IOP-080 ATC

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 ATC 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 BATTERIES-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 oper-ating the ATC (see prior page).
• 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 in-structions.
• 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 bat-tery 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 op-erating 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 low-est 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

GENERAL INFORMATION

MODEL NUMBER & OPTIONS

COMPARTMENT WIDTH

24 = 24" Wide Compartment

30 = 30" Wide Compartment

36 = 36" Wide Compartment

42 = 42" Wide Compartment

EXTRACTION METHOD 1

VAC = Vacuum MAG = Magnet

HC = Optional Hook and Chain (In addition to VAC or MAG)

CANTILEVER / ROLLER BED EXTENSION 2

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

MOUNTING METHOD

FP-C = Fork Pockets for Pallet Truck FP = Fork Pockets for Lift Truck

MPJ = Permanent Welding to Pallet Truck BLTON = Bolt on to Pallet Truck

ADDITIONAL OPTIONS

LPF = Low Profile Frame

LP = Low Profile Bolt in Slides

QDY = Quick Disconnect “Y” Connector HD = Heavy Duty Option

UNCTD = Uncoated Rollers (ATC-24 ONLY) RB = Rubber Bumpers

BSELV = Base Elevation DIR = Drop In Roller

DIR-LG = Drop In Roller for use with bed extension 2 TIER = Two Separate Roller Compartments

(Upper and Lower Compartment)

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

2 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.

SPECIFICATIONS

BATTERY CARRIAGES

AUTOMATIC TRANSFER CARRIAGE

Product Specifications - Imperial / Metric

	ATC 24	ATC 30	ATC 36	ATC 42
Max. Load Capacity 1	4,000 lbs / 1810 kg	4,000 lbs / 1810 kg	4,000 lbs / 1810 kg	5,000 lbs / 2265 kg
Voltage Requirement	12/24 VDC	12/24 VDC	12/24 VDC	12/24 VDC
Hydraulic Pump	Gear	Gear	Gear	Gear
Extractor Arm Travel Speed	0-24 FPM .12 M/S	0-24 FPM .12 M/S	0-24 FPM .12 M/S	0-24 FPM .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” Dia. / 254 mm	12” Dia. / 305 mm	12” Dia. / 305 mm	12” Dia. / 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. 150 mm Min. / 585 mm Max.	6” Min. / 29” Max. 150 mm Min. / 735 mm Max.	6” Min. / 35” Max. 150 mm Min. / 890 mm Max.	6” Min. / 41” Max. 150 mm Min. / 1040 mm Max.
Battery Length 3	41” Max. / 1040 mm	41” Max. / 1040 mm	41” Max. / 1040 mm	41” Max. / 1040 mm
Min. Battery Height Hook & Chain Magnet Vacuum	12” / 305 mm 18” / 455 mm 21” / 530 mm	12” / 305 mm 18” / 455 mm 21” / 530 mm	12” / 305 mm 18” / 455 mm 21” / 530 mm	12” / 305 mm 18” / 455 mm 21” / 530 mm
Overall. Length	61” / 1550 mm Standard 67”/ 1702 mm Cantilever Option	61” / 1550 mm Standard 67”/ 1702 mm Cantilever Option	61” / 1550 mm Standard 67”/ 1702 mm Cantilever Option	61” / 1550 mm Standard 67”/ 1702 mm Cantilever Option
Overall Width	29.5” / 750 mm	35.5” / 902 mm	41.5” / 1055 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 / 450 kg	1,000 lbs / 450 kg	1,000 lbs / 450 kg	1,000 lbs / 450 kg
Average Draw Bar Pull	750 lbs / 340 kg Vacuum 775 lbs / 350 kg Magnet	1,000 lbs / 450 kg Vacuum 775 lbs / 350 kg Magnet	1,000 lbs / 450 kg Vacuum 775 lbs / 350 kg Magnet	1,000 lbs / 450 kg Vacuum 775 lbs / 350 kg Magnet
Service Weight (unloaded)4	580 lbs / 265 kg	640 lbs / 295 kg	700 lbs / 320 kg	770 lbs / 350 kg

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 5. 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 6. in the mounting plate and into the mounting holes of the unit. See Figure 1.


FIGURE 1

7. Place one supplied fl at washer and locking nut on each of the mounting bolts.
8. Tighten the lock nuts evenly, ensuring the mounting 8. plate is fl at 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.
3. Slowly drive the lift truck into the fork pockets until the forks are fully engaged in the fork pockets.

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.

HYDRAULIC 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.

FP OPTION

HYDRAULIC RESERVOIR

OPERATING CONTROLS

1. SERIAL NUMBER / DATA TAG- Lists Model and Serial Number 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

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.

1. Press and hold the green “Power” button.
2. Slowly move the extractor arm control handle and verify proper arm travel fully in and out of the battery compartment.
3. 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.

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. See Figure 3.


FIGURE 3

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" difference.
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" 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 4.


FIGURE 4

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 entirely inside the ATC battery compartment, move the battery safety stop(s) to the upright position. See Figure 5. Secure the battery for transport by moving the battery forward using the extractor arm to “pin” the battery between the extractor arm and battery stop to prevent the battery from rocking front to back. Turn off the magnet or vacuum.


FIGURE 5

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. Move the extractor arm rearward slightly to move the battery away from the battery safety stop and lower the stop.
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.

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 certifi ed 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 unit’s casters and lift/lower functions operate 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” 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 3. 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 BTC 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
80812001	BATTERY STOP KIT	1	1.1.1
00162001	VACUUM CUP-10"	1	2.1.1	VACUUM UNITS ONLY (VERIFY CUP SIZE PRIOR TO ORDERING)
P0110	VACUUM CUP-12"
HW-KIT-1	STUD KIT-VACUUM	1	2.1.1	VACUUM UNITS ONLY
800920060	STUD-KIT-MAGNET		2.2.1	MAGNET UNITS ONLY
P0301-1	HOSE-COIL-VACUUM	1	3.0.1	VACUUM UNITS ONLY
E0009-2	SOLENOID-12VDC	1	4.2.1	(VERIFY UNIT VOLTAGE PRIOR TO ORDERING)
E0008-2	SOLENOID-24VDC
E0302	SWITCH-PULL	1	5.0.1	VAC / MAG UNITS ONLY
80032001	PUSH BUTTON ASSEMBLY	1	5.0.1

Use only BHS approved replacement parts.

BHS recommends that a full maintenance inspection report similar to the one provided be done 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 lit. This switch will reset automatically and the light will be lit again when the motor has cooled sufficiently.

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

1. Verify the battery voltage is the same as listed on the serial plate.

2. Verify the correct polarity at the light terminals.

If both these items are correct, then 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 not come on, call for service.

Disposal of Waste Material

Dispose of all fluids and waste according to local regulations.

ATC SERIES PLANNED MAINTENANCE INSPECTION REPORT

PARTS SECTIONS

CHASSIS

ARM SHAFT & SPROCKETS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08027001	SHAFT-DRIVE-ATC-24			1
	08127001	SHAFT-DRIVE-ATC-30
	08227001	SHAFT-DRIVE-ATC-36
	08327001	SHAFT-DRIVE-ATC-42
2	PT0107	SPROCKET-5015 X 1"		INCLUDES SET SCREWS	2
3	00197018	KEY-1/4" X 1 1/2"			3
4	PT0108	SPROCKET-5024 X 1"			1
5	PT0402	BEARING-PILLOW BLOCK-1"		ATC-24 & 30 / ATC-36 & 42	2 / 4
6	HW0407	BOLT-HHCS-3/8-16 X 2 3/4"		ATC-24 & 30	4
	HW0419	BOLT-HHCS-3/8-16 X 3"		ATC-36 & 42	8
7	08027002	SHIM-PILLOW BLOCK-14 GA	†	.075" THICK	A/R
	08027003	SHIM-PILLOW BLOCK-10 GA	†	.135" THICK
	08027005	SHIM-PILLOW BLOCK-16 GA	†	.059" THICK
8	HW0108	WASHER-FLAT-3/8"-SAE		ATC-24 & 30 / ATC-36 & 42	4 / 8
9	HW0107	WASHER-LOCK-3/8"		ATC-24 & 30 / ATC-36 & 42	4 / 8
10	HW0603	BOLT-FHSCS-5/8-11 X 2"			2
11	HW0114	WASHER-FLAT-5/8"-SAE			8
12	PT0111	SPROCKET-IDLER-50A15 X 5/8"			2
13	HW0010	NUT-JAM-5/8-11			2
14	08017021	ROD-THREADED-3/8-16 X 3 1/2"		ATC-24 & 30 / ATC-36 & 42	4 / 8
15	HW0006	NUT-NILN-3/8-16		ATC-24 & 30 / ATC-36 & 42	4 / 8

† INCLUDED IN MULTIPLE KITS

ARM & CHAIN ATTACHMENT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05057006	PLATE-TOP			2
2	00158001-2	CHAIN-ROLLER-#50	80052003	STANDARD ATC	2
	00158001-3	CHAIN-ROLLER-#50	80052004	ATC-CAN-7
	00158001-4	CHAIN-ROLLER-#50	80052001	ATC-CAN-14
3	PT0104	LINK-OFFSET-#50	†		2
4	PT0102	LINK-CONNECTING-#50	†		4
5	05057005	BLOCK-PULL	†		2
6	HW0307	BOLT-SHCS-1/4-20 X 1"	†		4
7	HW0103	WASHER-LOCK-1/4"	†		4
8	05056002	BLOCK-SLIDE	80052005		2
9	05057004	PLATE-BOTTOM	80052005		2
10	HW0407	BOLT-HHCS-3/8-16 X 2 3/4"	80052005		6
11	HW0409	BOLT-FHSCS-3/8-16 X 2"	80052005		2
12	HW0108	WASHER-FLAT-3/8"-SAE	80052005		6
13	HW0006	NUT-NILN-3/8-16	80052005		8

† INCLUDED IN MULTIPLE KITS

ARM DRIVE CHAIN

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00158001-1	CHAIN-ROLLER-#50	†		1
2	PT0102	LINK-CONNECTING-#50	†		1
3	PT0104	LINK-OFFSET-#50	†		1
4	PT0106-1	SPROCKET-5012 X 1"	80042003	INCLUDES SET SCREWS	1
5	HW1071	KEY-WOODRUFF-#808 STD		SUPPLIED WITH HYD. MOTOR	A/R

† INCLUDED IN MULTIPLE KITS

ROLLERS & BATTERY STOP

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00182005	ROLLER ASSEMBLY-ATC-24			10
	00182042	ROLLER ASSEMBLY-ATC-24-UNCOATED
	05282001	ROLLER ASSEMBLY-ATC-30
	08282001	ROLLER ASSEMBLY-ATC-36
	08382001	ROLLER ASSEMBLY-ATC-42
2	00187045	SHAFT-HEX-.438" X 26"		ATC-24	10
	05287001	SHAFT-HEX-.75" X 32"		ATC-30
	08287001	SHAFT-HEX-.75" X 38"		ATC-36
	08387001	SHAFT-HEX-.75" X 44"		ATC-42
3	HW1014-1	PIN-HITCH		FOR USE WITH .438" HEX SHAFT	20
	HW1058	PIN-HITCH		FOR USE WITH .75" HEX SHAFT
4	00194001	STOP-BATTERY	80812001		1
5	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"	80812001		1
6	HW0006	NUT-NILN-3/8-16	80812001		1

NOTES:

1. REFER TO STANDARD OPTIONS SECTION FOR “LPF”, “DIR”, “DIR-LG” AND “2 TIER” OPTIONS
2. NUMBER OF BATTERY STOPS WILL VARY DEPENDING UPON PARTICULAR OPTION(S) ORDERED

PRIMARY GUARDING

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08017015-2	DASHBOARD-ATC-24			1
	08117004-2	DASHBOARD-ATC-30
	08217004-2	DASHBOARD-ATC-36
	08317004-2	DASHBOARD-ATC-42
2	08215003-3	GUARD-CHAIN-LHS		STANDARD ATC	1
	08215006-3	GUARD-CHAIN-LHS		ATC-CAN-7
	08215009-3	GUARD-CHAIN-LHS		ATC-CAN-14
3	08215003-4	GUARD-CHAIN-RHS		STANDARD ATC	1
	08215006-4	GUARD-CHAIN-RHS		ATC-CAN-7
	08215009-4	GUARD-CHAIN-RHS		ATC-CAN-14
4	08017023	GUARD-REAR-ATC-24			1
	08117005	GUARD-REAR-ATC-30
	08217005	GUARD-REAR-ATC-36
	08317005	GUARD-REAR-ATC-42
5	HW0301	BOLT-SELF-TAP “F”-1/4-20 X 1/2"			14

LABELS & PLACARDS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08096008	PLACARD-POWER PUSH & HOLD			1
2	08096007	PLACARD-EXTRACTOR ARM-IN/OUT			1
3	08096005	PLACARD-VACUUM-ON/OFF		VACUUM UNITS ONLY	1
	08096006	PLACARD-MAGNET-ON/OFF		MAGNET UNITS ONLY
4	00196613	LABEL-”CONSULT MANUAL FOR TECHNI- CAL PROCEDURE”	80092002		1
5	00196216	LABEL-WARNING-”CHAIN ENTANGLEMENT HAZARD”	80092002		3
6	00196218	LABEL-WARNING-”ELECTRICAL VOLTAGE HAZARD”	80092002		1
7	00196214	LABEL-WARNING-”STRONG MAGNETIC FIELD”	80092002	MAGNET UNITS ONLY	1
8	00196612	LABEL-”READ INSTRUCTION MANUAL PRIOR TO USE”	80092002		1
9	00196615	LABEL-”DO NOT OPERATE WITH GUARDS REMOVED”	80092002		1
10	00196408	LABEL-DANGER-"DISCONNECT POWER BEFORE SERVICING UNIT"	80092002		1
11	00196611	LABEL-NOTICE-"TURN OFF MAGNET WHEN NOT IN USE TO PREVENT DAMAGE TO MAGNET"	80092002	MAGNET UNITS ONLY	1
12	00196701	DECAL-BHS-12" X 3.875"			2

EXTRACTOR ARM

STANDARD EXTRACTOR ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	08052009	ATC-24 STD EXTRACTOR ARM ASSY		INCL. ITEMS 1 THRU 5	1
	08152007	ATC-30 STD EXTRACTOR ARM ASSY		INCL. ITEMS 1 THRU 5
	08252007	ATC-36 STD EXTRACTOR ARM ASSY		INCL. ITEMS 1 THRU 5
	08352003	ATC-42 STD EXTRACTOR ARM ASSY		INCL. ITEMS 1 THRU 5
1	08055005	EXTRACTOR ARM-ATC-24			1
	08155004	EXTRACTOR ARM-ATC-30
	08255003	EXTRACTOR ARM-ATC-36
	08355003	EXTRACTOR ARM-ATC-42
2	08055008	PUSH/PULL ATTACHMENT			1
3	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			4
4	HW0108	WASHER-FLAT-3/8"-SAE			8
5	HW0006	NUT-NILN-3/8-16			4
6	05057007	PAD-PUSH			1
7	HW0413	BOLT-FHSMS-3/8-16 X 1 1/4"			2
8	HW0107	WASHER-LOCK-3/8"			2
9	HW0005	NUT-HEX-3/8-16			2
10	08092001	HOOK AND CHAIN ASSEMBLY			1

VACUUM EXTRACTOR ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	VACUUM CUP-10"	00162001	AVAILABLE IN KIT ONLY	1
	P0110	VACUUM CUP-12"		† OPTIONAL
2	00117059	PLATE-VACUUM CUP ADAPTER	00162001		1
3	HW0328	BOLT-HHCS-5/16-18 X 3/4"	00162001		4
4	P0505	BUSHING-RED-#6 NPT X #4 FNPT-BRASS	00162001		1
5	HW0427	STUD-VACUUM-3/8-16 X 4"	HW-KIT-1		4
6	HW0108	WASHER-FLAT-3/8"-SAE	HW-KIT-1		16
7	HW1001	SPRING-3/8"	HW-KIT-1		8
8	HW0006	NUT-NILN-3/8-16	HW-KIT-1		4
9	08055005	EXTRACTOR ARM-ATC-24			1
	08155004	EXTRACTOR ARM-ATC-30
	08255003	EXTRACTOR ARM-ATC-36
	08355003	EXTRACTOR ARM-ATC-42
10	08055003	MOUNT-VACUUM CUP-LHS			1
11	08055004	MOUNT-VACUUM CUP-RHS			1
12	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			4
13	HW0108	WASHER-FLAT-3/8"-SAE			8
14	HW0006	NUT-NILN-3/8-16			4
15	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS	00162001		A/R
REF	08052005	ATC-24 VACUUM EXTRACTOR ARM ASSY		INCL. ITEMS 9 THRU 14	1
	08152005	ATC-30 VACUUM EXTRACTOR ARM ASSY		INCL. ITEMS 9 THRU 14
	08252005	ATC-36 VACUUM EXTRACTOR ARM ASSY		INCL. ITEMS 9 THRU 14
	08352001	ATC-42 VACUUM EXTRACTOR ARM ASSY		INCL. ITEMS 9 THRU 14

† VERIFY SIZE PRIOR TO ORDERING

MAGNET EXTRACTOR ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0701-1	MAGNET-12VDC			1
	E0702-1	MAGNET-24VDC
2	HW0514	BOLT-HHCS-1/2-13 X 2 1/2"	80092006		2
3	HW0111	WASHER-FLAT-1/2"	80092006		6
4	HW1002	SPRING-1/2"	80092006		2
5	HW0007	NUT-HEX-1/2-13	80092006		2
6	08055005	EXTRACTOR ARM-ATC 24			1
	08155004	EXTRACTOR ARM-ATC 30
	08255003	EXTRACTOR ARM-ATC 36
	08355003	EXTRACTOR ARM-ATC 42
7	08055003	MOUNT-VACUUM CUP-LHS			1
8	08055004	MOUNT-VACUUM CUP-RHS			1
9	08057010	PLATE-MOUNTING-MAGNET			1
10	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			8
11	HW0108	WASHER-FLAT-3/8"-SAE			16
12	HW0006	NUT-NILN-3/8-16			8
REF	08052006	ATC-24 MAGNET EXTRACTOR ARM ASSY		INCLUDES ITEMS 6 THRU 12	1
	08152006	ATC-30 MAGNET EXTRACTOR ARM ASSY		INCLUDES ITEMS 6 THRU 12
	08252006	ATC-36 MAGNET EXTRACTOR ARM ASSY		INCLUDES ITEMS 6 THRU 12
	08352002	ATC-42 MAGNET EXTRACTOR ARM ASSY		INCLUDES ITEMS 6 THRU 12

PNEUMATICS

VACUUM PUMP

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	P0001	PUMP-VACUUM-12VDC	80062001		1
	P0002	PUMP-VACUUM-24VDC	80062002
2	P0301-1	HOSE-COIL-VACUUM			1
3	P0205	VALVE-VACUUM RELEASE-12VDC	80062001		1
	P0206	VALVE-VACUUM RELEASE-24VDC	80062002
4	P0208	FILTER-HIGH FLOW	†		1
5	P0503	NIPPLE-#4 NPT-BRASS	†		1
6	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS	†		1
7	HW0104	WASHER-FLAT-1/4"-SAE			4
8	HW0101	WASHER-LOCK-#10			4
9	HW0206	SCREW-RHMS-#10-32 X 3/4"			4
10	HC0505	BRUSH KIT		12V & 24V (NOT SHOWN)	1

† INCLUDED IN MULTIPLE KITS

HYDRAULICS

MANUAL LEVER VALVE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0201	MANUAL VALVE	80042002		1
REF	08046001	MODIFIED VALVE HANDLE ASSEMBLY	80042002	INCL. ITEMS 2 THRU 5	1
2	N/A	VALVE HANDLE-MODIFIED	†		1
3	HW1004	NUT-COUPLING-3/8-16	†		1
4	HW0804	SCREW-SHSS-3/8-16 X 1"	†		1
5	N/A	BALL-HANDLE	†		1
6	H1303	ADAPTER-90 DEG-#6 JICM X #8 NPTM	80042002		4
7	HW0106	WASHER-FLAT-5/16"-SAE			3
8	HW0322	BOLT-HHCS-5/16-18 X 2"			3
9	HW0105	WASHER-LOCK-5/16"			3
10	HW0004	NUT-HEX-5/16-18			3
11	HW0204	SCREW-RHMS-#10-24 X 1"	80042002		1
12	HW0001	NUT-HEX-#10-24	80042002		2

† INCLUDED IN MULTIPLE KITS

ARM DRIVE MOTOR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0121	MOTOR-HYDRAULIC-100CC	80042003	STANDARD	1
	HC0102	MOTOR-HYDRAULIC-125CC		USED FOR H.D. OPTION ONLY
2	H1002	BUSHING-RED-#10 SAEM X #4 FNPT	80042003		2
3	H0300	ELBOW-STR-90 DEG-#4 NPT	80042003		2
4	HW0108	WASHER-FLAT-3/8"-SAE	80042003		2
5	HW0107	WASHER-LOCK-3/8”	80042003		2
6	HW0402	BOLT-HHCS-3/8-16 X 1"	80042003		2
7	05045001	MOUNT-MOTOR	80042003		1
8	HW0404	BOLT-HHCS-3/8-16 X 1 1/2"”			4
9	HW0108	WASHER-FLAT-3/8"-SAE			4
10	HW0006	NUT-NILN-3/8-16			4
11	HW1071	KEY-WOODRUFF-#808 STD		SUPPLIED WITH ITEM 1	A/R

POWER UNIT

MONARCH POWER UNITS - EFFECTIVE: 03/06 TO PRESENT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	HC0002-4	POWER UNIT ASSEMBLY-12VDC			1
	HC0004-4	POWER UNIT ASSEMBLY-24VDC
1	E0029	MOTOR-12VDC-ISKRA		† SEE NOTES	1
	E0026	MOTOR-24VDC-ISKRA
2	E0009-2	SOLENOID-12VDC			1
	E0008-2	SOLENOID-24VDC
3	E0030	BRUSH KIT-12VDC (ISKRA MOTOR)		(NOT SHOWN)	1
	E0027	BRUSH KIT-24VDC (ISKRA MOTOR)
	HC0534	BRUSH KIT-12VDC (BOSCH MOTOR)		12VDC EFFECTIVE 03/06 TO 07/07 24VDC EFFECTIVE 03/06 TO 08/07 (NOT SHOWN)	1
	HC0533	BRUSH KIT-24VDC (BOSCH MOTOR)
4	H1008	ADAPTER-RED-#6 SAEM X #4 FNPT			2
5	H0300	ELBOW-STR-90 DEG-#4 NPT			2
6	HC0318	GAUGE-PRESSURE		INCL. WITH POWER UNIT ASSY	1
7	HW0107	WASHER-LOCK-3/8"			2
8	HW0402	BOLT-HHCS-3/8-16 X 1"			2
9	HC0550	RESERVOIR			1
10	HC0238	CAP-RESERVOIR			1
11	-	THERMAL SWITCH		†† SEE NOTES	1

NOTE:

ONE (1) ADDITIONAL ELBOW REQUIRED FOR UNITS EQUIPPED WITH GAUGE IN ALTERNATE ORIENTATION.

† BOSCH MOTOR NO LONGER AVAILABLE. ISKRA MOTOR IS DIRECT REPLACEMENT FOR BOSCH MOTOR.

†† INTERNAL OF MOTOR. CONSULT FACTORY

POWER UNIT RETROFIT KIT

BARNES POWER UNIT - EFFECTIVE: 02/02 TO 03/06

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	N/A	POWER UNIT ASSEMBLY (12VDC & 24VDC)		† SEE NOTES	-
1	N/A	MOTOR-12VDC-HALDEX		† SEE NOTES	-
	N/A	MOTOR-24VDC-HALDEX
2	E0009-2	SOLENOID-12VDC			1
	E0008-2	SOLENOID-24VDC
3	HC0512	BRUSH KIT-12VDC (HALDEX MOTOR)		NOT SHOWN	1
	HC0511	BRUSH KIT-24VDC (HALDEX MOTOR)

FENNER POWER UNIT - EFFECTIVE PRIOR TO 02/02

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	N/A	POWER UNIT ASSEMBLY(12VDC & 24VDC)		†† MUST ORDER RETROFIT KIT	-
1	N/A	MOTOR (12VDC & 24VDC)		†† MUST ORDER RETROFIT KIT	-
2	E0009-2	SOLENOID-12VDC			1
	E0008-2	SOLENOID-24VDC
3	N/A	BRUSH KIT (12VDC & 24VDC)		†† MUST ORDER RETROFIT KIT	-

† MUST ORDER NEW MONARCH POWER UNIT TO REPLACE BARNES POWER UNIT OR HALDEX MOTOR.

†† REPLACES FENNER POWER UNIT WITH NEW MONARCH POWER UNIT - SEE RETROFIT KIT BELOW

80000006-B / 80000007-B RETROFIT KIT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	80000006-B	POWER UNIT RETROFIT KIT-12VDC		INLCUDES ITEMS 1 - 6	1
	80000007-B	POWER UNIT RETROFIT KIT-24VDC
1	HC0002-4	POWER UNIT-12VDC		INCLUDES GUAGE	1
	HC0004-4	POWER UNIT-24VDC
2	08017049	ADAPTER PLATE			1
3	HW1076	BOLT-FHSCS-3/8-16 X 3/4"			2
4	HW0107	WASHER-LOCK-3/8"			2
5	HW0401	BOLT-HHCS-3/8-16 X 3/4"			2
6	H1008	ADAPTER-RED-#6 SAEM X #4 FNPT			2

NOTE: RETROFIT KIT REQ'D FOR UNITS BUILT PRIOR TO FEBRUARY 2002 EQUIPPED WITH FENNER POWER UNITS.

HOSES

ATC-24

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00142001-5	HOSE-HYDRAULIC-18"			2
2	00142001-10	HOSE-HYDRAULIC-22"			1
3	00142001-12	HOSE-HYDRAULIC-24"			1

ATC-30

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1,2	00142001-10	HOSE-HYDRAULIC-22"			3
3	00142001-14	HOSE-HYDRAULIC-27"			1

ATC-36

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1,2	00142001-12	HOSE-HYDRAULIC-24"			3
3	00142001-19	HOSE-HYDRAULIC-31"			1

ATC-42

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1,2	00142001-14	HOSE-HYDRAULIC-27"			3
3	00142001-19	HOSE-HYDRAULIC-31"			1

NOTE: HOSE LENGTHS ARE THE CUT LENGTHS OF THE HOSE MATERIAL AND DO NOT INCLUDE THE LENGTHS OF THE FITTINGS

HYDRAULIC SCHEMATIC

ELECTRICAL

DASHBOARD COMPONENTS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0308	ACTUATOR-PUSH BUTTON	80032001		1
2	E0307	CONTACT BLOCK-N/O	80032001		1
3	E1361	LIGHT-INDICATOR-12VDC			1
	E1360	LIGHT-INDICATOR-24VDC
4	PL0501	GROMMET-1/2" I.D.			2
5	E0302	SWITCH-PULL		†6-28VDC, 75 AMP	1

† USED ON VACUUM AND MAGNET UNITS ONLY.

MICRO SWITCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0303	MICRO SWITCH		USED PRIOR TO 03/06	1
2	08015006-2	BRACKET-MOUNTING-MICRO SWITCH		USED PRIOR TO 03/06	1

JUNCTION BOXES

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0611	JUNCTION BOX-4" X 2" X 2"			1
2	E0612	COVER-JUNCTION BOX			1
3	E0624	CONNECTOR-1/2"		INCLUDES LOCK NUT	3
4	HW0301	BOLT-SELF-TAP “F”-1/4-20 X 1/2"			2
5	E0703	ALARM-AUDIBLE		MAGNET OPTION ONLY	1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	YE0211	REALY-30A-12V			1
	YE0206	RELAY-30A-24V			1
2	YE0405	END BARRIER			1
3	YE0402	TERMINAL BLOCK			3
4	YE0406	END STOP			2
5	00138002	DIN RAIL			1
6	HW0130	SCREW-RHMS-#8-32 X 1/2"			2
7	HW0133	WASHER-FLAT-#8			2
8	HW0132	NUT-NILN-#8-32			2
9	E0703	ALARM-AUDIBLE			1
10	E0623	RESTRAINT-1/2"-90 DEG		GRIP RANGE .250" TO .375"	1
11	E0613	RESTRAINT-3/4" (USED PRIOR TO 02/10)		GRIP RANGE .500" TO .625"	1
	E0634	RESTRAINT-3/4" (USED FROM 02/10 TO PRES.)		GRIP RANGE .375" TO .450"	1
12	E0616	RESTRAINT-1/2"		GRIP RANGE .250" TO .375"	1
13	E0618	LOCKNUT-CONDUIT-3/4"			1
14	E0617	LOCKNUT-CONDUIT-1/2"			2
15	08036011	ENCLOSURE			1
16	08036012	PANEL-MOUNTING-COMPONENT			1
17	HW0303	BOLT-HHCS-1/4-20 X 1"			2
18	HW0104	WASHER-FLAT-1/4"-SAE			4
19	HW0103	WASHER-LOCK-1/4"			2
20	HW0002	NUT-HEX-1/4-20			2

JUNCTION BOX - MAGNET ARM

DISCONTINUED MAGNET ARM

JUNCTION BOX

EFFECTIVE PRIOR TO FEBRUARY '10

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0611	JUNCTION BOX-4 X 2 X 2			1
2	E0612	COVER-JUNCTION BOX			1
3	E0624	CONNECTOR-1/2		INCLUDES LOCK NUT	2
4	HW0301	BOLT-SELF-TAP “F”-1/4-20 X 1/2			2

MAGNET CORDS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	†	CORD-3 PIN-FEMALE (YELLOW)			1
2	†	CORD-COIL		14-3 CONDUCTOR SIZE	1

† MUST BE REPLACED WITH CURRENT STYLE, ONE-PIECE CORD. SEE SECTION 5.3.2

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	80032004	MAGNET REPLACEMENT CORD KIT		INCLUDES ITEMS 1-5	1
1	-	CORD-COIL-3 PIN-FEMALE		INCL. IN KIT	1
2	-	CLAMP-CABLE-1/2"			1
3	-	SCREW-RHMS-#10-24 X 1/2"			1
4	-	WASHER-LOCK-#10			1
5	-	NUT-HEX-#10-24

ELECTRICAL SCHEMATICS

STANDARD OPTIONS

COMPARTMENT EXTENSION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1a	00182007	ROLLER ASSEMBLY-14.563"		†	1
1b	00182003	ROLLER ASSEMBLY-18.563"		†
1c	43182002	ROLLER ASSEMBLY-23.875"		†
1d	05382002	ROLLER ASSEMBLY-31.563"		†
1e	08282001	ROLLER ASSEMBLY-36.563"		†
2a	00187012	SHAFT-HEX-.438" X 16.125"		††	1
2b	00187044	SHAFT-HEX-.438" X 20"		††
2c	43187002	SHAFT-HEX-.75" X 25.75"		††
2d	05387002	SHAFT-HEX-.75" X 33"		††
2e	08287001	SHAFT-HEX-.75" X 38"		††
3	HW1014-1	PIN-HITCH		FOR USE WITH .438" HEX SHAFT	2
	HW1058	PIN-HITCH		FOR USE WITH .75" HEX SHAFT

† THE ROLLERS LISTED ABOVE ARE THE MOST COMMON ROLLERS USED IN COMPARTMENT EXTENSIONS.

IF YOUR UNIT IS EQUIPPED WITH A ROLLER OTHER THAN THOSE LISTED, MEASURE THE WIDTH OF THE COMPARTMENT EXTENSION (SEE DETAIL A) AND CONSULT THE FACTORY.

†† HEX SHAFT LETTER “a” IS TO BE USED WITH ROLLER “a”, HEX SHAFT “b” WITH ROLLER “b” ETC.

AUXILIARY HOOK & CHAIN

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08092001	HOOK AND CHAIN ASSEMBLY			1

RUBBER BUMPERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW1037	BUMPER-RUBBER-RECESSED	80092001		2
2	HW0303	BOLT-HHCS-1/4-20 X 1"	80092001		2
3	HW0104	WASHER-FLAT-1/4"-SAE	80092001		2
4	HW0003	NUT-NILN-1/4-20	80092001		2

FP-C

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	ATC-FP-C	BOLT ON FORK POCKET KIT		INCL. ITEMS 1 THRU 5	A/R
1	N/A	BOLT ON FORK POCKETS			1
2	HW0431	BOLT-CARRIAGE-3/8-16 X 1 1/4"			4
3	HW0108	WASHER-FLAT-3/8"-SAE			4
4	HW0107	WASHER-LOCK-3/8"			4
5	HW0005	NUT-HEX-3/8-16			4

BOLT ON

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08417264	PLATE-MOUNTING-BOLT ON	80012003		2
2	HW0432	BOLT-FHSCS-3/8-16 X 4"	80012003		4
3	HW0108	WASHER-FLAT-3/8"-SAE	80012003		4
4	HW0006	NUT-NILN-3/8-16	80012003		4

LOW PROFILE - BOLT IN (LP)

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08415320	FRAME-BOLT IN-ATC-24			1
	08415379	FRAME-BOLT IN-ATC-30
	08415393	FRAME-BOLT IN-ATC-36
2	08416002	BLOCK-SLIDE			4
3	HW0405	BOLT-HHCS-3/8-16 X 2"			12
4	HW0108	WASHER-FLAT-3/8"-SAE			24
5	HW0006	NUT-NILN-3/8-16			12
6	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"		ATC-24	6
	HW0503	BOLT-HHCS-1/2-13 X 1 1/2"		ATC-30 & 36
7	HW0108	WASHER-FLAT-3/8"-SAE		ATC-24	12
	HW0112	WASHER-FLAT-1/2"-SAE		ATC-30 & 36
8	HW0107	WASHER-LOCK-3/8"		ATC-24	6
	HW0110	WASHER-LOCK-1/2"		ATC-30 & 36
9	HW0005	NUT-HEX-3/8-16		ATC-24	6
	HW0007	NUT-HEX-1/2-13		ATC-30 & 36

NOTE:

CONSULT FACTORY FOR UNITS BUILT PRIOR TO 03/03

LOW PROFILE FRAME (LPF)

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00182079	ROLLER ASSEMBLY-7.813"			10
2	00188151	SHAFT-HEX-.438" X 8.438"			10
3	08417307	SLIDE-BATTERY		ATC-24,30 / ATC-36	2/4
4	HW0306	BOLT-FHSCS-1/4-20 X 1"		ATC-24,30 / ATC-36	4/8
5	08417327	RETAINER-ROLLER			1
6	HW0301	BOLT-SELF-TAP “F”-1/4-20 X 1/2"			5

NOTE:

REFER TO PREVIOUS SECTIONS FOR ALL PARTS NOT LISTED HERE

DROP IN ROLLER (DIR)

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00182028	ROLLER ASSEMBLY-19.813"		ATC-24-DIR	7
	00182001	ROLLER ASSEMBLY-12.563"		ATC-30-DIR	14
	00182002	ROLLER ASSEMBLY-15.563"		ATC-36-DIR
	00182003	ROLLER ASSEMBLY-18.563"		ATC-42-DIR
2	00187064	SHAFT-HEX-.438" X 22"		ATC-24-DIR	7
	00187021	SHAFT-HEX-.438" X 27"		ATC-30-DIR
	00187008	SHAFT-HEX-.438" X 34"		ATC-36-DIR
	00187102	SHAFT-HEX-.438" X 39.25"		ATC-42-DIR
3	HW1014-1	PIN-HITCH-#203			14

NOTE:

REFER TO PREVIOUS SECTIONS FOR ALL OTHER PARTS.

2 TIRE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08417003	RETAINER-ROLLER-UPPER		USED PRIOR TO 05/04	4
	08417548	RETAINER-ROLLER-UPPER
2	HW0302	BOLT-HHCS-1/4-20 X 3/4"			16
3	HW0003	NUT-NILN-1/4-20			16
4	HW0212	SCREW-RHMS-#10-24 X 1/2"		USED PRIOR TO 05/04	16
5	HW0101	WASHER-LOCK-#10		USED PRIOR TO 05/04	16

NOTE:

CONSULT FACTORY FOR ROLLERS AND HEX SHAFTS.

REFER TO PREVIOUS SECTIONS FOR ALL OTHER PARTS NOT LISTED HERE.

SECONDARY GUARDING

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08017060	GUARD-RUBBER-ARM DRIVE CHAIN	80012008		1
2	08417362	RETAINER-GUARD-RUBBER-ARM DRIVE	80012008		2
3	HW0104	WASHER-FLAT-1/4"-SAE	80012008		8
4	HW0303	BOLT-HHCS-1/4-20 X 1"	80012008		4
5	HW0103	WASHER-LOCK-1/4"	80012008		4
6	HW0002	NUT-HEX-1/4-20	80012008		4
7	08417390	GUARD-CHAIN-RUBBER	80012001	STANDARD ATC	2
	08417391	GUARD-CHAIN-RUBBER	80012002	ATC-CAN-7
	08417444	GUARD-CHAIN-RUBBER	N/A	ATC-CAN-14
8	08017047	RETAINER-RUBBER GUARD	80012001	STANDARD ATC	2
	08417402	RETAINER-RUBBER GUARD	80012002	ATC-CAN-7
	08017050	RETAINER-RUBBER GUARD	N/A	ATC-CAN-14
9	HW0301	BOLT-SELF-TAP “F”-1/4-20 X 1/2"	†	STD / CAN-7 / CAN-14	A/R
10	08017062-2	GUARD-RIGID-ARM DRIVE CHAIN	80012008		1
11	00196216	LABEL-WARNING-”CHAIN ENTANGLEMENT HAZARD”	80012008	FOR ITEM 10 (NOT SHOWN)	1

† INCLUDED IN MULTIPLE KITS

PARTS KITS

ATC STANDARD CHAIN KIT

P/N: 80052003

QTY	PART#	DESCRIPTION
1	00158001-1	CHAIN-#50-DRIVE
2	00158001-2	CHAIN-#50-EXTRACTOR ARM
5	PT0102	#50 MASTER LINK
3	PT0104	#50 SINGLE PITCH OFFSET LINK
2	05057005	PULL BLOCK
4	HW0307	BOLT-SHCS-1/4-20 X 1”
4	HW0103	WASHER-LOCK-1/4”
4	08027003	SHIM-10 GA.
4	08027002	SHIM-14 GA.
4	08027005	SHIM-16 GA.

ATC-CAN-7 CHAIN KIT

P/N: 80052004

QTY	PART#	DESCRIPTION
1	00158001-1	CHAIN-#50-DRIVE
2	00158001-3	CHAIN-#50-EXTRACTOR ARM
5	PT0102	#50 MASTER LINK
3	PT0104	#50 SINGLE PITCH OFFSET LINK
2	05057005	PULL BLOCK
4	HW0307	BOLT-SHCS-1/4-20 X 1”
4	HW0103	WASHER-LOCK-1/4”
4	08027003	SHIM-10 GA.
4	08027002	SHIM-14 GA.
4	08027005	SHIM-16 GA.

ATC-CAN-14 CHAIN KIT

P/N: 80052001

QTY	PART#	DESCRIPTION
1	00158001-1	CHAIN-#50-DRIVE
2	00158001-4	CHAIN-#50-EXTRACTOR ARM
5	PT0102	#50 MASTER LINK
3	PT0104	#50 SINGLE PITCH OFFSET LINK
2	05057005	PULL BLOCK
4	HW0307	BOLT-SHCS-1/4-20 X 1”
4	HW0103	WASHER-LOCK-1/4”
4	08027003	SHIM-10 GA.
4	08027002	SHIM-14 GA.
4	08027005	SHIM-16 GA.

ATC / BTC / WTC
PULL BLOCK REPLACEMENT KIT

P/N: 80052002

QTY	PART#	DESCRIPTION
2	05057005	PULL BLOCK
4	HW0307	BOLT-SHCS-1/4-20 X 1"
4	HW0103	WASHER-LOCK-1/4”

ATC / BTC / WTC
SLIDE BLOCK KIT

P/N: 80052005

QTY	PART#	DESCRIPTION
2	05056002	SLIDE BLOCK
2	05057004	RETAINER PLATE-BOTTOM
8	HW0006	NUT-NILN-3/8-16
2	HW0409	BOLT-FHSCS-3/8-16 X 2”
6	HW0407	BOLT-HHCS-3/8-16 X 2 3/4”
16	HW0108	WASHER-FLAT-3/8”-SAE

ATC DRIVE MOTOR KIT

P/N: 80042003

QTY	PART#	DESCRIPTION
1	HC0121	MOTOR-100CC
1	05045001	MOTOR BRACKET
2	H1002	ADAPTER-#8 SAE X #6 FNPT
2	H0300	ELBOW-STR-90 DEG-#4 NPT
2	HW0402	BOLT-HHCS-3/8-16 X 1”
2	HW0107	WASHER-LOCK-3/8”
2	HW0108	WASHER-FLAT-3/8"-SAE
1	PT0106-1	SPROCKET-5012 X 1”

BATTERY STOP KIT

P/N: 80812001

QTY	PART#	DESCRIPTION
1	00194001	STOP-BATTERY
1	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"
1	HW0006	NUT-NILN-3/8-16
1	HW0108	WASHER-FLAT-3/8"-SAE

ATC LABEL KIT

P/N: 80092002

NOTE: FOR CARRIAGES WITH SERIAL NUMBERS PRIOR TO JE137587, CONSULT FACTORY FOR LABEL LOCATIONS

QTY	PART#	DESCRIPTION
3	00196216	LABEL-WARNING-"CHAIN ENTANGLEMENT HAZARD"
1	00196615	LABEL-"DO NOT OPERATE WITH GUARDS REMOVED"
1	00196612	LABEL-"READ INSTRUCTION MANUAL PRIOR TO USE"
1	00196613	LABEL-"CONSULT MANUAL FOR TECHNICAL PROCEDURE"
1	00196214	LABEL-WARNING-"STRONG MAGNETIC FIELD" (MAGNET UNITS ONLY)
2	00196218	LABEL-WARNING-"ELECTRIC VOLTAGE HAZARD" (1-VACUUM, 2-MAGNET)
1	00196611	LABEL-"TURN OFF MAGNET WHEN NOT IN USE..." (MAGNET UNITS ONLY)
1	00196408	LABEL-DANGER-"DISCONNECT POWER BEFORE SERVICING UNIT"

ATC / BTC VACUUM STUD SPRING KIT

P/N: HW-KIT-1

QTY	PART#	DESCRIPTION
4	HW0006	NUT-NILN-3/8-16
16	HW0108	WASHER-FLAT-3/8"-SAE
4	HW0427	STUD-3/8-16 X 4"
8	HW1001	SPRING-3/8"

10" VACUUM CUP ASSEMBLY

P/N: 00162001

QTY	PART#	DESCRIPTION
1	N/A	10" VACUUM CUP
1	00117059	PLATE-ADAPTER-VACUUM CUP
4	HW0328	BOLT-HHCS-5/16-18 X 3/4"
1	P0505	BUSHING-RED-#6 NPT X #4 FNPT-BRASS
1	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS
1	P0401	ELBOW-#4 NPTM X 1/4" BARB-BRASS
24	HW0108	WASHER-FLAT-3/8"-SAE

ATC MAGNET STUD KIT

P/N: 80092006

QTY	PART#	DESCRIPTION
2	HW0514	BOLT-HHCS-1/2-13 X 2 1/2"
2	HW1002	SPRING-1/2"
6	HW0111	WASHER-FLAT-1/2"
2	HW0007	NUT-HEX-1/2-13

ATC / BTC
VACUUM PUMP KIT (12V)

P/N: 80062001

QTY	PART#	DESCRIPTION
1	P0503	NIPPLE-#4 NPT-BRASS
1	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS
1	P0208	FILTER
1	P0205	SOLENOID-12V
1	P0001	VACUUM PUMP-12V

ATC VACUUM PUMP KIT (24V)

P/N: 80062002

QTY	PART#	DESCRIPTION
1	P0503	NIPPLE-#4 NPT-BRASS
1	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS
1	P0208	FILTER
1	P0205	SOLENOID-12V
1	P0002	VACUUM PUMP-24V

ATC / BTC
MANUAL VALVE KIT

P/N: 80042002

QTY	PART#	DESCRIPTION
1	08046001	MODIFIED LEVER VALVE KIT
1	HC0201	MANUAL VALVE
4	H1303	ADAPTER-90-DEG-#6 JIC X #8 NPT
1	HW0804	SCREW-SHSS-3/8-16 X 1"
1	HW1004	NUT-COUPLING-3/8-16
2	HW0001	NUT-HEX-#10-24
1	HW0204	SCREW-RHMS-#10-24 X 1"

ATC / BTC
MODIFIED LEVER VALVE KIT

P/N: 08046001

QTY	PART#	DESCRIPTION
1	HC0234-1	HANDLE KIT (INCLUDES MODIFIED HANDLE)
1	HW0804	SCREW-SHSS-3/8-16 X 1”
1	HW1004	NUT-COUPLING-3/8-16

ATC / BTC
PUSH BUTTON KIT

P/N: 80032001

QTY	PART#	DESCRIPTION
1	E0308	ACTUATOR-PUSH BUTTON
1	E0307	CONTACT BLOCK-N/O

RUBBER BUMPER KIT

P/N: 80092001

QTY	PART#	DESCRIPTION
1	HW1037	BUMPER-RUBBER-RECESSED
2	HW0104	WASHER-FLAT-1/4”-SAE
1	HW0003	NUT-NILN-1/4-20
1	HW0303	BOLT-HHCS-1/4-20 X 1”

ATC DRIVE CHAIN GUARD KIT

P/N: 80012008

QTY	PART#	DESCRIPTION
1	08017062-2	GUARD-RIGID-DRIVE CHAIN
1	08017060	GUARD-RUBBER-DRIVE CHAIN
2	08417362	RETAINER-GUARD
4	HW0303	BOLT-HHCS-1/4-20 X 1"
8	HW0104	WASHER-FLAT-1/4"-SAE
4	HW0103	WASHER-LOCK-1/4"
4	HW0002	NUT-HEX-1/4-20
1	00196216	LABEL-WARNING-"CHAIN ENTANGLEMENT..."

ATC CHAIN GUARD RUBBER FLAP KIT

P/N: 80012001

QTY	PART#	DESCRIPTION
2	08017047	RETAINER - RUBBER GUARD
2	08417390	RUBBER GUARD
16	HW0301	BOLT-SELF TAP-“F” 1/4-20 X 1/2”

ATC-CAN-7 CHAIN GUARD RUBBER FLAP KIT

P/N: 80012002

QTY	PART#	DESCRIPTION
2	08417402	RETAINER - RUBBER GUARD
2	08417391	RUBBER GUARD
18	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”

ATC MAGNET CABLE REPLACEMENT KIT

P/N: 80032004

For most ATC's, you will need to shorten the replacement cable (E0704-1) to ensure proper fi t. Cut the cable to the proper length shown below based on the cantilever (CAN-XX) option of your ATC:

ATC (no CAN) = 22 Coils

ATC-CAN-7 = 24 Coils

ATC-CAN-14 = No cutting required

QTY	PART#	DESCRIPTION
1	E0704-1	CORD-COIL-3 PIN-FEMALE
1	HW1023	CLAMP-CABLE-1/2"
1	HW0001	NUT-HEX-#10-24
1	HW0101	WASHER-LOCK-#10
1	HW0212	SCREW-RHMS-#10-24 X 1/2"

STATEMENT OF WARRANTY

Statement of Warranty

Click here for details on BHS' Statement of Warranty.