Vestil HYD-5 User manual

1
Vestil Manufacturing Corporation
2999 North Wayne St., Angola, IN 46703
Phone [phone] • Fax [phone]
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
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PARTS LIST
HEFTI-LIFT • HYD-5 & HYD-10
PARTS IDENTIFICATION HEFTI-LIFT
MODEL HYD-5 & HYD-10
24
7
8
9
1
6
5
3
10
11
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
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.
1
1
1
1
4
2
2
1
1
1
1
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.
1
2
1
1
4
2
2
1
1
1
1

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FOOT PUMP
HEFTI-LIFT • HYD-5 & HYD-10
PARTS IDENTIFICATION
FOOT PUMP (HEFTI-LIFT)
1 2
34
ITEM
NO.
1
2
3
4
A
B
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.
1
1
1
1
1
1
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.
1
2
3
4
A
B
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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
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

5
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.
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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.

7
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.
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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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
1
1
1
1
1
1
3
1
2
2
1
1
1
3

9
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.
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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.
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.

11
WARNING LABEL IDENTIFICATION
MAKE SURE ALL WARNING LABELS ARE IN PLACE!
PLATFORM MUST BE
LOWERED BEFORE
MOVING LIFT
210
!CAUTION !PRECAUCIÓN
LA PLATAFORMA DEBE DE
ESTAR EN LA POSICIÓN
BAJA ANTES DE MOVER
EL ELEVADOR
!ATTENTION
LA PLATE-FORME
DOIT ÊTRE ABAISSÉE
AVANT D’ACTIVER LE
MONTE-CHARGE
CAPA400Kgs (880lbs)
1
1
2
2
* Product safety signs or labels should be
periodically inspected and cleaned by the
product users as necessary to maintain
good legibility for safe viewing distance.
ANSI 535.4 (10.21)
Contact manufacturer for replacement labels.
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