IOP-146 PGC-PDC

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Power Drive Gantry Crane (PGC-PDC) Parts & Service Manual

TP-603 - SAFETY AND DE-ENERGIZATION PROCEDURES

GENERAL SAFETY

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

• Keep these instructions for future reference.

• For the purpose of this document, Portable Gantry Crane (PGC) will refer to the gantry structure as well as the hoist, functioning as one unit.

• Refer to the hoist manufacturer’s operating and maintenance instructions for proper operation and service procedures before operating or performing any service or maintenance to the PGC.

• PGC units shall only be used to handle industrial lead-acid batteries using a manufacturer approved battery lifting attachment.

• PGC 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.

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

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

• PGC units that do not travel on a designated guidance track should be maneuvered by two operators - one at each end of the PGC.

• 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 PGC per your corporate policy, if PGC is damaged or not functioning properly. Lockout/tagout and de-energize all systems prior to performing any maintenance or service to PGC.

LEAD-ACID BATTERIES-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.

OPERATIONAL SAFETY

OPERATIONAL SAFETY

• Only personnel trained in the proper and safe operation of PGC units may operate or service the PGC.

• Operators shall wear appropriate PPE suitable for working with industrial lead-acid batteries while operating the PGC (see prior page).

• All data plates, warning labels, placards, etc. shall be in place and legible at all times. Contact BHS for replacement 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 PGC.

• PGC shall be operated in an area with ambient light levels of at least 50 lux.

• Keep at least a straight arms length distance from battery while transporting a battery.

• Avoid abrupt changes in direction when transporting a battery on the PGC to prevent loss of the battery and/ or loss of control of the PGC unit.

• Watch for personnel, batteries, charger cables or other obstructions in the PGC travel path.

• Remove the PGC from service if the PGC or hoist is damaged, defective, or operating improperly (or becomes such while operating) until repairs can be made to correct any problem(s).

DO’s AND DON’T’s

• DO NOT exceed the maximum capacity of lowest rated component of a PGC unit.

• DO NOT modify or fit the PGC with attachments without prior, written approval from BHS.

• DO NOT perform any maintenance or service to the PGC with a battery loaded on the PGC.

• DO NOT use the PGC to lift, support or transport people.

• DO NOT operate the PGC with any guard or cover removed unless required for maintenance or repair.

• DO NOT operate the PGC with the electrical enclosure door open. Keep door latches secure.

• DO NOT change any program parameter on the Variable Frequency Drive (VFD).

• Use only BHS, Inc. programmed replacement Electronic Programming Modules (EPM’s).

• DO NOT run the PGC into the end stops.

• DO NOT try to push or maneuver a battery while in motion.

• DO NOT use your body weight to guide battery in or out of position.

• DO NOT operate the PGC if disengaged from the guidance track.

• DO NOT propel the PGC, battery and/or lifting device into equipment or personnel.

• Ensure the lift truck mast clears the lowest point of the PGC prior to driving the truck into the designated battery changing area.

• DO NOT use the PGC in a manner for which it is not intended. Some examples of prohibited use are but not limited to:

• As a vehicle jack
• To lift loads greater than its rated load capacity
• Where unintentional movement may exist
• Having direct contact with foodstuffs

• Always travel with the battery as low as possible.

• DO NOT use PGC with a twisted, kinked, damaged or worn load chain.

• DO NOT lift batteries over people.

• DO NOT step under a suspended battery.

• DO NOT operate PGC unless all persons are (and remain) clear of the suspended battery and moving gantry structure travel path.

• DO NOT operate PGC unless battery is centered under the hoist.

• DO NOT attempt to lengthen the load chain or repair a damaged load chain.

• Protect the PGC’s load chain from weld splatter* or other damaging contaminants.

• DO NOT use the load chain as a sling or wrap the load chain around a battery.

• DO NOT lift a battery unless the load chain is properly seated in the hoist’s chain wheel(s) or sprocket(s).

• DO NOT operate PGC beyond the limits of the load chain travel.

• DO NOT leave a battery suspended by the PGC unattended unless specific precautions have been taken.

• DO NOT allow the load chain or hook to be used as an electrical or welding ground*.

• DO NOT allow the load chain to be touched by a live welding electrode*.

• DO NOT operate PGC unless the approved battery lifting attachment is properly sized, properly seated in the load hook saddle and the load hook latch is closed.

• Lift battery carefully. Make sure battery is balanced, lifting device is properly engaged, and load holding action is secure before continuing.

• Ensure hoist limit switches function properly.

• Warn personnel of an approaching PGC or battery.

• Maintain a firm footing or be otherwise secure when operating the PGC.

• Check the hoist brake function by tensioning the hoist prior to each lift operation.

• Ensure there are no obstacles in the travel path that could present a trip hazard prior to operating the PGC.

• Ensure the hook latch is closed and not supporting any part of the battery lifting attachment.

• Ensure the battery is free to move and will clear all obstructions.

• Avoid swinging the battery, lifting device and/or load hook.

• Inspect the PGC regularly. Replace damaged or worn parts and keep appropriate records of service and maintenance.

• Use only manufacturer’s recommended parts when repairing the PGC.

• DO NOT use the hoist load limiting or warning device to measure a battery weight.

• DO NOT use the limit switches as routine operating stops unless expressly authorized by the manufacturer. Limit switches are emergency devices only.

• DO NOT allow your attention to be diverted from operating the PGC.

*NEVER weld inside a battery room. See LEAD-ACID BATTERIES-EXPLOSION HAZARD.

LIFTING DEVICE SAFETY

DO’s AND DON’T’s

• Always maneuver the battery at a straight arm’s length with your hand at the end of the beam.

• DO NOT place hands or fingers on or near hooks when handling a battery.

• Inspect the lifting device for damage or wear prior to each use and keep appropriate records of service and maintenance.

• Ensure the battery lifting device is properly seated in the load hook saddle and the load hook latch is closed.

• Ensure the battery lifting device hooks are properly engaged prior to lifting a battery.

• Ensure the battery lifting device is (and remains) level at all times when handling a battery.

• DO NOT leave the battery lifting device attached to the load hook when not in use. (See OSHA regulation B30.20-203.)

CORRECT HAND PLACEMENT FOR MANEUVERING A MOTIONLESS BATTERY

NOTE: When maneuvering a battery, the operator is within the “PRIMARY DANGER ZONE” and should use extreme caution.

INCORRECT HAND PLACEMENT FOR MANEUVERING A BATTERY

DE-ENERGIZATION

1. To de-energize components external to the electrical enclosure, turn the disconnect switch on the enclosure to the “OFF” position. See Figure 1.
Failure to disconnect electrical power to the PGC could result in electrical shock.


FIGURE 1

2. To de-energize the entire PGC, including the electrical enclosure, disconnect power to the PGC or shut off the electrical branch circuit breaker.
Failure to disconnect electrical power to the PGC could result in electrical shock.
3. Wait 3 minutes before performing any service to the unit to allow the capacitors in the motor drive circuit to fully discharge.
Failure to wait 3 minutes to allow capacitors to fully discharge could result in electrical shock.

GENERAL INFORMATION

SPECIFICATIONS

PGC-PDC Specifications - Imperial / Metric

	PGC-10PDC	PGC-12PDC	PGC-14PDC	PGC-16PDC	PGC-18PDC	PGC-20PDC
Capacity	4,000 lbs / 1814 kg	4,000 lbs / 1814 kg	4,000 lbs / 1814 kg	4,000 lbs / 1814 kg	4,000 lbs / 1814 kg	4,000 lbs / 1814 kg
Clear Between “A” Frame	10’ / 3050 mm	12’ / 3660 mm	14’ / 4270 mm	16’ / 4880 mm	18’/ 5490 mm	20’ / 6100 mm
Overall Beam Length	12’ / 3660 mm	14’ / 4270 mm	16’ / 4880 mm	18’ / 5490 mm	20’ / 6100 mm	22’ / 6710 mm
Overall Length Dimension	12’ 9” / 3890 mm	14’ 9” / 4500 mm	16’ 9” / 5110 mm	18’ 9” / 5720 mm	20’ 9” / 6320 mm	22’ 9” / 6930 mm
Overall System Length 1	14’ / 4270 mm	16’ / 4880 mm	18’ / 5490 mm	20’ / 6100 mm	22’ / 6710 mm	24’ / 7320 mm
Nominal Track / Wheel Distance 2	11 ’5” / 3480 mm	13’ 5” / 4090 mm	15’ 5” / 4700 mm	17’ 5” / 5310 mm	19’ 5” / 5920 mm	21 ’5” / 6530 mm
Overall Height 3	11’ 1” / 3380 mm	11’ 1” / 3380 mm	11’ 3” / 3430 mm	11’ 3” / 3430 mm	11’ 5” / 3480 mm	11’ 5” / 3480 mm
I-Beam Size	8” x 23# / 203.2 mm x 10.43 kg	8” x 23# / 203.2 mm x 10.43 kg	10” x 25.4# / 254.0 mm x 11.52 kg	10” x 25.4# / 254.0 mm x 11.52 kg	12” x 31.8# / 304.8 mm x 14.42 kg	12” x 31.8# / 304.8 mm x 14.42 kg
Weight	1,260 lbs / 571.53 kg	1,285 lbs / 582.87 kg	1,320 lbs / 598.74 kg	1,345 lbs / 610.08 kg	1,425 lbs / 646.37 kg	1,490 lbs / 678.85 kg
Under Beam Clearance Height	10’ 5” / 3170 mm	10’ 5” / 3170 mm	10’ 5” / 3170 mm	10’ 5” / 3170 mm	10’ 5” / 3170 mm	10’ 5” / 3170 mm
Under Chain Container Clearance Height	8’ 5” / 2570 mm	8’ 5” / 2570 mm	8’ 5” / 2570 mm	8’ 5” / 2570 mm	8’ 5” / 2570 mm	8’ 5” / 2570 mm
Max A.C. Amp Draw with Hoist at 480V / 3Ph / 60Hz4	5.2 Amp	5.2 Amp	5.2 Amp	5.2 Amp	5.2 Amp	5.2 Amp
Travel Speed	45 FPM / .2286 MPS	45 FPM / .2286 MPS	45 FPM / .2286 MPS	45 FPM / .2286 MPS	45 FPM / .2286 MPS	45 FPM / .2286 MPS
A-Frame Base Width	68” / 1727.20 mm	68” / 1727.20 mm	68” / 1727.20 mm	68” / 1727.20 mm	68” / 1727.20 mm	68” / 1727.20 mm

3PGC-PDC Specifications - Imperial / Metric

	3PGC-10PDC	3PGC-12PDC	3PGC-14PDC	3PGC-16PDC	3PGC-18PDC	3PGC-20PDC
Capacity	6,000 lbs / 2721.55 kg	6,000 lbs / 2721.55 kg	6,000 lbs / 2721.55 kg	6,000 lbs / 2721.55 kg	6,000 lbs / 2721.55 kg	6,000 lbs / 2721.55 kg
Clear Between “A” Frame	10’ / 3050 mm	12’ / 3660 mm	14’ / 4270 mm	16’ / 4880 mm	18’ / 5490 mm	20’ / 6100 mm
Overall Beam Length	12’ / 3660 mm	14’ / 4270 mm	16’ / 4880 mm	18’ / 5490 mm	20’ / 6100 mm	22’ / 6710 mm
Overall Length Dimension	12’ 9” / 3890 mm	14’ 9” / 4500 mm	16’ 9” / 5110 mm	18’ 9” / 5720 mm	20’ 9” / 6320 mm	22’ 9” / 6930 mm
Overall System Length 1	14’ / 4270 mm	16’ / 4880 mm	18’ / 5490 mm	20’ / 6100 mm	22’ / 6710 mm	24’ / 7320 mm
Nominal Track / Wheel Distance 2	11’ 5” / 3480 mm	13’ 5” / 4090 mm	15’ 5” / 4700 mm	17’ 5” / 5310 mm	19’ 5” / 5920 mm	21’ 5” / 6530 mm
Overall Height 3	11’ 1” / 3380 mm	11’ 1” / 3380 mm	11’ 3” / 3430 mm	11’ 3” / 3430 mm	11’ 5” / 3480 mm	11’ 5” / 3480 mm
I-Beam Size	8” x 23# / 203.2 mm x 10.43 kg	10” x 25.4# / 254.0 mm x 11.52 kg	10” x 25.4# / 254.0 mm x 11.52 kg	12” x 31.8# / 304.8 mm x 14.42 kg	15” x 42.9# / 381.0 mm x 19.46 kg	15” x 42.9# / 381.0 mm x 19.46 kg
Weight	1,260 lbs / 571.53 kg	1,320 lbs / 598.74 kg	1,370 lbs / 621.42 kg	1,455 lbs / 659.98 kg	1,511 lbs / 685.38 kg	1,627 lbs / 737.99 kg
Under Beam Clearance Height	10’ 5” / 3170 mm	10’ 5” / 3170 mm	10’ 5” / 3170 mm	10’ 5” / 3170 mm	10’ 5” / 3170 mm	10’ 5” / 3170 mm
Under Chain Container Clearance Height	8’ 5” / 2570 mm	8’ 5” / 2570 mm	8’ 5” / 2570 mm	8’ 5” / 2570 mm	8’ 5” / 2570 mm	8’ 5” / 2570 mm
Max A.C. Amp Draw with Hoist at 480V / 3Ph / 60Hz4	6.8 Amp	6.8 Amp	6.8 Amp	6.8 Amp	6.8 Amp	6.8 Amp
Travel Speed	45 FPM / .2286 MPS	45 FPM / .2286 MPS	45 FPM / .2286 MPS	45 FPM / .2286 MPS	45 FPM / .2286 MPS	45 FPM / .2286 MPS
A-Frame Base Width	68” / 1727.20 mm	68” / 1727.20 mm	68” / 1727.20 mm	68” / 1727.20 mm	68” / 1727.20 mm	68” / 1727.20 mm

INSTALLATION

The Powered Gantry System you have purchased was tested and left the factory in top condition. Inspect unit for any freight damages before starting installation.

Your unit has been pre-assembled and pre-wired for your convenience. The following steps should be followed to ensure proper and safe operation. Area of installation should be cleared and uncluttered so a forklift and personnel can safely work in the area.

1) Lay "I" beam on floor in direction it is to be used. Remove "A" frame legs from shipping tees and locate which side of system control box will be mounted to and put that leg on the appropriate side. Gussets of "A" frames should point inward toward each other.

2) Install the 1/2" bolts through beam mounting pad and into legs. Lightly snug bolts - do not tighten at this point.

3) After bolts are in place, make sure legs are perpendicular to floor and parallel to each other. To accomplish this, measure the distance from center-to-center of wheels on top and bottom of "A" frames. Then cross square by measuring diagonally from wheel center to wheel center. Cross square dimensions should be within 1/4" of each other.

4) After unit is in a squared position, tighten up the beam mounting bolts and recheck squareness. Beam bolts should be torqued to approximately 75 - 90 lb/ft

5) While unit is still lying down, use beam clamps supplied to route cable for #2 drive motor assembly across top flange of beam. Cable ties or electrical tape should be used to attach cable up side of "A" frames so as not to have any hang points.

6) Unit can now be stood upright by positioning forklift under center of "I" beam and slowly raising. The assistance of one or two men on each leg is advisable to keep the unit stabilized and counteract any over swinging which could damage wheel assemblies.

7) Mark location of one side of track by using a chalk line to keep marks straight. Layout one section at a time and visually inspect to make certain each piece is straight. Minor bows can be adjusted by anchoring each end then forcing in bowed area and anchoring. (6 - 3/8" concrete anchors are supplied for each 10' section of track.

8) There are two ways the second track (if required) can be installed.

OPTION #1:

Measure center-to-center on wheels of gantry, then position second track 1/8" - 1/4" wider than this dimension to allow for beam and leg deflection while under load.

OPTION #2:

Wait until hoist and trolley are mounted and "A" frame wiring is connected, then pick up approximately 1/2 of maximum load being handled and then anchor the outboard track as system is powered down the track at 5' intervals.

NOTE: Refer to hoist manual for proper set-up and adjustment procedures.

OPERATION

Read and understand all instructions and warnings, including TP-605 - Safety and De-energization Procedures, prior to operating this equipment.

The following instructions will guide you through the basic steps necessary to operate and change batteries with a PGC-PDC equipped with a BHS model BLB-6000 lifting beam.

NOTE: Deviation from the following procedure may be required due to variation of particular battery room design and/or layout.

1. If not already in place, position industrial truck (pallet or lift truck) which requires a battery change in the appropriate staging area.
2. Disconnect the battery leads and remove any battery restraints. Refer to the lift truck manual for proper procedure.
3. Position the hoist to the side (horizontally on the beam) on which the battery is to be extracted from the lift truck.
4. Move the PGC into position over the lift truck, aligning the hoist lift chain with the slot in the overhead guard of the lift truck.
5. Position the lifting beam in the direction the battery will be removed (typically parallel with the battery) and adjust the height to allow the lifting beam to be positioned over the battery.
6. Lower the lifting beam and engage the lifting beam hooks into the battery lifting eyes.

Refer to the lifting attachment manual for proper hook engagement and operating procedures.
7. Ensure both hooks are fully engaged in the battery lifting eyes and carefully lift the battery a sufficient distance to clear any structure of the lift truck battery compartment. Observe the clearance of the hoist block and overhead guard.

DO NOT allow the hook block to come in contact with the overhead guard. Damage to the hook block and or overhead guard may occur.
8. Move the battery out of the battery compartment until completely clear of the lift truck.

DO NOT place hands or fingers on or near hooks when handling a battery. A sudden unexpected shift of the battery or lifting beam could crush or sever hands and fingers. Refer to Safety and De-energization Procedures TP-605 for proper handling of a BHS lifting beam and battery.
9. Move the PGC to an open position on the battery stands and align the battery with the open slot ensuring sufficient clearance on both sides of the battery.
10. Adjust the height of the battery sufficient to clear the 11. battery stand deck.
11. Move the battery completely into the open position while observing the clearance of the lifting beam and hook block with battery stand charger shelf.

DO NOT allow the hook block to come in contact with the overhead guard. Damage to the hook block and or overhead guard may occur.
12. Lower the battery onto the battery stand deck until the lifting beam hooks disengage from the battery lifting eyes.
NOTE: It may be necessary to manually disconnect the lifting hooks if the lifting beam is equipped with locking-style hooks.
13. Maneuver the lifting beam as required by lifting and turning the beam so the hooks are clear of any batteries and battery/charger cables. Ensure the lifting beam and/or hook block is clear of the charger shelf and any battery/charger cables.

DO NOT allow the lifting beam or hook block to come in contact with or become entangled with the charger shelf or battery/charger cables. Damage to the lifting beam, charger shelf, and battery/chargers may occur.
14. Move the lifting beam away from the battery.
15. Move the PGC into position with the charged battery to be installed into the lift truck and disconnect the battery from the charger.

ALWAYS be sure charging has been completed and charger is not still charging battery. Dangerous sparking/arcing can occur if battery is unplugged from charger while charging.
16. The above process can be used to remove a charged battery from the battery stand and install it into the lift truck.

DO NOT drive the PGC into the travel path end stops. The end stops are designed to prevent the PGC from accidentally traveling beyond its designated travel path. Driving the PGC into the end stops could cause damage to the end stop and/or the PGC.

Driving the PGC into the end stops with a battery suspended form the hoist will cause the battery to swing which could cause the battery to fall. Serious personal injury or death may occur.

MANUAL UNLOADING

Lockout/tagout and de-energize all equipment prior to manually unloading any battery.

In the event of power loss or an operational malfunction of the PGC and/or hoist not allowing a battery to be unloaded using normal operating procedures, it is recommended to unload the battery from the hoist using a lift truck.

1. If accessible, use a lift truck of sufficient capacity along with a pallet to carefully lift the battery such that the lifting device can be disconnected from the battery. If the battery is too low to allow a pallet to be placed under it, lift the battery directly by the lift truck forks.
1. Lower the battery for safe travel and slowly transport the battery out of the immediate area so repairs can be made

Should the status of the PGC/hoist not permit access to or not allow for safe, manual unloading, only repairs required to safely maneuver the PGC/hoist to a position allowing for safe unloading should be made. Once the battery is safely unloaded, any remaining repairs can be made.



Extreme care should be taken when working around a suspended load as well as equipment suspending a load. Unexpected movement of the equipment could cause the load and/or equipment to shift, possibly causing the load to fall. Serious personal injury or death may occur.

MAINTENANCE

Every effort has been made in design and manufacturing of this unit to make it as trouble free and low maintenance as possible. The gear boxes are lifetime lubricated and require no service. The following are a few steps to be taken on a regular basis dependent upon environment and application. A good starting point is every 60 days then adjust your schedule as conditions require.

1. Check all bolts on wheels, drive motor mounts and I-Beam for tightness. #Check drive wheels chains for proper tension and lubricate with light machine oil or spray chain lubricant.
2. Hoist lift chain should be wiped with a towel saturated with light machine oil.
3. The two drive wheels and two idler casters are equipped with grease fittings. A sufficient amount of grease should be pumped into grease fittings until grease just starts coming out of axle washers inside of forks.
4. Inspect lift chain for excessive wear, damaged or twisted links. #Inspect gear boxes for leakage.

GANTRY CRANE SERIES PLANNED MAINTENANCE INSPECTION REPORT



SPARE PARTS

The following items are recommended by the factory to have on hand for PGC-PDC models to minimize any downtime due to minor breakdown that may occur under normal operating conditions.

BHS PART NUMBER	DESCRIPTION	QTY	REFERENCE SECTION	NOTES
HW0306	BOLT-FHSCS-1/4-20 X 1"	8	2.0.1
14024010	SPROCKET-36T	1	2.0.1
14026007	WHEEL-POLY- MODIFIED	1	2.0.1	VERIFY TYPE PRIOR TO ORDERING
14026006	WHEEL-V-GROOVE-MODIFED	1
E1219	FUSE	1	3.0.1	0.8A (ALL UNITS)
E0340	FUSE	3		10A (208/240/480V UNITS)
E0339	FUSE	3		12A (ALL UNITS)
X350004	FUSE	3		12A (575V UNITS)

Use only BHS approved replacement parts.

BHS recommends that a full maintenance inspection report similar to the one provided be done at least once a month.

Any parts found to be excessively worn or damaged should promptly be replaced unless said parts pose a safety risk to the operator and/or extractor, in which case the unit should be removed from service until the problem(s) are remedied (See Operator’s Daily Checklist.)

GANTRY CRANE SERIES PLANNED MAINTENANCE INSPECTION REPORT



TROUBLE SHOOTING



PARTS SECTIONS

CHASSIS

I-BEAM & LEGS



ITEM	BHS PART NUMBER	DESCRIPTION	NOTES	NO. REQ
1	PGC-BEAM-10	I-BEAM-12’ X 8”-23#-6 HOLE	2-TON	1
	PGC-BEAM-12	I-BEAM-14’ X 8”-23#-6 HOLE	2-TON	1
	PGC-BEAM-14	I-BEAM-16’ X 10”-25.4#-6 HOLE	2-TON	1
	PGC-BEAM-16	I-BEAM-18’ X 10”-25.4#-6 HOLE	2-TON	1
	PGC-BEAM-18	I-BEAM-20’ X 12”-31.8#-6 HOLE	2-TON	1
	PGC-BEAM-20	I-BEAM-22’ X 12"-31.8#-8 HOLE	2-TON	1
2	HW0504	BOLT-HHCS-1/2-13 X 2		12
3	HW0111	WASHER-FLAT-1/2-SAE		24
4	HW0110	WASHER-LOCK-1/2		12
5	HW0007	NUT-HEX-1/2-13		12
6	14015001	2-TON LEG FRAME	PANEL SIDE	1
7	14015002	2-TON LEG FRAME	NON-PANEL SIDE	1
8	3PGC-BEAM-12	I-BEAM-14’ X 10”-25.4#-8 HOLE	3-TON	1
	3PGC-BEAM-14	I-BEAM-16’ X 10”-25.4#-8 HOLE	3-TON	1
	3PGC-BEAM-16	I-BEAM-18’ X 12”-31.8#-8 HOLE	3-TON	1
	3PGC-BEAM-18	I-BEAM-20' X 15”-42.9#-8 HOLE	3-TON	1
9	HW0504	BOLT-HHCS-1/2-13 X 2		16
10	HW0111	WASHER-FLAT-1/2-SAE		32
11	HW0110	WASHER-LOCK-1/2		16
12	HW0007	NUT-HEX-1/2-13		16
13	15015001	3-TON LEG FRAME	PANEL SIDE	1
14	15015002	3-TON LEG FRAME	NON-PANEL SIDE	1

DRIVE & IDLER WHEELS

DRIVE WHEELS



ITEM	BHS PART NUMBER	DESCRIPTION	NOTES	NO. REQ
1	HW0511	BOLT-HHCS-1/2-13 X 3 3/4		8
2	HW0111	WASHER-FLAT-1/2-SAE		16
3	14025001	PGC DRIVE WHEEL MOUNT	PANEL SIDE	1
	14025003	PGC DRIVE WHEEL MOUNT	NON-PANEL SIDE	1
4	HW0306	BOLT-FHSCS-1/4-20 X 1		16
5	14024010	SPROCKET-GANTRY POWER DRIVE	36 TOOTH (SEE NOTES)	2
6	14027008	SPACER-SPROCKET/WHEEL		2
7	14026006	WHEEL-MODIFIED-V-GROOVE		2
	14026007	WHEEL-MODIFIED-POLY		2
8	14022014	V-GROOVE WHEEL ASSEMBLY	W/ 36 TOOTH SPROCKET (SEE NOTES)	1
	14022013	POLY WHEEL ASSEMBLY	W/ 36 TOOTH SPROCKET (SEE NOTES)	1
9	HW0701	BOLT-HHCS-3/4-10 X 5 1/2		2
10	HW0119	WASHER-FLAT-1-SAE		2
11	HW0017	NUT-HEX-3/4-10		2
12	C0090-1	SPANNER-BEARING-DRIVE WHEEL		2
13	HW0402	BOLT-HHCS-3/8-16 X 1 1/4		12
14	HW0108	WASHER-FLAT-3/8-SAE		4
15	HW0110	WASHER-LOCK-1/2		8
16	HW0007	NUT-HEX-1/2-13		8
17	HW0107	WASHER-LOCK-3/8		8
18	HW0108	WASHER-FLAT-3/8-SAE		8
19	HW0328	BOLT-HHCS-5/16-18 X 3/4		8
20	HW0106	WASHER-FLAT-5/16-SAE		16
21	HW0004	NUT-HEX-5/16-18		8
22	PT0003-1	SPROCKET-41 PITCH-13T-3/4		2
23	PT0005	LINK-CONNECTING-#41		2
24	14027009-2	MOUNT-GEARBOX		4
25	PT0100	GEAR BOX-30:1		2
26	00158001-21	CHAIN-DRIVE-#41	FOR USE W/ 40 TOOTH SPROCKET (SEE NOTES)	2
	00158001-26	CHAIN-DRIVE-#41	FOR USE W/ 36 TOOTH SPROCKET (SEE NOTES)	2
27	E0121-1	MOTOR-1/2 HP	56C-1750RPM INV RATED TS	2
28	HW0103	WASHER-LOCK-1/4		8
29	HW0329	BOLT-HHCS-6MM X 12MM		8
30	-	SHAFT	INCLUDED WITH PT0100	2
31	-	WASHER	INCLUDED WITH PT0100	2
32	-	RETAINING RING	INCLUDED WITH PT0100	2
33	14017015-2	GUARD-CHAIN		2
34	14022003	DRIVE WHEEL ASSEMBLY - V GROOVE	NON-PANEL SIDE	1
	14022005	DRIVE WHEEL ASSEMBLY - V GROOVE	PANEL SIDE	1
	14022004	DRIVE WHEEL ASSEMBLY - POLY OPTION	NON-PANEL SIDE	1
	14022006	DRIVE WHEEL ASSEMBLY - POLY OPTION	PANEL SIDE	1
35	HW0105	WASHER-LOCK-5/16		8
36	00197017	KEY-3/16 X 1	FOR ITEM 22 (NOT SHOWN)	1


NOTE: 40 TOOTH SPROCKETS NO LONGER AVAILABLE. MUST CONVERT SPROCKETS AND CHAIN TO 36 TOOTH.

IDLER WHEELS



ITEM	BHS PART NUMBER	DESCRIPTION	NOTES	NO. REQ
1	HW0511	BOLT-HHCS-1/2-13 X 3 3/4		8
2	HW0111	WASHER-FLAT-1/2-SAE		16
3	C0040	CASTER-10 X 3	FOR USE W/ V-GROOVE OPTION	2
	C0095	CASTER-10 X 3-POLY	FOR USE W/ POLY WHEEL OPTION	2
4	HW0110	WASHER-LOCK-1/2		16
5	HW0007	NUT-HEX-1/2-13		16
6	14025002	MOUNT-CASTER		2

ELECTRICAL

CONTROL PANEL



ITEM	BHS PART NUMBER	DESCRIPTION	NOTES	NO. REQ
1	E1020	BLOCK-TERMINAL-LARGE-EA1		20
2	E1040	BARRIER-TERMINAL-END-LARGE		4
3	E0908	TRACK-MOUNTING		1
4	E0340	FUSE-ATMR10	10A	3
	X350004	FUSE	12A-FAST ACTING	3
5	E1012	RELAY	11 PIN	1
6	E1013	SOCKET-RELAY-11 PIN		1
7	E0339	FUSE-FLQ-12	12A, 600V	3
8	E0122-1	BASE-DISCONNECT	† SEE NOTES	1
9	E0341	CLIP-GROUNDING		1
10	RM0004N30	LINE REACTOR	FOR USE WITH 208/240V	1
	RM0002M12	LINE REACTOR	FOR USE WITH 480V	1
	X350003	LINE REACTOR - 575 VOLT	FOR USE WITH 575V	1
11	E1212	TRANSFORMER	240/480V TO 120V	1
	E0208	TRANSFORMER	208V TO 120V	1
	X350000	TRANSFORMER	575V TO 120V	1
12	E1023	WIREWAY		AR
13	E0015	VARIABLE FREQUENCY DRIVE (VFD)	FOR USE WITH 208/240V	1
	E0014	VARIABLE FREQUENCY DRIVE (VFD)	FOR USE WITH 480V	1
	X350002	VARIABLE FREQUENCY DRIVE (VFD)	FOR USE WITH 575V	1
14	E1219	FUSE	0.8A, 240/480V	1
15	E0123-1	HANDLE-DISCONNECT	† SEE NOTES (NOT SHOWN)	1
16	E0124-2	SHAFT-DISCONNECT	†† SEE NOTES (NOT SHOWN)	1
17	E0128	ADAPTER-SHAFT	† SEE NOTES (NOT SHOWN)	1

† FOR UNITS BUILT PRIOR TO 01/12/10, A SHAFT ADAPTER (ITEM# 17) IS REQUIRED WHEN REPLACING EITHER ITEM #8 OR ITEM #15.

† † FOR UNITS BUILT PRIOR TO 01/12/10, ITEM #’S 8 AND 15 MUST BE REPLACED IF REPLACING ITEM #16.

IF THERE IS ANY QUESTION AS TO THE THE ITEMS NEEDED WHEN ORDERING A NEW DISCONNECT BASE, SHAFT OR HANDLE, PLEASE CONTACT BHS TECH SUPPORT WITH THE MANUFACTURER’S PART NUMBER OF THE DISCONNECT BASE AND HANDLE.



ITEM	BHS PART NUMBER	DESCRIPTION	NOTES	NO. REQ
1	HW0402	BOLT-HHCS 3/8-16 X 1		4
2	HW0108	WASHER-FLAT 3/8 SAE		8
3	HW0107	WASHER-LOCK 3/8		4
4	HW0005	NUT-HEX 3/8-16		4
5	*	CONTROL PANEL	(SEE NOTE)	1
6	*	CONNECTOR	(SEE NOTE)	2
7	*	CONNECTOR	(SEE NOTE)	2

NOTE: MODEL NUMBER, SERIAL NUMBER AND VOLTAGE REQUIREMENTS MUST BE SUPPLIED TO FACTORY FOR PROPER PART IDENTIFICATION.

CABLE FESTOON



ITEM	BHS PART NUMBER	DESCRIPTION	NOTES	NO. REQ
1	SWS0010	TROLLEY-CABLE-TOW		1
2	SWS0015	TROLLEY-CABLE		4
3		CLAMP-CABLE	INCLUDED WITH SWS0001	2
4		EYELET	INCLUDED WITH SWS0001	2
5		EYE-BOLT	INCLUDED WITH SWS0001	2
6		NUT	INCLUDED WITH SWS0001	4
7	SWS0001	HARDWARE KIT		1
8		BOLT	INCLUDED WITH SWS0021	2
9		FLAT WASHER	INCLUDED WITH SWS0021	4
10		CLAMP	INCLUDED WITH SWS0021	1
11		WING NUT	INCLUDED WITH SWS0021	2
12	SWS0021	CLIP-CABLE		6
13	CF0055	CABLE	NYLON COATED	AR
14	SWS0005	CLAMP-END-FIXED		1
15	14617122	BRACKET-CABLE		2
16	HW0401	BOLT-HHCS-3/8-16 X 3/4		2
17	HW0107	WASHER-LOCK3/8		4
18	HW0108	WASHER-FLAT-3/8-SAE		4

CONTROL PENDANT



ITEM	BHS PART NUMBER	DESCRIPTION	NOTES	NO. REQ
1	E0814	PENDANT-6 BUTTON (YELLOW)	WITH 6' CORD	1
2	E0518	16-10 SO CORD		A/R
3	PB358	PUSH BUTTON		6
4	536K50	CONTACT BLOCK		6




ITEM	BHS PART NUMBER	DESCRIPTION	NOTES	NO. REQ
1	N/A	PENDANT-6 BUTTON (ORANGE)	DISCONTINUED - MUST ORDER E0814	-
2	E0518	16-10 SO CORD		A/R
3	550-041	BUTTON COVER W/ LEGEND PLATE KIT	INCL. ALL 6 POSITIONS	1
4	550-039	SWITCH-2 BUTTON-1 SPEED		3

ELECTRICAL SCHEMATICS

















ELECTRICAL WIRING DIAGRAMS

















STATEMENT OF WARRANTY

Statement of Warranty

Click here for details on BHS' Statement of Warranty.