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

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3) Remove the snap-rings using the snap-ring pliers, and slide the wheels out. (Note: Some pallet-jack
models use nuts to hold the wheels on. Use appropriate tools if that is true for the pallet-jack that
the PowerPallet is being installed on.)
4) If the pallet mount kit came with spacer rings for the pallet-jack, slide them onto both sides of the
axle.
5) Place one mounting plate on one side of the PowerPallet and secure it with the M8 flat-head screws
provided. Secure one end of the cylindrical spacer rod to the mounting plate with M5 flat-head
screw.

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6) 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 wheels behind it).
7)
a) Slide the other mounting plate on to the opposite side and secure it to the PowerPallet with the
M8 flat-head screws.
b) Secure the other end of the cylindrical spacer rod between the 2 mounting plates with the M5
flat-head screw.
c) Readjust the screws on both sides (if necessary) to securely mount the PowerPallet
symmetrically about the wheel mounting shaft.
8) Slide the pallet-jack wheels back on to the shafts, secure them with the snap-rings using the snap-
ring pliers, and reattach the wheel end caps.
9) Make sure the screw-jack assembly is
secured by the fasteners with the drive-
spring properly mounted.

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10) Install the User Controller on the handle of the pallet-jack using the User Controller mounting plate
with the aid of the Philips screwdriver and the 8 plastite screws. Make sure the backs of the
mounting plate and the User Controller are laid completely flat against the handle of the pallet-jack
and the cable is properly placed in the slot provided for it.
11) Wrap the cable sleeve around the stem of the handle and the coiled cable, and close the zipper.
Place allen-wrench tool to adjust the screw-jack in the slot provided on the cable sleeve.

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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 alter this height
by using the allen-wrench tool provided to adjust the
compression in the drive-spring, thus being able to achieve
sufficient traction and optimal stability for any operable load.
At the correct setting the 7” diameter pallet jack steer wheels
will be approximately ¼” off the ground with no load on the
pallet jack. The adjustment screw may need to be adjusted
periodically as the drive roller wears out to keep the
PowerPallet at the proper setting.
Figure 3: Screw-Jack Height Adjustment
If the screw is turned clock-wise all the way, the drive-wheel is at its maximum height setting. It might
not make contact with the ground.
If the screw is turned counter clock-wise all the way, the drive-wheel is at its minimum height setting,
thus achieving maximum traction with the ground in contact.
The factory setting is 2 clock-wise rotations from the minimum height setting.
Curb-Wheel Height Adjustment
To adjust the curb-wheel height, remove the bottom plate using the M3 wrench to unscrew the
fasteners (See Figure 4). 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 4: Curb-Wheel Height Adjustment
Lower to the ground
adjustment
Higher from the
ground adjustment

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Operation
Terms & Definitions
Forward Travel
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 traveling forward.
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 traveling backward.
Figure 5: Forward and Backward Travel
Base Unit
The base unit consists of the chassis enclosing the motor, drive system and the controller board. It also
has a horn for warning and feedback.
Figure 6: PowerPallet Base Unit
Forward Travel
Backward Travel
Drive-wheel
Curb-wheel
Parking
Brake Lever
Battery Terminals
Battery
latch plate
Drive-spring
Drive-arm

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User Controller
The User Controller allows the user to control and operate the PowerPallet.
Figure 7: Parts of the User Controller
No.
Part
Use/Description
1
Belly-Button
- Power up machine
- Activate Belly-Stop
- Initiate firmware upgrade of the machine
2
Throttle
- Drive the motor
- Controlled descent on slope/hill
3
Mode-Button
- Switch mode of operation
- Exit Belly-Stop
- Power down machine when pressed along with Horn-Button
4
Horn-Button
- Beep Horn
- Power down machine when pressed along with Mode-Button
5
Left LED
- Indicates mode of operation
6
Right LED
- Indicates battery level
- Indicates high motor temperature & if motor is overheated
7
USB Port
- Update firmware using a USB flash drive
- USB Flash Drive Key (optional feature)
8
GREEN Power LED
- Indicates User Controller is powered
Direction of Rotation -Throttle “FORWARD”
Direction of Rotation -Throttle “REVERSE”
8
(Under Plastic)
(Back View)
No Rotation –Throttle “NEUTRAL”
1
2
5
3
7
4
6

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Li-Ion Battery Charging
The Li-Ion battery charger includes an external charger block that plugs into the battery cradle.
To charge the battery simply plug the power cord into the charger block, plug the charger block into the
charger base, plug the power cord into a mains circuit and set the battery on the charger base.
The LED indicator light that shows the battery charge status is located on this external battery charger
block.
There are no indicator lights on the Li-Ion charger base.
Green LED indicates:
Charger power connected or battery is fully charged.
Red LED indicates:
Battery is charging.
NiMH Battery Charging
The NiMH battery charger includes an integral control board in the charger base with LED indicator
lights on the charger front panel that indicates the battery charge status.
Green LED indicates:
Charger power connected or battery fully charged.
Red LED indicates:
Battery charging.
Flashing Green LED indicates:
Battery cells over temp (cool battery before recharging) or thermistor circuit error.
Device Operation
This section will detail the following:
Battery Installation and Removal
Power Up/Power Down
Operating Modes
Battery and Motor Temperature Indication
Belly-Stop Braking
Transition between Use States
Parking Brake
Manual Jack Operation
Li-Ion Charger LED Indicator

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Battery Installation
Figure 8: Installing the Battery
Step 1: Align and insert
centrally located steel tabs
on the front of the battery
into the slots on the battery
base-plate.
Step 2: Make sure the tabs on
the back plate securely capture
the battery from the back.

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Battery Removal
Figure 9: Removing the Battery
Power Up & Power Down
State
Action
Description
Power Up
Press Belly-Button with the battery installed
- Horn beeps once indicating the
machine is awake
- Left LED indicates Warehouse Mode
(default mode of operation), and the
Right LED indicates the battery level
Power Down
Any of these actions will power down the
machine:
Press Mode-Button + Horn-Button together
with the machine completely stopped
Leaving the machine idle for the timeout
period
Removing the PowerPallet battery from the
base unit
- Idle timeout period is 100 seconds
when the USB Flash Drive Key feature
is not used
- Idle timeout period is 15 seconds
when the USB Flash Drive Key feature
is used
Step 1: Pull battery latch plate
backward.
Step 2: Tilt battery forward and
slide it out from the slots on the
battery base-plate

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Operating Modes
The 3 modes of operation for the PowerPallet are described in table below. The Left LED indicates the current mode of operation.
Mode of Operation
Left LED
Driving
Braking
Warehouse/Fast
Press
Mode-
Button
to
change
mode
GREEN
Tilt handle to speed control position,
and then slowly rotate the throttle in
the direction you wish the drive-wheel
to rotate
-Full braking applied when handle is upright. Optional brake
when handle is horizontal
-Braking is ON when the throttle is in neutral position
-Variable braking1effective when throttle is rotated in the
opposite direction of drive-wheel rotation
Truck/Slow
(1/4th speed of
Warehouse Mode)
YELLOW
With handle upright or tilted within the
speed control positional limits, slowly
rotate the throttle in the direction you
wish the drive-wheel to rotate
-Optional brake when handle is horizontal
-Braking is ON when the throttle is in neutral position
-Variable braking1effective when throttle is rotated in the
opposite direction of drive-wheel rotation
Freewheel/Manual
RED
-Drive disabled
-Allows operator to manually operate
the pallet-jack
-Braking is OFF when throttle is in neutral position
-Variable braking effective when throttle is rotated
forward/backward
Figure 10: Handle Positions for Warehouse & Truck Modes
1
Variable braking force is proportional to the relative degree of throttle rotation away from the neutral position.
Handle Positions for
Warehouse/Fast Mode
Handle Positions for
Truck/Slow Mode