IOP-080 Automatic Transfer Carriage (ATC)

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Automatic Transfer Carriage (ATC) Parts & Service Manual

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

ATC Model Number Anatomy

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 Roller Compartment (Upper and Lower 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

Models & Specifications

	ATC 24	ATC 30	ATC 36	ATC 42
Max. Load Capacity 1	4,000 lbs / 1814 kg	4,000 lbs / 1814 kg	4,000 lbs / 1814 kg	5,000 lbs / 2268 kg
Voltage Requirement	12/24 V dc	12/24 V dc	12/24 V dc	12/24 V dc
Hydraulic Pump	Gear	Gear	Gear	Gear
Extractor Arm Travel Speed	0-24 ft/min 0.12 m/s	0-24 ft/min 0.12 m/s	0-24 ft/min 0.12 m/s	0-24 ft/min 0.12 m/s
Battery Attachment	Hook & Chain Standard Vacuum & Magnet Optional	Hook & Chain Standard Vacuum & Magnet Optional	Hook & Chain Standard Vacuum & Magnet Optional	Hook & Chain Standard Vacuum & Magnet Optional
Optional Magnet	4” x 12” / 101 mm x 305 mm	4” x 12” / 101 mm x 305 mm	4” x 12” / 101 mm x 305 mm	4” x 12” / 101 mm x 305 mm
Optional Vacuum 2	10” Diameter / 254 mm	12” Diameter / 305 mm	12” Diameter / 305 mm	12” Diameter / 305 mm
Primary Drive Reduction	2:1	2:1	2:1	2:1
Primary Drive Chain Size	#50	#50	#50	#50
Roller Diameter	2.4” / 61 mm	2.4” / 61 mm	2.4” / 61 mm	2.4” / 61 mm
Roller Shaft Size	7/16” Hex / 11 mm	3/4” Hex / 19 mm	3/4” Hex / 19 mm	3/4” Hex / 19 mm
Battery Width	6” Min. / 23” Max. 152 mm Min. / 584 mm Max.	6” Min. / 29” Max. 152 mm Min. / 736 mm Max.	6” Min. / 35” Max. 152 mm Min. / 889 mm Max.	6” Min. / 41” Max. 152 mm Min. / 1041 mm Max.
Battery Length 3	41” Max. / 1041 mm	41” Max. / 1041 mm	41” Max. / 1041 mm	41” Max. / 1041 mm
Min. Battery Height Hook & Chain Magnet Vacuum	12” / 305 mm 18” / 457 mm 21” / 533 mm	12” / 305 mm 18” / 457 mm 21” / 533 mm	12” / 305 mm 18” / 457 mm 21” / 533 mm	12” / 305 mm 18” / 457 mm 21” / 533 mm
Overall Length	62.75” / 1594 mm Standard 67.75”/ 1772 mm CAN-7 Option 76.75" / 1949 mm CAN-14 Option	62.75” / 1594 mm Standard 67.75”/ 1772 mm CAN-7 Option 76.75" / 1949 mm CAN-14 Option	62.75” / 1594 mm Standard 67.75”/ 1772 mm CAN-7 Option 76.75" / 1949 mm CAN-14 Option	62.75” / 1594 mm Standard 67.75”/ 1772 mm CAN-7 Option 76.75" / 1949 mm CAN-14 Option
Overall Width	29.5” / 749 mm	35.5” / 902 mm	41.5” / 1054 mm	47.5” / 1207 mm
Overall Height	34” / 864 mm	34” / 864 mm	34” / 864 mm	34” / 864 mm
Base to Roller Height	3” / 76 mm	3” / 76 mm	3” / 76 mm	3” / 76 mm
Roller Width	24.5” / 622 mm	30.5” / 775 mm	36.5” / 927 mm	42.5” / 1079 mm
Extended Arm Reach (Beyond Roller Bed)	6” / 152 mm Standard 13” / 330 mm Cantilever	6” / 152 mm Standard 13” / 330 mm Cantilever	6” / 152 mm Standard 13” / 330 mm Cantilever	6” / 152 mm Standard 13” / 330 mm Cantilever
Rated Draw Bar Pull	1,000 lbs / 453 kg	1,000 lbs / 453 kg	1,000 lbs / 453 kg	1,000 lbs / 453 kg
Average Draw Bar Pull	750 lbs / 340 kg Vacuum 775 lbs / 351 kg Magnet	1,000 lbs / 450 kg Vacuum 775 lbs / 351 kg Magnet	1,000 lbs / 450 kg Vacuum 775 lbs / 351 kg Magnet	1,000 lbs / 450 kg Vacuum 775 lbs / 351 kg Magnet
Service Weight (unloaded)4	580 lbs / 263 kg	640 lbs / 290 kg	700 lbs / 317 kg	770 lbs / 349 kg

NOTES: BHS recommends that high-speed travel be disabled on pallet truck and maximum speed set at turtle or lowest setting.

¹ Verify capacity of pallet truck being used at the specified load center (minimum 34” with 38” battery). Load center increases by 0.5” (12.7 mm) for every inch of battery over 38” (965 mm) in length. Certain options may affect load capacity. Consult factory.

² Minimum battery width for 10” (254 mm) diameter vacuum is 11.5” (292 mm). Minimum battery width for 12” (305 mm) diameter vacuum is 13.75” (350 mm).

³ Consult factory for additional options.

⁴ Weight does not include options. Add 80 lb (36 kg) for magnet extraction.

Installation

The ATC can be mounted permanently by welding it to a pallet truck, semi-permanently by bolting it to a pallet truck using the bolt on option, or can be removable by way of fork pockets (FP-C and FP options.)

The following instructions will guide you through the installation of your ATC.

PERMANENT MOUNTING (WELDING) - STANDARD UNITS

1. Center the ATC on the forks of the pallet truck with the rear of the unit approximately 1" away from the pallet truck power head.
2. Shim the unit to obtain 1/4"-1/2" rearward pitch. NOTE: Shim thickness will vary depending upon the amount of fork deflection and/or linkage wear of pallet truck load wheels. 1/4"-1/2" rearward pitch should be verified through the entire lift range of the pallet truck.
3. Weld the unit to the forks as shown. NOTE: 27" x 48" or 27" x 60" forks are recommended. Some applications may require 27" x 60" forks only.

PERMANENT MOUNTING (WELDING) - BSELV UNITS

1. Center the ATC on the forks of the pallet truck with the rear of the unit approximately 1" away from the pallet truck power head.
2. Verify rearward pitch. BSELV units are designed with 1/4" rearward pitch built into the frame structure. If unit does not have the required 1/4"-1/2" rearward pitch when placed on the pallet truck forks, shim the front of the unit to achieve the proper pitch. NOTE: Shim thickness will vary depending upon the amount of fork deflection and/or linkage wear of pallet truck load wheels. 1/4"-1/2" rearward pitch should be verified through the entire lift range of the pallet truck.
3. Weld the unit to the forks as shown. NOTE: 27" x 48" or 27" x 60" forks are recommended. Some applications may require 27" x 60" forks only.

BOLT ON MOUNTING

1. Center the ATC on the forks of the pallet truck with the rear of the unit against the pallet truck power head.
2. Shim the unit to obtain 1/4"-1/2" rearward pitch. NOTE: Shim thickness will vary depending upon the amount of fork deflection and/or linkage wear of pallet truck load wheels. 1/4"-1/2" rearward pitch should be verified through the entire lift range of the pallet truck.
3. Tack weld the shim to the unit to prevent it from moving.
4. Locate the supplied mounting plates and hardware.
5. Position mounting plate underneath one of the pallet truck forks aligned with the mounting holes in the rear rail of the ATC.
6. Insert the 3/8-16 x 4" mounting bolts through the holes in the mounting plate and into the mounting holes of the unit. See Figure 1.
   

   FIGURE 1
7. Place one supplied flat washer and locking nut on each of the mounting bolts.
8. Tighten the lock nuts evenly, ensuring the mounting plate is flat against the bottom of the fork when finished.
9. Repeat Steps 5-8 for the opposite mounting plate.

FP-C MOUNTING

1. Lower the pallet truck forks to the fully lowered position.
2. Slowly drive the pallet truck into the fork pockets, ensuring full engagement of the fork pocket "tongues" under the pallet truck power head. See Figure 2. NOTE: Minor modification of the fork pocket "tongues" may be required to attain full engagement with some pallet trucks.
   

   FIGURE 2

	DO NOT use an ATC equipped with the FP-C option with a lift truck. A dangerous load shift can occur when handling a battery which can cause a possible loss of the battery and/or ATC and possible tip-over of the lift truck in which both situations can result in damage to the equipment as well as personal injury or even death.

FP-MOUNTING

1. Lower the lift truck forks to approximately 1/2"-3/4" off the floor.
2. Position the forks to their widest point that will fit into the fork pockets.

Slowly drive the lift truck into the fork pockets until the forks are fully engaged in the fork pockets. See Figure 3.

FIGURE 3

ELECTRICAL CONNECTIONS

For ATC units equipped with the "QDY" option, unplug the pallet truck connector from the battery connector and plug the lift truck connector into one of the connectors on the ATC harness. Plug the unused connector on the ATC harness into the battery connector.

If the ATC unit was purchased without the "QDY" option, contact your local battery dealer for assistance in connecting the ATC cables to the pallet truck power cables.

NOTE: It is not recommended to hard wire the ATC cables directly to the battery terminals of the pallet truck battery. The ATC must be disconnected from the host truck’s battery before charging the battery.

ATC-QDY

HYDRUALIC SYSTEM

The reservoir should be filled within 1" of the top of the reservoir with approximately 0.8 Gal / 3.0 L of Chevron hydraulic oil AW ISO 32 or equivalent ISO 32 grade hydraulic oil with anti-wear additives and foam suppressant.

NOTE: It is not necessary to bleed the system after filling the unit.

HYDRUALIC RESERVOIR

Operating Controls

OPERATING CONTROLS

1. Serial Number & Data Tag	Lists model number, serial number and specifications of unit.
2. Vacuum/Magnet "On/Off' Switch	Turns Vacuum or Magnet (if equipped) on and off.
3. Extractor Arm Control Handle	Controls extractor arm movement in and out of battery compartment.
4. Power Push & Hold Button	Energizes main hydraulic power unit to move extractor arm in and out.
5. "Ready" Status Indicator Light	Indicates the unit is in a "Ready to Use" status when lit (See Service and Maintenance section if light is not lit.)
6. D.C. Input Power Cables	Main power cables to be connected to host pallet truck battery to supply power to unit.

OPERATIONAL TEST

1. After the initial installation has been completed or any service to the unit has been performed, an operational test should be conducted to ensure proper functions of the unit, prior to returning the ATC back into service.
2. Press and hold the green "Power" button.
3. Slowly move the extractor arm control handle and verify proper arm travel fully in and out of the battery compartment.
4. If equipped with optional vacuum or magnet extraction, verify operation by pulling up on the vacuum/magnet "on/off" switch. For vacuum units, verify the vacuum pump energizes and that there is suction at the vacuum port of the vacuum cup. For magnet units, verify the audible alarm is functioning as well as the magnet by carefully placing something magnetic in front of the magnet.

Operating Instructions

The following instructions will guide you through the basic steps necessary to operate and change batteries with an ATC.

Operators must be equipped with all necessary PPE and be properly trained in the handling of industrial lead-acid lift truck batteries. Operators must also be properly trained in the use of the battery handling equipment as well as the pallet jack or lift truck to which the unit is attached.

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.

OPERATION

1. If not already in place, position industrial truck (pallet or lift truck) which requires a battery change in the appropriate staging area.
2. Disconnect the battery leads and remove any battery restraints.
3. Move the ATC into position such that the battery compartment of the industrial truck is aligned with the roller compartment of the ATC.
4. Verify the battery safety stop(s) at the end of the ATC roller bed is in the down position and the containment bar is secured in the raised position. See Figures 4 & 5.
   

   FIGURE 4
   

   FIGURE 5
5. Adjust the vertical height of the ATC battery compartment to the battery compartment of the industrial truck or slightly higher. DO NOT exceed 1/4" (6 mm) difference. NOTE: It may be necessary to install the drop-in roller (DIR) if not already installed or remove the DIR if installed to obtain the proper roller height. Refer to the "Drop-In Roller Use" section for the proper installation and removal procedures.
6. Depress the green "power: push & hold" button on the control console to energize the main power unit.
7. With the power button depressed, move the extractor arm control handle forward to extend the extractor arm toward the battery.
8. Release the control handle and the power button once the vacuum cup or magnet has made contact with the battery. If the unit is equipped with hook and chain extraction, stop the extractor arm approximately 3"-4" (75 mm-100 mm) from the battery.
9. Energize the vacuum (or magnet) by pulling up on the vacuum (or magnet) on/off switch. For hook and chain units, attach the hook securely through the lifting eye of the battery. See Figure 6.
   

   FIGURE 6
10. Depress the power button and slowly pull the control handle rearward to begin removing the battery from the industrial truck battery compartment while inspecting the vertical alignment of both battery compartments. If vertical adjustment is needed, disengage the vacuum cup or magnet prior to adjusting the height of the ATC.
11. Once the battery is pulled all the way to the rear of the battery compartment onto the slide strips, move the battery safety stop(s) to the upright position and the drop bar to the lowered position. See Figure 7 & 8. Turn off the magnet or vacuum.
    

    FIGURE 7
    

    FIGURE 8
12. The battery may now be transported to the charging area.
13. Align the ATC with an open roller compartment in the battery charging area. Be sure to check the vertical alignment of the two roller compartments.
14. Lower the battery stop(s) and secure the containment bar in the raised position.
15. Move the battery in to the empty roller compartment by depressing the push button and moving the control handle forward. DO NOT FORCE THE EXTRACTOR ARM INTO THE BATTERY AFTER THE BATTERY IS COMPLETELY IN THE STAND.
16. Raise the battery safety stop on the battery roller stand and connect the battery to the appropriate charger. Remove the hook if using hook and chain extraction.
17. Locate and remove a fully charged battery to be installed into the industrial truck by following the above process.

Drop-In Roller Use

The following instructions will guide you through the basic steps necessary to properly set up and install the ATC Drop-In Roller (DIR) staging stand.

SET UP

1. Position the staging stand in the area where it is to be permanently anchored.
2. Ensure the unit is level side-to-side and front to rear. See Figure 9. NOTE: DIR staging stands do not require rearward pitch.
   

   FIGURE 9
3. If the unit is not level, adjust the feet as required by loosening the upper hex nut and adjusting the lower hex nut either up or down as required. Once the unit is level, tighten the upper hex nut. See Figure 10.
   

   FIGURE 10

ANCHORING

1. Once properly positioned, use the appropriate type drill bit for the type of floor the stand is being anchored to and drill holes in the floor through the stand's (4) anchoring pads the depth required per the anchor manufacturer.
2. Install the anchors per the anchor manufacturer's specifications.

INSTALLATION

1. Move the ATC into position such that the battery compartment of the DIR staging stand is aligned with the roller compartment of the ATC and lower the battery stop of the DIR staging stand.

1. Raise the DIR latch plate and roll the DIR unit into the ATC compartment. See Figure 11.
   

   FIGURE 11
2. Ensure the centering angle located on the rear of the DIR unit engages with the mating centering angle located at the rear of the ATC battery compartment. See ATC centering angle shown in Figure 12.
   

   FIGURE 12
3. Once the DIR unit is properly positioned in the ATC roller compartment, lower the latch plate to secure the DIR in place. See Figure 13.
   

   FIGURE 13

	THE DIR LATCH PLATE IS DESIGNED TO ONLY ENGAGE IF THE DIR UNIT IS COMPLETELY AND PROPERLY POSITIONED IN THE ATC ROLLER COMPARTMENT. IN THE RAISED POSITION, THE LATCH PLATE PREVENTS A BATTERY FROM BEING LOADED ONTO THE DIR.

REMOVAL

1. Move the ATC into position such that the battery compartment of the DIR staging stand is aligned with the roller compartment of the ATC.
2. Raise the DIR latch plate and roll the DIR unit onto the staging stand. See Figure 14.
   

   FIGURE 14
3. Raise the battery stop of the staging stand.

MANUAL UNLOADING

Lockout/tagout and de-energize all equipment prior to manually unloading any battery.

In the event of power loss or an operational malfunction of either the ATC or host pallet truck not allowing the battery to be unloaded using normal operating procedures, it is recommended the battery be removed from the ATC using certified and approved vertical extraction methods and devices.

	Read, understand and observe all safety warnings and procedures related to the vertical extraction device(s) being used.

If certified and approved vertical extraction methods and/ or devices are not available and the pallet truck functions normally, the battery may be unloaded by hand as follows:

1. Move the ATC into position such that the roller compartment of the ATC is aligned with an empty battery stand roller compartment. Verify the battery safety stop(s) of the empty roller compartment is in the down position.
2. Adjust the vertical height of the ATC roller compartment with the empty roller compartment or slightly higher. DO NOT exceed 1/4" (6 mm) difference. Verify the battery safety stop(s) at the end of the ATC roller bed is in the down position.
3. Carefully push the battery by hand from the ATC into the battery stand. Move the battery safety stop(s) of the battery stand to the up position.

	Hand position should be carefully selected to prevent accidental crushing. Maintain a secure footing to prevent slips, trips or falls.

Operator's Daily Checklist

Service & Maintenance

The following items are recommended by the factory to have on hand for ATC models to minimize any downtime due to minor breakdown that may occur under normal operating conditions.

BHS PART NUMBER	DESCRIPTION	QTY	REFERENCE SECTION	NOTES
80052005	SLIDE BLOCK KIT	1	1.0.2 - update
80812001	BATTERY STOP KIT	1	1.1.1- update
00162004	VACUUM CUP-10" 3-PC	1		VACUUM UNITS ONLY (VERIFY CUP SIZE PRIOR TO ORDERING)
00162003	VACUUM CUP-12" 3-PC	1
HW-KIT-1	STUD KIT-VACUUM	1	2.1.1 - update	VACUUM UNITS ONLY
80092006	STUD-KIT-MAGNET	1	2.1.1 - update	MAGNET UNITS ONLY
P0301-1	HOSE-COIL-VACUUM	1	3.0.1 - update	VACUUM UNITS ONLY
E0009-5	SOLENOID-12VDC	1	4.2.1 - update	(VERIFY UNIT VOLTAGE PRIOR TO OPENING)
E0008-5	SOLENOID-24VDC	1
E0302	SWITCH-PULL	1	5.0.1 - update	VAC / MAG UNITS ONLY
80032001	PUSH BUTTON ASSEMBLY	1	5.0.1 - update

Use only BHS approved replacement parts.

BHS offers many replacement parts kits containing relevant or related parts when replacing certain individual parts or replacing any obsolete / upgraded parts.

Go to www.bhs1.com and click "Parts" for all the latest parts kits and corresponding installation instructions (if applicable).

BHS recommends that a full maintenance inspection report similar to the one provided be completed at least once a month. Any parts found to be excessively worn or damaged should promptly be replaced unless said parts pose a safety risk to the operator and/or extractor, in which case the unit should be removed from service until the problem(s) are remedied (See Operator’s Daily Checklist.)

"READY" STATUS INDICATOR LIGHT

The ATC motor is protected by an internal thermal switch. If the motor gets too hot, the switch will open so the motor will not operate. When this happens, the green light will not be illuminated. This switch will reset automatically and the light will illuminate again once the motor has cooled sufficiently.

The unit is "Ready" for use when the green light is illuminated. If the light is not lit, check the following:

1. Verify the ATC has DC power
2. Verify the battery supply voltage is the same as listed on the serial plate
3. Verify the correct polarity at the light terminals

If all of these items are correct, the thermal switch may have opened. Let the motor cool for about 30 minutes and check the green light again. If the green light does illuminate, call for service.

DISPOSAL OF WASTE MATERIAL

Dispose of all fluids and waste according to local guidelines and regulations.