Vestil NE-CART-2, NE-CART-1, NE-CART-3, NE-CART-4 User Manual
INSTRUCTION MANUAL
FOR Two Speed Traction-Drive Carts
MODELS COVERED: NE-CART-1, NE-CART-2, NE-CART-3, NE-CART-4
NE-CART-1 NE-CART-2
NE-CART-3 NE-CART-4
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
VESTIL MANUFACTURING CORP.
URL: WWW.VESTILMFG.COM EMAIL: SALES@VESTIL.COM
1
E-CART (ELECTRIC CART)
CCOONNTTEENNTTSS
General …………………………………………………………………………………..
Specification ……………………………………………………………………………
Receiving instructions ………………………………………………………………
Rules for Safe use ……….……………………………………………………………
Safety Instructions & Warnings ……………………………………………
Symbols & Pictures ………………………………………………………….
Product description …………………………………………………………………
Designated use …. … …... … …………………………………………………….
Operation ……………………………………………………………………………….
Travel ………………………………………………………………………………..
Safety Reverse Switch …………………………………………………………….
Brake ………… …………………………………………………………………….
Horn …………………………………………………………………………………
Maintenanc e an d repair …………………………………………………………….
Trouble Shooting …………………………………………………………………….
Changing Batteries ………………………………………………………………….
Changing Motor Controller ………………………………………………………….
Belly Switch Trouble Shoot ………………………………………………………….
Free Wheeling ………………………………………………………………………..
Maintenance daily/before use, monthly, annually …………….………………….
Drive Transmission Lubrication …………………………………………………….
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4
5
6
7
8
9
9
9
10
10
11
11
12
12-15
16-17
18
19-33
34-35
36
37
Warranty ……………………………………………………………………..
Parts drawing & Parts list ………………………………………………….
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38
39-43
E-CART (ELECTRIC CART)
Introduction
Read and follow the instructions contained in
this operating manual.
Please read and follow all instructions in this User’s Instruction Manual before attempting
to operate your Material Handling Cart (E-CART) for the first time. If there is anything in this
manual that you don’t understand, or if you require additional assistance for setting it up.
Contact factory at 26-665-7586.
Only trained, well-informed personnel, who have been instructed in accordance with this
operation manual, may use or work on the stacker.
Liability or guarantee is waived if:
z The instructions in this operating manual are not observed.
z The high-lift stacking truck is operated, cleaned or maintained incorrectly.
z Alterations to the functions are carried out without the consent of manufacturer.
z Original spare parts are not used.
Safety instructions
This chapter informs the user about residual dangers relating to the correct use of the
products. It contains generally valid safety instructions which must be observed.
Safety instructions relating to specific actions or situations are listed prior to the respective
action and/or description of the situation in the chapter.
Principles
This product complies with state-of-the –art technical standards and recognized safety
regulations, but there are still dangers which may occur which must be considered.
Only operate the product in a perfect condition and observing the information contained in
the operating manual.
The operator is responsible for integrating the product with as little risk as possible into his
working environment. This obligation continues through every phase of the products
lifespan, beginning at the planning stage. Residual dangers are to be minimized.
Only trained, competent personnel who have been instructed using the operating manual
and the product are permitted to work with the truck.
The operating manual must be understood (responsibility, checking)
3
Specifications
Model #
Total Capacity
2nd Shelf Capacity
3rd Shelf Capacity
Platform Size (L x W)
2nd deck platform size (L x W)
2nd deck platform size (L x W)
Platform Height
2nd Deck Height
3rd Deck Height
Distance between the
platforms
Steering wheel
Drive wheel
Overall Size (L x W x H)
Handle Height
Railing Height
Travel Speed
(Fast)
Travel Speed
(Slow)
Turning Radius
Controller
Drive Motor
Battery
Battery Charger
Loaded
Unloaded
Loaded
Unloaded
NE-CART-1 NE-CART -2 NE-CART -3 NE-CART-4
750 lbs 750 lbs 750 lbs 400 lbs
N/A N/A 250 lbs 200 lbs
N/A
28 x 48” 24¾” x 46” 24¾” x 46” 24¾” x 46”
N/A N/A 24¾” x 46” 24¾” x 46”
N/A N/A N/A 24¾” x 46”
14”
N/A
N/A
N/A N/A 17¾” 17¾” (1 & 2) 16¾” (2 & 3)
(2) Ø9 x 3⅛” (solid-foam tires) (2) Ø9 x 3⅛” (solid-foam tires) (2) Ø9 x 3⅛” (solid-foam tires) (2) Ø9 x 3⅛” (solid-foam
(2) Ø10¼ x 3⅛” (solid-foam
tires)
59 x 28 x 44 11/16” 59 x 28 x 44 11/16” 59 x 28 x 44 11/16”
44 11/16” 44 11/16” 44 11/16” 44 11/16”
N/A
2.5 mph 2.5 mph 2.5 mph 2.5 mph
2.8 mph 2.8 mph 2.8 mph 2.8 mph
1.3 mph 1.3 mph 1.3 mph 1.3 mph
1.5 mph 1.5 mph 1.5 mph 1.5 mph
23⅝
” 23⅝” 23⅝” 2
Curtis 1212 Curtis 1212 Curtis 1212 Curtis 1212
DC24V/50
2 x 12V/80-95Ah 2 x 12V/80-95Ah 2 x 12V/80-95Ah 2 x 12V/80-95Ah
DC 24V/6A DC 24V/6A DC 24V/6A DC 24V/6A
0W D
(2) Ø10¼ x 3⅛” (solid-foam
N/A
14”
A 33” 33”
N/
N/A
(2) Ø10¼ x 3⅛” (solid-foam
tires)
40”
C24V/50
0W
N/A 150lbs
14” 14”
N/A 49¾”
(2) Ø10¼ x 3⅛” (solid-
tires)
12” 59¾”
DC24V/50
0W
tires)
foam tires)
59 x 28 x 59⅜”
3⅝”
DC24V/50
0W
Frame Height: 11½” Frame Height: 25¾” Frame height: 45⅜”
Hi/Low speed
Variable speed control throttle
24V Battery system
Battery Level Indicator
Automatic Brake
Steel Construction
Tread plate surface
Maximum incline is 5 degrees
On-board battery Charger (3-4 hour operation at full charge - 8 hours when used intermittently)
Horn & Belly-bump emergency safety stop.
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E-CART (ELECTRIC CART)
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 & strapping material, inspect for damage. IF DAMGE IS EVIDENT,
FILE A CLAIM WITH THE CARRIER IMMEDIATELY! Also, check fork size, type of power
unit, etc., to see that the unit is correct for the intended application.
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 stacker.
• Do not use the stacker if any damage or unusual noise is obser
Improper use of this lift truck could result in injury and damage to load or
•
ved.
equipment.
• Always watch the stacker and any load on it carefully when it is being used or
ed.
mov
DO NOT load beyond rated capacity
•
• DIST
RIBUTE load evenly
• Avoid sudden stops or quick turns to prevent accidental tipping of the load
Load must be centered and evenly distributed on the fo
•
Park the truck on level surfaces and not in the way of other products
•
• When parked, lower the load fork completely
•
When parked, push E-switch push-button dow
•
Do not perform any modifications to the stacker without the manufacturer’s
.
.
rks.
.
n.
approval. Failure to receive authorization for changes to the equipment could void
the warranty
•
Do not use brake fluid or jack oil in the hydraulic system. If oil is needed, use
an
ti-wear hydraulic oil with a viscosity grade of 150 SUS at 100°F, (ISO 32
40°C)
.
, or a non-synthetic transmission flui
an
@
d.
•
Use only replacement parts either supplied or approved by the manufacturer
5
.
E-CART (ELECTRIC CART)
Rules For Safe Use
These symbols below are used in this owners manual to identify warnings and cautions. It
is very important for to read and understand them.
Warning: Failure to note the warnings in this users manual may result in
personal injury
Caution: Failure to observe the cautions in this users manual may result in
damage to your E-CART.
Your E-CART is a powerful machine, for your safety and safety of the bystanders, please
read all instructions in this manual before operating your E-CART, they have been
prepared from years of experience with this type of equipment. Follow notes carefully to
ensure safety at all times.
Always make certain your machine is in full working order before your operation.
1. Do not operate E-CART without reading this instruction manual. Also read all of the
safety instructions and warnings stated in this manual.
2. Do not exceed the maximum safe gradient outlined for your vehicle.
3. Do not carry passengers or exceed the maximum carrying weight.
4. Do not turn suddenly at full speed, especially on uneven or sloping ground.
5. Avoid climbing or descending curbs, you may permanently damage E-CART.
6. Always stop fully before changing direction (forward or reverse)
7. Always avoid uneven surfaces.
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E-CART (ELECTRIC CART)
SAFETY INSTRUCTIONS AND WARNINGS
WARNING: Don’t attempt to operate E-CART for the first time without completely reading
and understanding all of the facts in this instruction manual.
When you begin to use E-CART, you will probably encounter situations in which you will
need some practice. Simply take your time and practice to control as you maneuver
through the doorways, on and off elevators, up and down ramps and over moderate terrain.
SAFETY CHECK
Get to know the feel of your E-CART and it’s capabilities. Factory recommends that you
perform a safety check before each use to make sure that E-CART operates smoothly and
safe. For details on how to perform these necessary inspections, see the care and
maintenance section of this manual. Perform following inspection prior to using your
E-CART.
• Check all battery connections, make sure they are serviceable and not corroded.
• Check batteries if they are fully charged.
• Check operation of brakes.
• Before leaving the cart, make sure turn off the power.
Warning: Don’t carry people on the E-CART, this may cause in personal injury and/or
property damage.
WEIGHT LIMIT
E-CART is designed for a maximum user weight limit of 750 lbs. (340 kgs.)
Warning: Exceeding the weight limit will avoid your warranty and may result in personal
injury and damage to E-CART. Vestil will not be held responsible for injuries and/or
property damage resulting from failure to observe these weight limitations.
Excessive high cornering speeds can create the possibility of cargo tipping. Factors which
affect the possibility of cargo tipping include, but are not limited to, cornering speed,
uneven surfaces, inclined surfaces, and abrupt directional changes. Don’t corner at high
speed! If you feel that your cargo may tip over on a corner, reduce your speed and steering
angle to prevent your cargo from tipping.
OUTDOOR DRIVING SURFACES
• Reduce speed when operating on uneven terrain or soft surfaces.
• Avoid long and unsafe grass that can tangle in the running gear or may hide debris
and holes.
• Avoid loosely packed sand and gravel.
INCLINES
• When descending an incline keep your speed adjustment set to the slowest speed
setting to ensure a safely controlled descent and drive in forward direction only.
Warning: Never drive down an incline at full speed.
• When climbing an incline, try to keep your E-CART moving, if you must stop, start
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E-CART (ELECTRIC CART)
Max 5°
Max 2°
up again slowly and then accelerate smoothly with caution. Avoid sudden stops,
lean forward towards your handlebars to increase stability.
Warning: Any attempt to climb or descend an incline steeper than shown below may
put your E-CART in an unstable position and cause it to tip, resulting in personal injury.
SYMBOLS & PICTURES
In
addition to the text and illustrations, this operating manual contains various symbols
which should draw attention to the safety requirements.
They generally have the following appearance:
Signal wording Explanation
DANGER
Warning of an imminent danger!
Non-observance cause death or serious injury
WARNING
Warning of a possibly incoming dangerous situation.
Non-observance may cause death or serious injury.
CAUTION
Warning of a possibly incoming dangerous situation.
May also be used for warnings of major damage to property.
Other
definitions:
DIRECTION
Marks recommendations for use and other useful information.
Does not warn of dangerous situations.
IMPORTANT
Warns of a harmful situation.
Non-observance may cause damage to material.
USE SYMBOLS & PICTURES
Possible danger to file
and limb or machine!
Do
not reach into
running motor!
Danger of crushing! W
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ear safety shoes
E-CART (ELECTRIC CART)
Product description
Designated use
The CART is to be used on hard level surfaces.
¾ To move the stacker between buildings, warehouses etc
The gradient of the slope must not be more than 5%
Make sure load is not loose or unstable.
Do not pick up loads on tips or forks or edge of platform.
Do not overload.
The road surfacing must be solid and have a good grip.
Travel routes must offer sufficient load-bearing capacity for the loaded CART.
The CART is not suitable for continuous use in cool-houses!
Ambient conditions
Temperature From
To
14
113
°F
°F
Degree of humidity ≤70 %
Permitted floor
incline
y Loaded
y Unloaded ¹
Max. 0.5
Max. 2.0
%
%
OPERATION
isually inspect E-CART for damaged and worn parts, before
V
Electric Cart is taken into operation.
read and understand all instructions
Caution!
Pedestrian controlled industrial trucks may only be operated by persons who
have been satisfactorily instructed in operating the truck and have proved their
ability to operate the truck to the responsible representative of the operating
company.
The first driving attempts should take place on level and spacious surfaces.
Authorized person should
Recommendation:
The operator who is to maneuver the CART should be allowed to practice, when
unloaded, until they can safely operate these functions.
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E-CART (ELECTRIC CART)
Travel
The butterfly switch controls the direction and speed of the lift truck.
Rotating the butterfly control towards the f o rks moves the truck in the forward
direction. Rotating the butterfly control away from the forks, moves the truck
in the reverse dir ection. The control is progre ssive – the further you rotate the
control, the faster the truck will travel.
DIRECTIONAL SPEED CONTROL THROTTLE
Emergency reverse safety button
At the top of the handle is a red safety reverse button. The button is
designed to change the travel direction away fro m the operator when depressed.
The truck will stop moving away from the operator when the button is re leased.
When the fork truck is traveling forward (away from the operator) the button
has no effect when activated.
If the belly switch becomes jammed or stuck, it will move forward (away
from the operator) for a maximum of 3 seconds at which time the control circuit
will become disabled until the handle is re-set to the full up or full down position
and the belly switch is returned to normal operation.
BELLY SWITCH (SAFETY REVERSE BUTTON)
10
E-CART (ELECTRIC CART)
TO BRAKE
This cart is equipped with a brake that is applied between 1~5 degrees of the
vertical position . When you release your hand from the handle. It will resume
the neutral position automatically, as the brake in work. Always make sure that
the brake is in work before operating the cart .
HORN
A horn is located on the front side of the handle.
HORN
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E-CART (ELECTRIC CART)
Maintenance and repair
TROUBLESHOOTING GUIDE -- ______
Warning: Before performing any task, always block drive wheel off of the ground.
Consult the factory for problems at time of installation, or for any problems not addressed
below.
Problem: Possible cause(s): Action:
Unit doesn’t mov e wh en c on t r ols a r e
used.
Unit will not charge
Unit will not go forward; reverse
works; belly switch just kills unit
(does not go forward and time 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 (<17)
Problem with motor controller
(check for LED flash code on side
of controller)
Fuse blown
Charger malfunction
Bad batteries
Broken wire, or loose connection
Contactor bad, motor controller bad
Broken wire, or loose connection,
contactor bad, motor controller
bad
Charge batteries.
Consult diagnostics
page/factory
Remove back shroud and check
fuses (3 fuses).
Verify output voltage on charger,
will only get a reading when
connected to batteries; should be
approximately 28 volts.
Load test batteries
Locate Pin 2 on Molex connector at
motor controller. Trace wiring to
contactor and verify connection.
When forward is depressed, there
should be 24 volts on this wire
from Molex connector to the
contactor, if not, the motor
controller may be bad; consult
diagnostics page/factory. If 2 4
volts is present at contactor,
verify ground connection. If
ground is good, remove both wires
and check with ohm meter;
resistance should be
approximately 38 ohms. If it’s
open or zero, the contactor should
be replaced.
Same as above; except locate Pin 3
on Molex connector on motor
controller…and follow procedure.
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E-CART (ELECTRIC CART)
Problem: Possible cause(s): Action:
Unit will not go forward, or reverse,
but belly switch still functions
properly.
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.
Broken wire, or loose connection,
bad motor controller,
Throttle assembly bad
Blown fuse
Broken wire, or loose connection
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 and
the unit does not move, the motor
controller may be bad, consult
diagnostics page/factory. If
there is no voltage, trace the
wiring back towards the tiller head
and check voltage on each side of
connectors. Continue this until
bad connection is found.
If the connections are all good, and
there is no voltage coming out of
throttle assembly, then the
throttle assembly may be bad.
Verify there is 24 volts going into
the assembly and that there is a
good ground. If there is still no
output voltage for pin 6, replace
throttle assembly. See Fig. 1
Verify fuses are good, replace if
blown.
Locate Pin 7 on Molex connector at
the motor controller. Trace wire
back up to tiller head and verify
continuity all the way to the
throttle assembly. Repair any
loose connections.
If there is continuity up to the
throttle assembly, then check the
ground wire that comes off of B-
on the motor controller (3
rd
terminal down). Add more length
to this wire if necessary, and
re-terminate with a ring terminal.
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