IOP-080 ATC

TP-616 - SAFETY AND DE-ENERGIZATION PROCEDURES

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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 fl uid 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 BTC 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 HAZARD

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

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 prior page).

• All data plates, warning labels, placards, etc shall be in place and legible at all times. Contact BHS for replacement 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 the 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).

DO’s AND DON’T’s

• DO NOT exceed the maximum capacity of the ATC.

• DO NOT modify or fit the ATC with attachments without prior, written approval from BHS.

• DO NOT perform any maintenance or service to the 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 removed 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 attempting 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 to:

           >>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 foodstuff
           >>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 components


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.
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 components.


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

SPECIFICATIONS

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 defl ection and/or linkage wear of pallet truck load wheels. 1/4"-1/2" rearward pitch should be verifi ed 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 modifi cation 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 fi lling the unit.

FP OPTION

HYDRAULIC RESERVOIR

OPERATING CONTROLS

The following is a brief operational overview of the BTC.

EXTRACTION CONTROLS
• Winch Extraction - Rotate the winch handle counterclockwise to extend the winch strap and rotate the winch handle clockwise to retract the winch strap. Winch direction is changed by switching the lever at the rear of the winch. See Figure 7


FIGURE 7

• Mechanical Extraction - Turn the hand wheel counterclockwise to extend the extractor arm toward the lift truck or battery stand and clockwise to retract the extractor arm. See Figure 8. Note: The extractor arm latch must be raised to move the arm when fully retracted. See Figure 9.
• 

  FIGURE 8

• 

  FIGURE 9

• Electric Extraction - With the green power button depressed, push the extraction valve handle to the right to extend the extractor arm toward the lift truck or battery stand and push the valve handle to the left to retract the extractor arm. See Figure 10.


FIGURE 10

• Vacuum (if equipped) - Pull up the vacuum switch to energize the vacuum pump and push down to de-energize the vacuum pump.
LIFT CONTROLS
• Mechanical Lift - Insert the jack handle into the jack handle socket and pump the jack handle up and down to raise the inner carriage. To lower the inner carriage, slowly turn the release handle located at the base of the manual jack counterclockwise. Turn the release handle clockwise to stop lowering the inner carriage. See Figures 11 & 12.
• 

  FIGURE 11

• 

  FIGURE 12

• Electric Lift - With the green power button depressed, push the lift valve handle to the left to raise the inner carriage and push the valve handle to the right to lower the inner carriage. See Figure 13.


FIGURE 13

BRAKES

• Vector Brakes - The vector brakes are used when transferring batteries from the BTC to the industrial truck or battery stand. To engage the vector brake, lift the release handle up and slide it forward allowing the vector brake to lower to the floor. To disengage, lift the release handle up until the notch in the release handle is allowed to move rearward, locking the brake in the raised position. See Figures 14 & 15.


FIGURE 14



FIGURE 15

• Floor Lock - The floor lock is to be used any time the BTC is left unattended. DO NOT use the floor lock during the change out process. To engage the fl oor lock, press down on the pedal with your foot. To disengage, press either of the two release tabs on the side of the floor lock with your foot. See Figure 16.


FIGURE 16

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 BTC back into service.

• Extractor Arm - Verify proper arm travel by slowly moving the extractor arm fully in and out of the battery compartment.
• Lift - Verify proper lift by slowly raising and lowering the inner carriage through the entire lift range.
• Vector Brakes - Verify operation by engaging and disengaging the vector brake to ensure smooth operation and verify complete contact of the brake pad with the floor. While engaged, carefully pull rearward on the cart to ensure proper engagement of the vector brakes.
Note: When unloaded, it is normal for the front casters of the carriage to lift off the floor as the vector brakes engage.
• Floor Lock - Verify operation by engaging the floor lock and ensure the carriage cannot move when pushed or pulled with moderate force.
• Vacuum (if equipped) - Verify the vacuum pump energizes and there is suction at the vacuum port of the vacuum cup.

OPERATING INSTRUCTIONS

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

Operators must be equipped with all necessary PPE and be properly trained in handling industrial lead-acid lift truck batteries.

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 BTC into position such that the roller compartment of the BTC is aligned with the battery compartment of the industrial truck.
4. Verify the battery safety stop at the end of the BTC roller bed is in the down position.
5. Adjust the vertical height of the BTC battery compartment to the battery compartment of the industrial truck or slightly higher. [DO NOT exceed 1/4" difference.].
6. Once the proper height is achieved, the extractor arm can be moved toward the lift truck battery.
   Hook and Chain - Stop the extractor arm approximately 3" - 4" from the battery.
   Vacuum Extraction - Bring the vacuum cup in contact with the battery. DO NOT force the extractor arm into the battery once contact is made.
7. For hook and chain units, attach the hook securely through the lifting eye of the battery and ensure full engagement. See Figure 17. For vacuum units, energize the vacuum.


FIGURE 17

8. Slowly begin removing the battery from the industrial truck battery compartment while inspecting the vertical alignment of both battery compartments. If vertical adjustment is required, disengage the vacuum cup (if equipped) prior to adjusting the height of the BTC.
9. Once the battery is entirely inside the BTC battery compartment, move the battery safety stop to the upright position. For electric units, 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. If equipped, turn off the vacuum.
10. The battery may now be transported to the charging area.
    Note: When possible, always push carriage so as to not create a hazard should you slip while pulling the carriage. Batteries are heavy and could cause personal injury under such conditions.
11. Align the BTC with an open roller compartment in the battery charging area.
12. Adjust the vertical height as needed for alignment with the battery stand.
13. Engage both vector brakes.
14. Lower the battery safety stop at the front of the carriage.
15. Slowly move the battery from the BTC into the battery stand. For vacuum equipped units, it is not necessary to energize the vacuum for this step.
16. After transfer, raise the battery stop on the stand and disconnect the hook from the battery. DO NOT force the extractor arm into the battery after the battery is completely in the stand.
17. Reposition the BTC at the location of the newly charged battery to be installed in the lift truck.
18. The above process can be used to remove a battery from the roller stand to be installed into the industrial truck.
19. After completing battery changes, the floor lock(s) should be engaged prior to leaving the BTC unattended.
As with all material handling equipment, the transfer carriage should be inspected prior to each use for any visual damage. It should also undergo a routine inspection by trained maintenance personnel to verify and maintain the load capacity of the unit.

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 the BTC not allowing the battery to be unloaded using normal operating procedures, it is recommended the battery be removed from the BTC 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. compartment of the BTC 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. Engage the vector brakes on both sides of the BTC.

3. Adjust the vertical height of the BTC 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 BTC roller bed is in the down position.

4. Carefully push the battery by hand from the BTC 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.

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.

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

BTC electric motors are 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.

HYDRAULIC SYSTEM

For electric units, the reservoir should be fi lled 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.

DISPOSAL OF WASTE MATERIAL

Dispose of all fluids and waste according to local regulations.