S-Series Powered Drive & Powered Lift Owner`s manual
Contents
1. Receiving instructions ddp Product GOSCI IDIOM z ua a iutaha si DESIGN ated USE ces wis wi su pam SH O Ihe TRUGK u n bag mmm L m edite ur aca Saa mansi Transport Operation Operation Operating elements uuu Dau II Ime ush ku Safety Driving DEAKING ANG NOM LATING ANG Owenn T a Vo ing mc Er Taking UD Me 16801 u Driving on sloping surfaces Maintenance and repair Changing iUm tu Changing motor controller 0 07700 2 2222 Belly switch trouble 2 4403 202 27 7 7 7 222 Maintenance daily before use monthly annually Maintenance and care of the load chains Ghain Temporary ay UD sa2. 4 n d gt 4 a x J ve 2 VF eS a w Solder connection Belly Switch actuator Solder connection Replace broken missing components assemble press the red belly switch cover back on the tiller head seating the red holes over the gray nubs Basically the opposite of the procedure in Fig 17 but without a screwdriver Fig 19 Filename Belly Switch trouble shoot VESTIL CO 43 Model S 62 AA FF FA The spring can be pushed into position Fig 20 This is the spring shown not seated completely Push the spring into the pocket and over the gray plastic nub Fig21 Filename Belly Switch trouble shoot VESTIL MFG Model S 62 AA FF FA 44 Install bushings Fig22 Put throttle thumb wheels back Fig23 Filename Belly Switch trouble shoot VESTIL MFG Model S 62 AA FF FA 45 Install Philips screw Fig24 Re installing the tiller cover is basically reversing steps Fig 5 thru 9 with the following precautions steps Make sure red tabs on each side goes on top of black nubs when installing tiller cover on the handle Fig 25 EN Red Tab on each side Filename Belly Switch trouble shoot VESTIL MFG CO Model S 62 AA FF FA 46 Black nub for right side shown here and the next photo fig 26 iv The red tab slides over the top of this black nub on each side when installing the tiller throttle assembly back on
3. ua aa aa aaa Parts List 54 60 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 you see damage when unloading make a note of iton the SHIPPER RECEIVER Remove all packing amp strapping material inspect for damage IF DAMGE IS EVIDENT FILE A CLAIM WITH THE CARRIERIMMEDIATELY Also check fork size type of power unit etc to see that the unit is correct for the intended application Warnings amp Safety Instructions Insure that all employees understand and follow the following instructions e Read and understand the owner s manual before using or servicing the stacker e Do not use the stacker if any damage or unusual noise is observed e Improper use of this lift truck could result in injury and damage to load or equipment e Always watch the stacker and any load on it carefully when it is being used or moved e Avoid sudden stops or quick turns to turns to prevent accidental tipping of the load e Load must be centered and evenly distributed on the forks e Park the truck on level surfaces and not in the way of other products e When parked lower the load fork completely e When parked push E switch push button down e Do not perform any modifications to the stacker without the manufacturer s approval Failure to receive authorization for changes to the equipment could vo
4. 33 Model S 62 AA FF FA S 62 XX verify this is the unit you are working on Make sure E switch is off pushed down Fig 2 34 Filename Belly Switch trouble shoot VESTIL MFG Model S 62 AA FF FA This is the top side of the tiller Fig3 This is the driver side of the tiller looking at the belly switch Fig 4 Filename Belly Switch trouble shoot 35 VESTIL Model S 62 AA FF FA This is the bottom side of the tiller handle 3 allen head screws need to be removed Fig5 Lift the front top edge of the tiller cover up Fig6 Filename Belly Switch trouble shoot 36 VESTIL Model S 62 AA FF FA Carefully pull the belly switch back off of the tiller while tipping the front up Fig 7 Filename Belly Switch trouble shoot 37 VESTIL Model S 62 AA FF FA The tiller assembly cover should come off just be careful not to drop it and rip out the wiring from the connectors At this point the tiller throttle assembly can be replaced with a new one by just unplugging the two connectors Or if the problem appears to be in the belly switch itself further breakdown of the assembly can continue to search for the problem Fig 8 38 Filename Belly Switch trouble shoot VESTIL CO Model S 62 AA FF FA Remove Philips screw on throttle Figl0 Throttle wheel will then pull off Take note of the orientation of the wheel on the s
5. SLG The oil level Oil should be 1 1 2 to 2 below the reservoir s fill hole with the lift in the fully raised position Worn or damaged hydraulic hoses and electrical wires Pivot point wear Roller s looseness and wear Integrity of retaining rings on all the rollers and at all pivot points Looseness wear or damage to the front rollers amp drive wheel bearings mounting hardware or surface material Proper functioning of any hand or foot operated mechanisms Proper water level in the battery Unusual noises or movement during operation 10 All the information safety and wearing labels being in place and in good condition 11 The need to clean off dirt and debris C YEARLY INSPECTIONS 1 I c The oil should be changed if the oil darkens becomes gritty or turns a milky color indicating the presence of water Replace with anti wear hydraulic oil with a viscosity grade of 150sus at 100 ISO 32 at 406 Ex AW 32 HO 150 hydraulic oil or a non synthetic transmission fluid You may use a synthetic transmission fluid if you flush the system with the synthetic fluid before filling the reservoir Check chain and chain connections for any mechanical damage Clean upright channels and mast rollers amp grease slightly Check magnetic brake travel amp if necessary change brake rotor Check carbon brushes for any wear in the lift motor amp if necessary change carbon brushes Maintenance and repair Ma
6. Electric Control Pane 1 21 334 Steel Cover 1 1100 Balance Castor 1101 Bolt 16 90 2 1102 Nut 6 n3 23 3313 Socket Bolt 8 10 2 Battery _ 2 Bolt M10x30 __ 2 1103 Spring Washer Z 16 8 140 EM 11 3301 DirectionalAxle 1 13 330 SpringWasher 12 4 14 31 ____ Spring Washer c10 8 32 1109 ____ HexNutMio 5 35 106 Swth h 2 SeelHop i 16 EN 3200 Driving Wheel EC Bearing 6203 48 16010 58 Part list Part Number Qty No Part Number FOuerMast i 2 16 2108 Snap Ring 30 4 203 Spring Washer 216 2 _ 5 2004 _ FrontwWheelAxe 2 6 1205 4 8 2007 7555 2 9 1101 5 8 1 10 2102 Spring Washer 28 2 11 21 7 BoltM8x20 7 2 12 21144 Roller Bushing 8 Bearing 2300 26 2100 Snap Ring lt 35 59 Part list 3204 3203 8202 8201 fe NC 5 Ne cT M0 c 321 3211 3212 S ui 3214 3216 3211 3218 m 3119 w 3300 60 Description __ Front button outlet outlet big outlet outlet small Main cover Spig 3101 3102 3103 3104 H 3107 3108 1 a ____ button
7. J1 J2 FU1 FU2 FU3 L1 Solenoid valve L2 DC24V 16W LB MC TSQ D1 S1 52 54 55 J3 1 1 1 1 1 1 7PCS 1PC 1PC 1PC DC24V ETR711 230 Power meter Throttle Diode IN5408 Diode D2 D8 IN4007 Battery charger 24V 15A Key switch 51 5001 Emergency stop so ZDK31 250 Clutch micro switch 59000 1703 Forward backward switch 54 TM1703 Back run safety device button ps KW2 OZ Lift limit switch 56 KW2 OZ Lift switch KW2 OZ Horn switch 59 2 07 Low switch KW2 OZ Power plug DC110V 200A Electric wire RV16mm2 Ss Electric wire RV0 5mm2 FUL 02 FU LB 011216 MC TSQ __ on D2 D8 IN NO N IN 25 26 27 28 29 30 31 2PCS 2 cO 2PCS 2PCS _ 2 Dur KCN E CNN EUM ae EUN um m 1 KE Sas ELEM S Eua a s 56 Part list Hydraulic Circuit Diagram Rod sima Stroke 1750am 9416 18 3 X X44 E 4 US V2 USU 2N 7 Working pressure LlPa 2 1 waite aa Ke NTWE 10 SL Horigontal DESCRIPTION DESCRIPTION Fr omaia i A _ E Microswitch Flow control valve Manual valve Howe 3 57 Part list T Number L1 1000 MainFrame 1 20 33100 SnapRig c80 2 3300
8. 3 on Molex connector on motor controller and follow procedure Problem Possible cause s Unit will not go forward or reverse Broken wire or loose connection but belly switch still functions bad motor controller properly Throttle assembly bad Unit will not move forward or Blown fuse reverse and the Belly switch will not function unit does turn on as indicated by the battery gage Broken wire or loose connection lighting up Unit will not go forward the belly Broken wire or loose connection switch functions reverse works bad motor controller Bad throttle assembly 19 Action Locate Pin 6 on Molex connector at the motor controller Try to drive the unit in forward there should be 0 to 5 volts 5 v is full throttle at this pin If there is voltage and the unit does not move the motor controller may be bad consult diagnostics page factory 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 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 6 replace throttle assembly See Fig 1 Verify fuses are good replace if blown Locate Pin 7 on Molex connector at the motor c
9. Instructions for Changing the Tiller Assembly S 62 AA FF FA estimated time 30 min READ ALL INSTRUCTIONS BEFORE PROCEEDING Only qualified personnel should work on this equipment Lock out all potential energy sources before attempting this installation turn off the unit and remove the key Warning Working with or near lead acid batteries is dangerous Batteries contain sulfuric acid and produce explosive gases 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 if this applies to your battery type sure the battery charger is unplugged from 115vac source 32 Filename Belly Switch trouble shoot
10. charge Unit will not go forward reverse works belly switch just kills unit does not go forward and time out Possible cause s Battery voltage low lt 17 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 Unit will not go reverse belly switch Broken wire or loose connection 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 contactor bad motor controller bad 18 Action Charge batteries Consult diagnostics page factory Remove back shroud and check fuses 3 fuses Verify output voltage on charger will only get a reading when connected to batteries should be approximately 28 volts Load test batteries Locate Pin 2 on Molex connector at motor controller Trace wiring to contactor and verify connection When forward is depressed there should be 24 volts on this wire from Molex connector to the contactor if not the motor controller may be bad consult diagnostics page factory If 24 volts is present at contactor verify ground connection ground is good remove both wires and check with ohm meter resistance should be approximately 38 ohms If it s open or zero the contactor should be replaced Same as above except locate Pin
11. integrating the product with as little risk as possible into his working environment This obligation continues through every phase of the products lifespan beginning at the planning stage Residual dangers are to be minimized Only trained competent personnel who have been instructed using the operating manual and the product are permitted to work with the truck The operating manual must be understood responsibility checking Declaration have read this manual and in particular have taken note of the caution Specification SPECIFICATION 2000 105 2000 Ibs 2000 165 Fork Lift Height Fork Dimension Overall fork width Ground Clearance Lowered Fork H H Overall Extended Head Dimension 81 7 8 26 1 2x30x29 3 4 Loading Center 23 5 8 Wheel Base Turning Radius 44 34 55 4x2 3 1 8x3 3 8 Front Wheel Drive Wheel 10 3 1 8 Overall Size 68x30x82 2 95 s Speed Unload 5 97 4 s 4 s 4 5 5 Unload 2 s Travel 5km h Drive Motor 24V 700W 24V 700W 24V 700W 24V 2 0KW 1207A 4102 2x12V 70Ah DC 24V 6A Soneil 950 Ibs 6 10 10 10 35 1 2 Note load capacity is based the situation when the center of the gravity is located at the center of length of forks When the center of gravity of goods is out of the center of forks the load capacity will be lessened compared to the center General CONTENTS ille m
12. ip verat con THAN Only sane et when the fork in fully low do Removinq from the pallet or liftinq the product Lifting belt specification Use polyester lifting sling or nylon sling and hoist with a minimum of 2 000 Ib capacity CAREFUL A To pick up the unit only use overhead hoist forklift or loading crane with sufficient carrying capacity Refer to the identification plate for the weight of the truck DANGER A When unloading the truck all personnel should be cleared from area OPERATION Visually inspect stacker for damaged and worn parts before stacker is taken into operation Authorized person should read and understand all instructions The lifting truck is ready for immediate use once the packaging has been removed e The battery is and charged The hydraulic tank is full driving gear is filled with oil filling for approx 200 operation hours steering roller and the running rollers are equipped with bearings which do not require maintenance all mast rollers are also free from maintenance Caution Pedestrian controlled industrial trucks may only be operated by persons who have been satisfactorily instructed in operating the truck and have proved their ability to operate the truck to the responsible representative of the operating company The first driving attempts should take place on level and spacious surfaces Recommendation Th
13. or Solenoid valve leaking contamination holding open the lowering valve or the check valve 22 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 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 throttle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground f there is still no output voltage for pin 12 replace throttle assembly Re fill hydraulic oil when forks are lowered Open vent screw on the lift cylinder with forks lowered all the way down Lift forks with vent screw open until oil is free from air bubbles Close the vent screw Remove amp inspect Remove any load from the forks Remove the nut holding solenoid coil on the valve stem and then unscrew the valve from the manifold Inspect the valve for contaminants and the valve s o rings and back up washers for cuts tears and other damage With valve immersed in mineral spirits or kerosene use a thin tool such as a small screwdriver or a small hex wrench to push the poppet in and out several times from
14. 3112 3113 3114 3115 3116 3117 3118 3119 3201 Electric throttle Handle bar Washer Handle board _3207 Bearing EUN 346 L 3u ans 3m9 320 3202 3203 __3204 __3205 3206 320 I pte oo Go 3300 Drive wheel system 1
15. 61124 15 26 Filename Changing Motor Controller in S 62 Stacker VESTIL MFG CO ModelS 62 A A FF FA The wiring must be marked The wiring should be marked in a unique way to remember where it all goes when re connecting One possible method 15 shown below d E i as c Remove the two 14mm bolts holding the motor controller mounting plate to the frame 27 Filename Changing Motor Controller in S 62 Stacker VESTIL MFG CO ModelS 62 A A FF FA Remove Molex connector from the motor controller 28 Filename Changing Motor Controller in S 62 Stacker VESTIL MFG CO ModelS 62 A A FF FA Remove the motor controller wiring with two 14mm wrenches 20 Filename Changing Motor Controller in S 62 Stacker VESTIL MFG CO ModelS 62 A A FF FA Wiring shown here removed Remove 3x 8mm screws holding the motor controller to the back plate with a Philips screwdriver and 8mm wrench 1 screw in back and two in the front 30 Filename Changing Motor Controller in S 62 Stacker VESTIL MFG CO ModelS 62 A A FF FA Remove the motor controller and replace with a new controller by reversing the above steps Verify the 4 spade terminal connections are still good on the forward reverse motor contactor The contactor is just below the motor controller Filename Switch trouble shoot VESTIL MFG CO Model S 62 AA FF FA
16. 71 Ape 500011 101921002 10100 UTATIQ SLM 12104 SH CEN 101221002 10100 1177 m I E 191174 eo1Aap 41929 UnJ 359g SPY UIIAS przsyoeq p Pi J D1IAS OIME 121111 H j 91185 moj 19790 1280 Part list Electric circuit 54 09921 12023 11251 RVl mm blan green RYO Smm red Smm areen RYO Sem gray RYO Sma pink ARVO Sme W u2218 40 24 kok k i black RYO Sun 10 ium 0 143 green RYO 5112 blue white RYO Smm Ni m pL orange Smm brown RVO Sum TS 5 55 YAST A8 TIJ 14 DAY 9214439 K WS DAY 9114 02 WHS OAR 1 UWS Ay 114 Part list S 62 Electric component list Specification 12V 70Ah 1207A 4102 Drive motor DC24V 0 7KW DP o __ M __ Lift motor DC24V 2 0KW luc ___ o 1 2 5 1PC 1PC 1PC 1PC 1PC 1PC 1PC Batter Controller Lift motor contactor MZJ200S 24V Drive motor contactor MZJ200S 24V Direction contactor DC88 1 24V Direction contactor DC88 1 24V Control circuit fuse 26 30 10A Hydraulic circuit fuse 150A Drive circuit fuse 100A Electromagnetic clutch DC24V 28W KZQ M1 M2
17. OPERATION amp SERVICE MANUAL S SERIES STACKER WITH POWERED DRIVE amp POWER Vestil Manufacturing Corp 2999 North Wayne St Angola IN 46703 Ph 260 665 7586 Fax 260 665 1339 E mail Sales vestil com Website www vestil com 1 General Read and follow the instructions contained in this operating manual without fail Only trained well informed personnel who have been instructed in accordance with this operation manual may use or work on the machine Liability or guarantee is waived if The instructions in this operating manual are not observed The high lift stacking truck is operated cleaned or maintained incorrectly Alterations to the functions are carried out without the consent of manufacturer Original spare parts are not used Safety instructions This chapter informs the user about residual dangers relating to the correct use of the products It contains generally valid safety instructions which must be observed Safety instructions relating to specific actions or situations are listed prior to the respective action and or description of the situation in the chapter Principles This product complies with state of the art technical standards and recognized safety regulations but there are still dangers which may occur which must be considered Only operate the product in a perfect condition and observing the information contained in the operating manual The operator is responsible for
18. VESTIL MFG CO Model S 62 AA FF FA 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 and the motor 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 batteries aren t being charged by the charger check the output charger fuse Verify fuse 1s good with an ohmmeter or close visual ohm meter best Fuse is a 10Amp 250 Volt GBD 10A Tf it is good check the battery s state of charge with a voltmeter The charger must be connected to the battery in order to read the output voltage of the battery charger Depending on the state of charge of the batteries the voltage should be somewhere around 27 to 28 volts dc If the batteries are fully charged and the units belly switch is not functioning the following procedure will show how to A Replace the tiller assembly which contains the belly switch and throttle controls B Iroubleshoot belly switch mechanism itself The following tools will be required omm allen wrench Philips bladed screw driver Small Regular flat bladed screw driver Filename Belly Switch trouble shoot VESTIL MFG CO
19. ated 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 above motor controller Re charge batteries 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 Re fill hydraulic oil 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 t should be around 39 ohms If it s 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 Look for binding in chain or rollers Remove the wire to the solenoid coil on the pump motor Measure the resistance it should be around 19 ohms f it is nearly zero ohms replace the solenoid Problem Unit will not reverse belly switch does not function forward ok Lifting height is not longer achieved Unit jerks when lifting Forks raise then drift down Possible cause s Broken wire or loose connection bad throttle assembly bad motor controller Hydraulic oil level is too low Air in the system Check valve
20. 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 if this applies to your battery type Make sure the battery charger is unplugged from 115vac source Battery Charger Operating Instructions 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 When properly connected the charge LED will indicate the status of charge current flowing to the battery as follows Power LED is always green when charger is plugged in The status light is as follows Red only the charger is providing full output to the battery Yellow the charger is topping off the battery Green the charger is providing a float or maintenance charge Remember to unplug the charger before moving the equipment Failure to do so could cause damage to cords receptacles and other equipment 23 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 and the motor A fully charged lead acid battery in good condition at room te
21. cal operating of the handle The brake can be operated at any point in the lateral operating of the handle When you release your hand from the handle it will resume neutral position automatically and will activate the brake Always make sure that the brake is in work before operating the stacker When parked always put the handle in the full vertical position with the brake applied and forks lowered Horn A horn is located on top of the handle To raise and lower The following are generally valid for the lifting and lowering procedure The red operating button of the EMERGENCY STOP pushbutton must be pulled upwards Lifting and lowering movements are initiated by pressing the pushbuttons on the handle head There are four buttons located on the two sides of the handle Each side of the control has one button for raising the forks and one button for lowering the forks Always make sure when lifting that the load is within the capacity rating of your truck and that the load has been stacked safely on the pallet Also make sure that there is no one standing near the forks when raising or lowering It is also important to make sure that the length of the forks corresponds to the opening in the bottom of the pallet The load rollers must be placed between boards so when you raise the forks the pallet will not be broken or damaged Always make sure when entering the pallet that the forks are in the fully lowered position Be careful when l
22. e operator who is to maneuver the truck and is to control the lifting mechanism should be allowed to practice when unloaded until they can safely operate these functions Only then should they undertake the loading transporting and unloading of load Operation Operating elements Operating elements 1 Handle 2 Emergency Stop 3 Lift up 4 Low down 5 Horn 6 Forward backward switch T Back run safety device button 8 switch 9 Power metre Operation Safety elements If the red panic button at the tiller head 16 actuated this switches over briefly to reverse motion and then stops the truck movement If travel or lift movements cannot be stopped with the operating elements hitting the emergency stop switch will interrupt the entire power supply Operation 1 upper braking range 2 travelling range 3 lower braking range 4m gt Backward Forward main direction of travel Driving Pull up the red push button of the E switch Tilt the Control handle to driving position the locking brake is released f you release Control handle this returns to the vertical start position the truck brakes and the locking brake activates The truck is steered via the Control handle Brake This stacker is equipped with a magnetic brake that is applied between 10 15 degrees of the vertical position and between 85 90 degrees of the lower position in the verti
23. goes forward for about 1 second and dies when the handle is pulled down When the handle is re set and pulled down the unit will move forward again then die 20 Action Locate Pin 12 on Molex connector at the motor controller Try to drive the unit in reverse there should 24 volts at this pin If there is voltage and the unit does not move the motor controller may be bad consult diagnostics page 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 throttle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground f there is still no output voltage for pin 12 replace throttle assembly See Fig 1 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 consult diagnostics page factory 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 goi
24. haft Correct orientation is shown here Fig 11 39 Filename Belly Switch trouble shoot VESTIL CO Model S 62 AA FF FA Do the same on the other side taking note of the orientation of the two plastic bushings If the throttle wheel had a tendency to stick contact Vestil Manufacturing for replacement bushings Fig 12 The front of the red cover should be connected via the gray nub Fig 13 Filename Belly Switch trouble shoot VESTIL CO 40 Model S 62 AA FF FA To remove the red cover use a small screwdriver and carefully lift the plastic up over the gray nub Fig 14 Do the same on the other side and remove Fig 15 Filename Belly Switch trouble shoot VESTIL MFG CO 41 Model S 62 AA FF FA This should expose a spring This spring has a specific orientation When assembled the spring sets in the red cup on the inside of the red belly cover Fig 16 Filename Belly Switch trouble shoot 42 VESTIL Model S 62 AA FF FA Another picture of the nub spring not shown At this point verify the solder joints are in tact and the two wires are attached to the switch as shown below Also verify the belly switch 15 not stuck in You should be able to push on the switch and the actuator will move freely in and out you should here a click as you do this the switch is stuck in contact Vestil Manufacturing for replacement options Figl8 3 r La ua R
25. id the warranty e Do not use brake fluid or jack oil in the hydraulic system If oil is needed use an anti wear hydraulic oil with a viscosity grade of 150 SUS at 100f ISO 32 40 C or a non synthetic transmission fluid e Use only replacement parts either supplied or approved by the manufacturer Safety notes Symbols and pictograms used In addition to the text and illustrations this operating manual contains various symbols which should draw attention to the safety requirements They generally have the following appearance Signal wording Warning of an imminent danger Non observance cause death or serious injury WARNING Warning of a possibly incoming dangerous situation Non observance may cause death or serious injury CAUTION Warning of a possibly incoming dangerous situation May also be used for warnings of major damage to property Other definitions DIRECTION Marks recommendations for use and other useful information Does not warn of dangerous situations IMPORTANT Warns of a harmful situation Non observance may cause damage to material Used symbols and pictograms Possible danger 10 limb or machine Do not step onto when load is raised It is forbidden to ride ing Danger of crushing on the truck Do not reach into x Suspension points for running motor IV Y 1 transport of truck Wear safety shoes Important Suspended Wear helmet warning Product descrip
26. ifting pallets that are too short or too long for the truck HE It is forbidden to climb or reach into any moving parts of the lifting truck e g the lifting frame thrust units lifting mechanisms etc Travel The butterfly switch controls the direction and speed of the lift truck Rotating the butterfly control towards the forks moves the truck in the forward direction Rotating the butterfly control away from the forks moves the truck in the reverse direction The control is progressive the further you rotate the control the faster the truck will travel DIRECTIONAL SPEED CONTROL THROTTLE Emergency reverse safety button At the top of the handle is a red safety reverse button The button is designed to change the travel direction away from the operator when depressed The truck will stop moving away from the operator when the button is released When the fork truck is traveling forward away from the operator the button has no effect when activated If the belly switch becomes jammed or stuck it will move forward away from the operator for a maximum of 3 seconds at which time the control circuit will become disabled until the handle is re set to the full up or full down position and the belly switch is returned to normal operation BELLY SWITCH SAFETY REVERSE BUTTON Operation Lifting load AN CAUTION Before lifting a load to be transported ensure that the load does not exceed the carrying ca
27. intenance and care of the load chains 50 In normal use the load chains should be re lubricated every 250 operating hours in the event of heavy soiling moisture and very high prolonged loading re lubrication should be effected after 100 operating hours If subject to corrosive media the chain should be cleaned and lubricated immediately Chain lubrication chain conservation Flyer chains are correctly lubricated and are in a perfect state if The chain is free of exterior soiling When touching the chain your finger is wetted with oil This assures that the lubrication of the chain links is sufficient Type of lubricant A low viscosity mineral machine or engine oil or synthetic oil should be used The viscosity of the lubricating oil is to selected so that it remains low viscose at all ambient temperatures encountered Under normal temperature conditions lubricating oils with a viscosity of SAE 20 to SAE 40 would be appropriate Lubricating methods The lubricant can be applied by means of brush paint brush or also using compressed air spray devices When using spray cans please make sure the following basic requirement is fulfilled After the thinner has vaporized a viscosity conforming to the above mentioned recommendation type of lubricant must be met Cleaning the chain If operation leads the chain to suffer so heavily from soiling that the penetration of the lubricating oil cannot be guaranteed the chain
28. ly It may be necessary to support the lifting gear in a suitable manner so as to relieve any stress on the load chains Check the hydraulic fluid level replenish if necessary Grease the stacker thoroughly Clean all bright and moving parts with a thin film of oil and grease respectively Store the stacker in a dry frost proof dust free place Do not use plastic sheeting to cover the stacker otherwise condensation could form under it Additional operations for vehicles with integral electrical systems a OG i Disconnect the batteries from the stacker electrical system Charge the batteries Clean the top of the battery case and terminals Grease the terminals lightly with terminal grease Check the electrolyte level top up if necessary not applicable to maintenance free or gel batteries Recharge the batteries every 90 days gel batteries every 6 months Spray a suitable contact spray on unattached electrical contacts eturn to service after a lay up Thoroughly clean and grease the stacker Remove the film of protective grease Check the hydraulic fluid tank and hydraulic fluid for condensation if necessary carry out a fluid change Inspect hydraulic hose lines for brittleness Test the functions of the vehicle particularly the safety equipment Part list Electric wiring 53 conLeoller 150 ASY E ANC APCOO 101392100 001199
29. mperature 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 batteries aren t being charged by the charger check the output charger fuse Verlfy fuse is good with an ohmmeter or close visual ohm meter best Fuse is 10Amp 250 Volt GBD 10A If it is good check the battery s state of charge with a voltmeter The charger must be connected to the battery In order to read the output voltage of the battery charger Depending on the state of charge of the batteries the voltage should be somewhere around 27 to 28 volts dc If it is determined the batteries are dead and need replaced change the batteries Tools Required 14mm wrench or crescent wrench Regular flat bladed screw driver 24 Filename Changing Motor Controller in S 62 Stacker VESTIL MFG CO ModelS 62 A A FF FA Instructions Changing the Motor Controller in estimated time 30 min READ ALL INSTRUCTIONS BEFORE PROCEEDING Only qualified personnel should work on this equipment Lock out all potential energy sources before attempting this installation turn off the unit and remove the key Warning Working with or near lead acid batteries is dangerous Batteries contain sulfuric acid and produce explosive gases battery explosion could result in loss of eyesight or se
30. must be cleaned This is only to be effected with paraffin derivatives such as diesel fuel petroleum cleaner s naphtha etc Do not clean with steam injectors cold cleaners or even corrosive and acidic substances They can directly lead to chain damage If the chains have to be cleaned with steam injectors please contact our customer service Maintenance and repair 51 Chain inspections Chains used in stackers should be inspected at least once a year or every three months if exposed to severe contamination or high continuous loading stress We recommend that attention be paid to the following points Unusual noise Surface rust Linkage rust Stiff links Distorted pins Loose link pins Damage Broken link plates Broken pins 10 Contamination 11 Stretching Even with the optimum amount of lubrication it is impossible to prevent a chain from stretching Wear extends only to that part of the chain which is led over the chain sprocket guide sprocket Thus when checking for wear only check the area need be inspected According to the regulations currently in force a chain is deemed to be worn if it has stretched by 39 If safety issues are particularly critical or a potential hazard is dependent on a single chain we consider it necessary to replace it if it is stretched by even 2 b dE LE Sa Measuring procedure To measure elongation through wear that part of the chain which runs over the chain sprocket guide sprocke
31. ng into the switch If there is still no output voltage for pin 13 replace the switch The belly switch is stuck on Tap the orange 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 15 still stuck contact the factory for a replacement switch Problem Possible cause s Unit will not raise motor does not Loose wire run Bad solenoid Upper limit switch out of adjustment Blown fuse Batteries discharged Unit will not raise motor runs Lower solenoid stuck on No hydraulic oil Unit will not lower Loose wire bad coil Upper limit switch out of adjustment Unit keeps blowing fuses when the Shorted solenoid for motor raise raise button is pressed 21 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 rise 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 rise verify the limit switch is normally closed and will open when activ
32. ontroller Trace wire back up to tiller head and verify continuity all the way to the throttle assembly Repair any loose connections If there is continuity up to the throttle assembly then check the ground wire that comes off of B on the motor controller 374 terminal down Add more length to this wire if necessary and re terminate with a ring terminal 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 consult diagnostics page 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 throttle assembly may be bad Verify there is 24 volts going into the assembly and that there is a good ground f there is still no output voltage for pin 11 replace throttle assembly See Fig 1 Problem Possible cause s Unit will not reverse belly switch does not function forward ok Broken wire or loose connection bad motor controller Bad throttle assembly Belly switch does not function forward ok reverse ok Broken wire loose connection bad motor controller Bad belly switch Unit will not reverse The unit only Stuck Switch
33. pacity of the truck The nominal carrying capacity and lifting heights can be viewed in the load diagram Ensure that the load can be taken up in a compact and stable manner Slipping or falling of the load must be avoided The load must not project into the lifting frame The load must be centered and evenly distributed on the forks The load must not project more than 50mm over the end of the lifting forks Transporting the load ZN CAUTION Raise the load only slightly to transport For safety reasons view transport only in a forward direction Only when lifting up or lowering down the load it is permissible to drive forwards or in reverse with a raised load Lift up or lower down loads on level surfaces When unloaded move stacker only with forks lowered Operation Driving on sloping surfaces CAUTION If a load is to be transported on a slope the load must be faced slope upwards lt is not permissible to drive on a slopes diagonally The max Slope increase which driven is stated in the product description CAUTION This manner of driving is prohibited 17 Maintenance and repair TROUBLESHOOTING GUIDE Warning Before performing any task always block drive wheel off of the ground Consult the factorv for problems at time of installation or for any problems not addressed below Problem Unit doesn t move when controls are used Unit will not
34. rious 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 if this applies to your battery type Make sure the battery charger is unplugged from 115vac source Troubleshooting If it has been determined the motor controller needs to be replaced the following procedure can be used Tools Required 2x 14mm wrench open face Philips head screwdriver amm wrench 25 Filename Changing Motor Controller in S 62 Stacker VESTIL CO ModelS 62 AA FF FA Verify power if off to the unit key switch off Remove yellow cover two screws on top y 2 X 3 ES The Campro motor controller 15 shown here VESHAL BATTERY CHARGER MODEL
35. t must be positioned in the stretched area With the aid of a measuring rod measure a section approximately 1 meter in length The number of divisions in the measured area multiplied by the chain divisions gives the nominal measurement The length extending beyond this measurement represents the wear which is limited to a maximum of 396 over the nominal length An elongation through wear of 3 is reached if 33 links of the chain in use measure the same length as 34 links of a new chain Chain replacement If two chains are used as a pair on the affected machine both should always be changed at the same time The installation and removal of chains should be carried out with all the care appropriate to any item of safety equipment Chains may only be repaired by authorized specialist personnel We do not recommend the lengthening of safety type lifting chains since the inserted chain link will not have been pre stretched Our product liability will be invalidated if a repaired chain is assembled from sections bearing different silver label numbers Maintenance and repair 32 Temporary lay up If for operating reasons the stacker is laid up for more than two months the following instructions are to be carried out A XX Place the stacker on blocks so that all the wheels are raised from the floor In this way they will be prevented from becoming permanently misshapen Clean the stacker thorough
36. the bottom end of the valve The valve should move freely about 1 16 from closed to open position If it sticks in the valve stem could be bent and will need to be replaced if it doesn t free up after cleaning Blow the valve off with a compressed air gun while again pushing the poppet in and out Filename Changing in 5 62 Stacker VESTIL MFG CO Model S 62 AA FF FA Instructions for Changing the Batteries estimated time 15 min READ ALL INSTRUCTIONS BEFORE PROCEEDING Only qualified personnel should work on this equipment Lock out all potential energy sources before attempting this installation turn off the unit and remove the key 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
37. the handle Fig 27 Filename Belly Switch trouble shoot VESTIL MFG CO Model 5 62 47 This shows sliding the red tabs over the black nub This is basically the reverse of Fie 7 Fig29 Black nub This is the top front where the two connectors are Make sure they are on each side of the stand off so the wires do not get pinched Fig28 Stand off between connectors Filename Belly Switch trouble shoot VESTIL CO 48 Model S 62 AA FF FA Gently push the tiller throttle assembly in place Again it s just reversing steps 5 through 9 to get the tiller throttle assembly back on the handle Re install the 3 allen screws verify no switches are sticking and that the thumb wheel moves freely Turn the unit on and verify operation This completes the assembly 5mm allen Screws 3 places Maintenance and repair A BEFORE EACH USE INSPECT FOR THE FOLLOWING 49 SONS Que SO Frayed wires Oil leaks Pinched or chafed hoses Damage or structural deformation to the structural members the cylinder brackets etc Unusual noise or binding or evidence thereof Proper functioning of all limit switches including those on the perimeter pinch point guard if applicable Horn works Load chain check for mechanical damage check for play slack chain Battery keep the surface of battery clean and dry Make sure battery is secured against slipping B INSPECT MONTHLY FOR 1
38. tion Designated use The stacker is designated for lifting lowering and transportation of loads according to the specifications of the identification plate The stacker is to be used on hard level surfaces gt move the stacker between buildings warehouses etc The gradient of the slope must not be more than 10 sure load is not loose or unstable Do not pick up loads on tips or forks or edge of platform not overload The road surfacing must be solid and have a good grip Travel routes must offer sufficient load bearing capacity for the loaded truck The stacker is not suitable for continuous use in cool houses 264 Ambient conditions Temperature m 14 113 Permitted floor incline e Loaded 0 e Unloaded 2 Dimensions weights N WARNING The user is responsible for determining the actual load bearing capacity of a high lift stacking truck This can depend on the user the condition of both the floor and the high lift stacking truck and the regularity of the maintenance intervals Product description Signs on the truck I Veshai Handling Equipment Co Lt Add pacis DE Boonie Zone Bro jag 3 Chidi Type Name _ Model Serial _ _ Mfg ste Load Cap Rated Fo 4 Lift L m Motor Power ke Weight ke abl L
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