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.
Rev. 0213 EPT, Manual.doc PRODUCT INTRODUCTION 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.
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.
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.
Rev. 0213 EPT, Manual.doc FIG. 1A: EPT-30 MODELS MAIN BODY COMPONENTS 2003 Item No. 2001 Part No.
Rev. 0213 EPT, Manual.doc FIG. 1B: EPT-30 MODELS (OPTIONAL) SCALE COMPONENTS Item No. 4001 4002 4003 4004 4005 4006 4007 4008 4009 4010 Part No. Description EPT-30-SCL-4001 Scale Display EPT-30-SCL-4002 Display Mounting Bracket EPT-30-SCL-4003 6mm Flat Washer EPT-30-SCL-4004 M6 x 10 Bolt EPT-30-SCL-4005 M6 x 30 Bolt EPT-30-SCL-4006 6mm Spring Washer EPT-30-SCL-4007 M6 Nut EPT-30-SCL-4008 M6 Nut EPT-30-SCL-4009 EPT-30-SCL-4010 Copyright 2013 Vestil Manufacturing Corp.
Rev. 0213 EPT, Manual.doc FIG. 2: EPT-30 MODELS HYDRAULIC CYLINDER ASSEMBLY Item No. Part No. 4200 4201 4202 4203 4204 4205 4301 4302 4303 4304 4305 4401 4402 4403 4300 EPT-30-4200 EPT-30-4201 EPT-30-4202 EPT-30-4203 EPT-30-4204 EPT-30-4205 EPT-30-4301 EPT-30-4302 EPT-30-4303 EPT-30-4304 EPT-30-4305 EPT-30-4401 EPT-30-4402 EPT-30-4403 EPT-30-4300 Copyright 2013 Vestil Manufacturing Corp.
Rev. 0213 EPT, Manual.doc FIG. 3: EPT-30 MODELS DRIVE WHEEL ASSEMBLY Item No. Not Shown 3300 3001 3002 3003 3004 3005 3006 3007 3007 3008 3009 3010 301 3012 3013 3014 Part No.
Rev. 0213 EPT, Manual.doc FIG. 4A: EPT-30 MODELS FORK AND CARRIAGE Item No. 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 Not Shown 1012 Part No.
Rev. 0213 EPT, Manual.doc FIG. 4B: EPT-30 MODELS FORKS AND CARRIAGE WITH INTEGRATED SCALE Item No. 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 Part No. Item No.
Rev. 0213 EPT, Manual.doc FIG. 5A: CONTROL YOKE AND HANDLE COMPONENTS (ALL MODELS) Copyright 2013 Vestil Manufacturing Corp.
Rev. 0213 Item No. 3100 3101 3102 3103 3103-2 3104 3105 3106 3107 3108 3109 3110 3111 3112 3113 3114 3114-2 3115 3115 3115 3116 3116-2 3117 3118 3119 3201 3202 3203 3204 3205 3206 3207 3208 3209 3210 3211 3212 3213 3214 3215 3216 3217 3218 3219 3220 3300 EPT, Manual.
Rev. 0213 EPT, Manual.doc FIG. 5B: CONTROL YOKE AND HANDLE COMPONENTS (ALL MODELS) WITH INTEGRAL SCALE Copyright 2013 Vestil Manufacturing Corp.
Rev. 0213 Item No. 3101 3102 3103 3103-2 3104 3105 3106 3107 3108 3109 3110 3111 3112 3113 3114 3114-2 3115 3116 3117 3118 3119 3120 3121 3122 3123 3124 3201 3202 3203 3204 3205 3206 3207 3208 3209 3210 3211 3212 3213 3214 3215 3216 3217 3218 3219 3300 Part No.
Rev. 0213 EPT, Manual.doc FIG. 6: Hydraulic Pump and Motor Assemblies (All Models) Item No. 4100 4101 4102 4103 4104 4105 4106 4107 4108 4109 4110 4111 4112 4113 4114 4115 4116 Part No. EPT-30-4100 EPT-30-4101 EPT-30-4102 EPT-30-4103 EPT-30-4104 EPT-30-4105 EPT-30-4106 EPT-30-4107 EPT-30-4108 EPT-30-4109 EPT-30-4110 EPT-30-4111 EPT-30-4112 EPT-30-4113 EPT-30-4114 EPT-30-4115 EPT-30-4116 Description Complete Motor Pump Assembly 24VDC (1.
Rev. 0213 EPT, Manual.doc FIG. 7: EPT-45 MAIN HOUSINGS AND SUPPORTING STRUCTURE Item No. 1001 1001 1002 1002 1003 1004 1005 1006 1007 1007 1008 1009 1010 1011 1012 1013 1013 EPT-45-1001 EPT-45-1001-1 EPT-45-1002 EPT-45-1002-2 EPT-45-1003 EPT-45-1004 EPT-45-1005 EPT-45-1006 EPT-45-1007 EPT045-1007-2 EPT-45-1008 EPT-45-1009 EPT-45-1010 EPT-45-1011 EPT-45-1012 EPT-45-1013 EPT-45-1013-2 Part No.
Rev. 0213 EPT, Manual.doc FIG. 9: EPT-45 CYLINDER AND FUSE PANEL Item No. 3005 3006 3007 3008 3009 3100 3200 3300 3300 Part No. Description Item No. Part No.
Rev. 0213 EPT, Manual.doc FIG. 10: EPT-45 FORK AND CARRIAGE ASSEMBLIES Item No. 2001 2002 2003 2004 2004-2 2005 2006 2007 2008 2009 2010 2010-1 2011 2012 2013 2014 Part No. 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 Description Item No.
Rev. 0213 EPT, Manual.doc 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. Always check the gauge before using the device; make sure that the battery is charged before using the pallet truck.
Rev. 0213 EPT, Manual.doc 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.
Rev. 0213 EPT, Manual.doc 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.
Rev. 0213 EPT, Manual.doc Plug the charger’s AC cord into an 115VAC power source: EPT-30’s: to access the cord, remove the top tray. AC charger cord 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.
Rev. 0213 EPT, Manual.doc TROUBLESHOOTING: 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). Battery voltage low (battery charge lower than 17 Volts) Charge batteries.
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. 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.
Rev. 0213 EPT, Manual.doc Problem: Possible cause(s): Action: Unit will not go forward; the belly switch functions; reverse works. Broken wire, or loose connection, bad motor controller 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.
Rev. 0213 EPT, Manual.doc Problem: Possible cause(s): Action: Unit will not raise; motor does not run Loose wire 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. Bad solenoid 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.
Rev. 0213 EPT, Manual.doc Problem: Possible cause(s): Action: Unit will not reverse; belly switch does not function; forward ok 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.
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.
Rev. 0213 EPT, Manual.doc 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.
Rev. 0213 EPT, Manual.doc 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).
Rev. 0213 EPT, Manual.doc 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 Piston Rod 16 17 Step 9: Remove the internal seal (photo 18 & 19). Photo 20 shows a fully disassembled cylinder.
Rev. 0213 EPT, Manual.doc Instructions for Changing the Throttle Assembly Estimated time: 30 minutes Necessary tools: 5mm Allen wrench Philips-blade screwdriver Small Regular (flat) blade screwdriver 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.
Rev. 0213 EPT, Manual.doc Step 2: Carefully pull the (red) belly switch cover away from the handle while continuing to lift the base of the housing. The housing should separate from the handle as shown in photo 4. Do not drop the assembly once it is disconnected from the handle, because the wires might be damaged or might rip out of the connectors 3 4 Step 3: Unplug the two connectors shown in photo 5. [NOTE: Wires may not attach to connectors.
Rev. 0213 EPT, Manual.doc Step 5: The (red) belly switch cover connects to the throttle assembly via a tab on each side, one of which is circled in Photo 9. To remove the switch cover, lift an edge with a flat blade screwdriver; then push the cover over the tab. Next, disengage the tab on the other side. You should now be able to separate the cover from the rest of the assembly. 9 10 Step 6: A spring rests in a seat molded into the inner surface of the switch cover (see Photo 11).
Rev. 0213 EPT, Manual.doc Step 8: Install the bushings onto the throttle wheel shaft. Notice that the bushing must be installed as shown the drawing to the right of Photo 16 below. This end onto wheel shaft 16 Step 9: Install the throttle wheels, and secure them to the wheel shaft with Philips head screws.
Rev. 0213 FIG. 2: EXPLODED PARTS VIEW OF BELLY SWITCH MECHANISM EPT, Manual.doc FIG. 3: ROTATED MECHANISM VIEW OF BELLY SWITCH Step 11: Press and hold the switch cover; then slide the assembly down the handle tongue. The tab slot of the switch cover must wrap around the tabs on both sides of the handle. Tab slot in the switch cover Tab Tab 22 23 Step 12: Make sure that the wires tuck securely inside the tiller handle; then press the assembly and handle together.
Rev. 0213 EPT, Manual.doc Instructions for Changing the Motor Controller Estimated time required: 30 minutes Tools Required: 2x 14mm wrench, open face; Philips head screwdriver; 8mm wrench or adjustable crescent wrench. 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.
Rev. 0213 EPT, Manual.doc Step 2: If necessary, mark each of the cables with a unique identifier to make it easier to reconnect them to the new motor controller. For instance, in the photograph below the red and green insulated ring terminals display a distinct number of hash marks to indicate order of attachment from top to bottom. In newer EPT’s, a yellow tag marked with a specific letter identifies each cable.
Rev. 0213 EPT, Manual.doc Step 6: After you have unfastened all 4 of the cable connections (first photograph below); then remove the three 8mm screws (1 screw in back and 2 in the front) holding the motor controller to the back plate with a Philips screwdriver, and 8mm wrench. Step 7: Remove the motor controller. Step 8: Verify that each of the 4 spade terminal connections on the forward / reverse motor contactor is sound. Step 9: Install a new controller by reversing steps 1 through 8.
Rev. 0213 EPT, Manual.doc Instructions for Replacing the Forward/Reverse Contactor Estimated time: 45 minutes Necessary tools: 1. Two 9/16 inch or 14mm sockets/wrenches; 2. Phillips head screwdriver 3. 10mm crescent wrench 4. 5/16 inch crescent wrench/socket 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.
Rev. 0213 EPT, Manual.doc Step 3: Use 10mm wrenches (or adjustable wrenches) to disconnect the horn from the mounting plate. Step 4: Disconnect cables B, A, F, and C from the FRC, using either a 9/16 inch crescent wrench (or socket) or a 14mm wrench. [Photograph below shows disconnection of A & F cables.] Step 4: Disconnect cables I and G from the terminal on the top side of the FRC. Close-up side view of the terminal on top of the FRC.
Rev. 0213 EPT, Manual.doc Step 6: Disconnect the FRC from the mounting plate. The FRC mounts on the plate with 2 Phillip’s head bolts and 5/16 inch nuts. After the bolts are unfastened, remove the FRC. 5/16 inch nuts Step 7: The FRC may not need to be replaced if the malfunction results from mechanical binding of some of the moving parts. To apply lubricant, remove the plastic caps shown below (identified with arrows) with a flatblade screwdriver.
Rev. 0213 EPT, Manual.doc Instructions for Changing the Battery Charger Estimated time: 30 minutes Tools Required: 10mm deep socket, or small wrench 14mm wrench, or crescent wrench Regular (flat) blade screw driver 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.
Rev. 0213 EPT, Manual.doc Step 2: Remove the black plastic cover by lifting it as shown below; then remove battery wiring from the negative post with 13mm wrench (negative terminal identified with a white arrow). There will be one large black wire, and one smaller black wire. The smaller black wire connects to the battery charger.
Rev. 0213 EPT, Manual.doc Step 5: Four mounting studs project through the base of the charger to secure it in place. Remove the nuts with a deep well 10mm socket, or small 10 mm wrench; then pull the charger off of the retaining bolts. Mounting studs & 10mm Nuts Step 6: Once the old battery charger is removed, the replacement charger can be installed. The new charger is attached to a mounting bracket (blue in the photograph below) so that it can install onto the 4 mounting studs.
Rev. 0213 EPT, Manual.doc Step 8: Connect the “POS” wire to the red, positive (+) post; then connect the “NEG” wire to the negative terminal. Reconnect the positive cable to the positive post and fasten it with the corresponding nut. On the other side, reconnect the negative cable to the negative post, and then fasten the connection with the post nut.
Rev. 0213 EPT, Manual.doc Instructions for Adding Quencharcs Estimated time: 15 minutes Tools Required: Regular flat bladed screw driver PURPOSE: If the pallet truck operates normally, but stops running when the horn is activated, then devices that suppress electrical noise called “Quencharcs” should be added. Each electrical coil (for example the horn, raise/lower buttons) generates noise, which interferes with normal motor operation. Only qualified personnel should work on this equipment.
Rev. 0213 EPT, Manual.doc Step 2: Disconnect the wires from the horn and the pump solenoid; then plug the horn and pump solenoid wires into to the quencharcs’ piggy back terminals. plug the piggy back terminals into the horn and pump solenoid as shown in the following pictures. Quencharc shown on horn (photo 4) Add one to the pump solenoid Add one to the horn 3 Quencharc installed on pump solenoid. 4 5 Step 3: Reinstall the yellow cover and reinstall the screws.
Rev. 0213 EPT, Manual.doc Maintenance and Inspections: According to ANSI B56.1, the pallet truck is a “motorized hand truck, pallet truck” (MHT). For this type of lift truck, only trained, authorized persons should perform inspections or maintenance. Inspections: ALWAYS review the following warning messages and procedures BEFORE inspecting the MHT. DO NOT use the pallet truck if an inspection reveals structural damage.
Rev. 0213 EPT, Manual.doc Step 1: Tag the MHT, “Out of Service.” Step 2: Complete an every use and a monthly inspection. If deformity, corrosion, rusting, or excessive wear of structural members is present, DO NOT use the MHT. Contact Vestil for instructions. - 49 Step 3: Remove any dirt or other matter from the forks and other surfaces. Step 4: Perform all other necessary adjustments and/or repairs, but DO NOT modify the truck.
Rev. 0213 EPT, Manual.doc MARKINGS: Only use the lifter if ALL labels are readable and undamaged. Contact Vestil for replacement labels if necessary, and DO NOT use the pallet truck until all replacement labels are affixed to the device. Proper label placement is shown below: Label #206 Label #220 Label #527 Label #295 Label #208 Copyright 2013 Vestil Manufacturing Corp.