Vestil DCR-880-H User Manual

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

Vestil Manufacturing Corp.

Table of Contents

provided in separate MPU-AC/DC manuals.*

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: info@vestil.com

DCR-880 Series Manually Propelled Drum Carriers

Instruction Manual

DCR-880-M DCR-880-H-HP DCR-880-H

Receiving Instructions

After delivery, remove the packaging from the product. Inspect the product closely to determine whether it sustained damage during transport. If damage is discovered, record a complete description of it on the bill of lading. If the product is undamaged, discard the packaging.

NOTE: The end-user is solely responsible for confirming that product design, use, and maintenance comply with laws, regulations, codes, and mandatory standards applied where the product is used.

Technical Service & Replacement Parts

For answers to questions not addressed in these instructions and to order replacement parts, labels, and accessories, call our Technical Service and Parts Department at (260) 665-7586. The department can also be contacted online at http://www.vestilmfg.com/parts_info.htm.

Electronic copies of Instruction Manuals

Additional copies of this instruction manual may be downloaded from https://www.vestil.com/page-manuals.php.

Signal words……………………………………………………………………………….............................................. 2

Safety instructions……………...…………………………………………………………………………………..……… 2

DCR-880-M exploded view, bill of materials, and specifications…………………………………………....……….. 3 - 4

DCR-880-H exploded view, bill of materials, and specifications……………………………………..,,……………... 5 - 6 DCR-880-H-HP exploded view, bill of materials, and specifications…………….…………..…..…………………... 7 - 8 DCR-880-H-DC exploded view, bill of materials, and specifications………………….………….…………….……. 9 - 10

DCR-880-H-HP-DC exploded view, bill of materials, and specifications…………..…………….………....……….. 11 - 12

*DC modular power unit exploded view and bill of materials………………………………..……………….……….. 13 - 14 *12VDC modular power unit electrical circuit diagram…………………………………………………..…….………. 14 *12VDC modular power unit layout…………………………………………………………………………..….………. 15

Record of Satisfactory Condition………………………………………………………………………………………… 16 Using the drum lifter………………………………...…………………………………………………………………….. 16 Lifting drums……………………………………………………………………………………………………………….. 17 Hydraulic circuit diagram (DCR-880-H & DCR-880-H-HP)……………..……………………………………..……… 18 Manual hydraulic system sequence of operation………...…………………………………………………………….. 18 - 19

*Hydraulic circuit diagram: DC-powered units……………………………………………………………..…………… 19 *Operation instructions for DC-powered units (DCR-880-H-DC & DCR-800-H-HP-DC)………………...………… 19 - 20

Bleeding air from the hydraulic circuit…………………………………………………………………………………… 20

Using the Battery Charger…………………………………………………………………………………….…….....…. 20 - 21

Inspections & Maintenance……………………………………………………………................................................ 21 - 22

Troubleshooting guide (DCR-880-H & DCR-880-H-HP)………………………………………………………………. 22 Troubleshooting guide (DCR-880-H-DC & DCR-880-H-HP-DC)…………………………………………………….. 23 - 24 Labeling diagram……………………………………………………………………………………………..………..….. 24 Limited warranty…………………………………………………………………………………..……………………….. 25

*NOTE: Pages 13-15, 19-20 provide views of, and instructions about, the modular power unit. These diagrams only

apply to units manufactured before 12-01-2018. Units manufactured on or after 12-01-2018 receive the 2 generation modular power unit (MPU GEN2). Diagrams and operating instructions for GEN2 power units are

nd

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

SIGNAL WORDS

This manual uses SIGNAL WORDS to indicate the likelihood of personal injuries, as well as the probable seriousness of those injuries, if the product is misused in the ways described. Other signal words call attention to uses of the product likely cause property damage. The signal words used appear below along with the meaning of each word.

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 likely to result in product/property damage, such as operation that might

damage the product.

SAFETY INSTRUCTIONS

Vestil strives to identify foreseeable hazards associated with the use of its products. However, no manual can address every conceivable risk. The most effective way to avoid injury is to exercise sound judgment when assembling, using, inspecting, and maintaining this product. Keep a copy of this manual with the product at all

times. For example, put a copy inside a plastic pouch and attach the pouch to the frame. Anyone who uses this product must be made aware that a copy of the manual is available and where to find it.

Serious personal injuries might result from improper or careless use of this product.

• Failure to read & understand the entire manual before using or servicing the product is a misuse of the product. Read the manual to refresh your understanding of proper use and maintenance procedures.

• DO NOT attempt to resolve any problem(s) with the product unless you are both authorized to do so and certain that it will be safe to use afterwards.

• DO NOT modify the product in any way UNLESS you first obtain written approval from Vestil. Unapproved modifications might make the lift unsafe to use and automatically void the Limited Warranty on p. 25.

• DO NOT exceed the capacity of the drum handler. The product is labeled with its capacity. See Label 287 in

Labeling diagram on p. 24.

• Inspect the product as directed in Inspections & Maintenance on p. 21-22. ONLY use the drum handler if it is in normal condition. If repairs are necessary, only install manufacturer-approved replacement parts.

• DO NOT change the setting of the pressure relief valve.

• ALWAYS carefully watch the drum handler and drum during use.

• DO NOT use this device UNLESS all product labels are readable and undamaged as shown in the Labeling diagram

on p. 24 AND all machine guards are in place.

• DO NOT ride on the drum handler or use it to move people.

• ALWAYS lower the carriage until the drum is entirely supported by the ground before leaving the drum handler.

• If part of the hydraulic system is damaged, AVOID contact with pressurized oil. High pressure oil easily punctures

skin which can cause injury, gangrene, or death.

• Unload the drum handler before performing any service work on it.

• The unit should always be labeled as shown in the Labeling Diagram on p. 24. Replace all labels that are damaged,

missing, or not easily readable.

• DO NOT use the drum handler if it cannot firmly and securely clamp the lip of the drum.

• Only use this product on compacted, improved surfaces.

Proper use, maintenance, and storage are essential for this product to function properly.

o Always use this product in accordance with the instructions in this manual. o Relieve hydraulic pressure whenever the unit is not in use by fully lowering the carriage. o Keep the product clean & dry. Lubricate moving parts at least once per month. o ONLY use manufacturer-approved replacement parts. Vestil is not responsible for issues or malfunctions that result

from the use of unapproved replacement parts.

o DCR-880-H and DCR-880-H-HP: 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 grade of 150 SUS at 100°F, (ISO 32 cSt @ 40°C), or Dexron transmission fluid. o Contact the manufacturer for MSDS information

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

DCR-880-M exploded view (bill of materials on following page)

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

Item

Part no.

Description

Qty.

Item

Part no.

Description

Qty.

Weldment, carriage, cylinder bracket

2

21-527-003

Assembly, roller bearing

4

23

40-612-006

Weldment, pin, saddle retainer

1

3

40-537-001

Weldment, detent, leg position

4

24

40-516-006

Weldment, bracket, jack mount

1

Bolt, 1/4”-20x1”, HHCS #2, zincplated

5

40-514-029

Weldment, leg, left

1

26

40-514-028

Weldment, frame

1 6 40-514-030

Weldment, leg, right

1

27

99-024-003

Guard/cover/endcap/plug

4

Hex nut, grade A, zinc-plated,

/4”-20

Flat washer, USS, zinc-plated,

/4”

9

37039

Nylock nut, zinc-plated, 3/4”-10

4

30

40-536-001

Weldment, jack

1

Flat washer, USS, plain finish,

/2”

11

37030

Nylon insert lock nut, 1/2”-13

2

32

28-112-031

Clevis pin, 3/4” x 41/2”

2

Bolt, 1/2”-13x11/2” HHCS ASTM A307 grade A, zinc-plated

Extended prong cotter pin, zincfinish, 1/8” x 11/2”

13

40-525-001

Weldment, handle

1

34

21-112-003

Pin, 1/2”-13x11/2”, retaining clevis

2

Hex bolt, grade A, zinc finish,

/8”-16x4”

Flat washer, low carbon, USS, zinc-plated, 3/8”

Nylon insert lock nut, grade 2, zinc finish, 3/8”-16

17

40-014-093

Frame, drum grip, casting

1

38

33354

Belleville spring washer, 1/2”ID

2

Flat washer, low carbon, zinc finish, 1/2”

19

40-612-004

Pin, clevis

1

40

21-113-030

Spacer, 1/4” length

2

Strap with ratchet, 6’ long, 2 hooks

21

45286

#11 hitch pin clip, 1/8” x 25/8”

2

DCR-880-M Standard features

Maximum overall width = 6815/16” Hand ratchet operated

DCR-880-M bill of materials

1

40-538-006 Weldment, carriage 1

4

16-132-181 Stem caster, PH-F-8/2-S-STM 4

7

8

10

12

14

15

16

36102

33004

33011

1

11209

40-016-052 Bracket, casting 1

40-016-053 Bracket, casting, FMDL series 1

40-514-011 Weldment, frame 1

2

22

40-538-007

25

28

29

31

33

35

36

37

11005

40-112-016 Pin, upper casting mount 1

40-112-017 Pin, spring attach 1

40-146-001 Spring, tension 1

65078

11119

3

33008

37024

1

2

3

1

8

1

18

20

65073

65076

1

/8” x 5/8” cotter pin 1

1

/8” x 1” cotter pin, zinc-plated 1

39

41

33012

40-145-008

Capacity = 880 lb. (400kg) Minimum inside width = 283/8” Minimum overall height = 45 Maximum overall height = 54 Minimum overall length = 43 Maximum overall length = 49 Minimum overall width = 35

1

/2” (115.6cm) Maximum inside width = 617/16”

3

/16” (137.6cm) Jaw lowered height = 31”

9

/16” (110.6cm) Jaw raised height = 47”

15

/16” (126.8cm) Casters = 8”x2” swiveling

7

/8” Net weight = 238 lb.

2

1

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

DCR-880-H exploded view (bill of materials on following page)

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

Item

Part no.

Description

Qty.

Item

Part no.

Description

Qty.

1

40-514-028

Weldment, frame

1

24

65076

1

/8” x 1” cotter pin, zinc-plated

2 2 40-538-006

Weldment, carriage

1

25

65073

1

/8” x 5/8” cotter pin

1 3 21-527-003

Assembly, roller bearing

4

26

40-112-016

Pin, upper casting mount

1 4 40-112-017

Pin, spring attach

1

27

40-112-015

Pin, cylinder mount

1 5 40-537-001

Weldment, detent, leg position

4

28

45286

#11 hitch pin clip, 1/8” x 25/8”

2

Weldment, carriage, cylinder bracket

7

40-514-029

Weldment, leg, left

1

30

40-612-006

Weldment, pin, saddle retainer

1 8 40-514-030

Weldment, leg, right

1

31

40-017-037

Stiffener, upper tie bar

1

Hex nut, grade A, zinc-plated,

/4”-20

Hex bolt, 3/8”-16x1”,grade A, zinc-plated

Hex bolt, grade A, zinc-plated,

/4”-20x2”

Flat washer, low carbon, USS, zinc-plated, 3/8”

Flat washer, USS, zinc-plated,

/4”

Hex nut, grade A, zinc-plated,

/8”-16

12

37039

Nylock nut, zinc-plated, 3/4”-10

4

35

99-024-003

Guard/cover/endcap/plug

4

Flat washer, USS, plain finish,

/2”

Extended prong cotter pin, zincfinish, 1/8” x 11/2”

15

37030

Nylon insert lock nut, 1/2”-13

2

38

21-112-003

Pin, 1/2”x115/16”, retaining clevis

2

Bolt, 1/2”-13x11/2” HHCS ASTM A307 grade A, zinc-plated

Hex bolt, grade A, zinc finish,

/8”-16x4”

Nylon insert lock nut, grade 2, zinc finish, 3/8”-16

Flat washer, low carbon, zinc finish, 1/2”

20

40-514-011

Weldment, frame

1

43

40-146-001

Spring, tension

1

21

40-014-093

Frame, drum grip, casting

1

44

21-113-030

Spacer, 1/4” length

2

Strap with ratchet, 6’ long, 2 hooks

Replacement seal kit for pump (item 23)

DCR-880-H Standard features

DCR-880-H bill of materials

6

16-132-181 Stem caster, PH-F-8/2-S-STM 4

9

10

11

13

14

16

17

18

19

36102

11011

33004

33011

37030 Nylon insert lock nut,

1

/2”-13 2

11209

40-525-001 Weldment, handle 1

40-016-052 Bracket, casting 1

40-016-053 Bracket, casting, FMDL series 1

2

29

40-538-007

32

33

34

36

37

39

40

41

42

11105

33008

36106

3

21-112-003 Pin, 1/2”-13x11/2”, retaining clevis 2

65078

33354 Belleville spring washer, 1/2”ID 2

11119

3

37024

33012

1

2

10

2

3

1

2

22

40-612-004 Pin, clevis 1

23

01-640-030 Pump, manual 1 * 01-136-412

Capacity = 1,500 lb. Lowered jaw height = 31” Minimum inside width = 283/8” Minimum overall height = 43 Maximum overall height = 53 Minimum overall length = 43” Maximum overall width = 68 Maximum overall length = 50

45

40-145-008

11

/16” Casters = 8”x2” swiveling Maximum inside width = 613/8”

1

/2” Raised jaw height = 49” Net weight = 272 lb.

1

/2” Minimum overall width = 357/8”

1

/2” Foot pump operated carriage

1

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

DCR-880-H-HP exploded view (bill of materials on following page)

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

Item

Part no.

Description

Qty.

Item

Part no.

Description

Qty.

1

40-514-034

Weldment, frame

1

24

40-612-004

Pin, clevis

1 2 40-538-006

Weldment, carriage

1

25

65076

1

/8” x 1” cotter pin, zinc-plated

1 3 21-527-003

Assembly, roller bearing

4

26

42034

U-bolt, zinc-plated, 5/16”-18x2”

1

Flat washer, zinc-plated, USS,

/16”

Nylon insert lock nut, grade 2, zinc finish, 5/16”-18

6

16-132-181

Stem caster, PH-F-8/2-S-STM

4

29

40-112-016

Pin, upper casting mount

1 7 40-514-029

Weldment, leg, left

1

30

40-112-017

Pin, spring attach

1 8 40-514-030

Weldment, leg, right

1

31

45286

#11 hitch pin clip, 1/8” x 25/8”

2

Hex nut, grade A, zinc-plated,

/4”-20

Hex bolt, grade A, zinc-plated,

/4”-20x2”

Flat washer, USS, zinc-plated,

/4”

Hex nut, grade A, zinc-plated,

/8”-16

13

37039

Nylock nut, zinc-plated, 3/4”-10

4

36

28-112-031

Clevis pin, 3/4” x 41/2”

2

Flat washer, USS, plain finish,

/2”

Extended prong cotter pin, zincfinish, 1/8” x 11/2”

15

37030

Nylon insert lock nut, 1/2”-13

2

38

21-112-003

Pin, 1/2”x115/16”, retaining clevis

2

Bolt, 1/2”-13x11/2” HHCS ASTM A307 grade A, zinc-plated

17

40-525-001

Weldment, handle

1

40

40-146-001

Spring, tension

1

Flat washer, low carbon, zinc finish, 1/2”

19

40-016-053

Bracket, casting, FMDL series

1

42

21-113-030

Spacer, 1/4” length

2

20

40-514-011

Weldment, frame

1

43

33-542-003

Assembly, chain (not shown)

1

Strap with ratchet, 6’ long, 2 hooks

Hex bolt, 3/8”-16x1”,grade A, zinc-plated

Flat washer, low carbon, USS, zinc-plated, 3/8”

Replacement seal kit for pump (item 4)

DCR-880-H-HP Standard features:

DCR-880-H-HP bill of materials

4

01-640-031 Pump, manual, 24” stroke FHJ 1

5

40-537-001 Weldment, detent, leg position 4

9

10

11

12

14

16

18

36102

11011

33004

1

99-024-003 Guard, cover, endcap, plug 4

33011

1

11209

40-016-052 Bracket, casting 1

2

27

28

32

33

34

35

37

39

41

33006

5

37021

40-612-006 Weldment, pin, saddle retainer 1

40-027-003 Assembly, pulley 1

40-017-037 Stiffener, upper tie bar 1

36106

3

65078

33354 Belleville spring washer, 1/2”ID 2

33012

2

3

2

21

40-014-093 Frame, drum grip, casting 1

22

23

11105

33008

Capacity = 880 lb. Minimum inside width = 283/8” Minimum overall width = 357/8” Minimum overall height = 72 Maximum overall height = 82” Lowered jaw height = 31” Net weight = 302 lb. Minimum overall length = 43 Maximum overall length = 50” Casters = 8”x2” swiveling

44

40-145-008

2

45

65073

1

/8” x 5/8” cotter pin 1

4 * 01-136-412

1

/4” Maximum inside width = 613/8” Maximum overall width = 687/8”

5

/8” Raised jaw height = 771/2” Foot pump operated carriage

1

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

DCR-880-H-DC exploded view (bill of materials on following page)

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

Item

Part no.

Description

Qty.

Item

Part no.

Description

Qty.

1

40-514-028

Weldment, frame

1

24

40-112-015

Pin, cylinder mount

2 2 40-538-006

Weldment, carriage

1

25

45286

#11 hitch pin clip, 1/8” x 25/8”

2

Weldment, carriage, cylinder bracket

4

40-537-001

Weldment, detent, leg position

4

27

40-612-006

Weldment, pin, saddle retainer

1 5 16-132-181

Stem caster, PH-F-8/2-S-STM

4

28

40-514-065

Weldment, frame, handle ext.

2

Weldment, frame, power unit bracket

7

40-514-030

Weldment, leg, right

1

30

40-514-062

Weldment, cylinder mount

1 8 36102

Hex nut, grade A, zinc-plated, 1/4”-20

2

31

40-511-001

Weldment, bracket, cylinder mount

1

Cylinder, hydraulic, 11/2”-18”, ram style, formed

Hex bolt, 3/8”-16x1”,grade A, zincplated

11

33011

Flat washer, USS, plain finish, 1/2”

4

34

40-017-037

Stiffener, upper tie bar

1

Hex bolt, 3/8”-16x1”,grade A, zincplated

Hex nut, grade A, zinc-plated, 3/8”16

Bolt, 1/2”-13x11/2” HHCS ASTM A307 grade A, zinc-plated

Flat washer, low carbon, USS, zincplated, 3/8”

15

40-525-001

Weldment, handle

1

38

28-112-031

3

/4” x 41/2” clevis pin

2

16

40-016-052

Bracket, casting

1

39

40-112-016

Pin, upper casting mount

1

17

40-016-053

Bracket, casting, FMDL series

1

40

40-112-017

Pin, spring attach

1

18

40-514-011

Weldment, frame

1

41

21-112-003

Pin, 1/2”-13x11/2”, retaining clevis

2

19

40-014-093

Frame, drum grip, casting

1

*42

99-158-001

Modular power unit

1

Hex bolt, grade A, zinc finish, 3/8”16x4”

Nylon insert lock nut, grade 2, zinc finish, 3/8”-16

22

65073

1

/8” x 5/8” cotter pin

1

45

40-146-001

Spring, tension

1

Extended prong cotter pin, zinc

plated

47

40-145-008

Strap with ratchet, 6’ long, 2 hooks

1

DCR-880-H-DC Standard features

DCR-880-H-DC bill of materials

3

21-527-003 Assembly, roller bearing 4

6

40-514-029 Weldment, leg, left 1

9

10

12

13

14

20

21

33004 Flat washer, USS, zinc-plated,

99-024-003 Guard/cover/endcap/plug 4

1

37030 Nylon insert lock nut,

11209

37039 Nylock nut, zinc-plated,

40-612-004 Pin, clevis 1

/2”-13 2

1

/2”-13 2

3

/4”-10 4

1

/4” 2

26

40-538-007

29

40-514-066

32

40-021-001

33

35

36

37

4

43

44

11105

36106

33008

11119

37024

1

2

10

1

23

65078

finish, 1/8” x 11/2” cotter pin, zinc-

*Units built after Dec. 1, 2018, receive 2nd generation modular power units (MPU-GEN2).

Capacity = 1,500 lb. Minimum inside width = 283/8” Minimum overall width = 357/8” Minimum overall height = 43 Maximum overall height = 55 Minimum overall length = 48 Maximum overall length = 55

46

6

33012

Flat washer, low carbon, zinc finish,

1

/2”

11

/16” Maximum inside width = 617/16” Maximum overall width = 6815/16”

1

/4” Lowered jaw height = 31” Net weight = 298 lb.

7

/8” Raised jaw height = 49” DC power-operated carriage

7

/8” Casters = 8”x2” swiveling

2

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

DCR-880-H-HP-DC exploded view (bill of materials on following page)

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

Item

Part no.

Description

Qty.

Item

Part no.

Description

Qty.

1

40-514-064

Weldment, frame, DC powered

1

27

40-514-062

Weldment, cylinder mount

1 2 40-538-006

Weldment, carriage

1

*28

99-158-002

Modular power unit

1

Hex bolt, 1/8”-20x1”,HHCS #2, zinc-plated

4

40-537-001

Weldment, detent, leg position

4

30

42034

U-bolt, zinc-plated, 5/16”-18x2”

1

Flat washer, zinc-plated, USS,

/16”

Nylon insert lock nut, grade 2, zinc finish, 5/16”-18

Flat washer, low carbon, USS, zinc-plated, 3/8”

Hex nut, grade A, zinc-plated, 1/4”20

Hex bolt, 3/8”-16x1”,grade A, zincplated

9

33004

Flat washer, USS, zinc-plated, 1/4”

2

35

40-027-003

Assembly, pulley

1

10

99-024-003

Guard, cover, endcap, plug

4

36

04-022-001

Limit switch with roller arm

1

11

37039

Nylock nut, zinc-plated, 3/4”-10

4

37

40-524-001

Weldment, guard, pump

1

12

33011

Flat washer, USS, plain finish, 1/2”

4

38

40-017-037

Stiffener, upper tie bar

1

Hex nut, grade A, zinc-plated, 3/8”16

14

37030

Nylon insert lock nut, 1/2”-13

2

40

28-112-031

Clevis pin, 3/4” x 41/2”

2

Bolt, 1/2”-13x11/2” HHCS ASTM A307 grade A, zinc-plated

Extended prong cotter pin, zincfinish, 1/8” x 11/2”

16

40-525-001

Weldment, handle

1

42

40-112-016

Pin, upper casting mount

1

17

40-016-052

Bracket, casting

1

43

40-112-017

Pin, spring attach

1

18

40-016-053

Bracket, casting, FMDL series

1

44

21-112-003

Pin, 1/2”x115/16”, retaining clevis

2

19

40-514-011

Weldment, frame

1

45

40-146-001

Spring, tension

1

Flat washer, low carbon, z-finish,

/2”

21

40-612-004

Pin, clevis

1

47

21-113-030

Spacer, 1/4” length

2

22

65076

1

/8” x 1” cotter pin, zinc-plated

1

48

40-145-008

Strap w/ ratchet, 6’ long, 2 hooks

1

23

45286

#11 hitch pin clip, 1/8” x 25/8”

2

49

33-542-003

Chain, chain assembly

1

24

40-612-006

Weldment, pin, saddle retainer

1

50

65073

1

/8” x 5/8” cotter pin

1

Weldment, frame, handle extension

99-021-927-

001

Cylinder, hydraulic, 11/2” x 28” ram style

*Units built after Dec. 1, 2018, receive 2nd generation modular power units (MPU-GEN2).

DCR-880-H-HP-DC Standard features

DCR-880-H-HP-DC bill of materials

3

21-527-003 Assembly, roller bearing 4

5

16-132-181 Stem caster, PH-F-8/2-S-STM 4

6

40-514-029 Weldment, leg, left 1

7

40-514-030 Weldment, leg, right 1

8

13

15

20

36102

1

37030 Nylon insert lock nut,

11209

40-014-093 Frame, drum grip, casting 1

/2”-13 2

29

31

32

33

34

8

39

41

4

46

11005

33006

37021

33008

11105

36106

65078

33012

5

1

2

4

2

3

2

25

40-514-065

26

40-514-066 Weldment, frame, MPU bracket 1

Capacity = 880 lb. Minimum inside width = 283/8” Minimum overall width = 357/8” Minimum overall height = 72 Maximum overall height = 82” Lowered jaw height = 31” Net weight = 302 lb. Minimum overall length = 43 Maximum overall length = 50” Casters = 8”x2” swiveling

51

2

1

/4” Maximum inside width = 613/8” Maximum overall width = 687/8”

5

/8” Raised jaw height = 771/2” Foot pump operated carriage

1

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DC modular power unit exploded view and bill of materials

Item

Part no.

Description

Quantity

1

99-016-933

Base bracket

1

3

01-033-024

24”, 18/3, 4-pin plug

1

5

99-023-001

Reservoir

1

7

24DC36

Battery

1

8

BV-48

Breather

1 9 15-533-013

Cable, battery, 23” black

1

23305

33008

3

/8” – 16 x 1” utility grade bolt

/8” flat washer

2

13

15-022-004

12V start solenoid relay

1

15

BG-12V

Battery gauge

1

17

ZB2BE101

Contact block N.O.

3

Operator, black, nonilluminated

19

ZB2BG4C

Key switch, 2-position

1

21

091802JY

Fiberglass cover

1

22

HS52

Clamp, worm gear

1

23

01-143-906

Pump

1

Manifold assembly (exploded view on p. 12)

1

/4in. – 20 x 13/4in. TPHMS

zinc-plated

1

/4in. – 20 x 1in. TPHMS

zinc-plated

23255 33687

SHCS utility grade High collar lock washer

4 4

28

152400-03

Molded cord

1

30

3MT ST3540

1in. hook and loop press

10”

*Units built after Dec. 1, 2018, receive 2nd generation modular power units (MPU-GEN2).

2 21-034-008 Charger (Soniel) 1

4 37927 Tinnerman clip 4

6 99-034-013 Battery strap 1

10 15-533-014 Cable, battery, 23” red 1

11

12 99-135-011 4”, 12VDC motor w/ tang dr. 1

14 HS64 Worm gear hose clamp 1

16 ZB2BZ009 Base, contact block 3

18 ZB2BA2C

20 01-134-007 Legend, ON - OFF 1

24 01-627-010

25 29201

26 29185

27

29

33688

150CCTM.OEM

3

/8” high collar lock washer

3

Connector, charge 1

2

1

2

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12VDC modular power unit electrical circuit diagram

Limit switch or jumper

Item

Part no.

Description

Qty.

31

568-015-BN70

O-ring

1

32

568-011-BN70

O-ring

1

33

99-153-058

Valve, cartridge, normally closed

1

34

99-034-010

Coil with weather-tite plug

1

35

99-153-006

Valve, pressure relief

1

36

568-334-BN70

O-ring

1

37

99-531-005

Filter

1

38

99-153-038

Flow control, 1.0GPM

1

39

01-127-010

Manifold

1

40

6801-06-06-NWO

MJ-MAORB 90 degree

1

41

99-153-011

Valve, check

1

NOTES:

*Units built after Dec. 1, 2018, receive 2nd generation modular power units (MPU-GEN2).

Exploded view of DC manifold assembly (item no. 24 on p.14)

Units built after Dec. 1, 2018, receive 2nd generation modular power units (MPU-GEN2).

Overcurrent & short-circuit protection and system disconnect must be provided.

wire used where applicable.

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12VDC modular power unit layout (part 2 of 2)

12VDC modular power unit layout (part 1 of 2)

NOTE: Units built after Dec. 1, 2018, receive 2nd generation modular power units (MPU-GEN2).

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Ratchet direction selector

Direction selector

Jack handle

Press foot pump treadle to raise carriage

Foot pump

treadle

Release lever

Jack slide

RECORD OF SATISFACTORY CONDITION (THE “RECORD”)

Thoroughly inspect the carrier before putting it into service. Record the condition and appearance of each of the frame members, fasteners, and casters/wheels. Thoroughly photograph the carrier from multiple angles. Include close range photographs of all labels, fasteners, and the drum gripping mechanism. Add the photographs to the record. Collate all photographs and writings into a single file. This file is a record of the carrier in satisfactory condition. Visually inspect all parts of the unit at least once per month. Compare your observations to the Record to determine whether the rack is in satisfactory condition. Do not use the carrier unless it is in satisfactory condition. Purely cosmetic changes, like damaged paint or powdercoat, are not changes from satisfactory condition. However, touchup paint should be applied as soon as damage occurs.

USING THE DRUM LIFTER (ALL MODELS)

DCR-series drum carriers are designed to handle 55-gallon steel, plastic, and fiber drums with lids. Three models,

DCR-880-M, DCR-880-H, and DCR-880-H-HP, are manually operated. Model DCR-880-M uses a ratcheting jack that raises and lowers the carriage. The drum carriage of models DCR-880-H and DCR-880-H-HP is driven by a hydraulic cylinder extended and retracted by a foot pump.

DCR-880-M (Mechanical Ratcheting Jack)

NOTE: For the jack to operate optimally, move the handle all-the-way up and all-the-way down with each

stroke. “Short jacking” occurs when the handle is not moved through its full range. Short jacking damages the teeth of the jack slide and can also damage the ratchet mechanism.

1. To raise the carriage: The direction selector must be in the “UP” position (see “Ratchet direction selector” below; selector shown in UP position). Raise the jack handle and press it down until you hear a click. Move the handle back-and-forth until the carriage rises to the necessary elevation.

2. To lower the carriage: Press the direction selector down. Then, move the jack handle up and down until the carriage reaches the desired height.

DCR-880-H and DCR-880-H-HP (Hydraulic Foot Pump)

Press down on the treadle to extend the cylinder. When the treadle is released it returns to its starting position.

Pump the treadle to raise the carriage and elevate the drum. To lower the carriage, step on the release lever on the side of the foot pump. Pressing the release lever opens a lowering valve. When the valve opens, the cylinder retracts and causes the carriage to lower. Descent can be stopped at any time simply by taking your foot off of the release lever. The carriage will maintain position until either the release lever or the treadle is pressed again.

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FIG. A: Leg positions

Inner leg pin

Support bracket firmly

Drum hook contacts inner

Attach strap Attach strap hooks to drum saddle.

Drum saddle

LIFTING DRUMS

Only use the drum handler on level, even, improved surfaces (i.e. concrete or asphalt) capable of supporting the combined weight of the handler and a full capacity load. The capacity of your unit is the maximum load it can lift. Capacities for every model appear in the sections titled “Specifications” on pages 4, 6, 8, 10, and 12. Each unit is also labeled with its capacity. Refer to label 287 in the Labeling diagram on p. 24.

Adjust leg position: The legs are adjustable to be able to access drums on pallets. Each leg has 2 positions. To change leg position, pull the inner pin (see FIG. A below) out of the pin holes in the frame. Pivot the leg as necessary and reinsert the pin to secure the leg in its new position.

Engage the drum: Position the unit close to the drum so that the legs extend around it. Adjust the elevation of the carriage to bring the rim gripper into contact with the rim of the drum.

1. DCR-880-M: Use the jack to position the

2. DCR-880-H & DCR-880-H-HP: Use the foot

3. DCR-880-H-DC & DCR-880-H-HP-DC:

The support bracket should contact the bottom of the lid rim. Rotate the drum hook forward so that it rests on the top

lid of the drum.

Strap the drum to the drum saddle: To press the drum firmly against the drum support. Wrap the ratchet strap around the drum and attach the hook at each end of the strap to the hook brackets on the drum saddle. Tighten the strap against the drum.

Transport the drum: Elevate the drum only a few inches above the ground while transporting it.

carriage. Be sure that the direction selector is in the UP position.

treadle and release lever to bring the gripper into proper position.

Confirm that the battery has adequate charge; then use the control buttons to adjust the position of the gripper.

rim surface

contacts underside of rim

hooks to drum saddle.

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Hydraulic Circuit Diagram – DCR-880-H and DCR-880-H-HP

The pump assembly consists of 10 primary components:

Chamber A

1. Oil reservoir 6. Release valve assembly

2. Inlet check poppet 7. Cylinder

3. Pump body 8. Piston return spring

4. Pressure relief valve 9. Pump pedal

5. Outlet check 10. Piston rod

The piston assembly incorporates a two-speed mechanism comprised of five main components:

1. Piston blind-side – Chamber A 4. High-volume / low-volume relief poppet

2. Rod-side – Chamber B 5. Piston rod

3. Back-fill check

MANUAL HYDRAULIC SYSTEM SEQUENCE OF OPERATION

Raising the carriage The sequence begins with the foot pedal in the neutral (“home”) position. The operator activates the hydraulic system by pressing the foot pedal down. This is referred to as the “power-stroke”. After releasing the foot pedal, the piston return spring (B) exerts an upward force on the piston. Oil flows from the reservoir, through the inlet check valve, and into chamber A. At the same time, oil trapped in chamber B from a prior cycle flows across the back-fill check into chamber A. When another power stroke occurs, the inlet check valve closes are prevents oil from flowing back into the reservoir. The outlet check valve simultaneously opens and oil flows into the cylinder. The piston return spring forces the piston and the foot pedal back to the home position and chamber A again fills with oil as the piston rises. The pump has two modes of operation: 1) Low-pressure, high-volume and 2) High-pressure, low-volume.

1. Low Pressure, High Volume.

When raising an unloaded or lightly loaded platform, the pump operates in low-pressure mode. As the operator

presses the foot pedal (power stroke):

a. Back-fill check remains closed; b. High / low volume relief poppet remains closed; AND c. All oil in chamber A flows into the cylinder.

2. High Pressure, Low Volume

When raising a partly loaded or heavily loaded platform, the pump operates in high-pressure mode. During a

power stroke:

a. Back-check remains closed; b. High / low volume relief poppet opens; c. A volume of oil equal to the annulus (piston diameter minus the rod diameter) flows from A to B; d. Oil equal to the cross-sectional area of the rod flows to the cylinder; AND e. The force required to open the high / low volume relief poppet adds to the cylinder load resistance.

Chamber B

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NOTE: Units built after

Pressure relief system If a load that exceeds the maximum rated load is placed on the deck, or a mechanical malfunction interferes with the movement of the deck, the pressure relief valve will open during a power-stroke. The pressure relief valve reduces the likelihood that excessive loads will damage the lifter frame or the hydraulic system. The pressure relief valve shunts oil directly from chamber A to the reservoir.

Release valve assembly The foot-actuated release valve assembly is the mechanism that allows the deck to lower. When the release pedal is pressed down, the release valve opens, and oil flows from the cylinder to the reservoir. The lowering rate is adjustable; instructions appear under Release pedal adjustment on p. 22. Lowering rate is also variable: the farther down the release pedal is pressed, the more rapidly the deck descends. The weight of a load on the deck affects the flow rate, and therefore, a heavier load will lower more rapidly than a lighter load, regardless of the lowering rate selected. When the operator lets the pedal loose, the release pedal tensioning spring returns the release pedal to the home position, which automatically closes the valve.

Hydraulic circuit diagram (DC-powered units; 01-127-010 Rev. C)

OPERATION INSTRUCTIONS FOR DC-POWERED UNITS (DCR-880-H-DC & DCR880-H-HP-DC)

NOTE: Units built after Dec. 1, 2018, receive 2nd generation modular power units (MPU-GEN2). The MPU-GEN2 owner manual

provides operation instructions.

The drum carriage of electrically powered units is controlled by a handheld controller as well as pushbuttons on the power unit housing. To raise or lower the carriage, press the appropriately marked button. When either button is released, the carriage will maintain position.

To raise the carriage, press the UP button on the pushbutton controller. This starts the electric motor which turns the hydraulic pump. Oil from the reservoir (inside the modular power unit) flows through a suction filter and into the pump. The pump delivers pressurized oil to the hydraulic cylinder through a check valve. The check valve allows oil to flow only in one direction, i.e. to the cylinders, and prevents oil from flowing back into the pump circuit when the pump stops. This traps oil in the cylinder causing the carriage to maintain elevation after the control button is released.

If a load exceeds the capacity of the lifter, pressure will build up in the circuit between the pump and the cylinders when the UP button is pressed. This pressure forces the relief valve to unseat which in turn allows oil to circulate back

Dec. 1, 2018, receive 2nd generation modular power units (MPUGEN2).

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to the reservoir rather than pushing it into the cylinder. This pressure relief mechanism prevents damage to the hydraulic system.

To lower the carriage, press the DOWN button. This energizes the lowering solenoid valve coil, which unseats the poppet valve and allows oil to return to the reservoir from the cylinder through the pressure-compensated flow control valve. Releasing the DOWN button de-energizes the solenoid and closes the valve poppet. The poppet valve and check valve together prevent oil from returning to the reservoir and cause the cylinders to stop retracting. The carriage will maintain its position until another command is received.

LOWERING SOLENOID VALVE

The lowering valve might occasionally need to be cleaned. See “Troubleshooting” on p. 23-24. Before working on any part of the hydraulic system, always lower the carriage.

1. Remove the cover from the power unit.

2. Identify the lowering valve (port LL in the manifold) and remove it.

3. Use a thin tool to press the poppet in (from the bottom of the valve) and open the valve.

4. Repeat several times while immersing the valve in kerosene or mineral spirits.

5. Blow compressed air through the valve while holding it open as described in step 3.

6. Inspect the O-rings and the PTFE washer (polytetrafluoroethylene). If either component is damaged, replace it.

7. Reinstall the valve. The valve should be tightened to approximately 20 ft.-Ib. of torque.

VELOCITY FUSE

There is a brass velocity fuse with a stainless steel spring in the base of the cylinder. This safety feature reduces the possibility of personal injury and damage to the DCR (or load) if there is a sudden loss of hydraulic pressure. If a fitting leaks or a hose is punctured, the platform lowers more rapidly. If the rate of descent exceeds the preset speed of the velocity fuse, the fuse closes. While the fuse is shut oil cannot flow. The carriage remains stationary until pressure is reestablished.

The velocity fuse might activate although no failure occurs, if, for instance, air enters the hydraulic system. To be able to raise or lower the carriage requires resetting the velocity fuse. To reset the fuse, activate the pump by jogging the UP button. Immediately after resetting the velocity fuse, lower the carriage and remove the drum. Then, cycle the carriage by raising the carriage all the way up and back down. Do this several times to purge air from the system.

BLEEDING AIR FROM THE HYDRAULIC CIRCUIT

If the carriage descends very slowly or not at all, air probably is trapped in the hydraulic circuit and must be bled from the system. To bleed air from the hydraulic circuit, follow these directions.

1.) Lower the carriage. If applicable, also disengage the drum.

2.) A “bleeder” screw is located at the top of the cylinder Loosen the bleeder screw by 1/4 to 1/2 turn to allow trapped air to escape. Jog the motor to push air out of the system.

3.) When the cylinder is free of air, only clear hydraulic fluid will flow from the bleeder screw opening. At that point, retighten the bleeder screw.

USING THE BATTERY CHARGER (DC UNITS ONLY)

Working on 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 near the battery or expose the battery to a spark or flame.

• ONLY charge batteries in dry, well-ventilated locations.

• DO NOT lay metallic items, like tools, on top of a battery

• NEVER touch both terminals simultaneously! Remove personal jewelry items such as rings and watches.

• Always have plenty of fresh water and soap nearby in case contact with battery acid occurs.

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

• The charger is equipped with an external ground wire (small green wire). During installation the charger must be

grounded to the equipment. Be sure this wire is always connected to the chassis, frame, or other metallic surface considered to be ground.

• Remove accumulated deposits on the terminals and confirm that all battery connections are sound.

• Replace defective electrical cords and wires immediately.

• DO NOT use the charger if the flanged inlet is damaged.

• DO NOT connect the charger to a damaged extension cord.

Every DC powered drum carrier is equipped with an onboard battery charger with a flanged electrical inlet. The inlet is mounted through the cover/housing of the power unit. The user must provide a 3-prong charging cord appropriate for the line and motor voltages.

The charger is current limited and will not exceed its rated output even if loads are placed on the battery while it is charging. The charger fuse will blow if it is connected in reverse polarity. To charge the battery:

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1.) Plug the charger into a 115V, 60 Hz receptacle by connecting the flanged inlet on the charger to an extension cord. Plug the other end of the cord into a wall socket. Use a short, thick extension cord to minimize voltage drop between the wall receptacle and the charger.

2.) When properly connected, the charge LED will indicate the status of charge current flowing to the battery.

• If only the red LED is on, the charger is providing full output to the battery.

• If both the red and green LED's are on, the charger is "topping off" the battery.

• When only the green LED is on, the unit is providing a "float" (maintenance) charge.

• DO NOT leave the charger on for long periods after the battery is fully charged.

3.) Unplug the charger before using the lifter to avoid damaging cords, receptacles, etc.

CHARGER TROUBLESHOOTING

If the charger does not work:

1) Make sure all battery connections sound.

2) Confirm that the AC power source (e.g. wall socket) is supplying power.

3) Examine the fuse (see p. 15). Replace only with a fuse having the same rating as the original fuse.

4) Determine battery condition. It may take some time before current begins to flow through a highly sulfated battery.

INSPECTIONS & MAINTENANCE

Regular maintenance is required to keep this product in nominal condition.

o Relieve hydraulic pressure whenever the unit is not in use by fully lowering the carriage. o Keep the product clean & dry. Lubricate moving parts at least once per month.

o If repairs are necessary, only install manufacturer-approved replacement parts. Vestil is not responsible for issues

or malfunctions that result from the use of unapproved replacement parts.

o ONLY use ISO AW -32 hydraulic fluid or its equal in the hydraulic system. 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 grade of 150 SUS at 100°F, (ISO 32 cSt @ 40°C), or Dexron transmission fluid.

Before using the DCR for the first time, make a written record of its appearance. Include observations about each component, being particularly detailed about the carriage and rim-grasping parts. Raise and lower the carriage. Include observations about how the unit sounds as the carriage moves, how much effort is required to move the jack handle or foot treadle, or how the unit responds to pushbutton signals. This record establishes “normal condition”. During future inspections, compare the appearance of the unit to the written record to determine if it is in normal condition. DO NOT use the FDT unless it is in normal condition.

(A) Before Each Use--Inspect the following:

1. Wiring: inspect the electrical wiring for cuts and frays.

2. Casters: examine the casters. Casters should be solidly fastened to the frame. Look for areas of severe wear and damage. Each caster should roll smoothly without wobbling.

3. Hydraulic hoses: check for pinches, punctures, or loose connections.

4. Structure: inspect the legs and frame for cracked welds, bends, etc.

5. Carriage and mast: observe the carriage as it cycles up and down the mast. Make note of unusual noise and motion (e.g. binding).

6. Pushbutton controller and modular power unit (MPU): inspect the controller and look for damage that exposes internal components.

(B) Monthly Inspections--at least once per month check the following:

1. Oil level. Oil should be 1" to 1-1/2" below the top of the tank with the lift in the fully lowered position. Add as necessary. Look for oil leaks, i.e. from hoses, the cylinder, or the reservoir.

2. MPU, hand control, and battery (DC models only): Remove the cover of the MPU and visually inspect the components. Check the water level in the battery. Check for worn or damaged hydraulic hoses, electrical wires, and cords. Repair as necessary.

3. Clevis pins and pivot points: inspect for excessive wear.

4. Cylinder: extend and retract the cylinder. It should not be bent, cracked, etc.

5. Carriage roller bearings (see Exploded View on p. 3; 5; 7; 9; and 11): check rollers and retaining hardware for normal condition.

6. Carriage and mast: cycle the lift function up (to the top) and back down while listening and watching for unusual noise, motion, or binding.

7. Labels (shown in Labeling diagram; p. 24): confirm that all labels are in place and in good, readable condition.

8. Surfaces: wash the unit to remove dirt and debris.

(C) Yearly Inspection Hydraulic oil should be changed at least once a year or sooner if the oil darkens or becomes gritty. Flush the reservoir

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3. Release pedal adjustment

Fill / breather

Treadle

Release

Retaining nut

4. Clean the Inlet Check

Release

Inlet check port plug

before refilling. Similarly, if the oil appears milky, water is present and the oil should be changed. If oil is needed, use

HO150 hydraulic fluid. Any anti-wear hydraulic fluid with a viscosity grade of 150 SUS at 100° F (ISO 32 @ 40° C) such as AW 32 or Dexron transmission fluid is acceptable.

TROUBLESHOOTING: DCR-880-H & -HP

Lower and unload the carriage before beginning service work on the unit. Purge all hydraulic pressure from the foot pump by holding the release open for two seconds once the drum is lowered to the floor.

If the pump malfunctions in any of the following ways:

• Cylinder rod fails to extend while pumping the foot treadle;

• Cylinder rod rises and lowers with each stroke of the foot pump

treadle; or

• Carriage descends on its own.

Try each of the following fixes until the pump works properly

1. Hydraulic fluid level adjustment: a. Fully lower the carriage by pressing the release lever and

holding it down.

b. Remove the fill/breather plug and insert a clean, flexible object,

like a cable tie, wire, or twist tie, down inside the cylinder to determine the oil level. The oil surface should be approximately 2” below the fill hole. If oil is needed, use HO150 hydraulic fluid.

Any anti-wear hydraulic fluid with a viscosity grade of 150 SUS at 100° F (ISO 32 @ 40° C) such as AW 32 or Dexron transmission fluid is acceptable.

2. Flush contamination from the check assemblies. Press the release

pedal down as far as it will go while pumping the foot treadle rapidly. This will create turbulence inside the pump, which might dislodge contamination that might be preventing one of the check balls from seating properly.

a. Loosen the release pedal

screw retaining nut.

b. Loosen the pedal screw

to a full counterclockwise turn using either a hex key wrench (Allen wrench) or a flat blade screw driver.

c. Grasp an empty drum with

the drum gripping mechanism and pump the foot pedal until the drum rises several inches above the ground. Press the release pedal. If the drum lowers, turn the screw another 1/2 counterclockwise turn. Raise the drum again. Continue this process until the drum maintains elevation. The drum should not lower when the release pedal is pressed.

d. Turn the release pedal screw clockwise 1/8 to1/4 turn. Press

the release lever. The drum should lower now. If it does not, turn the screw clockwise by another 1/8 turn and again press the release pedal. Continue this process until the desired lowering speed is achieved.

e. Tighten the retaining nut. To prevent the screw from rotating

at the same time, either hold the screw with your fingers or use the hex wrench or screwdriver into the fitting.

1

/2

Pedal Screw (flat head or hex head)

plug

(foot pedal)

Valve Assembly

a. Remove inlet check

port plug with a crescent wrench and remove the valve.

b. Clean the valve

components.

c. While the valve is

disassembled, pump the foot pedal 5 or more times. Fluid will discharge from the port, which should dislodge debris clogging the valve.

d. Reassemble the valve

& reconnect the port plug.

e. Add hydraulic fluid as

necessary according to the “Hydraulic Fluid Level Adjustment” instructions above.

pedal

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Issue

Possible Cause

Remedy

1. Carriage does not rise and

a. Low battery voltage. (Check light)

battery not made well.

a. Recharge battery

necessary.

2. Carriage does not rise but

c. Voltage at motor terminals might be too low

c. Measure voltage at motor terminals (as near

worn, contact factory for replacement parts.

3. Carriage rises too slowly.

k. Foreign material stuck in lowering solenoid

o. Inoperative pump.

k. Lower the carriage. Remove the lowering

o. See 2 (j)

4. Motor labors or is extremely

p. Battery voltage too low.

r. Binding cylinder.

p. See 1 (b)

r. Align cylinder correctly.

5. "Spongy” carriage rises in

elevated.

s. Fluid starvation.

s. See 2 (d), (f), (g), (j)

6. Carriage lowers too slowly

u. Lowering solenoid valve filter screen

u. Remove lowering solenoid valve and clean

Hydraulic Circuit Diagram on p. 19.

7. Carriage lowers too quickly.

z. Foreign material stuck in flow control valve.

descends).

z. Remove flow control valve from the valve

8. Carriage rises then lowers

aa. Lowering solenoid valve may be

aa. See 3 (k).

replacement parts.

9. Carriage elevates but does

ee. Incorrect lowering solenoid valve wiring.

gg. Faulty lowering solenoid coil.

ee. Correct per diagram (p. 19).

gg. Remove and replace. DO NOT remove the

TROUBLESHOOTING: DCR-880-H-DC & DCR-880-H-HP-DC

Contact technical support for assistance resolving issues not addressed in the guide.

motor does not run

motor is running or humming.

b. All chassis connections to negative post of

to run pump at existing load.

d. Fluid level in reservoir is low. e. Load exceeds capacity requirements. Relief valve is allowing hydraulic fluid to flow back into the reservoir. f. Suction filter is clogged, starving pump. g. Suction line fittings are loose allowing air to enter. h. Filter/Breather cap on tank is clogged. i. Lowering solenoid valve might be energized by faulty wiring or might be stuck open.

j. Hydraulic pump not operating.

valve causing fluid to flow back into the reservoir. l. Foreign material clogging suction filter or breather cap, or a hose is pinched. m. Low motor voltage. n. Unit overloaded.

b. Check and tighten or clean connections if

as possible) while pump runs under load. Check for loose wiring connections. d. Add fluid. (See p. 16 for proper fluid level.) e. DO NOT CHANGE RELIEF VALVE SETTING. Instead, reduce the load to rated capacity. f. Remove filter and clean. g. Inspect all fittings for proper tightness.

h. Remove cap and clean.

i. Remove lowering solenoid valve. Check and

clean. Refer to Lowering Solenoid Valves on p.

20.

j. Disconnect hydraulic line from power unit. Put pressure line in a large container and operate

the pump. If no output, check the pump motor

coupling and correct as appropriate. If pump is

solenoid valve and clean. Refer to p. 20.

l. Correct as appropriate. (See also, 2(f), (h).

m. See 1 (b) n. See 2 (e)

hot.

q. Oil starvation causing pump to bind & overheat. [NOTE: If this occurs, pump can be permanently damaged.]

jerks or is spongy when

when loaded.

t. Air in system.

clogged. v. Pinched tube or hose. w. Foreign material in flow control valve.

x. Binding cylinders. y. Foreign material in velocity fuse.

(In this case, carriage initially lowers at a

normal rate but accelerates as the carriage

slowly on its own.

incorrectly wired or is stuck open bb. Check valve stuck open. cc. Leaking hoses, fittings, pipes. dd. Cylinder packing is worn or damaged.

not lower.

ff. Lowering solenoid valve is stuck.

q. See 2 (d), (f), (g), (h), (j)

t. See air bleeding procedure (p. 17).

filter screen. v. Correct as appropriate. w. Remove and clean flow control valve. Refer to Hydraulic Circuit Diagram on p. 19. x. Align cylinders correctly. y. Remove and clean velocity fuse. Refer to

block and clean. Refer to Hydraulic Circuit

Diagram on p. 19.

bb. Remove and clean check valve. cc. See 2 (c). dd. Replace packing.

Contact factory for

ff. Lightly tap down the solenoid coil body to seat it properly. (DO NOT hit coil hard as it will permanently damage the internal system. DO NOT remove the solenoid valve from the block because the carriage will descend dangerously quickly.)

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

the velocity fuse to activate

lowering solenoid valve from the block because

A: Label 287

B: Label 643

A

D

C: Label 206 (on base frame by foot pump or

DCR-880-H-DC & DCR-880-H-HP-DC

B

A

D: Label 820

C D D A C

hh. Binding cylinders. ii. Air present in the hydraulic system causing

the carriage will lower in an uncontrolled manner. hh. See 4 (r). ii. To unlock, pressurize the hydraulic system.

LABELING DIAGRAM

Label content and location are subject to change so your product might not be labeled exactly as shown. Compare the diagram below to your Record of Satisfactory Condition. If there are any differences between actual labeling and this diagram, contact Technical Service.

Replace all labels that are damaged, missing, or not easily readable (e.g. faded). To order replacement labels or to inquire whether your unit is properly labeled, contact the technical service and parts department online at

http://www.vestilmfg.com/parts_info.htm or by calling (260) 665-7586 and asking for the Parts Department.

inside MPU on oil tank)

also have the following label 295 applied to the modular power unit

Label 295 (on MPU cover)

Table of Contents Rev. 1/22/2020 DCR-880, MANUAL

LIMITED WARRANTY

Vestil Manufacturing Corporation (“Vestil”) warrants this product to be free of defects in material and workmanship during the warranty period. Our warranty obligation is to provide a replacement for a defective, original part covered by the warranty after we receive a proper request from the Warrantee (you) for warranty service.

Who may request service?

Only a warrantee may request service. You are a warrantee if you purchased the product from Vestil or from an

authorized distributor AND Vestil has been fully paid.

Definition of “original part”?

An original part is a part used to make the product as shipped to the Warrantee.

What is a “proper request”?

A request for warranty service is proper if Vestil receives: 1) a photocopy of the Customer Invoice that displays the shipping date; AND 2) a written request for warranty service including your name and phone number. Send requests by one of the following methods: US Mail Fax Email Vestil Manufacturing Corporation (260) 665-1339 info@vestil.com 2999 North Wayne Street, PO Box 507 Phone Enter “Warranty service request” Angola, IN 46703 (260) 665-7586 in subject field.

In the written request, list the parts believed to be defective and include the address where replacements should be delivered. After Vestil receives your request for warranty service, an authorized representative will contact you to determine whether your claim is covered by the warranty. Before providing warranty service, Vestil will require you to send the entire product, or just the defective part (or parts), to its facility in Angola, IN.

What is covered under the warranty?

The warranty covers defects in the following original, dynamic parts: motors, hydraulic pumps, motor controllers, and cylinders. It also covers defects in original parts that wear under normal usage conditions (“wearing parts”), such as bearings, hoses, wheels, seals, brushes, and batteries.

How long is the warranty period?

The warranty period for original dynamic components is 90 days. For wearing parts, the warranty period is 90 days. Both warranty periods begin on the date Vestil ships the product to the Warrantee. If the product was purchased from an authorized distributor, the periods begin when the distributor ships the product. Vestil may, at its sole discretion, extend a warranty period for products shipped from authorized distributors by up to 30 days to account for shipping time.

If a defective part is covered by the warranty, what will Vestil do to correct the problem?

Vestil will provide an appropriate replacement for any covered part. An authorized representative of Vestil will contact you to discuss your claim.

What is not covered by the warranty?

The Warrantee (you) is responsible for paying labor costs and freight costs to return the product to Vestil for warranty service.

Events that automatically void this Limited Warranty.

• Misuse;

• Negligent assembly, installation, operation or repair;

• Installation/use in corrosive environments;

• Inadequate or improper maintenance;

• Damage sustained during shipping;

• Collisions or other accidents that damage the product;

• Unauthorized modifications: Do not modify the product IN ANY WAY without first receiving written authorization

from Vestil.

Do any other warranties apply to the product?

Vestil Manufacturing Corp. makes no other express warranties. All implied warranties are disclaimed to the extent allowed by law. Any implied warranty not disclaimed is limited in scope to the terms of this Limited Warranty. Vestil makes no warranty or representation that this product complies with any state or local design, performance, or safety code or standard. Noncompliance with any such code or standard is not a defect in material or workmanship.

Vestil DCR-880-H User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SIGNAL WORDS

SAFETY INSTRUCTIONS

LIFTING DRUMS

VELOCITY FUSE