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TT-974: Powered Roller Chains

Models Affected: Battery Extractors with Powered Rollers Subject: The powered rollers on Battery Extractors not only assist in moving batteries onto and off of the extractor, but also act as a brake, holding the batteries in place during machine operation. Ensuring this system of rollers is functioning properly is vital to efficient and safe operation of the extractor. Description: Each compartment of rollers is controlled by one motor directly coupled to the first roller. The additional rollers are linked together by a series of chains. Failure of one of the powered roller chains could result in all but one of the rollers spinning freely. Without the powered rollers, loading and unloading a battery will be quite difficult, and the loss… Continue Reading

TT-973: The Advantages of Dedicated Operators

Models Affected: All Battery Extractors Utilizing dedicated personnel to perform battery changes can provide several advantages over individual forklift operators changing their own batteries. Utilizing a dedicated extractor operator can lead to higher efficiency per battery change leading to substantial savings long term as well as increasing the longevity of the equipment. Description: Dedicating an operator to the battery handling process creates responsibility and accountability for the equipment. Without designated operators, there is typically no traceability if there is damage to the battery room equipment, meaning responsible parties cannot be identified when damage is found. This leads to less care being taken with the equipment. Every operator utilizing the battery changing equipment also leads to less familiarity with the equipment… Continue Reading

TT-972: BTC Caster Alignment

Models Affected: All BTC models (non track-mounted) Properly aligning the front rigid casters on BTC units is necessary to ensure ease of movement as well as maximizing caster life. Description: Though the front casters on the BTC models are rigid mounted casters, the mounting holes to secure the casters to the frame are slightly oversized. This can lead to some variance in the angle at which the casters are mounted. If not properly aligned at the time of installation, one or both casters could “pull” to one side or the other causing the outer frame to spread apart and then “pop” back to normal. This increases the effort required to manuever the BTC and could also result in premature wear… Continue Reading

TT-968: Re-Tensioning Lift Chains

Models Affected: All multi-level, Operator Aboard Battery Extractors Lift chains on multi-level Battery Extractors (BE) will require occasional re-tensioning. This Tech Tip will describe the easiest way to complete this task. Description: The lift chains on multi-level BE units must be properly tensioned in order to insure proper lifting of the inner carriage. If the chains are not equally tensioned, the cylinders may not lift simultaneously which can lead to repeated issues with the equalization chains. The equalization chains can skip links causing the carriage to lift out of level which can result in damage to the extractor frame and components. Recommendation: The proper tension for the lift chains is to have each cylinder pre-loaded. The chains should be tightened… Continue Reading

TT-967: Operator Aboard Battery Extractor Swing Arm Damage and Repair

Models Affected: BE-SL, DS, TS, and QS models including “N” models Typical swing arm damage, likely causes, and proper repair. Description: The Battery Extractor (BE) swing arms support the vacuum or magnet arm as it rotates between compartments. The swing arms also house the vacuum or magnet components. Under normal operation and with routine maintenance the swing arms should perform without fail. Instances where swing arm failures are experienced could be the result of improper operation. The swing arms are comprised of a formed channel with a hub welded in place which fits onto the actuator shaft providing the rotation of the arms between compartments. The typical failure of the swing arms is a shearing of the weld or tearing… Continue Reading

TT-966: Vacuum and Magnet Performance

Models Affected: All Extractors with vacuum or magnet extraction Important tips to ensure the vacuum cup or magent are performing to their full potential. Description: BHS extractors with vacuum or magnet extraction make batttery changes quick and efficient. Poor vacuum or magnet performance can lead to diminished efficiency and amplified operator frustration from repeatedly re-attaching the vacuum cup or magnet to a battery during each change-out. Addressing the following items will help to optimize the vacuum or magnet extraction. Recommendations: Proper Mounting – Magnets should be mounted so that they are parallel to the battery. Mounting hardware should be equally tightened so that the magnet pulls evenly so as not to pull one end away from the battery before the… Continue Reading

TT-965: Importance of Battery Compartment Maintenance

Models Affected: All battery extractors and carriages If not properly maintained, the condition of battery stand and forklift battery compartments can have negative effects on battery extractor or carriage operation. Compartments in poor condition increase the force required to transfer a battery leading to unnecessary stress on extractor components. Description: In order for a battery extractor or carriage to operate at its highest efficiency, the battery stands and forklift compartments (which batteries are being transferred to and from) should be well maintained. Faulty rollers result in the batteries being dragged across them requiring substantially more force to move the battery in and out of the compartment. Slide strip compartments by design require more force to remove and install a battery…. Continue Reading

TT-964: Operator Aboard Battery Extractor Magnet Mount Update

Models Affected: BE models with magnet extraction (not including SS or MS units) Battery Extractor (BE) magnet mount design has been updated. As of November 2014, the magnets are now mounted on independent bearing assemblies. The new mounting design reduces the number of parts in the assembly, increases the simplicity of the assembly, and adds durability and reliability. Description: The previous magnet mount had the magnets mounted on each end of a common shaft which ran through the arm. The assembly contained four screws which tensioned the magnets on the shaft. Previous Tech Tip #949 explains the importance of properly maintaining these “load adjusters”. If the load adjusters become loose, the magnets are allowed to fall forward which can lead… Continue Reading

TT-963: Proper ATC and WTC Mounting

Models Affected: All ATC and WTC Units To ensure proper and safe operation of an Automatic Transfer Carriage (ATC) or Walkie Transfer Carriage (WTC) the unit must be mounted properly to the host pallet truck, regardless of the mounting method being used. Description: ATC and WTC units can be mounted directly to the host pallet truck using one of two methods: Permanent mounting – The ATC or WTC can be welded directly to the forks of the host pallet truck. Semi-permanent mounting – An optional bolt-on kit (ATC/WTC-BLTON) is available to mount the carriage to the pallet truck via two steel plates which mount beneath the forks and bolt to the carriage, clamping the carriage to the pallet truck. This… Continue Reading

TT-962: ATC and WTC Fork Pockets

Models Affected: ATC and WTC Units with Fork Pocket option The proper and safe operation of an Automatic Transfer Carriage (ATC) or Walkie Transfer Carriage (WTC) when used with optional fork pockets. Description: ATC and WTC units can be permanently or semi permanently mounted to the host pallet truck. If a pallet truck cannot be dedicated to the ATC or WTC, optional fork pockets are available allowing the Carriage to be utilized without directly mounting it to the pallet truck (FP-C option). Fork pockets are also available for use with sit-down, counterbalance lift trucks (FP option). When using a unit with fork pockets it is important to ensure the pallet truck or lift truck is properly engaged with the fork… Continue Reading