IOP-080 Automatic Transfer Carriage (ATC)

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Automatic Transfer Carriage (ATC) Parts & Service Manual

General Information

The Automatic Transfer Carriage (ATC) is used to remove large batteries from electric industrial trucks. It is only used when attached to a host truck (fork truck / pallet truck). The host vehicle provides the ability for the ATC to raise and lower, as well as to travel across the floor.

The ATC is run by an operator that would typically be standing next to the ATC. The ATC is constructed of a steel frame, which houses the electrically powered hydraulic power unit. This provides the power for the arm to travel inward and outward. This function is controlled by a valve with a lever on the dash of the ATC. For vacuum cup equipped units, a vacuum pump is also contained within the frame. For magnet equipped units, the magnet is powered by the DC voltage of the host truck battery.

General Safety

Read and understand all instructions and warnings before using or servicing this equipment. Keep these instructions for future reference. Refer to the host pallet truck manual(s) for proper operation and service procedures before performing any service or maintenance to the pallet truck and/or Automatic Transfer Carriage (ATC) unit.

• ATC units shall only be used indoors in an industrial setting on a hard, nonslip, and level floor without defects including but not limited to holes, gouges, cracks, drains or obstacles comprised of concrete or other suitable industrial material.

• Forces required to operate the ATC vary with weight of the load, floor conditions, and carriage conditions.

• ATC units are not designed to be shipped or transported after initial delivery.

• A licensed structural engineer should be consulted prior to installing an ATC on any building level other than the ground floor.

• Perform system and safety check before operating.

• Failure to follow these instructions and warnings may result in property damage, personal injury or death.

WORK AREA

• Keep work area clean and well lit. Cluttered work areas and poor lighting can lead to accidents.
• Clean up/contain any fluid spills immediately to prevent slips or falls.
• Be aware of potential hazards when performing any service or maintenance to the unit.

SERVICE & MAINTENANCE

Service personnel shall wear Personal Protective Equipment (PPE) appropriate for the task being performed.

LOCKOUT/TAGOUT Lockout/tagout the SWT per your corporate policy, if damaged or not functioning properly. Lockout/tagout and de-energize all systems prior to performing any maintenance or service to unit.

LEAD-ACID BATTERY EXPLOSION HAZARD DO NOT allow open flames or sparks of any kind near a battery. Highly explosive gas is generated when charging a battery that can remain in battery cells for extended periods of time after charging is complete. Always wear appropriate PPE including rubber apron, gloves, boots and full face shield when performing service or maintenance to any lead-acid batteries. DO NOT place metal or other conductive objects on top of battery. Arcing may occur causing damage to the battery and/or serious personal injury or death. Use only chargers matching the voltage and amperage of the battery being charged. Overcharging a battery can cause damage to the battery, charger and/or serious personal injury or death. Turn off charger before disconnecting battery from charger. Arcing between battery and charger connectors can cause damage to the connectors and/or serious personal injury or death.

HYDRAULIC HAZARDS AVOID HIGH PRESSURE FLUIDS - Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. DO NOT use your hand. Any fluid injected into the skin under high pressure should be considered a serious medical emergency despite an initial normal appearance of the skin. There will be a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately.

Operational Safety

	ELECTROMAGNET HAZARD Units equipped with magnetic extraction generate strong magnetic fields. Persons with pacemakers SHOULD NOT operate or be in close proximity to equipment during operation. Failure to comply with this direction could result in serious personal injury or death.

OPERATIONAL SAFETY

• Only personnel trained in the proper and safe operation of ATC units may operate or service the ATC.
• Operators shall wear appropriate PPE suitable for working with industrial lead-acid batteries while operating the ATC (see General Safety).
• All data plates, warning labels, placards, etc. shall be in place and legible at all times. Contact BHS for re-placement data plates, warning labels, placards or instructions.
• All users and service personnel shall be familiar with the meaning and risks associated with all data plates, warning labels, etc.
• All operators and service personnel shall be aware of potential crush and shear points while operating or servicing the ATC.
• ATC shall be operated in an area with ambient light levels of at least 50 lux.
• Keep hands and arms out of the battery compartment while operating the ATC.
• Engage the battery stop(s) and properly secure the battery prior to transporting the battery.
• Attach hook and chain (if equipped) to the battery prior to transporting the battery.
• Avoid abrupt changes in direction when transporting a battery in the ATC to prevent loss of the battery and/or loss of control of the pallet truck/ATC unit.
• Remove ATC from service if damaged, defective, or operating improperly (or becomes such while operating) until repairs can be made to correct any problem(s).
• ATC units must only be used to change batteries at the lowest level when used as a backup in a multi-level system to prevent loss of the battery and/or loss of control of the lift truck/ATC unit.

DO’s AND DON’T’s

• DO NOT exceed the maximum capacity of ATC.
• DO NOT perform ANY battery changes above the lowest level in a multi-level system.
• DO NOT modify or fit the ATC with attachments with-out prior, written approval from BHS.
• DO NOT perform any maintenance or service to the pallet truck or ATC with a battery loaded on the ATC.
• DO NOT allow anyone to ride in or on the ATC.
• DO NOT operate the ATC with any guard or cover re-moved unless required for maintenance or repair.
• Disconnect ATC from the host truck’s battery prior to charging the host truck battery.
• Disconnect ATC from all power sources before at-tempting to perform service or maintenance to the unit.
• Mount the ATC to a pallet truck with a capacity equal to or greater than the maximum capacity of the ATC.
• DO NOT lift the ATC while attached to the host truck.

• DO NOT use the ATC in a manner for which it is not intended.  Some examples of prohibited use are but not limited t
  • As a scooter or to transport people
  • As a vehicle jack
  • To lift loads greater than its rated load capacity
  • Where unintentional movement may exist
  • Having direct contact with foodstuffs
  • In a potentially explosive atmosphere

De-Energization

ATC STANDARD

1. Disconnect the host truck's battery from its battery charger (if connected). If equipped with onboard battery and charger, unplug the charger.

2. Disconnect the DC power supply.

	Failure to Disconnect electrical power to the ATC could result in electrical shock. Serious personal injury or death will occur.

a. If equipped with an onboard battery, remove the positive cable from the battery post. Secure the positive cable so it cannot contact the positive battery post. See Figure 1 .

FIGURE 1

b. If connected to the host truck’s battery, unplug/disconnect the power connector/leads to the battery. See Figure 2.

FIGURE 2

3. Cycle the manual valve several times to relieve stored hydraulic pressure. See Figure 3.

Failure to release any stored hydraulic pressure could result in injury from: Escaping hydraulic fluid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section). Unexpected movement of hydraulic component

FIGURE 3

ATC WITH REMOTE

1. Unplug the battery charger (if equipped).

2. Remove the green wire from the small, positive terminal of the solenoid. Secure the green solenoid wire so it cannot contact any other terminals, ground points or metal parts. See Figure 1.

FIGURE 1

3. Activate the IN and OUT buttons of the remote to relieve stored hydraulic pressure. See Figure 2.

FIGURE 2

4. Disconnect the DC power supply.

	Failure to Disconnect electrical power to the ATC could result in electrical shock. Serious personal injury or death will occur.

a. If equipped with an onboard battery, remove the positive cable from the battery post. Secure the positive cable so it cannot contact the positive battery post. See Figure 3.

FIGURE 3

b. If connected to the host truck’s battery, unplug/disconnect the power connector/leads to the battery. See Figure 4.

FIGURE 4

Labels & Placards

Operators should be familiar with the meaning of the following labels and placards found on the ATC to ensure proper and safe operation.

	Read and understand instruction manual prior to use.
	Consult manual for technical procedure.
	DO NOT operate with guards or covers removed.
	DO NOT operate by or in close proximity to people with pacemakers.
	Chain Entanglement Hazrd Moving chains and sprockets can crush and cut Keep hands and fingers clear. DO NOT operate with guards removed. De-energize and lockout/tagout before servicing.
	Electrical Hazard Energized components can cause electrical shock. De-energize and lockout/tagout before servicing.
	Strong Magnet Field Hazard Attraction between magnet and metallic objects can crush. Keep unsecured metallic objects away from magnet. De-energize and lockout/tagout before servicing.
	Extractor Arm Control In/Out
	Magnet On / Off (if Equipped)
	Vaccum On / Off (if Equipped)
	Power: Push & Hold

Model Number & Options

NOMINAL ROLLER COMPARTMENT WIDTH

24 = 24" Wide Compartment

30 = 30" Wide Compartment

36 = 36" Wide Compartment

42 = 42" Wide Compartment

CANTILEVER / ROLLER BED EXTENSION *

CAN-7 = 7" Extension At Top, No Roller Bed Extension

CAN-7-6 = 7" Extension At Top, 6" Roller Bed Extension

CAN-14-6 = 14" Extension At Top, 6" Roller Bed Extension

CAN-14-8 = 14" Extension At Top, 8" Roller Bed Extension

* If no Cantilever option is listed (e.g. CAN-7) the unit is considered to be "standard" with no arm travel extension or roller bed extension.

EXTRACTION METHOD *

HC/VAC = Vacuum with Backup Hook & Chain

HC/MAG = Magnet with Backup Hook & Chain

* If no extraction method is listed (i.e. VAC or MAG) the extraction is Hook and Chain only.

MOUNTING METHOD

BLTON = Bolt on to Pallet Truck

FP = Fork Pockets for Lift Truck

FP-C = Fork Pockets for Pallet Truck

FP-3 = 3-way Fork Pockets for Pallet and Lift Truck

MPJ = Permanent Welding to Pallet Truck

ADDITIONAL OPTIONS *

ESC = Extra Service Capacity

HD = Heavy Duty Extraction Option

LPF = Low Profile Frame

LP = Low Profile Bolt in Slides

QDY = Electric Quick Disconnect “Y” Connector

MLI = Magnet Light Indicator (Magnet Units Only)

UNCTD = Uncoated Rollers (ATC-24 Units Only)

FS = Rear Friction Strips

RGD = Chain Guard Rubber Guards

BSELV = Base Elevation

DIR = Drop In Roller

DIR-LG = Drop In Roller for use with Bed Extension

DIR-FS = Drop In Roller with Rear Friction Strips

2TIER = Two Tier Separate Roller Compartments

BATT = Self-Contained Battery

CHGR = Self-Contained Charger (for use with ATC-BATT)

RMT = Remote Pendant Control

NS = Non-Standard / Custom Design or Components

* Consult factory for "NS" units to verify any custom components, if applicable