POWERHANDLING PowerRoll RVB Series Use and care manual

PowerHandling, Inc.
RVB-SERIES ASSEMBLY, OPERATION, SAFETY AND MAINTENANCE MANUAL
Published: 
PowerHandling, Inc.

Table of Contents
Page
Cover Page and Table of Contents
2
Instructions upon Receipt of Machine
3
Out of Box Assembly Instructions
4
Battery Use
7
Best practices for Li-Ion battery packs
8
General Principle of Operation
9
General Overview of Models Available Within the RVB/RWB-Series
10
Model Identification (Which Model RVB/RWB Do You Have?)
11
Operation & Safety
Maneuvering
12
Pushing the Load Forward
12
Pulling the Load Backward
12
Precautions to Take Before Rolling a Load
13
Option: Safety Stop / Chock
13
Quick-Charge / Quick-Change Battery Concept
14
Installation of the Charger
14
Overview and Recommended Operation Procedure
General Throttle Operation Guide
14
Stall and Near-Stall Conditions
15
Trouble Shooting Guide
Drive Roller Turns Unengaged, but W
on’t
Move the Load
16
Battery Pack Discharges Quickly
17
LED Indicator Light
18
General Mechanical Maintenance
19
Warranty & Guarantee (Machines, Parts, Materials & Labor)
20
2 of 20 2020/10

Instructions upon Receipt of Machine
Upon receipt, please inspect your box for signs of damage and immediately inform PowerHandling of the
damage. If possible also take digital photos of the damaged box and email them to [e-mail].
If there is no physical damage to the outside packaging, place the box on the ground or work table with the
“THIS WAY UP” arrows pointing up and open from the top.
IMPORTANT NOTE:
ENSURE ALL PACKAGING IS RETAINED
Do not discard packaging. After removal of machine, place all packaging into outer
shipping containers and store. By retaining the original packaging and instructions
the unit can be repacked securely should you need to return the machine at any
time for repairs, analysis, or upgrade by a PowerHandling facility.
Packaging varies according to the model, etc. In all cases the packaging has been custom designed to safely
and securely protect the machine in transport. Correct packaging is critical in being able to transport
PowerRolls without damage in transit as the units are extremely dense (very heavy for their size) and must be
securely packed in sturdy packaging that prevents movement of any parts of the machine within the outer
shipping container.
Open the outer and inner boxes to reveal the equipment inside, typically consisting of (1) PowerRoll, (2)
charged battery packs and (1) charger. Ensure all inside boxes have been opened, as parts are sometimes
shipped with machines. Verify all components in the box match the packing slip. If everything is accounted for,
unpack and assemble the machine per the Machine Assembly section of the manual. If any items are missing
please contact PowerHandling before continuing.
Please note that when sending a
PowerRoll back to the factory
, any
damage incurred due to incorrect
or insufficient packaging is the
responsibility of the sending party.
Please retain original packaging in
the event that such return
transportation is ever required.
3 of 20 2020/10

Out of Box Assembly Instructions
Swivel Handle
(“S”),
Swivel Pivot
(“SP”) &
Center Straight
(“C”) Handle PowerRolls require the handle assembly be attached
to the base machine unit and the quick-connect electrical connections completed.
Center Straight (“C”) Handle Assembly Instructions
STEP 1: Loosely install the four handle attachment
screws and lock washers on the machine base.
STEP 3: Position Handle Mount over mounting
screws
and lock washers by sliding mount down.
Ensure all lock
washers are seated under screw
heads and not trapped be
tween the mount and
base.
STEP 2: Carefully insert the (male) connector from
t
he wire harness of the handle to the (female)
connector exiting from the machine chassis.
STEP 4: Tighten all four handle mounting screws
and
then insert a battery pack. You’ll want to test
that
the drive roller rotates when given a throttle
input.
4 of 20 2020/10

Swivel (“S”) Handle A
STEP 1: Insert the handle carefully into the handle
mount, and route the cable with the
connector
through the handle mount.
STEP 2: Line up the holes in the handle and the
handle mount as shown.
ssembly Instructions
STEP 3: Fasten the set-screw making sure it sits
above the cable restraint as shown, thus securing
it.
STEP 4:
Follow step 4 from the Center Straight Handle
Instructions to securely assemble the Swivel
Handle to the machine
5 of 20 2020/10

Swivel Pivot(“SP”) Handl
STEP 1: Insert the handle carefully into the handle
mount, and route the cable with the connector
through the pivoting handle mount.
STEP 2: Line up the holes in the handle and the
handle mount as shown.
e Assembly Instructions
STEP 3: Fasten the set-screw making sure it sits
above the cable restraint as shown, thus securing
it.
STEP 4:
Follow step 4 from the Center Straight Handle
Instructions to securely assemble the Swivel Pivot
Handle to the machine
6 of 20 2020/10

Battery Use
First Time Use
If using the battery (received with the machine or replacement) for the first time, the battery should be
charged to a full charge before using it on the machine.
Charging
With one end of the charger cable connected to the charger, and the other end plugged in to a 110V-220V outlet,
place the battery in the battery compartment of the charger. Typical charging time is approx. 120 minutes.
The charger has two LED lights to indicate the state of the charger and battery pack, as per the table below:
CHARGING STATUS
(LED ON BATTERY CHARGER)
MEANING
Red The charger is “fast charging” the inserted battery pack.
Green
Either there is no battery pack on the charger
OR
The battery pack charge cycle is complete and the battery is ready for use.
Below is a copy of the decal on the charger summarizing the above information:
Note that the battery pack will begin to self-discharge when removed from the charger so the longer it remains
off the charger the less its capacity will be when it is finally inserted into a PowerRoll and used.
f the battery pac is ischarge to the poit at hich the performace a spee begis to rop off
cosierably the battery shol be charge ischargig beyo this poit ca potetially amage a
ecrease the service life of the battery pac atteries shol be charge as soo as they are eplete to
obtai the logest service life from them atteries that are left i a eplete state ill eteriorate a lose
capacity faster tha batteries that are charge as soo as they are eplete fter a ormal charge cycle the
battery shol be remove from the charger
7 of 20 2020/10

Rechargeable Battery Care
Rechargeable batteries require routine care. Read and follow the guidelines in this document to safely use PowerHandling
rechargeable batteries and achieve the maximum battery life span.
Overview
Do not leave batteries unused for extended periods of time, either in the product or in storage. When a battery has been
unused for 6 months check the charge status and charge or dispose of the battery as appropriate. The typical estimated life
of a Lithium-Ion battery is about two to three years or 400 to 600 charge cycles, whichever occurs first. One charge cycle is a
period of use from fully charged, to fully discharged, and fully recharged again. All rechargeable batteries have a limited life
and will gradually lose their capacity to hold a charge. This loss of capacity (aging) is irreversible. As the battery loses capacity,
the length of time it will power the product (run time) decreases. Rechargeable batteries continue to slowly discharge (self-
discharge) when not in use or while in storage. Routinely check the battery’s charge status.
Battery Maintenance
Observe and note the run time that a new fully-charged battery provides for powering your product. Use this new battery run
time as a basis to compare run times for older batteries. The run time of your battery will vary depending on the product’s
configuration and your specific application. Routinely check the battery’s charge status. Carefully monitor batteries that are
approaching the end of their estimated life.
Consider replacing the battery with a new one if you note either of the following conditions:
The battery run time drops below about 80% of the original run time.
The battery charge time increases significantly.
If a battery is stored or otherwise unused for an extended period, be sure to follow the storage instructions in this document.
Best practices for Li-Ion battery packs
ly se the provie io battery charger
he battery is heavily se allo to cool before placig o charger
io batteries last loger if they are ot ischarge completely
Remove the battery from the charger oce it is flly charge a allo to cool prior to se
o ot charge the battery i a elevate temperatre eviromet   
o ot short termials
o ot amage the batteries crsh ail eform rop etc
o ot pt batteries ito fire
o ot se batteries i a et eviromet
f battery gets etremely hot rig chargig set asie for evalatio
attery operatio is best betee the temperatres of  to   to 
o ot leave a eplete battery charge for very log t is best to recharge as soo as possible
harge io batteries i a area aay from combstibles here they ca be moitore for ay aomaly
that may occr
he storig remove the battery a store it separately from the charger or proct
f storig a battery for a etee ratio ischarge the battery to  capacity   measre
after  mites rest a recharge to this level at  moth itervals
fter a prologe storage perio moitor battery closely for ay aomalies he rechargig to brig it
bac ito service
f yo o ot follo the istrctios a the battery has o charge remaiig he yo chec it cosier
it to be amage o ot attempt to recharge it or to se it Replace it ith a e battery
8 of 20 2020/10

General Care
Avoid storing the battery in extreme temperatures, whether hot or cold
Do not allow the battery to accumulate condensation, as this could cause corrosion or a short-circuit
Recharge the battery after depleting to prolong the life of the battery
Remove battery from charger after charge cycle is complete
Disposal
Recycle your battery responsibly at a local battery-recycling center
DO NOT throw them in the garbage!
Check Rechargeable Battery Recycling Corporation www.Call2Recycle.org for more information
General Principle of Operation
IMPORTANT SAFETY WARNING:
Use only the battery provided with your machine
DO NOT use this battery with any other machine or application that has not been
recommended by PowerHandling
DO NOT disassemble the battery or open the battery case
DO NOT short circuit the discharge terminals on the battery
DO NOT crush or puncture the battery
Keep battery away from excessive heat and/or open flames
Protect the battery from water and other moisture. If the battery becomes wet during
use, dry it as soon as possible.
Failure to follow proper safety instructions will void the warranty, and may create a hazardous
condition that could cause a fire resulting in severe injury or death, and property damage
To overcome the inertia of a heavy load, PowerRolls require a significant amount of traction –both with the
load itself and the ground on which it’s being moved. Regardless of the amount of power (or specifically
‘torque’) generated, the load will not move without the necessary traction.
PowerRolls gain this traction by directing the weight of the load down onto the drive roller to generate the
traction required. In the case of moving cylindrical loads, small diameter / lighter loads can in fact be more of a
problem than larger heavier loads as the weight transfer onto the drive roller is not as good. This problem will
be apparent if the drive roller is observed to slip or spin against the load rather than wedging in under the load
and rotating it. Please refer to the “Trouble-Shooting” section for suggestions on how to address this issue.
9 of 20 2020/10

General Overview of Models Available Within the RVB-Series
PowerHandling’s product line and features are constantly being updated and improved, so please check for
more information and updates at www.powerhandling.com.
The RVB–Series PowerRoll can be ordered with three gearbox options. The gearbox, specifically the
amount of reduction of the gearbox, influences the torque output. Note the gearing does not
change the “power” of the PowerRoll, but rather with each increase in gearing it increases the
torque output while it correspondingly reduces the running speed.
Finally, models can be further customized according to the choice of handle assembly or other
attachments. For example ‘Roller’ models can be configured with one of any of the following:
oCenter Straight handle shaft (“C”)
oSwiveling handle shaft (“S”)
oSwiveling & Pivoting handle shaft (“SP”)
10 of 20 2020/10