Instructions Upon Receipt of Goods - Receipt, Checking for Damage and Unpacking

Please note if there is any noticeable damage to the exterior packaging and if so, immediately inform UMS / PowerHandling of the damage. If possible also take digital photos of the damaged box and email them to sales@ums.net.au

If there is no physical damage to the outside packaging, please place the box on the ground or worktable with the “THIS WAY UP” arrows pointing up and open from the top. Remove the top formed-foam layer to reveal the equipment inside, consisting of (1) machine, (2) charged Battery Packs and (1) Charger. If at this time there is any noticeable damage to the equipment inside, such as from pieces making contact with each other during shipping (they are packed such that this should not be able to occur), please again inform UMS / PowerHandling. If everything appears undamaged, remove all of the above from the shipping box and save the box along with all the interior packaging should you ever feel the need to return the machine to UMS / PowerHandling for repair or any upgrades.

Machine Assembly and Battery Pack Charging

Unwrap the Charger cable and connect one end to the Charger and the other to a grounded, 110V or 240V power supply (Further instructions on the charger operation appear later in this manual).

PLEASE NOTE: UMS / PowerHandling strongly recommend the use of a Step-Down Transformer to alleviate the possibility of damage to the Battery Charger due to electrical surges & spikes. Step-Down Transformers (Part # PH-SD 115-250) can be purchased at a nominal cost from UMS Pty Ltd. The non-use of a Step-Down Transformer will void the Battery Charger's warranty.

Then remove the PowerHandler, set it on the ground and rotate the handle shaft to the forward (centred) position and tilt forward to rest the elbow of the handle shaft on the drive roller. (This is its “Park” Position). In this position you can install the 2nd Battery Pack into the handle receptacle.

In both cases above, Battery Pack installation involves holding the Battery Pack by its handle (at the top) and moving it laterally into the receiving location (of Machine or Charger), nearer to the top of the cavity. When it reaches the back of the cavity, press down on the Battery Pack and it will slide down channel guides to make terminal (i.e. electrical) contact and you will feel it click into place.

In the case of the B Series, you will be able to push the throttle on the hand controller forward so the drive roller will rotate. (Refer to the detailed Operations Manual Enclosed for full instructions prior to operation).

General Overview

The B Series is a Battery-Operated Materials Handling device, capable of moving varying tons of smooth rolling weight on a level surface and configured with a Swivelling or Centre handle shaft. The swivelling handle allows the machine to roll forwards and roll backwards cylindrical objects (such as paper rolls, wire cable reels or the wheels of an aircraft or other heavy vehicle).

The top (drive) roller of the machine rolls the object to be moved while simultaneously making contact with the bottom (support) roller that moves the device (and therefore object) along the ground. To roll backwards, the Swivelling handle units can be manoeuvred in behind the load and the handle pivoted forward to enact a pulling motion (see diagram to the left).

To overcome the inertia of a heavy load, load moving devices require a significant amount of traction – both with the load and the ground on which it is being moved. Regardless of the amount of power (or specifically torque) generated, the load will not move without the necessary traction. Many materials handling devices achieve this traction with large, lead-acid batteries and also lead ballast in the device. The PowerHandler uses an entirely different approach, directing the weight of the load being moved down onto the drive roller to generate as much traction as the load requires. In the case of moving cylindrical loads, the small diameter, lighter loads are more of a problem. In these cases the weight of the load is directed more horizontally than vertically at the drive roller and there is a greater tendency for the drive roller to slip and spin against the load, rather than wedging in under it and rotating it. (Please refer to the “Trouble-Shooting” section for suggestions on how to address this issue if it occurs).

All B Series models function as a “system”, operating in conjunction with at least one additional Battery Pack and Charging Station. This Charger should be located in the same approximate vicinity the device is operating in. This proximity allows fast changing out of a depleted Battery Pack with a recharged Battery Pack from the Charger, providing virtually uninterrupted operation during a shift.

Series Overview (Other B-Series Models)

• B40S: Roll Fwd/Backward - Swivelling Handle Shaft

• B40C: Roll Fwd - Centre-Pivoting Handle Shaft

• B40C-HY: Roll Fwd/Push Fwd – Hybrid Pushing Bracket

• B40P: Push Fwd - Dedicated Pusher Model (Trolleys)

• B50S: Roll Fwd/Backward - Swivelling Handle Shaft

• B50C: Roll Fwd - Centre-Pivoting Handle Shaft

• B50C-HY: Roll Fwd/Push Fwd – Hybrid Pushing Bracket

• B50P: Push Fwd - Dedicated Pusher Model (Trolleys)

One-Way or (Optional) Two-Way Operation

All B-Series can be equipped with a one-way motor controller (standard) so it will only operate in the forward direction, or optionally equipped with a two-way (forward and reverse) controller and throttle switch. The Reverse feature can be helpful in certain applications even for a B40S, such as quickly removing the drive roller out from under a paper roll after it has been lifted up onto a raised dollie.

Low Profile or (Optional) High Profile Motor Guard

A B40S PowerHandler is generally equipped with a low profile motor guard which fits neatly over the motor leaving exposed the upper most brush housings (to achieve as low a profile as possible and minimize the risk of the guard interfering with the load being moved). This is also referred to as a “standard” motor guard. Alternatively, a B40S & B50S can be equipped with a high profile motor guard that has 15mm (5/8”) thick steel tubing protecting the motor. As this guard is higher than the drive roller, it is most suited to applications such as moving cable drums or vehicle wheels, where the working area being driven does not extend beyond the width of the drive roller. This is also referred to as a “cable” motor guard.

OPERATION MANUAL – B Series

Park Position – Rotate the Handle to bring the bottom elbow (below the Battery Pack) of the handle shaft to the forward-most position, and then tilt the handle forward so the elbow rests on the drive roller. This will balance the handle's weight over the base frame while providing the smallest possible 'foot-print' of floor space occupation while the machine is not in use.

Handle Adjustment – The handle shaft of the B40S is telescoping, allowing both the height and the orientation of the handle to be adjusted according to the height and preference of the operator.
With the B40S in its Park Position and a charged Battery Pack installed, release the Quick-Release Clamp at the sliding connection point of the handle shaft:

1. Extend or retract the upper handle shaft
   according to what is a comfortable working
   height for each operator. Typically, with the B40S in Park
   Position, this should be at the top of the hip-bone of the
   operator.

2. Rotate the handle grip to be pointing to the left, centre or right, which will provide different orientations of the handle grip as the handle shaft is rotated into each of its four operating position (rolling forwards or backwards, in each case from the left or right side).
   Generally, the most typical grip orientations can be determined from how the B40S will be used. So with the handle in the Park Position: If loads are being rolled forwards and only from the centre of the load, orient the grip to be pointing backwards;

Generally, the most typical grip orientations can be determined from how the B40S will be used. So with the handle in the Park Position:

• If loads are being rolled forwards and only from the centre of the load, orient the grip to be pointing backwards;

• If the operator operates the handle with the handle grip almost always to one side, orient the handle grip to that side. To the left (if the handle will be operated swivelled left) or to the right (if it will be operated swivelled right);

• If loads are being rolled forward from the side of the load (left or right) and/or the operator will be rolling loads backwards, orient the grip to be pointing forwards.

Each operator may have a different preferred handle grip height and orientation. However, this is easily and quickly adjustable for each operator at the commencement of the device‟s operation.

Manoeuvring

To move the machine to the load, take the handle grip in your hand (without depressing the throttle switch), rotate the handle shaft from the Park Position to either the left or right side before tilting it back (by pushing down on the handle grip) until the front support roller lifts up off the ground. In this position (the manoeuvre position) the device can be easily rolled into the required position on its rear wheels. The weight of the batteries in the handle shaft counter-balance the weight of the base frame, providing the operator almost effortless tilting and manoeuvring of the machine.

Precautions to Take Before Rolling a Load

The PowerHandler should be operated on relatively level and smooth concrete (or similar) flooring, as is typical for indoor industrial applications. Operation on sloping (gradient) floors or in outdoor work areas is not recommended.

Before moving a load, ensure the path over which the load will travel is not occupied (by either people or obstacles) and a slope away from the load is not present (which could result in the load accelerating at an uncontrolled rate). Ensure if appropriate, a “Safety Stop” is in place to stop the load at the end of its intended travel.

Operator's should refer to the safety procedures of the facility in which the PowerHandler is being used as to all appropriate steps and precautions required in ensuring a clear path is available, sufficient warning or safety lock-out is affected, a Safety Stop or other intended obstruction is in place so as to ensure that moving the load will not result in damage or injury to property or person (either the operator or another person).

Special Note: The PowerHandler in itself does not “control” any load it moves. It rolls the load forwards without braking or controlling that movement and therefore precautions must be taken to ensure such movement does not result in damage or injury to others.

Rolling Forwards

Once all appropriate precautionary measures have been taken and the load is ready to be moved, manoeuvre the PowerHandler to the contact point of the cylindrical load and then depress the throttle switch forwards to energize the motor. Being a variable-speed throttle, it is generally safest to engage the power gradually so as to prevent the possibility of accelerating the load too rapidly and rolling it beyond the intended travel distance (as a result of the momentum from a rapid acceleration). Caution should be exercised in this respect as the operator builds up familiarity with the machine, as the extremely compact size of the PowerHandler can deceive the operator into thinking it does not have much torque. However the torque output of the PowerHandler is considerable and as such the operator should be aware there is the possibility of over-driving a load and creating a potentially dangerous scenario.

Rolling Backwards

Rolling backwards is not unlike rolling forwards, however it is essential additional caution is exercised to ensure there are no obstacles to the operator as he walks backwards, pulling the load with him. Tripping/falling while pulling the load could result in the operator unintentionally depressing the throttle as he falls, accelerating the load backwards and onto himself. To minimize the risk of such circumstance, at a minimum the following additional precautions should be implemented:

1. The path checked for obstacles or other potential encumbrances to the operator's travel;

2. The operator to have the handle grip rotated “out” (Handle grip pointing backwards when the PowerHandler is in its Park Position);

3. The operator walking “outboard” of the load being rolled backwards;

4. A Safety Stop to be used to limit the travel of the load.

Special Note: On first use an operator‟s natural tendency may be to “lean into” or push the PowerHandler against the roll. However the addition of the operator‟s weight to the torque the PowerHandler already generates is negligible. This practice should be avoided as not only does it offer very little assistance to moving of the load, it also unnecessarily strains the components at the pivot point of the handle shaft, potentially creating maintenance issues in addition to potentially straining the operator‟s back or resulting in other soft-tissue injuries.

CHARGER & BATTERY PACKS- The Quick-Charge/Quick-Change Battery Concept

The B Series operates on the principle that most of the battery capacity is 'off-machine' and is charging while only a small amount of the capacity is 'on-machine' and being used. This allows the PowerHandler to be significantly more compact and lighter than conventional materials handling machines of comparable load capacity.

Therefore, it is important to locate the Charger and second Battery Pack as close as possible to the area in which the PowerHandler will be used. This will minimize the operator's battery switch-out time and improve both performance and efficiency.

How Many Battery Packs & How Many Chargers per Machine?

Depending on the duty cycle an application requires of a PowerHandler, the ratio of Chargers to machines may vary. While the typical configuration is one Charger with one Battery Pack services one PowerHandler, equipped with a Battery Pack (so in total, two Battery Packs). However, different applications may call for different ratios. For example:

• If a number of PowerHandlers are used within a region and they have a low-duty cycle, it may be possible to have one Charger and one additional Battery Pack to two or more PowerHandlers. In this case, a Battery Pack would be lasting much longer than the typical 1 hour recharge time required, so one charged Battery Pack can cycle through many PowerHandlers.

• If in the reverse situation a PowerHandler has a very high duty cycle, it may need two or more Chargers, each with an additional Battery Pack, as the application may deplete a Battery Pack before another is recharged (so multiple Packs would need to be recharging).

Installation of the Charger

The PowerHandling Charger is custom designed and built to operate only with PowerHandling‟s Battery Packs. Do not use a different Charger for a PowerHandling Battery Pack, nor use a different Battery Pack on the PowerHandling Charger.

• The Charger should be located such that the fan opening and the exhaust opening are located at least 2” from any surface which would restrict airflow.

• The AC input can be from any properly grounded wall outlet worldwide as shown in the “Specifications” section, including 110V/60Cycle and 240V/50 Cycle.

• The DC output voltage is 24 – 48 VDC.
   

PLEASE NOTE: UMS / PowerHandling strongly recommend the use of a Step-Down Transformer to alleviate the possibility of damage to the Battery Charger due to electrical surges & spikes. Step-Down Transformers (Part # PH-SD 115-250) can be purchased at a nominal cost from UMS Pty Ltd. The non-use of a Step-Down Transformer will void the Battery Charger‟s warranty.

CHARGER PROCEDURES

Four messages are displayed during the charging sequence:

1. The amount of charging current flowing into the NiCad battery pack.

2. The voltage of the battery being charged.

3. The duration of charge in hour, minutes and seconds.

4. The number of milliamps-hours of charge put into the battery pack. When the charger software detects a peak condition, charging will stop. The display will indicate the peak voltage reached, the duration of charging and the milliamp hours of charge delivered to the batter. The buzzer will then beep 3 times.

CHARGING YOUR NiCad BATTERY - WAITING FOR BATTERY DISPLAY:

If you see the display read “waiting for battery” you do not have the battery on the charger all the way or you have a bad battery. The only time you see this is when battery voltage is not present and the power supply has power.

AFTER CHARGING IS COMPLETE:

The digital display will indicate that the battery has peaked and it will display peaked voltage reached and the number of milliamps hour of charge put into the battery

MESSAGE ON LCD DISPLAY:

1. OVER VOLTAGE ERROR: This message will occurs if the battery pack get disconnected during its charge cycle and the power does not turn off. If you see this error you need to remove the battery and let the LCD screen clear.

2. WAITING FOR BATTERY: This message occurs when the charger does not detect a positive voltage of ½ volt or more at the output side of charger. Make sure you do not have a loose connection between the battery and the charger & the battery is properly seated onto the charger.

3. SHORTED OUTPUT: This message occurs if the battery is removed during the first minute of charging. Remove the battery and let the LCD screen clear and reconnect the battery.

INPUT VOLTAGE: 100-240 VAC 50/60 Hz

OUTPUT VOLTAGE: 24-48 VDC

TROUBLE-SHOOTING GUIDE – B Series

1. The Drive Roller turns okay when not under load, but once engaged, won’t move the load
   Determine whether the issue is torque (drive roller stops turning when engaged with the load) or grip (drive roller spins against the load, not moving it), then read the appropriate suggestions for that problem below.
   
   a) The Drive Roller stops turning when it engages with the load
   This is typically because of insufficient torque being provided to the drive roller and can occur for a number of reasons, including: The battery pack is not providing enough amps (either worn out or not re-charging correctly); The bushing inside the Drive Roller worn out or jammed; The Brushes on the Motor are dirty and needing cleaning or worn out and needing replacing; The load being moved or lifted is too great for the capacity of this device.
   
   b) The Drive Roller spins against the load, not moving it
   This is typically because of insufficient traction between the Drive Roller and the Load being moved and can occur for a number of reasons, including:
   
   On a brand new machine, there is often a problem with initial grip until the drive roller becomes “worn in”. This should only take a day or two, during which time the grip is not quite as good, but the machine will still work. The best way to “wear in” the drive roller is to use it – on loads that do not slip (e.g. larger diameter). Using it on rolls or other product that does slip will only delay the roller wearing in.
   
   The geometry may be exacerbating an existing traction problem. Reference the explanation in the 'Overview Section' on Page 4 describing how too small of a diameter load results in less of the inertial resistance of the load bush downward (vertical) and instead being backward (horizontal). A small diameter can be moved if there is plenty of friction contact and a large diameter load can be moved even with very little friction contact, but the combination of a small diameter and low friction greatly increases the likelihood of slipping.
   
   The drive roller has oil, grease or other low viscosity material embedded into or otherwise making contact with it, reducing its ability to achieve a friction contact. Note also as the drive roller makes pressure contact with the support roller while the machine is operating, it may be oil/grease is picked up from the floor and deposited onto the drive roller.
   
   To address low friction issues and reduce the impact of lubricants that end up interfering with the rollers, the application of Borax (Hydrated Sodium borate – an inexpensive cleaning agent, ref www.borax.com) to the drive roller is recommended. All new PowerHandlers and replacement drive rollers are sent out with Borax already applied.
    

2. Slow Response from Depressing of Throttle to Machine Movement
   The acceleration and deceleration ramp speeds are adjustable. Please request a copy of the “B-Series: On-Site Maintenance Note A1 - Adjustment of the Accel/Decel Settings” from UMS Pty Ltd / PowerHandling for detailed instructions on how to make this adjustment.
    

3. Battery Pack is Discharging too Quickly
   
   If the Battery Pack has already been in service for quite some time, it may be depleted. All current battery technologies are such that they lose a percentage of their total effective capacity on each discharge-recharge cycle. In time, this reaches a point that the Pack‟s life becomes very low and should be replaced. If two packs are being used equally this should result in both packs becoming ineffective at around the same time. If this is not what is occurring, please return the short-life pack to UMS Pty Ltd / PowerHandling for inspection and analysis.
   
   If the Battery Pack is still relatively new and has undergone few charge-discharge cycles, it is possible it is a faulty pack. If this is the case, there will likely be problems during both the charging and discharging of the pack.

Tip-Preventer Installation for A & B Series

1. Remove top bolt on motor side

2. Install tip preventer on axle shaft and install bolt and spacer into top bolt hole on motor side

3. Install tip preventer onto the axle shaft and install bolt and spacer into top bolt hole on non-motor side

WARRANTY/GUARANTEE (Machine, Parts/Materials and Labour)

U.M.S. Pty Ltd / PowerHandling Inc. hereby warrants and guarantees that all of its material will be free from defects in material and workmanship for a period of (6) months from the date the user receives same unit(s).

The warranty is conditional upon the following:

• The unit(s) being used in the normal manner and for the purpose(s) for which the unit(s) were intended.
   

• The unit(s) being used in accordance with PowerHandling's recommended operation and maintenance instructions, as outlined in the Operations and Maintenance Manual for the machine model being used.
   

• The unit(s) being fitted with replacement parts manufactured or provided by U.M.S. Pty Ltd / PowerHandling Inc. and these parts being correctly installed (either by U.M.S. Pty Ltd, and authorised dealer or workshop, or the customer

Any or all defects due to improper use, negligent maintenance or as a result of normal wear and tear are not covered by this guarantee.

In the event of a claim being made under the terms of this warranty, the customer must first obtain a Return Authorisation from U.M.S. Pty Ltd's Customer Services Manager. The unit(s) must then be forwarded to U.M.S. Pty Ltd', freight pre-paid, for servicing or replacement. All spare parts and labour costs incurred for the repair and /or replacement of the warranted unit(s) will be provided at no charge to the customer.

U.M.S. Pty Ltd / PowerHandling Inc. and it's distributors, agents, resellers etc. assume no other responsibility beyond the scope of this warranty. The repair or replacement of the said unit(s) will constitute the limit of U.M.S. Pty Ltd / PowerHandling's liability to the customer and without limitation of the foregoing, U.M.S. Pty Ltd / PowerHandling Inc. specifically disclaims and excludes rescission as a remedy, or the payment of compensatory or consequential damage, attorneys fee's or costs of litigation.

In the event a machine or part provided by U.M.S. Pty Ltd / PowerHandling Inc. is found to be defective, it is at PowerHandling's discretion to replace said part or machinery at PowerHandling's cost, or take delivery of the failed parts and refund the customer the funds originally received by it for that sale.