Vestil LDLT User Manual

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Page 1

VESTIL MANUFACTURING CORPORATION

2999 North Wayne St., P.O. Box 507

Angola, IN 46703 USA

Phone (260) 665-7586 • Fax (260) 665-1339

www.vestil.com • sales@vestil.com

Contents

Warnings and Safety Instructions .................... 1

Receiving Instructions ..................................... 1

Operating Instructions - HT, LDLT ................... 2

Instructions for Battery-Powered Units ............ 3

Power Unit's Operation - HT, LDLT ................. 4

Electrical, Hydraulic Diagrams - HT, LDLT ..... 5

Routine Maintenance & Safety Checks ........... 6

Trouble Shooting Guides - HT, LDLT ............. 7

Revised 10-03 21-126-102

A company dedicated to solving ergonomic and material handling problems since 1955.

OWNER'S MANUAL

HYDRAULIC POST TABLES & LONG DECK CART

Model HT, LDLT

1 & 2-Post Hydraulic Parts/Drawing .............8-9

4-Post Hydraulic & DC Parts/Drawing ......10-11

Foot Operated Jack Parts/Drawing ..........12 -15

2-Speed Operating Instructions .....................16

Trouble Shooting Guide ...........................17-18

2-Speed Foot Pump Parts/Drawing ........ 19 - 20

Warning Labels .............................................21

Warranty ........................................................ 22

WARNINGS & SAFETY INSTRUCTIONS

Insure that all employees understand and follow the following instructions.

• Read and understand the owner's manual before using or

servicing the table.

• For battery-powered units, review the additional warnings

included elsewhere in this manual.

• Do not use the table if any damage or unusual noise is

observed.

• Always watch the table and any load on it carefully when

it is being moved or used.

• Avoid sudden stops or quick turns to prevent accidental

tipping of the table.

• Use caution if you slide a load onto the table top.

• The table's load must be centered and evenly distributed

on the table.

• Do not perform any modifications to the table 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 bypersonnel

qualified to perform the required work.

• Do not use brake fluid or jack oil in the hydraulic system.

If oil is needed, use an anti-wear hydraulic oil with a viscosity grade of 150 SUS at 100°F, (ISO 32 @ 40° C), or a non-synthetic transmission fluid.

• Use only replacement parts either supplied or approved

by the manufacturer.

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 SHIPPER RECEIVER.

Remove all packing and strapping material, inspect for damage. IF DAMAGE IS EVIDENT, FILE A CLAIM WITH THE CARRIER IMMEDIATELY! Also, check the platform size, type of power unit, etc., to see that the unit is correct for the intended application.

4-POST

2-POST

Long Deck

SINGLE POST

HYDRAULIC POST TABLES

& LONG DECK CART

Page 2

OPERATION INSTRUCTIONS - HT, LDLT

LOADING:

The load rating, in pounds, is shown on the capacity tag located on the base. It indicates the net capacity of the table, assuming a centered load. Permanent damage to the table or injury to personnel could result from exceeding the listed capacity.

The load size should not exceed the table dimensions by more than 50% and should not exceed twenty-four inches in height.

Do not use the base of the hydraulic table as a storage shelf.

OPERATION:

The manually-powered hydraulic tables are furnished with a foot-pump.

On the single and two-post tables, step on the foot treadle to raise the table and step on the release lever on the right side of the pump to lower the table.

The four-post table has a two-speed foot pump, separate from the lifting cylinder. Step on the foot treadle to raise the table. You can change the pump from the low-volume to high-volume by pulling the slide on top of the foot pump back toward the foot treadle.

The DC-powered table is furnished with either a constant-pressure (dead-man style), push-button (standard), or twin foot switch (optional) control.

Pressing the "UP" push-button or foot switch will turn the power unit to raise the platform. The platform will raise only while the control is pressed. Upon releasing the control, the platform will stop and hold its position.

Pressing the "DOWN" push-button or foot switch will energize the lowering valve to allow the platform to descend. Again, releasing the control will stop the platform movement and the unit will hold its position. Be certain no part of any person or object is under any part of the platform before lowering the unit.

Attempting to raise the platform when the battery is low will cause the motor relay protection to prevent the motor's operation. Adequate battery voltage is indicated by a green LED on the motor relay. See the next page for more notes regarding operation of battery-powered units.

SAFETY:

Keep all personnel clear of the machine when it is in operation.

Do not exceed the table's load rating.

Use caution to avoid tipping the table when placing or sliding a load onto or off of the table.

Avoid obstacles that can cause the base to sudden stop when moving a loaded table, such as cracks in the floor or the corners of machines, etc. Doing so could cause the post table to tip over or allow the load to slide off the table.

Never use the table 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 table 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.

Page 3

ADDITIONAL INSTRUCTIONS FOR BATTERY-POWERED UNITS

WARNING!

! Working with or near lead batteries is dangerous. Batteries contain sulfuric acid and produce explosive gases. A battery

explosion could result in loss of eyesight or serious burns.

! Do not smoke or allow a spark or flame near batteries. Charge batteries in locations which are clean, dry, and well-ventilated.

! Do not lay tools or anything metallic on top of any battery. All repairs to a battery must be made by experienced and qualified

personnel.

! When working with batteries, remove personal items such as rings, bracelets, necklaces, and watches. Batteries can

produce enough energy to weld jewelry to metal, causing a severe burn.

! Always have fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

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

! Do not expose the lift or charger to rain or adverse conditions.

! Replace defective cords or wires immediately.

! Check the battery's water level frequently.

BATTERY CHARGER OPERATING INSTRUCTIONS:

Never operate the charger with either of the cables coiled. Operating the unit with the cord wrapping around itself can cause the cord to overheat, melt, and cause a short-circuit or a fire.

Plug the charger into a standard 115V receptacle. If an extension cord must be used, keep it as short and as large as possible. A small cord will decrease the output of the charger due to the voltage in the line. This will increase the charging time. It can also cause the 115V cord to overheat.

When properly connected, the charge LED will indicate the status of charge flowing to the battery, as follows:

Red only - the charger is providing full output to the battery.

Both red and green - the charger is "topping off" the battery.

Green only - the charger is providing a "float," or maintenance, charge.

Remember to unplug the charger before moving the equipment. Failure to do so could cause damage to cords, receptacles, and other equipment.

TROUBLESHOOTING:

If the unit does not operate, check all the wiring connections to make sure they're both mechanically and electrically sound

- specifically at the battery, the motor, and at any location a wire is connected to the chassis. Also make sure the quick-connect plug on the end of the pendant control cord is plugged in correctly.

A full-charged lead acid battery in good condition at room temperature should read 12.65 volts. At 11.9 volts it is considered to be fully discharged and in need of charging. When checking battery voltage, wait at least 1/2 hour after the charger has been turned off before checking the battery's voltage. If the motor doesn't run, observe the green LED on the motor relay. If it is not lit, or if the LED goes out when the "UP" control is pressed, the battery voltage should be checked with a voltmeter.

If the batteries aren't being charged by the charger, check the output charger fuse. If it is good, check the battery's state of charge with a voltmeter.

Page 4

THE POWER UNIT'S OPERATION - HT, LDLT

The electric/hydraulic table utilizes an electric motor directly coupled to a gear-type hydraulic pump to produce the needed fluid pressure and flow to allow the cylinders to perform the work of lifting the table load.

A hydraulic manifold houses the hydraulic control components, and is bolted directly onto the gear pump.

The power unit's hydraulic components are all treated for 3,000 psi working pressure.

Important parts of the power unit include:

• The electric motor operates on 12 VDC.

• The gear pump. Its shaft is coupled directly to the shaft of the electric motor.

• The check valve. Its purpose is to prevent the backflow of fluid through the pump. In this way it allows the table

to be held at a given elevation indefinitely.

• The pressure relief valve. Its job is to open a path for fluid to flow back to the reservoir in the event that the fluid

pressure built up by the pump exceeds 3,000 psi. Thus the pump cannot generate more than 3,000 psi.

• The lowering solenoid valve. This is an electrically-operated cartridge valve. It contains a screen to keep

contaminants from entering the valve.

• The pressure-compensated flow control spool. This rests under the lowering valve and regulates the fluid flow 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 table or not.

• The hydraulic lift cylinder. On units with a motor or two-speed foot pump, the cylinder has a bleeder valve located

at their top end to allow air to be bled from the hydraulic system.

• The safety velocity fuse. This is a device that is installed in the cylinder's hose port. It closes quickly in the event

of a catastrophic hose failure to prevent the table from collapsing down. The table remains stationary until pressure is reapplied to the system.

• The hydraulic fluid. The system uses HO150 hydraulic fluid. Any anti-wear hydraulic oil with a viscosity grade of

150 SUS at 100°F (ISO 32 @ 40°C) such as AW 32 or non-synthetic transmission fluid is acceptable.

When the table is to be raised, press the "UP" push-button or foot switch. 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. The pump pushes the then-pressurized oil through the check valve and out to the lift cylinders.

When the table is to be lowered, press the "DOWN" push-button or foot switch. The lowering valve opens, bypassing the check valve and allowing the oil in the cylinders to return back to the reservoir through the return hose. The rate at which the table lowers is regulated by the internal pressure-compensated flow spool.

In the event that the table 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 table entirely.

• Remove any load from the table.

• Remove the nut holding the solenoid coil on the valve stem, 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 form the bottom end of the valve. The valve should move freely, and 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 table 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 table entirely.

• Remove any load from the table.

• Hold a rag over the cylinder's bleeder valve (it looks like a grease zirk) 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.

Page 5

Page 6

ROUTINE MAINTENANCE & SAFETY CHECKS - HT, LDLT

Care should be taken to identify all potential hazards and comply with applicable safety procedures before beginning work.

Only qualified individuals trained to understand mechanical devices and their associated electrical and hydraulic circuits should attempt troubleshooting and repair of this equipment.

(A) Before each use inspect the following, where applicable:

1.) Frayed wires.

2.) Oil leaks.

3.) Pinched or chafed hoses.

4.) Damage or structural deformation to the structural members, the cylinder, the foot pump, etc.

5.) Unusual noise or binding or evidence thereof.

6.) Proper functioning of all limit switches.

(B) Inspect monthly for, where applicable:

1.) The oil level. Oil should be 1" to 1 1/2" below the cylinder's

or the reservoir's fill hole with the lift in the fully lowered position.

2.) Oil leaks.

3.) Worn or damaged hydraulic hoses and electrical wires, if applicable.

4.) Integrity of the retaining rings and pins at all pivot points.

5.) Looseness, wear, or damage to the casters' bearings, mounting hardware, or surface material.

6.) Proper water level in the battery. (DC units only.)

7.) Unusual noises.

8.) Information and warning labels being in place and in good condition.

9.) The need to clean off dirt and debris.

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 @ 40°C). Ex: AW 32 or HO 150 hydraulic fluid, or non-synthetic transmission fluid.

Page 7

TROUBLESHOOTING GUIDE, DC UNITS - HT, LDLT

Before performing any task, always lower the table entirely.

Care should be taken to identify all potential hazards and comply with applicable safety procedures before beginning.

Only qualified individuals trained to understand mechanical devices and their associated electrical and hydraulic circuits should attempt troubleshooting and repair of this equipment.

Consult the factory for any problems not addressed in this manual.

* Check the DC notes page for other troubleshooting notes specific to battery-powered units.

Problem:

1. Power unit doesn't run when "UP" button is pressed.

2. Motor runs, but table does not move or only moves slowly. Power unit not noisy.

3. The power unit runs but makes a higher-pitched sound; the table does not move, or the table moves only slowly.

4. Table raises, then drifts down.

5. Spongy or jerky table movement.

6. Table lowers too quickly.

7. Table won't lower.

8. Table lowers too slowly.

Possible Causes:

A. Upper-travel switch is engaged or

bad.

B. Push-button control cord not plugged

into motor relay assembly properly.

C. Bad motor relay assembly (green

LED not lit at all or turns off when the motor relay pulls in).

D. Battery voltage low (green LED turns

off as or just after the motor relay

pulls in). A. Pump is failing to build pressure. B. Contamination holding open the

lowering valve or the check valve. A. Pressure relief opening at full

pressure.

A. Contamination holding open the

lowering valve or the check valve. A. Excessive air in the hydraulic

cylinder. A. Flow control spool sticking.

A. Solenoid coil is bad.

B. Physical blockage of the structure.

C. Solenoid valve or suction hose

screen plugged. A. Pinched hose.

B. Flow control spool sticking.

C. Velocity fuse locking (table only

slowly creeps down).

Action:

A. Inspect and test switch. Replace if

bad.

B. Verify that the push-button cable's

plug is connected properly to the relay assembly's quick-connect.

C. Check for green LED on relay. Consult

the factory.

D. Test with meter. Charge battery if

low (< 12 volts). A fully charged

battery has 12.6 volts. A. Consult the factory. B. Remove and inspect. Clean per

instructions in this manual. A. Check for structural damage or

binding of the posts, etc. B. Check for table overload condition.

A. Remove and inspect. Clean per

instructions in this manual. A. Bleed air from the bleeder valve at

the top of the cylinder. A. Remove plug from FC port; push on

edge of flow spool to ensure it is fully

pressed into the cavity. Pull and

clean spool if dirty. A. Check with multimeter on diodecheck

function. (Reading for ohms will not

provide an accurate test of the coil.) B. Inspect for foreign material or

objects that might obstruct the table

or guide posts. C. Remove and inspect. Clean per

instructions in this manual. A. Check pressure, supply, and return

hoses for kinks. B. Remove plug from FC port; push on

flow spool to ensure it is fully pressed

into the cavity. Pull and clean spool

if dirty. C. Same as for jerky table movement.

Page 8

EXPLODED PARTS DRAWING

1& 2-POST HYDRAULIC TABLE

ITEM NO.

a/l - Available at Local Hardware Store

DESCRIPTION

Foot Pump (FHJ-18 style)

Foot Pump Mt. Bolts 1/4-20 x 2

Nut 1/4-20 Nylock

Washer 1/2-20 Flat Washer

Casters 3-1/2 x 1-1/4 Polyurethane

Caster with Total Locks, Polyurethane

Bolt, Caster Mt. 1/4-20 x 3-1/2, or equivalent

Bolt 3/8-16 unc x 5 Carriage Bolt, or equivalent

Nut, Nylock Caster Mt. 1/4-20

Nut 3/8-16

Pin, Upper Cylinder Mt. (roller pin) 3/16 x 1-1/2

5 x 2 Poly-on-Steel Rigid Caster

5 x 2 Poly-on-Steel Swivel with Lock

Seal Kit Foot Pump

Caster Kit (includes either 3a or 3b)

HD Caster Kit (see page 10)

PARTS LIST

1 & 2-POST HYDRAULIC TABLES

ENGINEER NO.

01-640-030

a/l

16-132-003

16-132-002

a/l

16-132-022

16-132-03

01-136-412

21-154-009

16-154-020

*See page 9 for Two-Post Table Exploded Drawing

PART NO.

HT2-FTP

a/l

HT2-CSTR

HT2-CSTRTL

a/l

HT2-HDCSTR

HT2-HDLCSTR

HT2-KITA

HT2-KITB

HT2-KITC

QTY.

Page 9

EXPLODED PARTS DRAWING

2-POST HYDRAULIC TABLES

* See page 8 for Parts List

6a 6b

2a 2b

* See page 8 for Parts List

3a 3b

Page 10

EXPLODED PARTS LIST

4-POST HYDRAULIC & DC POWERED POST TABLES

30 37 (NOT SHOWN)

7a,b 8a,b

1, 1a, 2, 3

Page 11

PARTS LIST

4-POST & DC POWERED HYDRAULIC POST TABLES

ITEM NO.

DESCRIPTION

Foot Pump, Two Speed

Bolt, Foot Pump Mt. 3/8-16 x 3

Nut, Foot Pump Mt. 3/8-16

Cylinder 1-1/8 x 18

Cylinder 1-3/4 x 18

Bolt, Cylinder 3/8-16 x 1-1/4

Nut, Cylinder 3/8-16

Casters, Rigid 4 x 2 Phenolic

Caster, Swivel 4 x 2 Phenolic with Brake

Bolt, Caster Mt. 3/8-16 x 5 Lg.

Nut, Caster Mt. 3/8-16

Hose Assembly - Pressure

Hose Assembly - Return

Bolt Caster, 3/8-16 x 1 (6,000 lb. unit only)

Nut Lock, Caster 3/8-16 x 1 (6,000 lb. unit only)

Washer 3/8 (not shown) (6,000 lb. unit only)

Seal Kit for Foot Pump

ENGINEER NO.

01-640-004

a/l

21-021-006

21-021-005

a/l

16-132-016

16-132-148

a/l

21-523-001

21-523-002

a/l

01-136-441

PART NO.

HT4-2SFP

a/l

HT4-CYL

HT6-CYL

a/l

HT4-RGPHN

HT4-SWPHN

a/l

HT4-PSRHA

HT4-RTNHA

a/l

HT4-FP-SK

QTY.

ITEM NO.

DC POWERED POST TABLES

DESCRIPTION

Motor

Pump

Bolt Motor/Pump Mt. 3/8-16 x 1

Hand Control

Hydraulic Hose Assembly Pressure

Hydraulic Hose Assembly Return

Battery

Motor, Solenoid Smart Start Switch

Battery Box, Strap

ENGINEER NO.

01-135-042

01-143-010

a/l

01-522-022

21-523-003

21-523-004

21-139-003

15-022-004

21-154-010

PART NO.

HTDC-MTR

HTDC-PMP

a/l

HTDC-HC

HTDC-HHAP

HTDC-HHAR

HTDC-BATT

HTDC-SOL

HTDC-BBS

QTY.

A/L A/K

Available at local hardware store Available only with purchase of kit

Page 12

FOOT OPERATED JACK ASSEMBLY

MODEL FHJ-C

Page 13

Reference Model Number Component Decription Number

FHJ-C-1-18 FHJ-C-1-24 FHJ-C-2 FHJ-C-3-18 FHJ-C-3-24 FHJ-C-4 FHJ-C-5 FHJ-C-6 FHJ-C-7 FHJ-C-8-18 FHJ-C-8-24 FHJ-C-9 FHJ-C-10 FHJ-C-11 FHJ-C-12 FHJ-C-13 FHJ-C-14 FHJ-C-15 FHJ-C-16 FHJ-C-17 FHJ-C-18 FHJ-C-19 FHJ-C-20 FHJ-C-21 FHJ-C-22 FHJ-C-23 FHJ-C-24 FHJ-C-25 FHJ-C-26 FHJ-C-27 FHJ-C-28 FHJ-C-29 FHJ-C-30 FHJ-C-31 FHJ-C-32 FHJ-C-33 FHJ-C-34 FHJ-C-35 FHJ-C-36 FHJ-C-37 FHJ-C-38 FHJ-C-39 FHJ-C-40 FHJ-C-41 FHJ-C-42 FHJ-C-43 FHJ-C-44 FHJ-C-45 FHJ-C-46 FHJ-C-47 FHJ-C-48 FHJ-C-49 FHJ-C-50 FHJ-C-51 FHJ-C-52 FHJ-C-53 FHJ-C-54 FHJ-C-55 FHJ-C-SK

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

1 1 2 3 3 4 5 6 7 8 8 9

Cylinder Assembly 18 Inch Cylinder Assembly 24 Inch O-Ring 31.5 x 1.8 Inside Cylinder Body 18 Inch Inside Cylinder Body 24 Inch O-Ring 31.5 x 1.8 O-Ring 34 x 3.5 O-Ring 56 x 3.5 Valve Plug Lift Piston 18 Inch Lift Piston 24 Inch U-Packing UHS28 Dust Ring DH28 Washer Pump Cylinder Screw Plug Steel Ball Screw Plug Cone Valve Spring O-RIng 28 x 2.4 Pump Piston U-Packing UHS18 Dust Ring DH18 Lock Shaft Spring Slide Screw Link shaft Roller Guide C-Ring Foot Assembly Rubber Rad Press Set Screw Spring Single Vlave Pin Single Vlave Pad O-Ring 10 x 1.9 Steel Ball 5 Spring Push Lever O-Ring 7 x 1.9 Push Lever Pad O-Ring 15 x 2.4 Lock Shaft Twist Spring Leading Pad Discharge Foot Assembly Socket Set Screw Adjusting Screw Hex Cap Nut Steel Ball Spring Seat Adjusting Pressure Spring Adjusting Pressure Plug O-Ring 11 x 1.9 Fix Screw Screw Air Breather O-Ring 10 x 1.9 Seal Kit

Page 14

FOOT OPERATED HYDRAULIC JACK ASSEMBLY

MODEL FHJ

Page 15

PARTS LIST FOOT OPERATED HYDRAULIC JACK - MODEL FHJ-C

ITEM # PART NUMBER DESCRIPTION QUANTITY

1 FHJ-P103 Snap Ring 2 2 FHJ-P104 Spring Holder 1 3 FHJ-P102 Plunger 1 4 FHJ-P105 Pressure Spring 1

K 5 FHJ-P106 Rod Wiper 1 K 6 HYD-02-2706 O-Ring 1

7 FHJ-P113 Check Valve Plug 1

K 8 HYD-01-2514 O-Ring 1

9 PLT-P1036 Valve Spring 1 10 PLT-P1037 Cone Valve 1 11 PLT-P1038 Cone Valve Seat 1

K 12 HYD-01-0803 O-Ring 2

13 SB-9-32 Steel Ball 1 14 FHJ-P153 Roller 1 15 FHJ-P151 Snap Ring 4 16 FHJ-P152 Pedal Pin 2 17 FHJ-P168 Foot Pedal 1 18 SB-5-32 Steel Ball 1 19 FHJ-P111 Relief Seat 1 20 FHJ-P110 Relief Spring 1 21 FHJ-P109 Relief Plug 1 22 FHJ-P121 Lowering Pedal Spring 1 23 FHJ-P119 Lowering Pedal 1 24 FHJ-P147 Filler Breather Plug 1 25 FHJ-P150 Pedal Crimp Spring 1 26 FHJ-P148 Lock Washer 1 27 FHJ-P149 Screw 1

K 28 FHJ-P107 Back-Up Ring 1 K 29 FHJ-P166 Dust Seal 1 K 30 FHJ-P167 Rod Seal 1 K 31 CYL-M0010-020 Dyna Seal 1

32 FHJ-P135 Gland Nut 1 33 FHJ-P163 Socket Head Cap Screw 1

K 34 HYD-02-2811 O-Ring (Gland) 1 K 35 HYD-02-6038 O-Ring (Inner Tube) 2

36 FHJ-P156-3020-00 Piston Rod 1 37 FHJ-P141-2424 Inner Tube 1 38 FHJ-P101-2424 Base & Tube Weldment 1 39 FHJ-P129 Bolt 1 40 FHJ-P130 Lock Washer 1 41 FHJ-P1015 Valve Spring 1 42 FHJ-P123 Pressure Pin 1

K 43 HYD-01-2506 O-Ring 1

44 FHJ-P124 Bushing 1

K 45 HYD-01-2637 O-Ring 1

46 FHJ-P122 Lowering Spacer 1 47 FHJ-P120 Lowering Sleeve 1 48 FHJ-P128 Set Screw 1 49 FHJ-P118 Push Bolt 1 50 FHJ-P164 Lock Nut 1 51 FHJ-P139 Piston 1 52 FHJ-P165 Snap Ring 1

A FHJ-SK Seal Kit 1

K Available in seal kit only

Page 16

OPERATING INSTRUCTIONS FOR TWO- SPEED FOOT PUMP

AIR BLEED PROCEDURE FOR TWO-SPEED FOOT PUMP

FEATURES: Your new lift equipment has been supplied with an exclusive single-speed or two-speed foot pump. The internal features of your pump includes a primary pressure relief, pressure compensated return flow control valve, and an integrated lowering valve. Replacements are necessary.

OPERATING INSTRUCTIONS: Stay clear of moving parts. The platform will rise as the foot pedal is pumped. Depressing the release lever will lower the table at a controlled rate of descent. In the event the platform has been overloaded, the pressure relief will open because of excessive pressure buildup in the hydraulic system. Oil will bypass into the reservoir. Never increase the pressure relief setting more than necessary. Do not exceed the rated capacity of your equipment.

TWO-SPEED SELECTION: The two-speed hydraulic foot pump offers two "speeds". The low speed products speed products

low volume/high pressure.

high volume/low pressure.

The high

The operator has the option of selecting the optimum pump speed for the application at hand. Pump speeds are selected by sliding the "lock collar" (Item #2 on the parts identification) in or out. An occasional drop of oil will keep the collar working freely.

Whether your pump is a new installation, or has been recently serviced, air has likely entered the hydraulic system. The design of this pump includes an "air bleed screw" which will aid in the removal of unwanted air from the foot pump area of the hydraulic system. Use the following steps to remove this air from the system.

1) Check all fittings to be sure they are tight. Ensure that the oil is filled to within 1" of the top of the reservoir when the lift is in the fully lowered position.

2) Locate the "air bleed screw" (item #34 on the pump body) and loosen approximately 1/2 turn counterclockwise. As soon as you have loosened the screw, slowly depress the foot pedal. This unit will force the air out of the pump chambers. Before you let the pump pedal return to the "up" or "home" position, tighten the air bleed screw. This will prevent air from reentering the pump chamber. Repeat the above procedure until the pump chamber is completely filled with oil and a "spongy" feel is no longer present. If the air bleeding procedure has been successful, the feel of the pump pedal will be firm and the complete stroke of the pump will produce fluid flow.

Air can also become trapped in the hydraulic cylinder(s). Review your owners manual for air removal instructions.

PRESSURE

CHECK VALVE

HYDRAULIC DIAGRAM FOR TWO-SPEED FOOT PUMP

2 SPEED

FOOT PUMP

PRESSURE CHECK VALVE

ADJ. PRESSURE RELIEF VALVE

LOWERING VALVE

PRESSURE COMPENSATED FLOW CONTROL

1GPM

TO CYLINDER

Page 17

HYDRAULIC FOOT PUMP --- TROUBLE SHOOTING GUIDE

TROUBLE SHOOTING

(Read all instructions thoroughly prior to performing any maintenance.)

SYMPTOMS

• Foot pumping action does not raise platform.

• Cylinder slowly drifts downward under load.

• Cylinder pumps up, but will not go down.

BLEEDER SCREW

CYLINDER ROD

REMEDY

Tools required: 3 & 5 mm hex key wrenches

Standard head screwdriver Adjustable wrench

1) Adjust Release Pedal

(Refer to figure below)

• Loosen setscrew on release pedal. Rotate pedal counterclockwise until pedal touches

the base. While holding pedal, use hex key

wrench to turn release shaft counterclockwise to stop. (NOTE: Do not loosen lock nut on release pedal shaft.) Tighten pedal set screws. Release pedal.

2) Check Fluid Level

• Remove fill/breather plug.

• Fluid should be filled to 2-2 1/2 inches from bottom edge of hole when cylinder rod is in the lowered position. If overfilled, fluid may seep from fill/breather plug. (ISO #AW-32 ANTIWEAR HYDRAULIC PUMP OIL ONLY.

FLUID MUST BE CLEAN! STRAIN FLUID IF

NECESSARY).

FLUID FILL LINE

RELEASE PEDAL

FILL/ BREATHER PLUG

PUMP PEDAL

RELEASE VALVE ASSEMBLY CAP

OVERLOAD BYPASS ADJUSTMENT SCREW

3 mm HEX KEY WRENCH

3) Clean Release Valve Assembly

• Remove release valve assembly cap and

RELEASE PEDAL

PEDAL SET SCREW

clean assembly (shown in exploded view.)

• While assembly is removed, pump foot pedal vigorously at least five times. CAUTION: Fluid will discharge from release valve hole. This will dislodge any foreign matter from the ball socket. Clear hole of debris and reassemble release valve and

PRODUCT BASE

RELEASE PEDAL ADJUSTMENT

tighten cap.

• Repeat procedure #2 to refill fluid.

4) Bleed Pump of Trapped Air

• Pump up cylinder at least 4 inches. While putting pressure on the platform, release bleeder screw until fluid flows free and clear from behind the screw. Then tighten bleeder screw and release pressure from platform. Repeat procedure until no signs of air are present. If after following the above procedures the problem still exists or if unit is leaking fluid, please contact the factory at (260)665-7586.

CCW MOTION

Page 18

TROUBLESHOOTING GUIDE - 2-SPEED FOOT PUMP

Before performing any task, always lower the table entirely.

Consult the factory for any problems at time of installation or for any problems not addressed below:

*Check the DC notes page for other troubleshooting notes specific to battery-powered units.

Problem:

1. Platform does not raise when the foot treadle is pressed. Foot treadle goes down without excessive force.

2. Platform will fit under no load, but not when fully loaded. Foot treadle goes down without excessive force.

3. Platform raises with the pump downstroke, but lowers with the pump upstroke.

4. Platform raises, then drifts down.

5. Platform raises, but in smaller increments than normal.

6. Excessive effort is required to operate the foot pump.

7. Platform won't lower when the release pedal is pressed or lowers too slowly.

•The hydraulic fluid. The system uses HO150 hydraulic fluid. Any antiwear hydraulic oil with a viscosity grade of 150 SUS at 100°F (ISO 32 @ 40°C) such as AW 32 or nonsynthetic transmission fluid is acceptable.

8. Platform lowers too quickly.

9. Platform lowers with a jerky motion.

Possible Causes:

A. No oil getting through the pump - not

enough oil in reservoir, or the pump has become "air-locked."

B. Pinched or kinked hose.

C. Relief valve is opening.

D. Inlet check valve assembly being

held open by contamination.

A. Same as above. B. Contamination holding open the relief

valve assembly.

C. Air in the pump piston. A. Outlet check valve assembly being

held open by contamination.

A. Same as above. A. Contamination holding open the relief

valve assembly or the inlet check valve assembly.

A. Operating pressure is too high for

effective use at the current pump displacement.

A. Pinched hose.

B. Release pin is bent or broken.

C. Velocity fuse is locked. D. Flow control spool sticking or plugged

by contamination.

E. Object under platform or obstructing

the leg assembly movement or roller travel.

F. Damaged to the leg assembly

structure. A. Same as last item above. A. Air in the hydraulic system, especially

the cylinder(s).

Action:

A. Check the reservoir's oil level. It

might be necessary to bleed air from the pump piston at the socket-head screw located on the left side of the pump cylinder.

B. Visually inspect all hoses. Replace

or reposition as necessary.

C. Check for excessive load on the

platform.

D. Open the port on the left side of the

pump and clean any foreign material from the ball and its seat. Press the foot treadle to help flush any

contamination out of the port. A. Same as above. B. Open the port to the right of the

release pedal. Inspect and clean the

parts. Press the foot treadle to flush

contamination out of the port. C. Bleed air from the piston. A. Open the port on the left side of the

pump and clean any foreign material

from the ball and its seat. A. Same as above. A. Reference the instructions above for

cleaning each assembly.

A. Slide the speed selector forward to

put the pump into low volume

operation. B. Check for excessive load on the

platform. A. Check all hoses for kinks, crimped

spots, or visual damage. Reroute or

replace as necessary. B. Inspect the release pin under the

release pedal. It should protrude

3/16", and should move in and out by

1/8"+. C. Bleed air from the cylinder. D. Remove the pressure hose to access

and inspect the flow control. Push on

the outside edge of the flow spool to

ensure it is fully pressed into the

cavity, and on the center to verify

that it moves freely. E. Inspect for and remove any physical

obstructions.

F. Inspect for evidence of rubbing,

binding, twisting, etc. of the leg set. A. Same as above. A. Bleed air from the system at the

cylinder.

Page 19

2-SPEED FOOT PUMP PARTS

4614

28, 26, 24

29, 27, 25

Page 20

TWO SPEED FOOT PUMP PARTS

Reference

Number

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Description

Assembly, Foot Pedal, Double Speed Release Lever Lever, First Link Assembly Pump Plunger Lever Second Link Outlet Check Spring (7/16” Steel Ball) Release Check Spring Inlet Check Spring (5/16” Steel Ball) Guide Shoulder Screw Guide Shoulder Screw Washer Release Lever Shoulder Screw Fitting O-Ring Plug Release Rod U-Cup Seal Fitting O-Ring Plug Dirt Plug Detent Latch Spring Dirt Plug Washer Pressure Compensated Flow Control Valve Sleeve Sintered Bronze Bearing Hexagon Socket Head Cap Screw Piston Return Spring Release Pin O-Ring Piston Wiper Seal (1.25) Piston U-Cup Seal (1.25) Piston Wiper Seal (1.00) Piston U-Cup Seal (1.00) Piston Wiper Seal (1.375) Piston U-Cup Seal (1.375) Spring Pin (0.25 x 1.5 lg.) Spring Pin (0.188 x 0.75 lg.) Round Head Groove Pin (0.375 x 1.50 lg.) Round Head Groove Pin (0.375 x 1 lg.) Round Head Groove Pin Washer Lever (Second Link) Roller Fitting Pressure Adjustment Plug Pressure Relief Spring Subassembly, Foot Pump Base Ground Dowell Pin (0.375 x 1.5 lg.) Socket Head Screw Sealing Washer Release Pin Seal Retaining Ring Assembly Hole Plug Detent Pin 5/16” Steel Chrome Ball 3/8” Steel Chrome Ball 7/16” Steel Chrome Ball Seal Kit Foot Pump Assembly

Engineer Number

n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 01-140-014 01-136-442

Part Number

VI081601 VI081604 VI081607 VI081605 VI081609 VI081610 VI081611 VI081612 VI081613 VI081614 VI081615 VI081616 VI081617 VI081618 VI081619 VI081620 VI081621 VI081622 VI081623 VI081624 VI081625 VI081627 VI081628 VI081629 VI081630 VI081655 VI081656 VI081660 VI081661 VI081631 VI081632 VI081633 VI081634 VI081635 VI081636 VI081641 VI081642 VI081644 VI081646 VI081647 VI081648 VI081651 VI081662 n/a n/a n/a CRT2000-SK CRT2000-FPA

Quantity

1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 5 1 1 1 3 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Page 21

WARNING LABEL IDENTIFICATION

MAKE SURE ALL WARNING LABELS ARE IN PLACE!

HYDRAULIC OIL OR NON-SYNTHETIC TRANSMISSION FLUID ACEITE HIDRAULICO O LIQUIDOS DE TRANSMISION NO SINTETICOS HUILE OU LIQUIDE HYDRAULIQUE NON-SYNTHÉTIQUE

VESTIL MANUFACTURING CORPORATION • Phone (260) 665-7586 • www.vestil.com

ISO 32 / 150 SUS

206

Rev. 1003

*Product safety signs or labels should be periodically inspected and cleaned by the product users as necessary to maintain good legibility for safe viewing distance ... ANSI 535.4 (10.21) Contact manufacturer for replacement labels.

CAUTION

PLATFORM MUST

BE LOWERED BEFORE

MOVING LIFT

VESTIL MANUFACTURING COMPANY • Angola, Indiana USA • Phone (260) 665-7586 • www.vestil.com 210 Rev 04/03

LA PLATAFORMA DEBE DE ESTAR

! !

ATENCIÓN

EN LA POSICIÓN BAJA ANTES DE

MOVER EL ELEVADOR

ATTENTION

LA PLATE-FORME DOIT ÊTRE

ABAISSÉE AVANT D’ACTIVER

LE MONTE-CHARGE

Page 22

LIMITED WARRANTY

ONE YEAR LIMITED WARRANTY. The manufacturer warrants for the original purchaser against defects in materials and workmanship under normal use one year after date of purchase. (Not to exceed 15 months after date of manufacture.) Any part which is determined by the manufacturer to be defective in material or workmanship and returned to the factory, shipping costs prepaid, will be, as the exclusive remedy, repaired or replaced at our option. Labor costs for warranty repairs and/or modifications are not covered unless done at manufacturer’s facilities. Any modifications performed without written approval of the manufacturer may void warranty. This limited warranty gives purchaser specific legal rights which vary from state to state.

LIMITATION OF LIABILITY. To the extent allowable under applicable law, the manufacturer’s liability for consequential and incidental damages is expressly disclaimed. The manufacturer’s liability in any event is limited to, and shall not exceed, the purchase price paid. Misuse or modification may void warranty.

WARRANTY DISCLAIMER. Our company has made a diligent effort to illustrate and describe the products shown accurately; however, such illustrations and descriptions are for the sole purpose of identification, and do not express or imply a warranty that the products are merchantable, or fit for a particular purpose, or that the products will necessarily conform to the illustrations or descriptions.

The provisions of the warranty shall be construed and enforced in accordance with the UNIFORM COMMERCIAL CODE and laws as enacted in the State of Indiana.

DISPOSITION. Our company will make a good faith effort for prompt correction or other adjustment with respect to any product which proves to be defective within the Limited Warranty. Warranty claims must be made in writing within said year.

SERVICE RECORD

DATE OF SERVICE:_____/_____/_____

WORK DONE BY:______________________________