Vestil EPT-2047-30, EPT-2048-45 User Manual

Rev. 0213 EPT, Manual.doc

VESTIL MANUFACTURING CORP.

2999 North Wayne Street, P.O. Box 507, Angola, IN 46703

Telephone: (260) 665-7586 -or- Toll Free (800) 348-0868

Fax: (260) 665-1339

www.vestilmfg.com e-mail: sales@vestil.com

EPT-SERIES ELECTRIC PALLET TRUCKS

OPERATION AND MAINTENANCE MANUAL

Receiving instructions: After delivery, IMMEDIATELY remove the packaging from the product in a manner that preserves the packaging and maintains the orientation of the product in the packaging; then inspect the product closely to determine whether it sustained damage during transport. If damage is discovered during the inspection,

immediately

record a complete description of the damage on the bill of lading. If the product is

undamaged, discard the packaging. NOTES

:

1) Compliance with laws, regulations, codes, and non-voluntary standards enforced in the location where the product is used is exclusively the responsibility of the owner/end-user.

2) VESTIL is not liable for any injury or property damage that occurs as a consequence of failing to apply either: a) Instructions in this manual; or b) Information provided on labels affixed to the product.

Neither is Vestil responsible for any consequential damages sustained as a result of failing to exercise sound judgment while assembling, installing, using or maintaining this product.

TABLE OF CONTENTS PAGE TABLE OF FIGURES PAGE Safety Principles 2 Fig. 1A EPT Main Body Components 5 Product Introduction 2 Fig. 1B EPT-30 (optional) Scale Components 6 Safety Guidelines 3 Fig. 2 EPT-30 Hydraulic Cylinder Assembly 7 Removing EPT from Pallet 3 - 4 Fig. 3 EPT-30 Drive Wheel Assembly 8

st

Use, 1 Operation 20-21 Fig. 4B EPT-30 Fork & Carriage (optional) Scale 10 Lifting & Transporting Loads 21 Fig. 5A Control Yoke & Handle Components 11-12 Batteries & Charger 21-22 Fig. 5B Control Yoke & Handle (optional) Scale 13-14 Fig. 6 Hydraulic Pump & Motor Assemblies 15 Troubleshooting

Changing Motor Assy. 37-39 Fig. 10 EPT-45 Fork & Carriage Assemblies 18

Changing Battery Charger 43-46 Maintenance & Inspections 49-50

Adding Quencharcs 47-48 Markings 51

Inspection, & Functions Tests 20 Fig. 4A EPT-30 Fork & Carriage 9

23-48 Fig. 7 EPT-45 Main Housings & Supporting Structure 16

Changing Cylinder 28-31 Fig. 8 Removable Battery Box & Components 16

Changing Throttle Assy. 32-36 Fig. 9 EPT-45 Cylinder & Fuse Panel 17 Replacing Forward/Reverse Contactor 40-42 Fig. 11 Function Controls, Gauges, & Safety Features 19

Rev. 0213 EPT, Manual.doc

PRODUCT INTRODUCTION

Specifications for each of the 4 models appear in the table below:

Net Wt. Fork Size Service MODEL (lbs.)

EPT-2047-30 660 20in. X 47in. 3.2 to 7.8 3,000 28 x 65 x 49 EPT-2547-30 671 25in. x 47in. 3.2 to 7.8 3,000 28 x 65 x 49 EPT-2048-45 990 20in. x 48in. 3.4 to 8 4,500 30x 78.5 x 49 EPT-2748-45 1012 27in. x 48in. 3.4 to 8 4,500 30x 78.5 x 49

Vestil Manufacturing Corp. created this manual to acquaint owners and users of our electric pallet trucks

with safe operation and maintenance procedures. Employers are responsible for instructing employees to

use the product properly. Employees and any other persons, who might foreseeably use, repair, or perform maintenance on the EPT must read and understand every instruction BEFORE using the device. Cart operators should have access to the manual at all times and should review the directions before each

use. Contact Vestil for answers to any question you have after reading the entire manu al.

Although Vestil diligently strives to identify foreseeable hazardous situations, this manual cannot address

every conceivable danger. The end-user is ultimately responsible for exercising sound judgment at all times.

Thank you for purchasing an electric pallet truck (“EPT,” “pallet truck,” “truck,” or “unit”) offered by Vestil Manufacturing Corporation (“Vestil”). Our EPT’s are durable, high-quality products that combine safety features and low-maintenance mechanisms. Despite the product’s relatively simple mechanics, all personnel must familiarize themselves with the safe operation instructions provided in this manual.

(W x L) in inches Range (in.)

Capacity

(lbs.)

Overall Size

(W X L x H) in inches

SAFETY PRINCIPLES

We offer four types of electric pallet truck (EPT): two 3,000 pound (~1364kg) capacity models, the EPT-204730 and 2547-30, and two 4,500 pound (~2045kg) capacity models, the EPT-2048-45 and 2748-45. Each unit conforms to the generalized specifications disclosed in this manual and fulfills our demanding standards for quality, safety and durability.

Vestil Manufacturing Corp. recognizes the critical importance of workplace safety. Each person who might participate in operation or maintenance of the product must read this manual. Read the entire manual and fully

understand the directions BEFORE using or performing maintenance on the cart. If you do not understand an instruction, contact Vestil for clarification. Failure to adhere to the directions in this manual might lead to serious personal injury or even death.

Vestil is not liable for any injury or property damage that occurs as a consequence of failing to apply the safe operation and maintenance procedures explained in this manual or that appear on labels affixed to the product. Furthermore, failure to exercise good judgment and common sense may result in property damage, serious personal injury, or death, and also are not the responsibility of Vestil.

This manual applies the hazard identification methods suggested for instruction manuals by the American National Standards Institute (ANSI). In accordance with ANSI guidelines for hazard identification language, this manual classifies personal injury risks and situations that could lead to property damage with SIGNAL WORDS. These signal words announce an associated safety message. The reader must understand that the signal word chosen indicates the seriousness of that hazard according to the following convention:

Identifies a hazardous situation which, if not avoided, WILL result in DEATH or SERIOUS INJURY. Use of this signal word is limited to the most extreme situations.

Identifies a hazardous situation which, if not avoided, COULD result in DEATH or SERIOUS INJURY.

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE injury.

Identifies practices not related to personal injury, such as operation that could damage the cart. No safety alert symbol (equilateral triangle enclosing an exclamation point) accompanies th is signal word.

Rev. 0213 EPT, Manual.doc

SAFETY GUIDELINES

Failure to read and understand the instructions included in this manual before using or servicing the pallet truck constitutes misuse of the product. Study the entire manual before you use the truck for the

first time and before each subsequent use. Read the manual to refresh your understanding of the safe use and maintenance procedures on p. 50-51. If questions remain after you finish reading the manual, contact Vestil for answers. DO NOT attempt to resolve any problem with the truck unless you are certain afterwards.

that it will be safe to use

To decrease the risk of electrocution:

¾ DO NOT contact or operate the pallet truck close to electrified wires or other sources of electricity; ¾ Before operating the EPT, always inspect the area where you will use it.

Improper use might result in serious personal injuries to the operator and/or bystanders. To minimize the possibility of injury, ALL persons who might operate, perform maintenance on, or service the EPT must read, understand and apply the following instructions: x DO NOT operate the EPT unless and until you are:

1. Trained to use the machine; AND

2. Certified as a trained operator by your employer in accordance with U.S. OSHA regulations (29 CFR

§1910.178) and any standards incorporated by reference (e.g. ANSI/ITSDF B56.1-2005).

x DO NOT attempt to lift or transport loads that exceed the rated capacity. x Inspect the machine before each use; DO NOT use the EPT unless it is in normal condition. Normal

operating condition exists if the EPT passes the inspection and functions tests described under the heading, “Inspect the EPT & Perform a Functions Tests” on p. 20.

x DO NOT use the unit until you read and understand the entire owner’s manual. Review the manual before

each use AND before performing maintenance on the device.

x DO NOT use the EPT if the load-supporting elements sustain any structural damage. Structural elements

include, but are not limited to, the forks, carriage, and wheels. If structural damage is present, immediately tag the unit “Out of Service” and inform maintenance personnel of the problem.

x DO NOT use the EPT if it makes unusual noises during operation. x DO NOT allow people to ride on the pallet truck. Only the operator of an EPT equipped with a properly

installed rider platform (EPT

x DO NOT attempt to lift an unevenly distributed load. Always center and evenly distribute the load on the forks. x DO NOT operate the EPT on surfaces (ramps or grades) angled more than 4 degrees. x DO NOT leave the EPT unattended while it supports a load. Always fully lower the forks, and then completely

disengage the skid or pallet. Complete the parking / storing procedure described in “Storing the EPT” on p.

22.

x DO NOT modify the pallet truck without first receiving written authorization from Vestil. Unauthorized

modifications may make the EPT unsafe to use.

To maximize the service life of the EPT and to prevent damage:

x Always store the machine in a secure, dry location where it will not interfere with traffic or other activities. x Maintain the product as suggested in “Maintenance & Inspections” on p. 49-50.

REMOVING THE PALLET TRUCK FROM THE SHIPPING PALLET:

The pallet truck is shipped in ready-to-use condition. However, it must first be removed from the shipping pallet before it can be used for the first time.

DO NOT attempt to drive the pallet truck off of the pallet; it might tip over and cause bodily injuries or property damage. To minimize the risk of injury to yourself or other persons, perform the following steps to remove the machine from the shipping pallet:

1. Remove all packing material.

2. Inform all personnel not participating in the unpacking process to clear the area.

3. Lift the EPT off of the pallet using either a hoist or a forklift with a capacity of at least 2,000 pounds. Always

apply the proper hoisting procedures or forklift operation practices you learned during your trai ning program.

To remove the EPT from the shipping pallet using a hoist: EPT-2###-45 models: Remove the battery box. a) Disconnect the power cable from the socket on top of the EPT housing (circled in photo 1 below). Unfasten the

box from the EPT frame by unscrewing the bolt in the center of the flange; the bolt is shown in photograph 2 (next page).

Rev. 0213 EPT, Manual.doc

b) Connect the sling to both hook points on the EPT (1 on each side; the picture below only shows the hook point on the right side); then lift the unit no more than 6 – 8 inches above the pallet. The EPT will tilt towards the control yoke. Additionally, it may swing from side-to-side once free of the pallet if you did not properly position the hoist above the center of the sling. Stabilize the suspended truck with one hand, and stand safely to the side while operating the hoist.

1

2

3

All Models: Securely connect the sling hooks to the hook points (see photographs below), lift the EPT a few inches off of the pallet, direct the EPT away from the pallet, and then lower it until it is entirely supported by the ground.

EPT-45 EPT-30

Hook point

To lift the EPT with a forklift:

Avoid contacting the drive wheel with the tines of your forklift; contact could damage the drive wheel.

Loading side

Approach the pallet truck from the operator side. Lift the EPT just a few inches above the pallet. Slowly back the forklift away from the pallet, and then carefully lower the forks until the EPT rests firmly on the ground.

Operator Side

Rev. 0213 EPT, Manual.doc

FIG. 1A: EPT-30 MODELS MAIN BODY COMPONENTS

2003

Item No. Part No. Description Item No. Part No. Description

2001 EPT-30-2001 Main Body Housing 2021 EPT-30-2021 22mm Snap Ring

EPT-30-2001-2

2002 EPT-30-2002 Battery Cover 2023 EPT-30-2023 M10 x 22 Screw 2003 EPT-30-2003 Battery (2 per unit) 2024 EPT-30-2024 Bolt 2004 EPT-30-2004 Battery Charger (OEM) 2025 EPT-30-2025 Bolt

EPT-30-2004-2 Replacement Charger (OEM Unit)

EPT-CORD Battery Charger Cord 2027 EPT-30-2027 M12 Nut 2005 EPT-30-2005 M6 Spring Washer 2028 EPT-30-2028 Wheel Frame 2006 EPT-30-2006 M6 Nut 2029 EPT-30-2029 Shaft 2007 EPT-30-2007 24V Battery Charge Gauge 2030 EPT-30-2030 Bushing 2008 EPT-30-2008 Key Switch 2031 EPT-30-2031 Bearing Plate 2009 EPT-30-2009 Emergency Stop Switch 2032 EPT-30-2032 Bearing 30205

EPT-30-KSA Key Switch Assembly 2033 EPT-30-2033 Bearing Plate 2010 EPT-30-2010 M6 Flat Washer 2034 EPT-30-2034 Ball Bearing 6205 2011 EPT-30-2011 M6 x 25 Bolt 2035 EPT-30-2035 25mm Washer 2012 EPT-30-2012 Set Pin 2036 EPT-30-2036 M10 Nut 2013 EPT-30-2013 Pivot Link Arm 2037 EPT-30-2037 8mm Washer 2014 EPT-30-2014 Bushing 2038 EPT-30-2038 Fixed Ring 2015 EPT-30-2015 16mm Snap Ring 2039 EPT-30-2039 Link Rod 2016 EPT-30-2016 Main Body 2040 EPT-30-2040 Bolt 2017 EPT-30-2017 20mm Snap Ring 2041 EPT-30-2041 Mounting Plate 2018 EPT-30-2018 Bushing 2042 EPT-30-2042 8mm Washer 2019 EPT-30-2019 Cylinder Pivot Pin, Upper 2043 EPT-30-2043 Bolt 2020 EPT-30-2020 Cylinder Pivot Pin, Lower 2044 EPT-30-2044 Wheel Stabilizer Assembly

2045 EPT-30-2045 Upper Travel Limit Switch

Housing Screw 2022 EPT-30-2022 10mm Washer

2026 EPT-30-2026 Wheel 76 x 36

Rev. 0213 EPT, Manual.doc

FIG. 1B: EPT-30 MODELS (OPTIONAL) SCALE COMPONENTS

Item No. Part No. Description

4001 EPT-30-SCL-4001 Scale Display 4002 EPT-30-SCL-4002 Display Mounting Bracket 4003 EPT-30-SCL-4003 6mm Flat Washer 4004 EPT-30-SCL-4004 M6 x 10 Bolt 4005 EPT-30-SCL-4005 M6 x 30 Bolt 4006 EPT-30-SCL-4006 6mm Spring Washer 4007 EPT-30-SCL-4007 M6 Nut 4008 EPT-30-SCL-4008 M6 Nut 4009 EPT-30-SCL-4009 4010 EPT-30-SCL-4010

Rev. 0213 EPT, Manual.doc

FIG. 2: EPT-30 MODELS HYDRAULIC CYLINDER ASSEMBLY

Item No. Part No. Description

4200 EPT-30-4200 Cylinder Assembly 4201 EPT-30-4201 Cylinder Body Tube 4202 EPT-30-4202 Gland Tube 4203 EPT-30-4203 Nut 4204 EPT-30-4204 Piston 4205 EPT-30-4205 Piston Rod 4301 EPT-30-4301 O-Ring 4302 EPT-30-4302 Seal Ring 4303 EPT-30-4303 Seal Ring 4304 EPT-30-4304 O-Ring 4305 EPT-30-4305 O-Ring 4401 EPT-30-4401 4402 EPT-30-4402 Hydraulic Hose 4403 EPT-30-4403 4300 EPT-30-4300 Seal Kit (EPT 30 & 45)

Rev. 0213 EPT, Manual.doc

FIG. 3: EPT-30 MODELS DRIVE WHEEL ASSEMBLY

Item No. Part No. Description Item No. Part No. Description

Not

Shown

EPT-30/45-DBA

3300 EPT-30-DWA 3001 EPT-30-3001

3002 EPT-30-3002 3003 EPT-30-3003 3004 EPT-30-3004 3005 EPT-30-3005 3006 EPT-30-3006 3007 EPT-30-3007

3007 EPT-30-3007-R 3008 EPT-30-3008

3009 EPT-30-3009 3010 EPT-30-3010

301 EPT-30-3011 3012 EPT-30-3012 3013 EPT-30-3013 3014 EPT-30-3014

Drive Brake Assembly Complete Drive Wheel

Assembly (includes Motor) 24VDC (700W) Drive Motor

Woodruf Key Motor Adaptor Ring 5 x 16 Dowel Pin M6 x 15 Cap Screw 6mm Washer Replacement Polyurethane

Drive Wheel Replacement Rubber Drive Wheel 140 x 180 x 12 Oil Seal

Wheel Bearing Snap Ring Bull Gear Grease Seal Gear Box Casting Idler Gear

3015 EPT-30-3015 Pinion Gear 3016 EPT-30-3016 Key

3017 EPT-30-3017 Pinion Gear Bearing 3018 EPT-30-3018 Cap 3019 EPT-30-3019 Cap Screw 3020 EPT-30-3020 M6 x 15 Cap Screw 3021 EPT-30-3021 Motor Retainer Cap Screw 3022 EPT-30-3022 Drive Gear 3023 EPT-30-3023 Spacer

3024 EPT-30-3024 Motor Shaft Pilot Bearing 3025 EPT-30-3025 Spacer

3026 EPT-30-3026 Brake Mounting Adapter 3027 EPT-30-3027 Splined Coupling 3028 EPT-30-3028 Snap Ring 3029 EPT-30-3029 Brake Pad 3030 EPT-30-3030 Brake Coil 3031 EPT-30-3031 Cap Screw

EPT-30-MTR-BLT

M6-1.0 x 185mm Motor Bolt

Rev. 0213 EPT, Manual.doc

FIG. 4A: EPT-30 MODELS FORK AND CARRIAGE

Item No. Part No. Description Item No. Part No. Description

1001 EPT-30-1001 Fork Assembly 1012 EPT-30-1012-2 Push Rod Pin (Hole in Center) 1002 EPT-30-1002 M6 Nut 1013 EPT-30-1013 40” Push Rod 1003 EPT-30-1003 Nose Wheel 1013-2 EPT-30-1013-2 37-1/2” Push Rod 1004 EPT-30-1004 M6 x 45 Screw 1014 EPT-30-1014 Lock Nut 1005 EPT-30-1005 Snap Ring 1015 EPT-30-1015 Clevis 1006 EPT-30-1006 Ball Bearing 6204z 1016 EPT-30-1016 Clevis Pin 1007 EPT-30-1007 75 x 96 Load Roller 1017 EPT-30-1017 22 x 20 Sleeve Bearing 1008 EPT-30-1008 Load Roller Axle 1018 EPT-30-1018 Trunion Shaft 1009 EPT-30-1009 5 x 30 Roll Pin 1019 EPT-30-1019 16mm Snap Ring 1010 EPT-30-1010 Load Roller Bracket 1020 EPT-30-1020 16 x 16 Clevis Pin Sleeve Bearing 1011 EPT-30-1011 Bracket Pin 1021 EPT-30-1021-25 Trunion (Mod el EPT-2547-30)

Not Shown

1012 EPT-30-1012 Push Rod Pin 1022 EPT-30-1022 22mm Snap Ring

EPT-30-EXT-RL

1023 EPT-30-1023 Pin

Steel Exit Roller 1021 EPT-30-1021-20 Trunion (Model EPT-204 7-30)

Rev. 0213 EPT, Manual.doc

FIG. 4B: EPT-30 MODELS FORKS AND CARRIAGE WITH INTEGRATED SCALE

Item No. Part No. Description Item No. Part No. Description

1001 1002 1003 1004 1005 1006 1007 1008 1009 1010

1011 1012 1013 1014

1015 1016 1017

EPT-30-SCL-1001 EPT-30-SCL-1002 EPT-30-SCL-1003 EPT-30-SCL-1004 EPT-30-SCL-1005 EPT-30-SCL-1006 EPT-30-SCL-1007 EPT-30-SCL-1008 EPT-30-SCL-1009 EPT-30-SCL-1010

EPT-30-SCL-1011 EPT-30-SCL-1012 EPT-30-SCL-1013 EPT-30-SCL-1014

EPT-30-SCL-1015 EPT-30-SCL-1016 EPT-30-SCL-1017

Fork Assembly 1018 Nose Wheel Frame 1019 M10 x 65 Screw 1020 Nose Wheel 1021 M10 Nut 1022-A Retaining Ring 1022-B Ball Bearing 6204z 1023 Drive/Load Wheel 75 x 90 1024 Drive/Load Wheel Axle 1025 Roll Pin 5 x 30 1026

Load Roller Bracket

Load Roller Bracket Pivot Pin

Push Rod Pivot Pin 4012

Push Rod (Owner must provide measurement)

M22 x 1.5 Lock Nut 4014 Push Rod Clevis 4015 Clevis Pin 4016

4011 4013

EPT-30-SCL-1018 EPT-30-SCL-1019 EPT-30-SCL-1020 EPT-30-SCL-1021 Clevis Pin Sleeve Bearing 16 x 16 EPT-30-SCL-1022-A EPT-30-SCL-1022-B EPT-30-SCL-1023 EPT-30-SCL-1024 EPT-30-SCL-1025 EPT-30-SCL-1026

Integral Scale Components

EPT-30-SCL-4011 EPT-30-SCL-4012 EPT-30-SCL-4013

EPT-30-SCL-4014 EPT-30-SCL-4015 EPT-30-SCL-4016

Sleeve Bearing 22 x 20 Trunion Pivot Shaft Retaining Ring 16

Trunion (EPT-2547-30-SCL) Trunion (EPT-2047-30-SCL) M8 x 30 Screw Washer M8 Nut Pin

Load Cell M12 x 45 Bolt 12mm Spring Washer

Washer Weighing Forks M12 x 38 Bolt

Rev. 0213 EPT, Manual.doc

FIG. 5A: CONTROL YOKE AND HANDLE COMPONENTS (ALL MODELS)

Rev. 0213 EPT, Manual.doc

Item No. Part Number Description

3100 EPT-30-3100-2 Control Handle 3101 EPT-30-3101 Screw 3102 EPT-30-3102 Handle Cover (Bottom) 3103 EPT-30-3103 Throttle Seat with Switches

3103-2 EPT-30-3103-2 Belly / Horn Switch

3104 EPT-30-3104 Electrical Outlet (Big) 3105 EPT-30-3105 Electrical Outlet (Small) 3106 EPT-30-3106 Throttle Knob (Left) 3107 EPT-30-310 7 Top Handle Cover (grey) 3108 EPT-30-3108 Spring – (Same as EPT-30-3114-2) 3109 EPT-30-3109 Horn Switch Operator 3110 EPT-30-3110 3111 EPT-30-3111 Throttle Knob (right) 3112 EPT-30-3112 M3 x 10 Screw 3113 EPT-30-3113 Throttle Shaft Bushing 3114 EPT-30-3114 Emergency Reverse Switch Cover

3114-2 EPT-30-3114-2 Emergency Reverse Return Spring

3115 EPT-30-3115 Throttle Assembly (identical to EPT-45-1112) 3115 EPT-30-3115-2 Throttle Assembly Unit 3115 EPT-30-3115-3 Curtis Throttle Assembly 3116 EPT-30-3116 Yoke Arm

3116-2 EPT-30-3116-2 Upper Removable Cover

3117 EPT-30-3117 Bolt 3118 EPT-30-3118 8mm Washer 3119 EPT-30-3119 Gas Shock 3201 EPT-30-3201 Snap Ring 20mm 3202 EPT-30-3202 Pivot Pin 3203 EPT-30-3203 Bushing 3204 EPT-30-3204 Handle Coupling (identical to EPT-45-1210) 3205 EPT-30-3205 Hex Head Cap Screw 3206 EPT-30-3206 8mm Washer 3207 EPT-30-3207 3208 EPT-30-3208 M56 x 1.5 Nut 3209 EPT-30-3209 56mm Washer 3210 EPT-30-3210 Washer 3211 EPT-30-3211 Bolt 3212 EPT-30-3212 Washer 3213 EPT-30-3213 Grease Zerk 3214 EPT-30-3214 Bearing Housing 3215 EPT-30-3215 Bearing 8112 3216 EPT-30-3216 Bearing 80113 3217 EPT-30-3217 Steering Post 3218 EPT-30-3218 M10 x 30 Bolt 3219 EPT-30-3219 10mm Washer 3220 EPT-30-3220 Handle Limit Switch 3300 EPT-30-3300 Drive Wheel System

Raise / Lower Button with Micro-Switch

Rubber Coupling Cover (same as EPT-45-1210)

Rev. 0213 EPT, Manual.doc

FIG. 5B: CONTROL YOKE AND HANDLE

C

OMPONENTS (ALL MODELS)

WITH

INTEGRAL SCALE

Rev. 0213 EPT, Manual.doc

Item No. Part No. Description

3101 EPT-30-SCL- M6 x 12 Bolt 3102 EPT-30-SCL- Handle Cover (Bottom) 3103 EPT-30-SCL- Throttle Seat

3103-2 EPT-30-SCL- Belly / Horn Switch

3104 EPT-30-SCL- Electrical Outlet (Large) 3105 EPT-30-SCL- Electrical Outlet (Small) 3106 EPT-30-SCL- Throttle Knob (left) 3107 EPT-30-SCL- Handle Cover (Top) 3108 EPT-30-SCL- Spring 3109 EPT-30-SCL- Horn Switch Operator 3110 EPT-30-SCL- Raise / Lower Button 3111 EPT-30-SCL- Throttle Knob 3112 EPT-30-SCL- M3 x 10 Screw 3113 EPT-30-SCL- Throttle Shaft Bushing 3114 EPT-30-SCL-

3114-2 EPT-30-SCL- Switch Cover Spring

3115 EPT-30-SCL- Throttle 3116 EPT-30-SCL- Yoke Arm 3117 EPT-30-SCL- M8 x 10 Bolt 3118 EPT-30-SCL- 8mm Spring Washer 3119 EPT-30-SCL- Gas Shock 3120 EPT-30-SCL- Handle Limit Switch 3121 EPT-30-SCL- M4 x 30 Screw 3122 EPT-30-SCL- M4 Nut 3123 EPT-30-SCL- M5 x 6 Screw 3124 EPT-30-SCL- Yoke Arm Access Panel 3201 EPT-30-SCL- 20mm Washer 3202 EPT-30-SCL- Pivot Pin 3203 EPT-30-SCL- 16 x 20 Sleeve Bearing 3204 EPT-30-SCL- Handle Coupling 3205 EPT-30-SCL- M8 x 30 Bolt 3206 EPT-30-SCL- 8mm Spring Washer 3207 EPT-30-SCL- Rubber Boot, Coupler Cover 3208 EPT-30-SCL- M56 x 1.5 Nut 3209 EPT-30-SCL- Washer 56 3210 EPT-30-SCL- Flat Washer 3211 EPT-30-SCL- M10 x 40 Bolt 3212 EPT-30-SCL- 10mm Spring Washer 3213 EPT-30-SCL- M8 x 1 Grease Zerk 3214 EPT-30-SCL- Bearing Housing 3215 EPT-30-SCL- Bearing 8112 3216 EPT-30-SCL- Ball Bearing 80113 3217 EPT-30-SCL- Steering Post 3218 EPT-30-SCL- M10 x 30 Bolt 3219 EPT-30-SCL- 10mm Flat Washer 3300 EPT-30-SCL- Drive Wheel Assembly

Emergency Stop / Reverse Switch Cover (Red)

Rev. 0213 EPT, Manual.doc

FIG. 6

: Hydraulic Pump and Motor Assemblies (All Models)

Item No. Part No. Description

4100 EPT-30-4100 Complete Motor Pump Assembly 4101 EPT-30-4101 24VDC (1.3kW) DC Motor 4102 EPT-30-4102 Motor-to-Pump Shaft Coupling 4103 EPT-30-4103 Manifold Base 4104 EPT-30-4104 Flow Control Valve 5LMRN 4105 EPT-30-4105 Solenoid Valve 4106 EPT-30-4106 Check Valve 4107 EPT-30-4107 Bolt 4108 EPT-30-4108 90 x 3.1 O-Ring 4109 EPT-30-4109 Pick Up Tube 4110 EPT-30-4110 Breather 4111 EPT-30-4111 Hydraulic Fluid Reservoir 4112 EPT-30-4112 Intake Strainer 4113 EPT-30-4113 Pump Retaining Bolt 4114 EPT-30-4114 Hydraulic Gear Pump 4115 EPT-30-4115 Return Tube 4116 EPT-30-4116 Relief Valve

Rev. 0213 EPT, Manual.doc

7: EPT-45 MAIN HOUSINGS AND SUPPORTING STRUCTURE

FIG.

Item No. Part No. Description

1001 1001 1002 1002 1003 1004 1005 1006 1007 1007 1008 1009 1010 1011 1012 1013 1013

1014

EPT-45-1001 M6 Hood Retaining Screw

EPT-45-1001-1 M5 Hood Retaining Screw

EPT-45-1002 Gear-Drive Cover (Fiberglass)

EPT-45-1002-2 Gear-Drive Cover (Plastic)

EPT-45-1003 Rear Cover Bracket EPT-45-1004 Bolt EPT-45-1005 Spring Washer EPT-45-1006 Washer EPT-45-1007 Rear Cover (Fiberglass)

EPT045-1007-2 Rear Cover (Plastic)

EPT-45-1008 Rear Frame EPT-45-1009 Screw EPT-45-1010 Spring Washer EPT-45-1011 Snap Ring EPT-45-1012 Bearing EPT-45-1013 Wheel

EPT-45-1013-2 Complete Stabilizing Wheel

EPT-45-1014 Wheel Axle

FIG. 8: EPT-45 REMOVABLE BATTERY BOX AND COMPONENTS

Assembly

Item No. Part No. Description

3002 EPT-45-3002 Battery 3003 EPT-45-3003 Battery Charger – OEM 3003 EPT-45-3003-2 Battery Charger – Soneil 3003 EPT-45-3003-3 Battery Disconnect Connector

EPT-CORD Battery Charger Cord

3004 EPT-45-3004 Battery Box

Rev. 0213 EPT, Manual.doc

FIG.

9: EPT-45 CYLINDER AND FUSE PANEL

Item No. Part No. Description Item No. Part No. Description

3005 EPT-45-3005 Spring Washer 3401 3006 EPT-45-3006 Bolt 3402 3007 EPT-45-3007 Retaining Ring 3403 3008 EPT-45-3008 Upper Cylinder Pin 3403 3009 EPT-45-3009 Lower Cylinder Pin 3404 3100 EPT-45-3100 Power Pack 3405 3200 EPT-45-3200 Hydraulic Hose 3406 3300 EPT-45-3300 Hydraulic Cylinder 3406 EPT-45-3406-2 3300 EPT-45-3300-2 Hydraulic Cylinder 3407

3408

EPT-45-3401 150Amp Drive Motor Circuit Fuse EPT-45-3402 100Amp Pump Circuit Fuse EPT-45-3403 5Amp Control Circuit Fuse

EPT-45-3403-2 Fuse Holder

EPT-45-3404 Motor Controller EPT-45-3405 Main Circuit Contactor EPT-45-3406 Forward/Reverse Contactor

Forward/Reverse Contactor (Curtis) EPT-45-3407 Pump Motor Contactor EPT-45-3408 Horn

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FIG. 10: EPT-45 FORK AND CARRIAGE ASSEMBLIES

Item No. Part No. Description Item No. Part No. Description

2001 2002 2003 2004

2004-2

2005 2006 2007 2008 2009 2010

2010-1

2011 2012 2013 2014

EPT-45-2001 EPT-45-2002 EPT-45-2003 EPT-45-2004

EPT-45-2004-2

EPT-45-2005 EPT-45-2006 EPT-45-2007 EPT-45-2008 EPT-45-2009 EPT-45-2010

EPT-45-2010-1

EPT-45-2011 EPT-45-2012 EPT-45-2013 EPT-45-2014

Retaining Ring 2015 Link Arm 2016 Sleeve Bearing 22 x 20 2017 Fork Frame 2018 Upper Travel Limit Switch 2019 Pin 2020 Sleeve Bearing 22 x 20 2021 Plate 2022 Snap Ring 2023

Trunion (caller must measure)

Clevis Pin 2025 Snap Ring 2025 Nut 2026 Washer 2027 Clevis 2028 Clevis Lock Nut

2024

EPT-45-2015 EPT-45-2016 EPT-45-2017 EPT-45-2018 EPT-45-2019 EPT-45-2020 EPT-45-2021 EPT-45-2022 EPT-45-2023 EPT-45-2024 EPT-45-2025

EPT-45-2025-2

EPT-45-2026 EPT-45-2027 EPT-45-2028

EPT-45-KSA Key Switch Assembly

Push Rod Sleeve Bearing Trunion Shaft Roll Pin Push Rod Pin Load Roller Frame Roll Pin Load Roller Frame Pin Roll Pin Load Roller Pin Load Roller Load Roller Bearing Washer Roll Pin

Rev. 0213 EPT, Manual.doc

p

A

p

FIG. 11: Function Controls, Gauges, and Safety Features

BATTERY CHARGE GAUGE:

The battery charge gauge indicates the status of the battery. It is located on top of the EPT main body and to the right of the control yoke. As the battery discharges, display lines disappear from right to left.

lways check the gauge before using the device; make sure that the battery is charged before using the

allet truck.

BELLY SWITCH:

The belly switch protects the operator from injury while driving the EPT in reverse. When pressed, the truck will change direction, i.e. move forward, for approximately 3 seconds; after 3 seconds it will stop completely. If the belly switch becomes jammed or stuck, the stacker will move forward (away from the operator) for at most 3 seconds; the control circuit will remain disabled until reset. ¾ To reset the circuit, either raise the handle to the

fully vertical position (or simply release the

handle), or press it downwards to the fully

horizontal position.

EMERGENCY STOP (“E-STOP”) BUTTON:

Press the E-stop button to immediately interrupt all powered functions. Use the E-stop during operation if the travel or fork (raise and lower) functions do not respond normally to operator commands.

Use the E-stop as a service brake to secure the EPT when

arked.

MOVEMENT CONTROLLERS:

To drive the EPT in the

forward

movement control forward with your thumbs as indicated by the solid arrow superimposed on photograph below. To move the pallet truck in reverse the control wheel in the opposite direction, which is shown with a dashed arrow.

direction, rotate the

, rotate

Reverse Forward

POWER:

EPT-30’s and 45’s activate differently. EPT-30’s feature a removable, red key-like power disconnect switch shown at right. Turn the switch clockwise to turn on the power. Turn off power by turning the switch counterclockwise.

EPT-45’s are activated simply by pulling the red Estop button up. Turn off power by pressing the button down.

The degree of rotation determines the speed of movement, so the farther you press the wheel in either direction, the faster the EPT will travel, up to a maximum speed of ~3mph when unloaded or ~2.6mph when loaded to capacity. Simply by releasing the movement control, the EPT will decelerate to a com

lete stop.

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USE INSTRUCTIONS:

1. Determine Condition of Floor or Other Supporting Surface: Inspect the floor (or other surface; for example

a parking lot, dock board or dock leveler) prior to use. The supporting surface must be smooth and dry so choose a route that avoids obstacles, spills, and surface damage.

Casters might become stuck in gaps or cracks in the surface, which could cause the EPT to stop

suddenly. A sudden stop can cause the load to shift and the load and truck might tip over.

2. Inspect the EPT & Perform a Functions Test: Inspection Prior to Use:

ALWAYS inspect the unit before you use it.

Begin the inspection by removing all debris found on the surface of

the forks and the housing, and then:

a. Check the forks for deformation and cracks; b. Check the floor beneath the truck and the truck itself for leaked hydraulic fluid or battery acid.

DO NOT use the EPT if you discover any damage or abnormalities. Tag the unit “Out-of-Service”

and report the problem[s] to authorized maintenance personnel. Functions Test:

Verify that the unit works properly. Drive the stacker to a location where the following tests can be performed without contacting overhead obstructions or items on the ground:

1. Raise the forks to the maximum elevation;

2. Return the forks to the lowest position.

3. Raise the forks, and while raising them, press the E-stop button. The forks should immediately stop moving. Reset the E-stop by returning the control yoke to either position 1 or 3 (see Operation Step 3 below on this page), and then pull up on the red button.

4. Fully raise the forks, and while lowering the forks press the E-stop. The forks should immediately stop moving. Reset the E-stop.

5. Drive the EPT in reverse at low speed and while driving press the belly switch. The machine should immediately move in the opposite direction for ~3 seconds and then stop. Reset the control yoke.

6. Drive the EPT in both the forward and reverse directions for a few seconds.

7. Test the horn (see Fig. 1, p. 9).

8. Verify that the control yoke automatically returns to the vertical position when released (see Operation Step 3 on this page).

Only use the pallet truck if all mechanisms function normally. If [a] malfunctions occurred, park the

stacker in a safe location, tag it “Out-of-Service” and then report the malfunctions to maintenance personnel.

Operation:

Step 1

: Turn on the power. [See “Power” callout box on p. 9].

Step 2: Pull the red E-Stop button up to disengage the service brake.

Step 3: Tilt the control yoke to the drive position (#2), which is shown

in the photograph to the right.

NOTE: The EPT uses magnetic brakes, which engage when the handle is in or near either of the neutral positions (1 and 3). The yoke is designed to automatically return to neutral position #1 after the handle is released; therefore, the brakes will engage automatically as well.

1 = Neutral 2 = Drive 3 = Neutral

Step 4: Rotate the movement control wheel in the appropriate direction to move either forward or in reverse. [See “Movement Controls” text box and the corresponding photo on p. 9]

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(

)

Step 5

: Drive the pallet truck to the desired location. To steer the unit, turn the yoke to the right or left of the center line. Moving the yoke to the right will cause the EPT to turn to the right, and moving the yoke to the left of the center line will cause the unit to turn left. The degree of deflection from the centerline determines how sharply the EPT turns. The illustration at right demonstrates how the position of the yoke determines the direction the machine follows.

Lifting and Transporting Loads:

DO NOT operate the EPT until you read AND understand every instruction. If you do not understand an instruction, contact Vestil for clarification. To reduce the possibility of sustaining or causing serious personal injuries, ALWAYS:

1. Make sure that all other persons clear the area while you use the EPT.

2. Apply the fork truck operation and lifting practices learned during your operator training, and applied by your employer. Follow the instructions below ONLY to the extent that they do not disagree with the operating practices required by your employer.

x Make sure that the net weight to be lifted (load + skid) does not exceed the rated load (capacity) of your truck;

x Center and evenly distribute the load on the forks. The load must not project more than 2” beyond the tips of the forks.

3. Review the safety guidelines on p. 3 before each use:

x Apply proper loading techniques (p. 8); x Ask a coworker to help you load and unload the lifter.

4. “Operator” means a person, who is trained and authorized to use a manually propelled high lift device. ONLY persons who have successfully completed a training program, like the courses outlined on p. 4-5 of B56.10-2006, should operate the HYRDA-Lift. Safe operation requires operators to:

x Develop safe working habits and a process for identifying hazards that exist or might be encountered during

operation;

x Conduct thorough inspections of the usage area to identify unusual/hazardous conditions. Walk the path you will

use to transport loads with the lifter beforehand. Do not use the HYDRA lift if the floor (or other supporting surface) is uneven or damaged or cannot support the combined weight of the operator, the lifter and the load.

x Make sure that the lifter has been inspected as recommended in the “Inspections & Maintenance” section of this

manual (p. 9). Use the lifter ONLY IF it is deemed safe to use by designated inspection personnel.

To engage a pallet/skid, drive the unit to a position in front of the intended load. Before engaging the load, confirm that the forks will fit within the fork pockets. Fully lower the forks to allow them to slide into the fork pockets of the skid. Confirm that the net weight of the load plus the skid do not exceed the capacity of the EPT.

Continue forward until either the skid rests against the back (vertical/upright portion), or the forks are as far underneath the skid as they can be. When the skid contacts the back of the forks, put the yoke in a neutral position to stop forward motion. Wait until the stacker stops completely, and then lift the skid off of the ground/supporting surface by pressing one of the two fork raising buttons. [See Fig. 1 on p. 9].

Proper Transport Configuration: To avoid unintended contact between the skid/pallet and surface features, transport the load to the desired location with the forks elevated.

To release the load, stop in the desired location; fully lower the forks; and then slowly drive the EPT forward until the forks are no longer beneath the skid/pallet.

Batteries and Charger:

The charger allows electrical current to flow from

Disconnect battery cable

EPT-45’s

a wall socket through the batteries. While operating the charger, contact with water (rain, snow, etc.) could result in electric shock or electrocution. Do NOT recharge the batteries if the EPT is outdoors. Only recharge the batteries indoors.

Turn off your EPT:

x EPT-45’s: Push E-stop to turn off the EPT; x EPT-30’s: Press the E-stop button and turn the

key switch to the off position;

Press E-stop

Disconnect the battery cable (EPT-45’s);

Rev. 0213 EPT, Manual.doc

Plug the charger’s AC cord into an 115VAC power source:

x EPT-30’s

: to access the cord, remove the top tray.

AC charger cord

x EPT-45’s

: the AC cord is tucked inside the battery box on the right side (circled in the second photo

below)

Plug this end into a standard 115 volt outlet and charge batteries for at least 8 hours. The charger will not overcharge the batteries, so leaving the unit plugged in overnight or over a weekend is ok. However, the charger should only be used indoors! When the charge cycle completes, disconnect the AC cord from the outlet, and reinstall the tray (EPT-30’s).

Storing the EPT

: Unload the lifter; then return it to the designated storage location.

1. Interfere with or obstruct traffic or other operations;

2. Be exposed to corrosive chemicals or water, either as a consequence of weather or of worksite

conditions.



A proper storage location is one where the unused lifter will not:



Rev. 0213 EPT, Manual.doc

ROUBLESHOOTING:

T

Before performing any corrective action described in the following table, block the drive

wheel off of the ground.

Contact Vestil for problems at time of installation, or for any problems not addressed below.

Problem: Possible cause(s): Action:

Unit does not respond to movement controls (does not move either forward or in reverse).

Unit will not charge

Unit will not go forward; reverse works; belly switch just kills unit (does not go forward and faults out)

Unit will not go reverse; belly switch 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)

Battery voltage low (battery charge lower than 17 Volts)

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

Broken wire, or loose connection, contactor bad, motor controller bad

Charge batteries. Bad batteries; load test batteries and replace if necessary.

Consult diagnostics page Table 2 Troubleshooting Chart; or Refer to 15-124-029 electrical drawing for proper voltage readings and operation; or Consult Factory

Remove back shroud and check fuses (3 fuses). Verify output voltage on charger, it should be 26 to 30 volts, dc, connected to batteries, and plugged into 115vac.

Load test the batteries Locate Pin 2 on Molex connector at motor controller. Trace wiring to contactor and verify connection.

While attempting to go forward, tap on the contactor with a screwdriver handle. If the unit moves forward, then the contactor may need replaced, or plungers lubed with a light oil.

Remove both wires from each side of the contactor, and check with ohm meter; resistance should be approximately 38 ohms. If it’s open or zero, the contactor should be replaced.

Consult diagnostics page Table 2 Troubleshooting Chart; or Refer to 15-124-029 electrical drawing for proper voltage readings and operation; or Consult Factory. Same as above; except locate Pin 3 on Molex connector on motor controller…and follow procedure.

Rev. 0213 EPT, Manual.doc

Problem:

Possible cause(s): Action:

Unit will not go forward, or reverse.

Broken wire, or loose connection, bad motor controller.

Throttle assembly bad

Locate Pin 6 on Molex connector at the motor controller. Try to drive the unit in forward, there should be 0 to 5 volts (5V is full throttle) at this pin. If there is voltage at pin 5, and 24 volts on either pin 11, or 12 and the unit does not move, the motor controller may be bad. Consult diagnostics page Table 2 Troubleshooting Chart; or Refer to 15-124-029 electrical drawing for proper voltage readings and operation; or Consult Factory.

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 throttle assembly, and that there is a good ground. If there is still no output voltage for pin 6, or forward and reverse outputs replace throttle assembly. Consult diagnostics page Table 2 Troubleshooting Chart; or Refer to 15-124-029 electrical drawing for proper voltage readings and operation; or Consult Factory

Unit will not move forward, or reverse, and the Belly switch will not function, unit does turn on as indicated by the battery gage lighting up.

Blown fuse

Broken wire, or loose connection

Verify fuses are good, replace if blown.

Locate Pin 7 on Molex connector at the motor controller. Trace wire back up to tiller head and verify continuity all the way to the throttle assembly. Repair any loose connections.

When replacing throttles, it may be necessary, and does not hurt to run a jumper wire from pin 7 to B-.

Check the ground wire that comes off of “B-“ on the motor controller. Re-terminate with a ring terminal if loose.

Run jumper wire around large diode coming off of small AGC fuse. If this diode is bad it can cause the unit to not move.

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Problem:

Possible cause(s): Action:

Unit will not go forward; the belly switch functions; reverse works.

Belly switch does not function; forward ok; reverse ok

Unit will not move at all.

Broken wire, or loose connection, bad motor controller

Bad throttle assembly

Broken wire, or loose connection, bad motor controller

Bad belly switch

Stuck Switch

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. 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. If there is still no output voltage for pin 11, replace throttle assembly. Reference 15124-029. 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. 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 going into the switch; and check to see if it is coming back out of the switch when depressed. If there is no output voltage, replace the switch. The belly switch is stuck on. Tap the orange belly switch 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 is still stuck, contact the factory for a replacement switch.

Rev. 0213 EPT, Manual.doc

Problem:

Possible cause(s): Action:

Unit will not raise; motor does not run

Loose wire

Bad solenoid

Upper limit switch out of adjustment

Blown fuse

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 raise, 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 raise, verify the limit switch is normally closed and will open when activated. 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.

Unit will not raise; motor runs Lower solenoid stuck on 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. If the lower switch is not stuck “on,” the pump could be bad, consult factory.

Unit will not lower

Unit keeps blowing fuses when the raise button is pressed

Loose wire; bad coil

Upper limit switch out of adjustment

Shorted solenoid for motor raise Remove the wire to the solenoid

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. It should be around 39 ohms. If it’s open, or shorted replace the coil.

Loosen hydraulic line at pump to relieve pressure build up. Readjust limit switch so unit stops at 7 to 8 inches above the ground.

coil on the pump motor. Measure the resistance, it should be around 19 ohms. If it is nearly zero ohms replace the solenoid.

Rev. 0213 EPT, Manual.doc

Problem:

Unit will not reverse; belly switch does not function; forward ok

Possible cause(s): Action:

Broken wire, or loose connection, bad throttle assembly, bad motor controller.

Locate Pin 12 on Molex connector at the motor controller. Try to drive the unit in reverse, 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 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. If there is still no output voltage for pin 12, replace throttle assembly. Reference 15124-029.

Rev. 0213 EPT, Manual.doc

Instructions for Changing the Cylinder

Estimated time: 45 minutes Necessary tools:

14mm wrench, 16mm wrench, or 2 adjustable crescent wrenches Regular (flat) blade screwdriver “Dental” Pick

Only trained, authorized personnel should perform maintenance on this equipment. Lead acid batteries present hazards to the person(s) working on, with, or in the vicinity of them. To minimize the risk of serious personal injury, read every one of the instructions and DO NOT proceed with maintenance unless you understand each of them. x Lock out all potential energy sources (i.e. battery) before attempting this installation according to OSHA

lockout/tagout procedures (29 CFR 1910.147); turn off the unit and remove the key.

x DO NOT work on, with, or in the vicinity of the battery UNLESS you are wearing personal protective equipment,

particularly a face shield. Batteries contain sulfuric acid and produce explosive gases. A battery explosion could result in loss of eyesight or serious burns.

x DO NOT smoke near the battery or expose the battery to sparks or flames. x Charge batteries ONLY in clean, dry, and well-ventilated locations. x DO NOT lay tools or anything metallic on top of a battery. x Remove personal items like rings, bracelets, necklaces, and watches BEFORE beginning to work on the battery.

The battery can produce energy sufficient to weld jewelry to metal; underlying skin could be severely burned.

x Keep fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. Immediately rinse any

skin that has been contacted by acid. If acid gets in your eyes, rinse them thoroughly with eye wash. After rinsing the affected area, notify your supervisor about the incident.

x DO NOT expose the unit or the charger to rain or other adverse conditions. ALWAYS return the unit to its

designated storage location when you finish using it. The designated storage location should offer protection from the elements and should not interfere with or obstruct traffic.

x Replace defective cords or wires immediately. x Routinely check the water level in the battery. x Make sure the battery charger is unplugged from the 115V source BEFORE driv ing the unit. x Operating the pallet truck when battery voltage is low can cause premature motor contact failure.

Turn off power to the pallet truck and remove the key. Purpose: To repair a leaking cylinder or to replace a damaged cylinder with a n ew cylinder.

Step 1

the negative disconnect the red cables from the positive terminal (red arrow). NOTE: Make a record of the cable connections,

so that you will be able to reconnect the batteries later.

: Remove the black plastic cover by lifting it as shown below; then disconnect the black battery cables from

post with 13mm wrench (negative terminal identified with a white arrow in Photo1 below). Next,

21

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Step 2

: Lift both sides of the battery, so that the battery remains level. To facilitate level lifting, attach tie wraps or

other NONMETALLIC material (for example, two short lengths of nylon rope) to the terminals; then lift both sides simultaneously (see Photo 3). The cylinder hose will be visible through the opening in the base of the battery box after the batteries are removed. See Photo 4.

DO NOT create a path between the terminals by connecting the tie wraps (or sections of nylon rope).

Cylinder Hose

3 4

Step 3: Disconnect the cylinder from the lower retaining bracket: 1) Disconnect the hose from the bottom of the cylinder with a 16mm wrench (see Photo 5); 2) To prevent leakage from the hose, pull the free end of the hose into the battery box (shown in Photo 7); 3) Remove the snap ring from the pin (see Photo 6); 4) Pull the pin out of the bracket and cylinder.

6

5

Disconnect hydraulic hose from cylinder with 16mm (or adjustable) wrench

Lower retaining bracket

Snap ring (another snap ring is fastened to the other end of the pin)

7

Retaining pin

Step 4: Disconnect the cylinder from the upper retaining bracket: 1) Remove the snap ring from the pin that extends through the piston rod (photo 8); then 2) Remove the pin (see Photo 9) and collect the bushings.

Remove Snap Ring

Bushings

If the pin requires encouragement to move, use a flat punch and hammer.

8 9

Upper retaining bracket

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Step 5

: The cylinder is now completely disconnected from the EPT frame; remove the disconnected cylinder.

To install a new cylinder: perform steps 1 through 4 in reverse order with the replacement cylinder. To repair the cylinder: follow the remaining steps.

Step 6

: Separate the piston rod from the barrel. To loosen the rod, immobilize the cylinder in a vise and use a flat

punch and a hammer to tap the cylinder head in a counterclockwise direction (see Photos 10 & 11). Once the cylinder head loosens, you should be able to rotate it by hand to withdraw it from the barrel (see Photo 12).

11

10

Retaining pin opening in piston rod

12

Step 7: With a small screwdriver, remove the Seal and the O-Ring from the piston, both of which are identified in Photo 13.

13 14

Seal

15

O-Ring

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Step 8

: Remove the bushings from the top of the cylinder rod, (see Photo 16; Note: In the photograph, one bushing

has already been removed.) Slide the cylinder head off of the piston rod.

Cylinder Head

Piston Rod

16 17

Step 9

: Remove the internal seal (photo 18 & 19). Photo 20 shows a fully disassembled cylinder.

Piston

Inner Seal

Cylinder Head

18 19

Bushing

Inner Seal

Cylinder Head

Piston Rod

O-Ring

Cylinder Barrel

Piston

Outer Seal

20

Step 10: Replace the seals; then perform steps 1 through 9 in reverse order to reassemble the cylinder and to refasten it to the pallet truck.

Rev. 0213 EPT, Manual.doc

Instructions for Changing the Throttle Assembly

Estimated time: 30 minutes Necessary tools:

5mm Allen wrench Philips-blade screwdriver

Step 1: Open the throttle assembly by removing the three 5mm Allen head bolts from the underside of the handle (photo

1); then lift the base of the assembly away from the handle (photo 2).

Small Regular (flat) blade screwdriver