Cradle

The “Cradle” is an enclosure, usually attached to ballast castings / weights, that contains the connection mechanism to the forklift or AGV and houses the loaded battery while the vehicle is in operation. This heavy, steel structure secures the battery while in operation, conducts the power from the battery into the forklift, and communicates the status of the battery with the forklift (optional), Battery Discharge Indicator (BDI), and operator.

The cradle contains a small onboard rechargeable battery to continuously provide power to auxiliary loads while the battery is being exchanged by the robot. This power is provided by a 12V, 5Ah LFP (lithium iron phosphate) battery located behind the Brush Bracket Assembly and can be set to 24, 36, or 48V (firmware update) at up to 1A of load.

Figure 38 Cradle Interior View

Mechanical Service - Cradle

Periodically, items will need to be replaced either due to damage or malfunction. For a complete list of components and build instructions, see drawing 102201.

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HIGH CURRENT SOURCE

Prior to working on the cradle, ensure that the power is turned off by holding the green power button for 5 seconds; the green light should turn off. If a battery is present, ensure that the battery is also turned off by holding down the power button on the battery until the green light turns off.

NEVER rely on disconnection of the 12V 5Ah battery in the cradle to remove battery power from the cradle. This small battery is only used for startup, NOT for maintaining power while operational.

ALWAYS disconnect the positive or negative terminal from the 12V 5Ah battery while working on a cradle with a battery is installed.

ALWAYS check for voltage on the battery terminals before working on the cradle while a battery is installed.

Rear Access Panel – v1

This panel is removed when servicing components inside the rear of the cradle. For removal, follow these steps:

1. Using a flat head screwdriver, rotate the (2) captive screws at the bottom of the panel counterclockwise ¼ turn. The screws should now be loose.

2. The panel hinges at the top – pull out the bottom of the panel a few degrees and then pull at the top; it will come out ~1/8” and the panel should now be rotated up to horizontal and then pulled out all the way.

Rear Access Panel – v2

The version-2 panel is reversed and opens from the top edge and is designed to be easier to remove when the cradle is retained in the vehicle along the bottom edge.

1. Using a flat head screwdriver, rotate the (2) captive screws at the top of the panel counterclockwise ¼ turn. The screws should now be loose.

2. Pull the top of the access cover outward from the cradle. The panel sits into the bottom of the opening with a tab and can be lifted / removed after the top is free.

Brush Assembly

The only components that shall be replaced on the brush assembly are the 12V battery and the power supply. If the brushes or PCB’s need to be replaced, the entire assembly should be replaced, and the old assembly will be repaired and returned by Lion Power.

1. Shut off cradle and battery power.

2. Remove rear access panel.

3. Disconnect the negative and positive quick connects from the 12V battery.

4. Using a 13 mm socket, remove the (2) M8 hex head screws that attach the bus bars to the brush assembly. Torque to 20 Nm upon re-installation.

5. Remove the connector plugging into that back of the assembly just above the power supply.

6. Using a Phillips head screwdriver, remove the fork terminals from the power supply. Use Figure 39 as a reference for connection locations.

7. Disconnect the brush thermistors from the main harness that are left and right of the 12V battery.

8. Using a 13mm socket, remove the (2) M8 flange head hex screws at the base of the brush assembly. The brush assembly can now be removed.

Figure 39 Power Supply Connections

9. Install the new brush assembly by following the reverse of these instructions.

Figure 40 Step 7 - Temp Sense Connections

IR Receiver (Gen 1)

1. Remove the jam nut on the back of IR receiver and disconnect from the side of the NFC board. The IR receiver can now be removed.

IR Reciver (Gen 2)

1. To remove the IR receiver, use a T25 torx bit for the (2) screw on the side of the enclosure.

2. Remove the connector from the back of the housing by pressing the tab and pulling the connector out towards the back of the cradle.

Bus Bars / Cables

To remove the bus bars, follow the instructions below:

1. Shut off cradle and battery power. 2. Remove rear access panel. 3. Begin by removing electrical quick connectors at the bottom of each bus bar. 4. At the bottom of the bus bars, unscrew and remove the M8 hex head screws. Be sure to keep the lock washers under the screw head.

2. At the top of the bus bars, unscrew and remove the M8 hex head screws. The bus bars should now be free and can be replaced.

3. Install new bus bars and torque the (4) hex head screws to 20 N.m. 7. Re-install the electrical quick connect at the bottom of each bus bar. There should be a “click” feel when the connector is fully installed.

Electrical Pass Thru Terminals

To replace the pass thru terminals on the brush bracket or on the cradle follow these instructions:

1. With the cradle and battery turned off, remove the rear access panel. 2. Remove the bus bar or cable that is attached to the terminal that needs to be replaced. Be sure to disconnect the electrical quick connector at the bottom of the bus bar.

2. Remove the (2) M4 SHCS that fastens the pass thru terminal and remove the pass thru terminal.

3. Locate the new terminal, install the screws, and tighten to 3 N.m.

4. Re-connect the quick connect terminals and bus bars and torque to the bus bar fasteners to 20 N.m.

Front Lower Bracket

The front lower bracket keeps the battery retained inside the cradle. Follow these instructions for replacement:

1. With the battery removed from the cradle, remove the (3) M6 hex head screws that fasten the front lower bracket to the cradle.

2. Remove the old bracket, install the new one, and torque the fasteners to 14 N.m. The bracket should be flush with the side brackets.

Front Side Brackets

The front side brackets act as mounting for the IR receiver and shape the retrieval window. To replace them, follow these instructions:

1. Remove the (3) M6 hex head screws that fasten the front side bracket to the cradle.

2. Install the new bracket with the flange towards the exterior of the cradle. Torque the (3) M6 screws to 14 N.m.

Start Button Replacement

The start button can wake up and put the cradle to sleep. To replace the start button, follow these instructions:

1. With the cradle turned off, remove the rear access panel.

2. Disconnect the negative connector on 12V battery on the brush bracket.

3. Remove the black connector on the back of the start button. Some versions may have quick connects terminals on the back of the button. Make note of the colors in which position for re-assembly.

4. Remove the nut on the back of the start button. The button can now be removed.

5. Install the new start button, tighten the nut, connect the harness, and re-connect the negative battery terminal on the 12V battery.

6. The rear access panel can now be installed.

NFC Board Assembly Replacement

To replace the NFC board assembly, you must disconnect the black harness connector and the power supply bracket. See instructions below.

1. Shut off cradle and battery power.

2. Remove rear access panel.

3. Disconnect the negative quick connect from the 12V battery.

4. Put a zip tie or flat head screwdriver into the top of the black connector to release the tab and pull out the connector.

5. Using a 2.5mm hex driver remove the (2) M4 screws (or 4 in some cases) on the left and right side of the power supply. The power supply bracket should now be loose but doesn’t need to be removed.

6. Using a 2.5mm hex driver, remove the (4) M4 screws that hold the NFC assembly bracket to the plastic brush bracket. The NFC can now be removed. The Power supply bracket should tilt out of the way to remove the NFC assembly.

7. Follow these instructions in reverse for re-installation. Torque the M4 fasteners to 2 N.m (20 in.lbs). DO NOT OVER TORQUE.

Main Harness Replacement

1. Turn the cradle off with the start button. 2. Remove the positive and negative connections from the battery. 3. Remove the connections to the bus bars, power supply, brush thermistors. 4. Remove the screws from the upper gray connector and BDI bulkhead connector.

   • a. BDI Bulkhead: 2.5mm hex, torque to 2 Nm upon reinstallation b. Grey connector: T30 bit, tighten until contact with housing for reinstallation.

2. With a flat head screw driver, insert the tip into the top of the connector going into the NFC board to remove it, the connector can now be removed.

3. Reinstall the harness following this instruction in reverse.

“Data” Connector / 12-pin Deutsch Repair

	Part Description	Part #	Qty
	Connector,Deutsch,Flange,DTM,12-pin	DTM04-12PB-L012	-
	Contact,Deutsch,Size 20,Pin	0460-202-20141	-
	Wedgelock,Deutsch,DTM	WM-12P	-
The Deutsch connector interface can be repaired by following standard Deutsch DTM
maintenance standards for pinning and de-pinning the connectors.				Remove any damaged
connectors and re-crimp a new pin on the		wire, then reinsert.
Any crimp style can be used, but ensure the pins are nickel plated for compatibility.
Data Connector Pinout is below:

	**Pin **	**Color **	Gauge		Terminal P/N	Description
	1	Rd	18		0460-202-20241	36/48V Aux
	2	Bk	18		0460-202-20241	36/48V Aux Return
	3	Rd	20		0460-202-20241	12V SLA Charge
	4	Ye	18		0460-202-20241	CAN HI
	5	Gr	18		0460-202-20241	CAN LO
	6	Rd	18		0460-202-20241	Start LED 12V
	7	Wh	20		0460-202-20241	SWS 1
	8	Or	20		0460-202-20241	SWS Loopback
	9	Or	20		0460-202-20241	SWS Signal
	10	Bu	20		0460-202-20241	Start Monitor
	11	Gr	20		0460-202-20241	CAN2 HI(diag)
	12	Ye	20		0460-202-20241	CAN2 LO(diag)

“BDI” Connector / M12 Flange Repair

In some cases, the BDI connector may need to be replaced. This is typically due to a connector not being tightened enough to seal out moisture or might be due to physical damage from debris.

Regardless of the cause, replacement can be done by cutting the old connector off, then splicing in a new connector.

Replacement connectors can be ordered from Lion Power.

Part Description	Part #	Qty
Connector,M12F,0.2m leads	103079	1

Pinout is shown below:

**Pin **	**Color **	**Gauge **	**Terminal P/N **	Description
1<br>2<br>3<br>4	Br<br>Wh<br>Bu<br>Bk	20<br>20<br>20<br>20	N/A<br>N/A<br>N/A<br>N/A	CAN HI<br>CAN LO<br>36/48V Aux<br>36/48V Aux Return

12V LFP Battery Replacement

In the rare event that the 12V 5Ah battery in the cradle fails, it may need to be replaced. Terminals that are damaged on the battery are not user-serviceable.

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The 12V5Ah battery used in the cradle is a Lithium-Polymer battery and should be recycled according to local laws and requirements. DO NOT DISPOSE OF LITHIUM BATTERIES IN THE TRASH.

Vehicle Setup / Cradle Performance

Voltage / SoC Curve

Vehicles can use the following open-circuit-voltage (OCV) data to determine lift-lockout limits and shutdown limit setpoints to promote proper operation of the vehicles.

• NOTE: The Battery loaded into the cradle also has operating limits that will trigger Warning and Error responses if operating parameters are violated. These limits can be found in section 0. This is for the protection of the battery and operator.

Batteries are made up of a parallel grouping of battery cells connected together in series to generate a specific voltage. Below is a table of batteries used in the RoboSwap system. The voltage listed on the table is not tied to any certain Ah capacity of battery. It can be used regardless of battery capacity.

State of<br>Charge<br>SOC (%)	Lead-Acid<br>Cell<br>Equivalent	24V<br>**(25.9Vnom) **	36V<br>**(37Vnom) **	48V<br>**(51.8Vnom) **
-3	2.017	24.20	34.57	48.39
0	2.033	24.40	34.85	48.79
2	2.042	24.50	35.00	48.99
5	2.054	24.65	35.22	49.30
10	2.081	24.97	35.67	49.93
25	2.101	25.21	36.01	50.41
35	2.117	25.40	36.29	50.81
50	2.136	25.63	36.61	51.25
80	2.245	26.94	38.49	53.89
95	2.300	27.60	39.44	55.21
100	2.328	27.94	39.92	55.89