OWNER S MANUAL. CART-23 & -24, ALL MODELS Serial number

Transcription

1 08/ dc VESTIL MANUFACTURING CORP N. Wayne St., Angla, IN Ph: Fax: Website: Operatin Instructins. 2-3 Rutine Maintenance & Safety Checks 4 Explded Pwer Unit Drawing & BOM Electrical & Hydraulic Diagrams CART-23 & -24, ALL MODELS Serial number OWNER S MANUAL Pwer Unit s Operatin Trubleshting Safety Label Identificatin...11 Warranty IMPORTANT NOTES, WARNINGS AND SAFETY INSTRUCTIONS Ensure that all emplyees understand and fllw the fllwing. Failure t read and understand this wner s manual befre using r servicing the cart cnstitutes a misuse f the prduct. All persns wh will use r care fr this prduct must be familiar with this material. The lad must be remved and the platfrm fully lwered befre any wrk is perfrmed n the cart. Ensure that all safety and warning labels stay in place and are legible. D nt use the cart if any damage r unusual nise is bserved. Always watch the platfrm and the lad carefully when the cart is in peratin. The cart is intended fr use nly n cmpacted, imprved surfaces. D nt use brake fluid r jack ils in the hydraulic system. If il is needed, use an anti-wear hydraulic il with a viscsity grade f 150 SUS at 100 F, (ISO C), r Dexrn transmissin fluid. Cntact the manufacturer fr any needed MSDS infrmatin. D nt perfrm any mdificatins t the cart withut the manufacturer s apprval. Failure t receive authrizatin fr changes t the equipment culd vid the warranty. Maintenance and repairs are t be dne nly by persnnel qualified t perfrm the required wrk. Cnsideratin will nt be given fr warranty repair charges withut prir written authrizatin by the manufacturer. WHEN ORDERING REPLACEMENT PARTS: We take pride in using quality parts n the equipment we manufacture. We are nt respnsible fr equipment prblems resulting frm the use f unapprved replacement parts. T rder replacement r spare parts fr this equipment, cntact the factry. In any cmmunicatin with the factry please be prepared t prvide the machine s serial number, which is indicated n the machine dataplate. RECEIVING INSTRUCTIONS Every unit is thrughly tested and inspected prir t shipment. Hwever, it is pssible that the unit culd incur damage during transit. Inspect the unit clsely when it arrives. If yu see evidence f damage r rugh handling t either the packaging r t the prduct when it is being unladed, immediately make a nte f it n the Bill Of Lading! It is imprtant that yu remve the prduct s packaging upn its arrival t ensure that there is n cncealed damage r t enable a timely claim with the carrier fr freight damage. Als verify that the prduct and its specificatins are as rdered. VESTIL MFG. CO. 1

2 11/13/02 08/17/05 CART manual, pwer unit peratin.dc OPERATION INSTRUCTIONS CART-23, -24 Ensure that all emplyees invlved in the peratin f this cart understand and fllw these instructins! The standard mdel CART is suitable fr use in mst industrial and cmmercial lcatins. It is intended t be used t transprt and lift stable, evenly-distributed, nn-hazardus lads and cntainers with rigid sides having a size r ftprint apprximately the same size as the platfrm. Lading: The lad rating, in punds, is shwn n the machine dataplate lcated n the left crner f the push handle end f the platfrm. It indicates the net capacity f the CART with a static lad that is centered and evenly distributed n the platfrm. Warning: The platfrm s rllers are nt captured. Therefre, d nt verhang any lad at the hinged end f the platfrm that culd cause the rller end f the platfrm t tip up and dump the lad. Fr applicatins invlving side r end edge lading, cnsult the factry. Nte: The additin f any ancillary equipment t the cart by third parties must be taken int accunt when determining the maximum wrking lad t be placed n the platfrm. Warning: D nt exceed the cart s lad ratings. Injury t persnnel r permanent damage t the cart culd result frm exceeding the listed capacity. Operatin: Inspect the perimeter pinch pint guards peratin daily (DC units). Warning: Keep all persnnel clear f the machine when it is in peratin. Be certain n part f any persn r bject is under any part f the platfrm befre lwering the unit. Cautin: Always carefully watch the platfrm and any lad n it when it is in peratin. D nt exceed a rate f tw feet per secnd when transprting a lad with the cart. The standard manually-pwered CART is furnished with a tw-speed ft pump. Under empty r lw lad cnditins, the pump pushes a higher vlume f fluid t the cylinder and thus lifts the platfrm with fewer ft strkes. With a mderate t full lad, the pump will autmatically reduce its utput in rder t generate the required hydraulic pressure. T lift the platfrm, simply repeatedly press the ft pump s ft treadle. T lwer the platfrm, press the small lever at the left crner f the pump with yur te. The unit will hld its psitin when the lwering lever is released. The standard DC-pwered CART is furnished with a cnstant-pressure (dead-man style) pushbuttn cntrl. Pressing the UP pushbuttn will turn n the pwer unit t raise the platfrm. The platfrm will raise nly while the cntrl is pressed. Upn releasing the cntrl, the platfrm will stp and hld its psitin. Pressing the DOWN pushbuttn will energize the lwering valve t allw the platfrm t descend by gravity (the mtr des nt run). Again, releasing the cntrl will stp the platfrm mvement, and the unit will hld its psitin. Cautin: Never use the cart if any damage r unusual nise is bserved, if it is in need f repairs, r if it seems t be malfunctining. Ntify yur supervisr r maintenance persnnel if yu ntice anything ut f the rdinary. On DC-pwered units, attempting t raise the lift when the battery is lw will cause the mtr relay prtectin t prevent the mtr s peratin. Adequate battery vltage is indicated by a green LED n the mtr relay. See the next page fr mre ntes regarding peratin f battery-pwered units. Ensure that all safety and warning labels stay in place and are legible. Refer t the labels page in this manual. 2 f 12

3 11/13/02 08/17/05 CART manual, pwer unit peratin.dc ADDITIONAL INSTRUCTIONS FOR BATTERY-POWERED UNITS Nte: If this prduct has the 24V pwered tractin-drive ptin, cnsult that ptin s infrmatin fr mre specific details regarding the batteries and battery charger. Warning!! Wrking with r near lead acid batteries is dangerus. Batteries cntain sulfuric acid and prduce explsive gases. A battery explsin culd result in lss f eyesight r serius burns.! D nt smke r allw a spark r flame near batteries. Charge batteries in lcatins that are clean, dry, and well ventilated. D nt lay tls r anything metallic n tp f any battery. All repairs t a battery must be made by experienced and qualified persnnel.! When wrking with batteries, remve persnal items such as rings, bracelets, necklaces, and watches. Batteries can prduce enugh energy t weld jewelry t metal, causing a severe burn.! Always have fresh water and sap nearby in case battery acid cntacts skin, clthing, r eyes.! Operating the battery with a lw battery vltage can cause premature mtr cntact failure.! D nt expse the lift r the charger t rain r adverse cnditins.! Replace defective crds r wires immediately.! Check the battery s water level frequently. Battery Charger Operating Instructins Never perate the charger with either f the cables ciled. Operating a battery charger with the crd either ciled r wrapped arund itself culd cause the crd t verheat, melt, and cause a shrt-circuit r a fire. Cnnectin: the ribbed wire f the charger s utput crd must be cnnected t the battery s negative (-) terminal. The nn-ribbed wire (with wrds printed n it) must be cnnected t the battery s psitive (+) terminal. When prperly cnnected, the charger will indicate the status f its utput: Flashing green LED the charger is nt seeing a gd cnnectin t the battery. Slid yellw LED the charger is prviding charging current t the battery. Slid green LED the charger is maintaining a fully charged battery. Plug the charger int a standard 115V receptacle. If an extensin crd must be used, keep it as shrt as pssible. Cautin: Remember t unplug the charger befre mving the equipment. Failure t d s culd cause damage t crds, receptacles, and ther equipment. The battery charger can be left cnnected t the battery indefinitely withut risk f harming the battery. Trubleshting: If the unit des nt perate, check all f the wiring cnnectins t make sure they re bth mechanically and electrically sund specifically at the battery, the mtr, and at any lcatin a wire is cnnected t the chassis. Als, make sure the quick-cnnect plug n the end f the pendant cntrl crd is plugged in crrectly (if applicable). A fully charged lead acid battery in gd cnditin at rm temperature shuld read vlts. At 11.9 vlts it is cnsidered t be fully discharged and in need f charging. When checking battery vltage, wait at least 1/2 hur after the charger has been turned ff befre checking the battery s vltage. If the batteries dn t seem t be taking a charge, check the charger s 115V supply circuit and the charger s utput with a vltmeter. If all check kay, cnfirm the battery s state f charge using a hydrmeter r a vltmeter. 3 f 12

4 11/13/02 08/17/05 CART manual, pwer unit peratin.dc ROUTINE MAINTENANCE & SAFETY CHECKS, CART-23, -24 Warning: Care shuld be taken t identify all ptential hazards and cmply with applicable safety prcedures befre beginning wrk. Warning: Remve any lad, raise the platfrm, and install maintenance prps befre beginning any inspectins r wrk n the unit. Only qualified individuals trained t understand mechanical devices and their assciated electrical and hydraulic circuits shuld attempt trubleshting and repair f this equipment (A) Inspect daily fr: 1.) Frayed wires (DC units). 2.) Oil leaks. 3.) Pinched r chafed hses. 4.) Damage r structural defrmatin t the structural members, the cylinder brackets, etc. 5.) Unusual nise r binding, r evidence theref. 6.) Prper functining f all limit switches, including thse n the perimeter pinch pint guard (DC units). (B) Inspect mnthly fr: 1.) The il level. Oil shuld be 1 t 1½ belw the reservir s fill hle with the lift in the fully lwered psitin. 2.) Oil leaks. 3.) Wrn r damaged electrical wires (DC units) r hydraulic hses. 4.) Pivt pint wear. 5.) Rllers lseness and wear. 6.) Integrity f the retaining hardware n all rllers and n all pivt pint pins. 7.) Lseness, wear, r damage t the casters bearings, munting hardware, r surface material. 8.) Prper water level in the battery (DC units nly.) 9.) Unusual nises. 10.) All the infrmatin, safety, and warning labels being in place and in gd cnditin. 11.) The need t clean ff dirt and debris. (C) Yearly inspectin The il shuld be changed if the il darkens, becmes gritty, r turns a milky clr (indicating the presence f water). Replace with an anti-wear hydraulic il with a viscsity grade f 150 SUS at 100 F, (ISO 32 at 40 C). Ex: AW 32 r HO 150 hydraulic il, r a nn-synthetic transmissin fluid. Yu may use a synthetic transmissin fluid if yu flush the system with the synthetic fluid befre filling the reservir. 4 f 12

5 11/13/02 08/17/05 CART manual, pwer unit peratin.dc MODULAR POWER UNIT PARTS BREAKDOWN -- DC-1 Nte: Mtrs, cylinders, and pumps can vary by mdel. Cnsult the manufacturer t determine the exact part numbers fr these items. 5 f 12

6 11/13/02 08/17/05 CART manual, pwer unit peratin.dc MODULAR POWER UNIT PARTS BREAKDOWN -- DC-2 Nte: Mtrs, cylinders, and pumps can vary by mdel. Cnsult the manufacturer t determine the exact part numbers fr these items. 6 f 12

7 11/13/02 08/17/05 CART manual, pwer unit peratin.dc ELECTRICAL DIAGRAM -- MODULAR POWER UNIT Warning: Care shuld be taken t identify all ptential hazards and cmply with applicable safety prcedures befre beginning wrk. Fully lwer r secure the frks, and ensure that all system pressure and pwer have been remved, befre attempting t wrk n the electrical r hydraulic systems. Fully lwer the frks befre beginning any inspectins r wrk n the unit. Only qualified individuals trained t understand mechanical devices and their assciated electrical and hydraulic circuits shuld attempt trubleshting and repair f this equipment 7 f 12

8 11/13/02 08/17/05 CART manual, pwer unit peratin.dc HYDRAULIC DIAGRAM LIFT-HOLD-LOWER CIRCUITS Warning: Care shuld be taken t identify all ptential hazards and cmply with applicable safety prcedures befre beginning wrk. Fully lwer r secure the frks, and ensure that all system pressure and pwer have been remved, befre attempting t wrk n the electrical r hydraulic systems. Fully lwer the unit befre beginning any inspectins r wrk. Only qualified individuals trained t understand mechanical devices and their assciated electrical and hydraulic circuits shuld attempt trubleshting and repair f this equipment Cautin: D nt use brake fluid r jack ils in the hydraulic system. If il is needed, use an anti-wear hydraulic il with a viscsity f 150 SUS at 100 F (ISO 40 C), r nn-synthetic transmissin fluid. 8 f 12

9 11/13/02 08/17/05 CART manual, pwer unit peratin.dc THE POWER UNIT S OPERATION CART-23, -24 The electric / hydraulic scissr lift utilizes an electric mtr directly cupled t a gear-type hydraulic pump t prduce the needed fluid pressure and flw t allw the cylinders t perfrm the wrk f lifting the platfrm lad. A hydraulic manifld huses the hydraulic cntrl cmpnents, and is blted directly nt the gear pump. The pwer unit s hydraulic cmpnents are all rated fr 3,000 psi wrking pressure. Imprtant parts f the pwer unit include: The electric mtr. Operates n a 12 VDC battery. The gear pump. Its shaft is cupled directly t the shaft f the electric mtr. The check valve. Its purpse is t prevent the backflw f fluid thrugh the pump. In this way it allws the platfrm t be held at a given elevatin indefinitely. The pressure relief valve. Its jb is t pen a path fr fluid t flw back t the reservir in the event that the fluid pressure built up by the pump exceeds 3,000 psi. The lwering slenid valve. This is an electrically-perated cartridge valve. It cntains a screen t keep cntaminants frm entering the valve. The pressure-cmpensated flw cntrl spl. This rests under the lwering valve, and regulates the fluid flw back t the reservir when the valve pens. It allws the table t always lwer at the same rate regardless f whether there is a lad n the platfrm r nt. The hydraulic lift cylinder(s). These are single-acting cylinders. The safety velcity fuse. This is a device that is installed in the cylinder s hse prt. It clses quickly in the event f a catastrphic hse failure t prevent the lift frm cllapsing dwn. The platfrm remains statinary until pressure is reapplied t the system. The hydraulic fluid. The system uses HO150 hydraulic fluid. Any anti-wear hydraulic fluid with an SUS viscsity f at 100 F (SAE viscsity grade f 32) such as AW-32 r Dexrn transmissin fluid are acceptable. When the platfrm is t be raised, press the UP pushbuttn. The mtr turns, which in turning spins the hydraulic gear pump. Oil is drawn frm the reservir thrugh the suctin filter and int the pump. The pump pushes the then-pressurized il thrugh the check valve and ut t the lift cylinders. When the platfrm is t be lwered, press the DOWN pushbuttn. The lwering valve pens, bypassing the check valve and allwing the il in the cylinders t return back t the reservir thrugh the return hse. The rate at which the platfrm lwers is regulated by the internal pressure-cmpensated flw spl. In the event that the platfrm creeps dwn slwly after releasing the DOWN cntrl, it will be necessary t remve the lwering cartridge valve fr inspectin and cleaning, as fllws: Remve any lad frm the platfrm. Raise the lift and then lwer the maintenance prps. Guide the prps int the cylinder push assembly as yu lwer the platfrm. Hld the DOWN pushbuttn until the lift rests n the prps. Remve the nut hlding the slenid cil n the valve stem, then remve the cil, and then unscrew the valve frm the manifld. Inspect the valve fr cntaminants, and the valve s -rings and back-up washers fr cuts, tears, r ther damage. With the valve immersed in mineral spirits r kersene, use a thin tl such as a small screwdriver r a small hex wrench t push the pppet in and ut several times frm the bttm end f the valve. The valve shuld mve freely, abut 1/16 frm clsed t pen psitin. If it sticks in, the valve stem culd be bent and will need t be replaced if it desn t free up after cleaning. Blw the valve ff with a cmpressed-air gun while again pushing the pppet in and ut. Inspect the bttm f the manifld s valve cavity fr cntaminants. Again with the thin tl, press n the middle f the flw cntrl spl lcated in the bttm f the cavity. It shuld mve dwn and back up freely. Reinstall the valve int the manifld, tightening the valve with apprximately 20 lb-ft f trque. If the platfrm lwers extremely slwly, r nt at all, the cylinder s velcity fuse culd be clsing. This can be caused by air in the hydraulic cylinders. T bleed the air frm the system: Remve any lad frm the platfrm. Raise the lift and then lwer the maintenance prps. Guide the prps int the cylinder push assembly as yu lwer the platfrm. Hld the DOWN pushbuttn until the lift rests n the prps. Pull the bttm f the cylinder ut f the push assembly and raise the end up higher than any ther part f the hydraulic system. Rtate the cylinder s the hse prt is pinting up. Lsen the hse fitting ½ turn, then jg the mtr. Oil and air will sputter frm the lse fitting nce n air is bserved, tighten the fitting and replace the cylinder int the push assembly. 9 f 12

10 11/13/02 08/17/05 CART manual, pwer unit peratin.dc TROUBLESHOOTING GUIDE -- CART-23, -24 Warning: Befre perfrming any task, always remve any lad and lwer the platfrm fully t the flr. * Check the DC ntes page fr trubleshting ther prblems specific t battery-pwered units. Cnsult the factry fr prblems at time f installatin, r fr any prblems nt addressed belw. Prblem: Pssible cause(s): Actin: Upper-travel limit switch is Test with meter; replace if bad. engaged r bad. Bad mtr relay cil. Battery vltage lw. Pwer unit desn t run when UP buttn is pressed (DC units). Mtr runs, platfrm desn t mve (DC units). Mtr hums r pump squeals, but the platfrm des nt mve, r the platfrm mves nly slwly (DC units). Spngy r jerky platfrm mvement. Platfrm wn t lwer. Cntrl cable s cnnectr is lse. Pump has gne bad. Platfrm verladed. Pressure relief pening at full pressure. Excessive air in the hydraulic cylinders. Slenid cil is bad r cnnectr is lse (DC units). Slenid valve r suctin hse screen plugged (DC units). Physical blckage f the structure. Test with meter; replace if bad. If LED n mtr relay is nt n, check battery vltage with meter. Check quick-cnnect plug. Cnsult factry. Verify that the lad desn t exceed the table s capacity. Check fr structural damage r binding f the scissr legs, etc. Check fr platfrm verlad cnditin. Bleed air per prcedure described in this manual. Check with meter. Check quickcnnect plug. Remve and inspect. Clean per instructins in this manual. Inspect fr freign material r bjects that might blck the leg set r its rllers. Platfrm lwers t slwly. Platfrm raises, then drifts dwn. Pinched hse. Flw cntrl spl sticking. Velcity fuse lcking (platfrm nly slwly creeps dwn). Cntaminatin hlding pen the lwering valve r the check valve. Check pressure, supply, and return hses fr kinks. Remve plug frm FC prt; push n flw spl t ensure it is fully pressed int the cavity. Same as fr jerky platfrm mvement. Remve and inspect. Clean per instructins in this manual. 10 f 12

11 11/13/02 08/17/05 CART manual, pwer unit peratin.dc SAFETY LABEL IDENTIFICATION * Prduct safety signs r labels shuld be peridically inspected and cleaned by the prduct users as necessary t maintain gd legibility fr safe viewing distance -- ANSI (10.21). Cntact the manufacturer fr replacement labels. CART-2x-1x-DC CART-2x-1x-M 11 f 12

12 11/13/02 08/17/05 CART manual, pwer unit peratin.dc POWERED PRODUCTS WARRANTY ONE YEAR LIMITED WARRANTY The manufacturer warrants fr the riginal purchaser against defects in materials and wrkmanship under nrmal use ne year after date f shipment (nt t exceed 15 mnths after date f manufacture). Any part that is determined by the manufacturer t be defective in material r wrkmanship and returned t the factry, shipping csts prepaid, will be, as the exclusive remedy, repaired r replaced at ur ptin. Labr csts fr warranty repairs and/r mdificatins are nt cvered unless pre-apprved by the manufacturer r dne at the manufacturer s facilities. Any mdificatins perfrmed withut prir written apprval f the manufacturer may vid warranty. This limited warranty gives purchaser specific legal rights which vary frm state t state. All specificatins are subject t change withut ntice. LIMITATION OF LIABILITY T the extent allwable under applicable law, the manufacturer s liability fr cnsequential and incidental damages is expressly disclaimed. The manufacturer s liability in any event is limited t, and shall nt exceed, the purchase price paid. Misuse r mdificatin may vid warranty. Warranty des nt cver labr r cnsequential damages including, but nt limited t, business interruptin csts, lst prfits, r lst business pprtunities. WARRANTY DISCLAIMER The manufacturer has made a diligent effrt t accurately illustrate and describe their prducts. Hwever, such illustratins and descriptins are fr the sle purpse f identificatin, and d nt express r imply a warranty that the prducts are merchantable r fit fr a particular purpse, r that the prducts will necessarily cnfrm t the illustratins r descriptins. The prvisins f the warranty shall be cnstrued and enfrced in accrdance with the Unifrm Cmmercial Cde and laws as enacted in the State f Indiana. DISPOSITION Our cmpany will make a gd faith effrt fr prmpt crrectin r ther adjustment with respect t any prduct that prves t be defective within the Limited Warranty Perid. Warranty claims must be made in writing within said year. 12 f 12