complete manual here.
Contents
1. 8 5 51 1 5 1 8 BaSe Unite y aden T 8 Thrott amp ezu s ss n aaa ua a a askush uqaqa ee hasa 8 Forward Stevo 10 Reverse or backward travel saisisit aidsa ae aaaeaii aaa akka aiaa aana Kaada eaS 10 Battery Installation and REMOVAIL ccccccccsssssssecececesseseseeseeececesseeaaeseceescesseseaeeseesessessesaeaeseeeeseeeseseaaeeas 10 DEVICE Operati f kuu uu 11 SEAN u E 11 DrIVI B u ua uu E E E E EE 11 12 D vice 12 Operating MOde INAICAtION 12 Battery Level Ea aS 13 Warning Indications cccccccccssesssssssecesececeesesnnaececececeeseaeaeeesecssecsesaeaeeeeessseeseeaaaesesecsseesaaeaeeeseesseeeees 13 PowerPallet User Manual Page 2 of 18 Control Se2. POWERHANDLING USER MANUAL Published 22 October 2014 Revision 20141022001 DO NOT INSTALL OPERATE OR SERVICE THIS PRODUCT UNLESS YOU HAVE READ AND FULLY UNDERSTAND THE ENTIRE CONTENTS OF THIS MANUAL FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE BODILY INJURY OR DEATH Contents amp Tables cscs ct uuu REAA qhasa 4 DESC ELON l 5 lint OdUCt ON ny au a al 5 General D esSCriptI R 5 S e r S 5 Braking by Handle POSItON 5 PROXIMITY DETECTION ul uu 5 Belly BURtOI 5 Installation ass awaspa a dinesna a eaen ea aaea aae a e aea Eaa 6 PUES cs 6 6 C rb Whe bridightu u 6 7 Screw Jack ACjUStMEN ccccccccccecessssensesecececesseseaaesecececesseeaaeeeeesecessesaeaeseseeecessesaeaecesesesesseaaaeeeeeesseeags 7 OPERAtlOM u E ee eee eee 8 General usu Aa 8
3. position before lowering the handle and button to switch attempting to drive u Full Braking applied when no user proximity is Warehouse Ing app detected Mode and Truck Mode Allows operator to drive with handle in upright Truck Mode ORANGE position at a slower speed 1 4 of the speed in Slower Warehouse Mode Note Machine needs to be stopped with Slider on the Throttle in neutral position before attempting to drive PowerPallet User Manual Page 14 of 18 Motor Settings The Motor Settings can be changed to achieve the best performance in various environments Each setting picks the optimal level for max speed acceleration and braking for the corresponding environment See table below on how to access the motor settings Table 5 Motor Settings RECOMMENDED LED INDICATION SETTING ENVIRONMENT THROTTLE INPUT ion Right DESCRIPTION gt To enter settings 1 Supermarket Concrete mode press and Solid RED hold Mode Button 2 Supermarket Vinyl for 2 3 seconds until Flashing RED Default LEDs flash ORANGE and then rotate Flashing Solid 8 3 Back of truck Light Slider on Throttle ORANGE mode press ORANGE Mode Button forward to Max while in to cycle i Flashing 4 Back of truck Heavy settings gt To exit settings mode ORANGE m i mode press and 5 Warehouse Medium hold Mode Button Solid GREEN for 2 3 seconds until I 6 W
4. device will load the already existing program and run Troubleshooting If the PowerPallet does not perform as expected try following the instructions in the table below to troubleshoot the problem Problem Diagnosis Possible Solution For any problem first check p Does problem match any of the Follow corresponding Warning Indications amp f warnings recommended action Battery Levels Is the drive wheel off the ground Motor turns but does not Is the drive wheel slipping on the Adjust the screw jack to lower drive the pallet jack ground while the pallet jack wheels the drive wheel are in contact with the ground Throttle not responsive in Operate in Warehouse Mode Is the throttle wet Truck Mode until Throttle is dry Make a note of the problem Reset machine by removing the environment and the situation leading battery waiting 15 seconds and Problem not listed up to its occurrence re installing the battery Problem persists after reset Reinstall Upgrade software Note If the problem is not fixed by any of the above methods please contact customer support PowerPallet User Manual Page 17 of 18 Revision History Date Revision Changes 22 October 2014 002 Manual Mode added Troubleshooting and Machine maintenance sections updated Software Update Revised Additional Horn Settings added Color AMBER replaced by ORANGE 2 October 2014 001 Initial
5. Manual Page 9 of 18 Forward motion If the truck is moving away from the operator when the operator is standing directly behind the handle of the pallet jack and away from the forks it is said to be moving forward Reverse or backward travel If the truck is moving towards the operator when the operator is standing directly behind the handle of the pallet jack and away from the forks it is said to be moving in reverse or traveling backward Battery Installation and Removal The PowerPallet runs on a rechargeable 46V Ni MH battery provided by PowerHandling which needs to be properly placed for the machine to function normally See correct procedure below Figure 3 Installing the Battery Step 1 Align and insert centrally Step 2 Make sure the tabs on the back plate located steel tabs on the front of the securely capture the battery from the back battery into the slots on the battery base plate To remove the battery pull the tab located on the back plate rotate the battery about its front tab and slide it out from the slot shown in Step 1 of the installation process PowerPallet User Manual Page 10 of 18 Device Operation Startup When the battery is properly placed on the machine the PowerPallet is ready and starts up in sleep mode with both LEDs turned off To wake up the machine for normal operation the Belly Button with the power symbol should be depressed On pressing the Belly Button the horn beeps once indicating
6. Snap Ring Pliers 2 Battery Charger Philips H1 screwdriver 3 Battery Pack Flat head screwdriver 4 Pallet Mount kit Pallet Jack specific M3 and M5 Allen Wrenches Ps O Curb Wheel Height To adjust the curb wheel height remove the bottom plate using the M3 wrench to unscrew the fasteners See figure 1 Once the plate is removed the curb wheel can be set in 2 positions 1 Lower to the ground The flat side of the axle is positioned facing the ground and away from the machine 2 Higher from the ground The flat side of the axle is positioned facing the machine and away from the ground Once the desired height is set place the bottom plate back and secure it with the M5 flat head screws Figure 1 Curb wheel adjustment PowerPallet User Manual Page 6 of 18 Assembly 1 wn Set the rear end of the pallet jack such that the wheels are off the ground Place some weights gt 20kg on the front forks to prevent it from tipping over during installation Remove end caps of both wheels using a flat head screwdriver Remove the snap rings using the snap ring pliers and slide the wheels out Place one mounting plate on one side of the PowerPallet and secure it with the screws provided Gently lift and slide this assembly on to the corresponding shaft of the pallet jack The assembly can be held in place by mounting on one of the pallet jack s wheels behind it Slide the other mounting plate on to the opposite side a
7. battery which runs a brushless DC electric motor The PowerPallet is compact enough to retain the maneuverability of the manual pallet jack that it is being bolted on to Weight including Battery Pack 17kg 38lbs Max Load Capacity on flat concrete 2 267kg 5 000Ibs Max Speed unloaded on flat concrete 100m min 3 7mph Safety Features Braking by Handle Position In the default drive mode Warehouse Mode the PowerPallet applies full braking when the handle is in the upright position or in the horizontal position This feature reduces the possibility of the operator getting pinned by the steering handle and or getting stuck between the steering handle and a wall Proximity Detection In the other drive mode Truck Mode with slower speed setting the PowerPallet drives the motor only when a human presence is detected within close proximity to the Throttle The Throttle has capacitive sensing built into it that senses if there is a human presence in the vicinity of the Throttle If no proximity is detected full braking is applied to the motor to prevent any forward backward motion Belly Button Pressing or bumping against the Belly Button stops all executing functions applies full braking and brings the truck to a stop This feature reduces the possibility of the operator getting pinned by the steering handle PowerPallet User Manual Page 5 of 18 Installation Adjustments List of Parts Tools Required 1 Machine 1
8. ccccccccsssscssssecssseecsnecessaecsessecseeeessaesessaecseeeecseeeesaeesssaesseseecseeessaeesssaessenees 9 Figure 3 Installing the Battery 10 Figure 4 Handle Control Positions in Drive Mode 11 Table 1 Main Operating Mod s 12 Table 2 Battery Levels 13 Table 3 LED amp Horn Warnings lt x u Sas aya ssusq asss asss 13 Table 4 Drive 65 1 1 14 Table Se Motor Setting S erir nino EOE O REO ROEE ROEE 15 Table 6 leen SEH NSS u u 5 asss 15 PowerPallet User Manual Page 4 of 18 Description Introduction This document describes the PowerPallet a unique bolt on device that instantly converts a manual pallet jack into a powerful fast yet ultra compact motorized pallet jack The safety features assembly instructions user operation maintenance software upgrade and troubleshooting features pertaining to the device are listed in this manual General Description The PowerPallet provides power assist by retrofitting on to any major name brand manual pallet jack It operates on a Ni MH
9. e Please follow all safety procedures required by the workplace city state and country where the machine will be used Terms and Definitions Base unit The base unit consists of the chassis which encloses the motor and the controller board It also has 2 horns for warning and feedback Throttle The Throttle acts as the main means for user interface It recognizes user input and communicates it to the motor controller located on the device and also returns useful machine feedback The parts of the Throttle and their basic functionality are shown and described on the next page PowerPallet User Manual Page 8 of 18 1 2 3 4 5 6 POWERPALLET Z 5 100 FULL BRAKING BATTERY 0 EMPTY 6 Figure 2 Parts of the Throttle Horn Button Beeps the Horn on the Machine when depressed 2 way Slider Runs Motor in the direction of rotation Returns to center neutral when released Belly Button Wakes up device from sleep mode Activates Belly Stop mode when depressed while the device is awake LED 1 Tri color Red Orange and Green LED primarily indicates mode of operation It is also used to relay other important feedback to the user LED 2 Tri color Red Orange Green LED primarily indicates battery level It is also used to relay other important feedback to the user Mode Button Used to control or change mode of operation and to release from Belly Stop mode PowerPallet User
10. injury or load and or property damage The following precautions must be adhered to at all times e Anyperson operating the machine must be trained and authorized to do so 9 Allwarnings and instructions must be carefully read and understood before operating the device e Inspect the unit before use Do not operate if anything seems out of place 9 Donotoperate the machine without the pallet jack wheels mounted and secured properly on the wheel shaft e Footprotection must be worn while operating the device e Observe applicable traffic regulations Yield right of way to pedestrians Slow down and sound horn at cross aisles and wherever a clear sight of travel is absent or compromised e Start stop travel steer and brake smoothly Slow down for turns and on uneven or slippery conditions that could cause the truck to slide or overturn e leave sufficient room for braking depending on load being carried and speed of travel e Do not overload the pallet truck beyond its rated load capacity e Do not carry loads that the operator cannot handle manually The PowerPallet is only meant to provide a power assist and does not increase the load carrying capacity e Make sure load is centered and located as far back as possible against the chassis e Do not carry people or try to ride on the machine e Do not operate the machine under the influence of alcohol or drugs e Regular inspection of the device must be performed by a qualified person
11. the device is awake the left LED will indicate the default drive mode i e Warehouse Mode and the right LED will indicate the battery level Driving 1 Follow startup procedure mentioned above 2 Lower the steering handle to a comfortable position above horizontal to activate speed control See fig 3 below Braking ON B Defour ale of Figure 4 Handle Control Positions in Drive Mode 3 Slowly rotate the slider on the throttle in the direction you wish the wheel to drive The farther the slider s relative position is from its neutral position the faster the device will move 1 In Truck Mode braking in the upright handle position can be over ridden when user proximity is detected All other operating conditions apply as described See Main Operating Modes amp Driving Modes for details PowerPallet User Manual Page 11 of 18 Braking To slow down or stop release the slider allowing it to return to neutral position The level of braking applied depends on the control setting selected see Control Settings When in Warehouse Mode raising or lowering the steering handle to an upright or horizontal position as shown in fig 3 engages full braking and brings the machine to a stop In Truck Mode full braking is applied whenever user proximity is not detected by the Throttle Pressing the Belly Button also brings the machine to a stop by applying full braking See Belly Button To resume driving the Mode Button ne
12. ATTERY LEVEL RIGHT LED INDICATION DESCRIPTION Good GREEN gt 70 remaining OK ORANGE 40 70 remaining Low RED 10 40 remaining Extremely Low lt 10 remaining Drive Disabled Replace or Recharge immediately Warning Indications Table 3 LED amp Horn Warnings LED INDICATION WARNING HORN DESCRIPTION RECOMMENDED ACTION Left Right i Slider Throttle input Lower steering handle to Rapid ee Flash _ detected with operable position to steering handle activate Speed Control Attempting to GREEN See n pee hua w ne upright or horizontal See Driving Slider Throttle input Place both hands closer to Feature Rapid Levels Flash I detected with no the Slider on the Throttle user proximity before attempting to ORANGE y detection drive the machine Horn beeps imult l Machi See Rapid pis Y ue Move truck to a safe area Meter Operating Flash with Rene red and allow motor to cool Overheated flash if severely limited to Modes ORANGE ae down machine is preserve Motor driven sider NORIN Machine would m neutral when contin e to act like To resume driving the Mode Button is Both LEDs RED oo motor allow slider to it s in Belly Stop pressed in Belly return to neutral position mode Stop Mode Communication lost F Remove battery wait for Communication Horn Beeps between the Failure Continuously Controller and Throttle 15 se
13. Release Support Contact Us North America Central America South America PowerHandling Inc 3223 N Market Street Spokane WA 99207 USA Email sales powerhandling com Tel 1 509 244 8860 Fax 1 509 267 6428 PowerPallet User Manual Europe Middle East Africa PowerHandling Europe Industriestraat 6 6361 HD Nuth Netherlands Email sales eu powerhandling com Tel 31 45 524 4710 Fax 31 0 45 744 001 Asia Pacific Incl China India Japan S Korea amp ASEAN PowerHandling Asia Pacific Co Ltd 6 23 Moo 4 Lamlukka Pathumthani Bangkok 12150 Thailand Email sales_ap powerhandling com Tel 66 2968 3735 Fax 66 2549 5441 Page 18 of 18
14. arehouse Fast Left LED stops Pashmg flashing ORANGE GREEN Note On exiting the settings mode the LEDs resume indication of the Main operating Modes Horn Settings The Horn settings and how to access them are described in the table below Table 6 Horn Settings HORN HORN SETTING RIGHT LED ETTIN THROTTLE INPUT DESCRIPTION 5 FUNCTION OUTPUT 5 u CONFIRMATION INDICATION s s 1 Beeps only Soft gt To enter settings when Horn mode press and hold 2 Button is toud Mode Button for 2 3 pressed seconds until LEDs In settings x Beeps when flash ORANGE and Left LED flashes Rapid flash 3 Soft mode press motor then press Horn GREEN lt setting gt GREEN J Mode Button drives Button of times with while in 4 Loud i to cycle forward simultaneous settings through the k Beeps when gt To exit settings Horn beeps mode settings gt motor Soft mode press and hold 85 drives either Mode Button for 2 3 6 forward or Loud seconds until Right LED backward stops flashing GREEN Note For Horn settings 3 through 6 horn functions as described in addition to beeping when the Horn Button is depressed PowerPallet User Manual Page 15 of 18 Last Saved Settings The machine stores the control settings Motor settings and Horn settings each time they have been changed This enables the operator to resume operation of the machine with the last sa
15. attery where the terminals could be shorted Service lt To be added gt PowerPallet User Manual Page 16 of 18 Software Upgrade The software on the device can be upgraded or reinstalled using a USB 2 0 flash drive formatted to a FAT32 file system The upgrade file can be found on the company website The upgrade process is listed below 1 Download the update file names PHPPPRR BIN from www powerhandling com 2 Copythe downloaded file on to a 1 2 4 GB USB 2 0 flash drive formatted to a FAT32 file system 3 Remove battery from the PowerPallet if battery is present 4 Dismount the right wheel of the pallet jack from the wheel axle after removing the snap ring holding it in place 5 Remove the dust cap on the USB programming port located behind the side plate of the PowerPallet chassis Insert the USB flash drive containing the update file into the USB programming port 7 While holding down the Mode button insert the battery on the unit 8 The LEDs on the Throttle will light up ORANGE to indicate the file verification process Release the Mode button once the LEDs light up ORANGE 9 If the upgrade is successful the LEDs will rapidly blink GREEN 4 times 10 Detach the USB flash drive and re insert the dust cap into the USB programming port 11 Re mount the right wheel on the wheel axle and secure it with the snap ring 12 Device is ready to operate with the updated software Note If the file verification process fails
16. conds and reconnect battery No Valid Software Both LEDs blink RED and ORANGE alternatively Machine will not function without valid software Update the device with the latest software See Software Upgrade section Motor moving without input or Downhill rolling Beeps continuously Event where Motor RPM is detected with no input from the Slider on the Throttle lt Add legal advice gt PowerPallet User Manual Page 13 of 18 Control Settings The operator has the flexibility to choose from a variety of operational modes and settings designed for various work environments These are accessed by specific input combinations on the Throttle There are 2 drive modes 3 settings for the horn and 6 different speed and acceleration settings providing 36 possible combinations The rest of this section describes the settings and how the operator can access them Drive Modes The PowerPallet has 2 drive modes See the Driving section for driving instructions The table below shows how to switch between the 2 drive modes and their brief description Table 4 Drive Modes LEFT LED DRIVE MODE CHANGE MODE INDICATION DESCRIPTION Full braking applied when handle is upright or Warehouse horizontal Braking is ON if there is no Slider Input from the Mode Default Drivin GREEN Throttle 8 Slider on the Throttle needs to be in neutral Mode gt Press Mode
17. eds to be pushed while the slider is in the neutral position Device Feedback The PowerPallet provides feedback to the operator by means of the 2 LEDs on the Throttle and horn signals Operating Mode Indication Table 1 Main Operating Modes MODE LED BRAKING DESCRIPTION Left Right Default startup mode Machine enters Sleep Mode if it is OFF OFF No Horn Full idle for 100 seconds Press Belly Button to wake up the machine from Sleep Mode Allows operator to drive the machine Machine brakes to stop when Slider F See on the Throttle is released to Drive r Brake to Mode Drive Sto neutral Modes Level of braking when the Slider on See the Throttle is released depends on See Horn h Battery otor settings chosen Levels Settings 566 Driving Modes for more details Sleep Mode Press Horn and Mode buttons simultaneously to enter Manual Manual Mode RED None Mode Drive disabled Allows operator to manually operate the pallet jack Applies full braking and brings machine to complete stop when Horn beeps 7 Belly Stop I Belly Button is pressed Flashing RED simultaneously Full Mode i Press Mode Button to exit Belly Stop with LED Flash I mode Slider on the Throttle must be in neutral PowerPallet User Manual Page 12 of 18 Battery Level Indication Table 2 Battery Levels B
18. nd secure it to the PowerPallet with the remaining screws Place the cylindrical spacer rod between the 2 mounting plates and secure it with the M5 flat head screws on both ends Readjust the screws on both sides if necessary to securely mount the PowerPallet symmetrically about the wheel mounting shaft Slide the pallet jack s wheels back on to the shafts secure them with the snap rings using the snap ring pliers and reattach the wheel end caps Install the Throttle on the handle of the pallet jack using the throttle mounting plate with the aid of the Philips screwdriver Make sure the backs of the mounting plate and the throttle are laid completely flat against the handle of the pallet jack 10 Wrap the cable sleeve around the stem of the handle and the coiled cable and close the zipper 11 Place tool to adjust the screw jack in the slot provided on the cable sleeve Screw Jack Adjustment The machine comes with an adjustable screw jack that allows the operator to set the height of the drive wheel with respect to the wheels of the pallet jack The operator can change this height by using the tool provided to achieve sufficient traction and optimal stability for any load PowerPallet User Manual Page 7 of 18 Operation General The general features precautions and operating and control instructions to use the PowerPallet are described in this section Precautions Improper operation of the equipment may result in operator
19. ttIBRBS u uu 14 Drive MOOS u navies 14 5 5 15 HOM 15 last Saved Setting EEE aE EE 16 Maintenance 16 Machine Maintenance Eiee TE 16 Battery MaintOn ane u 16 E 16 Software 1 6 1 17 Tre Blesh 0tiB8 2 u aad EE EERE FEER 17 REVISION HISTORY uu u u 18 S DDOTU22 as u au vetsioe E atest Mista aisle hiss needa ished 18 CONTACT Us RO OEE 18 PowerPallet User Manual Page 3 of 18 Figures amp Tables Figure 1 Curb wheel adjustment a 6 Figure 2 Parts of the
20. ved settings on startup even if the machine has been powered down for a while or if the battery was removed Note After a power down and restart the machine wakes up from Sleep Mode in the Warehouse mode even if the machine was shut down in the Truck Mode or Manual Mode with the last saved Motor and Horn settings Maintenance amp Service The PowerPallet has been designed and built to be virtually maintenance free The following instructions are recommended for achieving the best performance and increasing the life of the machine and battery Refer to our website www powerhandling com for step by step videos Machine Maintenance 1 Measure the diameter of the Drive wheel with urethane Make sure the outer diameter of the urethane is greater than 55mm 2 Check urethane thickness on the curb wheel Lube the drive chain at least once a year for smooth operation 4 Check wire terminal connectors so that they are securely connected Warning Perform any kind of maintenance with the battery removed from the machine Battery Maintenance 1 Recharge the battery whenever possible to maximize battery life 2 Do not leave the battery on the shelf for long periods of time A fully charged battery will lose about 20 of its charge if left unattended for about a week 3 Do not place leave battery on an unplugged charger unit Do not leave battery on the PowerPallet unit for too long or when stored away 5 Take care to not place store the b
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