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Ultra Lift 1500, Operation Manual

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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 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for 1500

Page 1: ...OPERATION MANUAL the best move you ll ever make Ultra Lift Corporation 475 Stockton Avenue Unit E San Jose CA 94126 800 346 3057 408 287 9400 Fax 408 297 1199 wwww ultralift com info ultralift com ...

Page 2: ...IR 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 An...

Page 3: ...NTAINMENT 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 phys...

Page 4: ...rap 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...

Page 5: ...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 clos...

Page 6: ...hen 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...

Page 7: ...SH 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 po...

Page 8: ... 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 unti...

Page 9: ...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 raise...

Page 10: ...s 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 ...

Page 11: ...e 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 ...

Page 12: ...ir 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...

Page 13: ...tairs 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 downwar...

Page 14: ... 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 f...

Page 15: ...NICS 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 ...

Page 16: ...o 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 t...

Page 17: ...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 ...

Page 18: ...witch 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...

Page 19: ... 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...

Page 20: ... 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 re...

Page 21: ...ed battery capacity and life NOTE Batteries that are in storage must be topped off monthly to prevent crystallization of the electrolyte The charger provided with your Ultra Lift is fully automatic and shuts off complete with the battery is charged It will also automatically turn on again when the battery is discharged This means that the charger can remain connected to the battery indefinitely wi...

Page 22: ...charging plug so that the large curved slot is opposite the large terminal in the charging receptacle Slide the plug straight into the receptacle until it bottoms out Do Not rotate the plug Leave the charger plugged in until you are ready to use the Ultra Lift again DO NOT FORCE THE PLUG 2 When you are ready to use the Ultra Lift pull the charging plug straight out DO NOT FORCE THE PLUG 20 ...

Page 23: ...the drive screw into up and down movement of the frames To minimize drive screw and bearing wear and to reduce drag on the machine it is very important to keep the drive screw properly lubricated In heavy usage situations it is recommended that the drive screw be lubricated at least twice each week Lubricate the screw more often if the machine is being used heavily on stair climbs or in a dusty or...

Page 24: ...s and Axles On a monthly basis extend the Lift Frame and spray Tri Flow around the ends of the axles of all four frame rollers Run the machine up down and up again to disperse the spray c Main Wheels The two main wheels are provided with grease fittings Lubricate each wheel twice per year with lithium grease 2 Rust Prevention When you are required to use your Ultra Lift in rainy weather at the end...

Page 25: ...s for any bending or bulging a Main Frame including Main Handles b Lift Frame c Extension Handle d Leverage Bar e Tripod Assemble Tripod and Leverage Bar into 4 Wheel Dolly position to confirm that they fit properly Confirm that the main wheels and axle are straight 2 Hardware Check to see that all screws nuts and bolts are tight in place Tighten any that are loose and immediately replace any that...

Page 26: ...is observed identify the cause and make necessary repairs before using the Ultra Lift IV ANTI REVERSE BRAKE The anti reverse brake contains two oilite friction bearings and one roller bearing that are subject to wear and will eventually require replacement The procedure for disassembling the brake examining the components and reassembling the brake takes approximately 15 minutes The first brake in...

Page 27: ...T PLATE 27 Wide x 6 Deep STRAP BAR 27 Wide x 3 High STRAP 2 Wide x 14 Long MAIN WHEELS 8 Diameter x 2 5 Wide Dual Sealed Ball Bearings CASTERS 4 Diameter x 1 25 Wide Polyurethane Wheels BATTERY 12 Volt Deep Cycle Spill Proof Permanently Sealed Class U 1 Capacity 33 to 35 Amp Hour DRIVE MOTOR 1 2 Horsepower D C Dual Direction Each Model 1500 is shipped complete with battery one strap bar snap out 4...

Page 28: ... ii ...

Page 29: ...has been damaged by alteration or by service either performed or attempted by anyone other than Ultra Lift Corporation or an authorized Ultra Lift Dealer All warranty service whether provided by an authorized Ultra Lift Dealer or by Ultra Lift Corporation must be approved in advance by Ultra Lift Corporation Contact Ultra Lift Corporation at 800 346 3057 or 408 287 9400 to obtain an authorization ...

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