Vestil HBD User Manual
VESTIL MANUFACTURING CORPORATION
P.O. Box 507, Angola, IN 46703
Phone (260) 665-7586 • Fax (260) 665-1339
sales@vestil.com • www.vestil.com
Contents
Warnings and Safety Instructions................... 1
Receiving Instructions .................................... 1
Installation Instructions ...................................2
Routine Maintenance Instructions ..................2
Operation Instructions .................................... 3
Power Unit Operation .................................. 4-5
Air Bleed Instructions ..................................... 5
Motor and Transformer Diagram..................... 6
Revised 03-03
A company dedicated to solving ergonomic and
material handling problems since 1955
.
OWNER'S
MANUAL
HYDRAULIC BOX DUMPER
series HBD
Electrical Schematic (1-4K) ...........................7
Electrical Schematic (6K) ..............................8
Hydraulic Schematic ..................................... 9
Exploded Parts Drawing .............................10
Parts List ............................................... 11-12
Troubleshooting Guide ................................13
Warning Label Identification ........................14
Limited Warranty .........................................15
WARNINGS & SAFETY INSTRUCTIONS
Ensure that all employees understand and follow the
following instructions!!!
• Read and understand the owner's manual before using or
servicing the dumper.
• The load must be removed from the chute and the chute
fully lowered before any work is performed on the lift.
• Ensure that all safety and warning labels stay in place and
are legible. See the label page in this manual.
• The dumper's frame must be securely anchored to the floor.
See the installation instructions.
• Do not use the dumper if any damage or unusual noise is
observed.
• Always watch the chute and the barrel carefully when the
dumper in operation.
• Do not perform any modifications to the dumper without the
manufacturer's approval. Failure to receive authorization
for changes to the equipment could void the warranty.
• Maintenance and repairs are to be done only by personnel
qualified to perform the required work.
• 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.
• Use only replacement parts either supplied or approved by
the manufacturer.
Remove all packing and strapping material. Inspect
for damage. IF DAMAGE IS EVIDENT, FILE A CLAIM
WITH THE CARRIER IMMEDIATELY! Also, check the unit
size, type of power unit, etc., to ensure the dumper is correct for the intended application.
RECEIVING INSTRUCTIONS
Every unit is thoroughly tested and inspected prior
to shipment. However, it is possible that the unit may incur
damage during transit. If you see damage when unloading,
make a note of it on the BILL OF LADING.
HYDRAULIC BOX DUMPER
SERIES HBD
1
INSTALLATION INSTRUCTIONS
Review this entire page before installing the dumper.
Consult the factory in the event there are questions or problems at the time of installation.
The installation must be made in compliance with all the regulations applicable to the machine and its location. The installer
must verify that the equipment is installed so it will be suited to the environment in which it will be used.
Installation must be performed by suitably trained personnel with access to the proper equipment. The electrical aspects of
the installation should be performed by an electrician.
For installation you will need the following:
1. A forklift.
2. Lag bolts, a masonry drill, a masonry bit a wrench to fit the lag bolt nuts, grout and steel shims. Consult the building's
architect or facility engineer to determine the best size and type of hardware with which to anchor the machine to the floor.
3. A power supply circuit matching the motor voltage and current requirements. Refer to the labels on the control
enclosure and the electrical section in this manual for more information. The end-user is responsible for supplying
the branch circuit's required overcurrent and short-circuit protection.
1. Move the dumper into place with a forklift.
2. Anchor the frame to the floor through the 5/8" holes in the tie-down brackets located near the corners of the frame.
3. Shim and/or grout under the full length of the frame sides.
4. Make the required power supply connection.
5. Operate the dumper through several full up / down cycles. Verify that the upper travel limit switch and the lower travel
limit switch (if applicable) function properly.
6. Check the hydraulic oil level. It should be filled to within 1" to 1-1/2" of the reservoir's fill hole. Refer to the hydraulic
section in this manual for more information.
7. Clean up any debris or spilled oil, and verify that all of the warning and safety labels are intact.
ROUTINE MAINTENANCE & SAFETY CHECKS
• Care should be taken to identify all potential hazards and comply with applicable safety procedures before beginning work.
• Fully lower the chute to the floor before beginning any inspection or work on the unit.
• Only qualified individuals trained to understand mechanical devices and their associated electrical and hydraulic circuits should be
attempt troubleshooting and repair of this equipment.
(A) Before each use inspect for the following:
1. Frayed wires
2. Oil leaks
3. Pinched or chafed hoses
4. Damaged or loose hold-down tube or socket.
5. Damage or structural deformation to the structural members, the cylinder brackets, etc.
6. Unusual noise or binding, or evidence thereof.
7. Proper functioning of all limit switches.
(B) Monthly Inspections:
1. The oil level. Oil should be 1" to 1-1/2" below the reservoir's fill hole with the chute fully tilted.
2. Worn or damaged hydraulic hoses and electrical wires.
3. Proper operation of the barrel hold-down clamps.
4. Pivot point wear at the hinge pins and cylinder ends.
5. Intact pin and clevis retaining rings and/or fasteners.
6. Frame anchor bolts' tightness, and for cracks in the concrete around them. (Stationary units only.)
7. Looseness, wear, or damage to the casters' bearings, mounting hardware, or surface material. (Portable units only.)
8. Proper water level in the battery. (DC units only)
9. Unusual noises.
10. Information and warning labels being in place and in good condition.
11. The need to clean off dirt and debris.
(C) Yearly Inspections
The oil should be changed if the oil darkens, becomes gritty, or turns a milky color (indicating the presence of water).
Replace with an anti-wear hydraulic oil with a viscosity grade of 150 SUS at 100°F, (ISO 32 cSt @ 40°C). Ex: AW-32 or HO
150 hydraulic fluid, or Dexron transmission fluid.
2
OPERATION INSTUCTIONS
LOADING:
The box dumper is designed for loads in open-topped box containers measuring at least 1/2 as wide and 3/4 as deep as the
chute when loaded into the chute.
Insert the container so it is against the back of the chute. Insert the hold-down tube into the appropriate sockets in the sides
of the chute to prevent the container from sliding when dumped. The container should never be more than 5" below the hold-
down tube.
The load rating is shown on the machine dataplate located on the right-side upright frame channel (typically just above the
push-button control hanger). It indicates the net capacity of the dumper. Permanent damage to the lift or injury to personnel
could result from exceeding the listed capacity.
OPERATION:
The lift is furnished with a constant pressure (dead-man style) push-button control.
Pressing the "UP" push-button will turn on the power unit to raise the chute. The chute will raise only while the control is
pressed. Upon releasing the control, the chute will stop and hold its position. A limit switch will turn off the motor when the
chute reaches its maximum rotation angle.
Pressing the "DOWN" push-button will energize the lowering valve (1-4 K) or turn on the power unit (6K) to allow the chute
to descend. Again, releasing the control will stop the chute movement, and the unit will hold its position. On 6K units, a limit
switch will turn off the motor when the chute has fully lowered. Be certain no part of any person or object is under any part
of the chute before lowering it.
In the event that the load exceeds the dumping capacity, the hydraulic system's relief valve will open and not allow the unit
to lift.
SAFETY:
• Keep all personnel clear of the machine when it is in operation.
• Always load the unit properly.
• Regularly inspect the hold-down tubes and the sockets in the sides of the chutes.
• Never use the dumper if it is in need of repairs or if it seems to be malfunctioning.
• Notify your maintenance personnel if you notice anything out of the ordinary, such as odd noises, erratic motion, or damage
to any part of the lift or its components.
ORDERING REPLACEMENT PARTS:
• We take pride in using quality parts on the equipment we manufacture. We are not responsible for equipment problems
resulting from the use of unapproved replacement parts.
• To order replacement or spare parts for this equipment, contact the factory.
• In any communication with the factory please be prepared to provide the machine's serial number, which is indicated on
the machine dataplate.
3
POWER UNIT'S OPERATION
The electric / hydraulic box dumper utilizes an electric motor directly coupled to gear-type hydraulic pump to produce the
needed fluid pressure and flow to allow the cylinders to perform the work of dumping a box container.
A hydraulic manifold houses the hydraulic control components, and is bolted directly onto the gear pump.
The power unit's hydraulic components are all rated for 3,000 psi working pressure.
IMPORTANT PARTS OF THE POWER UNIT INCLUDE:
•
The electric motor.
•
The gear pump.
depending on the motor horsepower used.
The check valve (1-4K).
•
to be held at a given elevation indefinitely.
•
The pressure relief valve.
built up by the pump exceeds 3,000 psi. Thus the system cannot see more than 3,000 psi.
•
The lowering solenoid valve.
from entering the valve.
•
The counterbalance valves (6K).
•
The pressure-compensated flow control spool (1-4K).
back to the reservoir when the valve opens. It allows the table to always lower at the same rate regardless of whether there
is a load on the platform or not. Several sizes are available.
•
The hydraulic lift cylinder(s).
a bleeder valve located at their top end to allow air to be bled from the hydraulic system.
•
The safety velocity fuse.
claustrophobic hose failure to prevent the chute from collapsing down. The chute remains stationary until pressure is
reapplied to the system.
•
They hydraulic fluid.
SUS at 100°F (ISO 32 @ 40°C) such as AW-32 or Dexron transmission fluid are acceptable.
Motors are available for operation on single or three phase AC supplies (all are dual-voltage capable).
Its shaft is coupled directly to the shaft of the electric motor. Several displacements are available,
Its purpose is to prevent the backflow of fluid through the pump. In this way it allows the platform
Its job is to open a path for fluid to flow back to the reservoir in the event that the fluid pressure
This is an electrically-operated cartridge valve. It contains a screen to keep contaminants
These valves allow for smooth motion in double-acting hydraulic circuits.
This rests under the lowering valve, and regulates the fluid flow
Displacement-style (1-4K), or double-acting (6K) cylinders. The displacement style have
This is a device that is installed in the cylinder's hose port. It closes quickly in the event of a
The system uses HO150 hydraulic fluid. Any anti-wear hydraulic fluid with a viscosity grade of 150
WHEN THE CHUTE IS TO BE TILTED, PRESS THE "UP" PUSH-BUTTON. THE MOTOR TURNS, AND IN TURNING IT
SPINS THE HYDRAULIC GEAR PUMP. OIL IS DRAWN FROM THE RESERVOIR THROUGH THE SUCTION FILTER AND
INTO THE PUMP:
•
For 2K & 4K capacities.
•
For 6K capacity:
of the lift cylinders. Oil is pushed out to the cylinders' rod end and through counterbalance valve 2CB, which prevents the
chute from jumping when it nears the highest point of its rotation.
Releasing the push-button at any point will stop the rotation, and the chute will hold at that tilt angle.
An upper travel limit switch turns off the motor when the chute is at its full tilt angle.
WHEN THE CHUTE IS TO BE LOWERED, PRESS THE "DOWN" PUSH-BUTTON:
•
For 2K & 4K capacities.
back to the reservoir through the return hose. The rate at which the platform lowers is regulated by the internal pressurecompensated flow spool.
•
For 6K capacity:
the rod end of the lift cylinder. Oil is pushed out of the cylinders' blind end and through counterbalance valve 1CB, which
regulates the speed and smoothness with which the chute lowers. A limit switch turns off the motor when the chute is fully
lowered. Releasing the push-button at any point will stop the rotation, and the chute will hold at that tilt angle.
CONTINUED ON NEXT PAGE...
The pump pushes the pressurized oil through the energized directional valve RT and into the blind end
The motor turns the pump pushes the pressurized oil through the energized directional valve LT and into
The pump pushes the pressurized oil through the check valve and out to the lift cylinders.
The lowering valve opens, bypassing the check valve and allowing the oil in the cylinders to return
4
POWER UNIT'S OPERATION - continued
IN THE EVENT THAT THE CHUTE CREEPS DOWN SLOWLY AFTER RELEASING THE "DOWN" CONTROL, IT WILL BE
NECESSARY TO REMOVE THE LOWERING CARTRIDGE VALVE FOR INSPECTION AND CLEANING, AS FOLLOWS:
• Lower the chute until it is fully lowered.
• Remove any load from the chute.
• Remove the nut holding solenoid coil on the valve stem, then remove the coil, and then unscrew the valve from the manifold.
• Inspect the valve for contaminants, and the valve's o-rings and backup washers for cuts, tears, or other damage.
• With the valve immersed in mineral spirits or kerosene, use a thin tool such as a small screwdriver or a small hex wrench
to push the poppet in and out several times from the bottom end of the valve. The valve should move freely, about 1/16"
from closed to open position. If it sticks in, the valve stem could be bent and will need to be replaced if it doesn't free up
after cleaning. Blow the valve off with a compressed-air gun while again pushing the poppet in and out.
• Inspect the bottom of the manifold's valve cavity for contaminants.
• Again with the thin tool, press on the middle of the flow control spool located in the bottom of the cavity. It should move
down and back up freely.
• Reinstall the valve into the manifold, tightening the valve with approximately 20 lb.-ft. of torque.
IF THE PLATFORM LOWERS EXTREMELY SLOWLY, OR NOT AT ALL, THE CYLINDER'S VELOCITY FUSE COULD BE
CLOSING. THIS CAN BE CAUSED BY AIR IN THE HYDRAULIC CYLINDERS. TO BLEED THE AIR FROM THE SYSTEM:
• Lower the chute until it is fully lowered.
• Remove any load from the chute.
• Hold a rag over the cylinder's bleeder valve (it looks like a grease zerk) and open the valve about 1/2 turn with a 1/4" or
5/16" wrench. Oil and air will sputter from the valve - once no air is observed, close the valve.
AIR BLEED INSTRUCTIONS FOR DISPLACEMENT-STYLE HYDRAULIC CYLINDERS
When air enters the hydraulic cylinders of the lift, it can often cause undesirable effects.
Some symptoms of air in the cylinders include:
• jerkiness or bounciness when operating the unit;
• a delay before movement begins when the "UP" control (push-button or pedal) is pressed, and;
• locking of the safety velocity fuse(s) in the lift cylinder(s) when the "DOWN" control (push-button or pedal) is pressed,
which prevents the unit from lowering.
To bleed the displacement-style cylinders:
If the cylinders are inaccessible with the unit lowered, as with our scissor lift tables, raise the platform and then lower the
legs so that they rest on the unit's maintenance props. Otherwise, if the cylinders are accessible with the unit fully lowered,
begin with the unit in the lowered position.
Locate the bleeder valve on the top end of the cylinder(s). It will look something like a grease zerk. Use a 5/16" or 3/8" wrench
to open the bleeder valve about 1/2 turn and then place a rag over it to contain the oil that will come out with the air when
it is bled. Jog the motor by pressing the "UP" control for just a second. If there is air in the cylinder, oil and air should spit
and sputter out of the bleeder valve.
Jog the motor several times (wait at least five seconds in-between) until the sputtering stops and only clear oil streams from
the bleeder valve. When you're certain all the air has escaped, close the valve(s).
Check the level of the hydraulic fluid in the reservoir. If the oil is not within 1-1/2" of the fill hole, add oil until it reaches that
level. The operate the unit and verify that it raises and lowers smoothly.
5
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