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Manual Cart

Operation​

The manual cart is designed to lift batteries in the same manner as the robot, using the pin on the front of the battery. The pin adapter on the cart is intended to be placed 1-2 inches below the pin. As the cart is lifted, the adapter will connect with the pin from the bottom and surround the pin. In the same way, as the battery reaches its final location, the cart is lowered, and the adapter will slowly drop the battery onto a surface and release the pin from the bottom. Additionally, the adapter has side to side travel on the cart for flexibility of the cart’s stopped position relative to the forklift and charging rack.

Installation and Removal from Forklift Cradle​

The cart has an additional action for installing and removing batteries from a truck cradle due to its tightly controlled position within the cradle. A handle on the right side (when standing at the controls of the cart) can be pulled to provide a slight tilt to the battery for installation and removal. The procedure should be as follows:

  1. Lower the cart pin adapter 1-2 inches below the battery in the cradle.

  2. Move the cradle into position up against the side of the forklift.

  3. Lock the cart into position using the foot brake at the back of the cart.

  4. Press the “up” button on the cart, paying special attention to the position of the battery pin relative to the cart adapter. Slide the adapter side to side on the cart as necessary to prevent binding.

  5. When the top of the pin makes it all the way into the cart adapter, stop the cart upward travel.

  6. Pull the tilt handle to its locked tilted position.

  7. Proceed with lifting the battery just above the front lip of the forklift.

  8. Move that cart to its next location.

  9. Lower the battery into its final location.

  10. Once battery is supported by rack or cradle, push the lever up to release the tilt function and continue lowering manual cart until it is clear of the battery pin.

  11. To install a fresh battery into a forklift cradle, perform the steps above in the opposite direction.

Installation and Removal from Charging Rack​

  1. Lower the cart pin adapter 1-2 inches below the battery in the rack. 2. Move the cradle into position up against the rack. 3. Lock the cart into position using the foot brake at the back of the cart. 4. Press the “up” button on the cart, paying special attention to the position of the battery pin relative to the cart adapter. Slide the adapter side to side on the cart as necessary to prevent binding.

  2. When the top of the pin makes it all the way into the cart adapter, stop the cart upward travel.

  3. Pull the tilt handle to its locked tilted position. 7. Move that cart to its next location.

  4. To install a depleted battery into a rack charging bay, perform the steps above in the opposite direction.

Maintenance, Adjustments and Storage​

For routine inspection, see Manual Cart Inspection, Section 4.3.2.4

Adjusting leveling mechanism​

  • In some cases, the leveling mechanism of the manual cart may fall out of adjustment which would result in difficult battery swaps. To inspect and adjust the mechanism: 1. Remove the tw

  • M6 screws holding on the front cover.

    1. Locate the connecting rod of the leveling mechanism. 3. With the handle facing up, turn the rod by hand until the machined handle adapter inside face is parallel to the side of the main pin assembly. See figure below.

Handle adapter inside face should be parallel to assembly

  • Turn connecting rod to adjust angle of handle adapter

Adjusting Retracting Pin​

In some cases, the retractable pin that sits over battery once leveled out can fall out of adjustment, resulting in the pin preventing a battery from sliding into the manual cart assembly. To adjust this retracting action:

  1. Remove the plastic cap on the top of the assembly as shown below:

  2. Remove the lower linkage cover as shown in the image below:

  3. Pull the leveling handle out so that there is minimal tension on the cable linkage and the pin is fully extended.

Handle pulled out; pin extended.​

Handle in vertical home position, pin retracted and ready to accept a battery.

  1. Locate the cable clamp attaching the braided cable to the ring on the back of the retracting pin assembly:

  2. Losen the nuts (7mm deep socket) and adjust the cable such that the pin is slightly under tension when retightened.

  3. Test the retracted position by placing the handle back in the vertical home position and ensure the pin is retracted to within 2mm of the housing as shown in the images in step 3.

  4. Readjust cable length as necessary to ensure pin is sufficiently retracted in home position.

  5. Reinstall plastic cap and lower cover as show in steps 1 and 2.

Replacing Leveling Mechanism (M6 and M8 versions)​

There are currently two versions of the leveling mechanism in the field. To confirm which version is being worked on, identify the terminating linkage bracket below:

M6 version is identified by the sheet metal bracket as shown below:

|---|---|---| |102848| |102849| |102847| |102516| |102518| |102850| |M6 Linkage Assembly| |Part Description|Part #|Quantity| |ARM, PIVOT, CART, OFFSET, 0.5in DRIVE|102847|1| |PIN, CLEVIS, 06mm OD, 18mm USABLE LENGTH|102518|1| |END, ROD, BALL-JOINT, M6, LEFT - FEMALE THREAD|102850|1| |ROD, CONNECTING, M6, 76mm LONG, EXT THREAD|102848|1| |END, ROD, BALL-JOINT, M6, RIGHT - FEMALE THREAD|102849|1| |BRACKET, MOUNTING, EYELET|102516|1|

M8 version is identified by the machined steel bracket as shown below:

102998<br>Sy<br>——<br>-L102998<br>Sy<br>——<br>-L102998<br>Sy<br>——<br>-L
M8 Linkage Assembly
Part DescriptionPart #Quantity
ARM, PIVOT, CART, OFFSET, 0.5in DRIVE, 8mm1029961
PIN, CLEVIS, 8mm X 23mm, ZINC1030351
ROD END, M8, RIGHT HAND1029981
CONNECTING ROD, M8, TURNBUCKLE1029991
ROD END, M8, LEFT HAND1029971
SCREW, BUTTON HEAD, M8x25, STAINLESS, TORX1027221
LOCKNUT, FLANGED, M81018521
BRACE, LINKAGE1030001

To replace the entire linkage or any part of the linkage assembly, remove the 3 clevis pins and the 2-M6 screws shown in the image below:

After reinstalling components, ensure linkage is properly adjusted as shown in Section 6.2.2.1.