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Automatic Transfer Carriage (ATC) Parts & Service Manual

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

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

General Safety

Read and understand all instructions and warnings before using or servicing this equipment.

Keep these instructions for future reference.

Refer to the host pallet truck manual(s) for proper operation and service procedures before performing any service or maintenance to the pallet truck and/or Automatic Transfer Carriage (ATC) unit.

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

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

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

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

Perform system and safety check before operating.

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

WORK AREA

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

SERVICE & MAINTENANCE

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

LOCKOUT/TAGOUT

Lockout/tagout the SWT per your corporate policy, if damaged or not functioning properly.

Lockout/tagout and de-energize all systems prior to performing any maintenance or service to unit.

LEAD-ACID BATTERY EXPLOSION HAZARD

DO NOT allow open ﬂames or sparks of any kind near a battery.

Highly explosive gas is generated when charging a battery that can remain in battery cells for extended periods of time after charging is complete.

Always wear appropriate PPE including rubber apron, gloves, boots and full face shield when performing service or maintenance to any lead-acid batteries.

DO NOT place metal or other conductive objects on top of battery. Arcing may occur causing damage to the battery and/or serious personal injury or death.

Use only chargers matching the voltage and amperage of the battery being charged. Overcharging a battery can cause damage to the battery, charger and/or serious personal injury or death.

Turn off charger before disconnecting battery from charger. Arcing between battery and charger connectors can cause damage to the connectors and/or serious personal injury or death.

WARNING: High-Pressure Hydraulics Hazard

HYDRAULIC HAZARDS

AVOID HIGH PRESSURE FLUIDS - Escaping fluid under pressure can penetrate the skin causing serious injury.

Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure.

Use a piece of cardboard or paper to search for leaks. DO NOT use your hand.

Any fluid injected into the skin under high pressure should be considered a serious medical emergency despite an initial normal appearance of the skin.

There will be a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately.

Operational Safety

ELECTROMAGNET HAZARD

Units equipped with magnetic extraction generate strong magnetic fields. Persons with pacemakers SHOULD

NOT operate or be in close proximity to equipment during operation. Failure to comply with this direction

could result in serious personal injury or death.

OPERATIONAL SAFETY

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

DO’s AND DON’T’s

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

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

De-Energization

ATC STANDARD

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

2. Disconnect the DC power supply.

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

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

FIGURE 1

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

FIGURE 2

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

Failure to release any stored hydraulic pressure could result in injury from:

Escaping hydraulic fluid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section).
Unexpected movement of hydraulic component

FIGURE 3

ATC WITH REMOTE

1. Unplug the battery charger (if equipped).

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

FIGURE 1

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

FIGURE 2

4. Disconnect the DC power supply.

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

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

FIGURE 3

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

FIGURE 4

Labels & Placards

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

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

Model Number & Options

ATC Model Number Anatomy

NOMINAL ROLLER COMPARTMENT WIDTH

24 = 24" Wide Compartment

30 = 30" Wide Compartment

36 = 36" Wide Compartment

42 = 42" Wide Compartment

CANTILEVER / ROLLER BED EXTENSION *

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

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

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

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

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

EXTRACTION METHOD *

HC/VAC = Vacuum with Backup Hook & Chain

HC/MAG = Magnet with Backup Hook & Chain

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

MOUNTING METHOD

BLTON = Bolt on to Pallet Truck

FP = Fork Pockets for Lift Truck

FP-C = Fork Pockets for Pallet Truck

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

MPJ = Permanent Welding to Pallet Truck

ADDITIONAL OPTIONS *

ESC = Extra Service Capacity

HD = Heavy Duty Extraction Option

LPF = Low Profile Frame

LP = Low Profile Bolt in Slides

QDY = Electric Quick Disconnect “Y” Connector

MLI = Magnet Light Indicator (Magnet Units Only)

UNCTD = Uncoated Rollers (ATC-24 Units Only)

FS = Rear Friction Strips

RGD = Chain Guard Rubber Guards

BSELV = Base Elevation

DIR = Drop In Roller

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

DIR-FS = Drop In Roller with Rear Friction Strips

2TIER = Two Tier Roller Compartment (Upper and Lower Compartments)

BATT = Self-Contained Battery

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

RMT = Remote Pendant Control

NS = Non-Standard / Custom Design or Components

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

Models & Specifications

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

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

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

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

³ Consult factory for additional options.

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

Installation

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

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

PERMANENT MOUNTING (WELDING) - STANDARD UNITS

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.
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.
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

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.
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.
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

Center the ATC on the forks of the pallet truck with the rear of the unit against the pallet truck power head.
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.
Tack weld the shim to the unit to prevent it from moving.
Locate the supplied mounting plates and hardware.
Position mounting plate underneath one of the pallet truck forks aligned with the mounting holes in the rear rail of the ATC.
Insert the 3/8-16 x 4" mounting bolts through the holes in the mounting plate and into the mounting holes of the unit. See Figure 1.

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

FP-C MOUNTING

Lower the pallet truck forks to the fully lowered position.
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

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

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

FIGURE 3

ELECTRICAL CONNECTIONS

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

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

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

Electric Quick Disconnect “Y” Connector Option

ATC-QDY

HYDRUALIC SYSTEM

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

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

HYDRUALIC RESERVOIR

Operating Controls

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

IOP-080 Automatic Transfer Carriage (ATC)

Contents

Automatic Transfer Carriage (ATC) Parts & Service Manual