UltraLift 1500 User manual

OPERATION MANUAL
the best move you’ll ever make!
Ultra Lift Corporation, 475 Stockton Avenue, Unit E, San Jose, CA 94126
[phone]; [phone]; Fax [phone]
wwww.ultralift.com; [email protected]

ULTRA LIFT CORPORATION
OPERATOR’S MANUAL
MODEL 1500 POWERED HAND TRUCK
TABLE OF CONTENTS
Page
INTRODUCTION…………………………………………………………………….. 1
I. STRAPPING THE LOAD……………………………………………………………. 2
II. THE CONTROL SWITCH…………………………………………………………… 4
III. BREAKING BACK THE LOAD…………………………………………………….. 5
IV. MOVING OVER FLAT SURFACES……………………………………………….. 6
A. Four-Wheel Dolly………………………………………………………………… 6
V. LOADING & UNLOADING TRUCKS……………………………………………… 7
A. Loading……………………………………………………………………………. 7
B. Unloading…………………………………………………………………………. 8
C. Portable Dock Leveler………..……………………………………………………… 9
VI. STAIR MOVES………………………………………………………………………. 10
A. Climbing Stairs…………………………………………………………………… 10
B. Descending Stairs…………………………………………………………………. 11
VII. OVERCOMING CURBS & OBSTACLES…………………………………………. 12
A. Curbs……………………………………………………………………………… 12
B. Thresholds………………………………………………………………………… 12
C. Other Obstacles…………………………………………………………………… 12
VIII. MECHANICS OF OPERATION…………………………………………………….. 13
A. Main Frame Assembly……………………………………………………………. 14
B. Lift Frame Assembly……………………………………………………………… 15
C. Drive System……………………………………………………………………… 16
D. Electrical System………………………………………………………………….. 17
IX. BATTERY CHARGING…………………………………………………………….. 19
X. OVERVIEW/MAINTENANCE & INSPECTION PROCEDURES………………… 21
A. Objectives…………………………………………………………………………. 21
B. Regular Maintenance………………………………………………………………. 21
C. Routine Inspection………………………………………………………………… 23
D. Anti-Reverse Brake………………………………………………………………… 24
XI. SPECIFICATIONS: MODEL 1500 POWERED HAND TRUCK……………………. i
XII. DRIVE SYSTEM ASSEMBLY: EXPLOSION……………………………………….. ii
XII. WARRANTY………………………………………………………………………….. iii

POWERED HAND TRUCK
ULTRA LIFT customers use a combination of motorized lifting, leverage and
balance to greatly reduce the operator effort required and improve operator safety
in all types of moves:
•LOAD BREAK BACK
•ACROSS LEVEL SURFACES
•OVER OBSTACLES SUCH AS CURBS, THRESHOLDS &
ROUGH TERRAIN
•TALL LOADS UNDER LOW DOORWAYS
•ON AND OFF TRUCKS
•UP AND DOWN STAIRS
•IN AND OUT OF CONTAINMENT AREAS
One person equipped with an ULTRA LIFT can safely move most loads weighing
up to 650 – 750 pounds. Two people can handle many loads weighing up to 1500
pounds. The factors that determine the maximum load one or two operators can
safely handle are the type of move being made (level surfaces, up stairs, etc.); load
shape and weight distribution; operator skill level with ULTRA LIFT; and the
physical size and strength of the operator(s).
Your ULTRA LIFT Powered Hand Truck will enable you to complete any hand
truck move with reduced labor and increased operator safety.
-1-

1. STRAPPING THE LOAD
The adjustable Strap Bar can be positioned on the Lift Frame at the height required for the
particular load being moved. Mounting brackets welded to the back face of the Strap Bar
lock around the inside of the Lift Frame rails to hold the Strap Bar in place. See Figure 1
below:
Figure 1. Strap Bar Assembly
Bracket Cam Lock & Handle
Strap on Handle
1. Mount the Strap Bar to the Lift Frame at the best position for the load being moved.
Open the strap handle as shown above and grip the handle end of the Strap Bar with
your left hand. Grip the cam lock end of the Strap Bar with your right hand.
2. Rotate the Strap Bar. Angle the Strap Bar so that the brackets can be moved between
the Lift Frame struts. With the Strap Bar in this position, place the back edge of the Strap
Bar against the front face of the Lift Frame struts.
3. Slide the top end of the Strap Bar sideways to lock one bracket around the Lift Frame
strut. Rotate the lower end upward until the second bracket locks behind the opposite
strut and continue to rotate until the Strap Bar is firmly locked in place.
Note: The Strap Bar brackets can be adjusted as required if the Strap Bar is either too tight
to fit onto the Lift Frame or is too loose and doesn’t stay in place. To adjust an overly tight
fit, lightly tap each bracket toward the center of the Strap Bar. To tighten a loose fit, lightly
tap the brackets out. Do this adjustment off the Ultra Lift.
Figure 2. Strapping Alternatives
One Strap Bar Two Strap Bars
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4. With the Strap Bar positioned for your load (see Figure 2) tilt the load forward
and slide the Lift Plate under it as you would with any hand truck.
5. Strap the load to the Lift Frame in the following sequence:
•Open the Strap Handle and Cam Lock as shown in Figure 3.
•Wrap the strap around the load and feed it through behind the Cam Lock
as shown in Figure 3.
•Leave a slight bit of slack in the strap and close the Cam Lock as shown in
Figure 4.
•Avoid the risk of pinched fingers! With the palm of your hand, close the
Strap Handle to secure the load. Closing the Strap Handle will
dramatically increase strap tension and it is normal for the Strap Handle to
snap into position. If you have difficulty closing the Strap Handle, release
the Cam Lock to create more slack. Retighten the Cam Lock and close the
Strap Handle.
Figure 3. Thread the Strap
Strap Bar Load Strap Cam Lock Open
Strap Handle Opened Strap
Figure 4. Lock the Strap
Cam Lock Closed
Figure 5. Tighten the Strap
Strap Handle Closed
-3-

II. THE CONTROL SWITCH
Your ULTRA LIFT has been designed for ease of operation. A single control
switch moves the load and the wheels.
PUSH the switch to raise the wheels
or to lower the load.
PULL the switch to lower the wheels
or to raise the load.
A. RAISING THE LOAD
Think of raising the load as a three-step process:
1. The operator steps to the level onto which the load will be raised (e.g.
truck bed, loading dock or curb). The extension handle is then pushed
slightly forward to keep the load on the ground.
2. PUSH the control switch away from you to raise the wheels to the higher
level.
3. With a firm grip pull the extension handle toward you; then PULL the
control switch to raise the load to the higher level.
NOTE: When climbing stairs never put the Ultra Lift and the load
on the same step! See page 10 for specifics of stair
climbing.
B. LOWERING THE LOAD
Lowering the load is a reverse of the three-step process. The operator must be
standing at the same level as the load to start the move.
1. Roll the load toward the edge of the truck, loading dock, or curb so that
the main wheels stop within 3” to 6” of the edge. While holding back
firmly on the extension handle PUSH the control switch away from you to
lower the load to the ground. Keep a firm grip on the extension handle
while lowering the load.
2. When the load is on the ground push the extension handle forward, then
PULL the control switch toward you to lower the wheels to the load.
3. Start to roll the load away from you while you are still on the higher level,
then step down to the lower level to continue the move.
NOTE: See page 10 and 11 for specifics on descending stairs.
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III. BREAKING BACK THE LOAD
Breaking back a heavy load with a standard hand truck is a difficult task. The
operator must physically lift the load off the ground and raise it over the wheels.
The wheels are the fulcrum (break back point) and the load is at maximum distance
from the fulcrum. Your ULTRA LIFT takes the work out of breaking back even
the heaviest loads.
1. PUSH the control switch to raise
the wheels as shown. This
reduces the effort required for
two reasons:
a. The fulcrum shifts from the
wheels to the edge of the load.
b. With the wheels ‘out of the
way’ the load can be tilted
backward until the wheels
rest on the ground as shown.
No lifting is required.
2. If the wheels are raised to the
correct height before break back,
the load will balance in an
inclined position as shown.
IMPORTANT
To further reduce the effort
required to break back tall or
heavy loads, drop the leverage
bar as shown and push down
firmly with your foot.
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IV. MOVING OVER FLAT SURFACES
Start with the load inclined in the balance position as shown in Figure 7.
Grasp the extension handle with your left hand and the main handle with
your right and proceed as follows:
1. Tilt the load back by pulling down on the extension handle.
You will feel some of the weight of the load.
2. PULL or PUSH the control switch to move the load up or
down along the frame. Find the point where the load is
well balanced over the wheels. When the balance point
is found, very little effort is required to hold the load
steady, and the operator can concentrate on pushing the
load to the final destination.
3. At the final destination Ultra Lift takes the work out of
setting a heavy load down and also protects the load from
damage during the process. The problem with a standard
hand truck is that the operator often reaches a point where
“the load takes over” as it is tilted down and slams to the
ground. Such impact can cause costly damage to delicate
items such as computers, copy machines, and appliances.
Ultra Lift power eliminates the problem. To set the load
down, PUSH the control switch and “power” the load to
the ground. With the edge of the load on the ground,
tilt the load forward until the bottom of the load is flat
on the ground. For very heavy loads, drop the leverage
bar before tilting the load forward and use foot pressure
for added control.
A. FOUR WHEEL DOLLY
If the load must be moved a long distance over a flat surface,
assemble the four wheel dolly before breaking back the load.
Refer to Section VIIIA for assembly instructions.
Break the load back until the dolly wheels are on the ground.
PUSH or PULL the control switch as required to stabilize the load
on the four-wheel dolly and push it to the final destination. Set
the load down as described above and disassemble the dolly.
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V. LOADING AND UNLOADING TRUCKS
The procedure for loading and unloading trucks is easy to learn. Try it with various
types of loads to develop the technique that best suits you.
•PRACTICE WITH A LIGHT LOAD TO DEVELOP YOUR SKILLS
BEFORE MOVING A HEAVY LOAD.
•LEARN THE LIMITS OF YOUR OWN STRENGTH.
Although Ultra Lift provides the power, you mush provide back-pressure in
loading trucks, climbing stairs, and overcoming obstacles.
•LOAD SHAPE IS AN IMPORTANT FACTOR IN ALL TYPES OF
MOVES.
For example, tall loads are easier to move than short compact loads of the
same weight.
•ACCESSORIES SUCH AS THE MODEL SCL (STRAP AND CHANNEL
LOADING SYSTEM), MODEL THB (TRUCKBED HOOK BOX), OR
OTHER TIE DOWN DEVICES (ITEM C BELOW) GREATLY REDUCE
THE EFFORT REQUIRED IN LOADING A TRUCK.
A. LOADING A TRUCK
1. Move your Ultra Lift to the
tailgate of the truck as illustrated.
Leave enough space for the
wheels to clear the tailgate when
they are raised.
2. PUSH the control switch to raise
the wheels as illustrated. Test
the strength of the tailgate before
raising a heavy load. A heavy
load may dent or buckle a light
duty tailgate. Some tailgates may
be removed during loading. A
second alternative is to place a
piece of plywood over the tailgate
during loading.
-7-

3. Grip the extension handle firmly with
your left hand and the main handle
with your right to counter balance the
Ultra Lift while PULLING the
control switch to raise the load to the
truck bed. When the load is just
above truck bed level, roll the Ultra
Lift back into the truck and set the
load down.
4. Your Ultra Lift has a vertical lifting
capability of 36”. Any truck with a
bed height of 36” or less can be
loaded in one step. Higher trucks,
such as over-the-road trailers, can be
reached in two steps by placing a
platform or box behind the truck and
moving the load from ground level to
the box and then to the truck bed.
B. UNLOADING A TRUCK
Unloading requires a reverse of the loading procedure. Start with the wheels
approximately 4” from the edge of the truck bed and let the wheels roll slightly
forward as the load approaches the ground.
NOTE: For some loads it will be necessary to drop the
leverage bar and apply foot pressure for extra
counterbalance force as you raise or lower the load.
Loads that are heavier may require additional tie
down assistance for counterbalance.
-8-

C. PORTABLE DOCK LEVELER
Your Ultra Lift can be used as a dock leveler to move loads between docks and
trucks that are at different heights. For heavy loads, use the 4 wheel dolly
configuration and apply foot pressure to the tripod cross bar for extra
counterbalance force as you raise or lower the load. If the load is too heavy
for the operator to counterbalance, a second person is required. Both
the operator and the second person should always remain above the load.
NOTE: Never operate the machine with anyone below
the load.
-9-

VI. STAIR MOVES
Moving loads up and clown stairs requires a variation of the procedures used for loading and unloading
trucks. An important Ultra Lift safety feature is that the operator is always ABOVE THE LOAD during
stair moves.
A. CLIMBING STAIRS
1. Roll the loaded Ultra Lift to the stairs as
shown. Leave approximately 6” – 8”
between the wheels and the first stair.
2. PUSH the control switch to raise the
wheels and tilt the load back until the
wheels rest on the second stair as shown.
3. Push downward on the extension handle to
counterbalance the load and at the same time
PULL the control switch to move the load
up to the first stair as shown.

4. Repeat the second step.
Pivot the load forward
on the heel of the lift
plate and raise the wheels
to the third stair as shown.
To complete the climb,
repeat the third step and
continue to repeat steps
two and three until the
next floor is reached.
Figure 19
SAFETY FIRST!NEVER OPERATE THE
MACHINE ON STAIRS WITH ANYONE
BELOW THE LOAD!
NOTE: If you are moving a heavy load on wood stairs, be certain to bring the
the lift plate well onto the stair. Do not set the lift plate down on the
overhanging lip of a wood stair.
B. DESCENDING STAIRS
Descending stairs is a reverse of the stair climbing procedure; however, it will be
necessary to break back the load an additional 3” inches so the lift frame clears the
stair.
When lowering the load you will note that it continues to travel downward for
2” to 4” after the control switch is released. This is by design. The overtravel
allows you to coast onto the next stair. Practice with a light load to develop this
technique.
-11-

VII. OVERCOMING CURBS AND OBSTACLES
Obstacles such as curbs, thresholds, broken pavement, and even icy patches
can be overcome by variations of the operating techniques described above.
A. CURBS
Climbing over or off of a curb can be thought of as loading or unloading
a very short truck.
1. Roll the load up to the curb and PUSH the control switch to raise the
wheels at least 18 inches.
2. Tilt the load back until the wheels rest on the ground beyond the
curb.
3. With downward pressure on the extension handle PULL the control
switch toward you to raise the load up to the curb level.
To step off a curb, reverse the process. Remember to break the load back
a little further so that the left frame clears the curb. Also, be certain to
extend the load far enough off the curb to allow space for the wheels to
be lowered behind the load.
B. THRESHOLDS
Thresholds are handled in a similar fashion. The loaded Ultra Lift is backed
up to the threshold:
1. PUSH the control switch to raise the wheels at least 18 inches and as much
as 36 inches beyond the threshold.
2. Tilt the load back until the wheels rest on the floor beyond the threshold.
3. Push down on the extension handle to move the load off the ground while
PULLING the control switch towards you to pull the wheels over the
threshold without allowing the load to hit the threshold.
C. OTHER OBSTACLES
Broken pavement, depressions, bumps, and icy patches can be stepped over
in a similar fashion. You can either power the wheels over the obstacle and
bring the load on behind or extend the load over the obstacle and bring the
wheels along behind the load.
-12-

VIII. MECHANICS OF OPERATION
Your ULTRA LIFT consists of two primary structural members, a drive
system, and an electrical system.
Figure 20. Side View: 4 Wheel Dolly Assembled
Figure 21. Front View: 2 Wheel Dolly Configuration
-13-

A. MAIN FRAME ASSEMBLY
The Main Frame is of welded aluminum construction and all components,
except the Lift Frame and strap bar, are attached directly to it.
1. Frame Extension Handle. As shown in Figure 21, the handle fits through
brackets welded to the top of the main frame and is held in place by two
lock pins. Remove the pins to raise or lower the handle and vary overall
machine height from 62” (for working in tight quarters) to 72” for extra
leverage and control of tall, heavy loads. The adjustable extension handle
makes Ultra Lift a “one size fits all” powered hand truck.
2. Fold Out 4 Wheel Dolly. As shown in Figure 20, the dolly is a tripod
attachment that swings out from the Main Frame and locks to the leverage
bar to form a 4 Wheel Dolly. The assembly procedure takes just seconds:
•Release the leverage bar from its stored position
by removing the lock pin that holds it in place.
•Release the tripod legs by turning the swivel lock
that holds the tripod against the main frame.
•Swing the tripod and leverage bar together so that
the holes in the tripod legs align with the leverage
bar tubes. Slide the large lock pins through the
tubes and into the tripod legs to lock the dolly
assembly together.
To dissemble the 4 Wheel Dolly, set the load down in a balanced position with
the caster wheels off the ground and reverse the above procedure.
3. Drive System. Described in detail below, all components of the drive
system are mounted on the Main Frame and move with it.
4. Electrical System. Described in detail below, all components of the electrical
system are mounted on the Main Frame and move with it.
-14-

B. LIFT FRAME ASSEMBLY
The Lift Frame is of welded aluminum construction and the sides of the frame fit inside
the Main Frame. The Drive Screw, which is fixed at top and bottom to the Main
Frame, passes through a device called a ball nut which is bolted o the top cross brace of
the Lift Frame. Rotation of the Drive Screw moves the Lift Frame relative to the Main
Frame via the bearings in the ball nut.
1. Adjustable Strap Bar. The strap bar can be positioned along the Lift Frame as
required for the particular load being moved. Mounting brackets on the back of the
strap bar fit around the inside of the Lift Frame. To move the strap bar (Figure 21),
face the front of the machine and grasp one end firmly in each hand. Pull one end
up while pushing the other down. The strap bar will twist loose and can be moved
to a new location by reversing the procedure.
The strap bar can be adjusted as required if it is either too tight to fit onto the Lift
Frame or is too loose and doesn’t stay in place. To adjust an overly tight fit, lightly
tap each bracket toward the center of the strap bar. To tighten a loose fit, lightly tap
the brackets out. Do this adjustment off the Ultra Lift.
The strap bar serves as a connection point for many Ultra Lift Accessories,
including the Concave Barrel Attachment, Double Cylinder Attachment, File
Handling Attachment, Horizontal Move Assembly, Vertical Move Assembly, and
Set Offs.
An optional second strap bar can be added for increased stability on very bulky or
odd-shaped loads.
-15-

C. DRIVE SYSTEM
The drive is an electromechanical system that is powered by a non-hazardous 12 volt,
deep cycle, spill-proof, sealed battery. As illustrated in Figure 23, the entire drive is
mounted to the Main Frame and moves with it.
Figure 23
1. Drive Motor. The dual direction 1.2 H.P. motor is mounted in the motor housing
at the bottom of the Main Frame. When the control switch is activated, the motor
turns the drive screw.
2. Overload Clutch. Mechanical power is transferred from the motor to the drive
screw via a ball détente type of clutch which protects the drive screw from over-
running in either direction. Over-running occurs when the operator continues
to apply power after the Lift Frame has reached its extreme up or down position
relative to the Main Frame. At such extremes, the clutch will slip and protect the
drive screw. As the clutch begins to slip, a loud warning sound (rachet) will be
heard. Immediately release the power switch.
-16-

The overload clutch is an important Ultra Lift innovation. It is a patented device
that eliminates the bent or damaged drive screws that were a common problem with
earlier powered hand trucks.
3. Stop Collar. The stop collar fits over the drive screw and is held in position just above
the clutch by a set screw. The stop collar limits downward travel of the Lift Frame so
that the clutch can slip in the extreme downward position. Without a stop collar, the
Lift Frame could compress the clutch and limit the slipping action.
4. Ball Nut. As stated previously, the ball nut assembly is bolted to the Lift Frame.
Rotary motion of the drive screw is transformed to vertical frame motion by the ball
bearings in the ball nut.
5. Drive Screw Top Mount. The top mount is bolted to the Main Frame and anchors
the top end of the drive screw to the frame. The aluminum mounting bracket is lined
with a nylon tube to minimize friction as the drive screw rotates.
6. Anti-Reverse Brake. The purpose of the brake is to prevent the weight of the load
from turning the drive screw in the downward direction when power is off. The
Ultra Lift brake is a wrap spring design and does not need adjustment. It is
automatically on when the load is moving downward, but is off when the load is
being raised. The result is that no battery power is wasted overcoming the friction
type of brake that was used in earlier powered hand trucks.
D. ELECTRICAL SYSTEM
The heart of the electrical system is a 12 volt, spill-proof, deep cycle, sealed battery
that powers the motor. All electrical components described below are mounted on the
Main Frame and move with it.
1. Battery. The battery is enclosed in an aluminum housing mounted to the Main Frame.
Since the battery is spill-proof, the Ultra Lift can be laid down flat with no concern
that chemicals will spill and damage either the machine or floor. The deep cycle
battery has been specifically designed to be discharged and recharged for as long
as 1 – 2 years.
-17-

2. Control Switch. Mounted on the top of the main frame, the three-position control
switch directs current through one set of circuits to turn the drive screw one direction
and a second set to reverse rotation. The center position is a neutral or “off”
position. Single switch operation allows the operator to maintain a firm grip on
the extension handle with his or her left hand while gripping the right side main
handle in the right hand and operating the switch with the right thumb.
3. Motor and Solenoids. The 1.2 H.P. motor and four solenoids are mounted in the
motor housing at the base of the main frame. The solenoids are electrical devices
which establish circuits for current flow as the control switch is operated.
4. Charge Level Indicator. A push button on the side of the battery housing allows you
to obtain a direct reading of the charge left in the battery. The charge level meter is
divided into green, yellow, and red zones and when the push button is depressed
the dial will indicate the remaining charge. If the dial is well into the green area,
the battery is well charged. As the dial drops lower into the green and toward the
yellow charging is advisable before attempting any heavy move, particularly if the
move involves stairs. If the dial is in the yellow or red zones, no load should be
moved until the battery is charged or replaced. See Section IX B for battery
charging instructions.
5. Charging Plug. It is not necessary to remove the battery housing cover to charge
the battery. To simplify charging, the battery terminals are wired to a charge
receptacle which is accessible on the side of the battery housing. The battery
charger provided with your Ultra Lift has a hard-wired charging plug that
interfaces with the receptacle in the battery box. See Section IX B.
6. Transit Charging System. To charge your Ultra Lift directly from the 12 volt
system of your vehicle, the most effective technique is to purchase an inverter
that will plug into the vehicle power outlet. Plug the Ultra Lift battery
charger into the inverter. The charge plug on the battery charger then connects
to the Ultra Lift through the receptacle in the battery housing. This system will
not be required at all if you able to charge your Ultra Lift at the end of each
workday, as is recommended.
-18-