Powermate Aluminum LE Series Operating Manual Download | Manualshive

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PowerMate

®

Operation Manual

WARNING

Failure to obey the Instructions and Safety
rules in this manual could result in death or
serious injury.

Read the Operating Manual completely.
Only competent, trained operators may use
this equipment.
Training is essential to understanding all
the features and capabilities of your
PowerMate, and ensure good safe work
practices

.

Training courses are available through

L P INTERNATIONAL INC., please call

1-800-697-6283

PN 013100 Rev.D2

Eng. 12/ 12/ 12

1.01

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Summary of Contents for Aluminum LE Series

Page 1: ...T20 030 07 For Serial Numbers 34000 and higher PN 013900 Rev D2 PN 339570 Rev D2 Eng 12 12 12 ...

Page 2: ...LE 2 Screw Assembly LE 2 Carriage Brake Assembly Kit Bearing Override Kit Section 5 Maintenance Maintenance After Every Year of Operation Procedure for Repairing Drive Screw Assembly Override Bearing Assembly Drive Screw Removal and Installation Procedure to Reassemble Machine Ballnut Removal and Replacement Installation of Sealed Batteries Bottom Rubber Guard Replacement Switch Charge Plug Replac...

Page 3: ...Read the Operating Manual completely Only competent trained operators may use this equipment Training is essential to understanding all the features and capabilities of your PowerMate and ensure good safe work practices Training courses are available through L P INTERNATIONAL INC please call 1 800 697 6283 PN 013100 Rev D2 Eng 12 12 12 1 01 ...

Page 4: ...r Wheel Brakes Optional Equipment Barrel Attachment Extended Depth or Width Toe Plate Hot Water Tank Attachment Cylinder Attachment WARNING The use of this equipment with any options other than those specified in this manual may create a hazard The PowerMate Model LE 1 is a motorized electric hand truck used for the safe movement of heavy and awkward loads It can move loads up and down stairs on a...

Page 5: ...ions Follow the General Safety Rules Strapbars Adjust the location of the strapbars Adjust tighten and release the straps Stow loose strapping when not in use Flat Surface Raise the wheels to incline the load back Reposition the load in balance over the wheels Move over obstacles on the floor Bring the load back to an upright position Stairclimbing Position the wheels and heelplate on a stair Clim...

Page 6: ...h if not avoided will result in death or serious injury Safety Alert Symbol This symbol indicates a potential personal injury hazard Safety information following this symbol must be followed to avoid possible injury or death HAZARD GRAPHICAL SYMBOLS SAFETY LABEL MAINTENANCE Safety of the operator and surrounding environment must be considered at all times To that end safety labelling on the PowerM...

Page 7: ...CK 057030A 1 8 WARNING DECAL KEEP OFF 057050A 1 9 WARNING DECAL CRUSH HAZARD FOOT PICTOGRAM 057140A 4 10 WARNING DECAL SCREW GUARD 057070A 1 11 WARNING DECAL ROTATING SHAFT HAIR Large 057110A 1 12 WARNING DECAL ROTATING SHAFT HAIR PICTOGRAM 057130A 1 13 WARNING DECAL PINCH POINT HAZARD 057090A 1 14 WARNING DECAL ROTATING SHAFT PICTOGRAM 057100A 1 15 DECAL SAFETY INSTRUCTION LS 057190A 1 16 DECAL F...

Page 8: ...057030A 1 7 WARNING LABEL CRUSH FOOT PICTOGRAM 057140A 4 8 WARNING DECAL SCREW GUARD 057070A 1 9 WARNING DECAL PINCH POINT HAZARD 057090A 1 10 WARNING DECAL MOVING PARTS Large 057060A 1 11 WARNING DECAL KEEP OFF 057050A 1 12 DECAL SAFETY INSTRUCTION LS 057190A 1 13 DECAL FAULT ALERTS 057160A 1 14 DECAL FUSE 10 AMPS 057170A 1 15 DECAL CIRCUIT BREAKER PRESS OFF 057150A 1 16 DECAL ROTARY SWITCH 05718...

Page 9: ... are required at all times WARNING Only trained personnel shall operate PowerMate equipment Failure to comply may result in possible severe injury to the operator and or others and damage and or loss of property Wear safety shoes Keep hair loose clothing fingers and all parts of the body away from pinch points and moving rotating parts Use equipment handles and controls for manoeuvring and operati...

Page 10: ...onsiderations etc Always use the recommended number of operators for a load Check the work site Inspect the area to be traversed with the PowerMate unit Avoid debris rough surfaces pot holes bumps steep grades etc Avoid spills of any kind slippery surfaces soft ground and standing water Observe any condition that may cause loss of control of the PowerMate unit leading to injury and or property dam...

Page 11: ...means of securing the equipment to the bed or bodies of vehicles and rails wall brackets etc Operators shall determine the balance of unfamiliar loads prior moving the load Work performed in a balanced condition is done easier and safer New operators should gain practice experience with lighter loads of approximately 250 lbs with a medium center of gravity before progressing to heavier loads Do no...

Page 12: ...e sides of a battery with any spark producing item Make sure work area is well ventilated Never touch both battery terminals with bare hands at the same time Remove rings watches and dangling jewelry when working with batteries The metal in the jewelry can cause a shock and burns if contacted with the battery terminals Only use insulated non conducting tools when making connections on a battery Ne...

Page 13: ...t least equal to that of the charger Cords rated for less amperage than the charger may overheat Ensure the pins of the extension cord plug are the same number size shape as those on the charger Ensure the extension cord is wired properly and in good condition CAUTION Position the charger and charger cords so that it is not tripped over pulled or placed in contact with heated surfaces Route charge...

Page 14: ...ulling the plug not the cord Do not handle the plug with wet hands Unplug the charger when not in use CHARGING SAFETY INSTRUCTIONS continued 12V IN VEHICLE CHARGER WARNING The In vehicle charger cannot protect against vehicle damage caused by faults in the wiring from the vehicle battery to the charger or faults in any other portion of the vehicle wiring harness The user must ensure that the wirin...

Page 15: ...ge the Charger Plug from the Receptacle by using a slight counter clockwise turn and pull 5 The PowerMate can be re activated for use by moving the Circuit Breaker Toggle to the on up position and moving the Control Toggle Switch to the I On position NOTE The PowerMate can remain on the Battery Charger at all times ensuring a fully charged unit when called upon In any case the Circuit Breaker Togg...

Page 16: ...ocation can be moved safely complete the following three steps 1 Determine the weight of your load in pounds lbs 2 Establish where the weight is concentrated in the load This center of gravity location is measured in inches in and is determined by A The distance forward from the back of the load B The distance up from the bottom of the load 3 On the Load Recommendation Chart locate center of gravi...

Page 17: ...kg 150 lbs 68 kgs 150 lbs 68 kgs 150 lbs 68 kg 200 lbs 91 kgs 200 lbs 91 kgs 200 lbs 91 kg 150 lbs 68 kgs 200 lbs 90 kgs 250 lbs 114 kg 200 lbs 92 kgs 250 lbs 114 kgs 350 lbs 159 kg 400 lbs 182 kgs 500 lbs 227 kgs 600 lbs 272 kg 500 lbs 227 kgs 600 lbs 272 kgs 700 lbs 318 kg 400 lbs 182 kgs 500 lbs 227 kgs 600 lbs 272 kg 150 lbs 68 kgs 250 lbs 113 kgs 450 lbs 204 kg 150 lbs 68 kgs 150 lbs 68 kgs 1...

Page 18: ...ock Set the main frame wheel brakes See Diagram B 4 Jog the right hand side of the center rocker switch Load Up to raise the load carriage to a more balanced position ahead of the main frame wheels 5 Pivot the equipment backwards on the main frame wheels to raise the heelplate off of the ground 6 Jog the right hand pushbutton thumb switch Load Up to partially raise the load See Diagram C 7 Jog the...

Page 19: ...ame wheels See Diagram D 5 Alternate between steps 3 4 to lower the heelplate to the ground out from the rear of the vehicle or the base of the dock See Diagram C This will provide clearance for the main frame wheels when they are lowered 6 Push the left side of the center rocker switch Load Down to lower the load carriage to the ground See Diagram B 7 Pivot the equipment forward on the heelplate ...

Page 20: ...ing securely on the second step Set the main frame wheel brakes 4 Jog the right side of the center rocker switch Load Up to raise the load carriage to a more balanced position ahead of the main frame wheels See Diagram B 5 Pivot the equipment backwards on the main frame wheels to raise the heelplate off of the ground Jog the right hand pushbutton thumb switch Load Up to raise the load until the he...

Page 21: ...e wheels 4 Jog the left hand pushbutton thumb switch Load Down to lower the load until the heelplate is resting securely on the second step down See Diagram E 5 Pivot the equipment forward on the heelplate just enough to clear the main frame wheels Jog the right had pushbutton thumb switch Load Up to lower the main frame wheels to the first step down See Diagram F 6 Pivot the equipment backward on...

Page 22: ...The 12 volt DC battery system is maintenance free and sealed The gelled electrolyte inside the battery requires no maintenance whatsoever throughout its life DO NOT ATTEMPT TO OPEN THESE BATTERIES The best battery life and equipment performance will be attained by keeping the battery fully charged The equipment has a small female battery charging receptacle located near the control handles This re...

Page 23: ...ONENT DRAWING 31 33 17 17 32 15 16 18 1 36 1 46 47 48 36 2 51 37 50 39 38 43 42 41 40 40 44 52 49 35 34 23 20 19 12 10 11 10 10 10 5 8 22 2 4 24 13 29 6 8 9 3 3 7 22 27 25 28 14 21 26 30 45 PN 013500 Rev D2 1st sheet of 013500 Eng 12 12 12 4 01 ...

Page 24: ...CK SUBASSY LS 336053 24 FUSE 10 AMP AGC 051705 25 BUZZER ASSEMBLY 301522 26 MOTOR ASSEMBLY L SERIES White 315610D 27 STOP PEDAL PF 310366 28 BATTERY PACK SUB ASSEMBLY LS RH 316054 29 HANDLE HOUSING LE 130050 30 HANDLE GRIP LS 055310 31 FLANGE TWIST LOCK PLASTIC 050380 32 SWITCH ROCKER DPDT 6 TERMINAL 060220 33 WIRE ASSEMBLY MOTOR RED 317122 1 88 BOTTOM RUBBER GUARD 410060 34 TOEPLATE LE 230150 35 ...

Page 25: ...erMate Operation Manual A 61 57 62 48 48 43 60 42 41 46 45 44 24 25 36 34 32 33 32 31 30 27 26 56 22 58 50 6 59 2 7 3 6 19 11 21 17 16 1 15 14 13 12 20 18 10 4 8 9 39 54 52 40 28 47 22 35 51 5 40 44 55 47 23 49 38 37 35 29 26 27 4 03 PN 013500 Rev D2 EC 1st sheet of 013500 EC Eng 12 12 12 ...

Page 26: ...PLING PF 29 1 335570 WHEEL BRAKE CONTROL PF LH 30 1 335580 WHEEL BRAKE CONTROL PF RH 31 1 335530 AXLE WHEEL 8 SOLID PF LE PARTS LIST ITEM QT PART No DESCRIPTION 32 8 050060 WASHER 3 4 SAE 33 2 051320 WHEEL 8 CAST SPOKE 34 2 050110 COTTER PIN 1 8 x 1 ZINC 35 1 130580 HANDLE WHEEL BRAKE LE 1 36 1 335480 BRAKE HANDLE GUIDE PF LE 37 1 060101 SPRING WHEEL BRAKE LE 3 00 SOFT 38 1 060100 SPRING WHEEL BRA...

Page 27: ...SCREW 052090 15 SET SCREW 1 4 20NC x 5 16 050550 16 BALLNUT BRACKET 310250 17 WASHER DISC SPRING 5 8 050830 18 BALLNUT 5 8 050170 19 DRIVE SCREW 5 8 102040 20 WASHER 5 8 051850 21 COUPLING 300840 22 BOLT 1 4 20NC x 1 1 2 050640 23 LOCK NUT 1 4 20NC 050610 24 PLATE WASHER 1 2 055640 25 LOAD LOCKING SPRING 050171 26 LOAD LOCK PIN 102045 27 C A B Pin Brake Washer 6 to Drive Screw 20 with Roll Pin 7 P...

Page 28: ...ET SCREW 1 4 20NC x 5 16 050550 16 BALLNUT BRACKET ALUMINUM 310250 17 WASHER DISC SPRING 5 8 050830 18 BALLNUT 5 8 SQUARE 050170 19 DRIVE SCREW 5 8 x 41 437 110220 20 WASHER 5 8 SAE ZINC 051850 21 COUPLING PAINT FINAL 300840 22 BOLT 1 4 20NC x 1 1 2 HH GR5 ZINC 050640 23 NUT 1 4 20 RING LOCK ZINC 050610 24 WASHER 1 2 PLATE 1 3 8 LS 055640 25 SPRING LOAD LOCKING 050171 26 PIN LOAD LOCK 102045 27 Ba...

Page 29: ...PLATE ZINC 050040 2 13 URETHANE BUMPER 1 2 L x 5 8 ID 100700 2 14 BALLNUT LOCKNUT 5 8 DRIVE SCREW 052090 1 15 SET SCREW 1 4 20NC x 5 16 050550 2 16 BALLNUT BRACKET ALUMINUM 310250 1 17 WASHER DISC SPRING 5 8 050830 1 18 BALLNUT 5 8 SQUARE 050170 1 19 DRIVE SCREW 5 8 x 39 15 16 110222 1 20 WASHER 5 8 SAE ZINC 051850 1 21 COUPLING PAINT FINAL 300840 1 22 BOLT 1 4 20NC x 1 1 2 HH GR5 ZINC 050640 2 23...

Page 30: ...050810 WASHER TOP BRAKE DRIVE 1 050820 WASHER THRUST BRONZE 060 4 050840 WASHER BOTTOM BRAKE DRIVE 1 050850 WASHER THRUST STEEL 1 2 x 060 1 050920 ROLL PIN SPIROL 3 16 x 1 1 8 1 051680 WASHER RETAINER 1 150940 BALLNUT ARBOR 1 050174 SPRING CLIP ARBOR 2 050175 050175 050174 050840 050140 050840 150940 050800 051680 050820 050810 050810 050850 050840 050920 050840 050175 050120 PN 013590 Rev D2 Eng ...

Page 31: ...ZINC 2 050040 BEARING THRUST STEEL 1 050120 WASHER DISC SPRING 5 8 1 050830 WASHER THRUST STEEL 1 2 x 060 2 050920 URETHANE BUMPER 1 2 L x 5 8 ID 1 100700 CARDBOARD ARBOR 1 050174 SPRING CLIP ARBOR 2 050175 050175 050174 050120 050175 050040 050830 100700 050040 050920 050920 PN 013600 Rev D2 Eng 12 12 12 4 09 ...

Page 32: ...t or frayed and that the strap locking handles are secure 6 Remove the drive screws as outlined under Drive Screw Removal and Installation Clean the drive screws and ballnuts Do not remove the ballnuts from the drive screws 7 Check for a close running fit between the drive screws and the ballnuts There should be no wobble or excessive clearance and the ballnuts should run smoothly and freely There...

Page 33: ...ed and competent service person Use only approved repair parts any others may create a hazard PowerMate Operation Manual MAINTENANCE AFTER EVERY 25 HOURS OF OPERATION 1 Remove the front drive screw guard Extend the main frames fully Clean and lubricate the two drive screws with light machine oil Replace the drivescrew guard 2 Check that the two ballnut locknuts are properly adjusted as outlined el...

Page 34: ...ng it off the top of the machine NOTE The Screw assemblies for the Load Carriage and the stairclimber on both the LE 1 and the LE 2 are all the same except for the Screw length only on the LE 2 Load Carriage Screw Assembly BRAKE ASSEMBLY REPLACEMENT 1 With reference to the Screw Assembly drawing for the particular model remove the two bolts item 23 and nuts item 24 Proceed to remove the brake cap ...

Page 35: ... bearing assembly as outlined in the Override Bearing Assembly procedure 3 Apply a band of tape around the drive screw 20 at each end of the ballnut 19 This will prevent the ballnut from disengaging the drive screw until the appropriate time The set screws 16 in the ballnut locknut 15 may be loosened and the locknut removed Pass the screw out through the ballnut bracket 17 and remove the spring di...

Page 36: ...allnut 19 is positioned approximately halfway along the drive screw 20 Slide the load carriage frame over the carriage inner frame from the handle end 7 Grip the drive screw 20 and rotate to engage the coupling 22 with the spline on the load carriage motor The bearing retainer can now be fastened to the carriage inner frame with bolts 23 and nuts 24 8 Reset the circuit breaker and operate 9 Adjust...

Page 37: ... and slide the ballnut up onto the cardboard arbor Attach spring clips to both ends of the arbor to retain the ballnut 6 To install a ballnut the reverse happens Rem ove the spring clip from the cardboard arbor on the square end of the ballnut Be sure the arbor does not disengage the arbor or all the balls in the ballnut will fall out 7 Place the end of the arbor firm ly centered and square onto t...

Page 38: ...tall 1 Styrofoam Packing between Batteries and Battery Box ends 10 Connect Red Positive Wires to the Circuit Breaker bottom LOAD post 11 Connect Black Negative Wires to the Controller Negative tangs on the circuit board 12 Replace axle wheels brake linkages and Battery Box Cover 13 Re install Fuse place the Circuit Breaker Switch in the up connect position and test unit NOTE Lead acid batteries ar...

Page 39: ...ign the holes of the new Rubber Guard and the Toeplate 4 Apply the two 2 C Clamps either side of the center hole leaving room to apply a Washer 5 Insert a Carriage Bolt and Washer through the center hole as shown and place a Washer on the exposed thread Applying thumb pressure to the head of the Bolt start the 1 4 Nut onto the thread Remove the C Clamps and tighten the 1 4 Nut with the 7 16 wrench...

Page 40: ...o the new Rocker Switch in correct order 5 If the charge plug Item 13 requires replacement remove the two 6 32NC nuts and screws Item 12 and pull out the charge plug with wires 6 Transfer wires from the charge plug to the replacement charge plug maintaining wire placement Reinstall the plug into the Handle Housing insert the two 6 32NC Screws and secure with the two 6 32NC Nuts 7 Transfer the wire...

Page 41: ...2 x 23 101960 1 10 BOLT 1 4 20 x 7 8 CARRIAGE ZINC 050740 4 11 R STRAPBAR ASSEMBLY L SERIES TOOLS REQUIRED 7 16 Wrench 5 16 Flat Screw Driver Aluminum Strapbar 1 4 Locknut Replacement Strap and Toggle 1 4 Locknut 1 1 4 Plate Washer 2 1 4 20NC x 1 1 4 Pan Head Screw 2 1 4 Plate Washer REPLACEMENT STRAP INSTALLATION 11 12 6 3 2 4 6 9 5 4 7 8 1 PN 013640 Rev D2 Eng 12 12 12 NOTE Head of screws must b...

Page 42: ...Circuit Breaker Stair Climber Motor Stacker Motor X Terminal These wires pass thru the left wire channel These wires pass thru the right wire channel Buzzer Buzzer Stacker Controller Bottom Stair Climber Controller Top LH Battery 12V 10AH Sealed Dryfit Pack No 316053 Center Battery 12V 6A Sealed Dryfit Pack No 336053 RH Battery 12V 10AH Sealed Dryfit Pack No 316054 PN 013690 Rev D2 Eng 12 12 12 10...

Page 43: ... LH Battery 12V 10AH Sealed Dryfit Pack No 316053 RH Battery 12V 10AH Sealed Dryfit Pack No 316054 Center Battery 12V 6A Sealed Dryfit Pack No 336053 Circuit Breaker Stair Climber Motor Stacker Motor X Terminal These wires pass thru the left wire channel These wires pass thru the right wire channel Buzzer Buzzer Stacker Controller Stair Climber Controller SWITCH BATTERY DISCONNECT Fuse 10A 5 12 PN...

Page 44: ... E S E R IE S S P E C IF IC A T IO N S C E M o d e l L E 1 L E 2 W e ig h t 7 8 5 kg s 7 5 0 kg s H e ig h t 1 5 m 1 2 9 m W id th 6 1 m S tr a p b a r W id th 6 2 m L e n g th 5 0 m B a lls c r e w 1 5 8 8 m m S tr o k e L e n g th 1 0 2 m 8 6 m E x te n s io n S p e e d 1 2 7 m m p e r s e c no lo ad L o a d C a p a c ity S ta ir C lim b in g 2 7 2 kg s 2 7 2 kg s D o c k V e h ic le L o a d in ...

Page 45: ...n time 25 30sec exceeded Release and re apply switch Two Beeps Low Battery Recharge Battery Three Beeps Battery or Battery shorted to frame HALT USE AND RETURN FOR REPAIR System Fault FAULTY UNIT HALT USE AND RETURN FOR REPAIR Four Beeps Overheating due to excessive use many minutes Allow five minutes to cool Reduced peak current reduces power loss in batteries motor and cabling Reduced peak curre...

Page 46: ...0 version of dryfit batteries good cyclic capability At 100 discharge up to discharge cut off voltage of 1 75 Volts cell more than 200 cycles can be obtained Considerably more cycles are possible with partial discharges DIN 57510 VDE 0510 Rechargeable batteries and battery systems stationary batteries Long life Under continuous charge operation the life is 4 5 years end of life being defined as wh...

Page 47: ...uous In order to ensure maximum performance of the charger the following wire sizes are recommended Attach a 1 4 Male Terminal Disconnect to the negative Gnd wire and a 1 4 Female Terminal Disconnect to the positive wire Slip on a piece of Heat Shrink Tubing provided over the lead in connections and connect the lead in wires to the mating charger input wires Slide the Heat Shrink Tubing over the c...

Page 48: ...Mate LE 1 wheels to pass between Step 3 Extend PowerMate approx 30 Step 4 Tip loaded PowerMate back so that its wheels nest in wheel cradles on the RT Cart Attachment NOTE Load must be secure to the PowerMate with strap prior to placing the unit on the RT Cart Attachment Step 5 Thread 1 2 bolts finger tight to engage inside rim of the PowerMate wheels Typ both sides PowerMate Wheel PN 013730 Rev D...

Page 49: ...AT ASSEMBLY Available in two sizes the Pivot Pad is made of durable material which allows you to turn the PowerMate with it s load on a dime Move your loads effortlessly around tight corners while protecting your customer s property Pivot Pad 24 wide x 30 l ong x 1 4 thick Mat Assembly 28 wide x 44 long x 1 4 thick 430900 ROUGH TERRAIN CART LE 1 Perfect for moving heavy loads across gravel grass m...

Page 50: ...tic shut off Safe to leave plugged into the PowerMate at all times Will not overcharge the battery PowerMate ACCESSORIES SPARE PARTS FOR LE SERIES MODELS PowerMate Operation Manual L P INTERNATIONAL INC P O Box 696 151 Savannah Oaks Dr Brantford ON N3T 5P9 TEL 519 759 3292 FAX 519 759 3298 1 800 697 6283 www powermate info For LE Series Units Ser No 30550 and higher PN 013930 Rev D2 Eng 12 12 12 8...

Page 51: ...rom date of purchase when given normal use and maintenance in accordance with operation manual The above warranty will apply only to the original purchaser L P INTERNATIONAL INC do not hold themselves responsible for any damage caused by atmospheric or chemical influences nor defects due to unskilled operation lack of maintenance and use of unprescribed lubricants Neither do they accept responsibi...

Page 52: ...INTENTIONALLY BLANK ...

Page 53: ...el Serial conforms to the protection requirements of Council directive 2006 42 EC Machinery Directive 2004 108 EC Electromagnetic Compatibility Directive on the approximation of the laws of the Member States relating to machinery directive and electromagnetic compatibility STANDARDS including Annex 1 of 2006 42 EC and 4 Lifting NAME L Jeavons TITLE General Manager SIGNATURE S01 007 01 ...

Page 54: ...cceptable Inspect the push button switches and rocker switch for condition and operation Make sure the wiring is secure Test the circuit breaker for operation Cycle the unit testing for operation direction and smoothness Observe the roller operation in the outer frame rails Oil rollers as required Inspect the drive screws and ballnuts for damage bending during operation and lubrication Ensure the ...

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