18 4 19 Photo 20 shows a fully disassembled cylinder TER
22. e tips of the forks 3 Review the safety guidelines on p 3 before each use e Apply proper loading technigues p 8 e Ask a coworker to help you load and unload the lifter 4 Operator means a person who is trained and authorized to use a manually propelled high lift device ONLY persons who have successfully completed a training program like the courses outlined on p 4 5 of B56 10 2006 should operate the HYRDA Lift Safe operation requires operators to e Develop safe working habits and a process for identifying hazards that exist or might be encountered during operation e Conduct thorough inspections of the usage area to identify unusual hazardous conditions Walk the path you will use to transport loads with the lifter beforehand Do not use the HYDRA lift if the floor or other supporting surface is uneven or damaged or cannot support the combined weight of the operator the lifter and the load e Make sure that the lifter has been inspected as recommended in the Inspections 8 Maintenance section of this manual p 9 Use the lifter ONLY IF it is deemed safe to use by designated inspection personnel To engage a pallet skid drive the unit to a position in front of the intended load Before engaging the load confirm that the forks will fit within the fork pockets Fully lower the forks to allow them to slide into the fork pockets of the skid Confirm that the net weight of the load plus the skid do not exceed the capacity o
23. e wiring back towards the tiller head and check voltage on each side of connectors Continue this until bad connection is found If the connections are all good and there is no voltage coming out of throttle assembly then the throttle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground If there is still no output voltage for pin 11 replace throttle assembly Reference 15 124 029 Locate Pin 13 on Molex connector at the motor controller Try to drive the unit in reverse and hit the belly switch there should be 24 volts at this pin If there is voltage and the unit does not move the motor controller may be bad If there is no voltage trace the wiring back towards the tiller head and check voltage or continuity on each side of connectors Continue this until bad connection is found If the connections are all good and there is no voltage then the switch may be bad Verify there is 24 volts going into the switch and check to see if it is coming back out of the switch when depressed If there is no output voltage replace the switch The belly switch is stuck on Tap the orange belly switch assembly to see if the switch can be freed If this doesn t work disassemble the tiller head by removing 3 screws from bottom Slightly loosen up the two screws that hold the switch in place this may free the switch If it is still stuck contact the factory for a replacement
24. embers is present DO NOT use the MHT 49 estil for instructions Step 3 Remove any dirt or other matter from the forks and other surfaces Step 4 Perform all other necessary adjustments and or repairs but DO NOT modify the truck AWARNING The reader should understand the significant difference between necessary adjustments and repairs and modifications An adjustment is a simple correction that restores the MHT to normal operating condition such as tightening loose fasteners or removing dirt or other debris from the surface a repair refers to replacing worn parts with new or replacement parts gt DO NOT use the truck if adjustments and or repairs are incomplete Return it to service ONLY after finishing all necessary repairs and adjustments A modification is a change that alters the MHT from normal operating condition like bending the structural members or removing a part or several parts NEVER modify the unit without the express written approval of Vestil Modifications may render the product unsafe to use Step 5 Make a dated record of the repairs adjustments and or replacements made Copyright 2013 Vestil Manufacturing Corp Page 50 of 51 Rev 0213 EPT Manual doc MARKINGS Only use the lifter if ALL labels are readable and undamaged Contact Vestil for replacement labels if necessary and DO NOT use the pallet truck until all replacement labels are affixed to the device Proper label placement is shown below
25. er s are properly filled the oil level should be 1 1 2 to 2 inches below the reservoir fill hole Return the forks to the fully lowered position 2 Damage to or excessive wear of a Pivot points b Hydraulic hoses c Electric wires d Retaining rings for the rollers drive wheels and all pivot points e Bearings Wobbliness or looseness of rollers and or drive wheels Proper function of the hand or foot actuated mechanisms Proper battery water level Unusual noise or abnormal movement during operation Legibility and undamaged condition of all product labels LOA o Maintenance the end user must implement a scheduled maintenance program to ensure the proper function and safety of the lifter Pages 12 13 of ANSI ITSDF standard B56 1 2005 describe some recommended maintenance procedures and the following steps should be utilized in conjunction with those recommendations AWARNING The user is responsible for training persons to work on the MHT Work on refers to operating loading cleaning servicing maintaining or repairing the product ONLY trained authorized maintenance personnel or independent contractors chosen by the user should perform inspection maintenance or repair work Copyright 2013 Vestil Manufacturing Corp Page 49 of 51 Rev 0213 EPT Manual doc Step 1 Tag the MHT Out of Service Step 2 Complete an every use and a monthly inspection If deformity corrosion rusting or excessive wear of structural m
26. f the EPT Continue forward until either the skid rests against the back vertical upright portion or the forks are as far underneath the skid as they can be When the skid contacts the back of the forks put the yoke in a neutral position to stop forward motion Wait until the stacker stops completely and then lift the skid off of the ground supporting surface by pressing one of the two fork raising buttons See Fig 1 on p 9 Proper Transport Configuration To avoid unintended contact between the skid pallet and surface features transport the load to the desired location with the forks elevated To release the load stop in the desired location fully lower the forks and then slowly drive the EPT forward until the forks are no longer beneath the skid pallet Batteries and Charger s Disconnect battery cable DANGER The charger allows electrical current to flow from Mi EPT 45 s a wall socket through the batteries While operating the charger contact with water rain snow etc could result in electric shock or electrocution Do NOT recharge the batteries if the EPT is outdoors Only recharge the batteries indoors Turn off your EPT e EPT 45 s Push E stop to turn off the EPT e EPT 30 s Press the E stop button and turn the key switch to the off position Press E stop Disconnect the battery cable EPT 45 s Copyright 2013 Vestil Manufacturing Corp Page 21 of 51 Rev 0213 EPT Manual doc Plug the
27. g the charger before moving the equipment Failure to do so could cause damage to cords receptacles and other equipment The following procedure will explain how to replace the existing charger with a Soneil charger Step 1 Remove the screws 2 shown below then remove the yellow cover The battery charger is located on the left side of the unit Copyright 2013 Vestil Manufacturing Corp Page 43 of 51 Rev 0213 EPT Manual doc Step 2 Remove the black plastic cover by lifting it as shown below then remove battery wiring from the negative post with 13mm wrench negative terminal identified with a white arrow There will be one large black wire and one smaller black wire The smaller black wire connects to the battery charger Step 3 Follow the wires that connect the charger to the batteries from the bottom of the charger circled in the photograph below to the ends of each wire which connect to the positive and negative battery terminals Once you understand how the wires get from the charger to the battery compartment carefully pull the two battery charger wires out of the battery compariment Copyright 2013 Vestil Manufacturing Corp Page 44 of 51 Rev 0213 EPT Manual doc Step 5 Four mounting studs project through the base of the charger to secure it in place Remove the nuts with a deep well 10mm socket or small 10 mm wrench then pull the charger off of the retaining bolts E Ae Z Mounting
28. go reverse belly switch works i e when the handle is in operating range and rotating throttle in reverse and the belly switch is hit the unit moves forward and times out Possible cause s Battery voltage low battery charge lower than 17 Volts Problem with motor controller check for LED flash code on side of controller Fuse blown Charger malfunction Bad batteries Broken wire or loose connection Contactor bad motor controller bad Broken wire or loose connection contactor bad motor controller bad Copyright 2013 Vestil Manufacturing Corp Action Charge batteries Bad batteries load test batteries and replace if necessary Consult diagnostics page Table 2 Troubleshooting Chart or Refer to 15 124 029 electrical drawing for proper voltage readings and operation or Consult Factory Remove back shroud and check fuses 3 fuses Verify output voltage on charger it should be 26 to 30 volts dc connected to batteries and plugged into 115vac Load test the batteries Locate Pin 2 on Molex connector at motor controller Trace wiring to contactor and verify connection While attempting to go forward tap on the contactor with a screwdriver handle If the unit moves forward then the contactor may need replaced or plungers lubed with a light oil Remove both wires from each side of the contactor and check with ohm meter resistance should be approximately 38 ohms If it s open or zer
29. ll use it AWARNING Improper use might result in serious personal injuries to the operator and or bystanders To minimize the possibility of injury ALL persons who might operate perform maintenance on or service the EPT must read understand and apply the following instructions e DO NOT operate the EPT unless and until you are 1 Trained to use the machine AND 2 Certified as a trained operator by your employer in accordance with U S OSHA regulations 29 CFR 1910 178 and any standards incorporated by reference e g ANSI ITSDF B56 1 2005 DO NOT attempt to lift or transport loads that exceed the rated capacity Inspect the machine before each use DO NOT use the EPT unless it is in normal condition Normal operating condition exists if the EPT passes the inspection and functions tests described under the heading Inspect the EPT amp Perform a Functions Tests on p 20 DO NOT use the unit until you read and understand the entire owner s manual Review the manual before each use AND before performing maintenance on the device DO NOT use the EPT if the load supporting elements sustain any structural damage Structural elements include but are not limited to the forks carriage and wheels If structural damage is present immediately tag the unit Out of Service and inform maintenance personnel of the problem DO NOT use the EPT if it makes unusual noises during operation DO NOT allow people to ride on the pallet truck Only the
30. ly EPT 30 s feature a removable red key like power disconnect switch shown at right Turn the switch clockwise to turn on the power Turn off power by turning the switch counterclockwise EPT 45 s are activated simply by pulling the red E stop button up Turn off power by pressing the button down Copyright 2013 Vestil Manufacturing Corp Press button to raise forks EPT Manual doc Function Controls Gauges and Safety Features Handles Raise Forks Belly Switch Emergency Stop Movement Controllers Butterfly Switches MOVEMENT CONTROLLERS To drive the EPT in the forward direction rotate the movement control forward with your thumbs as indicated by the solid arrow superimposed on photograph below To move the pallet truck in reverse rotate the control wheel in the opposite direction which is shown with a dashed arrow Reverse Forward The degree of rotation determines the speed of movement so the farther you press the wheel in either direction the faster the EPT will travel up to a maximum speed of 3mph when unloaded or 2 6mph when loaded to capacity Simply by releasing the movement control the EPT will decelerate to a complete stop Page 19 of 51 Rev 0213 EPT Manual doc USE INSTRUCTIONS 1 Determine Condition of Floor or Other Supporting Surface Inspect the floor or other surface for example a parking lot dock board or dock leveler prior to use The supporting
31. n to the belly switch mechanism Step 1 Open the throttle assembly by removing the three 5mm Allen head bolts from the underside of the handle photo 1 then lift the base of the assembly away from the handle photo 2 Throttle assembly 5mm Allen screws Copyright 2013 Vestil Manufacturing Corp Page 32 of 51 Rev 0213 EPT Manual doc Step 2 Carefully pull the red belly switch cover away from the handle while continuing to lift the base of the housing The housing should separate from the handle as shown in photo 4 Legal Do not drop the assembly once it is disconnected from the handle because the wires might be damaged or might rip out of the connectors Step 3 Unplug the two connectors shown in photo 5 NOTE Wires may not attach to connectors If this is the case record the wire combinations before you separate them At this point the entire assembly can be replaced with a new one by simply plugging the replacement assembly into the two connectors If the problem appears to be in the belly switch continue to disassemble the throttle Remove the Philips screw located at the center of the throttle control wheel photo 6 Step 4 Note the orientation of the control wheel on the shaft correct orientation shown in Photo 7 then slide the it off of the shaft Remove the remaining wheel from the other side note the orientation of the two plastic bushings identified with arrows in photo 8
32. nd soap nearby in case battery acid contacts skin clothing or eyes Immediately rinse any skin that has been contacted by acid If acid gets in your eyes rinse them thoroughly with eye wash After rinsing the affected area notify your supervisor about the incident DO NOT expose the unit or the charger to rain or other adverse conditions ALWAYS return the unit to its designated storage location when you finish using it The designated storage location should offer protection from the elements and should not interfere with or obstruct traffic Replace defective cords or wires immediately Routinely check the water level in the battery Make sure the battery charger is unplugged from the 115V source BEFORE driving the unit Operating the pallet truck when battery voltage is low can cause premature motor contact failure Step 1 The quencharcs Vestil supplies Photo 1 have baby back terminals circled Remove the screws 2 shown below then remove the yellow cover Copyright 2013 Vestil Manufacturing Corp Page 47 of 51 Rev 0213 EPT Manual doc Step 2 Disconnect the wires from the horn and the pump solenoid then plug the horn and pump solenoid wires into to the quencharcs piggy back terminals plug the piggy back terminals into the horn and pump solenoid as shown in the following pictures Quencharc shown on horn photo 4 Add one to the pump solenoid Add one to the horn Step 3 Reinstall the yellow cover and rein
33. o the contactor should be replaced Consult diagnostics page Table 2 Troubleshooting Chart or Refer to 15 124 029 electrical drawing for proper voltage readings and operation or Consult Factory Same as above except locate Pin 3 on Molex connector on motor controller and follow procedure Page 23 of 51 Rev 0213 EPT Manual doc Problem Possibl Action Unit will not go forward or Broken wire or loose connection Locate Pin 6 on Molex connector reverse bad motor controller at the motor controller Try to drive the unit in forward there should be 0 to 5 volts 5V is full throttle at this pin If there is voltage at pin 5 and 24 volts on either pin 11 or 12 and the unit does not move the motor controller may be bad Consult diagnostics page Table 2 Troubleshooting Chart or Refer to 15 124 029 electrical drawing for proper voltage readings and operation or Consult Factory Throttle assembly bad If the connections are all good and there is no voltage coming out of throttle assembly then the throttle assembly may be bad Verify there is 24 volts going into the throttle assembly and that there is a good ground If there is still no output voltage for pin 6 or forward and reverse outputs replace throttle assembly Consult diagnostics page Table 2 Troubleshooting Chart or Refer to 15 124 029 electrical drawing for proper voltage readings and operation or Consult Factory Unit will not move forward or Blo
34. od Clevis 4015 _ EPT 30 SCL 4015 JWeighing Forks 1017 _ EPT 30 SCL 1017 Clevis Pin 4016 EPT 30 SCL 4016 M12 x 38 Boli Copyright 2013 Vestil Manufacturing Corp Page 10 of 51 Rev 0213 EPT Manual doc FIG 5A CONTROL YOKE AND HANDLE COMPONENTS ALL MODELS 3116 2 3220 3204 3203 jf k jima s EA 3205 ho 3206 3207__ ete 3208 BD 3209 ok zm ELY EM SE q M8 3213 SS 3214 EPT 30 3100 lt gt 3215 Ke BA me 3217 A RAJ 3219 tre S TIR 3300 Copyright 2013 Vestil Manufacturing Corp Page 11 of 51 Rev 0213 EPT Manual doc Item No Part Number Description Hex Head Cap Screw EPT 30 3300 Copyright 2013 Vestil Manufacturing Corp Page 12 of 51 Rev 0213 EPT Manual doc FIG 5B CONTROL YOKE AND HANDLE COMPONENTS ALL MODELS WITH INTEGRAL SCALE BR 3121 3120 3122 Copyright 2013 Vestil Manufacturing Corp Page 13 of 51 Rev 0213 EPT Manual doc em No PartNo Description Copyright 2013 Vestil Manufacturing Corp Page 14 of 51 Rev 0213 EPT Manual doc FIG 6 Hydraulic Pump and Motor Assemblies All Models 4100 4106 4107 CH 4115 sa 4114 4108 4113 4109 RULE 4110 A 4111 ltemNo PartNo Description _________________ 4100 EPT 30 4100 Complete Motor Pump Assembly 24VDC 1 3kW DC Motor 4102 EPT 30 4102 Motor to Pump Shaft Coupling ___ 4103 EPT 30 4103 Manifold Base
35. ograph 3 The diagram identifies each of the Fas a wee 1 cables that attach to the AI g TM D Sa Bac Campro motor controller and to Me LE Y NY 4 TENI Nap G Front the FRC me a4 po a Side C 2 y Forward Reverse Contactor Copyright 2013 Vestil Manufacturing Corp Page 40 of 51 Rev 0213 EPT Manual doc Step 4 Disconnect cables B A F Step 3 Use 10mm wrenches or adjustable wrenches to disconnect and C from the FRC using either a the horn from the mounting plate 9 16 inch crescent wrench or a socket or a 14mm wrench Photograph below shows disconnection of A amp F cables Step 4 Disconnect cables and G from the terminal on the top side of the FRC J IT aF 1 si Wir E v a Li Close up side view of the terminal on a VW N E top of the FRC in photograph below _ Tii Green 8 Black wire Orange wire Copyright 2013 Vestil Manufacturing Corp Page 41 of 51 Rev 0213 EPT Manual doc Step 6 Disconnect the FRC from the mounting plate The FRC mounts on the plate with 2 Phillip s head bolts and 5 16 inch nuts After the bolts are unfastened remove the FRC 5 16 inch F nuts Step 7 The FRC may not need to be replaced if the malfunction results from mechanical binding of some of the moving parts To apply lubricant remove the plastic caps shown below identified with arrows with a flat blade screwdriver 4 Remove Side View i plastic caps A
36. ole in Center 1002 EPT 30 1002 M6 Nut 1013 EPT 30 1013 40 Push Rod 22mm Snap Ring Pin Copyright 2013 Vestil Manufacturing Corp Page 9 of 51 Rev 0213 EPT Manual doc FIG 4B EPT 30 MODELS FORKS AND CARRIAGE WITH INTEGRATED SCALE 1022 B ltem No Part No Description ltem No Part No Description 1001 jEPT 30 SCL 1001 Fork Assembly 1018 EPT 30 SCL 1018 Sleeve Bearing 22 x 20 1002 EPT 30 SCL 1002 Nose Wheel Frame 1019 EPT 30 SCL 1019 Trunion Pivot Shaft 1003 jEPT 30 SCL 1003 M10 x 65 Screw 1020 EPT 30 SCL 1020 Retaining Ring 16 1004 EPT 30 SCL 1004 Nose Wheel 1021 EPT 30 SCL 1021 Clevis Pin Sleeve Bearing 16 x 16 1005 EPT 30 SCL 1005 M10 Nut 1022 A EPT 30 SCL 1022 A Trunion EPT 2547 30 SCL 1006 EPT 30 5CL 1006 Retaining Ring 1022 B EPT 30 SCL 1022 B Trunion EPT 2047 30 SCL 1007 jEPT 30 SCL 1007 Ball Bearing 6204z 1023 EPT 30 SCL 1023 M8 x 30 Screw 1008 EPT 30 SCL 1008 Drive Load Wheel 75 x 90 1024 EPT 30 SCL 1024 Washer 1009 EPT 30 SCL 1009 Drive Load Wheel Axle 1025 EPT 30 SCL 1025 M8 Nut 1010 EPT 30 SCL 1010 Roll Pin 5 x 30 1026 EPT 30 SCL 1026 Pin 1011 Load Roller Bracket Integral Scale Components 1012 EPT 30 SCL 1012 Load Roller Bracket Pivot Pin 4011 Load Cell 1013 Push Rod Pivot Pin 4012 M12 x 45 Bolt 1014 Push Rod Owner must provide 4013 12mm Spring Washer measurement 1015 M22 x 1 5 Lock Nut 4014 1016 _ EPT 30 SCL 1016 Push R
37. pply lubricant Step 8 Install the replacement FRC by performing Steps 1 through 7 in reverse order Similarly if you simply lubricated the original FRC perform steps 1 2 3 6 and 7 in reverse order Copyright 2013 Vestil Manufacturing Corp Page 42 of 51 Rev 0213 EPT Manual doc Instructions for Changing the Battery Charger Estimated time 30 minutes Tools Required 10mm deep socket or small wrench 14mm wrench or crescent wrench Regular flat blade screw driver AWARNING Only trained authorized personnel should perform maintenance on this equipment Lead acid batteries present hazards to the person s working on with or in the vicinity of them To minimize the risk of serious personal injury read every one of the instructions and DO NOT proceed with maintenance unless you understand each of them e Lock out all potential energy sources before attempting this installation according to OSHA lockout tagout procedures 29 CFR 1910 147 turn off the unit and remove the key DO NOT work on with or in the vicinity of the battery UNLESS you are wearing personal protective equipment particularly a face shield Batteries contain sulfuric acid and produce explosive gases A battery explosion could result in loss of eyesight or serious burns DO NOT smoke near the battery or expose the battery to sparks or flames Charge batteries ONLY in clean dry and well ventilated locations DO NOT lay tools or anything metallic on top of a bat
38. provided in this manual Specifications for each of the 4 models appear in the table below Net Wt Fork Size Service Capacity Overall Size MODEL Ibs WxL in inches Range in Ibs W X L x H in inches EPT 2047 30 660 20in X47in 32t078 3000 28x65x49 EPT 2048 45 990 20in x48in 34to8 4500 30x78 5x49 Vestil Manufacturing Corp created this manual to acguaint owners and users of our electric pallet trucks with safe operation and maintenance procedures Employers are responsible for instructing employees to use the product properly Employees and any other persons who might foreseeably use repair or perform maintenance on the EPT must read and understand every instruction BEFORE using the device Cart operators should have access to the manual at all times and should review the directions before each use Contact Vestil for answers to any question you have after reading the entire manual Although Vestil diligently strives to identify foreseeable hazardous situations this manual cannot address every conceivable danger The end user is ultimately responsible for exercising sound judgment at all times SAFETY PRINCIPLES We offer four types of electric pallet truck EPT two 3 000 pound 1364kg capacity models the EPT 2047 30 and 2547 30 and two 4 500 pound 2045kg capacity models the EPT 2048 45 and 2748 45 Each unit conforms to the generalized specifications disclosed in this manual and fulfills our
39. rminal red arrow NOTE Make a record of the cable connections so that you will be able to reconnect the batteries later Copyright 2013 Vestil Manufacturing Corp Page 28 of 51 Rev 0213 EPT Manual doc Step 2 Lift both sides of the battery so that the battery remains level To facilitate level lifting attach tie wraps or other NONMETALLIC material for example two short lengths of nylon rope to the terminals then lift both sides simultaneously see Photo 3 The cylinder hose will be visible through the opening in the base of the battery box after the batteries are removed See Photo 4 AWARNING DO NOT create a path between the terminals by connecting the tie wraps or sections of nylon rope al i eos k 4 Step 3 Disconnect the cylinder from the lower retaining bracket 1 Disconnect the hose from the bottom of the cylinder with a 16mm wrench see Photo 5 2 To prevent leakage from the hose pull the free end of the hose into the battery box shown in Photo 7 3 Remove the snap ring from the pin see Photo 6 4 Pull the pin out of the bracket and cylinder Disconnect hydraulic hose from cylinder with 16mm or adjustable wrench Snap ring another snap Lower retaining ring is fastened to the bracket other end of the pin Retaining pin Step 4 Disconnect the cylinder from the upper retaining bracket 1 Remove the snap ring from the pin that extends through the piston rod photo 8 then 2 Remove th
40. rottle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground If there is still no output voltage for pin 12 replace throttle assembly Reference 15 124 029 Page 27 of 51 Rev 0213 EPT Manual doc Instructions for Changing the Cylinder Estimated time 45 minutes Necessary tools 14mm wrench 16mm wrench or 2 adjustable crescent wrenches Regular flat blade screwdriver Dental Pick AWARNING Only trained authorized personnel should perform maintenance on this equipment Lead acid batteries present hazards to the person s working on with or in the vicinity of them To minimize the risk of serious personal injury read every one of the instructions and DO NOT proceed with maintenance unless you understand each of them e Lock out all potential energy sources i e battery before attempting this installation according to OSHA lockout tagout procedures 29 CFR 1910 147 turn off the unit and remove the key DO NOT work on with or in the vicinity of the battery UNLESS you are wearing personal protective equipment particularly a face shield Batteries contain sulfuric acid and produce explosive gases A battery explosion could result in loss of eyesight or serious burns DO NOT smoke near the battery or expose the battery to sparks or flames Charge batteries ONLY in clean dry and well ventilated locations DO NOT lay tools or anything metallic on top of a battery Remove person
41. rresponding photo on p 9 Copyright 2013 Vestil Manufacturing Corp Page 20 of 51 Rev 0213 EPT Manual doc Step 5 Drive the pallet truck to the desired location To steer the unit turn the yoke to the right or left of the center line Moving the yoke to the right will cause the EPT to turn to the right and moving the yoke to the left of the center line will cause the unit to turn left The degree of deflection from the centerline determines how sharply the EPT turns The illustration at right demonstrates how the position of the yoke determines the direction the machine follows Direction of motion Lifting and Transporting Loads Center line JAWARNING DO NOT operate the EPT until you read AND understand every instruction If you do not understand an instruction contact Vestil for clarification To reduce the possibility of sustaining or causing serious personal injuries ALWAYS 1 Make sure that all other persons clear the area while you use the EPT 2 Apply the fork truck operation and lifting practices learned during your operator training and applied by your employer Follow the instructions below ONLY to the extent that they do not disagree with the operating practices reguired by your employer e Make sure that the net weight to be lifted load 4 skid does not exceed the rated load capacity of your truck e Center and evenly distribute the load on the forks The load must not project more than 2 beyond th
42. ry Remove personal items like rings bracelets necklaces and watches BEFORE beginning to work on the battery The battery can produce energy sufficient to weld jewelry to metal underlying skin could be severely burned Keep fresh water and soap nearby in case battery acid contacts skin clothing or eyes Immediately rinse any skin that has been contacted by acid If acid gets in your eyes rinse them thoroughly with eye wash After rinsing the affected area notify your supervisor about the incident DO NOT expose the unit or the charger to rain or other adverse conditions ALWAYS return the unit to its designated storage location when you finish using it The designated storage location should offer protection from the elements and should not interfere with or obstruct traffic Replace defective cords or wires immediately Routinely check the water level in the battery Make sure the battery charger is unplugged from the 115V source BEFORE driving the unit Operating the pallet truck when battery voltage is low can cause premature motor contact failure Turn off power to the pallet truck and remove the key Purpose To repair a non functional or malfunctioning belly switch i e the batteries are fully charged but the belly switch does not function The following procedure includes instructions for A Replacing the entire throttle assembly which incorporates the belly switch and throttle controls AND B A method for restoring normal functio
43. stall the screws Copyright 2013 Vestil Manufacturing Corp Page 48 of 51 Rev 0213 EPT Manual doc Maintenance and Inspections According to ANSI B56 1 the pallet truck is a motorized hand truck pallet truck MHT For this type of lift truck only trained authorized persons should perform inspections or maintenance Inspections ALWAYS review the following warning messages and procedures BEFORE inspecting the MHT AWARNING DO NOT use the pallet truck if an inspection reveals structural damage Structural damage includes but is not limited to cracked welds warping or other deformation of the cylinder brackets forks front rollers and wheel s handle or the housing that protects the electrical components If an inspection exposes any problem restore the MHT to normal operating condition BEFORE returning it to NOT service The MHT must not be used until all repairs have been completed According to B56 1 2005 e A User is a person or organization responsible for employing powered industrial trucks Therefore the person or business that owns the MHT is a user e Authorized means any person designated by the user to operate or maintain the equipment In other words the owner most likely your employer is responsible for training and selecting people to inspect and maintain the MHT NOTE A user may choose to contract with a person or an organization for maintenance services Vestil is not responsible for the ac
44. sult factory Verify 24 volts at coil when lower is pushed if no voltage trace wiring back to tiller head looking for voltage on each side of the connectors until the bad connection is found If voltage is present at the coil and the unit does not lower remove the connector to the coil and measure the coil resistance It should be around 39 ohms If its open or shorted replace the coil Loosen hydraulic line at pump to relieve pressure build up Re adjust limit switch so unit stops at 7 to 8 inches above the ground Remove the wire to the solenoid coil on the pump motor Measure the resistance it should be around 19 ohms If it is nearly zero ohms replace the solenoid Page 26 of 51 Problem Unit will not reverse belly switch Broken wire or loose connection does not function forward ok Rev 0213 P ibl bad throttle assembly bad motor controller Copyright 2013 Vestil Manufacturing Corp EPT Manual doc Action Locate Pin 12 on Molex connector at the motor controller Try to drive the unit in reverse there should be 24 volts at this pin If there is voltage and the unit does not move the motor controller may be bad consult factory If there is no voltage trace the wiring back towards the tiller head and check voltage on each side of connectors Continue this until bad connection is found If the connections are all good and there is no voltage coming out of throttle assembly then the th
45. surface must be smooth and dry so choose a route that avoids obstacles spills and surface damage ACAUTION Casters might become stuck in gaps or cracks in the surface which could cause the EPT to stop suddenly A sudden stop can cause the load to shift and the load and truck might tip over 2 Inspect the EPT amp Perform a Functions Test Inspection Prior to Use ALWAYS inspect the unit before you use it Begin the inspection by removing all debris found on the surface of the forks and the housing and then a Check the forks for deformation and cracks b Check the floor beneath the truck and the truck itself for leaked hydraulic fluid or battery acid JAWARNING DO NOT use the EPT if you discover any damage or abnormalities Tag the unit Out of Service and report the problem s to authorized maintenance personnel Functions Test Verify that the unit works properly Drive the stacker to a location where the following tests can be performed without contacting overhead obstructions or items on the ground 1 Raise the forks to the maximum elevation 2 Return the forks to the lowest position 3 Raise the forks and while raising them press the E stop button The forks should immediately stop moving Reset the E stop by returning the control yoke to either position 1 or 3 see Operation Step 3 below on this page and then pull up on the red button 4 Fully raise the forks and while lowering the forks press the E stop Th
46. switch Page 25 of 51 Problem Unit will not raise motor does not run Unit will not raise motor runs Unit will not lower Unit keeps blowing fuses when the raise button is pressed Rev 0213 Possibl Loose wire Bad solenoid Upper limit switch out of adjustment Blown fuse Lower solenoid stuck on Loose wire bad coil Upper limit switch out of adjustment Shorted solenoid for motor raise Copyright 2013 Vestil Manufacturing Corp EPT Manual doc Action Verify 24 volts at coil when raise is pushed if no voltage trace wiring back to till her head looking for voltage on each side of the connectors until the bad connection is found If voltage is present at the solenoid and the unit does not ralse remove the two wires to the coil and measure the coil resistance It should be around 19 ohms If it s open or shorted replace the solenoid Bypass upper limit switch and see if the unit raises DO NOT TAKE IT ALL THE WAY UP If it does raise verify the limit switch is normally closed and will open when activated If the limit switch is ok try to adjust the switch accordingly so that the units raise height is approximately 7 to 8 Check fuses Check to see if the lowering switch is stuck on If it is remove the tiller head via 3 screws on bottom and replace switch or tap on switch to see if it can be freed up If the lower switch is not stuck on the pump could be bad con
47. t EPT 45 KSA Key Switch Assembly Copyright 2013 Vestil Manufacturing Corp Page 18 of 51 Rev 0213 FIG 11 BATTERY CHARGE GAUGE The battery charge gauge indicates the status of the battery It is located on top of the EPT main body and to the right of the control yoke As the battery discharges display lines disappear from right to left Always check the gauge before using the device make sure that the battery is charged before using the pallet truck Press button to lower forks BELLY SWITCH The belly switch protects the operator from injury while driving the EPT in reverse When pressed the truck will change direction i e move forward for approximately 3 seconds after 3 seconds it will stop completely If the belly switch becomes jammed or stuck the stacker will move forward away from the operator for at most 3 seconds the control circuit will remain disabled until reset gt To reset the circuit either raise the handle to the fully vertical position or simply release the handle or press it downwards to the fully horizontal position EMERGENCY STOP E STOP BUTTON Press the E stop button to immediately interrupt all powered functions Use the E stop during operation if the travel or fork raise and lower functions do not respond normally to operator commands Use the E stop as a service brake to secure the EPT when parked POWER EPT 30 s and 45 s activate different
48. tery Remove personal items like rings bracelets necklaces and watches BEFORE beginning to work on the battery The battery can produce energy sufficient to weld jewelry to metal any underlying skin could be severely burned Keep fresh water and soap nearby in case battery acid contacts skin clothing or eyes Immediately rinse any skin that has been contacted by acid If acid gets in your eyes rinse them thoroughly with eye wash After rinsing the affected area notify your supervisor about the incident DO NOT expose the unit or the charger to rain or other adverse conditions ALWAYS return the unit to its designated storage location when you finish using it The designated storage location should offer protection from the elements and should not interfere with or obstruct traffic Replace defective cords or wires immediately Routinely check the water level in the battery Make sure the battery charger is unplugged from the 115V source BEFORE driving the unit Operating the pallet truck when battery voltage is low can cause premature motor contact failure Battery Charger Operating Instructions for New Charger after Installation Plug the charger into a standard 115V receptacle If an extension cord must be used keep it as short and as large as possible A small cord will decrease the output of the charger due to the voltage drop in the line This will increase the charging time It can also cause the 115V cord to overheat Remember to unplu
49. tery Remove personal items like rings bracelets necklaces and watches BEFORE beginning to work on the battery The battery can produce energy sufficient to weld jewelry to metal underlying skin could be severely burned Keep fresh water and soap nearby in case battery acid contacts skin clothing or eyes Immediately rinse any skin that has been contacted by acid If acid gets in your eyes rinse them thoroughly with eye wash After rinsing the affected area notify your supervisor about the incident DO NOT expose the unit or the charger to rain or other adverse conditions ALWAYS return the unit to its designated storage location when you finish using it The designated storage location should offer protection from the elements and should not interfere with or obstruct traffic Replace defective cords or wires immediately Routinely check the water level in the battery Make sure the battery charger is unplugged from the 115V source BEFORE driving the unit Operating the pallet truck when battery voltage is low can cause premature motor contact failure Turn off power to the unit and remove the key Step 1 Remove the screws 2 shown below then remove the yellow cover The battery charger is located on the left side of the unit the Campro motor controller is adjacent to the charger and is identified with an arrow in Photo 2 below Copyright 2013 Vestil Manufacturing Corp Page 37 of 51 Rev 0213 EPT Manual doc Step 2 If necessar
50. tion Fig 1B EPT 30 optional Scale Components Safety Guidelines Fig 2 EPT 30 Hydraulic Cylinder Assembly Removing EPT from Pallet 3 4 Fig 3 EPT 30 Drive Wheel Assembly Use 1 Inspection amp Functions Tests 20 Fig 4A EPT 30 Fork amp Carriage Operation 20 21 Fig 4B EPT 30 Fork amp Carriage optional Scale Lifting amp Transporting Loads 21 Fig 5A Control Yoke 8 Handle Components Batteries 4 Charger Fig 5B Control Yoke amp Handle optional Scale Fig 6 Hydraulic Pump Motor Assemblies Troubleshooting Fig 7 EPT 45 Main Housings Supporting Structure Changing Cylinder Fig 8 Removable Battery Box 8 Components Changing Throttle Assy Fig 9 EPT 45 Cylinder amp Fuse Panel Changing Motor Assy Fig 10 EPT 45 Fork amp Carriage Assemblies Replacing Forward Reverse Contactor Fig 11 Function Controls Gauges amp Safety Features 19 Changing Battery Charger Maintenance amp Inspections Adding Quencharcs Markings 51 Copyright 2013 Vestil Manufacturing Corp Page 1 of 51 Rev 0213 EPT Manual doc PRODUCT INTRODUCTION Thank you for purchasing an electric pallet truck EPT pallet truck truck or unit offered by Vestil Manufacturing Corporation Vestil Our EPT s are durable high quality products that combine safety features and low maintenance mechanisms Despite the product s relatively simple mechanics all personnel must familiarize themselves with the safe operation instructions
51. tions of independently contracted maintenance service providers e DO NOT use brake fluid or jack oil in the hydraulic system If oil is needed use an anti wear hydraulic oil viscosity grade 150 SUS at 100 F ISO 32 40 C or a non synthetic transmission fluid e Only use replacement parts either supplied or approved by the manufacturer The person s authorized by the end user to inspect the MHT must do so before it is used for the first time and before each subsequent use If the MHT is rarely used inspect the unit at least once per month or before each use whichever is more frequent Before the inspection a disconnect the battery and b either chock the wheels or lift the MHT until the drive wheels no longer contact the ground Inspect the pallet truck prior to each use Specifically look for 1 Frayed wires 2 Oil leaks 3 Pinched or damaged hoses 4 Structural damage cracked welds warping or other deformation of the cylinder brackets forks front rollers or drive wheel s handle or the housing that protects the electrical components Proper function of all limit switches Proper horn operation Normal battery condition clean not leaking electrolyte solution secure connections with both terminals Also make sure that the battery is immobilized so that it cannot move during operation 8 Proper rotation of all wheels na Inspect the MHT each month 1 Oil level raise the forks to the maximum height when the cylind
52. us situation which if not avoided WILL result in DEATH or SERIOUS INJURY Use of this signal word is limited to the most extreme situations AWARNING Identifies a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY ACAUTION Indicates a hazardous situation which if not avoided COULD result in MINOR or MODERATE injury Identifies practices not related to personal injury such as operation that could damage the cart OH 1 013 No safety alert symbol equilateral triangle enclosing an exclamation point accompanies this signal word Copyright 2013 Vestil Manufacturing Corp Page 2 of 51 Rev 0213 EPT Manual doc SAFETY GUIDELINES Failure to read and understand the instructions included in this manual before using or servicing the pallet truck constitutes misuse of the product Study the entire manual before you use the truck for the first time and before each subseguent use Read the manual to refresh your understanding of the safe use and maintenance procedures on p 50 51 If guestions remain after you finish reading the manual contact Vestil for answers DO NOT attempt to resolve any problem with the truck unless you are certain that it will be safe to use afterwards ADANGER To decrease the risk of electrocution gt DO NOT contact or operate the pallet truck close to electrified wires or other sources of electricity gt Before operating the EPT always inspect the area where you wi
53. versing steps 1 through 8 Copyright 2013 Vestil Manufacturing Corp Page 39 of 51 Rev 0213 EPT Manual doc Instructions for Replacing the Forward Reverse Contactor Estimated time 45 minutes Necessary tools 1 Two 9 16 inch or 14mm sockets wrenches 3 10mm crescent wrench 2 Phillips head screwdriver 4 5 16 inch crescent wrench socket AWARNING Only trained authorized personnel should perform maintenance on this equipment Lead acid batteries present hazards to the person s working on with or in the vicinity of them To minimize the risk of serious personal injury read every one of the instructions and DO NOT proceed with maintenance unless you understand each of them e Lock out all potential energy sources i e battery before attempting this installation according to OSHA lockout tagout procedures 29 CFR 1910 147 turn off the unit and remove the key DO NOT work on with or in the vicinity of the battery UNLESS you are wearing personal protective equipment particularly a face shield Batteries contain sulfuric acid and produce explosive gases A battery explosion could result in loss of eyesight or serious burns DO NOT smoke near the battery or expose the battery to sparks or flames Charge batteries ONLY in clean dry and well ventilated locations DO NOT lay tools or anything metallic on top of a battery Remove personal items like rings bracelets necklaces and watches BEFORE beginning to work on the battery The battery c
54. with a forklift Operator Side Loading side Approach the pallet truck from the operator side Lift the EPT just a few inches above the pallet Slowly back the forklift away from the pallet and then carefully lower the forks until the EPT rests firmly on the ground Copyright 2013 Vestil Manufacturing Corp Page 4 of 51 Rev 0213 EPT Manual doc FIG 1A EPT 30 MODELS MAIN BODY COMPONENTS 2004 200 Item No Part No Descri 2001 EPT 30 2001 Main Body Housing 2021 EPT 30 2021 22mm Snap Ring EPT 80 2001 2 Housing Screw EPT 30 2004 2 Replacement Charger OEM Unit EPT CORD Battery Charger Cord _ EPT S0 KSA Key Switch Assembly Copyright 2013 Vestil Manufacturing Corp Page 5 of 51 Rev 0213 EPT Manual doc FIG 1B EPT 30 MODELS OPTIONAL SCALE COMPONENTS 2008 2002 ltem No Part No Description 4009 EPT 30 SCL 4009 fo 4010 EPT 30 SCL 4010 0 Copyright 2013 Vestil Manufacturing Corp Page 6 of 51 Rev 0213 EPT Manual doc FIG 2 EPT 30 MODELS HYDRAULIC CYLINDER ASSEMBLY 4302 4402 Item No Part No Description 4200 EPT 30 4200 Cylinder Assembly 4201 EPT 30 4201 Cylinder Body Tube 4202 EPT 30 4202 GlandTube _ 4203 EPT 30 4203 Nut 4204 EPT 30 4204 Piston 4205 EPT 30 4205 Piston Rod 4301 EPT 30 4301 O Ring 4302 EPT 30 4302 Seal Ring 4303 EPT 30 4303
55. wn fuse Verify fuses are good replace if reverse and the Belly switch will blown not function unit does turn on as indicated by the battery gage Broken wire or loose connection Locate Pin 7 on Molex connector lighting up at the motor controller Trace wire back up to tiller head and verify continuity all the way to the throttle assembly Repair any loose connections When replacing throttles it may be necessary and does not hurt to run a jumper wire from pin 7 to Check the ground wire that comes off of B on the motor controller Re terminate with a ring terminal if loose Run jumper wire around large diode coming off of small AGC fuse If this diode is bad it can cause the unit to not move Copyright 2013 Vestil Manufacturing Corp Page 24 of 51 Rev 0213 Problem P ibl Unit will not go forward the belly switch functions reverse works Broken wire or loose connection bad motor controller Bad throttle assembly Broken wire or loose connection bad motor controller Belly switch does not function forward ok reverse ok Bad belly switch Unit will not move at all Stuck Switch Copyright 2013 Vestil Manufacturing Corp EPT Manual doc Action Locate Pin 11 on Molex connector at the motor controller Try to drive the unit in forward there should be 24 volts at this pin If there is voltage and the unit does not move the motor controller may be bad If there is no voltage trace th
56. y mark each of the cables with a unique identifier to make it easier to reconnect them to the new motor controller For instance in the photograph below the red and green insulated ring terminals display a distinci number of hash marks to indicate order of attachment from top to bottom In newer EPT s a yellow tag marked with a specific letter identifies each cable The diagram below and to the right indicates where cables A through attach to the Motor Controller or the Forward Reverse Contactor Motor Controller MA o Molex Connector Back Step 3 Remove the two 1 front 1 back 14mm bolts that fasten the motor controller mounting plate identified with a yellow asterisk to the frame Step 4 Remove the Molex connector from Step 5 Disconnect the motor controller wiring with two the motor controller 14mm wrenches m 3 E E bo o NA A f 1 K i j Copyright 2013 Vestil Manufacturing Corp Page 38 of 51 Rev 0213 EPT Manual doc Step 6 After you have unfastened all 4 of the cable connections first photograph below then remove the three 8mm screws 1 screw in back and 2 in the front holding the motor controller to the back plate with a Philips screwdriver and 8mm wrench Pur Y V Step 7 Remove the motor controller Step 8 Verify that each of the 4 spade terminal connections on the forward reverse motor contactor is sound Step 9 Install a new controller by re
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