Vestil S-CB-118 User Manual

OPERATION & SERVICE MANUAL

S SERIES STACKER WITH POWERED DRIVE & POWER LIFT

Vestil Manufacturing Corp.

2999 North Wayne St., Angola, IN 46703

Ph: 260-665-7586 . Fax: [phone] E-mail: [e-mail]

Website: www.vestil.com

1

General

Read and follow the instructions contained in this operating manual without fail!

Only trained, well-informed personnel, who have been instructed in accordance with this operation manual, may use or work on the machine.

Liability or guarantee is waived if:

The instructions in this operating manual are not observed.

The high-lift stacking truck is operated, cleaned or maintained incorrectly.

Alterations to the functions are carried out without the consent of manufacturer.

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)

Declaration:

I have read this manual and, in particular, have taken note of the caution.

Name	Date	Signature

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Specification

SPECIFICATION

			S-62-FF	S-62-AA	S-62-FA
	Capacity		2000 lbs.	2000 lbs.	2000 lbs.
	Fork Lift Height		62"	62"	62"
	Fork Dimension		42x5.9x2 3/8"	42x4x1-1/4""	42x5.9x2 3/8"
	Overall fork width		26-3/4"	26-3/4"	26-3/4"
	Ground Clearance		1"	1"	1"
	Lowered Fork H.		3-3/8"	2-1/8"	2-9/16"
	H. Overall Extended		81-7/8"	81-7/8"	81-7/8"
	Head Dimension		26-1/2x30x29-3/4"	26-1/2x30x29-3/4"	26-1/2x30x29-3/4"
	Loading Center		23-5/8"	23-5/8"	23-5/8"
	Wheel Base		44-3/4"	44-3/4"	44-3/4"
	Turning Radius		55"	55"	55"
	Support Wheel		Φ4x2"	Φ4x2"	Φ4x2"
	Front Wheel		Φ3-1/8x3-3/8"	Φ3-1/8x3-3/8"	Φ3-1/8x3-3/8"
	Drive Wheel		Φ10x3-1/8"	Φ10x3-1/8"	Φ10x3-1/8"
	Overall Size		68x30x82	69x46x82	68x46x82
	Lift	Load	2.95"/s	2.95"/s	2.95"/s
	Speed	Unload	5.9"/s	5.9"/s	5.9"/s
	Lower	Load	4"/s	4"/s	4"/s
	Speed	Unload	2"/s	2"/s	2"/s
	Travel	Load	5km/h	5km/h	5km/h
	Speed	Unload	6km/h	6km/h	6km/h
	Drive Motor		24V/700W	24V/700W	24V/700W
	Lift Motor		24V/2.0KW	24V/2.0KW	24V/2.0KW
	Controller		1207A-4102	1207A-4102	1207A-4102
	Battery		2x12V/70Ah	2x12V/70Ah	2x12V/70Ah
	Battery Charger		DC 24V/6A Soneil	DC 24V/6A Soneil	DC 24V/6A Soneil
	Weight		950 lbs.	990 lbs.	970 lbs.
	Load Grade ability		6%	6%	6%
	Unload Grade ability		10%	10%	10%
	Width of Aisle		35-1/2"	52"	52"

Note: The load capacity is based on the situation when the center of the gravity is located at the center of length of forks. When the center of gravity of goods is out of the center of forks, the load capacity will be lessened compared to the center.

3

CONTENTS

General …………………………………………………………………………………	2
Specification ……………………………………………………	3
Receiving instructions ………………………………………………………………	5
Safety Notes ……….……………………………………………………………………	6
Product description …………………………………………………………………	7
Designated use …. … …... … ……………………………………………………	7
Signs on the Truck ………………………………………………………………..	8
Transport …………………………………………………………………………………	9
Operation ………………………………………………………………………………	10
Operation ………………………………………………………………………………	11
Operating elements ………………………………………………………………
Safety elements …………………………………………………………………	12
Driving, braking and horn…………………………………………………………	13
Lifting and lowering ………… ……………………………………………………	14
Traveling …………………………………………………………………………..	15
Taking up the load…………………………………………………………………	16
Driving on sloping surfaces………………………………………………………	17
Maintenance and repair ……………………………………………………………	18
Trouble shooting …………………………………………………………………	18-22
Changing batteries ………………………………………………………………	23-24
Changing motor controller ……………………………………………………..	25-31
Belly switch trouble shoot ………………………………………………………	32-49
Maintenance daily/before use, monthly, annually …………….……………..	50
Maintenance and care of the load chains ……………………………………	51
Chain inspections …………………………………………………………………	52
Temporary lay-up …………………………………………………………………	53
Parts List …………………………………………………………………………………	54-60

4

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 CARRIERIMMEDIATELY! 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 observed.

∙Improper use of this lift truck could result in injury and damage to load or equipment.

∙Always watch the stacker and any load on it carefully when it is being used or moved.

∙Avoid sudden stops or quick turns to turns to prevent accidental tipping of the load.

∙Load must be centered and evenly distributed on the forks.

∙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 down.

∙Do not perform any modifications to the stacker without the manufacturer’s 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 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.

5

Safety notes

Symbols and pictograms used

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.

Used symbols and pictograms

Possible		danger	to		Do not step onto when
file	and	limb	or
					load is raised!
machine!
Danger of crushing!					It is forbidden to ride
					on the truck!
Do	not	reach	into		Suspension points for
running motor!					transport of truck!

Wear safety shoes

Important

Wear helmet	Suspended	load
	warning!

6

Product description

Designated use

The stacker is designated for lifting, lowering and transportation of loads according to the specifications of the identification plate.

The stacker is to be used on hard level surfaces.

To move the stacker between buildings, warehouses etc

The gradient of the slope must not be more than 10%

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 truck.

The stacker is not suitable for continuous use in cool-houses!

Ambient conditions

Temperature			From	14	°F
			To	113	°F
Degree of humidity				≤70	%
Permitted		floor
incline
	Loaded			Max. 0.5	%
	Unloaded ¹			Max. 2.0	%
Dimensions and weights
Mass (dead weight)			m	480/750	kg

WARNING!

The user is responsible for determining the actual load bearing capacity of a high-lift stacking truck. This can depend on the user, the condition of both the floor and the high-lift stacking truck and the regularity of the maintenance intervals.

7

Product description

8

Removing from the pallet or lifting the product

Lifting belt specification— Use polyester lifting sling or nylon sling and hoist with a minimum of 2,000 lb. capacity.

CAREFUL

To pick up the unit only use overhead hoist, forklift or loading crane with sufficient carrying capacity!

Refer to the identification plate for the weight of the truck.

DANGER

When unloading the truck, all personnel should be cleared from area.

9

OPERATION

Visually inspect stacker for damaged and worn parts, before stacker is taken into operation. Authorized person should read and understand all instructions

The lifting truck is ready for immediate use once the packaging has been removed.

The battery is full and charged.

The hydraulic tank is full.

The driving gear is filled with oil filling for approx. 200 operation hours.

The steering roller and the running rollers are equipped with bearings which do not require maintenance; all mast rollers are also free from maintenance.

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.

Recommendation:

The operator who is to maneuver the truck and is to control the lifting mechanism should be allowed to practice, when unloaded, until they can safely operate these functions.

Only then should they undertake the loading, transporting and unloading of load.

10

Operation

11

Operation

12

Operation

Driving

Pull up the red push button of the E-switch

Tilt the Control handle to driving position, the locking brake is released

If you release Control handle, this returns to the vertical start position, the truck brakes and the locking brake activates

The truck is steered via the Control handle

Brake:

This stacker is equipped with a magnetic brake that is applied between 10-15 degrees of the vertical position and between 85 -90 degrees of the lower position in the vertical operating of the handle. The brake can be operated at any point in the lateral operating of the handle. When you release your hand from the handle, it will resume neutral position automatically, and will activate the brake. Always make sure that the brake is in work before operating the stacker. When parked, always put the handle in the full vertical position with the brake applied and forks lowered.

Horn:

A horn is located on top of the handle.

13

To raise and lower

The following are generally valid for the lifting and lowering procedure:

The red operating button of the EMERGENCY STOP pushbutton must be pulled upwards

Lifting and lowering movements are initiated by pressing the pushbuttons on the handle head.

There are four buttons located on the two sides of the handle. Each side of the control has one button for raising the forks and one button for lowering the forks. Always make sure when lifting that the load is within the capacity rating of your truck and that the load has been stacked safely on the pallet. Also, make sure that there is no one standing near the forks when raising or lowering. It is also important to make sure that the length of the forks corresponds to the opening in the bottom of the pallet. The load rollers must be placed between boards so when you raise the forks, the pallet will not be broken or damaged. Always make sure when entering the pallet that the forks are in the fully lowered position. Be careful when lifting pallets that are too short or too long for the truck

Warning

It is forbidden to climb or reach into any moving parts of the lifting truck-e.g. the lifting frame, thrust units, lifting mechanisms etc.

14

Travel

The butterfly switch controls the direction and speed of the lift truck. Rotating the butterfly control towards the forks moves the truck in the forward direction. Rotating the butterfly control away from the forks, moves the truck in the reverse direction. The control is progressive – 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 from the operator when depressed. The truck will stop moving away from the operator when the button is released. 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)

15

Operation

Lifting load

CAUTION!

Before lifting a load to be transported, ensure that the load does not exceed the carrying capacity of the truck.

The nominal carrying capacity and lifting heights can be viewed in the load diagram.

Ensure that the load can be taken up in a compact and stable manner. Slipping or falling of the load must be avoided.

The load must not project into the lifting frame.

The load must be centered and evenly distributed on the forks.

The load must not project more than 50mm over the end of the lifting forks.

Transporting the load

CAUTION!

Raise the load only slightly to transport

For safety reasons (view) transport only in a forward direction

Only when lifting up or lowering down the load it is permissible to drive forwards or in reverse with a raised load

Lift up or lower down loads on level surfaces

When unloaded, move stacker only with forks lowered

16

Operation

Driving on sloping surfaces

17

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 move when controls are	Battery voltage low (<17)
used.
	Problem with motor controller
	(check for LED flash code on side
	of controller)
	Fuse blown
Unit will not charge	Charger malfunction

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.

	Bad batteries	Load test batteries
Unit will not go forward; reverse	Broken wire, or loose connection	Locate Pin 2 on Molex connector at
works; belly switch just kills unit		motor controller. Trace wiring to
(does not go forward and time out)		contactor and verify connection.
	Contactor bad, motor controller bad	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 24
		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.

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)

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

Same as above; except locate Pin 3 on Molex connector on motor controller…and follow procedure.

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