Motorized Hand Truck Owner’s Manual Important Startup Instructions 1. Read the Owners Manual thoroughly before first use. 2. Charge the Motorized Hand Truck for six hours before using it for the first time. If the battery completely discharges, recharging may take up to 18 hours. See pages 5-7 for battery and charging information. Date of Purchase: ________________________ 1 1-800-MAGLINE (624-5463) www.magliner.
Table of Contents General Safety Instructions........................................................................................................ 3 Startup Instructions..................................................................................................................... 3 Motorized Hand Truck................................................................................................................. 4 Battery Information.................................................................
Thank you for your purchase! If you have any questions regarding your new Magliner product please call our customer service department at 1-800-MAGLINE (624-5463) or (989) 5121000. Please read this manual thoroughly to become familiar with the safe operation and maintenance of your new Motorized Hand Truck. General Safety Instructions • Inspect before each use for damaged and loose fasteners/connections. • Inspect the unit for cracks, wear or damage.
Motorized Hand Truck Handle Front Attachment Release Front Attachment Rear Stabilizer Arm Battery Box Motor brake (free-wheel) lever Wheel and Tire Assembly High-Low Speed Switch Charge Port On/Off Switch Throttle/Speed Control 4 1-800-MAGLINE (624-5463) www.magliner.
Battery The battery must be charged for a minimum of six hours before using it the first time. If the battery completely discharges, recharging may take up to 18 hours. When not in use, it is recommended to keep the battery plugged in to maintain a maximum charge and extend the battery life. The charger will not overcharge the batteries. General Battery Warnings • Do not connect accessories to the battery; this will cause premature battery failure.
Battery Life The Motorized Hand Truck is powered by a 36V system using three 12V batteries connected in series.* A fully-charged battery pack will last at least one typical day; however, extreme temperature ranges and extreme loads can have an effect on the amount of power available during one charging cycle. You will know that your batteries need replacing when you notice diminished range or operational time.
Charging the Battery The Motorized Hand Truck is provided with an off-board 36V charger. To charge the machine, plug one end of the charger into a 110V wall outlet, and the other end into charger port. An LED light on the charger will blink (or turn amber or red) while the unit is charging. When the unit is completely charged, the light will turn solid green. For optimum performance, charge in temperatures from 50100 degrees F.
Changing Front Attachment The quick attach feature that permits the easy and quick exchange of application specific tools. It requires no pins, bolts, or any other fastener, and no special tools. The diagram below shows how it works. Tool attached and locked Lean truck forward and pull release handle to remove Tool released REVERSE THIS PROCESS TO ATTACH NEXT ATTACHMENT Squeeze upward to release attachment Release Lever 8 1-800-MAGLINE (624-5463) www.magliner.
Rear Stabilizer Arm The rear stabilizer arm supports the hand truck in the incline position for ease of use. The stabilizer arm has two positions – stowed and deployed. In the stowed position, the stabilizer arm is folded up into the frame of the hand truck to minimize the overall footprint. In the deployed position, the stabilizer arm is folded down so that the load is carried on the two drive wheels and on the rear caster wheel as well.
Motorized Hand Truck Drive System Automatic Electronic Braking The drive system features regenerative braking by which the electronic controller uses the motor to slow down the machine in both forward and reverse directions. To slow down the machine, reduce throttle input, or release the throttle lever, and the machine will brake to a stop. While driving downhill, this feature allows direct control over the speed of the machine, as long as the load on the machine does not exceed the design parameters.
Reverse Operation While operating the Hand Truck in reverse, DO NOT stand behind the unit driving it toward you looking over your shoulder. The proper way to operate the unit in reverse is to STAND BESIDE THE UNIT. Correct Incorrect Storage and Transportation The Hand Truck can be stored in any position as the batteries are sealed and there are no fluids to leak out. The most common (and suggested) storage orientation is unloaded (empty) sitting on its three wheels and placed on charge.
Pre-Trip Inspection 1. Before each use, check for damaged or missing components. Replace damaged or missing components immediately with Magliner replacement parts. 2. Check all fasteners, and make sure to tighten or replace loose or missing hardware. 3. Check welds and material near welds for cracking or damage. 4. Make sure that pneumatic tires are properly inflated to 20-25 psi. 5. Unplug the charger from the hand truck by carefully pulling the connector out of the charger port in the throttle.
Using the Motorized Hand Truck On/Off Switch 1. Turn the rocker switch to ON position. 2. If the switch is left on for approximately 20 minutes without use, the controller goes into a power save mode (sleep mode). 3. To wake the controller, cycle the rocker switch to the off position for 2 seconds, and then back to the on position.
Considerations When Using Propulsion • Always operate the Hand Truck only as fast as safety considerations allow. • When turning tight corners, keep the unit close to the turn in the direction of travel; for example, when turning right, keep the unit close to the turn on the right. When turning left, keep the unit close to the turn on the left. • Use extra caution when moving loads on ramps or moving loads in reverse as described on page 11. • While unattended, turn the unit off.
Preventative Maintenance Area Inspection Frequency Drive Wheels Daily Fasteners Daily Battery Charging Daily Casters Daily Transaxle Daily Procedure/Normal Condition Inspect wheels and tires for wear and cracks. Keep pneumatic tires inflated to 20-25 psi. Tighten any loose hardware. Red, amber or green charging light should turn on when charging. Inspect for wear; clean dirt and debris. Transaxle should be kept free and clear of debris.
Troubleshooting Problem Motor does not run Possible Causes Power switch in OFF position Turn switch to ON position Controller in sleep mode Cycle switch, OFF 2 sec, then ON Batteries are drained Recharge batteries Motor brake lever released on drive system Re-engage motor brake on drive system Electrical fault Unplug, then plug in both motor and throttle connectors Circuit breaker has tripped Motor shuts off during use/abruptly stops Insufficient range Machine slows down aggressively while in
NOTES 17 1-800-MAGLINE (624-5463) www.magliner.
NOTES 18 1-800-MAGLINE (624-5463) www.magliner.
MAGLINE® INC. 1205 West Cedar Street Standish, Michigan 48658 1-800-MAGLINE (624-5463) Email: customerservice@magliner.com www.magliner.com B9399 19 1-800-MAGLINE (624-5463) ©2018 Magline, Inc. www.magliner.
36V Battery Pack – Battery Change Instructions . Battery Specs: 12 Volt, 12 Amp-hour lead acid sealed, Type AGM Magline part number 61075 1. Remove battery pack from machine and set on hard level surface with clear cover facing up. 2. Remove the four corner screws that hold the clear cover on, and slide the cover off. 3. Remove the four screws that hold the battery pack end cap OPPOSITE battery box connector bracket, and set it aside. 4.
Magline, Inc. • 1205 West Cedar Street • Standish, MI 48658 Phone: (989) 512.1000 • Fax (800) 968.7504 • Toll Free (800) MAGLINE (624-5463) www.magliner.
36V Battery Box Inspection and Troubleshooting If the battery range on your 36V Motorized Hand Truck or Motorized Dewar Cart is diminished or if it is not working at all, there is most likely a problem with the batteries and/or recharging function. It is typically one of three issues: 1. The batteries are old and need to be replaced – see battery replacement manual. The typical life is 12-14 months for a set of batteries 2.
STEP 2 – Determine System Voltage at Battery Pack Charge Port: Motorized Dewar Cart – Remove Right Side Panel (standing behind the machine facing forward) Motorized Hand Truck – Open Battery Pack Access Door Take the battery box out of the machine, and connect the meter to the battery box charger port the same way as you did on the throttle. Again, you should be reading 33 to 38 volts. If you are reading 33 to 38 volts, try recharging the battery pack off the machine for a few hours and retest.
The battery box control fuse is housed in a small yellow housing and can be inspected by removing the battery box connection bracket as shown: Remove these two screws Battery Box Connection Bracket Check the 6-Amp fuse that is connected to charge port. If the 6-Amp fuse is blown, replace it and re assemble. If not blown, proceed to STEP 3 Magline, Inc. • 1205 West Cedar Street • Standish, MI 48658 Phone: (989) 512.1000 • Fax (800) 968.7504 • Toll Free (800) MAGLINE (624-5463) www.magliner.
STEP 3: Check In Line Fuse Circuit on the Machine Motorized Dewar Cart – Remove Left Side Panel (standing behind the machine facing forward) Motorized Hand Truck – Remove Left Side Panel (standing behind machine facing forward) Look for yellow in line fuse (Dewar Cart Only) 2-Pin Molex Connector – spare – do not plug in. Tip: Unplugging both connectors makes it easier to check fuse – just remember to plug them back in after! 14-Pin Molex Connector. 4-Pin Molex Connector.
Control Fuse Check - Detailed Instructions 6-Amp Control fuse holder We suggest you unplug the 14-pin and 4-pin connectors from the controller to make it easier to access the fuse holder. 6-Amp Control fuse Gently pull the fuse holder apart as shown. Note that end with the black wire tie is designed to say in place tied to the cable. Gently pull the fuse itself out of the holder and examine it. The fuse shown here is a new, working fuse. The small zig zag wire is complete all the way across the fuse.
36V BATTERY CHARGER TROUBLE SHOOTING Background: To prevent damage to the battery charger, it is recommended that you do not put it on-board the machine. Follow the steps below to determine if there is a issue with your battery charger. Normal Operation: 1. When the charger is plugged in, there a red and green light that remain on and solid. If no light is visible with the charger plugged in, it has failed and you will need to call Magline. 2.
MEASURE CHARGER VOLTAGE Make sure charger is NOT plugged into the wall outlet or the machine. PIN 1 Carefully attach the red lead from the volt meter to pin 1. Then attach the black lead to pin 2. It is best to use insulated alligator clips because if the red lead (+40VDC touches the metal housing of the charger port, it will short the charger and destroy it. PIN 2 PIN 3 RED ON PIN 1 Once the leads are securely in place, then plug in the charger and measure the voltage.
