POWERHANDLING PowerPallet 2000 User manual

PowerHandling, Inc.
PowerPallet User Manual
Published: May 2021

PowerPallet User Manual Page 2of 29
FCC Notice
This device complies with part 15 of the FCC Rules. Operation is subject to the following 2 conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference
received, including interference that may cause undesired operation.
Training Information
According to Federal law (OSHA §1910.178, Rev. 1999), only properly trained operators are permitted to
operate a powered industrial truck.
You must be trained and certified by your employer that you are qualified to operate this powered
industrial truck.
Do not operate this machine without being fully qualified by your employer to do so.
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.

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Precautions
Improper operation of the equipment may result in operator injury, or load, and/or property damage.
The following precautions must be adhered to at all times:
Any person operating the machine must be trained and authorized to do so.
All warnings and instructions must be carefully read and understood before operating the device.
Do not operate in hazardous areas/environment.
Inspect the unit before use. Do not operate if anything seems out of place.
Do not operate the machine without the pallet-jack wheels mounted and secured properly on the wheel shaft.
Approved footwear must be worn while operating the device.
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.
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.
Leave sufficient room for braking depending on load being carried and speed of travel. Check braking distance
of the machine before operating it for work.
Do not load the pallet-jack beyond its rated load capacity.
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.
Make sure load is centered and located as far back as possible against the chassis.
Do not carry people or try to ride on the machine.
Do not operate the machine under the influence of alcohol or drugs.
Regular daily inspection of the device, including drive wheel condition and brake performance, must be
performed by a qualified person. Any abnormal condition should be noted and the machine removed from use.
Follow all safety procedures required by the workplace, city, state and country where the machine will be used.

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Contents
FCC Notice.....................................................................................................................................................2
Training Information .....................................................................................................................................2
Precautions ...................................................................................................................................................3
Figures...........................................................................................................................................................6
Description....................................................................................................................................................7
Introduction ..............................................................................................................................................7
General Use and Application ....................................................................................................................7
PowerPallet Specifications........................................................................................................................7
Battery Specifications ...............................................................................................................................7
Standard Safety Features..........................................................................................................................8
Braking by Handle Position ...................................................................................................................8
Belly-Button ..........................................................................................................................................8
Parking Brake ........................................................................................................................................8
USB Flash Drive Key (Optional Feature)................................................................................................8
Installation ....................................................................................................................................................9
List of Parts................................................................................................................................................9
Tools Required ........................................................................................................................................10
Assembly.................................................................................................................................................10
Screw-Jack Adjustment...........................................................................................................................14
Curb-Wheel Height Adjustment..............................................................................................................14
Operation....................................................................................................................................................15
Terms & Definitions ................................................................................................................................15
Forward Travel....................................................................................................................................15
Backward Travel..................................................................................................................................15
Base Unit.............................................................................................................................................15
User Controller....................................................................................................................................16
Device Operation ....................................................................................................................................17
Battery Installation..............................................................................................................................18
Battery Removal..................................................................................................................................19
Power Up & Power Down ...................................................................................................................19
Operating Modes ................................................................................................................................20

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Battery & Motor Temperature Indication ..........................................................................................21
Belly-Stop ............................................................................................................................................21
Parking Brake ......................................................................................................................................21
Errors and Warnings .........................................................................................................................222
Maintenance.............................................................................................................................................233
Machine Maintenance ..........................................................................................................................233
Battery Maintenance ............................................................................................................................233
Service.......................................................................................................................................................255
Manual Jack Operation .........................................................................................................................255
Drive-Spring Removal........................................................................................................................255
Drive-Spring Installation ...................................................................................................................265
Replacement Parts................................................................................................................................265
USB Flash Drive Key (Optional Feature)................................................................................................265
Firmware Update ..................................................................................................................................277
Acceleration and Brake Settings Update ..............................................................................................277
Firmware & Settings Update Process ...................................................................................................277
Troubleshooting....................................................................................................................................288
Sales & Support.........................................................................................................................................288
Warranty & Guarantee (Machines & Parts / Materials & Labor) .............................................................299
Overview & Conditions .......................................................................................................................29
Exceptions - Use/Misuse Related........................................................................................................29
Exceptions –Long Term Consumables................................................................................................29
Terms & Conditions.............................................................................................................................29

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Figures
Figure 1: Parts (Out of the box) ......................................................................................................................
Figure 2: Tools Required for Installation.........................................................................................................
Figure 3: Screw-Jack Height Adjustment ........................................................................................................
Figure 4: Curb-Wheel Height Adjustment.......................................................................................................
Figure 5: Forward and Backward Travel .........................................................................................................
Figure 6: PowerPallet Base Unit......................................................................................................................
Figure 7: Parts of the User Controller .............................................................................................................
Figure 8: Installing the Battery........................................................................................................................
Figure 9: Removing the Battery ......................................................................................................................
Figure 10: Handle Positions for Warehouse & Truck Modes..........................................................................
Figure 11: Parking Brake: Engage & Disengage Positions...............................................................................

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Description
Introduction
This document describes the PowerPallet, a unique bolt-on machine that converts a manual pallet-jack
into a powerful, fast, yet ultra-compact motorized pallet-jack. The standard safety features, assembly
instructions, terms and definitions, operation, maintenance, service and troubleshooting pertaining to
the machine are detailed in this manual.
The PowerPallet provides power-assist by attaching on to many major name-brand manual pallet-jacks.
Due to the compact design of the PowerPallet, it retains the maneuverability of the manual pallet-jack
that it is being bolted on to.
General Use and Application
The PowerPallet is meant for light duty applications, and intermittent use.
Some of the many applications may include use in:
Back of truck
Retail store
Manufacturing plants
Dock assist
PowerPallet Specifications
Weight (not including Battery)
27 lbs.
Max. load capacity (on flat concrete)
3500 lbs. or rated capacity of pallet-jack,
whichever is less
Max. speed (unloaded, on flat concrete)
93.3m/min (3.48mph)
Drive motor
Brushless DC electric motor
Slope rating (concrete)
Not rated for slopes.
Battery Specifications
Composition
Li-Ion (Rechargeable)
NiMH (Rechargeable)
Power
5Ah, 51.8V (Li-Ion)
5Ah, 46V (NiMH)
Type (ID)
Type E
Type E
Weight
4lbs. (Li-Ion)
9 lbs. (NiMH)
Do not attempt to operate the machine with any other battery or power source
other than the PowerPallet battery.

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Standard Safety Features
Braking by Handle Position
In Warehouse mode, the PowerPallet applies full braking when the handle moves into the upright
position. There is an optional setting to apply full braking when the PowerPallet handle moves into the
horizontal position.
In the Truck mode, there is an optional setting to apply full brakes when the PowerPallet handle moves
into the horizontal position.
Note: In the Manual mode, braking by handle position is disabled.
Belly-Button
Pressing or bumping against the Belly-Button while the truck is stationary or moving backward stops
current operation, and drives the truck away a few feet from the operator as long as the Belly-Button is
depressed. This feature reduces the possibility of the operator getting pinned by the steering handle.
Parking Brake
The PowerPallet has a safety parking brake on the left side of the unit that can be easily engaged to lock
the PowerPallet motor from driving. This prevents any undesired rolling of the machine.
USB Flash Drive Key (Optional Feature)
The PowerPallet can be programmed to require a USB flash drive as a key before operating the machine.
This feature adds a level of security to client use. This can be achieved by a simple firmware update.

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Installation
List of Parts
Figure 1: Parts (Out of the box)
1. PowerPallet Base unit with User Controller
2. User Controller mounting bracket
3. Pallet mount kit (pallet-jack specific)
4. Spacer rod
5. Fasteners
6. Allen-wrench tool for screw-jack adjustment
7. Pallet-jack handle sleeves
8. Battery charger & power cable
9. Battery
1
2
3
4
5
6
7
8
9

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Tools Required
Figure 2: Tools Required for Installation
Assembly
1) Set the rear end of the pallet-jack such that the wheels are off the ground. Place some weights
(>20kg) on the front forks, to prevent it from tipping over during installation.
2) Remove end caps of both wheels using a flat-head screwdriver.
1. M3 and M5 Allen-wrenches
2. Philips #1 screwdriver
3. Snap-ring pliers
4. Allen-wrench tool for screw-
jack adjustment
5. Flat-head screwdriver