TM

OPERATION & MAINTENANCE MANUAL

142865 11/10

www.appletonmfg.com

RollMoverTM Manual

intRoduCtion: Move loads With ease

If your enterprise needs to move heavy loads safely and efficiently, Appleton Manufacturing Divisions new RollMover TM is the tool for you. This light-weight, rechargeable battery powered material mover is designed to help you with even the most difficult load moving challenges, all while improving productivity and eliminating common shop floor dangers.

HDV3 RollMover TM

HD Battery Pack

HDLRV3 RollMover TM Battery Charger

Manufacturer Appleton Manufacturing Div. 1025 Breezewood Lane Neenah, WI 54956 USA 1-800-531-2002

Sales - USA

Service and Spare Parts - USA

Appleton Manufacturing Div. Appleton Manufacturing Div. 1025 Breezewood Lane 1025 Breezewood Lane Neenah, WI 54956 Neenah, WI 54956 USA USA 1-800-531-2002 1-800-531-2002 Sales Agent UK, Ireland Rolpex, Ltd. PO Box 12 Marple, Stockport Cheshire, SK6 6EF, UK 44 161 449 7707 Service and Spare Parts Agent UK, Ireland Rolpex, Ltd. PO Box 12 Marple, Stockport Chester, SK6 6EF, UK 44 161 449 7707
appleton Mfg. division

RollMoverTM Manual

naMe plate:
Below is an example of the RollMover name plate. the name plate is located inside the battery compartment at the top of the left side frame.

Manufacturer Model Rated Voltage

Manufacturers Phone Serial Number Electrical Drawing Number

Neenah, WI 54956

RollMoverTM Manual

safety notiCes:
general Warning symbol definitions Immediate hazards which WILL result in serious injury or death. The instruction is stated first followed by the possible outcome of failing to heed the instruction. Hazards or unsafe practices which COULD result in serious personal injury or death. Hazards or unsafe practices where failure to heed instructions MAY result in minor personal injury or property damage. Alerts operator to important messages or operating procedures. RollMoverTM safety notices
DANGER

DANGER

WARNING

CAUTION

Do not use the RollMoverTM as a roll chuck or stopping device. Failure to heed instructions WILL result in personal injury and /or property damage. Always switch the RollMoverTM OFF when not in use. Remove the battery pack when servicing the RollMoverTM. Remove the battery pack if the RollMoverTM is not being used for an extended period of time. Noise level at the workstation is below 76dB(A).
RollMoverTM weights (RollMoverTM and Battery):

DANGER CAUTION

CAUTION

CAUTION

HDV3: 50Kg, HDLRV3: 56Kg.

Move rolls safely! Make sure there are no people or obstacles in the area before moving rolls.
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oveRvieW:
the components listed below are for your reference. each component is discussed in this manual. Forward/Reverse Switch Twist-Grip Swivel Handlebar Throttle Battery ON/OFF Compartment Switch Drive Roller Mobility Wheels Battery Handle Strap Battery Charging Cradle and Connector Battery Connector and Handle

Charging Light

Air Intake Filter AC line power cord

Display Window

Battery Charger

Power Switch

The means of disconnecting the battery charger from the power supply is the AC line plug which must be located in the vicinity of the battery charger.
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RollMoverTM Manual

attaChing the handleBaR: The RollMoverTM is shipped with the handlebar detached. Please follow these instructions to assemble the unit:

Yoke

Insert shoulder bolt through handlebar bushings and thread into yoke

Tighten shoulder bolt using allen wrench provided

Cable Clip

Connect wire harnesses as shownmake sure they click together

Tuck wire harness connection into space below yoke. Insert cable into clip as shown leaving some slack cable to allow handlebar to rotate without pinching or kinking the cable.

appleton Mfg. division

RollMoverTM Manual

hoW to use the RollMoverTM:

ChaRging BatteRy paCks
Must folloW this sequenCe: Plug the charger into an appropriate 230VAC wall outlet Switch the Charger ON using the Power Switch Verify that the display shows the Waiting for batt. screen shown below Waiting for batt. Source = 12.00V
Note: all values shown on these screens are examples

Place Battery Pack into the Charging Cradle using the Battery Handle Strap Plug Battery Pack into the Charger Connector Verify that the display shows the Chg screen shown below and that the Charging Light is illuminated 3.00A Chg 29.45V 0:22:45 1.840AH

Charge is complete when the Charging Light turns off and the display shows the Peaked @... screen shown below Peaked @ 29.45V 0:48:45 3.450AH

Unplug the Battery Connector from the Charger Connector-use the Battery Connector Handle - DO NOT pull on the batttery wires! Remove the Battery Pack from the Charger Cradle-use the Battery Handle Strap - DO NOT lift with the batttery wires! Battery Handle Strap Battery Pack Battery Connector & Handle Charger Connector Charging Light Display Window Power Switch AC line power cord

Battery Charging Cradle

Neenah, WI 54956

RollMoverTM Manual

install BatteRy paCk into RollMoverTM Make sure the RollMoverTM is turned off. Open the rear cover of the RollMover TM and install a fully charged Battery Pack (see Charging Battery Packs) into the RollMover TM. DO NOT lift Battery Pack by the wires - use the Battery Handle Strap! Plug the Battery Connector into the RollMover TM Connector. Close the rear cover. The RollMover TM is now ready to go to work.
Battery Handle Strap Place charged Battery Pack into Battery Compartment Battery Pack Battery Connector & Handle Battery Holder RollMover TM Connector

Connect Battery Connector securely to RollMover TM Connector Close Rear Cover

Connectors

Rear Cover

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RollMoverTM Manual

Moving Rolls Before moving a roll, check that the RollMover TM is functioning properly. Switch the RollMover TM on, select forward or reverse direction and slowly turn the Twist-Grip Throttle counterclockwise. The drive roller should turn slowly and speed up with increased throttle twist.
ON/OFF Switch

Twist-Grip Throttle (turn counter-clockwise)

FWD/REV Switch

First, position the Swivel Handle as needed for the roll to be pushed. Push the RollMover TM squarely under the roll until the Drive Roller is in full contact with the roll. Slowly turn the Twist-Grip Throttle counter-clockwise. The RollMoverTM will engage the roll and roll it away from you.

Continue to apply throttle for desired rolling speed. To stop the RollMover TM, simply turn the Twist-Grip Throttle back clockwise until the RollMover TM stops.
CAUTION

Be aware that the roll may continue to roll until it coasts to a stop.

When finished moving rolls, always switch the RollMover TM off and park it in a safe place. Push downward on the swivel handle to lift the support rollers. The rear mobility wheels are used to move the RollMover TM and conserve battery life when not moving rolls.
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RollMoverTM Manual

WARNING

In the unlikely event that the RollMover fails to stop after turning the twist grip throttle all the way clockwise and/or turning the RollMover off by the on/off switch, push down and pull back on the handle to disengage the RollMover from the moving roll. Switch the RollMover off, if not already done, and disconnect the battery. Call Customer Service for technical assistance (see sales & technical support contact information on page 1).
Push Down

Pull Back

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RollMoverTM Manual

MaintenanCe:
See drawings located in the Appendix for part numbers. Call Customer Service to order parts or for technical assistance (see sales & technical support contact information on page 1). The following maintenance tasks are recommended to ensure proper operation of your RollMover TM and its associated components.
CAUTION

Remove battery pack before performing any service to the RollMover TM. Always follow vendors instructions for safe handling of lubricants.

CAUTION

daily Check Twist-Grip Throttle operation. Make sure it operates smoothly and returns FULLY to the off position when released. Check wiring for loose connections and fraying. Weekly become loose, retighten using thread locking compound as needed. Check rollers. Inspect for wear, replace if needed (See drawing for instructions). Check bearings (we recommend replacing roller bearings when rollers are replaced). eveRy 3 Months
Clean and lubricate roller chain and sprockets: Check all fasteners for tightness. Should a fastener

Lubricate chain and sprockets with SAE 30 oil, check that sprockets are aligned, keys are in place and set screws are tight. Be sure to reinstall the chain guard! Check motor brushes for wear. Replace if worn. See MOTOR BRUSHES section on next page. Clean cooling air intake filter of the Battery Charger.
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RollMoverTM Manual

MotoR BRushes The RollMover TM is powered by a Brushed DC Motor. The motor has 4 brushes that must be checked periodically and replaced when worn. The motor guard must be removed to perform the following procedures. To check brushes:
Remove brush cap, and fiber washer Carefully pull brush assembly out of housing

New Brush To install brushes:

Worn Brush-time to replace

If re-using the brushes, make sure to reinstall them in the same orientation as they were removed. Thoroughly clean carbon dust from inside motor by blowing out with compressed air aimed into empty brush holes in endbell of motor. CAUTION Wear eye protection when using compressed air to clean motor Slide brush assembly into housing Place the fiber washer on top of the spring holder Screw on the brush cap, DO NOT OVERTIGHTEN! IMPORTANT!!! Always break in new brushes by running the RollMoverTM at about 1/2 speed under no load conditions for 5-10 minutes.
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RollMoverTM Manual

BatteRy CaRe Depending on condition of use, each Battery Pack should provide approximately 300-500 charge cycles if properly cared for. ONLY carry Battery Packs by the Battery Handle Strap. Always use the handle provided on the battery connector to plug and unplug the battery. It is best to fully discharge the Battery Pack before recharging it. Store battery packs in a dry, cool place. Avoid storing Battery Packs in areas of extreme temperature. Store Battery Packs in a discharged state for optimum battery life. Regularly inspect the Battery Packs for any signs of damage to the outer wrap, wires, and connector. Replace Battery Packs when their performance begins to fade or if there is any sign of damage.
CAUTION

Use only with recommended charger Do Not incinerate Do Not crush Do Not immerse in liquid Do Not lift by wire leads, use Battery Handle Strap Cells may vent or rupture if incorrectly handled Do Not open battery Always observe polarity (+/-) Do not short circuit, may ignite, explode, leak, or get hot causing personal injury

Nickel Cadmium batteries must be recycled or disposed of properly. For information about recycling call: 1-800-822-8837

Neenah, WI 54956

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RollMoverTM Manual

BatteRy ChaRgeR
Check that the cooling fan is operational, you should

feel air blowing out through the top of the Battery Charging Cradle.

Clean Air Intake Filter media using clean/dry compressed air. This filter media may also be washed with water and mild soap then allowed to dry. Periodically replace the Air Intake Filter media.
DANGER

Unplug battery charger from power source before opening battery charger cover.

clean/dry compressed air.

Battery Connector

Blow any dust from inside charger enclosure using

Battery Charging Cradle

Charging Light

Display Window

Air Intake Filter & media

Power Switch

AC line power cord

The Charge Current is factory set at approximately 3.0 amps. Attempting to charge at rates higher than 3.0 amps can result in a charger fault. If a fault is suspected, please refer to the TROUBLESHOOTING: BATTERY CHARGER section of this manual.

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RollMoverTM Manual

tRouBleshooting: RollMover TM

PROBLEM

POSSIBLE CAUSES

SOLUTION Turn switch on Check switch Check throttle operation (see elec. schem) Replace power fuse Replace wiring as needed Charge battery Inspect battery connector, connect battery Contact Appleton Mfg. Replace drive chain Replace chain sprocket Replace pinion gear (motor)

RollMover TM does not Switch turned off respond to throttle input Switch faulty Faulty twist-grip throttle Power fuse blown Broken electrical circuit Battery not charged Battery not properly connected Faulty speed controller RollMoverTM motor turns Broken drive chain Broken chain sprocket but the unit does not Broken pinion gear (motor) move forward

RollMoverTM exhibits decreased performance

Weak battery Motor brushes worn Faulty power wiring Faulty speed controller Overheated speed controller

Charge battery, replace if needed Replace motor brushes (see pg 10) Inspect/replace power wiring Contact Appleton Mfg. Allow speed controller to cool

See drawings located in the Appendix for part numbers. Call Customer Service to order parts or for technical assistance (see sales & technical support contact information on page 1).

Neenah, WI 54956

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RollMoverTM Manual

tRouBleshooting: BatteRy ChaRgeR

PROBLEM Battery not charging POSSIBLE CAUSES SOLUTION Charger not powered Plug in and turn power switch ON Charger fuse blown Replace fuse (see page 12) Charger Module faulted Reset Charger Module (see page 14) Battery not properly connected Inspect battery connector, connect battery

Charger Module Display Screen Descriptions

Charger Module Display Screen

Amps Adjust Knob Note the indicator arrow indicating factory-set position of the Charge Current when aligned with the white line on the knob All values shown are examples Charger is ready to charge battery Battery is being charged Charge Current (amps) Charge Voltage

Waiting for batt. Source = 12.00V

3.00A Chg 29.45V 0:22:45 1.840AH

Time elapsed (hr:min:sec) Amount of charge delivered to battery so far (amp-hours)

Charger faulted & needs to be reset

Battery is fully charged

Source < 10.50V 0:22:45 1.840AH

See following page for resetting instructions
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Peaked @ 31.78V 0:48:46 3.850AH

appleton Mfg. division

RollMoverTM Manual

Resetting the ChaRgeR Hazardous voltage present inside charger enclosure. DANGER Only authorized personnel should open enclosure to perform this procedure! The Charge Current is factory set at approximately 4.0 amps. Attempting to charge at rates higher than 4.0 amps can result in a charger fault. If a fault is suspected, do the following: 1) Look through the display window to verify that the Charger Module is displaying the Source < 10.50V fault screen 0:22:45 1.840AH
All values shown are examples

2) Disconnect battery from the charger (see pages 5-6) 3) Open the enclosure door and turn the Amps Adjust Knob counter-clockwise until the mark on the knob is approximately in the 9 oclock position 4) Turn the charger OFF and wait about 5 seconds 5) Turn the charger ON and wait about 5 seconds 6) Verify that the charger module is reset and displaying the ready to charge screen Waiting for batt. 7) Plug battery into charger connector 8) Verify that battery is charging 9) While battery is charging, slowly turn the Amps Adjust knob clockwise until the charge current of approx. 4.00 amps (or less) is displayed. 3.00A Chg 29.45V 10) Close and secure the enclosure door
0:22:45

Source = 12.00V

1.840AH

See drawings located in the Appendix for part numbers. Call Customer Service to order parts or for technical assistance (see sales & technical support contact information on page 1).
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WaRRanty

LIMITED WARRANTY, LIMITED REMEDIES AND DISCLAIMER OF LIABILITIES Seller warrants that the Goods will be of Sellers standard quality and free from defects in manufacturing and materials. This warranty shall extend for a period of six months from the date of delivery. Should any failure to conform to this warranty appear within the six month period, Buyer must give written notice and a specific description of such nonconformity to Sellers customer service representative within twenty days of the discovery of such nonconformity or it shall be deeded to have been waived. Seller must be given the opportunity to inspect the Goods. Seller will, at its option, remedy any nonconformity by repairing any defective Goods, making available repaired or replacement Goods, or by the issuance of a credit for the defective goods. Replacement of nonconforming Goods means delivering to Buyer conforming Goods. It does not include any cost or liability for replacing the replacement Goods in or on any other product. Repair or replacement of defective Goods, or the credit to Buyer of the value thereof, does not extend the six month warranty period. THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. With respect to parts not manufactured by Seller, the warranty obligations of Seller shall in all respects conform and be limited to the warranty actually given to Seller by the supplier. This warranty excludes consumable items. THE REMEDIES SET FORTH ABOVE SHALL CONSTITUTE BUYERS EXCLUSIVE REMEDIES FOR SELLERS BREACH OF ANY WARRANTY WITH RESPECT TO THE GOODS OR ANY OTHER LIABILITY OF SELLER TO BUYER (OTHER THAN WARRANTIES RELATING TO TITLE AND INFRINGEMENT), INCLUDING ANY ARISING OUT OF THE NEGLIGENCE OF SELLER, STRICT LIABILITY IN TORT OR ANY OTHER LEGAL THEORY. SELLERS LIABILITY HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE GOODS SOLD BY SELLER TO BUYER WHICH ARE PROVED TO BE DEFECTIVE. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER OR ANYONE CLAIMING THROUGH BUYER FOR (AND BUYER AGREES TO HOLD SELLER HARMLESS AGAINST) ANY DAMAGES, WHETHER DIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, INCLUDING LOST PROFITS, ARISING OUT OF THE SALE, PURCHASE OR USE OF OR INABILITY TO USE ANY GOODS, OTHER THAN AS EXPRESSLY SET FORTH HEREIN. Sellers warranty shall not be enlarged and no obligation or liability shall arise out of Sellers rendering of technical advice or services in connection with Buyers purchase of the Goods. In the event that Buyer provides Seller with specifications for Goods to be sold hereunder, and requests that the Goods to be produced in accordance with such specifications, Seller is under no duty to test, analyze, or study such specifications to determine whether they are appropriate for Buyers needs.In such event, Seller makes no representation or warranty that the Goods produced in accordance with such specifications will be suitable for Buyers application. ANY WARRANTIES SPECIFICALLY SET FORTH HEREIN, AND ANY LIABILITY OF SELLER FOR ANY BREACH OF WARRANTY, ARE CONDITIONED UPON PROPER STORAGE AND USE OF THE GOODS. IMPROPER STORAGE, MAINTENANCE, HANDLING, INSTALLATION, REPAIR, ALTERATION, USE OF THE GOODS, OR USE OF PARTS NOT SUPPLIED BY APPLETON MFG. DIV. WILL VOID ALL WARRANTIES CONTAINED HEREIN.

Appleton Mfg. Division

P.O. Box 618

Neenah, WI. 54957-0618