Southworth PalletPal 360Air User manual

Owner’s Manual
PalletPalTM 360 Air
Level Loader
Southworth Products Corp
P.O. Box 1380 • Portland, Maine 04104-1380
Distributed by Ergonomic Partners, Inc.
Email: [email protected]
Web: www.ergonomicpartners.com
PH: 314-884-8884 | FAX: [phone]
Serial # ______________________________________________
Placed in Service ______________________________________
December 2012
Distributed by Ergonomic Partners, Inc. | [email protected] | 314-884-8884 | www.ergonomicpartners.com

OWNER’S MANUAL
2PALLETPAL 360 AIR
This manual was current at the time of printing.
To obtain the latest, most updated version, please
contact Southworth's Customer Service Department.

PALLETPAL 360 AIR 3
SOUTHWORTH
CONTENTS
INTRODUCTION ........................................................................................Page 4
RESPONSIBILITY OF OWNERS AND USERS .................................................. 5
SAFETY .......................................................................................................... 6
INSTALLATION INSTRUCTIONS ...................................................................... 7
Unpacking the Unit ........................................................................ 7
Setup and Instructions ................................................................... 7
Operation notes ............................................................................... 8
Specications................................................................................... 9
OPERATING INSTRUCTIONS ......................................................................... 10
Labels and Precautionary Markings ............................................ 10
Loading Manually .......................................................................... 11
Removing Loads Manually............................................................ 11
Operating Safely – Manual Use .................................................... 11
Loading with a Fork Lift ............................................................... 12
Unloading with a Fork Lift............................................................. 12
Moving the PalletPal 360 Air ......................................................... 12
TROUBLESHOOTING....................................................................................... 13
Troubleshooting Check List.......................................................... 13
Maintenance ................................................................................... 13
Ordering Replacement Parts ........................................................ 14
WARRANTY....................................................................................................... 15
TABLES
Setup Reference Table ....................................................................................... 7
LIST OF FIGURES
Figure 1 Safety Labels................................................................................. 10
Figure 2 Loading Manually .......................................................................... 11
Figure 3 Unloading Manually ...................................................................... 11
Figure 4 Warning - Load in Layers .............................................................. 11
Figure 5 Loading with a Fork Lift ............................................................... 12
Figure 6 Unloading with a Fork Lift ............................................................ 12
Figure 7 Moving the PalletPal 360 Air ........................................................ 12

OWNER’S MANUAL
4PALLETPAL 360 AIR
INTRODUCTION
The PalletPal 360 Air Level Loader is a simple device that will automatically main-
tain a load at the ideal height for manual loading and unloading. If a palletized load
is placed on the unit, the unit gradually rises as boxes or parts are removed. This
automatically maintains the top of the load at the correct working height.
The unit may also be used for the reverse application. An empty pallet may be placed
on the PalletPal 360 Air. The unit gradually lowers as boxes or parts are added.
Again, this keeps the top of the load at the correct height. Complete pallets may be
loaded or unloaded using a stacker or fork lift. See Figures 5 and 6.
This manual contains information to help you to learn about the safe and proper
installation, use, and upkeep of your PalletPal 360 Air unit. Please be sure that this
manual is available to anyone who uses or services the unit.
PalletPal 360 Air units may be used in a wide variety of industrial settings. The
instructions in this manual are not necessarily all-inclusive, as Southworth cannot
anticipate all conceivable or unique situations.
In the interest of safety, please read this whole manual carefully.
Be familiar with the contents of this manual before you install or
use the PalletPal 360 Air unit. If you are not sure of the proper
procedure to be followed, please call Southworth Products Corp
for more information.
Southworth’s product warranty is shown on the rear cover of this manual. This
instruction manual is not intended to be or to create any other warranty, express or
implied, including any implied warranty of merchantability or tness for a particular
purpose, all of which are hereby expressly excluded. As set forth more specically
in the product warranty, Southworth’s obligation under that warranty is limited to
the repair or replacement of defective components, which shall be the buyer’s sole
remedy, and Southworth shall not be liable for any loss, injury, or damage to persons
or property, nor for any direct, indirect, or consequential damage of any kind resulting
from the PalletPal 360 Air unit.

PALLETPAL 360 AIR 5
SOUTHWORTH
Responsibility of Owners and Users
Inspection and Maintenance
The device shall be inspected and maintained in proper working order in accor-
dance with Southworth’s owner’s manual.
Removal from Service
Any device not in safe operating condition such as, but not limited to, excessive
leakage, missing rollers, pins, or fasteners, any bent or cracked structural mem-
bers, cut or frayed pneumatic lines, damaged or malfunctioning controls or safety
devices, etc. shall be removed from service until it is repaired to the original
manufacturer’s standards.
Deection
It is the responsibility of the user/purchaser to advise the manufacturer where
deection may be critical to the application.
Repairs
All repairs shall be made by qualied personnel in conformance with South-
worth’s instructions.
Operators
Only trained personnel and authorized personnel shall be permitted to operate
the positioner.
Before Operation
Before using the device, the operator shall have:
• Read and/or had explained, and understood, the manufacturer’s operating
instructions and safety rules.
• Inspected the device for proper operation and condition. Any suspect item
shall be carefully examined and a determination made by a qualied per-
son as to whether it constitutes a hazard. All items not in conformance
with Southworth’s specication shall be corrected before further use of the
equipment.
During Operation
The device shall only be used in accordance with this owner’s manual.
• Do not overload.
• Ensure that all safety devices are operational and in place.
ModicationsorAlterations
Modications or alterations to any Southworth industrial positioning equipment
shall be made only with written permission from Southworth.

OWNER’S MANUAL
6PALLETPAL 360 AIR
SAFETY
The PalletPal 360 Air unit has been carefully designed to be as safe as possible for operators and service
workers. If you take a few common-sense precautions, you will be able to use the unit safely. However,
the PalletPal 360 Air is a powerful unit with moving parts, and is capable of causing personal injury if
proper precautions are not taken.
Therefore, throughout this manual, Southworth has identied certain hazards which may occur in the
use and servicing of the PalletPal 360 Air unit, and provided appropriate instructions or precautions
which should be taken to avoid these hazards. In some cases, Southworth has also pointed out the
consequences which may occur if Southworth’s instructions or precautions are not followed. Southworth
uses the following system of identifying the severity of the hazards associated with its products:
DANGER! Immediate hazard which will result in severe personal injury or death.
WARNING! Hazard or unsafe practice which could result in severe personal injury or death.
CAUTION! Hazard or unsafe practice which could result in minor personal injury or property damage.
Please read and follow this instruction manual, including all safety instructions and precautions,
carefully and completely.
WARNING!
Donotinatethesystemtomorethan61PSIatthefullyraisedposition.Iftheactuation
system pressure is higher than 61 PSI under any circumstance it may cause the failure of
the air actuation system thus resulting in severe injury.
WARNING!
Never try to service the machine without carefully reading the maintenance part of this
manual. Otherwise severe personal injury may result.
Figure 1 shows the safety labels on this unit. Please be sure that all of the labels are in place, and are
visible to the machine operators. Never paint over the labels. If any of the labels are missing, please
contact Southworth for replacements. The safety labels help to protect your workers.

PALLETPAL 360 AIR 7
SOUTHWORTH
7. If you have any questions about the steps in
the installation process, please call Southworth
Customer Service at 1-800-743-1000.
Set-Up and Instructions
The PalletPal 360 Air can be setup to handle
pallet loads of any weight within the unit's capac-
ity range. Load capacity depends on the initial
actuator pressure. The actuator pressure can be
set from 6 PSI to 61 PSI to achieve capacities
ranging from approximately 300 lbs to 4500 lbs.
Once air is inated into unit's air actuation system,
a corresponding load capacity can be set. The unit
will then lower or rise as the load is being added
or removed from the unit, and thus works as an
automatic pallet leveler. A rule of thumb for setting
up the unit is that the amount of air inated into the
air actuator should allow the unit to be lowered to
its compressed height with load equal to 75% of
the set capacity (including the weight of the pallet).
INSTALLATION INSTRUCTIONS
Unpacking the Unit
1. Before you start to install the unit, check for
local codes and ordinances that may apply. It is
your responsibility to obtain any necessary permits.
2. Please read all of these instructions carefully.
Be sure to read and understand all of the warnings.
3. Inspect the shipping pallet carefully for any
damage which may have affected the unit. If you
see signs of damage, notify the shipper immedi-
ately. Also make a note of this on the shipping
papers that you are asked to sign.
4. Choose the place where you want to set the
unit. It is very important that the PalletPal 360 Air
be located on a smooth and at surface. Check
the oor surface carefully and make sure that it is
free of all loose debris and dirt.
WARNING!
The unit is attached to the skid using
metal bands. These bands are under
high tension. The edges are sharp.
Wear safety glasses and gloves when
you handle or cut the banding.
5. Remove the metal banding that secures the
unit to the pallet. Remove all packing material.
Shift the unit to the oor. Support the base as you
do this.
6. Check to see that the base frame of the unit
is sitting rmly on the oor. Try to move or rock
the frame of the unit. The base frame should be
stable, and should not move. Check to see that the
base frame is level. If any part of the base frame
is more than 1/2" out of level in relation to any other
part, reposition to a atter, more level surface area.
SET-UP REFERENCE TABLE
Capacity <700 1000 1500 2000 2500 3000 3500 4000 4500
Capacity X 75% - 750 1125 1500 1875 2250 2625 3000 3375
Initial Pressure (PSI)
(no load on unit) 711 18 26 34 42 49 56 62

OWNER’S MANUAL
8PALLETPAL 360 AIR
OPERATION NOTES
WARNING!
Never sit or ride on the turntable or operate the
unit if anyone is on it.
WARNING!
Never operate the unit if the load is off center.
The load may shift, and you may be injured.
This can also damage the unit.
WARNING!
Keep the area around the unit clean. Do not
allow any dirt, debris, spilled oil, or excess
grease to collect. These materials may cause
you to slip while the unit is operating, and you
may be injured.
WARNING!
Stay clear of the turntable when it is moving.
As the pallet turns, a part of the load may rotate
around and hit you. Never turn the load when
anyone is standing beside the unit.
WARNING!
Do not try to use this unit with damaged or
broken pallets. Broken pallets may have
boards or nails which hang down below the
main part of the pallet. As the pallet is turned,
these boards or nails may catch on the frame
of the unit. This can cause the pallet to stop
turning suddenly, causing the load to shift.
You may be injured, and the unit may be
damaged. The boards or nails on the bottom
of the pallet should not extend down more than
1/8inch.

PALLETPAL 360 AIR 9
SOUTHWORTH
Load capacity 400 to 4500 lbs.
Load size 50" wide x 50" long x 72" high (max.)
Base frame 36" x 36"
Compressed height 9 1/2 inches
Extended height 27 3/4 inches
Air source 80 PSI
Maximum system air pressure 61 PSI
Safety relief valve setting 125 PSI
Rotating ring, outer diameter 43-5/8 inches
Rotating ring, inner diameter 40-5/8 inches
Ship weight 375 lbs
Operating environment indoor
Operating temperature -0F to +120F
Specications

OWNER’S MANUAL
10 PALLETPAL 360 AIR
Figure 1.
Item 2990413
Decal 5900191
Item 2990414
OPERATING INSTRUCTIONS
Labels and Precautinary Markings

PALLETPAL 360 AIR 11
SOUTHWORTH
OPERATING INSTRUCTIONS (continued)
Operating Safely -- Manual Use
1. Never push the load off of the side of the unit. If
you do this, the frame of the unit may jump upward.
2. Never use the unit when anyone is sitting or
riding on the turntable.
3. Do not try to use this unit with damaged or
broken pallets. Broken pallets may have boards
or nails which hang down below the main part of
the pallet. As the pallet is turned, these boards
or nails may catch on the frame. The pallet may
stop turning suddenly and this can cause the load
to shift. You may be injured and the unit may be
damaged. If the boards or nails on the bottom of
the pallet extend down more than 1/8 inch, they will
interfere with the turning action.
4. Stay clear of the turntable when it is moving.
As the pallet turns, a part of the load may rotate
around and hit you.
5. Keep the area around the unit clean. Do not
allow any dirt, debris, spilled oil, or excess grease
to collect. These materials may cause you to slip
while the unit is operating and you may be injured.
Loading Manually
Add boxes or parts until the pallet is full. The unit
will gradually lower the pallet until it reaches the
bottom. See Figure 2.
Removing Loads Manually
Remove boxes or parts until the pallet is empty.
The unit will gradually raise the pallet. See Fig-
ure 3.
Figure 2. Loading Manually
WARNING!
Ensure that loading and unloading of
the PalletPal 360 Air is done in even
layers. Loading or unloading a load on
one side may cause the load to tip over
and you may be injured. This can also
damage the unit.
Figure 3. Unloading Manually
Figure 4. Warning - Load in Layers

OWNER’S MANUAL
12 PALLETPAL 360 AIR
Figure 7. Moving the PalletPal 360 Air
Figure 6. Unloading with a Fork Lift
Unloading with a Fork Lift
Moving the PalletPal 360 Air
CAUTION!
Do not move the PalletPal 360 Air while
it is loaded. This will damage the base
frame of the unit. The pockets on the
base frame are designed to support an
unloaded PalletPal 360 Air, but cannot
support any extra weight.
1. Remove any load from the top of the Pallet-
Pal 360 Air.
2. Insert the forks into the pockets in the base
frame. See Figure 7.
Loading with a Fork Lift
1. Place the load on the lift, then lower the fork
lift. Before removing the load, be sure the unit is
carrying the weight, not the fork lift. See Figure 5.
• Lower the load until the airbag on the Pal-
letPal 360 Air is fully compressed.
• Be sure the forks on the lift are clear of the
inside of the pallet.
WARNING!
If you skip these steps, the load may
drop suddenly when you remove the
fork lift. You may be hurt or the unit or
load may be damaged.
WARNING!
Never drop the load on the turntable. If
you do this while the turntable is mov-
ing, the load may shift. You may be
injured or the unit may be damaged.
2. Be sure the load is centered on the
turntable.
Figure 5. Loading with a Fork Lift
WARNING!
If the load is off-center, it may shift when
the turntable is turned. You may be hurt
or the unit or load may be damaged.
1. Insert the forks into the pallet, and lift the pallet
clear of the top of the unit. See Figure 6.
• Be sure the pallet clears the top of the turn-
table before you move the fork lift.
WARNING!
If you skip these steps, the unit may
jump up suddenly when you remove
the pallet. You may be hurt or the unit
or load may be damaged.

PALLETPAL 360 AIR 13
SOUTHWORTH
Troubleshooting
Troubleshooting Check List
Problem Possible Cause Check This
The unit lowers too easily Not enough air pressure See set-up procedure pg 7
(too early)
The unit does not lower
enough (too late) Too much air pressure See set-up procedure pg 7
The top of the unit rotates The base frame of the unit may not Move the unit to a level surface or
away from you. be level. install the optional leveling feet.
Excessive “rumble” when Wear or lack of lubrication to Remove turntable, replace bearings.
unit operates. bearings under turntable.
Wear on underside Normal condition caused by No repair necessary.
of turntable. wear-hardening of metal.
Maintenance
Routine Periodic Maintenance
Every 90 days -
• Check for loose hardware and signs of
excessive wear.
• Check to be sure that the unit is placed on a
rm level surface.
Setup Procedures
1. The PalletPal 360 Air must be properly installed
according to the installation section of this manual.
2. With no load on the unit use shop air or an
air compressor to pressurize the air actuation
system to the required initial pressure. The unit
is equipped with an air pressure gauge and an
air manifold valve that includes a valve stem, a
manual relief knob, and a safety relief valve. Add
air to the actuator system through the valve stem,
and release air from the system by loosening the
manual relief valve.
3. Gradually load the PalletPal 360 Air to 75% of
the setup capacity. Check to see if the unit is fully
compressed. If not, turn the manual relief knob to
slowly bleed air out of the system until the platform
reaches minimum, fully compressed height; then
tighten the manual relief knob. The setup proce-
dure is now complete and the PalletPal 360 Air is
ready for use.
4. If a different load is to be handled, or if the op-
erator prefers a higher or lower loading/unloading
position from that of the standard setup, add air to,
or bleed air from the actuation system to achieve
the necessary height. The gauge should never be
more than 62 PSI when the unit has no load on it.
* NOTE: The actuation system of the PalletPal 360
Air contains captive air much like an automotive
tire and will lose small amounts of air over time.
Therefore, air may have to be occasionally added
to the system to compensate for the loss.
Quick Setup
If you do not know or cannot estimate the weight
of the pallet load to be handled, use the following
instructions:
With no load on the unit, pressurize the actuation
system to 62 psi. Place about half of the pallet
load onto the unit, then slowly bleed air from the
system using the manual relieve knob until the
pallet reaches the most convenient height for the
operator to continue loading the pallet.

OWNER’S MANUAL
14 PALLETPAL 360 AIR
Ordering Replacement Parts
Southworth has carefully chosen the components in your unit to be the best available for
the purpose. Replacement parts should be identical to the original equipment. Southworth
will not be responsible for equipment failures resulting from the use of incorrect replacement
parts or from unauthorized modications to the unit.
Southworth can supply all replacement parts for your PalletPal. With your order, please
include the model number and the serial number of the unit. You can nd these numbers on
the name plate. This plate is located within the scissors mechanism.
To order replacement parts, please call the Parts Department at [phone] or (800)
743-1000. Parts are shipped subject to the following terms:
• FOB factory
• Returns only with the approval of our parts department.
• Payment net 30 days (except parts covered by warranty).
• Freight collect (except parts covered by warranty).
Parts replaced under warranty are on a “charge-credit” basis. We will invoice you when we
ship the replacement part, then credit you when you return the worn or damaged part.
Southworth Products Corp
P.O. Box 1380, Portland, ME 04104-1380
www.SouthworthProducts.com
Email: [email protected]
Telephone: [phone] or (207)-878-0700
Fax: [phone]

PALLETPAL 360 AIR 15
SOUTHWORTH
Southworth Products Corp warrants this product to be free from defects in
material or workmanship for a period of 2 years of single shift usage from
date of shipment, providing claim is made in writing within that time period.
This warranty shall not cover modied designs for special applications,
failure or defective operation caused by misuse, misapplication, negligence
or accident, exceeding recommended capacities, failure to perform required
maintenance or altering or repairing, unless alteration is authorized by
Southworth Products Corp. Except as set forth herein, there are no other
warranties, express or implied, including the warranties of merchantability and
tness for a particular purpose, all of which are hereby excluded.
Southworth Products Corp makes no warranty or representation with respect
to the compliance of any product with state or local safety or product standard
codes, and any failure to comply with such codes shall not be considered a
defect of material or workmanship under this warranty. Southworth Products
Corp shall not be liable for any direct or consequential damages arising out of
such noncompliance.
Southworth Products Corp’s obligation under this warranty is limited to the
replacement or repair of defective components at its factory or another loca-
tion at Southworth Products Corp’s discretion. This is buyer’s sole remedy.
Except as stated herein, Southworth Products Corp will not be liable for any
loss, injury or damage to persons or property, nor for direct, indirect, or con-
sequential damage of any kind, resulting from failure or defective operation of
said product.
This warranty may be altered only in writing by Southworth Products Corp,
Portland, Maine.
SOUTHWORTH PRODUCTS CORP
P.O. Box 1380, Portland, ME 04104-1380
Telephone: [phone] • [phone]
2 YEAR WARRANTY

Distributed by Ergonomic Partners, Inc.
Email: [email protected]
Web: www.ergonomicpartners.com
PH: 314-884-8884 | FAX: [phone]
Southworth is the world class supplier of products designed to improve productivity and enhance
safety. Our staff has over 400 years of engineering experience. If one of our standard products
does not meet your needs, our engineers can custom design equipment specifically suited to your
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