IOP-407 BE-TSN

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Triple Stack Competitor Replacement Battery Extractors (BE-TSN) Parts & Service Manual

TP-606 - 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.

Battery Extractor (BE) units shall only be operated by suitable persons of at least 18 years of age, who have been trained in the proper and safe operation of the BE and expressly certiﬁed/charged, in writing, by the user or their representative.

Only one person is permitted to travel on the BE at any time.

BE 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 comprised of concrete or other suitable industrial material meeting the minimum requirements speciﬁed by BHS as well as any local requirements.

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

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

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

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.

HYDRAULIC HAZARDS

AVOID HIGH PRESSURE FLUIDS-Escaping ﬂuid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject ﬂuids under high pressure. Use a piece of cardboard or paper to search for leaks. DO NOT use your hand.

Any ﬂuid injected into the skin under high pressure should be considered a serious medical emergency despite an initial normal appearance of the skin. There will be a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately.

OPERATIONAL SAFETY

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

Operators shall wear appropriate PPE suitable for working with industrial lead-acid batteries while operating the BE (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 BE.

Keep hands and arms out of the battery compartment while operating the BE.

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

All operators shall be aware of the location of the end stops in the travel path to prevent driving the BE into the end stops.

DO’s AND DON’T’s

DO NOT exceed the maximum capacity of the BE.

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

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

DO NOT allow anyone to ride in or on the BE.

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

Disconnect the BE from all power sources before attempting to perform service or maintenance to the unit.

DO NOT drive the BE into the end stops.

DO NOT operate the BE if disengaged from the guidance track.

DO NOT allow a battery to exit the BE when a lift truck or battery stand is not present to accept the battery.

DO NOT rotate the arm onto a battery such that any part of the extractor arm, vacuum cup or magnet contacts the top of the battery.

DO NOT allow anyone to enter the area under the carriage without the service stands properly installed.

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

To transport people
As a vehicle jack
To lift loads greater than its rated load capacity
Where unintentional movement may exist
Having direct contact with foodstuff
In a potentially explosive atmosphere

DE-ENERGIZATION

Fully lower the BE roller bed or position the roller bed on service stands if service requires the bed be raised. See Figures 1 & 2

Failure to properly support the roller bed when performing service under the BE could result in injury from the roller bed lowering unexpectedly.

FIGURE 1

FIGURE 2

Turn key on dashboard to the “OFF” position. See Figure 3.

FIGURE 3

Disconnect power to the extractor or shut off the electrical branch circuit breaker.

Failure to disconnect electrical power to the BE could result in electrical shock. Serious personal injury or death will occur.

Actuate all hydraulic levers in both directions to release any stored hydraulic pressure. See Figure 4.

Failure to release any stored hydraulic pressure could result in injury from:

Escaping hydraulic ﬂuid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section).

Unexpected movement of hydraulic components.

FIGURE 4

LABELS & PLACARDS

GENERAL INFORMATION

SPECIFICATION DATA

Product Specifications - Imperial / Metric	BE-24-2-SLN	BE-36-2-SLN	BE-24-2-DSN	BE-36-2-DSN	BE-24-2-TSN	BE-36-2-TSN
Travel Speed	0-190 FPM / 0-1 mps		0-190 FPM / 0-1 mps		0-190 FPM / 0-1 mps
Raise - Lower Speed	0-10 FPM / 0 -.05 mps		0-16 FPM / 0-.08 mps		0-26 FPM / 0-.13 mps
Powered Roller Speed	0-37 FPM / 0-.18 mps		0-37 FPM / 0-.18 mps		0-37 FPM / 0-.18 mps
Arm Traverse Speed	0-20 FPM / 0-.10 mps		0-20 FPM / 0-.10 mps		0-20 FPM / 0-.10 mps
Arm Rotation Time	6 - 8 Seconds		6 - 8 Seconds		6 - 8 Seconds
Draw Bar Pull Vacuum (12” Round Cup)	1,000 lbs / 450 kg		1,000 lbs / 450 kg		1,000 lbs / 450 kg
Vacuum Attach Time / Release Time	< 1 sec / < 1 sec		< 1 sec / < 1 sec		< 1 sec / < 1 sec
Input Voltage	240/480 VAC/60Hz		240/480 VAC/60Hz		240/480 VAC/60Hz
AC Current Draw	13.6 / 6.8 Amps		13.6 / 6.8 Amps		27.2 / 13.6 Amps
Control Circuit Voltage	120 VAC		120 VAC		120 VAC
Hydraulic Power Unit	5 HP / 3.73 KW		5 HP / 3.73 KW		10 HP / 7.46 KW
Hydraulic Pump	8 GPM / 30 LPM		8 GPM / 30 LPM		16 GPM / 60 LPM
Power Unit	Hydraulic, Variable Displacement		Hydraulic, Variable Displacement		Hydraulic, Variable Displacement
Operating Pressure	1,500 PSI / 103 Bar		1,500 PSI / 103 Bar		1,500 PSI / 103 Bar
Vacuum Pump	1/3 HP / .25 KW		1/3 HP / .25 KW		1/3 HP / .25 KW
Vacuum	21” Hg / 0.73 kg/cm2		21” Hg / 0.73 kg/cm2		21” Hg / 0.73 kg/cm2
Full Load Capacity	10,000 lbs / 4535 kg		10,000 lbs / 4535 kg		10,000 lbs / 4535 kg
Weight (Empty)	5,300 lbs / 2404 kg	5,700 lbs / 2585 kg	5,500 lbs / 2495 kg	6,100 lbs / 2767 kg	7,500 lbs / 3402 kg	7,800 lbs / 3538 kg
Total Compartment Rollers / Powered	11/5		11/5		11/5
Guide Track	2” x 2.5” Angle / 51 mm x 64 mm		2” x 2.5” Angle / 51 mm x 64 mm		3” x 2.5” Angle / 76 mm x 64 mm
Overall Dimensions (L x W x H)	130” x 67” x 65” / 3302 mm x 1702 mm x 1651 mm	154” x 67” x 65” / 3912 mm x 1702 mm x 1651 mm	128” x 67” x 90” / 3252 mm x 1829 mm x 2286 mm	152” x 67” x 90” / 3861 mm x 1702 mm x 2286 mm	156 .5” x 67” x 158.06” / 3975 mm x 1702 mm x 4015 mm	180.5” x 67” x 158.06” / 4585 mm x 1702 mm x 4015 mm
Vacuum Arm Reach (Stand Side)	9” / 229 mm		9” / 229 mm		9” / 229 mm
Vacuum Arm Reach (Hydraulic Extension)	5” - 17” / 127 mm - 432 mm		5” - 17” / 127 mm - 432 mm		5” - 17” / 127 mm - 432 mm
Wheel Base	95.75” / 2432 mm	119.75” / 3042 mm	95.75” / 2432 mm	119.75” / 3042 mm	98” / 2489 mm	122” / 3099 mm
Drive Wheel Centerline	48” / 1219 mm		48” / 1219 mm		48” / 1219 mm
Battery Compartment Width	24” / 610 mm	36” / 915 mm	24” / 610 mm	36” / 915 mm	24” / 610 mm	36” / 915 mm
Maximum Battery Dimensions (L x W x H)	48” x 23” x 36” / 1220 mm x 580 mm x 910 mm	48” x 35” x 36” / 1220 mm x 890 mm x 910 mm	48” x 23” x 36” / 1220 mm x 580 mm x 910 mm	48” x 35” x 36” / 1220 mm x 890 mm x 910 mm	48” x 23” x 36” 1220 mm x 580 mm x 910 mm	48” x 35” x 36” / 1220 mm x 890 mm x 910 mm
Minimum Battery Width	12” / 305 mm		12” / 305 mm		12” / 305 mm
Minimum Battery Height	17.75” / 450 mm		17.75” / 450 mm		17.75” / 450 mm
Ground Clearance	.625” / 15 mm		.625” / 15 mm		.625” / 15 mm
Roller Height	6.5” Min - 26.5” Max 165 mm Min - 670 mm Max		6.5” Min - 56” Max 165 mm Min - 1420 mm Max		6.5” Min - 96” Max 165 mm Min - 2435 mm Max

Note: Speciﬁcations may vary +/- 5% due to temperature, ﬂoor considerations and operator efﬁciency. Values represented under normal operating conditions.

PRE-INSTALLATION CHECK

FLOOR CONDITIONS

The ﬂoor is the single most critical area of the battery room. A bad ﬂoor can cause signiﬁcant issues with the installation as well as downtime and maintenance problems with the extractor. The ﬂoor should be veriﬁed as to its minimum thickness and strength with user. As noted on the drawing, the speciﬁc requirement of ﬂatness for your particular type of system is listed. Below is a chart stating ﬂoor requirements. If possible, especially on double stack and higher systems, a digital level should be used to shoot the grade for compliance with the speciﬁcation. The ﬂoor should also be inspected for severe cracks or excessively wide expansion joints in the travel path of the machine. If ﬂoor drains are present, they must not have a grade to the opening that encroaches into the travel path.

F-min is a rating method used to evaluate the ﬂatness and levelness of a ﬂoor designated as “deﬁned travel path”. For example, an F-min rating of 60 means that there is no more than .129” of variation in the transverse axis (wheels left to right) and .287” variation in the longitudinal axis (front to back) on the equipment.

To avoid potential damage to drive wheel assemblies, guide track, structural components, guide rollers and issues with the inner frame equalization the “deﬁned travel path” of the Battery Extractor should meet or exceed the recommended F-min speciﬁcation. See chart below for the model speciﬁcations

Model	F-Min	+/- Longitudinal	+/- Transverse	Slope Defect
SL, DS	40	.287”	.192”	.096”
TS	60	.186”	.129”	.066”
QS	85	.131”	.091”	.047”

OPERATING CONTROLS

OPERATOR CONSOLE

OPERATION OVERVIEW

All operators should be familiar with the operator console of the extractor before performing any battery changes. The controls of the console are simple and well marked. It consists of six, manually operated, hydraulic control valves and a three position selector switch which controls the left and right vacuum cups.
All manual valves are moved in the direction of the function travel which it controls with exception of the lift/ lower valve, which is pulled toward the operator for “up” and pushed away for “down.”
The extractor arm must be in the center of the carriage or the unit will not travel forward or reverse.
To ensure smooth operation, all valve movements should be made in a slow, deliberate motion.

OPERATING INSTRUCTIONS

PRE-CHANGE OUT PREPARATION

Position the lift truck for change out in the designated change out area.
Remove all battery restraints and disconnect the battery cables following the manufacturer's guidelines. (Be sure to position the battery cables so as not to be damaged by the battery during change out.)
Board the battery extractor and close the safety gate. (The gate must be fully closed or the unit will not operate.)
Depress the foot pedal.
Turn the key switch to the “ON” position.

DISCHARGED BATTERY REMOVAL

Move the extractor left or right to position the center of compartment with the center of the lift truck battery compartment. (Lead roller of extractor is equipped with a centering groove. Users may ﬁnd it beneﬁcial to mark center of lift truck compartment to aid in alignment.)
Align the extractor’s roller compartment height with the lift truck’s battery compartment.
Rotate extractor arm into battery compartment aligned in Step 2.
Move the extractor arm toward the battery until the vacuum cup/magnet contacts the battery.

DO NOT force cup to battery after initial contact with battery is made.

Energize vacuum by turning selector switch to proper direction, left or right.
Move extractor arm away from lift truck toward center of extractor roller bed, removing discharged battery. (Battery should be pulled past ﬁrst three idler rollers onto ﬁrst or second powered roller.)
Turn off vacuum and move extractor arm away from battery 1” to 2”.
Rotate extractor arm out of battery compartment into opposite compartment (if empty) and center arm in carriage.
Move battery into center of compartment using powered rollers.

CHARGED BATTERY RETRIEVAL

Locate a charged battery for the appropriate type of lift truck being changed.
Raise battery extractor roller compartment to proper level to gain access as needed to disconnect desired battery from its charger and disengage battery safety stop.

ALWAYS be sure charging has been completed and the charger is not still charging the battery. Dangerous sparking/arcing can occur if the battery is unplugged from the charger while charging.

Move extractor to appropriate rack position and align empty roller compartment with the center of the battery storage rack compartment. (The battery safety stop of each compartment is the center of that compartment and should be used for alignment with the groove in the lead roller of the battery extractor compartment.)
Rotate arm into empty compartment (if not already positioned there.)
Move extractor arm toward battery until vacuum cup contacts battery.
Energize vacuum cup by turning selector switch to proper direction, left or right.

DO NOT force cup to battery after initial contact with battery is made.

Move extractor arm away from battery rack toward center of extractor roller bed, removing charged battery. (Battery should be pulled past ﬁrst three idler rollers onto ﬁrst or second powered roller.)
Turn off vacuum and move extractor arm away from battery 1” to 2”.
Rotate extractor arm out of battery compartment into fully vertical position.
Move battery into center of compartment using powered rollers.

DISCHARGED BATTERY RETURN

If required, adjust extractor compartment height to battery rack level with open battery compartment. Drive extractor to align roller compartment containing discharged battery with open battery compartment.
Return discharged battery to battery rack using powered rollers.

In most instances, batteries can be deposited into battery racks in one motion using only powered rollers. When this does not work, the battery may need slight assistance from extractor arm. To do this, rotate arm into compartment such as one would if removing battery from rack. If extractor is vacuum equipped, position top edge of cup slightly higher than edge of battery (or over lifting eye if so equipped) to prevent cup from adhering to battery - No vacuum is necessary for pushing. DO NOT activate vacuum switch. Slowly push battery into rack until fully into compartment.

Engage the battery safety stop and connect the battery to the charger as required.

CHARGED BATTERY INSTALLATION

Lower extractor to fully lowered position.
Drive the extractor back to the lift truck and align the roller compartment containing the charged battery as performed in steps 1 and 2 of ”Discharged Battery Removal”.
Move the charged battery toward the lift truck compartment by moving the extractor arm out, verifying precise battery alignment.

Many batteries are a tight ﬁt into the lift truck battery compartments. Care MUST be taken to ensure alignment is precise to avoid damage to the battery, lift truck, and/or battery extractor.

Adjust the extractor vertically as well as horizontally, if needed.
Insert battery into lift truck as far as possible using only the powered rollers.
Rotate extractor arm into compartment and SLOWLY push battery into lift truck. (Be sure to watch battery cables for interference.)
Return extractor arm to center of roller bed and lower extractor to fully lowered position. Drive extractor out of immediate area.
Turn off key switch, remove key from switch and carefully exit extractor.
Secure newly installed battery in lift truck and reconnect battery cables.
Return lift truck to service.

DO NOT drive the B.E. into the travel path end stops. The end stops are designed to prevent the B.E. from accidentally traveling beyond its designated travel path. Driving the B.E. into the end stops will cause the B.E. to stop suddenly, possibly causing damage to the end stop, the B.E. and/or personal injury.

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 BE not allowing a battery to be unloaded using normal operating procedures, it is recommended a battery be removed from the BE using certiﬁed and approved vertical extraction methods and devices.

Read, understand and observe all safety warnings and procedures related to the vertical extraction device(s) being used.

Should the status of the BE not allow for safe vertical extraction due to position in the battery aisle, only repairs required to safely maneuver the BE to a position allowing for safe vertical extraction should be made. Once any batteries are safely unloaded, any remaining repairs can be made.

Extreme care should be taken when working under or around equipment supporting elevated loads. Unexpected movement of the equipment could cause the load and/or equipment to fall. ALWAYS be sure devices of adequate size and strength are in place to prevent any personnel working under the elevated load from being crushed. Serious personal injury or death will occur.

RECOMMENDED SPARE PARTS

Refer to the Spare Parts Kit (Pt# BE-SPKV-TS) at the beginning of Section 7 for the list of items recommended by the factory to have on hand for BE-TSN models to minimize any downtime due to minor breakdown that may occur under normal operating conditions.

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.)

PARTS SECTIONS

CHASSIS

EQUALIZTION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0222	LINK-CONNECTING-#60			8
2	HW0017	NUT-HEX-3/4-10			8
3	HW0115	WASHER-LOCK-3/4			4
4	43097001	STUD-ANCHOR-5”		UPPER	4
5	HW0020	NUT-JAM-3/4-10			4
6	43097002	STUD-ANCHOR-2”		LOWER	4
7	00158001-40	CHAIN-ROLLER-#60			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0416	COLLAR-SHAFT-1 1/2”			4
2	43097006	KEY-3/8” X 2 3/4”			4
3	PT0224	SPROCKET-60B12 X 1 1/2”		KEYED INLINE	8
4	PT0405	FLANGE BEARING-2 BOLT-1 1/2”			4
5	HW0502	BOLT-HHCS-1/2-13 X 1 1/4”			8
6	HW0110	WASHER-LOCK-1/2”			8
7	43127001	SHAFT-EQUALIZATION		BE-24-2	2
7	43327001	SHAFT-EQUALIZATION		BE-36-2	2
8	PT0503	BEARING-FLANGED LOAD-2 1/4”			8
9	HW0025	NUT-JAM-7/8-14			8

BRIDGE & CROSS BAR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW0502	BOLT-HHCS-1/2-13 X 1 1/4”			12
2	HW0110	WASHER-LOCK-1/2”			20
3	HW0112	WASHER-FLAT-1/2”-SAE			20
4	HW0515	BOLT-HHCS-1/2-13 X 2”		FULLY THREADED	8
5	HW0007	NUT-HEX-1/2-13			8

LIFT CYLINDER CONNECTIONS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00158001-13	CHAIN-ROLLER-#80			4
2	HW0014	NUT-HEX-1-8			8
3	43897002	STUD-LIFT-INNER FRAME			4
4	PT0204	LINK-CONNECTING-#80			8
5	43897001	STUD-LIFT-OUTER FRAME			4
6	43815018	BRACKET-CYLINDER SUPPORT			4
7	SS0761	U-BOLT-CYLINDER MOUNTING			4
8	HW0108	WASHER-FLAT-3/8”-SAE			12
9	HW0107	WASHER-LOCK-3/8”			12
10	HW0005	NUT-HEX-3/8-16			8
11	HW0514	BOLT-HHCS-1/2-13 X 2 1/2”		IDLER CASTER END OF UNIT	2
11	HW0504	BOLT-HHCS-1/2-13 X 2”		DRIVE WHEEL END OF UNIT	2
12	HW0110	WASHER-LOCK-1/2”			4
13	HW0112	WASHER-FLAT-1/2”-SAE			4
14	HW0402	BOLT-HHCS-3/8-16 X 1”			4
15	43822002	CLEVIS ASSEMBLY		SOLD AS ASSEMBLY ONLY	4

GUIDANCE ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43017021	GUIDE ARM WELDMENT			2
2	43017025	SPACER-GUIDE ARM			4
3	PT0510	CAM ROLLER-1 3/4”			4
4	HW0115	WASHER-LOCK-3/4”			4
5	HW0011	NUT-HEX-3/4-16			4
6	HW0509	BOLT-HHCS-1/2-13 X 4 1/2”			4
7	HW0112	WASHER-FLAT-1/2”-SAE			4
8	HW0110	WASHER-LOCK-1/2”			4
9	HW0007	NUT-HEX-1/2-13			4

IDLER ROLLERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43182001	LEAD ROLLER ASSEMBLY-24”		W/ ALIGNMENT GROOVE	4
1	43382001	LEAD ROLLER ASSEMBLY-36”		W/ ALIGNMENT GROOVE	4
2	43182002	IDLER ROLLER ASSEMBLY-24”			8
2	43382002	IDLER ROLLER ASSEMBLY-36”			8
3	43187002	SHAFT-HEX-.75” X 25.75”			8
3	43387002	SHAFT-HEX-.75” X 37.75”			8
4	43187003	SHAFT-HEX-.75” X 27.5”			4
4	43387003	SHAFT-HEX-.75” X 39.5”			4
5	HW1058	PIN-HITCH			24

POWERED ROLLERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43182003	POWERED ROLLER-24”			10
1	43382003	POWERED ROLLER-36”			10
2	43087001	JOURNAL-POWERED ROLLER			10
3	PT0404	FLANGE BEARING-3-BOLT-1”			20
4	HW0321	BOLT-HHCS-5/16-18 X 1 1/4”			60
5	HW0105	WASHER-LOCK-5/16”			60
6	HW0004	NUT-HEX-5/16-18			60
7	PT0033	SPROCKET-35B18 X 1”			16
8	00197028	KEY-1/4” X 1 1/4”			8
9	00158001-38	CHAIN-ROLLER-#35		† 49 PITCH LENGTH	4
9	00158001-39	CHAIN-ROLLER-#35		51 PITCH LENGTH	4
10	PT0031	LINK-CONNECTING-#35			8
11	PT0418	COLLAR-SHAFT-1”			10
12	PT0032	LINK-OFFSET-#35		† NOT SHOWN	4

† OFFSET LINKS FOR USE WITH 49 PITCH LENGTH CHAINS ONLY.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0120	MOTOR-HYDRAULIC-160CC			2
2	HW1071	KEY-WOODRUFF-#808 STD		SUPPLIED WITH ITEM 1	A/R
3	H1544	ADAPTER-#6 JICM X #10 SAEM			4
4	HW0402	BOLT-HHCS-3/8-16 X 1”			18
5	HW0107	WASHER-LOCK-3/8”			18
6	50017005	PLATE-MOTOR MOUNTING			2
7	PT0302-1	COUPLING BODY-#40 X 1”			4
8	PT0301	CHAIN-COUPLING-#40		INCL. CONNECTING PIN	2
9	00197026	KEY-1/4” X 1”			4

HOSE CARRIER

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0629	CARRIER TRACK		81 LINKS REQ’D	10’
2	PT0630	BRACKET-UPPER MOUNTING		SOLD AS SET - INCL. ITEM #5	1
3	HW0212	SCREW-RHMS-#10-24 X 1/2”			2
4	SS0202	NUT-NILN-#10-24			2
5	PT0630	BRACKET-LOWER MOUNTING		SOLD AS SET - INCL. ITEM #2	1
6	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			6
7	HW0303	BOLT-HHCS-1/4-20 X 1”			2
8	HW0104	WASHER-FLAT-1/4”-SAE			2
9	HW0103	WASHER-LOCK-1/4”			2
10	HW0002	NUT-HEX-1/4-20			2
11	43817056-2	BRACKET-CARRIER TRACK MOUNTING			1
12	HW0401	BOLT-HHCS-3/8-16 X 3/4”			4
13	HW0107	WASHER-LOCK-3/8”			4
14	HW0108	WASHER-FLAT-3/8”-SAE			4
15	43817057	PLATE-CARRIER TRACK SUPPORT			1
16	HW0504	BOLT-HHCS-1/2-13 X 2”			2
17	HW0110	WASHER-LOCK-1/2”			2
18	HW0112	WASHER-FLAT-1/2”-SAE			2

CABLE RETRACTOR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	CCR-12HD	TAKE UP REEL-CARRIER TRACK			1
2	HW0403	BOLT-HHCS-3/8-16 X 1 1/4”			2
3	HW0108	WASHER-FLAT-3/8”-SAE			4
4	HW0107	WASHER-LOCK-3/8”			2
5	HW0005	NUT-HEX-3/8-16			2

OPERATOR GATE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43017064-2	LATCH-SWIING GATE			1
2	HW0030	BOLT-HHCS-3/8-16 X 2 1/4”			1
3	HW0031	NUT-LOCK-3/8-16			1
4	HW9000	HINGE-SPRING			1
5	HW0301	BOLT-SELF TAP ”F”-1/4-20 X 1/2”			3
6	HW1037	STOP-GATE	80092001		1
7	HW0303	BOLT-HHCS-1/4-20 X 1”	80092001		1
8	HW0104	WASHER-FLAT-1/4”-SAE	80092001	(NOT SHOWN)	1
9	HW0003	NUT-NILN-1/4-20	80092001	(NOT SHOWN)	1

GUARDS - OUTSIDE CARRIAGE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	53017009	GUARD-FAR END-TOP			1
2	53017010	GUARD-FAR END-MIDDLE			1
3	53017011	GUARD-FAR END-BOTTOM			1
4	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			33

GUARDS - INNER CARRIAGE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	53017015-2	DASH BOARD-OPERATOR CONSOLE			1
2	53017013-2	GUARD-FRONT-OPERATOR CONSOLE			1
3	53017012-2	GUARD-INNER-FRAME			2
4	50017010-2	GUARD-LINEAR DRIVE SCREW			1
5	50017011-2	GUARD-SIDE-ARM CARRIER SHAFT			2
6	53017014	KICK PLATE-OPERATOR CONSOLE			1
7	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			48
8	HW0306	BOLT-FHSCS-1/4-20 X 1”			4
9	HW0104	WASHER-FLAT-1/4”-SAE			4
10	HW0103	WASHER-LOCK-1/4”			4
11	HW0002	NUT-HEX-1/4-20			4
12	PL0602	VINYL EDGING		6’ EA. FOR ITEM #5 - NOT SHOWN	12’
13	PL0602	VINYL EDGING		AT FOOT SWITCH - NOT SHOWN	1’

GUARDS - LIFT CYLINDER

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43815016	GUARD-CLEVIS		OPERATOR RIGHT/FAR LEFT	2
1	43815017	GUARD-CLEVIS		OPERATOR LEFT/FAR RIGHT	2
2	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			8

EXTRACTOR ARM

VACUUM STUDS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	P0505	BUSHING-RED-#6 NPT X #4 NPTF-BRASS			2
2	P0402	HOSE BARB-1/4 X #4 NPTM-BRASS		FIXED SIDE ONLY	1
3	HW0428	STUD-VACUUM-3/8-16 X 5”	HW-KIT-2		8
4	HW0108	WASHER-FLAT-3/8”-SAE	HW-KIT-2		40
5	HW1001	SPRING-3/8”	HW-KIT-2		24
6	HW0006	NUT-NILN-3/8-16	HW-KIT-2		8

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	P0110	VACUUM CUP-12” ROUND		† SEE NOTE	2
	N/A	VACUUM CUP-10” ROUND	00162001	† AVAILABLE AS KIT ONLY	2
2	00117059	PLATE-VACUUM CUP ADAPTER	00162001		2
3	HW0328	BOLT-HHCS-5/16-18 X 3/4”	00162001		8
4	P0401	ELBOW-#4 NPTM X 1/4” BARB-BRASS	00162001		2
5	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS	00162001		2
6	P0505	BUSHING-RED-#6 NPT X #4 NPTF-BRASS	00162001		2
7	00166001	CASTING-12” VACUUM CUP	00162003		2
8	00164001	SEAL-RUBBER	00162003		2
9	00165001	PLATE-FRONT	00162003		2
10	HW0311	BOLT-FHSCS-1/4-20 X 5/8”	00162003		16

† ONE-PIECE CONSTRUCTION

SWING ARMS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41257014	TIE PLATE-SWING ARM			1
2	43055004	SWING ARM-RHS	†	NOT SOLD INDIVIDUALLY	1
3	43055002	SWING ARM-LHS	†	NOT SOLD INDIVIDUALLY	1
4	HW0603	BOLT-FHSCS-5/8-11 X 2”			4
5	HW0113	WASHER-LOCK-5/8”			4
6	HW0010	NUT-JAM-5/8-11			4
7	PT0413	COLLAR-SHAFT-3”	80252001		2
8	43027001	SHAFT-ROTARY ACTUATOR	80252001		1
9	HW1013	KEY-3/8” X 12”	80252001		1
10	PT0419	BEARING-SAE 841-2” ID, 3” OD, 1/8” THICK	80252001		3
11	43052005	CAP-BEARING		INCLUDES BEARING	2
12	HW0303	BOLT-HHCS-1/4-20 X 1”			6
13	HW0103	WASHER-LOCK-1/4”			6
14	43057014	STANDOFF-WIRE			1
15	HW0312	SCREW-SHSS-1/4-20 X 1”-CUP POINT			1
16	H1565	ADAPTER-45 DEG-#6 JICM X #4 NPTM			4
17	H1600	ADAPTER-90 DEG-#6 JICM X #8 SAEM			2

† INCLUDED IN MULTIPLE KITS

SWING ARM STOPS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43055007	MOUNT-STOP-SWING ARM			2
2	43057024	STOP-SWING ARM		BE-24	4
2	43057023	STOP-SWING ARM		BE-36	4
3	HW0304	BOLT-HHCS-1/4-20 X 1 1/2”			4
4	HW0104	WASHER-FLAT-1/4”-SAE			8
5	HW0103	WASHER-LOCK-1/4”			4
6	HW0002	NUT-HEX-1/4-20			4
7	HW0403	BOLT-HHCS-3/8-16 X 1 1/4”			4
8	HW0107	WASHER-LOCK-3/8”			4
9	HW0108	WASHER-FLAT-3/8”-SAE			4

VACUUM PUMP

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	P0005	PUMP-VACUUM			1
2	P0208	FILTER-HI FLOW			3
3	P0503	NIPPLE-#4 NPT-BRASS			3
4	P0502	TEE-#4 NPTF-BRASS			1
5	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS			4
6	P0402	HOSE BARB-1/4” X #4 NPTM-BRASS			5
7	P0207	VALVE-VACUUM RELEASE			2
8	P0302	HOSE-VACUUM-1/4” ID		TWO 6” PIECES	1’
9	P0302	HOSE-VACUUM-1/4” ID		FIXED SIDE	1’
10	P0301-1	HOSE-COIL-VACUUM			1
11	E0611	JUNCTION BOX-4” X 2” X 2”			1
12	E0612	COVER-JUNCTION BOX			1
13	HW0212	SCREW-RHMS-#10-24 X 1/2”			2
14	E0624	CONNECTOR-1/2”			1
15	E0608-1	RESTRAINT-1/2”-90 DEG		GRIP SIZE .450 - .560	1
15a	E0617	LOCKNUT-CONDUIT-1/2”		NOT SHOWN	2
16	E0501	CORD-14-4 SW/SOW			15’
17	43057014	STANDOFF-CABLE			1
18	HW0206	SCREW-RHMS-#10-32 X 3/4”			4
19	HW0306	BOLT-FHSCS-1/4-20 X 1”			1
20	43057021	PLATE-STIFFENER	†		2
21	HW0402	BOLT-HHCS-3/8-16 X 1”	†		12
22	HW0107	WASHER-LOCK-3/8”	†		12
23	HW0005	NUT-HEX-3/8-16	†		12
24	HW0108	WASHER-FLAT-3/8”-SAE	†	NOT SHOWN	24
25	P0111	FILTER-VACUUM-IN LINE			2

† INCLUDED IN MULTIPLE KITS

EXTRACTOR ARM MOUNTING

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW0504	BOLT-HHCS-1/2-13 X 2”		† SEE NOTE	6
2	HW0112	WASHER-FLAT-1/2”-SAE			6
3	HW0110	WASHER-LOCK-1/2”			6
4	HW0007	NUT-HEX-1/2-13			6
5	41655008	EXTENSION-EXTRACTOR ARM		BE-36	A/R

† QTY 12 REQUIRED WITH EXTRACTOR ARM EXTENSION.

HOSE MOUNTING

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41257035	STANDOFF			2
2	HW1072	RESTRAINT-HOSE			2
3	HW0104	WASHER-FLAT-1/4”-SAE			2
4	HW0103	WASHER-LOCK-1/4”			2
5	HW0318	BOLT-SHCS-1/4-20 X 1 1/2”			2
6	HW0302	BOLT-HHCS-1/4-20 X 3/4”			1
7	HW0312	SCREW-SHSS-1/4-20 X 1”-CUP POINT			1

ARM CYLINDER

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	50055002	ARM-EXTENSION			1
2	HC0416	CYLINDER-EXTENED REACH			1
3	H1578	ADAPTER-90 DEG-#6 JICM X #6 NPTM			2
4	41257031	PIN-CLEVIS END			1
5	00197036	PIN-ROD END			1
6	HW1058	PIN-HITCH			4

BEARING PLATES

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	50055001	HOUSING-EXTENDED REACH			1
2	50057008	PLATE-END			1
3	HW0303	BOLT-HHCS-1/4-20 X 1”			4
4	HW0104	WASHER-FLAT-1/4”-SAE			8
5	HW0103	WASHER-LOCK-1/4”			4
6	HW0002	NUT-HEX-1/4-20			24
7	50058003	PLATE-BEARING		SIDE	2
8	50058006	PLATE-SHIM		SIDE	2
9	50058004	PLATE-BEARING		UPPER/ LOWER	2
10	50058005	PLATE-SHIM		UPPER/ LOWER	2
11	HW0812	SCREW-SHSS-1/4-20 X 5/8”-HALF DOG			20

ROTARY ACTUATOR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43046001	ROTARY ACTUATOR			1
2	80000002	ROTARY ACTUATOR BASE ASSEMBLY		WITHOUT ACTUATOR	1
2A	N/A	VERTICAL CARRIER PLATE-OUTER		INCL. WITH 80000002	2
2B	N/A	VERTICAL CARRIER PLATE-INNER		INCL. WITH 80000002	1
2C	N/A	CARRIER BASE PLATE		INCL. WITH 80000002	1
3	HW1070	PIN-PULL DOWEL-5/8” X 1 1/2”			2
4	HW0508	BOLT-SHCS-1/2-13 X 3/4”			3
5	HW1045	PIN-PULL DOWEL-3/8” X 1 1/2”		INCL. WITH 80000002	6
6	HW0412	BOLT-SHCS-3/8-16 X 1 1/4”		INCL. WITH 80000002	12
7	H0010	FITTING-BULKHEAD-3/4-16 X #4 NPTF			4
8	H1579	ADAPTER-90 DEG-#6 JICM X #4 NPTM			4

CARRIER SHAFTS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	50057001	CARRIER SHAFT-EXTRACTOR ARM		3” DIA.	2
2	43054007	BEARING-EXTRACTOR ARM CARRIER	80252002		4
3	HW0412	BOLT-SHCS-3/8-16 X 1 1/4”	80252002		16
4	PT0413	COLLAR-SHAFT-3”			4
5	50057009	PLATE-END			4
6	50057010	SHIM-END PLATE			A/R
7	HW1076	BOLT-FHSCS-3/8-16 X 1”			12
	PT0624	FITTING-ZERK	80252002	NOT SHOWN	4

DRIVE NUT ASSEMBLY

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43054006	DRIVE NUT ASSEMBLY	80252003		1
2	HW0426	BOLT-SHCS-3/8-16 X 5 1/2”	80252003	† SEE NOTES	4
3	HW0108	WASHER-FLAT-3/8”-SAE	80252003	† SEE NOTES	4
4	HW0006	NUT-NILN-3/8-16	80252003	† SEE NOTES	4
5	PT0624	FITTING-ZERK	80252003		1
6	43017009-2	BRACKET-SCREW GUARD MOUNTING			2
7	HW0303	BOLT-HHCS-1/4-20 X 1”			4
8	HW0103	WASHER-LOCK-1/4”			4
9	HW0104	WASHER-FLAT-1/4”-SAE			4

† IT IS RECOMMENDED TO REPLACE MOUNTING HARDWARE WHEN REPLACING DRIVE NUT ASSEMBLY

DRIVE SCREW

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	50024001	SCREW-LINEAR DRIVE			1
2	PT0119	SPROCKET-50B15 X 1 3/16”			1
3	43097004	KEY-1/4” X 7/8”			1
4	00158001-15	CHAIN-ROLLER-#50			1
5	PT0102	LINK-CONNECTING-#50			1
6	PT0406	FLANGE BEARING-4 BOLT-1 3/16”		ALLOY CASTING	2
7	HW0503	BOLT-HHCS-1/2-13 X 1 1/2”			8
8	HW0110	WASHER-LOCK-1/2”			8
9	PT0107	SPROCKET-50B15 X 1”			1
10	HC0121	MOTOR-HYDRAULIC-100CC		SAE 2-BOLT MOUNT	1
11	H1605	ADAPTER-90 DEG-#6 JICM X #10 SAEM			2
12	HW1071	KEY-WOODRUFF-#808 STD		SUPPLIED WITH ITEM 10	A/R
13	HW0403	BOLT-HHCS-3/8-16 X 1 1/4”			6
14	HW0107	WASHER-LOCK-3/8”			6
15	43017007	PLATE-MOUNTING-SCREW DRIVE MOTOR			1
16	43057019	PLATE-COVER			2
17	HW0415	BOLT-SHCS-3/8-16 X 3/4”			8

HOSE CARRIER PLATE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41696001	BRACKET-MOVABLE END			1
2	HW0306	BOLT-FHSCS-1/4-20 X 1”			4
3	HW0104	WASHER-FLAT-1/4”-SAE			10
4	HW0103	WASHER-LOCK-1/4”			6
5	HW0002	NUT-HEX-1/4-20			6
6	PT0627	HOSE CARRIER		12 LINKS REQD.	34”
7	PT0628	BRACKET-FIXED END			1
8	HC0262	VALVE-CROSS PORT RELIEF			1
8a	HC0236	REPLACEMENT CARTRIDGE		† FOR ITEM 8 (NOT SHOWN)	2
9	HW0308	BOLT-HHCS-1/4-20 X 2 1/2”			2
10	H1546	ADAPTER-#6 JICM X #8 SAEM			2
11	H1617	ADAPTER-45 DEG-#6 JICM X #8 SAEM			2
12	HC0237	VALVE-SEQUENCING			1
13	HW0317	BOLT-HHCS-1/4-20 X 3 1/2”			2
14	H1560	ADAPTER-45 DEG-#8 JICM X #8 SAEM			4
15	H1600	ADAPTER-90 DEG-#6 JICM X #8 SAEM			2
16	50017006	PLATE-HOSE CARRIER			1
17	HW0403	BOLT-HHCS-3/8-16 X 1 1/4”			4
18	HW0108	WASHER-FLAT-3/8”-SAE			8
19	HW0107	WASHER-LOCK-3/8”			4
20	HW0005	NUT-HEX-3/8-16			4

† CARTRIDGES ARE FOR REPLACEMENT ONLY

DRIVE AND IDLER CASTERS

FLOOR DRIVE ASSEMBLY

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	43822004	FLOOR DRIVE ASSEMBLY			2
1	43825001	FRAME-FLOOR DRIVE			2
2	C0510	WHEEL-10” X 5”-POLY	80322001		2
3	PT0430	FLANGE BEARING-4 BOLT-1 1/2”	80322001		4
4	HW0504	BOLT-HHCS-1/2-13 X 2”			8
5	HW0112	WASHER-FLAT-1/2”-SAE			16
6	HW0110	WASHER-LOCK-1/2”			16
7	HW0007	NUT-HEX-1/2-13			16
8	HW0516	BOLT-HHCS-1/2-13 X 6 1/2”			8
9	43827006	SPACER-DRIVE WHEEL		MUST BE ORDERED AS SET OF 4	8
10	43827004	PLATE-MOTOR MOUNTING			2
11	43822003	SHAFT-WHEEL	80322001	INCL. COUPLING BODY	2
12	43897004	KEY-3/8” X 4 3/4”	80322001		2
13	PT0321	CHAIN-COUPLING-#50		INCL. CONNECTING PIN	2
14	43726004	COUPLING BODY-TAPER BORE-#50			2
15	43726002	BUSHING-TAPER LOCK-1”			2
16	HW0323	BOLT-HHCS-5/16-18 X 1”			8
17	HC0126	MOTOR-HYDRAULIC-400CC			2
18	HW1071	KEY-WOODRUFF-#808 STD		INCL. WITH ITEM 17	A/R
19	HW0416	BOLT-SHCS-3/8-16 X 1”			8
20	HW0107	WASHER-LOCK-3/8”			8
21	H1612	ADAPTER-90 DEG-#8 JICM X #10 SAEM			4

CASTERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	C0500	CASTER-RIDGID-10” X 5”-POLY			2
2	HW0504	BOLT-HHCS-1/2-13 X 2”			6
3	HW0514	BOLT-HHCS-1/2-13 X 2 1/2”			2
4	HW0112	WASHER-FLAT-1/2”-SAE			16
5	HW0110	WASHER-LOCK-1/2”			8
6	HW0007	NUT-HEX-1/2-13			8

ELECTRICAL

AC POWER STANCHION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	STANCHION-POWER		CONSULT FACTORY	1
2	HW0511	BOLT-HHCS-1/2-13 X 3 3/4”			2
3	HW0112	WASHER-FLAT-1/2”-SAE			2
4	HW0110	WASHER-LOCK-1/2”			2
5	HW0007	NUT-HEX-1/2-13			2
6	46837014-2	TOW ARM-COLLECTOR TROLLEY			1
7	46838015	SPACER BLOCK-TOW ARM			1
8	HW1030	U-BOLT-3/8-16 X 2” X 5”		SQUARE BEND	1
9	HW0108	WASHER-FLAT-3/8”-SAE			2
10	HW0107	WASHER-LOCK-3/8”			2
11	HW0005	NUT-HEX-3/8-16			2
12	E0632	RESTRAINT-3/4”		GRIP RANGE .625” TO .750”	1
13	E0618	LOCKNUT-CONDUIT-3/4”			1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	STANCHION-POWER		CONSULT FACTORY	1
2	HW1030	U-BOLT-3/8-16 X 2” X 5”		SQUARE BEND	1
3	HW0108	WASHER-FLAT-3/8”-SAE			2
4	HW0107	WASHER-LOCK-3/8”			2
5	HW0005	NUT-HEX-3/8-16”			2
6	41237056-2	BRACKET-TOW ARM			1
7	46838015	SPACER BLOCK-TOW ARM			1
8	BD0030	TOW ARM-TROLLEY			1
9	HW0323	BOLT-HHCS-5/16-18 X 1”			2
10	HW0106	WASHER-FLAT-5/16”-SAE			2
11	HW0150	WASHER-FLAT-5/16”-FENDER			2
12	HW0105	WASHER-LOCK-5/16”			2
13	HW0004	NUT-HEX-5/16-18			2
14	HW0511	BOLT-HHCS-1/2-13 X 3 3/4”		MOUNTING HARDWARE (NOT SHOWN)	2
15	HW0112	WASHER-FLAT-1/2”-SAE			2
16	HW0110	WASHER-LOCK-1/2”			2
17	HW0007	NUT-HEX-1/2-13			2

CONTROL PANEL

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0638	ENCLOSURE-CONTROL PANEL		16” X 14” X 6”	1
2	HW0303	BOLT-HHCS-1/4-20 X 1”			4
3	HW0103	WASHER-LOCK-1/4”			4
4	HW0002	NUT-HEX1/4-20			4
5	E0616	RESTRAINT-1/2”		GRIP RANGE .250” TO .375”	1
6	E0632	RESTRAINT-3/4”		GRIP RANGE .625” TO .750”	2
7	E0613	RESTRAINT-3/4”		GRIP RANGE .500” TO .625”	2
8	E0617	LOCKNUT-CONDUIT-1/2”		NOT SHOWN	1
9	E0618	LOCKNUT-CONDUIT-3/4”		NOT SHOWN	4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0640	PANEL-COMPONENT MOUNTING		NO HOLES DRILLED	1
2	E0120	MAGNETIC STARTER-NEMA 1 3/4”		WITH OVERLOAD	1
3	HW0130	SCREW-RHMS-#8-32 X 1/2”			17
4	HW0133	WASHER-FLAT-#8-SAE			17
5	HW0132	NUT-NILN-#8-32		NOT SHOWN	17
6	E0207-1	TRANSFORMER		0.75 Kva	1
7	HW0104	WASHER-FLAT-1/4”-SAE			4
8	HW0003	NUT-NILN-1/4-20			4
9	HW0302	BOLT-HHCS-1/4-20 X 3/4”		NOT SHOWN	4
10	E1023	WIRE WAY			5 3/8”
11	E1023	WIRE WAY			5 3/4”
12	E1023	WIRE WAY			4 3/8”
13	E1023	WIRE WAY			11 3/4”
14	E1024	TRACK-TERMINAL BLOCK			5 7/8”
15	E1024	TRACK-TERMINAL BLOCK			4 5/8”
16	E1020	TERMINAL BLOCK			16
17	E1040	END BARRIER			2
18	E1330	END ANCHOR			4
19	E0341	GROUND LUG			1
20	E0902	FUSE		FLM6	1

OPERATOR CONSOLE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0327	KEYED ACTUATOR ASSEMBLY		INCL. 2 KEYS & CONTACT BLOCK	1
2	E0351	KEY-REPLACEMENT		SET OF 2 KEYS	A/R
3	E0309	HOUR METER		INCL. MOUNTING HARDWARE	1
4	E0315	SWITCH-SELECTOR-3 POSITION	80232001	ON-OFF-ON	1
5	E0812	LEGEND PLATE-VACUUM			1
6	E1006	CONTACT BLOCK-N/O	80232001		2
7	E1007	CONTACT BLOCK-N/C	80232001		2

FOOT SWITCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0301-1	SWITCH-FOOT OPERATED		† SEE NOTES	1
2	HC0303	BOLT-HHCS-1/4-20 X 1”		IF EQUIPPED	2
3	HC0103	WASHER-1/4”-LOCK		IF EQUIPPED	2

GATE SWITCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	YE0305	SWITCH-ROLLER			1
2	SS0303	WASHER-FLAT-#8			2
3	SS0111	SCREW-SHCS-#8-32 X 1 1/2”			2
4	SS0203	NUT-NILN-#8-32			2
5	E0616	RESTRAINT-1/2”		GRIP SIZE .250” TO .375”	1

PROXIMITY SWITCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0314	SENSOR-PROXIMITY-30MM			1
2	43017027-2	BRACKET-PROXIMITY SENSOR			1
3	HW0306	BOLT-FHSCS-1/4-20 X 1”			2
4	HW0103	WASHER-LOCK-1/4”			2
5	HW0002	NUT-HEX-1/4-20			2
6	43017037-2	ANGLE-PROXIMITY SENSOR TARGET			1
7	HW0311	BOLT-FHSCS-1/4-20 X 5/8”			2

JUNCTION BOX

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E1342	ENCLOSURE-6” X 6” X 4”		NO HOLES DRILLED	1
2	E0622	RESTRAINT-1/2”		GRIP SIZE .450” TO .500”	1
3	E0608-1	RESTRAINT-1/2”-90 DEG		GRIP SIZE .450” TO .500”	2
4	E0623	RESTRAINT-1/2”-90 DEG		GRIP SIZE .250” TO .375”	2
5	E0616	RESTRAINT-1/2”		GRIP SIZE .250” TO .375”	1
6	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			4
7	E0617	LOCKNUT-CONDUIT-1/2”		NOT SHOWN	6

JUNCTION BOX PANEL

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0639	PANEL-COMPONENT MOUNTING		WITHOUT HOLES	1
2	E1024	TRACK-TERMINAL BLOCK		4 7/8”	1
3	E1020	TERMINAL BLOCK			9
4	E1330	END ANCHOR			2
5	E1040	END BARRIER			1
6	E0341	GROUND LUG			1
7	HW0130	SCREW-RHMS-#8-32 X 1/2”		2 FOR TRACK MOUNTING	3
8	HW0132	NUT-NILN-#8-32		2 FOR TRACK MOUNTING	3
9	HW0133	WASHER-FLAT-#8-SAE		2 FOR TRACK MOUNTING	3

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0611	JUNCTION BOX-4” X 2” X 2”			3
2	E0612	COVER-JUNCTION BOX			3
3	E0622	RESTRAINT-1/2”		GRIP SIZE .450” TO .500”	5
4	E0617	LOCKNUT-CONDUIT-1/2”			5
5	E0632	RESTRAINT-3/4”		GRIP SIZE .625” TO .750”	1
6	E0618	LOCKNUT-CONDUIT-3/4”			1
7	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			6

WIRING DIAGRAMS

HYDRAULICS

POWER UNITS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0011	MOTOR-ELECTRIC-10HP			1
2	HC0326	ADAPTER-PUMP TO MOTOR			1
3	HC0325	PUMP-16 GPM-VARIABLE DISP.-VANE TYPE			1
4	HC0327	COUPLING BODY-1 3/8”		MOTOR END	1
5	HC0329	SPIDER-COUPLING INSERT			1
6	HC0328	COUPLING BODY-7/8”		PUMP END	1
7	HW0502	BOLT-HHCS-1/2-13 X 1 1/4”			2
8	HW0110	WASHER-LOCK-1/2”			2
9	HW0112	WASHER-FLAT-1/2”-SAE			2
10	H1606	ADAPTER-90 DEG-#8 JICM X #8 SAEM			1
11	H1549	ADAPTER-#20 JICM X #24 SAEM			1
12	H1595	ADAPTER-90 DEG-#20 JICM X #20 JICSW			1
13	H1609	ADAPTER-90 DEG-#12 JICM X #16 SAEM			1
14	H1522	ADAPTER-#12 JICSW X #12 SAEM			1
15	HC0260	VALVE-MAIN SYSTEM RELIEF			1
15a	HC0236	REPLACEMENT CARTRIGE		† FOR ITEM 15 (NOT SHOWN)	A/R
16	HC0318	GAUGE-PRESSURE			1
17	H0206	PLUG-#4 NPT			1
18	H1547	ADAPTER-#8 JICM X #10 SAEM			1
19	H1522	ADAPTER-#12 JICSW X #12 SAEM			1
20	H1542	ADAPTER-#12 JICM X #12 SAEM			1
21	HC0280	VALVE-CHECK			1
22	H1542	ADAPTER-#12 JICM X #12 SAEM			1
23	E0613	RESTRAINT-3/4”		GRIP RANGE .500” TO .625”	1
23a	E0618	LOCKNUT-CONDUIT-3/4”		FOR ITEM 23 - NOT SHOWN	1
24	HW0403	BOLT-HHCS-3/8-16 X 1 1/4”			4
25	HW0108	WASHER-FLAT-3/8”-SAE			8
26	HW0107	WASHER-LOCK-3/8”			4
27	HW0005	NUT-HEX-3/8-16			4

† CARTRIDGE FOR REPLACEMENT ONLY.

RESERVOIR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0330-1	TANK-VERITCAL-30 GAL		INCL. ITEMS 1 THRU 4	1
2	HC0340	GAUGE-SIGHT		W/ THERMOMETER	1
3	HC0306	STRAINER-SUCTION			1
4	HC0308	FILLER/BREATHER ASSEMBLY			1
5	H1590	ADAPTER-90 DEG-#16 JICM X #16 NPTF			1
6	BI0102	ELBOW-#12 NPTF			1
7	BI0020	NIPPLE-#12 NPT X 3			1
8	BI0301	TEE-#12 NPTF			2
9	H1502	ADAPTER-#8 JICM X #12 NPTM			1
10	BI0002	NIPPLE-CLOSE-#12 NPT			2
11	HC0307	RETURN LINE FILTER ASSEMBLY		HOUSING AND FILTER	1
12	HC0317	FILTER-RETURN LINE		REPLACEMENT FILTER	1
13	H1509	ADAPTER-#10 JICM X #12 NPTM			2
14	HW0402	BOLT-HHCS-3/8-16 X 1”			4
15	HW0108	WASHER-FLAT-3/8”-SAE			8
16	HW0107	WASHER-LOCK-3/8”			4
17	HW0005	NUT-HEX-3/8-16			4

VALVE ASSEMBLY

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0257	VALVE-LEVER			1
2	HC0252	MANIFOLD-D05-1 BANK			1
3	HW0318	BOLT-SHCS-1/4-20 X 1 1/2”			4
4	H1642	PLUG-#12 SAE			1
5	H1542	ADAPTER-#12 JICM X #12 SAEM			3
6	H1606	ADAPTER-90 DEG-#8 JICM X #8 SAEM			2
7	HW0303	BOLT-HHCS-1/4-20 X 1”			4
8	HW0104	WASHER-FLAT-1/4”-SAE			8
9	HW0103	WASHER-LOCK-1/4			4
10	HW0002	NUT-HEX-1/4-20			4
11	43817085	PLATE-ADAPTER-VALVE		† NOT SHOWN	1
12	SS0104	BOLT-SHCS-1/4-20 X 5/8”-SST		† NOT SHOWN	4
13	SS0300	WASHER-FLAT-1/4”-SAE-SST		† NOT SHOWN	4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0233	VALVE-LEVER			2
2	HC0251	MANIFOLD-D03-2 BANK			1
3	H1545	ADAPTER-#10 JICM X #10 SAEM			4
4	H1606	ADAPTER-90 DEG-#8 JICM X #8 SAEM			2
5	H1600	ADAPTER-90 DEG-#6 JICM X #8 SAEM			2
6	H1587	ADAPTER-#6 JICSW X #4 NPTM			2
7	HC0211	VALVE-ADJUSTABLE FLOW CONTROL			2
8	H1504	ADAPTER-#6 JICM X #4 NPTM			2
9	H1640	PLUG-#6 SAE			1
10	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			4
11	43817033-2	RISER PLATE			1
12	HW0303	BOLT-HHCS-1/4-20 X 1”			4
13	HW0104	WASHER-FLAT-1/4”-SAE			8
14	HW0103	WASHER-LOCK-1/4”			4
15	HW0002	NUT-HEX-1/4-20			4
16	HC0233-SK	SEAL KIT		FOR ITEM 1 (NOT SHOWN)	A/R

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0233	VALVE-LEVER			3
2	HC0250	MANIFOLD-D03-3 BANK			1
3	H1610	ADAPTER-90 DEG-#10 JICM X #10 SAEM			2
4	H1641	PLUG-#10 SAE			1
5	H1000	ADAPTER-#8 SAEM X #4 NPTF			4
6	H0001	NIPPLE-#4 NPT			4
7	HC0211	VALVE-ADJUSTABLE FLOW CONTROL			4
8	H1504	ADAPTER-#6 JICM X #4 NPTM			4
9	H1640	PLUG-#6 SAE			1
10	H1540	ADAPTER-#8 JICM X #8 SAEM			2
11	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			4
12	43817034-2	RISER PLATE			1
13	HW0303	BOLT-HHCS-1/4-20 X 1”			4
14	HW0104	WASHER-FLAT-1/4”-SAE			8
15	HW0103	WASHER-LOCK-1/4”			4
16	HW0002	NUT-HEX-1/4-20			4
17	HC0233-SK	SEAL KIT		FOR ITEM 1 (NOT SHOWN)	A/R

LIFT CYLINDER

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43822002	CLEVIS ASSEMBLY		SOLD AS ASSEMBLY ONLY	4
2	HW0813	SCREW-SHSS-3/8-16 X 1/2”		NYLON TIPPED	8
3	HC0420	CYLINDER-LIFT			4
4	H1606	ADAPTER-90 DEG-#8 JICM X #8 SAEM			4
5	H1107	ADAPTER-90 DEG-#8 SAEM X #8 NPTSW			4
6	HC0425	VELOCITY FUSE			4
7	HC0420-SK	SEAL KIT		NOT SHOWN	A/R

LIFT CIRCUIT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43017014-2	SUPPORT-PILOT DOWN MANIFOLD			1
2	43718008	STANDOFF			1
3	HW0308	BOLT-HHCS-1/4-20 X 2 1/2”			2
4	HW0303	BOLT-HHCS-1/4-20 X 1”			2
5	HW0315	BOLT-HHCS-1/4-20 X 4 1/2”			1
6	HW0104	WASHER-FLAT-1/4”-SAE			10
7	HW0103	WASHER-LOCK-1/4			5
8	HW0002	NUT-HEX-1/4-20			5

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0215	VALVE-CHECK-CARTRIDGE			8
2	H1560	ADAPTER-45 DEG-#8 JICM X #8 SAEM			4
3	H1670	ADAPTER-45 DEG-#12 JICM X #10 SAEM			1
4	H1647	ADAPTER-90 DEG-#10 SAEM X #8 NPTF			1
5	H0007	NIPPLE-#8 NPT			1
6	HC0270	VALVE-ADJUSTABLE FLOW CONTROL		PRESSURE COMPENSATED	1
7	H1680	ADAPTER-#10 JICM X #8 NPTM			1
8	H1690	ADAPTER-#10 JICSW X #10 SAEM			1
9	H1612	ADAPTER-90 DEG-#8 JICM X #10 SAEM			1
10	HC0283	VALVE-COUNTER BALANCE			1
11	H1552	ADAPTER-#6 JICM X #6 SAEM			1
12	H1587	ADAPTER-#6 JICSW X #4 NPTM			1
13	H1501	ADAPTER-#8 JICM X #6 NPTM			2
14	43047002	MANIFOLD-PILOT DOWN			1
15	H1579	ADAPTER-90 DEG-#6 JICM X #4 NPTM			2

CROSS PORT RELIEF

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			2
2	HW0308	BOLT-HHCS-1/4-20 X 2 1/2”			2
3	HW0104	WASHER-FLAT-1/4”-SAE			4
4	HW0103	WASHER-LOCK-1/4”			2
5	HW0002	NUT-HEX-1/4-20			2

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0262	VALVE-CROSS PORT RELIEF			1
1a	HC0236	REPLACEMENT CARTRIDGE		† FOR ITEM 1 (NOT SHOWN)	A/R
2	H1540	ADAPTER-#8 JICM X #8 SAEM			2
3	H1521	ADAPTER-#8 JICSW X #8 SAEM			3
4	H1507	ADAPTER-#8 JICM X #8 NPTM			3
5	1A043	VALVE-ADJUSTABLE FLOW CONTROL			2
6	H1568	ADAPTER-45 DEG-#8 JICM X #8 NPTM			1
7	H1606	ADAPTER-90 DEG-#8 JICM X #8 SAEM			1
8	HC0265-1	SOLENOID-FLOOR DRIVE CUT OUT			1
9	E0611	JUNCTION BOX-4” X 2” X 2”			1
10	E0612	COVER-JUNCTION BOX			1
11	BI0001	NIPPLE-CLOSE-#8 NPT			1
12	E0617	LOCKNUT-CONDUIT-1/2”			2
13	E0616	RESTRAINT-1/2”		GRIP SIZE .250” TO .375”	1

† CARTRIDGES ARE FOR REPLACEMENT ONLY

COUNTER BALANCE VALVE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0263	VALVE-COUNTER BALANCE			1
2	H1615	ADAPTER-90 DEG-#6 JICM X #6 SAEM			2
3	H1552	ADAPTER-#6 JICM X #6 SAEM			2
4	HW0305	BOLT-HHCS-1/4-20 X 2”			2
5	HW0104	WASHER-FLAT-1/4”-SAE			4
6	HW0103	WASHER-LOCK-1/4”			2
7	HW0002	NUT-HEX-1/4-20			2

TRANSITION PLATE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43817067-2	PLATE-TRANSITION			1
2	H0020	UNION-BULKHEAD-45 DEG-#6 JICM			8
3	H0021	NUT-BULKHEAD-#6 JIC			8
4	PL0501	GROMMET-1/2			1
5	HW0303	BOLT-HHCS-1/4-20 X 1”			2
6	HW0104	WASHER-FLAT-1/4”-SAE			4
7	HW0103	WASHER-LOCK-1/4”			2
8	HW0002	NUT-HEX-1/4-20			2

RETURN LINE MANIFOLD

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43847001	MANIFOLD-RETURN LINE			1
2	H1501	ADAPTER-#8 JICM X #6 NPTM			1
3	H1503	ADAPTER-#12 JICM X #12 NPTM			2
4	HW0308	BOLT-HHCS-1/4-20 X 2 1/2			2
5	HW0104	WASHER-FLAT-1/4”-SAE			4
6	HW0103	WASHER-LOCK-1/4”			2
7	HW0002	NUT-HEX-1/4-20			2
8	43817069-2	BRACKET-BULKHEAD			1
9	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			2
10	H0015	UNION-BULKHEAD-90 DEG-#12 JICM			1
11	H0016	NUT-BULKHEAD-#12 JIC			1

HYDRAULIC SCHEMATICS

SERVICE AND MAINTENANCE

DAILY INSPECTION LIST

The points listed below should be visually inspected daily prior to initial start up of the Battery Extractor to ensure safe and proper operation of the unit and to help avoid unnecessary down time.

1. Walk around unit and inspect for any physical damage to machine not previously noted.

2. Verify all guards are in place.

3. Inspect the AC power feed for any damage.

4. Inspect vacuum cups for damage to cup sealing surface, backup casting, and vacuum hoses.

5. Inspect travel path and area around unit for any hydraulic oil that could be a potential repair/maintenance issue and/or safety hazard.

6. Check oil level in hydraulic reservoir at ﬁll level gauge.

7. Check that operator safety gate and all safety switches are in proper working order.

8. Verify extractor path is free of obstructions.

9. Check roller beds for any debris and clean as required.

10. Board unit, engage system and verify all functions are operating properly and that no abnormal or unusual noises are present.

USE FORM IF-5008 WHEN PREFORMING DAILY INSPECTIONS.

OPERATOR'S DAILY CHECKLIST

RECOMMENDED LUBRICATION INTERVALS

	# OF PLACES	INTERVALS
1. Lubricate grease fittings using #2 lithium based grease A. Extractor arm drive nut and carrier bearings B. Idler casters	5 places 2 places	50 hrs/Weekly 500 hrs/Weekly
2. Wipe off and lubricate chains using light machine oil A. #80 Lift chains (Not applicable to BE-SL units) B. #60 Equalization chains C. #35 Powered roller chains	4 places 4 places 8 places	500 hrs/Monthly 500 hrs/Monthly 500 hrs/Monthly
3. Change return line hydraulic fluid filter (Oil filtration of at least 20 microns is recommended)	1 place	500 hrs/Twice quarterly
4. Change/Test hydraulic fluid	-	500 hrs/Quarterly
5. Complete preventative maintenance (PM) (Use form IF-5029 for Vacuum equipped units Use form IF-5028 for Magnet equipped units)	-	500 hrs/Quarterly *

These recommendations are based on average use in a typical warehouse environment and may be adjusted based on individual circumstances. Dusty and/or extreme hot/cold environments may require more frequent lubrication.

BHS recommends implementing an oil sampling and analysis program to monitor hydraulic fluid condition and determine when hydraulic fluid changes are required. The fluid analysis program should be a continuous process and all results should be evaluated. Changes in the condition of the hydraulic system may indicate component wear, fluid deterioration and contamination.

The mounted bearings used on the power rollers, equalization shafts, drive wheels, and drive screw are are sealed and shielded bearings. Lubrication may breach the seals of these bearings, therefore these bearings should not be lubricated unless the machine has been cleaned with a high pressure wash on a regular basis (not recommended).
Hydraulic fluid should not exceed 140° F (60° C) for extended periods.

INTERVALSRESERVOIR	CAPACITIES (APPROX.)
»BE-SL	18 gal (68 L)
»BE-DS	18 gal (68 L)
»BE-TS	30 gal (114 L) pre 2014 45 gal (170 L) post 2014
»BE-QS	60 gal (227 L)

The reservoir should be filled so fluid level is within a half inch (1/2") of the top of sight glass. Use Chevron AW 68 or equivalent ISO 68 grade hydraulic oil with anti-wear additives and foam suppressant.

Battery Extractor Series - Vacuum Extraction Planned Maintenance Inspection Report

EQUALIZATION CHAIN

Installation / Resetting Procedures

P/N: 80292002-I

E.Q. CHAIN RESETTING

These instructions outline the procedures for replacing or resetting the equalization chains on single, double, and triple stack battery extractors.

Tools Required:

1 - Large standard screw driver 1 - 1/8” Allen key

1 - 5/32” Allen key 2 - 1 1/8” End wrenches

1 - 3/16” Allen key 1 - Needle nose pliers

1 - Steel ruler 1 - 80292002 EQ. adjustment stop kit

Step 1)

You will need to remove the inner and outer frame guards to access the lower studs to ease the adjustment process. The next step is to level the inner frame of the extractor using the 80292002 equalization adjustment stop kit.

NOTE: THIS PROCESS REQUIRES THE EXTRACTOR TO BE FULLY UNLOADED. BE SURE TO POSITION THE BATTERY EXTRACTOR IN A LEVEL AREA OF THE FLOOR.

Installation of the equalization adjustment stop kit requires (4) persons plus a trained battery extractor operator to raise and lower the extractor from the operator platform.

First, have the operator raise the extractor approximately 30” from the fully lowered position. Next, have (4) persons install a service stop in each corner of the roller beds as shown in the following photos.

Be sure that the word “UP” and the etched arrow are pointing toward the top of the machine.

Once all four stops have been installed as shown, have the operator slowly lower the platform until the roller bed is ﬁrmly seated against all (4) stops.

BE SURE ALL STOPS ARE CORRECTLY SEATED AS SHOWN HERE

Step 2) If you are replacing or adjusting existing EQ chains at this point you will need to remove the hex nuts and lock washers from the upper EQ chain studs and lower the chains. Retain the hex nuts and lock washers for reassembly. Remove and discard the master links from the upper and lower EQ chain studs and remove the chain from the studs.

NOTE: If the equalization chains are being reset due to a master link failure, it is recommended that the stud where the master link failed be replaced at this time.

Step 3) Thread the lower EQ chain studs into the frame until they are ﬂush with the bottom of the frame then turn an additional one half turn with the holes aligned front to back. (See ﬁgure 2)

FIGURE 2

Step 4) Attach the # 60 EQ chains to the upper and lower studs using the new #60 master links and lay chains in the frame until all 4 chains are reattached. Be sure the hex nut is threaded down near the master link. (See Figure 3)

FIGURE 3

Step 5) Align the EQ shafts so that the key stocks are in the 2 o’clock position. This will bring the set screws on the sprockets to the top of the sprocket when the inner frame is lowered. (See Figure 4)

FIGURE 4

Starting with the inside #60 EQ chain, route the chain over the sprocket directly above the lower EQ chain stud and then under the inside sprocket on the opposite EQ shaft. (See Figures 4 & 5) Be sure to take out as much slack as possible between the sprockets. Then attach the upper EQ Chain Stud to the top cross bar. (See Figure 6)

FIGURE 5

FIGURE 6

Next route the outer chain over the outer EQ sprocket and under the outer sprocket on the opposite EQ shaft and attach the upper stud to the top cross bar. Repeat this process for the opposite side of the extractor. Do not tighten the upper EQ stud adjusting nuts at this time. Be sure a lock washer is installed between the top cross bar and lower hex nut. (See ﬁgure 6)

Adjust the lower stud up or down to take the slack out of the equalization chain between the lower stud and the sprocket. It will probably be necessary to use a large standard screwdriver to get the ﬁ nal chain over the sprocket. NOTE: It is recommended that the operator end is done ﬁ rst since it has more obstacles hindering complete and easy access.

Step 6) Once all the chains have been installed you should now tighten the upper hex nuts on the upper studs until it takes about 10 pounds of force to produce ¼” deﬂection in the middle of the vertical section of the EQ chain. Tighten the lower hex nut on the upper cross bar studs to lock the studs in position.

Step 7)

Using a steel ruler measure the distance of the chain at the lower stud to the inside frame and set the distance of the corresponding sprocket to that distance. (See ﬁgures 7 and 8) Repeat this process for the remaining 3 sprockets. Raise and lower the inner frame several times and listen for any chain popping noise to conﬁrm the sprockets are in line with the lower studs. If there is no popping noise then tighten the set screws on the sprockets and slide the clamp collars against the outside sprocket and tighten the clamp collars.

FIGURE 7

FIGURE 8

80292001-I
BATTERY EXTRACTOR SERVICE STAND INSTALLATION INSTRUCTIONS

THESE INSTRUCTIONS REFER TO BHS PARTS KITS 80292001 & 80392001

REMOVE ALL BATTERIES FROM EXTRACTOR PRIOR TO INSTALLATION

Tools required:

None

Procedure:

Three (3) persons are required to perform the installation of the service stands. DO NOT ATTEMPT INSTALLATION WITH LESS THAN (3) PERSONS.
Begin by having a qualiﬁed operator enter the operator platform and raise the roller compartment platform of the extractor to the required height. (For single level applications, the required height will be approximately 25 inches from the fully lowered position. For double & triple stack applications, the required height will be approximately 55 inches from the fully lowered position.
Once the required platform height is achieved, the stands can be installed as shown in the following photographs. Installation is accomplished by engaging the top of the stand before the bottom. The top ﬂanges of each stand have been tapered to aid in proper alignment of the stand with the roller compartment divider weldments Be sure that the tabs on the top of the stand are properly engaged with the roller compartment divider weldments as shown.

The bottom of the stand can now be slid over the lower frame rail as shown.

Once BOTH stands have been properly ﬁtted, have the battery extractor operator SLOWLY lower the roller compartment platform while the other (2) persons are holding the stands in place.

SINGLE LEVEL STAND PROPERLY INSTALLED

DOUBLE, TRIPLE, & QUAD LEVEL STAND PROPERLY INSTALLED

Once the roller compartment platform is ﬁrmly seated against the service stands, carefully check the top and bottom of both stands for proper ﬁtment. The stands should not move when pulled on during inspection.
Remember to disconnect power prior to the battery extractor and follow all applicable OSHA lockout / tag-out procedures prior to performing service.
On double & triple stack battery extractors; the operator on the operator platform either must remain on the operator platform during service or be provided egress by an approved OSHA method. (The above does not apply to single level battery extractors as the operator platform is ﬁ xed from vertical movement.)

TROUBLE SHOOTING GUIDE

PROBLEM SYMPTOM	PROBABLE CAUSE	SOLUTION
Hydraulic power Unit does not operate. No electric to power unit motor.	No AC power to Unit. Reset on magnetic motor starter tripped. Gate switch not actuated. Foot Pedal switch not engaged.	Check fuses or breaker. Check reset button. Make sure safety gate is engaging switch. Check foot pedal for obstruction.
Power unit runs but no pressure reading at gauge also no functions move.	AC input is in reverse phase. Motor is running backwards. Main system relief valve stuck open or defective. Coupling between motor and pump loose.	Reverse any two of the three hot lines to unit. Check relief valve cartridge for trash or debris. Replace as required. Inspect coupling assy.
Magnetic starter contact chatters-at startup. Contact chatters while traveling.	1 leg of 3 phase input power out. Safety gate and/or gate switch out of adjustment.	Check fuse or circuit breaker at service panel. Check and adjust gate or switch as required to ensure full engagement of plunger on gate switch and that the safety gate is not bouncing due to vibration.
No floor travel empty or loaded-all other func- tions work properly.	Extractor arm off center-left to right. Proximity switch or sensing bracket out of target range. Proximity switch defective or broken. Bad solenoid coil on floor cutout valve. Spool on floor cutout valve stuck open.	Center arm. Adjust as needed to achieve 1/4” clearance. Check switch and replace. Check solenoid and replace if needed. Remove and clean spool cartridge or replace.
Floor travel moves but is sluggish and stalls with a load at certain points.	Uneven floor conditions. High/low spots. Excessive tire wear. Wheel shaft-to-motor shaft coupling on drive wheel assembly loose or broken. Debris lodged under battery extractor.	Check flatness of floor. Check guidance track for scraping of guide arm on top of angle. Measure under clearance of battery extractor. Should be no less than 5/8” replace poly wheels as needed. Inspect drive assembly while under load to see if shafts and couplings are moving in unison. Repair as needed. Inspect under unit and remove debris.
Inner cartridge bounces while lifting under load but not when empty.	1. Down speed adjustment valve open too far.	1. Adjust as needed to eliminate carriage bounce.
Inner carriage does not lift evenly. Four corners do not land evenly against outer frame tube.	Equalization chains are out of adjustment. Excessive chain or sprocket wear. Equalization chains are out of synchronization. Possibly may have jumped a sprocket tooth. Broken bearing housing on mounted shaft. Lift cylinder roping chains out of adjustment.	Readjust with the top stud until equal tension is achieved. Replace as needed. Evaluate and resynchronize as required. Inspect and replace. Readjust as needed to equal tension on all four cylinders in full down position.

TECH TIPS

Vacuum Cup Replacement

Tech Tip TT-901

Models Effected: All Vacuum Equipped Extractors

Subject:

Vacuum Cup Replacement for Battery Extractor Systems.

Description:

Vacuum cups are the most frequently replaced items on a battery extractor. This is due to damage of the cup by way of tearing the sealing edge of the cup, separation of the rubber from the metal backing plate, or bending/breaking the metal backing plate.

Recommendation:

When extracting a lift truck battery from either a lift truck or a charging stand, DO NOT change the elevation of the roller bed, or rotate the extractor arm while engaged on a battery case. This causes the cup to slide along the battery case leading to the edge of the cup curling or rolling under and eventually leading to the damage of the cup assembly. To eliminate this from happening, veriﬁcation of the roller bed height and extractor arm position is critical prior to engaging the cup to the battery case. To help reduce the problem of the cup edge curling under, we recommend a silicone type lubricant applied on the face of the cup to help the cup slide on the battery case.

Repair:

If the vacuum cup has been torn or separated from the metal backing plate, the cup will need to be replaced. BHS offers three cup options with a standard mounting layout. All three options are available for use on any BHS vacuum equipped extractor.

10" REPLACEMENT CUP
P/N: 00162001
STANDARD ON ATC-24 UNITS WITH VACUUM EXTRACTION.

12" REPLACEMENT CUP
P/N: P0110
STANDARD ON ATC UNITS 30" AND ABOVE

3 PIECE, 12" REPLACEMENT CUP
P/N: 00162003
CURRENT STANDARD ON BE UNITS. ALLOWS REPLACEMENT OF RUBBER PAD ONLY.

Moving an Inoperable Battery Extractor

Tech Tip TT-902

Models Effected: All Man-on-Board Extractors

Subject:

Proper procedure for moving a Battery Extractor without AC power to energize the machine.

Description:

It may be necessary to move the Battery Extractor when AC power is unavailable. This could be due to a lack of AC power at the time of install, a problem with the AC power feed, or other such instances. Regardless of the circumstances, special precautions must be taken in order to ensure no damage occurs to the drive wheel motors. DO NOT push the Battery Extractor once it is removed from the shipping skid. Pushing the battery extractor may damage the drive motor seals; thus voiding the warranty.

Recommendation:

Raise the drive wheels so that they do not contact the ﬂoor. The drive wheels are typically located at the operator’s end of the machine. Using a forklift to raise this end of the machine while moving the Battery Extractor, will prevent damage to the drive wheel motors. If the machine was moved improperly and damage has occurred, replacement of the hydraulic motors may be necessary.

INCORRECT
Pushing Extractor

CORRECT
Raising Extractor

Hydraulic Systems and Temperature Extremes

Tech Tip TT-903

Models Effected: All Hydraulic Systems

Subject:

Operating temperatures of a hydraulic system have a direct effect on oil, components, and the overall performance of the system. Temperature extremes, whether high or low, can create conditions that will break down the oil and cause component failure well before their anticipated life span.

Description:

Low Temperature increases the viscosity, or thickness, of the oil; this forces the pump to work harder pulling the oil on the inlet side. In some instances, the air dissolved in the oil will desorb and form air bubbles. These bubbles can implode violently inside the pump as it tries to compress this bubbly oil on the high-pressure side causing vibration and sounding as if marbles are inside the pump (cavitation). These implosions actually destroy the internal parts of the pump and the micro-particles are then carried throughout the system to cause additional damage to components downstream.

High Temperature decreases oil viscosity. This thinner oil causes excess wear on moving components. As the oil thins, it loses its lubricating value, which increases friction and creates more heat. This cycle continues until the oil becomes burnt and oxidized, giving it a brown color and burnt smell. At this point the oil is of no value and only damages the system. As long as the system remains below 140° F, the breakdown rate of the oil is minimized. Every 15°F over 140° F decreases the life of the oil by 50%. If the oil has an expected life of 1000 hours and the system runs at 170°F, even intermittently, the oil life is reduced to 250 hours.

Recommendation: BHS systems are shipped from the factory with Chevron AW-68 oil. This provides low temperature performance when ambient temperatures are as low as 60° F. For applications where the temperature may be consistently lower than that, we offer AW-32 oil for ambient temperatures down to 40° F. This application may be found in a refrigerated warehouse.

Be aware of your oil temperature. High temperature extremes are typically caused by a problem within the system that must be addressed as soon as possible to avoid further damage to the oil and components.

BHS recommends hydraulic oil be changed every 500 hours under normal conditions and ﬁlters be changed at least every 250 hours of operation. Oil sampling and testing can be very helpful in determining a proper maintenance schedule for your application and environment, or if a change in viscosity is needed.

Hydraulic Oil Cleanliness

Tech Tip TT-904

Models Effected: All Hydraulic Systems

Subject:

One of the most common factors of poor performance and damage to a hydraulic system is also one of the easiest to avoid - dirty hydraulic ﬂuid. Although invisible to the naked eye, germ size particles at high counts are detrimental to the performance of close tolerance valves and system components. A single large particle or an accumulation of small particles may cause valve control to become erratic. The presence of many small particles also leads to shortened pump, motor, and actuator life by causing accelerated wear to seals and bearings.

Description:

Contamination enters a system in many ways. The following are some of the most common:

Built In Contamination – Typical built-in contaminants include metal burrs, dust, lint from rags, and sealant which can be introduced into the system during the assembly process.
New Oil – New oil is not necessarily clean oil and should be pre-ﬁltered before it is put into the machine. Improperly cleaned reservoirs contain contaminants that mix with the new oil and are recirculated into the system.
Environmental Contamination – Dust, dirt, and other airborne contaminants typically found in manufacturing environments can enter a system through exposed cylinder rods. Removal of any cap, cover, plug or line connection will expose a system to environmental contaminants.
Generated Contamination – Even the best maintained machine in the cleanest environment will have contamination introduced from the normal wear of components and degradation of oil. Exposure to the sources described above will accelerate the generation of contaminants.

Recommendation:

Proper monitoring and maintenance of system ﬂuids can improve operating performance more than any other single factor. BHS recommends to change oil ﬁlters (20 micron or better) at least every 250 hours of operation and to change hydraulic oil every 500 hours under normal conditions. Oil sampling and testing can be very helpful in determining a proper maintenance schedule for your application and environment.

Trimming Powered Rollers

Tech Tip TT-905

Models Affected: BE-SL,DS,TS & QS Models

Subject:

Trimming the plastic coating on powered rollers for battery extractors.

Description:

Due to the weight of batteries traveling on the powered rollers, the plastic coating on the rollers may extrude or become elongated, much like rolling a piece of clay between your hand and a table. Over time the plastic coating of the powered rollers will be forced toward the end of the rollers, eventually coming in contact with the frame of the roller bed. See Figures 1 & 2. Once in contact with the frame, the rollers become more difficult to turn, causing excessive strain on the power roller components. Left uncorrected, the rollers will become bound against the frame and damage to components will occur.

Recommendation:

Trimming the plastic coating on the powered rollers as part of a regularly scheduled preventative maintenance program will keep the plastic from contacting the frame. With the right tools and proper instruction, trimming the powered rollers is a quick and easy two person procedure.

Repair:

BHS offers a Power Roller Trim Kit (P/N 80282001) which contains the trimming tool along with detailed instructions to properly and safely trim the powered rollers.

FIGURE1

FIGURE2

POWERED ROLLER AFTER TRIMMING

Extractor Swing Arm Cover / Stiffener Plate Mounting

Tech Tip TT-909

Models Effected: Operator Aboard Extractors

Subject: Proper mounting of extractor swing arm cover/stiffener plates.

Description:

The plates that cover the vacuum pump or magnet circuitry on the extractor should be properly mounted and secured. These plates not only protect the components in the extractor arm, but are part of the overall structure of the extractor swing arms. Improper plate mounting increases the chance of damage to the extractor swing arms due to excessive ﬂexing.

Recommendation:

It is important that both plates be properly mounted and secured on the extractor swing arms at all times during Battery Extractor (BE) operation. Install and secure new cover/stiffener plates if the current cover/stiffener plates are missing or damaged. In addition, replace any damaged or missing mounting hardware.

Repair:

If only new plates and hardware are required, BHS offers a Swing Arm Stiffener Plate Kit (P/N 80252004) to replace damaged or missing components. If the extractor swing arms need replacement along with the covers/stiffener plates, contact the BHS Tech Support Department for additional kits to best suit your needs.

COVER/STIFFENER PLATES & HARDWARE MISSING

COVER/STIFFENER PLATES PROPERLY INSTALLED

Electromagnet Performance

Tech Tip TT-910

Models Effected: Operator Aboard Extractors

Subject:

Electromagnet performance

Description:

There are several conditions that can adversely effect the pulling power of electromagnets. The following are some of the most common issues and steps that should be taken to address these issues (if applicable).

1.) BATTERY CONDITION/STRUCTURE

a. Paint: A battery that has several thick coats of paint or a chipped and deteriorating coat of paint can cause a drastic reduction in magnet performance.

Corrective Action: Remove any excess layers of paint to yield a smooth contact area for the magnet.

b. Decals: Decals of any kind that are in the contact area of the magnet can cause a drastic reduction in magnet performance. Even the thinnest of decals can cause problems.

Corrective Action: Remove any decals in the contact area of the magnet.

c. Battery Case "Crowning": A battery case may appear to have a ﬂ at surface, but in reality have a slight outward bow or "crown" to it – even a brand new battery. This "crown" will reduce the contact area of the magnet to the battery case and can cause a drastic reduction in magnet performance.

Corrective Action: A thicker plate of steel may be welded to the battery case to give a ﬂatter surface for the magnet to attach. Check with the battery manufacturer prior to performing any welding or modiﬁcation to a battery.

d. Battery Case Thickness: The battery case thickness can play a large part in magnet performance. A thin battery case may be too shallow for the ﬁeld of the magnet to attach, causing a reduction in magnet performance. Also, a thinner case battery can lead to the previously mentioned condition of "crowning" while extraction is taking place, causing the magnet to prematurely release.

Corrective Action: A thicker plate may be welded to the battery case to give a deeper ﬁeld area for the magnet to attach and eliminate the "crowning" effect during extraction. Check with the battery manufacturer prior to performing any welding or modiﬁcation to a battery.

e. Case Bottom: If a battery has a very dirty and/or rough and corroded bottom, it can cause an increase in friction when pulling from slide strips or an increase in rolling resistance when pulling from a roller compartment.

Corrective Action: A thorough neutralizing and cleaning of the bottom of the battery is required. It is recommended the battery be scraped to remove as much scale, rust, and corrosion as possible. The battery should then be recoated with a good quality acid resistant enamel. This will greatly reduce friction and help extend the life of all components making contact with the bottom of the battery.

2.) BATTERY COMPARTMENT CONFIGURATION

a. Slide Strips: The most common impact on magnet performance when using slide strips is the number of slides in the compartment. All lift truck batteries have a natural "crown" to the bottom of the battery cases. When trucks are equipped with (3) slide strips, the majority of the battery weight rests on the center slide strip. This concentration of weight along with a battery shifting around for an entire work shift, causes the slide strip to cold ﬂow or conform to the irregularities of the bottom of the battery case. When this occurs, an excessive amount of force is necessary to start battery movement to overcome the increased friction between the battery case and the slide strip. Corrective Action: In some instances, the center slide strip can be removed to allow for even distribution of the battery weight on the two remaining slide strips. Check with the lift truck manufacturer prior to performing any modiﬁcations to the lift truck.

b. Compartment Roller Trays: The condition of the roller compartment of a lift truck can effect magnet performance. Dirty or corroded rollers, damaged rollers or missing rollers combined with poor condition of the battery case bottom can cause a decrease in magnet performance.

Corrective Action: Maintenance to and/or replacement of rollers or roller trays should be performed.

Collector Trolley Alignment

Tech Tip TT-911

Models Effected: All Energy Rail Powered Equipment

Subject:

Proper installation and maintenance of the energy rail, collector trolley, and tow arm.

Description:

Proper alignment of the tow arm and collector trolley with the energy rail is critical and should be inspected regularly. Improper alignment of the trolley/tow arm with the energy rail will cause side loading of the trolley resulting in uneven brush wear. This uneven wear will result in premature failure of the brushes which could cause intermittent machine operation requiring replacement of the brushes or collector trolley.

Recommendation: The tow arm and collector trolley must be properly aligned with the energy rail. Check the tow arm and collector trolley on a regular basis to ensure proper alignment, verify the hardware is secure, and that the tow arm is not bent. Inspect by slowly driving the Battery Extractor the length of the system while checking for proper alignment. Adjust the collector trolley/tow arm mounting or energy rail as required. Note that a straight energy rail is not necessarily properly aligned. Variances in floor levelness may require the energy rail to be adjusted to align with the trolley in some areas.

IMPROPER ALIGNMENT

PROPER ALIGNMENT

Repair:

If the tow arm is bent, replacement parts are required to correct the damage.

Proper Vacuum Cup Mounting

Tech Tip TT-913

Models Effected: All BHS units with vacuum extraction

Subject:

Proper vacuum cup mounting is important for efﬁcient operation as well as reducing risk of damage.

Description:

Loose, missing, or damaged vacuum cup mounting hardware can allow the vacuum cup to pull off-line or diagonally. This may cause the cup to disengage from the battery case during extraction creating lost time and unsafe situations. Improperly mounted hardware can also cause damage to the extractor arm as the stud threads can deform the inside of the mounting holes.

Recommendation:

Vacuum cup hardware should be monitored daily as part of a daily inspection. Inspect for proper tightness (the springs should be snug without being compressed while allowing a 1/4" pitch to the vacuum cup). Also inspect for damaged or missing hardware and replace as required.

BHS offers (2) hardware kits. The HW-KIT-1 for ATC units with vacuum extraction contains (4) 4" studs and (8) springs along with the required nuts and washers for installation. The HW-KIT-2 for BE units with vacuum extraction contains (4) 5" studs and (12) springs as well as required nuts and washers. Proper installation of either kit requires that the studs be tightened securely into the vacuum cup or adapter plate (10" cups only). See photos below for proper installation of washers and springs. The nuts should then be installed and tightened until the springs are just tight enough that they cannot be moved by hand. The nuts on the lower studs should then be tightened additionally to supply a 1/4" forward pitch to the vacuum cup.

Hardware kits contain all hardware required for mounting one vacuum cup HW-KIT-2 (BE units) shown

Proper installation of HW-KIT-1 (ATC units) 10" vacuum cup shown

Proper installation of HW-KIT-2 (BE units) 12" vacuum cup shown

PARTS KITS

BE-TS W/ VACUUM SPARE PARTS KIT

P/N: BE-SPKV-TS

QTY	PART#	DESCRIPTION
1	00162003	VACUUM CUP ASSEMBLY-12"
1	43822004	DRIVE WHEEL ASSY
1	80232001	SELECTOR SWITCH KIT
1	C0500	CASTER-10" X 5"-POLY
1	E0314	PROXIMITY SENSOR
1	E0327	KEY SWITCH
1	E0351	KEY SET-REPLACEMENT
1	HC0121	100CC HYDRAULIC MOTOR
1	HC0233	BRANNON LEVER VALVE
1	HC0236	CROSS PORT RELIEF CARTRIDGE
1	HC0257	LEVER VALVE-LIFT/LOWER
1	HC0317	OIL FILTER
1	HW-KIT-2	VACUUM STUD KIT

10" VACUUM CUP ASSEMBLY

P/N: 00162001

QTY	PART#	DESCRIPTION
1	N/A	10" VACUUM CUP
1	00117059	PLATE-ADAPTER-VACUUM CUP
4	HW0328	BOLT-HHCS-5/16-18 X 3/4"
1	P0505	BUSHING-RED-#6 NPT X #4 FNPT-BRASS
1	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS
1	P0401	ELBOW-#4 NPTM X 1/4" BARB-BRASS
24	HW0108	WASHER-FLAT-3/8"-SAE

BATTERY EXTRACTOR
12" VACUUM CUP ASSEMBLY

P/N: 00162003

QTY	PART#	DESCRIPTION
1	00166001	CASTING-12" VACUUM CUP
1	00165001	FRONT PLATE-12" VACUUM CUP
1	00164001	RUBBER PAD-12" VACUUM CUP
8	HW0311	BOLT-FHSCS-1/4-20 X 3/4"

BATTERY EXTRACTOR VACUUM STUD SPRING KIT

P/N: HW-KIT-2

QTY	PART#	DESCRIPTION
4	HW0006	NUT-NILN-3/8-16
20	HW0108	WASHER-FLAT-3/8"-SAE
4	HW0428	STUD-3/8-16 X 5"
12	HW1001	SPRING-3/8"

BATTERY EXTRACTOR
BE SWING ARM/STIFFENER KIT

P/N: 80252005

QTY	PART#	DESCRIPTION
1	43055002	SWING ARM-LH
1	43055004	SWING ARM-RH
2	43057021	STIFFENER-SWING ARM
12	HW0402	BOLT-HHCS-3/8-16 X 1”
12	HW0005	NUT-HEX-3/8-16
12	HW0107	WASHER-LOCK-3/8”
24	HW0108	WASHER-FLAT-3/8”-SAE

BATTERY EXTRACTOR
BE SWING ARM REPLACEMENT KIT

P/N: 80252001

QTY	PART#	DESCRIPTION
2	PT0413	SHAFT COLLAR
3	PT0419	THRUST BEARING
1	HW1013	KEY STOCK
1	43027001	ROTARY ACTUATOR SHAFT
1	43055002	SWING ARM-LH
1	43055004	SWING ARM-RH
2	43057021	STIFFENER PLATE
12	HW0402	BOLT-HHCS-3/8-16 X 1"
24	HW0108	WASHER-FLAT-3/8"-SAE
12	HW0107	WASHER-LOCK-3/8"
12	HW0005	NUT-HEX-3/8-16

BATTERY EXTRACTOR
BE SWING ARM STIFFENER PLATE KIT

P/N: 80252004

QTY	PART#	DESCRIPTION
2	43057021	STIFFENER-SWING ARM
12	HW0402	BOLT-HHCS 3/8-16 X 1”
12	HW0005	NUT-HEX-3/8-16
12	HW0107	WASHER-LOCK-3/8”
24	HW0108	WASHER-FLAT-3/8”-SAE

BATTERY EXTRACTOR
LINEAR SLIDE BLOCK KIT

P/N: 80252002

QTY	PART#	DESCRIPTION
4	43054007	LINEAR SLIDE BLOCK
16	HW0412	BOLT-SHCS-3/8-16 X 1 1/4"
4	PT0624	FITTING-ZERK

BATTERY EXTRACTOR
LEAD SCREW DRIVE NUT KIT

P/N: 80252003

QTY	PART#	DESCRIPTION
1	43054006	DRIVE NUT ASSEMBLY
4	HW0426	BOLT-SHCS 3/8-16 X 5 1/2"
4	HW0108	WASHER-FLAT-3/8"-SAE
4	HW0006	NUT-NILN-3/8-16
1	PT0624	FITTING-ZERK

BE-TS/QS DRIVE WHEEL REPAIR KIT

P/N: 80322001

QTY	PART#	DESCRIPTION
1	C0510	WHEEL-POLY-10" X 5 1/2"
1	43822003	SHAFT-WHEEL
2	PT0430	FLANGE BEARING-4 BOLT-1 1/2"
1	43897004	KEY-3/8" X 4 3/4"

BATTERY EXTRACTOR BE VACUUM SWITCH KIT

P/N: 80232001

UNASSEMBLED

ASSEMBLED

QTY	PART#	DESCRIPTION
1	E0315	SELECTOR SWITCH-3 POSITION-30MM
2	E1006	BLOCK-CONTACT-N/O-30MM
2	E1007	BLOCK-CONTACT-N/C-30MM

BATTERY EXTRACTOR
BE SERVICE STAND KIT - DOUBLE, TRIPLE, & QUAD STACK MACHINES

P/N: 80392001

NOTE: EACH STAND WEIGHS 25 LBS

QTY	PART#	DESCRIPTION
2	46815001	SERVICE STAND
1	80292001-i	INSTRUCTIONS

BATTERY EXTRACTOR
EQUALIZATION ADJUSTMENT STOP KIT

P/N: 80292002

NOTE: NOT FOR USE ON QUAD STACK BATTERY EXTRACTORS

QTY	PART#	DESCRIPTION
4	90015114	18" SERVICE STAND
1	80292002-i	INSTALLATION INSTRUCTIONS

BATTERY EXTRACTOR POWER ROLLER TRIM KIT

P/N: 80282001

QTY	PART#	DESCRIPTION
1	43080100	TRIMMING TOOL
1	TP-608	INSTRUCTIONS

STATEMENT OF WARRANTY

Statement of Warranty

Click here for details on BHS' Statement of Warranty.

IOP-407 BE-TSN

Triple Stack Competitor Replacement Battery Extractors (BE-TSN) Parts & Service Manual

GENERAL SAFETY

WORK AREA

SERVICE & MAINTENANCE

LOCKOUT/TAGOUT

LEAD-ACID BATTERIES-EXPLOSION HAZARD

HYDRAULIC HAZARDS

OPERATIONAL SAFETY

OPERATIONAL SAFETY

DO’s AND DON’T’s

DE-ENERGIZATION

LABELS & PLACARDS

GENERAL INFORMATION

SPECIFICATION DATA

PRE-INSTALLATION CHECK

OPERATING CONTROLS

OPERATING INSTRUCTIONS

MANUAL UNLOADING

RECOMMENDED SPARE PARTS

PARTS SECTIONS

CHASSIS

EQUALIZTION

BRIDGE & CROSS BAR

LIFT CYLINDER CONNECTIONS

GUIDANCE ARM

IDLER ROLLERS

POWERED ROLLERS

HOSE CARRIER

CABLE RETRACTOR

OPERATOR GATE

GUARDS - OUTSIDE CARRIAGE

GUARDS - INNER CARRIAGE

GUARDS - LIFT CYLINDER

EXTRACTOR ARM

VACUUM STUDS

SWING ARMS

SWING ARM STOPS

VACUUM PUMP

EXTRACTOR ARM MOUNTING

HOSE MOUNTING

ARM CYLINDER

BEARING PLATES

ROTARY ACTUATOR

CARRIER SHAFTS

DRIVE NUT ASSEMBLY

DRIVE SCREW

HOSE CARRIER PLATE

DRIVE AND IDLER CASTERS

FLOOR DRIVE ASSEMBLY

CASTERS

ELECTRICAL

AC POWER STANCHION

CONTROL PANEL

OPERATOR CONSOLE

FOOT SWITCH

GATE SWITCH

PROXIMITY SWITCH

JUNCTION BOX

JUNCTION BOX PANEL

WIRING DIAGRAMS

HYDRAULICS

POWER UNITS

RESERVOIR

VALVE ASSEMBLY

LIFT CYLINDER

LIFT CIRCUIT

CROSS PORT RELIEF

COUNTER BALANCE VALVE

TRANSITION PLATE

RETURN LINE MANIFOLD

HYDRAULIC SCHEMATICS

SERVICE AND MAINTENANCE

DAILY INSPECTION LIST

OPERATOR'S DAILY CHECKLIST

RECOMMENDED LUBRICATION INTERVALS

Battery Extractor Series - Vacuum Extraction Planned Maintenance Inspection Report

EQUALIZATION CHAIN

E.Q. CHAIN RESETTING

80292001-I BATTERY EXTRACTOR SERVICE STAND INSTALLATION INSTRUCTIONS

80292001-I
BATTERY EXTRACTOR SERVICE STAND INSTALLATION INSTRUCTIONS

BATTERY EXTRACTOR
12" VACUUM CUP ASSEMBLY

BATTERY EXTRACTOR
BE SWING ARM/STIFFENER KIT

BATTERY EXTRACTOR
BE SWING ARM REPLACEMENT KIT

BATTERY EXTRACTOR
BE SWING ARM STIFFENER PLATE KIT

BATTERY EXTRACTOR
LINEAR SLIDE BLOCK KIT

BATTERY EXTRACTOR
LEAD SCREW DRIVE NUT KIT

BATTERY EXTRACTOR
BE SERVICE STAND KIT - DOUBLE, TRIPLE, & QUAD STACK MACHINES

BATTERY EXTRACTOR
EQUALIZATION ADJUSTMENT STOP KIT