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PowerPallet User Manual 

Page 

22

 of 

29

 

Errors and Warnings 

The PowerPallet indicates any errors or warnings using the Left and Right LEDs, and the horn. The table 
below lists the various indications and their corresponding descriptions. 

Warning Indication 

Warning 

Description 

Recommended Action 

Left LED flashes GREEN in 

Warehouse Mode or 

YELLOW in Truck Mode 

Attempting to over-

ride safety feature 

Throttle input 

detected with steering 

handle upright or 

horizontal 

See 

Handle Positions for 

Warehouse & Truck Modes

 

Motor stalled for 

longer than 2 seconds 

Insufficient throttle 

input 

Increase throttle rotation 

Insufficient torque to 

move load 

Reduce load on the pallet-

jack 

Parking brake 

engaged 

Disengage parking brake 

before attempting to drive 

Battery too low to 

move load 

Replace battery with fully 

charged battery 

Both LEDs flashing RED 

with no horn beeping 

Belly-Stop active, 

Mode-Button pressed 

but throttle not in 

neutral position 

Machine would 

continue to act as if 

Belly-Stop is active 

To resume operation, return 

throttle to neutral position 

Horn beeps continuously 

Communication loss 

Communication lost 

between the 

controller and throttle 

Remove battery, wait for 15 

seconds, and reconnect 

battery 

Both LEDs flashing 

YELLOW on powering up 

No USB Key 

(optional feature) 

Machine will not 

operate without USB 

flash drive key 

installed 

Power down, insert USB 

flash drive key, and power 

up machine 

Both LEDs blink RED and 

YELLOW alternatively 

No Application 

Firmware 

Machine will not 

function without valid 

software 

Update the device with the 

latest software 

(See 

Firmware Update

 

section) 

Both LEDs blink RED and 

GREEN alternatively 

Update Bootloader 

Horn beeps continuously 

Downhill rolling 

Machine rolling with 

no input from the 

throttle 

-

 

If safe to do so, bring 

unit to a stop, lowering 

the load 

 

-

 

Ensure if within 

operating parameter, if 

not, take machine out of 

service to get it fixed 

 

 

Summary of Contents for PowerPallet 2000

Page 1: ...PowerHandling Inc PowerPallet User Manual Published May 2021...

Page 2: ...tion 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...

Page 3: ...rt 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 bei...

Page 4: ...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...

Page 5: ...n 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 Sett...

Page 6: ...ack 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 Fi...

Page 7: ...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 st...

Page 8: ...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...

Page 9: ...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...

Page 10: ...k 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...

Page 11: ...ols 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 o...

Page 12: ...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 mou...

Page 13: ...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 f...

Page 14: ...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 setti...

Page 15: ...rds 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...

Page 16: ...ation 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 Rig...

Page 17: ...ected 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...

Page 18: ...allation 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...

Page 19: ...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 t...

Page 20: ...k 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 Opti...

Page 21: ...ton 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 If the truck is moving forw...

Page 22: ...ith no horn beeping Belly Stop active Mode Button pressed but throttle not in neutral position Machine would continue to act as if Belly Stop is active To resume operation return throttle to neutral p...

Page 23: ...he typical estimated life of a Lithium Ion battery is about two to three years or 400 to 600 charge cycles whichever occurs first The typical estimated life of a NiMH battery is about one to two years...

Page 24: ...not expose a battery to temperatures above 60 C 140 F Avoid exposing the battery to excessive shock or vibration Do not use a damaged battery If a battery pack has leaking fluids do not touch any flui...

Page 25: ...P 1 Mount one side of the pallet jack and the base unit of the PowerPallet over a pallet Make sure the drive arm is not resting on the pallet and the drive wheel is off the ground STEP 2 Cut and remov...

Page 26: ...er and reinstall a new plastic cable tie Replacement Parts Contact Sales Support for replacement parts and procedure for replacement USB Flash Drive Key Optional Feature The PowerPallet can be program...

Page 27: ...rocess Note If the USB Flash Drive Key feature is used the Firmware Settings Update Process can be skipped Just change the text file pp_key txt on the flash drive to the desired settings and power up...

Page 28: ...pallet jack Is the drive wheel off the ground Adjust the screw jack to lower the drive wheel Is the drive wheel slipping on the ground while the pallet jack wheels are in contact with the ground Is t...

Page 29: ...eyond the scope of this Warranty The repair or replacement of the said unit constitutes the limit of PowerHandling s liability to the customer and PowerHandling specifically disclaims and excludes res...

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