EnerSys PRO Series User manual

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UNI-TUGGER
OWNER’S MANUAL
OPERATOR’S MANUAL / PARTS MANUAL
PRO SPRO Serieseries®
BATTERY HANDLING EQUIPMENTBATTERY HANDLING EQUIPMENT
BATTERY HANDLING EQUIPMENT

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UNI-TUGGER
BATTERY HANDLING EQUIPMENT
UTE-XX-24-FM
FM-Front Mount
DC Voltage (V)
Compartment Width (30 in; 36 in)
The information contained in the publication is for customer use only.
All rights reserved. Reproduction in any form or by any means, adaptation, translation or other use
without the express written permission of Carney Battery Handling is prohibited.
OWNER’S MANUAL
OPERATOR’S MANUAL / PARTS MANUAL
ENERSYS EMEA
EH Europe GmbH
Baarerstrasse 18
6300 Zug
Switzerland
Phone: [phone] • Fax: [phone]
Email: [e-mail]
http://www.enersysinc.com
BATTERY HANDLING SOLUTIONS
EnerSys EMEA Motive Power - Working in partnership with Carney Battery Handling Ltd.
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SYMBOL IDENTIFICATION CHART
Refer to
accompanying
documentation.
Refer to Manual.
Do not operate
without all guards and
covers in place.
Crush Hazard – Keep
Hands Clear.
Entanglement Hazard
– From chain, gear or
pulley.
Pinch Point Hazard
Crush Hazard From
Falling Load
Crush Hazard – Keep
Feet Clear
Eye Protection
Required
Safety Shoes
Required
Slip Hazard
Heavy Object – Do not
exceed recommended
load weight.
Protective Clothing
Required
Rubber Gloves
Required
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DANGERS, WARNINGS, AND CAUTIONS LABELS
Labels, languages, and symbols shown below may be different than the ones on the unit.
Check the unit for actual labels
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This manual contains important information to help you properly operate and maintain your “BATTERY
TUGGER” for maximum performance, economy and safety. By practicing correct operating procedures
and by carrying out the recommended preventive maintenance suggestions, you will experience long,
dependable and safe service.
TABLE OF CONTENTS
TABLE OF CONTENTS...............................................................................................................7
GENERAL INFORMATION.........................................................................................................8
Pallet Truck Front Mounting (Figure – 1a)..............................................................................9
Fork Truck Front Mounting (Figure – 1b)................................................................................9
UNI-Tugger battery handling equipment / Lift Truck positioning (Figure – 2)..................9
OperatingInstructions.............................................................................................................10
Extraction from the Lift Truck.................................................................................................11
UNI-Tugger battery handling equipment Assembly with 24V DC VSJ (Figure – A)......12
UNI-Tugger battery handling equipment Assembly (Figure – B).....................................13
Battery Tugger Assembly (Figure – C)..................................................................................14
Battery Tugger Assembly (Figure – D)..................................................................................15
Battery Tugger 24V DC VSJ Assembly (Figure – E)............................................................16
Joystick Control Switch Assembly (Figure – F)...................................................................17
Electrical Schematic 24V VSJ Control (Figure –3.1)..........................................................18
Electrical Schematic 24V Linear Actuators (Figure –3.2).................................................19
Battery Tugger Quick Clamp (Figure – 4).............................................................................20
Battery Tugger Quick Clamp (Figure – 4.1)..........................................................................21
Electromagnet Maintenance (Figure – 6)............................................................................22
Drive Mechanism Maintenance (Figure – 7).......................................................................23
Slider Strip Maintenance (Figure – 8)...................................................................................24
STATEMENT OF WARRANTY..................................................................................................26
Pacemaker and Magnet information....................................................................................27
HOW TO PLACE AN ORDER FOR PARTS..............................................................................28
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GENERAL INFORMATION
Congratulations on purchasing a new “UNI-TUGGER” battery handling equipment. With
the proper care and regular maintenance you will receive years of trouble free service.
If yourequire technicalsupport or otherrepair services, orif youare ordering replacement
parts, please provide us the following information.
Model #
Serial #
Customer
Date in Service
WARNING
OPERATING TUGGER WITH LOW VOLTAGE
WILL PREMATURELY CAUSE MOTOR BRUSHES TO FAIL.
(THIS WILL NOT BE COVERED UNDER WARRANTY)
Note:
If your Tugger is equipped with an emergency stop button and it is
activated, you must wait 20 seconds before pulling the button back up
(This is required for the controller to re-boot itself)
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Pallet Truck Front Mounting (Figure – 1a)
Fork Truck Front Mounting (Figure – 1b)
UNI-Tugger / Lift Truck positioning (Figure – 2)
Example Showing Extraction Using Pallet Truck
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OPERATING INSTRUCTIONS
Description:
The UNI Tugger battery handling equipment is a non-propelled, electrically powered
battery changer that is designed for medium volume applications and all sizes of
batteries, such as those found in reach trucks, pallet trucks and 3 & 4 wheel counter-
balance trucks.
Before operating the “UNI-TUGGER” battery handling equipment it must be mounted
onto a mobile lift truck or pallet truck as shown in gure #1a, or b. It is important
that the operator thoroughly review and understand the proper Safety Procedures
and Instructions as outlined in this Owner’s Manual and the Owner’s Manual for the
mobile truck. It is also important that the “UNI-TUGGER” battery handling equipment
be secured to the mobile lifting truck, either bolted permanently or “Quick Clamp”
(see Battery Tugger Quick Clamp (Figure – 4) on page 19). Fastening is recommended
however fastening can be quick release to allow the host truck to be used in regular
operations.
All operators must be trained or certied (if required) in the use of the “UNI-TUGGER”
battery handling equipment.
UNI -Tugger Battery Handling Equipment
Safety shoes, safety glasses and protective clothing are mandatory in
Battery Rooms. Be sure to wear them at all times. Rubber gloves, rubber
aprons and full face shields are required when washing and servicing
forklift batteries. Always use caution and common sense.
Preparation:
1. Park the lift truck in a perpendicular position adjacent to the “UNI-TUGGER”
battery handling equipment (Fig. 2, page 8).
2. Prepare the lift truck for battery removal as follows:
• Lower the forks until they sit at on the oor.
• Engage the parking brake.
• Remove any protective covers.
• Unplug the battery and position the connector plug
And cable so as to prevent snagging or pinching during
the battery removal process.
• Remove the battery retaining gate.
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Extraction from the Lift Truck
1. Position the UNI-Tugger battery handling equipment in front
of the battery compartment and lower the unit so the front rollers are
approximately ½” below the bottom of the battery to be removed.
2. Power the magnet out until it contacts the battery to be removed.
Then turn on the magnet toggle switch. Power the magnet back to pull
the battery out, until it is just over the large black entry rollers on the UNI-
Tugger battery handling equipment.
3. Raise the UNI-Tugger battery handling equipment using the forklift
controls until the rollers support the weight of the battery and continue to
pull the battery all the way into the UNI-Tugger battery handling equipment.
4. Drive the forklift to an appropriate empty roller stand.
5. Raise or lower the UNI-Tugger battery handling equipment to the
roller stand height, then power the magnet to push the battery out onto the
roller stand.
Insertion into the Lift Truck:
1. Raise the UNI-Tugger battery handling equipment using the mobile lifting truck
controls and/or using linear actuator controls to the roller stand level and retrieve the
charged battery.
2. Position the UNI-Tugger battery handling equipment in front of the lift truck
battery compartment, and then raise or lower the battery to be just slightly above
(approx. ½”) the level of the lift truck’s roller or slider bed.
3. Power the magnet and battery as far as it will go into the lift truck. If using a
powered pallet truck, make sure the pallet jack handle is in the vertical position, i.e.
brakes are on.
Conclusion:
1. Drive the “UNI-TUGGER” battery handling equipment away from
the lift truck and park it in a safe location.
2. Check the discharged battery, connect the cables and turn on the
charger.
3. Prepare the lift truck for operation as follows:
• Install the battery retaining gate
• Plug in the battery
• Install the protective covers
• Check the battery indicator gauge
NOTE: The activation of the controls for the magnet bridge arm (forward/reverse)
and the lift up/down can only occur with the simultaneous activation of the two-
handed operation button that is mounted next to the emergency stop. The magnet on/
off control does not require the activation of the two-handed operation button.
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UNI-Tugger Battery Handling Equipment Assembly with
24V DC VSJ (Figure – A)
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UNI-Tugger Battery Handling Equipment Assembly
(Figure – B)
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Battery Tugger Assembly (Figure – C)
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Battery Tugger Assembly (Figure – D)
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Battery Tugger 24V DC VSJ Assembly (Figure – E)
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Joystick Control Switch Assembly (Figure – F)
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Electrical Schematic 24V VSJ Control (Figure –3.1)
CONNECTORS
FUSE 6A
FUSE 15A
BATTERY B+
BATTERY
+-
B- CONNECTORS
BATTERY
MOTOR
DC
(+)
MAGNET
MAGNET
CONTACTOR
RETRACTED
LIMIT SWITCH
TIMER CONTACT
6
7
C1
TR TIMER
MOTOR
MOTOR
CONTACTOR
LIMIT SWITCH
EXTENDED
C1
EMERGENCY
DISCONNECT SWITCH
(optional)
0
BTE 24V CURTIS CONTROLLER JOYSTICK VARIABLE SPEED
M.W. 24/07/2017
TITLE:
DRAWN BY: CAD File:
NOTE:
WIRES ON UNIT IDENTIFIED BY NUMBERS SHOWN
MOTOR 24 V DC
CONTACTOR
MAGNET
LED LIGHT
(optional)
0
5
4
ELECTRICAL SCHEMATIC 24V CURTIS CONTROLLER
JOYSTICK VARIABLE SPEED
MAG
(-)
3
CONTROLLER
B- (0)
1
C2
0
M1
M2
JOYSTICK
AUX. B
AUX. A
SIGNAL
GROUND
2
B
B
B- (NEG)
B- (NEG)
A
0
ORANGE / BLACK TRACE
GREEN / BLACK TRACE
WHITE
RED / BLACK TRACE
BLUE
BLACK
RED
BLACK
MAGNET ON
WHITE / BLACK TRACE
MANUAL RESET
CIRCUIT BREAKER
60A
BTE 24V CURTIS CONTROLLER VSJ 3.3-R4
Rev. Description Date Approved
R1 Change 50A fuse to 60A Circuit Breaker 3 Nov. 2014 J.B.
8
10
Amber Strobe
Light(Optional)
Retracted
Limit Switch
R2 Add amber strobe light and retracted limit swithch 14 Nov. 2014 J.B.
R3 DC/DC Power Driver & Diode Laser added 10 Nov. 2015
PD
DC/DC Power Driver
Red Laser
Diode Module
(Optional)
0
3V+
3V-
L
L
FORWARD
MAGNET
TRAVEL LED
(OPTIONAL)
REVERSE
MAGNET
TRAVEL LED
(OPTIONAL)
TWO HANDED
OPERATION BUTTON
(OPTIONAL)
R4 Add Magnet travel led; Two handel operation button 28 June 2017
MAGNET
TOGGLE
SWITCH
12
1
VS
RED
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Electrical Schematic 24V Linear Actuators (Figure –3.2)
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Battery Tugger Quick Clamp (Figure – 4)
BT-QC
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