The A Series Air Operated Materials Handling machines are 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 pull backwards cylindrical objects (such as paper rolls, wire cable reels or the wheels of an aircraft or other heavy vehicle).
Overview
The A-Series is available in various models and versions as listed below:
A25C:
Push Model, Small Motor, Fixed Handle
A25S:
Push/Pull Model, Small Motor, Rotating Handle
A30C:
Push Model, Medium Motor, Fixed Handle
A30S:
Push/Pull Model, Medium Motor, Rotating Handle
A40C:
Push Model, Large Motor, Fixed Handle
A40S:
Push/Pull Model, Large Motor, Rotating Handle
Click on any image for a slide show
Rolling Paper 2,000kg (4,500lbs) off/on 1" (25mm) dollies
Rolling (backwards) 2,000kg (4,500lbs) onto 1" (35mm)
Rolling Wire Spools up to 4tons (9,000lb) into a Take-Up
Pushing a 40,000kg (90,000lb) rail tank car
Pushing a 15,000kg (35,000lb) passenger rail car
Rolling RV's/caravans up ramps into delivery trucks
Pushing RV's/caravans laterally on dollies
Drum Rolled Forward with Safety Stops
Click on the Reel to watch the video
PowerHandling A25S/A30S
Pneumatically Driven Rotary Vane Air Motor with Three-Stage Planetary Gearbox.
A25S - Max Speed 30 m/min & Max Force at Drive Roller 13 Kilo-Newtons
A30S - Max Speed 22 m/min & Max Force at Drive Roller 16 Kilo-Newtons
Suited to High-Duty-Cycle (Short or No Rest Periods) and Maximum-Capacity Load Applications.
Max Rolling Capacity - Steel Flanged Cable Reels on Flat Concrete 22,000kg / 28,000kg
Paper or Plastic Rolls on Flat Concrete _9,000kg / 11,000kg Max Lifting Capacity - Lifting a Paper Roll up onto a 25mm Dollie or Incline 2,700kg / 3,400kg Direct Drive Design (No Chains/Sprockets) for maximum torque & reliability and minimal maintenance.
An All-Welded (not bolt-together) Main Chassis for higher strength – Steel, Reinforced, Chrome-Plated.
Swivelling “L” Handle to allow “separating” of rolls, plus Pivoting Rear Axle to allow “pulling” of rolls.
Note: Optional “Center” Handle (A25C) available, plus Optional “Hybrid” option (-HY) to allow both “rolling” & “pushing” of a load.
Not as capable of “separating” rolls, & unable to “pull” rolls.
Extremely Compact with Large Diameter (100mm) Rear Wheels for faster and easier manoeuvring.
PowerHandling A40S
Pneumatically Driven Rotary Vane Air Motor with Three-Stage Planetary Gearbox. A40S - Max Speed 17 m/min & Max Force at Drive Roller 21 Kilo-Newtons
Suited to High-Duty-Cycle (Short or No Rest Periods) and Maximum Capacity Load Applications. Max Rolling Capacity - Steel Flanged Cable Reels on Flat Concrete 28,000kg / 35,000kg Paper or Plastic Rolls on Flat Concrete 11,000kg / 14,000kg
Max Lifting Capacity - Lifting a Paper Roll up onto a 25mm Dollie or Incline 3,400kg / 4,300kg Direct Drive Design (No Chains/Sprockets) for maximum torque and reliability and minimal maintenance.
An All-Welded (not bolt-together) Main Chassis for higher strength – Steel, Reinforced, Chrome-Plated.
Swivelling “L” Handle to allow “separating” of rolls, plus Pivoting Rear Axle to allow “pulling” of rolls. Note: Optional “Center” Handle (A40C) available, plus Optional “Hybrid” option (-HY) to allow both “rolling” and “pushing” of a load. Not as capable of “separating” rolls, and unable to “pull” rolls.
Extremely Compact with Large Diameter (100mm) Rear Wheels for faster and easier manoeuvring
GENERAL OVERVIEW
The A Series Air Operated Materials Handling machines are 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 pull 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 A-Series rolls the object to be moved, while simultaneously making contact with the bottom (support) roller that moves the A-Series unit (and therefore the object) forward. To pull, the A-Series machine may be brought behind the round object and the handle may be rotated forward to enact a pulling motion.
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. The PowerHandler uses an entirely different approach then other companies, 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).
SERIES OVERVIEW
The A-Series is available in various models and versions as listed below:
A25C: Push Model, Small Motor, Fixed Handle
A25S: Push/Pull Model, Small Motor, Rotating Handle
A30C: Push Model, Medium Motor, Fixed Handle
A30S: Push/Pull Model, Medium Motor, Rotating Handle
A40C: Push Model. Large Motor, Fixed Handle
A40S: Push/Pull Model, Large Motor, Rotating Handle
INSTRUCTIONS UPON RECEIPT OF GOODS
Please note if there is any noticeable damage to the exterior packaging and if so, immediately inform U.M.S Pty Ltd 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. 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 U.M.S Pty Ltd.
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 have the need to return the machine to U.M.S / PowerHandling for repair or any upgrades.
PRECAUTIONS TO TAKE BEFORE ROLLING A LOAD
The A-Series 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.
The compressed air line to the A-Series unit should be connected (such as from overhead retractable hose reels to reduce the likelihood of the operator tripping on the lines) and the unit located in its desired working area.
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). Caution should also be exercised in rolling loads up inclines due to the risk of the load rolling back onto the operator.
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 the appropriate precautionary measures have been taken and the load is ready to be moved, the operator should push down on the handle‟s air-valve to tilt the unit onto its rear wheels so it can be rolled up to the load. He then depresses the lever of the air-valve on the handle grip. The further the lever is depressed, the more air flow to the unit and more speed/torque the unit will generate. It is generally safest to engage the air flow 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 that there is the possibility of over-driving a load and creating a potentially dangerous scenario.
PULLING BACKWARDS
Pulling 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 air-valve lever 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:
The path checked for obstacles or other potential encumbrances to the operator's travel
The operator walking “outboard” of the load being rolled backwards
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.
TROUBLE-SHOOTING
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.
1. 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 bushing inside the drive roller worn out or jammed;
The vanes 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.
2. 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 3 describing how too small of a diameter load results in less of the inertial resistance of the load being 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 pick up oil and/or grease from the floor and deposit it 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.
MAINTENANCE INSTRUCTIONS
The air supply must be clean (i.e. filtered). Large contaminants in the air supply will clog the screens in the PowerHandling air valve and at the inlet to the air motor. This will reduce the air volume delivered to the vanes and result in reduced torque and speed. Small contaminants in the air supply will pass through these screens and enter the vanes and cylinder of the air motor. Some will be immediately exhausted but others will remain, causing damage and premature wear of the vanes, bearings and seals. The effect of this accumulated debris will be diminished torque and speed and ultimately motor failure.
The air supply must be dry.
Moisture in the compressed air supply will result in corrosion inside the air motor‟s vanes and precipitate the need for replacement of the vane kit. The effect of moisture will be diminished torque and speed and ultimately motor failure. Lubrication to be provided to air motor and planetary gear set.
To maximize the life of your air motor the air supply should be “continuous oil lubricated”. Failing this, bi-daily insertion of a few drops of oil into the air line should be included in the maintenance procedures of the plant. In addition, the planetary gearbox (gear-sets and bearings) should be greased in conjunction with a regular overhaul.
Recommended air pressure and volume.
The A-Series air motors consume up to 32 cfm at 85 psi (6 bar). Generally, standard “factory supply air” will accommodate this recommended pressure and flow rate, however special attention should be paid to point 5 below, regarding the internal diameter of air lines, connectors and fitting.
Air lines and connectors should not limit or constrict air flow (volume).
All airlines, connectors and fittings should be a minimum of 1/2” (12 mm) internal diameter to achieve continuous full motor output. Less than 1/2” (12 mm) will limit air volume supply and reduce torque and speed.
General mechanical maintenance.
The A-Series has been designed to be as robust and maintenance-free as possible. However, the following items should be checked periodically for wear and the relevant parts repaired or replaced (with original parts from U.M.S / PowerHandling) as necessary:
Check the drive and support rollers for wear. Replace once the urethane wear is to a degree that unit performance is being adversely affected. Ideally these rollers should both be replaced at the same time.
Check the air valve for correct operation. Clean filter-screen if partially blocked, remove contaminants if present, replace as necessary.
Periodically check all bearings to ensure all still offer smooth, unhindered rotation. Clean or replace as necessary.
Check the rear wheels for wear and/or bearing failure, replace as necessary. Generally appraise performance of unit to ensure performance. Ideally, establish a “benchmark” of the load that can be moved with a new/overhauled A-Series unit (until motor stall) and periodically compare the performance of all units in service to this benchmark.
TIP-PREVENTER INSTALLATION FOR A & B SERIES
Remove top bolt on motor side
Install tip preventer on axle shaft and install bolt and spacer into top bolt hole on motor side
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.
Safety
How Can PowerHandlers Improve Workplace Safety? Many workplace injuries occur despite the existence of tools and procedures designed to prevent them. The problem, as every Plant Safety Manager can attest, is that workers are prone to taking "short-cuts" — whatever is quickest or easiest.
The key to the PowerHandler's success in reducing workplace injuries is due to a combination of two simple factors:
Their availability — They are incredibly small machines considering the power that they have, so they can be conveniently located where they will be needed. This eliminates waiting for a forklift or having to walk out of the work area to bring in a larger moving machine. Their ease of use — They are incredibly quick and easy to manoeuvre into position, and powerful enough to move the loads that need to be moved quickly, easily, and safely.
It sounds too simple, but substantial customer feedback has already shown us that if operators like using it, they use it. This has proven to be the key to worker safety in our load moving applications. Providing safer tools that operators want to use, and therefore, do use.
Downloads
Right click and "Save Target As" and select the location to save the file.
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).
All B Series models function as a “system”, operating in conjunction with at least one additional Battery Pack and Charging Station.
General Overview
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)
Click on any image for a slide show
Rolling Cable Spools of approx 40tons (90,000lb)
Rolling Cable Spools of approx 15tons (35,000lb)
Hybrid model both rolling and pushing paper rolls
Rolling 3 x clay-coated paper rolls on the flat
Rolling paper rolls and lifting onto 1" (25mm) dollies
Rolling a 90,000kg (210,000lb) Boeing 767
Rolling Truck of approx 13,000kg (28,000lbs) out of dip
Rolling Military Vehicle of approx 32,000kg (70,000lbs)
Click on the Reel to watch the video
PowerHandling B40S & B50S
Battery Operated (48Volts) Sealed Un-Cooled Four-Brush Motor with Three-Stage Planetary Gearbox. B40S - Max Speed 19 m/min & Max Force at Drive Roller 17 Kilo-Newtons B50S - Max Speed 15 m/min & Max Force at Drive Roller 22 Kilo-Newtons
Suited to - Low Duty-Cycle (Regular Rest Periods) and Max Capacity-Loads; OR - Medium Duty-Cycle (Short or Irregular Rests) and Med/Low Capacity Loads.
Max Rolling Capacity - Steel Flanged Cable Reels on Flat Concrete 29,000kg / 37,000kg - Paper or Plastic Rolls on Flat Concrete 12,000kg / 15,000kg
Max Lifting Capacity - Lifting a Paper Roll up onto a 25mm Dollie or Incline 3,600kg / 4,600kg
Direct Drive Design (No Chains/Sprockets) for maximum torque and reliability and minimal maintenance.
An All-Welded (not bolt-together) Main Chassis for higher strength – Steel, Reinforced, Chrome-Plated.
Swivelling “L” Handle to allow “separating” of rolls, plus Pivoting Rear Axle to allow “pulling” of rolls. Note: Optional “Center” Handle (B40C) available, plus Optional “Hybrid” option (-HY) to allow both “rolling” and “pushing” of a load. Not as capable of “separating” rolls, and unable to “pull” rolls.
Extremely Compact with Large Diameter (100mm) Rear Wheels for faster and easier manoeuvring.
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:
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.
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:
The path checked for obstacles or other potential encumbrances to the operator's travel;
The operator to have the handle grip rotated “out” (Handle grip pointing backwards when the PowerHandler is in its Park Position);
The operator walking “outboard” of the load being rolled backwards;
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:
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.
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.
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.
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.
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.
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
Remove top bolt on motor side
Install tip preventer on axle shaft and install bolt and spacer into top bolt hole on motor side
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.
Safety
How Can PowerHandlers Improve Workplace Safety? Many workplace injuries occur despite the existence of tools and procedures designed to prevent them. The problem, as every Plant Safety Manager can attest, is that workers are prone to taking "short-cuts" — whatever is quickest or easiest.
The key to the PowerHandler's success in reducing workplace injuries is due to a combination of two simple factors:
Their availability — They are incredibly small machines considering the power that they have, so they can be conveniently located where they will be needed. This eliminates waiting for a forklift or having to walk out of the work area to bring in a larger moving machine. Their ease of use — They are incredibly quick and easy to manoeuvre into position, and powerful enough to move the loads that need to be moved quickly, easily, and safely.
It sounds too simple, but substantial customer feedback has already shown us that if operators like using it, they use it. This has proven to be the key to worker safety in our load moving applications. Providing safer tools that operators want to use, and therefore, do use.
Downloads
Right click and "Save Target As" and select the location to save the file.
The E 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 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.
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.
General Overview
Battery Operated (36Volts) Fan-Cooled Brushed Motor with Three-Stage Planetary Gearbox. Combination Gear and Chain-and-Sprocket Design provides multiple speed/torque options. An All-Welded (not bolt-together) Main Chassis for higher strength – Steel, Reinforced, Chrome-Plated. Swivelling “L” Handle to allow “separating” of rolls, plus Pivoting Rear Axle to allow “pulling” of rolls.
Extremely Compact with Large Diameter (115mm) Rear Wheels for faster and easier manoeuvring.
Rolling Truck of approx 13,000kg (28,000lbs) backwards
Click on the Reel to watch the video
PowerHandling E20S
Battery Operated (36Volts) Fan-Cooled Brushed Motor with Three-Stage Planetary Gearbox. E20S - Max Speed 21 m/min & Max Force at Drive Roller 12 Kilo-Newtons. Suited to High-Duty-Cycle (Short or No Rest Periods) and Medium-Capacity Load Applications.
Max Rolling Capacity - Steel Flanged Cable Reels on Flat Concrete 20,000kg Paper or Plastic Rolls on Flat Concrete 8,000kg Max Lifting Capacity - Lifting a Paper Roll up onto a 25mm Dollie or Incline 2,500kg
Combination Gear and Chain-and-Sprocket Design provides multiple speed/torque options.
An All-Welded (not bolt-together) Main Chassis for higher strength – Steel, Reinforced, Chrome-Plated.
Swivelling “L” Handle to allow “separating” of rolls, plus Pivoting Rear Axle to allow “pulling” of rolls.
Extremely Compact with Large Diameter (115mm) Rear Wheels for faster and easier manoeuvring.
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 PowerHandling of the damage. If possible also take digital photos of the damaged box and email them to sales@powerhandling.com.
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 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 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 be returning the machine after the trial period (or if in the future you may be returning the machine to PowerHandling for repair or any upgrades).
Unpacking and Assembling Your E Series PowerHandler
1) Prior to unpacking, read the enclosed Operation, Maintenance and Safety Manual
2) Supplied in the manual are the tools needed to assemble the PowerHandler and adjust the handle to the operating position.
- 4mm Hex Wrench
- 5mm Hex Wrench
- Connector, Lock
3) Now that you have read the manual, you are ready to assemble the PowerHandler and begin using it.
4) Plug the connector together, making sure to match the colours on the plug. Attached the connector lock supplied in the manual packet.
5) Insert the upper handle into the lower handle. Align the slot in the upper handle with the bolt in the lower handle. Tighten the bolt on the lower handle, ensuring the upper handle is held in place.
6) The upper handle shaft is designed to move up and down based on operator height. Align one of the four holes in the shaft to the position that is most comfortable for the operator. Do not pull the handle past the holes shown in the picture.
7) Align your selected hole with the set screw in the upper handle. Tighten the set screw, ensuring the shaft cannot move.
The PowerHandler is now completely assembled and ready for operation. If you have questions not covered in the Operations Manual, please phone (02) 9680 7944 or email sales@ums.net.com.
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. Two LED's (small lights on the top display panel of the Charger) should illuminate. (Further instructions on the charger operation appear later in this manual). Set the PowerHandler 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 Charger, you will see a 2 light illuminate on the top display panel which indicates the Battery Pack is correctly seated. (Refer to the detailed Operations Manual Enclosed for full instructions prior to operation).
NOTE: that you may receive one of two different brands of PowerHandling chargers. Operating instructions are the same for either charger, there is no functional difference. One charger has LED's to show the status of the charge, one has a digital display for the status of the battery.
General Overview
The E 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 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 E 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.
Two-Way Operation All E-Series are equipped with a two-way motor controller (standard) so it will only operate in forward and reverse. The Reverse feature can be helpful in certain applications, such as quickly removing the drive roller out from under a paper roll after it has been lifted up onto a raised dollie.
OPERATION MANUAL - E 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.
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 E20S 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:
The path checked for obstacles or other potential encumbrances to the operator's travel;
The operator to have the handle grip rotated "out" (Handle grip pointing backwards when the PowerHandler is in its Park Position);
The operator walking "outboard" of the load being rolled backwards;
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.
The E 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.
PLEASE NOTE: Due to the erratic electricity power supply in Australia and New Zealand, U.M.S. Pty Limited strongly advises the use of a step down transformer to alleviate the damage done to the battery charger from Electrical Surges and Spikes. This Step Down Transformer (Part # PH-SD115-250) is available from U.M.S. Pty Limited at a nominal charge.
Charger Procedures
NO POWER
No LED's illuminated.
The Charger is not connected to the AC Mains Power Supply or there is a major component failure in the Charger such that no LED's are illuminated.
WAITING FOR BATTERY
The left-most LED is illuminated "solid" (i.e. not flashing) GREEN and the middle LED is "flashing" ORANGE.
Power is coming into the Charger but no Battery Pack is mounted on the Charger.
Alternatively, a Battery Pack is mounted on the Charger, but not making correct terminal connection.
CHARGING
The left-most LED is illuminated solid GREEN and the middle LED is solid YELLOW.
This means there is a Battery Pack connected to the Charger and it is in the "Rapid Charging" Phase.
This phase should last approx 1 hour for a fully discharged Pack and will charge to approx 80% of the Battery Pack's Full-Charge capacity.
CHARGED
Both the left-most and right-most LED's are illuminated solid GREEN.
This means the Battery Pack is doing its "Topping Charge", where it fills the remaining 20% of the Battery Pack's Charge Capacity.
This phase can last another hour, however this phase is not necessary to have been completed for the Battery Pack to be removed for reuse.
IDLE SHUT-DOWN
Only the left-most LED is illuminated solid GREEN.
This means the Battery Pack is still installed and is fully charged.
The Battery Pack can be left indefinitely on the Charger without damaging the Battery Pack. The temperature and condition of the Battery Pack is monitored and a "Trickle Charge" is supplied as needed to keep it fully topped up.
Special Note 1: The Charger provides REVERSE BATTERY VOLTAGE PROTECTION, meaning protection is provided to the Battery Pack via a 15 amp fuse in the in-line fuse holder in the positive output connection lead.
Special Note 2: The ambient operating temperature for the Charger should be between 32°F and 104°F (0°C to 40°C). During charging when heat is generated, the Charger provides OVER TEMPERATURE PROTECTION such that if an over temperature condition develops in the Charger's heat sink (and FET) on the input circuitry, the output current of the charger will be proportionally reduced to reduce the heat generation at the heat sink and allow it to drop to an acceptable level. The Charger's power devices are thermally coupled to internal heat sinks, which are cooled by forced air convection by a cooling fan mounted internally in one end of the charger unit to create air movement from one end to the other.
Special Note 3: With this style charger "Peaked" means battery is fully charged.
TROUBLE-SHOOTING GUIDE - E 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' describing how too small of a diameter load results in less of the inertial resistance of the load pushing 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) 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 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.
Warranty/Guarantee (Machine, Parts/Materials and Labour)
U.M.S. Pty Limited/PowerHandling Inc. hereby warrants and guarantees all of its material handling machines will be free from defects in materials and workmanship for a period of six (6) months from the date the user receives same unit(s).
This Warranty is conditional upon the following:
The unit(s) being used in a normal manner and for the purpose(s) for which the unit(s) were intended.
The unit(s) being used in accordance with U.M.S. Pty Limited/PowerHandling Inc.'s recommended operation and maintenance instructions, as outlined in this Operation and Maintenance Manual.
The unit(s) being fitted with replacement parts manufactured or provided by U.M.S. Pty Limited/PowerHandling Inc.only. Non-PowerHandling manufactured parts used on the unit(s) will void all warranties.
These parts being correctly installed (either by U.M.S. Pty Limited/PowerHandling Inc., an authorized dealer provided by U.M.S. Pty Limited/PowerHandling Inc., or the customer).
Any and 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 Authorization from their sales representative. This unit(s) should then be forwarded to U.M.S. Pty Limited/PowerHandling Inc. at the address listed above for servicing and/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 Limited/PowerHandling Inc. and its 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 PowerHandling's liability to the customer and without limitation of the forgoing; PowerHandling specifically disclaims and excludes rescission as a remedy, or the payment of compensatory or consequential damages, attorney's fees or costs of litigation.
In the event a machine or part provide by U.M.S. Pty Limited/PowerHandling Inc. is found to be defective, it is at U.M.S. Pty Limited/PowerHandling Inc.'s discretion to replace said part or machinery at U.M.S. Pty Limited/PowerHandling Inc.'s cost, or take delivery of the failed parts and refund the customer the funds originally received by it for that sale.
Safety
How Can PowerHandlers Improve Workplace Safety? Many workplace injuries occur despite the existence of tools and procedures designed to prevent them. The problem, as every Plant Safety Manager can attest, is that workers are prone to taking "short-cuts" — whatever is quickest or easiest.
The key to the PowerHandler's success in reducing workplace injuries is due to a combination of two simple factors:
Their availability — They are incredibly small machines considering the power that they have, so they can be conveniently located where they will be needed. This eliminates waiting for a forklift or having to walk out of the work area to bring in a larger moving machine. Their ease of use — They are incredibly quick and easy to manoeuvre into position, and powerful enough to move the loads that need to be moved quickly, easily, and safely.
It sounds too simple, but substantial customer feedback has already shown us that if operators like using it, they use it. This has proven to be the key to worker safety in our load moving applications. Providing safer tools that operators want to use, and therefore, do use.
Downloads
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Pneumatically Driven Rotary Vane Air Motor with Three-Stage Planetary Gearbox.
Suited to High-Duty-Cycle (Short or No Rest Periods) and Maximum-Capacity Load Applications.
Includes the Chain-and-Sprocket drive transfer of the original R-Series design, but now also incorporating many A-Series features incl. stronger telescoping handle shaft and coupling, larger rear wheels, etc.
An All-Welded (not bolt-together) Main Chassis for higher strength – Steel, Reinforced, Chrome-Plated.
Swivelling “L” Handle to allow “separating” of rolls, but without the Pivoting Rear Axle for “pulling” rolls.
Extremely Compact with Large Diameter (100mm) Rear Wheels for faster and easier manoeuvring.
Click on any image for a slide show
Rolling Wire Spools up to 4tons (9,000lb) into a Take-Up
Rolling Wire Spools up to 4tons (9,000lb) into a Take-Up
Rolling Paper 2,000kg (4,500lbs) onto 1" (25mm) dollies
Click on the Reel to watch the video
PowerHandling J10S
Pneumatically Driven Rotary Vane Air Motor with Three-Stage Planetary Gearbox. J10S - Max Speed 19 m/min & Max Force at Drive Roller 8.5 Kilo-Newtons.
Suited to High-Duty-Cycle (Short or No Rest Periods) and Maximum-Capacity Load Applications.
Max Rolling Capacity - Steel Flanged Cable Reels on Flat Concrete 15,000kgs. Paper or Plastic Rolls on Flat Concrete 6,000kgs.
Max Lifting Capacity - Lifting a Paper Roll up onto a 25mm Dollie or Incline 1,800kgs.
Includes the Chain-and-Sprocket drive transfer of the original R-Series design, but now also incorporating many A-Series features incl. stronger telescoping handle shaft and coupling, larger rear wheels, etc.
An All-Welded (not bolt-together) Main Chassis for higher strength – Steel, Reinforced, Chrome-Plated.
Swivelling “L” Handle to allow “separating” of rolls, but without the Pivoting Rear Axle for “pulling” rolls.
Extremely Compact with Large Diameter (100mm) Rear Wheels for faster and easier manoeuvring.
PowerHandling J25S & J30S
Pneumatically Driven Rotary Vane Air Motor with Three-Stage Planetary Gearbox. J25S - Max Speed 16 m/min & Max Force at Drive Roller 14.8 Kilo-Newtons. J30S - Max Speed 14 m/min & Max Force at Drive Roller 17.8 Kilo-Newtons.
Suited to High-Duty-Cycle (Short or No Rest Periods) and Maximum-Capacity Load Applications.
Max Rolling Capacity - Steel Flanged Cable Reels on Flat Concrete 25,000kgs / 30,000kgs Paper or Plastic Rolls on Flat Concrete 10,000kgs / 12,000kgs
Max Lifting Capacity - Lifting a Paper Roll up onto a 25mm Dollie or Incline 3,100kgs / 3,700kgs
Includes the Chain-and-Sprocket drive transfer of the original R-Series design, but now also incorporating many A-Series features incl. stronger telescoping handle shaft and coupling, larger rear wheels, etc.
An All-Welded (not bolt-together) Main Chassis for higher strength – Steel, Reinforced, Chrome-Plated.
Swivelling “L” Handle to allow “separating” of rolls, but without the Pivoting Rear Axle for “pulling” rolls.
Extremely Compact with Large Diameter (100mm) Rear Wheels for faster and easier manoeuvring.
Safety
How Can PowerHandlers Improve Workplace Safety? Many workplace injuries occur despite the existence of tools and procedures designed to prevent them. The problem, as every Plant Safety Manager can attest, is that workers are prone to taking "short-cuts" — whatever is quickest or easiest.
The key to the PowerHandler's success in reducing workplace injuries is due to a combination of two simple factors:
Their availability — They are incredibly small machines considering the power that they have, so they can be conveniently located where they will be needed. This eliminates waiting for a forklift or having to walk out of the work area to bring in a larger moving machine. Their ease of use — They are incredibly quick and easy to manoeuvre into position, and powerful enough to move the loads that need to be moved quickly, easily, and safely.
It sounds too simple, but substantial customer feedback has already shown us that if operators like using it, they use it. This has proven to be the key to worker safety in our load moving applications. Providing safer tools that operators want to use, and therefore, do use.
Direct Drive design houses the motor and planetary gearbox "inside" the drive roller.
H-Series use a high-torque, 4-brush, sealed motor suited to high loads but lower duty cycles.
Telescoping Handle Shaft allows the operator to instantly adjust handle height and handle orientation according to their own height and personal operating preference.
All-Welded Chassis is a "box-style" design that encloses all airlines and connectors within the frame, protecting them from impact or debris.
High Traction Support Roller features a grooved herringbone profile for maximum traction, well suited to wet and high debris environments.
Large Diameter Rear Wheels are the key to their quick and easy manoeuvring.
Rolling Wire Spools of approx 1-3tons (2,000-7,000lbs)
Rolling Paper Rolls of approx 2,300kg (5,000lbs)
Rolling Paper 1,700kg (3,700lbs) onto 1" (25mm) dollies
Rolling Paper 1,700kg (3,700lbs) on/off 1" (25mm) dollies
Click on the Reel to watch the video
PowerHandling H40S
H-Series was developed to handle higher torque applications and higher duty cycles than any other battery operated machine ever designed.
Direct Drive design houses the motor and planetary gearbox "inside" the drive roller.
All-Welded Chassis is a "box-style" design that encloses all airlines and connectors within the frame, protecting them from impact or debris. This seam welded construction is more expensive than using simple bolt-secured rods as cross-ties, but it provides substantially more structural integrity and strength. The frame is also point-load reinforced and hard chrome plated.
Heavy-Duty Handle-to-Base Coupling design is so strong, it is virtually indestructible from mechanical abuse. In fact since its introduction, we've not heard of a single in-field failure! This coupling design allows smooth rotation while eliminating the possibility of air leaks.
Large Diameter Rear Wheels are the key to their quick and easy manoeuvring. These 115mm (4½") diameter, solid steel, polyurethane surfaced wheels feature large double sealed ball bearings riding on 20mm (3/4") solid steel axles. The result is an extremely heavy-duty package that provides very smooth rolling and exceptional manoeuvrability.
H-Series use a high-torque, 4-brush, sealed motor suited to high loads but lower duty cycles. The H-Series also has temperature-controlled external fan cooling for longer run times, while all models use 3-stage, inline Planetary Gearboxes.
Intelligent Chargers can quick-charge 36V or 48V packs "offline" in 150 minutes, while simultaneously, the machine can continue to operate using the second battery pack.
Telescoping Handle Shaft allows the operator to instantly adjust handle height and handle orientation according to their own height and personal operating preference. Additionally, the 30mm (1 & 3/16") diameter steel tubing of the lower handle body greatly improves the handle shaft's strength, preventing it from bending under load.
High Traction Support Roller features a grooved herringbone profile for maximum traction, well suited to wet and high debris environments. The Fluro Orange, high quality, US-manufactured, polyurethane surface provides long wear life. The highest torque A40S and H40S models have an extended width for even greater traction. Additionally, the chassis is reinforced at the support roller axle shaft to better support the shaft under high load conditions.
Reversible, Variable Speed Throttle allows the operator to quickly change from forward running to reverse running. This is very helpful when a load is driven or lifted and becomes "stuck" or "wedged" under the load. Rather than having to gradually "wiggle" the machine out from the under the load, the motor can be switched into reverse and driven out, saving time and effort.
Safety
How Can PowerHandlers Improve Workplace Safety? Many workplace injuries occur despite the existence of tools and procedures designed to prevent them. The problem, as every Plant Safety Manager can attest, is that workers are prone to taking "short-cuts" — whatever is quickest or easiest.
The key to the PowerHandler's success in reducing workplace injuries is due to a combination of two simple factors:
Their availability — They are incredibly small machines considering the power that they have, so they can be conveniently located where they will be needed. This eliminates waiting for a forklift or having to walk out of the work area to bring in a larger moving machine. Their ease of use — They are incredibly quick and easy to manoeuvre into position, and powerful enough to move the loads that need to be moved quickly, easily, and safely.
It sounds too simple, but substantial customer feedback has already shown us that if operators like using it, they use it. This has proven to be the key to worker safety in our load moving applications. Providing safer tools that operators want to use, and therefore, do use.
We pride ourselves in offering a professional competitive service to some of the largest companies within Australia and NZ.
Once all the appropriate precautionary measures have been taken and the load is ready to be moved, the operator should push down on the handle‟s air-valve to tilt the unit onto its rear wheels so it can be rolled up to the load. He then depresses the lever of the air-valve on the handle grip. The further the lever is depressed, the more air flow to the unit and more speed/torque the unit will generate. It is generally safest to engage the air flow 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).
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 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
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:
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. 
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).
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).
Battery Pack 
with a recharged Battery Pack from the Charger, providing virtually uninterrupted operation during a shift.
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.
