Vestil HYD-5 Bedienungsanleitung

Vestil Manufacturing Corporation

2999 North Wayne St., Angola, IN 46703

Phone (260) 665-7586 • Fax (260) 665-1339

E-mail: [email protected] Website: www.vestil.com

SAFETY PRECAUTIONS

Read owner's manual completely before operating unit!

•Never exceed the maximum loading capacity of 880 pounds.

• Stand clear of load while loading and unloading.

• Load must be evenly distributed on deck to insure stability.

• Use caution in moving a loaded unit; avoid obstructions and

floor defects.

• Always apply wheel brakes when unit is not in motion.

• Never go under deck if there is weight on unit.

• Do not continue to pump on the foot lever if the deck is not

raising.

• Remove weight before working on unit.

• Do not use brake fluid or jack oils. Use AW-32 hydraulic oil

or equivalent.

• Use only replacement parts supplied or approved by the

manufacturer.

• Consult factory before performing any modification to the

original equipment.

• Make sure all operator safety labels are in place (p.11).

RECEIVING INSTRUCTIONS

Every unit is thoroughly tested and inspected prior to

shipment. However, it is possible that the unit may incur

damage during transit. If damage is noticed when unloading,

make a note of it on the BILLOFLADING. Remove all packing

and strapping material, then inspect the unit again for damage.

IF DAMAGE IS EVIDENT, FILE A CLAIM WITH THE CAR-

RIERIMMEDIATELY!

WARRANTY

This product is warranted for 90 DAYS from date

of purchase to be free of manufacturing defects in material

and workmanship. The manufacturer's obligation hereun-

der is limited to repairing such products during the warranty

period, provided the product is sent prepaid back to the

factory.

This warranty does not cover normal wear of parts

or damage resulting from any of the following: negligent

use or misuse of the product, use or application contrary

to installation instructions, or disassembly, repair or alter-

ation by any person prior to authorization from a factory

representative.

HEFTI-LIFT • MODEL HYD-5 & HYD-10

OWNER'S

MANUAL

Revised0507 33-126-101

A company dedicated to solving ergonomic and material

handling problems since 1955.

HEFTI-LIFT

MODEL HYD 5 & HYD-10

Ergonomic Solutions

Contents

Safety Precautions .......................................... 1

Receiving Instructions ..................................... 1

Warranty.......................................................... 1

Parts List for HYD-5 & HYD-10 .................... 2-3

Troubleshooting Guide for HYD-5 & HYD-10 .. 4

Operating Instructions for HYD-10-DC ........ 5-6

Electrical Diagram for HYD-10-DC ................. 7

Bill of Materials for HYD-10-DC ..................... 8

Hydraulic Diagram for HYD-10-DC ................ 9

Troubleshooting Guide for HYD-10-DC ....... 10

Warning Label Identification ......................... 11

PARTS LIST

HEFTI-LIFT • HYD-5 & HYD-10

PARTS IDENTIFICATION HEFTI-LIFT

MODEL HYD-5 & HYD-10

ITEM

NO.

DESCRIPTION

Chain Cover

Chain Assembly

Brake Assembly

Mast

Guide Wheel and Axle

Front Wheel and Axle

Rear Wheel and Axle

Forks Assembly

Top Deck

Front Plastic Shield

Back Plastic Shield

QTY.

HYD-5

ENGINEER NO.

33-154-004

33-154-005

33-154-006

33-154-032

33-154-007

33-154-008

33-154-009

33-528-001

33-013-001

33-024-011

33-024-010

HYD-10

ENGINEER NO.

33-154-016

33-154-017

33-154-006

33-514-018

33-154-007

33-154-008

33-154-009

33-528-001

33-013-001

33-024-013

33-024-012

QTY.

FOOT PUMP

HEFTI-LIFT • HYD-5 & HYD-10

PARTS IDENTIFICATION

FOOT PUMP (HEFTI-LIFT)

1 2

ITEM

NO.

DESCRIPTION

Release Knob Assembly

Pump Assembly

Foot Pedal Assembly

Plunger Assembly

Pump Seal Kit

Complete Assembly

HYD-5

PART NO.

HYD5-FP01

HYD5-FP02

HYD5-FP03

HYD5-FP04

HYD5-KITA

HYD5-KITB

QTY.

a/k Available only with purchase of kit

HYD-5

ENGINEER NO.

33-154-010

33-154-011

33-154-012

33-154-013

33-144-401

33-154-014

HYD-10

PART NO.

HYD10-FP01

HYD10-FP02

HYD10-FP03

HYD10-FP04

HYD10-KITA

HYD10-KITB

HYD-10

ENGINEER NO.

33-154-010

33-154-018

33-154-012

33-154-013

33-144-401

33-154-014

KIT

NO.

Troubleshooting Quick Reference Guide for HYD-5 & HYD-10

(For further information please contact the factory)

WARNING! BEFORE PERFORMING ANY MAINTENANCE WORK ALWAYS ENSURE THAT THE DECK/FORKS ARE IN LOWER POSITION

Observation Possible Cause Remedy

1.) Deck/forks do not raise.

2.) Foot pedal goes down but deck/forks do not

raise.

3.) Unit will pump under no load or when rapidly

stroked, or pedal will stroke without

pumping.

4.) Deck/forks raise when the pump is stroked

but lower on return stroke.

5.) Deck/forks raise but is too slow.

6.) Spongy or jerky operation.

7.) Deck/forks raise but do not lower.

a. Excessive load.

b. Oil is low.

c. Relief valve set too low.

d. Released pin is not rotating to closed

position.

e. Breather cap is not allowing air into cylinder.

a. Particle of dirt under the pressure relief

valve.

b. Particle of dirt under inlet check valve.

a. Pump is air locked.

b. Inlet check valve has foreign material on

seat.

c. Relief valve setting is out of adjustment.

d. Foreign material on pressure relief valve

seat.

e. Release pin has foreign material on the seat

or is stuck in the open position.

a. Outlet check valve is leaking.

a. Foreign material stuck under pressure relief

valve or under inlet check valve.

a. Check for foreign material stuck in the deck

or frame rails.

b. Oil is low.

a. Foreign object blocking roller travel.

b. Release pin is not rotating to open position.

a. Remove part of the load.

b. Fill oil as necessary.

c. Increase only as necessary.

d. Check linkage for proper rotation.

e. Be sure cap has air hole. Clean cap out

with compressed air.

a. Lower deck/forks - Remove and clean

steel ball and seat. (Refer figure 1)

b. Lower deck/forks - Remove and clean inlet

ball and seat. (Refer figure 1)

a. Bleed air from system inlet.

b. Same as 2(b).

c. Adjust relief valve setting higher.

d. Same as 2(a).

e. Lower deck/forks - Remove and clean

steel ball and seat. (Refer figure 1)

a.1. Lower deck/forks - Remove and clean

steel ball and seat. (Refer figure 1)

a.2. Pump vigorously to remove debris.

a. Same as 2(a) / 2(b).

a. Correct as necessary.

b. Same as 1(b).

a. Correct as necessary.

b. Same as 1(d).

RELEASE PIN

STEEL BALL

SPRING

VALVE PLUG

STEEL BALL

SPRING

SPACER

SCREW

VALVE PLUG

STEEL BALL

SPRING

VALVE PLUG (OUTLET CHECK VALVE)

(INLET CHECK VALVE)

(PRESSURE RELIEF VALVE) FIGURE 1

OPERATING INSTRUCTIONS - HYD-10-DC

Ensure that all employees involved in the operation of this lift understand and follow the following instructions!

Loading:

The load rating, in pounds, is shown on the machine dataplate. It indicates the net capacity of the lift with the load

centered and evenly distributed on the platform.

Warning:

For applications involving side or end edge loading, consult the factory.

Note:

The addition of any ancillary equipment to the platform by third parties must be taken into account when determin-

ing the maximum working load to be placed on the table.

Warning:

Do not exceed the lift’s load ratings. Structural damage to the lift or injury to personnel could result from

exceeding the listed capacity.

Operation:

Warning:

Keep all personnel clear of the machine when it is in operation. Be certain no part of any person or object is

under any part of the platform before lowering the unit.

Caution:

Always carefully watch the lift and any load on it when it is in operation.

The DC powered lift is furnished with a constant-pressure (dead-man style) pushbutton control.

Pressing the “UP” pushbutton, or pulling the lever up, will turn on the power unit to raise the platform. The platform will

raise only while the control is pressed. Upon releasing the control, the platform will stop and hold its position.

Pressing the “DOWN” pushbutton will energize the lowering valve, or pushing the lever down will open a manual valve, to

allow the platform to descend by gravity (the motor does not run). Again, releasing the control will stop the platform

movement, and the unit will hold its position.

Caution:

Never use the lift if any damage or unusual noise is observed, if it is in need of repairs, or if it seems to be

malfunctioning. Notify your supervisor or maintenance personnel if you notice anything out of the ordinary.

Ensure that all safety and warning labels stay in place and are legible. Refer to the labels page in this manual.

ADDITIONAL INSTRUCTIONS FOR BATTERY-POWERED UNITS

WARNING!

! Working with or near lead acid batteries is dangerous. Batteries contain sulfuric acid and produce

explosive gases. A battery explosion could result in loss of eyesight or serious burns.

! Do not smoke or allow a spark or flame near batteries. Charge batteries in locations which are clean, dry,

and well-ventilated. Do not lay tools or anything metallic on top of any battery. All repairs to a battery must

be made by experienced and qualified personnel.

! When working with batteries, remove personal items such as rings, bracelets, necklaces, and watches.

Batteries can produce enough energy to weld jewelry to metal, causing a severe burn.

! Always have fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

! Operating the battery with a low battery voltage can cause premature motor contact failure.

! Do not expose the lift or charger to rain or adverse conditions.

! Replace defective cords or wires immediately.

! Check the battery’s water level frequently.

BATTERY CHARGER OPERATING INSTRUCTIONS

Never operate the charger with either of the cables coiled. Operating the unit with the cord wrapped around itself could

cause the cord to overheat, melt, and cause a short-circuit or a fire.

Plug the charger into a standard 115V receptacle. If an extension cord must be used, keep it as short as possible.

Connection: the ribbed wire of the charger’s output cord must be connected to the battery’s negative (-) terminal. The

non-ribbed wire must be connected to the battery’s positive (+) terminal. Reversing this polarity will blow the charger’s

output fuse.

Caution:

Remember to unplug the charger before moving the equipment. Failure to do so could cause damage to cords,

receptacles and other equipment.

TROUBLESHOOTING

If the unit does not operate, check all of the wiring connections to make sure they’re both mechanically and electrically

sound – specifically at the battery, the motor, and at any location a wire is connected to the chassis. Also make sure the

quick-connect plug on the end of the pendant control cord is plugged in correctly.

A fully-charged lead acid battery in good condition at room temperature should read 12.65 volts. At 11.9 volts it is

considered to be fully discharged and in need of charging. When checking battery voltage, wait at least 1/2 hour after the

charger has been turned off before checking the battery’s voltage.

If the motor doesn’t run, observe the green LED on the motor relay. If it is not lit, or if the LED goes out when the “UP”

control is pressed, the battery voltage should be checked with a voltmeter.

If the batteries don’t seem to be taking a charge, check the charger’s 115V supply circuit, the charger’s 10A output fuse,

and the charger’s output with a voltmeter. If all check okay, confirm the battery’s state of charge using a hydrometer or a

voltmeter.

ELECTRICAL DIAGRAM • HYD-10-DC

Warning: Care should be taken to identify all potential hazards and comply with applicable safety procedures before begin-

ning work. Fully lower or securely support the platform, and ensure that system pressure and power have been removed,

before attempting to work on any of the hydraulic components!

Only qualified individuals trained to understand mechanical devices and their associated electrical and hydraulic circuits should

attempt troubleshooting and repair of this equipment.

ELECTRICAL BILL OF MATERIALS • HYD-10-DC

When contacting the factory for replacement parts or for any correspondence, please provide the products serial number.

Only qualified individuals trained to understand mechanical devices and their associated electrical and hydraulic circuits

should attempt troubleshooting and repair of this equipment.

ITEM

NUMBER

DESCRIPTION

12 VCD power unit (motor, pump, manifold, valves)

12 VCD battery

12 VCD, 5 amp battery charger

Battery charge indicator

Solenoid start switch

Key selector switch operator

Contact block mounting blaock

Normally-closed contact block

Flush pushbutton operator

Normally-open contact block

Lowering valve solenoid

Lowering valve

Hydraulic cylinder

Hydraulic fluid (quarts)

PART

NUMBER

H10DC-PU

H10DC-BAT

H10DC-BATCHG

H10DC-BCI

H10DC-SSW

H10DC-KS

H10DC-CMB

H10DC-NCCB

H10DC-PB

H10DC-NOCB

H10DC-LVS

H10DC-HSV

H10DC-CYL

HO150

QUANTITY

HYDRAULIC DIAGRAM • LIFT-HOLD-LOWER CIRCUITS

• Care should be taken to identify all potential hazards and comply with applicable safety procedures before beginning work.

• Raise the lift and install the maintenance props before beginning any inspections or work on the unit.

• Only qualified individuals trained to understand mechanical devices and their associated electrical and hydraulic circuits

should attempt troubleshooting and repair of this equipment

CAUTION:

Do not use brake fluid or jack oils in the hydraulic system. If oil is needed, use an anti-wear hydraulic oil with a

viscosity of 150 SUS at 100°F (ISO 32 @ 40°C), or non-synthetic transmission fluid.

TROUBLESHOOTING GUIDE

HYD-10-DC

• WARNING: Care should be taken to identify all potential hazards and comply with all applicable safety procedures before

beginning troubleshooting or repairs.

• CAUTION: Before performing any troubleshooting or repairs, the load must be removed from the platform. Then either

raise the platform and install maintenance props or fully lower the platform to the floor.

• Only qualified individuals trained to understand mechanical devices and their associated electrical and hydraulic circuits

should attempt troubleshooting and repair of this equipment.

Consult the factory for problems at time of installation, or for any problems not addressed in this manual.

* Check the charger notes page for troubleshooting other problems specific to battery-powered units.

PROBLEM Possible Cause Remedy

Power unit doesn’t run when “UP”

buttonispressed.

Motor runs, platform doesn’t move.

Power unit not noisy.

Motor hums or pump squeals, but

the platform does not move, or the

platform moves only slowly.

Platform raises, then drifts down.

Spongy or jerky platform move-

ment.

Platform won’t lower.

Platform lowers too slowly.

Platform lowers too quickly.

Bad motor relay coil.

Battery voltage low.

Pump is failing to build pressure.

See last paragraph, above.

Platform overloaded.

Pressure relief opening at full

pressure.

Contamination holding open the

lowering valve or the check valve.

See last paragraph, above.

Excessive air in the hydraulic

cylinders.

Solenoid coil is bad or connector is

loose.

Physical blockage of the structure.

Solenoid valve screen or suction

hose screen plugged.

Pinched hose.

Velocity fuse locking (platform will

only very slowly creep down).

Flowcontrolstuck.

See last paragraph, above.

Test with meter; replace if bad.

Check battery voltage with meter.

Consultthefactory.

Same as above.

Verify that the load doesn’t exceed

the lift's capacity.

Check for structural damage or

binding of the load rollers, etc.

Check for platform overload

condition.

Remove and inspect.

Same as above.

Bleed air from the cylinder(s).

Check with meter.

Inspect for foreign material or

objects that might block the

platform or its rollers.

Remove and inspect.

Check pressure, supply, and return

hosesforkinks.

Same as for jerky platform

movement.

Pull and inspect the flow control,

clear if necessary.

Same as above.

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