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

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 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

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

PRIMARY GUARDING

LABELS & PLACARDS

EXTRACTOR ARM

STANDARD EXTRACTOR ARM

VACUUM EXTRACTOR ARM

MAGNET EXTRACTOR ARM

PNEUMATICS

VACUUM PUMP

HYDRAULICS

MANUAL LEVER VALVE

ARM DRIVE MOTOR

POWER UNIT

POWER UNIT RETROFIT KIT

HOSES

HYDRAULIC SCHEMATIC

ELECTRICAL

DASHBOARD COMPONENTS

MICRO SWITCH

JUNCTION BOXES

JUNCTION BOX - MAGNET ARM

MAGNET CORDS

ELECTRICAL SCHEMATICS

STANDARD OPTIONS

COMPARTMENT EXTENSION

AUXILIARY HOOK & CHAIN

RUBBER BUMPERS

FP-C

BOLT ON

LOW PROFILE - BOLT IN (LP)

LOW PROFILE FRAME (LPF)

DROP IN ROLLER (DIR)

2 TIRE

SECONDARY GUARDING

PARTS KITS

STATEMENT OF WARRANTY

Statement of Warranty

Battery Handling Systems, Inc. and its subsidiaries and affiliates (collectively “BHS”) warrants to the original purchaser of its equipment, that the equipment shall be free from defects in material and workmanship under normal and proper use, operation, and maintenance during the applicable warranty period set forth below for the product containing the alleged defect:

• Thirteen (13) months from the date of shipment to the original purchaser with respect to frames, weldments, electric drives, motors (except brushes), motor driven pumps, valves, and drive wheel assemblies (except wheels) only.
• Ninety (90) days from the date of shipment to the original purchaser with respect to all other parts not covered above.
• Bulbs, fuses, and filters are not included in this ninety (90) day warranty, unless found to be defective prior to use or within (90) days of shipment to the original purchaser, whichever occurs first.
  BHS’s warranty obligations hereunder are contingent upon the following conditions: (1) BHS or its authorized dealer is promptly (but in no event later than thirty (30) days following the discovery of the claimed defect) notified of the defect; (2) the purchaser establishes to BHS’s reasonable satisfaction that any goods have been properly installed, maintained, and operated; (3) the purchaser returns the defective goods or any part thereof to BHS; and (4) the purchaser complies with all other warranty procedures required by BHS (such procedures are available upon request). Upon a determination by BHS that a product is defective within the above-mentioned warranty period(s), BHS may, at its exclusive option, either provide parts and labor to repair or replace said defective equipment, or grant a credit or refund of the purchase price of the defective equipment. Repaired or replacement equipment and parts will carry the foregoing warranty for the remainder of the original warranty period or ninety (90) days from the date of shipment of the repaired/replaced equipment, whichever is longer.

BHS will cover normal ground freight charges such as ground UPS, common carrier, etc. for the delivery of repaired or replaced equipment or parts covered by this warranty. The cost of any express delivery, if requested, will be the sole responsibility of the purchaser, and the purchaser agrees to provide its account number with its preferred carrier to BHS or to pay the entire cost of express delivery as a condition of BHS’s provision of such express delivery. Unless expressly authorized in writing by BHS, the foregoing warranty does not cover the cost of removal or reinstallation of equipment (or the cost of other activities ancillary thereto), the cost of which will be borne solely by the purchaser.

This warranty is void in the case of abuse, misuse, abnormal use, accidents, overloading, improper installation, repair, or maintenance (other than by BHS), modification of products, application of products not in accordance with the instruction manual and product application bulletins, or any other reason BHS determines that said product is not operating properly as a result of causes other than defective manufacture.

This warranty shall apply exclusively to products sold to the purchaser by BHS. BHS shall not have any liability or obligation to the purchaser, under this warranty or other- wise, with respect to any defect or failure of performance in products which are not sold or manufactured by BHS, including any such products which are commingled with or incorporated into any BHS products, or any products into which BHS products are incorporated as a system component or otherwise without the prior written approval of BHS. This warranty does not cover accessories and attachments not manufactured by BHS. The original manufacturer’s warranty, if any, for such accessories or attachments takes precedence and all claims shall be directed to their respective manufacturers.

ANY LITIGATION TO ENFORCE THE FOREGOING WARRANTY MUST BE COMMENCED NO LATER THAN ONE (1) YEAR AFTER DISCOVERY REASONABLY SHOULD HAVE BEEN MADE OF ANY FACTS OR OTHER INFORMATION SUGGESTING THE EXISTENCE OF A PRODUCT FAILURE OR A PRODUCT DEFECT. THE WARRANTY SET FORTH HEREIN IS THE COMPLETE AND ENTIRE WARRANTY MADE BY BHS AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MER- CHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, NON-INFRINGEMENT, OR OTHERWISE, ARE HEREBY EXPRESSLY EXCLUDED. NO PERSON IS AUTHORIZED TO MAKE ANY OTHER OR ADDITIONAL WARRANTY ON BEHALF OF BHS. THE RIGHT TO REPAIR, REPLACEMENT, OR CREDIT/REFUND, AS SET FORTH HEREIN, IS THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF THE ABOVE WARRANTY. BHS SHALL NOT BE LIABLE FOR CHARGES OR EXPENSES OF ANY NATURE UNDER THE FOREGOING WARRANTY INCURRED WITHOUT BHS’S CONSENT. FURTHER, UNDER NO CIRCUMSTANCES, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER IN WARRANTY, CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OR FOR ANY OTHER TORT OR CLAIM), SHALL BHS BE LIABLE TO THE PURCHASER OR ANYONE ELSE FOR ANY: (A) INCIDENTAL DAMAGES (EXCEPT AS SPECIFICALLY PROVIDED FOR ABOVE), OR CONSEQUENTIAL, INDIRECT, SPECIAL OR PUNITIVE DAMAGES RELATIVE TO OR ARISING FROM OR CAUSED DIRECTLY OR INDIRECTLY BY SAID PRODUCTS OR THE USE THEREOF OR ANY DEFICIENCY, DEFECT, OR INADEQUACY OF SAID PRODUCTS; OR (B) DIRECT DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE BHS EQUIPMENT GIVING RISE TO THE CLAIM OR CAUSE OF ACTION, OR AT THE ELECTION OF BHS, THE RESTORATION OR REPLACEMENT OR REPAIR OF SUCH EQUIPMENT. “CONSEQUENTIAL DAMAGES” INCLUDE, WITHOUT LIMITATION, LOST PROFITS, BUSINESS INTERRUPTION DAMAGES, LOSS OF USE DAMAGES, AND DAMAGE TO REPUTATION OR GOODWILL. This Warranty is governed by and construed in accordance with the laws of the State of Missouri, without regard to conflict of law principles. All disputes or controversies arising out of or in connection with this Warranty shall be subject to the exclusive jurisdiction of the U.S. District Court for the Eastern District of the State of Missouri and any and all process in connection with any litigation arising out of such dispute or controversy may be served by registered, certified mail, return receipt requested, outside Missouri, with the same force and effect as if service had been made in Missouri.

If part of this Warranty is held to be invalid or unenforceable, such invalidity or unenforceability shall not invalidate or render unenforceable the entire Warranty, but rather the Warranty shall be construed as if not containing the particular invalid or unenforceable provision.

WARRANTY PROCEDURES

Warranty Procedures

Please refer to Battery Handling Systems, Inc.'s Statement of Warranty and Liability (which is set forth on the reverse side hereof or available upon request) for a complete description of BHS' warranty. In the event of conflict between BHS' warranty and these procedures, the warranty will control.

Battery Handling Systems, Inc.'s warranty policy is intended to protect original purchasers who submit valid claims, as well as to identify and eliminate claims where product failure is the result of customer abuse, neglect or misapplication.

Step 1: Gather Information

The following information must be provided immediately.

• A description of the product that includes, at a minimum, the model, serial number, and hour meter reading (if applicable).
• Customer name, location, and contact information including phone number.
• Installation date, installation provider (dealer), servicing dealer, and selling dealer.
• Any prior repairs, modification, or adjustments.

Step 2: Contact BHS

Contact BHS at:

Phone: 1.877.247.4968
Fax: 1.314.423.5948
Email: service@bhs1.com

Step 3: Authorization

BHS will authorize further evaluation, repair, or replacement. A warranty claim form indicating BHS prior authorization for any such action will be issued to claimant. The completed warranty claim form must be submitted with any request for warranty credit.

Step 4: Request RGA Number

• Suspected defective parts must be returned to BHS under an issued Return Goods Authorization (RGA) number.
• BHS will specify the proper disposition of the parts through the issue of an RGA number.
• Return shipment method will also be specified at time of RGA issue. RGAs are good for thirty (30) days from date issued; no credit will be issued for items returned after the RGA has expired.

Step 5: Claim Warranty

• Submit Warranty Claim forms and supporting documents to: Battery Handling Systems, Inc.
  P.O. Box 28990
  St. Louis, MO 63132
  Fax: 1.314.423.5948
  Email: service@bhs1.com
• Labor allowance hours are determined by our engineering staff.
• Actual travel time, labor time, and parts costs must be indicated as separate items as provided on the form.

Step 6: BHS will process warranty claim and notify purchaser of final disposition.