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Vestil EPT Series User manual

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Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 1 of 51
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 PAGE
Safety Principles 2 Fig. 1A EPT Main Body Components 5
Product Introduction 2 Fig. 1B EPT-30 (optional) Scale Components 6
Safety Guidelines 3 Fig. 2 EPT-30 Hydraulic Cylinder Assembly 7
Removing EPT from Pallet 3 - 4 Fig. 3 EPT-30 Drive Wheel Assembly 8
Use, 1st Inspection, & Functions Tests 20 Fig. 4A EPT-30 Fork & Carriage 9
Operation 20-21 Fig. 4B EPT-30 Fork & Carriage (optional) Scale 10
Lifting & Transporting Loads 21 Fig. 5A Control Yoke & Handle Components 11-12
Batteries & Charger 21-22 Fig. 5B Control Yoke & Handle (optional) Scale 13-14
Fig. 6 Hydraulic Pump & Motor Assemblies 15
Troubleshooting 23-48 Fig. 7 EPT-45 Main Housings & Supporting Structure 16
Changing Cylinder 28-31 Fig. 8 Removable Battery Box & Components 16
Changing Throttle Assy. 32-36 Fig. 9 EPT-45 Cylinder & Fuse Panel 17
Changing Motor Assy. 37-39 Fig. 10 EPT-45 Fork & Carriage Assemblies 18
Replacing Forward/Reverse Contactor 40-42 Fig. 11 Function Controls, Gauges, & Safety Features 19
Changing Battery Charger 43-46 Maintenance & Inspections 49-50
Adding Quencharcs 47-48 Markings 51
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: [email protected]
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 2 of 51
PRODUCT INTRODUCTION
Specifications for each of the 4 models appear in the table below:
Net Wt. Fork Size Service
MODEL (lbs.) (W x L) in inches Range (in.) Capacity
(lbs.) Overall Size
(W X L x H) in inches
EPT-2047-30 660 20in. X 47in. 3.2 to 7.8 3,000 28 x 65 x 49
EPT-2547-30 671 25in. x 47in. 3.2 to 7.8 3,000 28 x 65 x 49
EPT-2048-45 990 20in. x 48in. 3.4 to 8 4,500 30x 78.5 x 49
EPT-2748-45 1012 27in. x 48in. 3.4 to 8 4,500 30x 78.5 x 49
Vestil Manufacturing Corp. created this manual to acquaint 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 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:
Identifies a hazardous situation which, if not avoided, WILL result in DEATH or SERIOUS
INJURY. Use of this signal word is limited to the most extreme situations.
Identifies a hazardous situation which, if not avoided, COULD result in DEATH or
SERIOUS INJURY.
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.
No safety alert symbol (equilateral triangle enclosing an exclamation point) accompanies this
signal word.
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 provided in this manual.
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 3 of 51
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 subsequent use.Read the manual to refresh your understanding of the safe use and
maintenance procedures on p. 50-51. If questions 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.
To decrease the risk of electrocution:
¾DO NOT contact or operate the pallet truck close to electrified wires or other sources of electricity;
¾Before operating the EPT, always inspect the area where you will use it.
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:
xDO 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).
xDO NOT attempt to lift or transport loads that exceed the rated capacity.
xInspect 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 & Perform a Functions Tests” on p. 20.
xDO 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.
xDO 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.
xDO NOT use the EPT if it makes unusual noises during operation.
xDO NOT allow people to ride on the pallet truck. Only the operator of an EPT equipped with a properly
installed rider platform (EPT
xDO NOT attempt to lift an unevenly distributed load. Always center and evenly distribute the load on the forks.
xDO NOT operate the EPT on surfaces (ramps or grades) angled more than 4 degrees.
xDO 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.
xDO NOT modify the pallet truck without first receiving written authorization from Vestil. Unauthorized
modifications may make the EPT unsafe to use.
To maximize the service life of the EPT and to prevent damage:
xAlways store the machine in a secure, dry location where it will not interfere with traffic or other activities.
xMaintain the product as suggested in “Maintenance & 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.
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 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).
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 4 of 51
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.
To lift the EPT with a forklift:
Avoid contacting the drive wheel with the tines of your
forklift; contact could damage the drive wheel.
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.
Operator
Side
Loading
side
Hook point
1
2
3
EPT-45 EPT-30
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 5 of 51
Item No. Part No. Description Item No. Part No. Description
2001 EPT-30-2001 Main Body Housing 2021 EPT-30-2021 22mm Snap Ring
EPT-30-2001-2 Housing Screw 2022 EPT-30-2022 10mm Washer
2002 EPT-30-2002 Battery Cover 2023 EPT-30-2023 M10 x 22 Screw
2003 EPT-30-2003 Battery (2 per unit) 2024 EPT-30-2024 Bolt
2004 EPT-30-2004 Battery Charger (OEM) 2025 EPT-30-2025 Bolt
EPT-30-2004-2 Replacement Charger (OEM Unit) 2026 EPT-30-2026 Wheel 76 x 36
EPT-CORD Battery Charger Cord 2027 EPT-30-2027 M12 Nut
2005 EPT-30-2005 M6 Spring Washer 2028 EPT-30-2028 Wheel Frame
2006 EPT-30-2006 M6 Nut 2029 EPT-30-2029 Shaft
2007 EPT-30-2007 24V Battery Charge Gauge 2030 EPT-30-2030 Bushing
2008 EPT-30-2008 Key Switch 2031 EPT-30-2031 Bearing Plate
2009 EPT-30-2009 Emergency Stop Switch 2032 EPT-30-2032 Bearing 30205
EPT-30-KSA Key Switch Assembly 2033 EPT-30-2033 Bearing Plate
2010 EPT-30-2010 M6 Flat Washer 2034 EPT-30-2034 Ball Bearing 6205
2011 EPT-30-2011 M6 x 25 Bolt 2035 EPT-30-2035 25mm Washer
2012 EPT-30-2012 Set Pin 2036 EPT-30-2036 M10 Nut
2013 EPT-30-2013 Pivot Link Arm 2037 EPT-30-2037 8mm Washer
2014 EPT-30-2014 Bushing 2038 EPT-30-2038 Fixed Ring
2015 EPT-30-2015 16mm Snap Ring 2039 EPT-30-2039 Link Rod
2016 EPT-30-2016 Main Body 2040 EPT-30-2040 Bolt
2017 EPT-30-2017 20mm Snap Ring 2041 EPT-30-2041 Mounting Plate
2018 EPT-30-2018 Bushing 2042 EPT-30-2042 8mm Washer
2019 EPT-30-2019 Cylinder Pivot Pin, Upper 2043 EPT-30-2043 Bolt
2020 EPT-30-2020 Cylinder Pivot Pin, Lower 2044 EPT-30-2044 Wheel Stabilizer Assembly
2045 EPT-30-2045 Upper Travel Limit Switch
FIG. 1A:EPT-30 MODELS MAIN BODY COMPONENTS
2003
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 6 of 51
Item No. Part No. Description
4001 EPT-30-SCL-4001 Scale Display
4002 EPT-30-SCL-4002 Display Mounting Bracket
4003 EPT-30-SCL-4003 6mm Flat Washer
4004 EPT-30-SCL-4004 M6 x 10 Bolt
4005 EPT-30-SCL-4005 M6 x 30 Bolt
4006 EPT-30-SCL-4006 6mm Spring Washer
4007 EPT-30-SCL-4007 M6 Nut
4008 EPT-30-SCL-4008 M6 Nut
4009 EPT-30-SCL-4009
4010 EPT-30-SCL-4010
FIG. 1B:EPT-30 MODELS (OPTIONAL)SCALE COMPONENTS
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 7 of 51
Item No. Part No. Description
4200 EPT-30-4200 Cylinder Assembly
4201 EPT-30-4201 Cylinder Body Tube
4202 EPT-30-4202 Gland Tube
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 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 & 45)
FIG. 2: EPT-30 MODELS HYDRAULIC CYLINDER ASSEMBLY
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 8 of 51
Item No. Part No. Description Item No. Part No. Description
Not
Shown EPT-30/45-DBA Drive Brake Assembly 3015 EPT-30-3015 Pinion Gear
3300 EPT-30-DWA
Complete Drive Wheel
Assembly (includes Motor) 3016 EPT-30-3016 Key
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
5 x 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
3007 EPT-30-3007
Replacement Polyurethane
Drive Wheel 3023 EPT-30-3023 Spacer
3007 EPT-30-3007-R
Replacement Rubber Drive
Wheel 3024 EPT-30-3024 Motor Shaft Pilot Bearing
3008 EPT-30-3008
140 x 180 x 12 Oil Seal 3025 EPT-30-3025 Spacer
3009 EPT-30-3009
Wheel Bearing 3026 EPT-30-3026 Brake Mounting Adapter
3010 EPT-30-3010
Snap Ring 3027 EPT-30-3027 Splined Coupling
301 EPT-30-3011
Bull Gear 3028 EPT-30-3028 Snap Ring
3012 EPT-30-3012
Grease Seal 3029 EPT-30-3029 Brake Pad
3013 EPT-30-3013
Gear Box Casting 3030 EPT-30-3030 Brake Coil
3014 EPT-30-3014
Idler Gear 3031 EPT-30-3031 Cap Screw
EPT-30-MTR-BLT M6-1.0 x 185mm Motor Bolt
FIG. 3: EPT-30 MODELS DRIVE WHEEL ASSEMBLY
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 9 of 51
Item No. Part No. Description Item No. Part No. Description
1001 EPT-30-1001 Fork Assembly 1012 EPT-30-1012-2 Push Rod Pin (Hole in Center)
1002 EPT-30-1002 M6 Nut 1013 EPT-30-1013 40” Push Rod
1003 EPT-30-1003 Nose Wheel 1013-2 EPT-30-1013-2 37-1/2” Push Rod
1004 EPT-30-1004 M6 x 45 Screw 1014 EPT-30-1014 Lock Nut
1005 EPT-30-1005 Snap Ring 1015 EPT-30-1015 Clevis
1006 EPT-30-1006 Ball Bearing 6204z 1016 EPT-30-1016 Clevis Pin
1007 EPT-30-1007 75 x 96 Load Roller 1017 EPT-30-1017 22 x 20 Sleeve Bearing
1008 EPT-30-1008 Load Roller Axle 1018 EPT-30-1018 Trunion Shaft
1009 EPT-30-1009 5 x 30 Roll Pin 1019 EPT-30-1019 16mm Snap Ring
1010 EPT-30-1010 Load Roller Bracket 1020 EPT-30-1020 16 x 16 Clevis Pin Sleeve Bearing
1011 EPT-30-1011 Bracket Pin 1021 EPT-30-1021-25 Trunion (Model EPT-2547-30)
Not Shown EPT-30-EXT-RL Steel Exit Roller 1021 EPT-30-1021-20 Trunion (Model EPT-2047-30)
1012 EPT-30-1012 Push Rod Pin 1022 EPT-30-1022 22mm Snap Ring
1023 EPT-30-1023 Pin
FIG. 4A:EPT-30 MODELS FORK AND CARRIAGE
Rev. 0213 EPT, Manual.doc
Copyright 2013 Vestil Manufacturing Corp. Page 10 of 51
Item No. Part No. Description Item No. Part No. Description
1001 EPT-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 EPT-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-SCL-1006 Retaining Ring 1022-B EPT-30-SCL-1022-B Trunion (EPT-2047-30-SCL)
1007 EPT-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 EPT-30-SCL-1011 Load Roller Bracket Integral Scale Components
1012 EPT-30-SCL-1012 Load Roller Bracket Pivot Pin 4011 EPT-30-SCL-4011 Load Cell
1013 EPT-30-SCL-1013 Push Rod Pivot Pin 4012 EPT-30-SCL-4012 M12 x 45 Bolt
1014 EPT-30-SCL-1014 Push Rod (Owner must provide
measurement) 4013 EPT-30-SCL-4013 12mm Spring Washer
1015 EPT-30-SCL-1015 M22 x 1.5 Lock Nut 4014 EPT-30-SCL-4014 Washer
1016 EPT-30-SCL-1016 Push Rod Clevis 4015 EPT-30-SCL-4015 Weighing Forks
1017 EPT-30-SCL-1017 Clevis Pin 4016 EPT-30-SCL-4016 M12 x 38 Bolt
FIG. 4B:EPT-30 MODELS FORKS AND CARRIAGE WITH INTEGRATED SCALE