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Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL

LL-PMPS-Series Pallet Handlers Instruction Manual

RECEIVING INSTRUCTIONS

After delivery, remove the packaging from the product. Inspect the product closely to determine whether it

sustained damage during transport. If damage is discovered, record a complete description of it on the bill of lading. If

the product is undamaged, discard the packaging.

NOTE: The end-user is solely responsible for confirming that product design, use, and maintenance comply with laws,

regulations, codes, and mandatory standards applied where the product is used.

REPLACEMENT PARTS AND TECHNICAL SERVICE

If you have questions that are not addressed in these instructions and to order replacement parts, labels, and

accessories, call (260) 665-7586 and ask for the Service and Parts Department. The department can also be

contacted online at http://www.vestilmfg.com/parts_info.htm.

Table of Contents

Signal Words………………………………………………………………………………………………………..….

..………….2

Hazards……………………………………………………………………………………………………………..…..

..………….2

Specifications…………………………………………………………………………………………………………..

..………….3

Exploded View and Bill of Materials: LL-PMPS-50…………………………………………………….……….....

..………….4

Exploded View and Bill of Materials: LL-PMPS-60…………………………………………………………...……

..………….5

Exploded View and Bill of Materials: LL-PMPS-72……………………………………………………………......

..………….6

*DC Modular Power Unit Exploded View, Manifold Assembly, Circuit Diagram, and Layout Views……........

..……7, 8, 9

*AC Modular Power Unit Exploded View, Manifold Assembly, Circuit Diagram, and Layout View……….…..

...10, 11, 12

Loading Instructions…………………………………………………………………………………………………...

..………..12

Adjusting the Outriggers……………………………………………………………………………………………....

..………..12

Exploded View: Autoshifter Foot Pump..…………………………………………………………………………...

..………..13

Autoshifter Bill of Materials……………………………………………………………………………………………

..………..14

Hydraulic Circuit Diagram: Manual Units (Auto-Shifter Foot Pump)………………………………………………

..………..14

Operating the Lifter: Manual Units (Autoshifter Foot Pump)………………………………………………………

..………..15

Purging Air from the Pump; Purging Air from the Cylinder…………………………………………………………

..………..15

Troubleshooting: Manual Units (Auto-Shifter Foot Pump)…………………………………………………………

..………..16

*Hydraulic Circuit Diagram: Electric Units (Modular Power Unit)…………………...…………………………….

..………..17

*Operating the Lifter: Electric Units (Modular Power Unit)…………………………………………………………

..………..17

*Lowering Solenoid; Velocity fuse; Bleeding Air from the Hydraulic Circuit……………………………………..

.……17, 18

*Battery Charger Operation……………………………...……………………………………………………………

..………..18

Record of Satisfactory Condition……………………………………………………………………………………..

..………..19

Inspections & Maintenance……………………………………………………………………………………………

..………..19

Replacement Parts; Troubleshooting Guide: Electric Units (Modular Power Unit)……………………………..

..………..20

Labeling Diagram………………………………………………………………………………………………………

..………..21

Limited Warranty……………………………………………………………………………………………………….

..………..22

*NOTE: Figures 10A – 12B are views of the modular power unit. These diagrams only apply to units manufactured

before 12-01-2018. Units manufactured on or after 12-01-2018 receive a redesigned modular power unit (MPU

GEN2). Diagrams and operating instructions for GEN2 power units are provided in separate MPU-AC/DC manuals.*

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

Web: www.vestilmfg.com e-mail: info@vestil.com

Summary of content (22 pages)

PAGE 1
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL 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 Web: www.vestilmfg.com e-mail: info@vestil.com LL-PMPS-Series Pallet Handlers Instruction Manual RECEIVING INSTRUCTIONS After delivery, remove the packaging from the product. Inspect the product closely to determine whether it sustained damage during transport.
PAGE 2
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL SIGNAL WORDS This manual uses SIGNAL WORDS to direct the reader’s attention to important safety-related messages. These messages describe uses of the product that could result in personal injury or property damage. Each signal word corresponds to a specific hazard level. The following are definitions of signal words that might appear in this manual. Identifies a hazardous situation which, if not avoided, WILL result in DEATH or SERIOUS INJURY.
PAGE 3
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL SPECIFICATIONS Dimensions, net weight, and capacity information for each model LL-PMPS appears in the following diagrams and table. Net weight figures do not include weights of modular power units. To determine MPU weight, refer to the Specifications section of your MPU-GEN2 instruction manual. 11/2” 3.8cm Model A B C D Net Weight Capacity LL-PMPS-50-AC 721/2” 184.2 cm 89” 226.1 cm 4011/16” 103.3 cm 50” 127 cm 742 lb. 337.3 kg 1,200 lb.
PAGE 4
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL EXPLODED VIEW AND BILL OF MATERIALS: LL-PMPS-50 38-006-008 Not included with –AIR units Item Part no. Description Qty.
PAGE 5
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL EXPLODED PARTS DIAGRAM AND BILL OF MATERIALS: LL-PMPS-60 38-006-008 Not included with –AIR units Item Part no. Description Qty. Item Part no.
PAGE 6
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL EXPLODED PARTS DIAGRAM AND BILL OF MATERIALS: LL-PMPS-72 38-006-015 Not included with –AIR units Item 1 38-514-042 Part no. Frame, weldment Description 2 15-514-078 Frame, weldment, left leg Qty.
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Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL DC MODULAR POWER UNIT EXPLODED VIEW AND BILL OF MATERIALS NOTE: THIS DIAGRAM APPLIES T UNITS BUILT BEFORE DEC. 1, 2018. UNITS MANUFACTURED ON OR AFTER DEC. 1, 2018, ND RECEIVE 2 GENERATION MODULAR POWER UNITS (MPU-GEN2). SEPARATE INSTRUCTION MANUALS ARE PROVIDED FOR THESE POWER UNITS. Item Description Qty.
PAGE 8
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL EXPLODED VIEW OF DC MANIFOLD ASSEMBLY (ITEM NO. 24 ON P. 7) NOTE: THIS DIAGRAM APPLIES T UNITS BUILT BEFORE DEC. 1, 2018. UNITS MANUFACTURED ON OR AFTER ND DEC. 1, 2018, RECEIVE 2 GENERATION MODULAR POWER UNITS (MPU-GEN2). SEPARATE INSTRUCTION MANUALS ARE PROVIDED FOR THESE POWER UNITS. Item Part no.
PAGE 9
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL 12VDC MODULAR POWER UNIT LAYOUT (PART 1 OF 2) NOTE: THIS DIAGRAM APPLIES T UNITS BUILT BEFORE DEC. 1, 2018. UNITS MANUFACTURED ON OR AFTER ND DEC. 1, 2018, RECEIVE 2 GENERATION MODULAR POWER UNITS (MPU-GEN2). SEPARATE INSTRUCTION MANUALS ARE PROVIDED FOR THESE POWER UNITS. 12VDC MODULAR POWER UNIT LAYOUT (PART 2 OF 2) NOTE: THIS DIAGRAM APPLIES T UNITS BUILT BEFORE DEC. 1, 2018. UNITS MANUFACTURED ON OR AFTER ND DEC.
PAGE 10
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL AC MODULAR POWER UNIT EXPLODED PARTS DIAGRAM AND PARTS LIST NOTE: THIS DIAGRAM APPLIES T UNITS BUILT BEFORE DEC. 1, 2018. UNITS MANUFACTURED ON OR AFTER ND DEC. 1, 2018, RECEIVE 2 GENERATION MODULAR POWER UNITS (MPU-GEN2). SEPARATE INSTRUCTION MANUALS ARE PROVIDED FOR THESE POWER UNITS. Part no. 1 99-016-933 Base bracket 1 2 21-034-008 Electrical box (see FIG.
PAGE 11
Table of Contents Rev. 9/13/2019 ELECTRICAL BOX (ITEM NO. 2 ON P. 10) MANIFOLD (ITEM NO. 12 ON P. 10) LL-PMPS MANUAL NOTE: THIS DIAGRAM APPLIES T UNITS BUILT BEFORE DEC. 1, 2018. UNITS MANUFACTURED ON OR ND AFTER DEC. 1, 2018, RECEIVE 2 GENERATION MODULAR POWER UNITS (MPU-GEN2). SEPARATE INSTRUCTION MANUALS ARE PROVIDED FOR THESE POWER UNITS. Item Part no. 1 71616 2 01-129-001 3 132560 4 27531 5 32028 6 99-034-941 7 01-029-006 8 99-029-142 Description Qty.
PAGE 12
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL MODULAR POWER UNIT LAYOUT: 115VAC LOADING INSTRUCTIONS The capacity of this LL-PMPS-series lifter is 1,200 lb. Every unit is labeled with this information (label 287 on p. 21). DO NOT attempt to lift loads that exceed the 1,200 lb. (545.5kg) capacity! Personal injury or permanent damage to the lifter might occur. When applying a load to the forks, always follow these guidelines: 1. The load should firmly contact the heels of the forks 2.
PAGE 13
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL EXPLODED VIEW: AUTOSHIFTER FOOT PUMP [BILL OF MATERIALS ON NEXT PAGE] Detail view of items 9.1-9.3 Item 9.1 9.2 9.3 Part no. Description 99-031-022 99-144-017 99-145-127 Release valve pin seal retainer Seal, release valve Star washer Outlet check valve assembly (2 total) Quantity 1 1 1 Relief valve assembly Release valve assembly Pressure comp. flow control Unloader assembly NOTE: Color added to the diagram purely for contrast.
PAGE 14
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL Bill of Materials: Items marked with an asterisk (*) are components of seal kit 99-136-013. Item Part No. Description Qty. 1 99-039-001 2 3 4 99-041-001 99-041-002 99-110-007 Manifold, manual pump, 1.75/0.75 bore 1 3 Piston, pump, 1 /4” x /4” Piston, pump, unloader 1 Bearing, ball, /4” 5 99-110-006 6 Item Part No. Description Qty.
PAGE 15
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL OPERATING THE LIFTER: MANUAL UNITS (AUTOSHIFTER FOOT PUMP) Manually operated versions of this machine utilize auto-shifting, two-speed pumps. Pump speed is automatically selected based on the output pressure of the hydraulic system. For example, when the forks are unloaded, pressure in the hydraulic system is low and the pump operates in high speed mode. Each stroke of the foot pedal pumps approximately 1.2 cubic inches of oil.
PAGE 16
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL TROUBLESHOOTING: MANUAL UNITS (AUTO-SHIFTER FOOT PUMP) Issue 1. Forks do not rise despite pumping pedal Explanation a. Too much weight on the forks (load exceeds capacity). b. c. d. 2. A lot of force is required to pump the pedal and the forks do not rise or rise very slowly e. 3. Forks rise only when unloaded or pedal pumped rapidly; I can pump the pedal but the forks do not move. g. f. h. i. j. 4.
PAGE 17
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL HYDRAULIC CIRCUIT DIAGRAM: ELECTRICALLY POWERED UNITS 11/2in. x 18in. displacement cylinder with internal velocity fuse LC/TC Pressure check valve Motor Hydraulic pump Adjustable pressure relief valve 100 micron suction filter LC/TC Lowering valve LY/FC Pressure compensated flow control 10 micron return filter OPERATING THE LIFTER: ELECTRIC UNITS (MODULAR POWER UNIT) If your unit was manufactured on or after Dec.
PAGE 18
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL 5. Inspect the O-rings and the PTFE washer (polytetrafluoroethylene). If either component is damaged (for example, torn or cut) replace it. 6. Reinstall the valve. The valve should be tightened to approximately 20 ft.-Ib. of torque. VELOCITY FUSE There is a brass velocity fuse with a stainless steel spring in the base of each cylinder. If a fitting leaks or a hose is ruptured, the platform lowers more rapidly.
PAGE 19
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL RECORD OF SATISFACTORY CONDITION Record the condition of the lifter before putting it into regular service. Thoroughly photograph the machine from multiple angles. Include close range photos of all labeling, the handle, casters/wheels, the cylinder, cylinder attachment points and attachment hardware (pins, bolts, nuts, etc.), leg clamp brackets, and modular power unit (MPU). Remove the cover from the MPU and photograph the internal components.
PAGE 20
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL REPLACEMENT PARTS Only use manufacturer-approved replacement parts to repair this machine. To order parts for your equipment, please contact the Parts Department. In any correspondence with the factory please include the Serial Number which is inscribed on the nameplate of the equipment. Use only the part numbers provided in this Owner's Manual. When ordering parts for AC power units, please be prepared with the motor phase and voltage of the equipment.
PAGE 21
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL LABELING DIAGRAM The unit should be labeled as shown in the diagram. However, label content and location are subject to change so your product might not be labeled exactly as shown. Replace all labels that are damaged, missing, or not easily readable (e.g. faded). To order replacement labels, contact the technical service and parts department online at http://www.vestilmfg.com/parts_info.htm.
PAGE 22
Table of Contents Rev. 9/13/2019 LL-PMPS MANUAL LIMITED WARRANTY Vestil Manufacturing Corporation (“Vestil”) warrants this product to be free of defects in material and workmanship during the warranty period. Our warranty obligation is to provide a replacement for a defective, original part covered by the warranty after we receive a proper request from the Warrantee (you) for warranty service. Who may request service? Only a warrantee may request service.