View source for IOP-350 (MBE-42)

== TP-626  -  SAFETY AND DE-ENERGIZATION PROCEDURES ==
'''Register your equipment with [https://na.bhs1.com/media-library/bhs-optima/  BHS Optima], BHS's free app.'''
===GENERAL INFORMATION ===

The Mobile Battery Extractor (MBE) is used to remove large batteries from electric industrial trucks. A powerhead provides the ability to travel across the ﬂoor as well as provide DC power for all MBE controls.

The MBE consists of a 3rd party powerhead permanently afﬁxed to a BHS fabricated extractor unit.  Any references to the MBE refer to both portions operating as one complete unit unless otherwise stated.  All service related items contained in this manual are for the BHS fabricated portion only.  The manufacturers manual(s) must be read and understood concerning any and all information related to the powerhead portion of the unit.

The MBE is maneuvered by the operator from the rear of the unit using the powerhead controls.  Battery extraction is controlled by the operator via a control pendant that would typically be standing next to the MBE.  The MBE is constructed of a steel frame, which houses a fully enclosed, self contained, electrically powered, hydraulic power unit located at the rear of the inside frame.  The power unit provides power to raise the inside frame using a hydraulic cylinder and power to move the extractor arm inward and outward using a hydraulic motor.  The lift and extraction functions are controlled by an electrical control pendant located at the left, rear of the unit.  The unit is equipped with vacuum extraction which has a vacuum pump located at the rear of the inside frame.  The vacuum is controlled by an on/off switch on the control pendant.

Where possible, images are of the latest powerhead configuration.  Images shown may differ slightly from actual units based on the manufacture date.

=== GENERAL SAFETY ===
*Read and understand all instructions and warnings before using or servicing this equipment.

*Keep these instructions for future reference.

*Refer to the powerhead manual(s) for proper operation and service procedures before performing any service or maintenance to the powerhead and/or Mobile Battery Extractor (MBE) unit. 

*MBE units shall only be used indoors in an industrial setting on a hard, nonslip, and level ﬂ oor without defects including but not limited to holes, gouges, cracks, drains or obstacles comprised of concrete or other suitable industrial material. 

*Forces required to operate the MBE vary with weight of the load, ﬂoor conditions, and carriage conditions. 

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

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

*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 ﬂ uid 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 BWC per your corporate policy, if damaged or not functioning properly.  Lockout/tagout and deenergize all systems prior to performing any maintenance or service to unit.

====LEAD-ACID BATTERIES-EXPLOSION HAZARD====

[[File:Warning bhs sign (2).JPG]]

'''Do not allow open ﬂ ames 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.

====BATTERY WASH WATER HAZARDS====

[[File:Warning bhs sign (1).JPG]]

'''HYDRAULIC HAZARD '''

'''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  ===
====OPERATIONAL SAFETY ====
*Only personnel trained in the proper and safe operation of MBE units may operate or service the MBE. 

*Operators shall wear appropriate PPE suitable for  working with industrial lead-acid batteries while operating the BWC (see prior pages). 

*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 MBE. 

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

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

*Engage the battery safety bar and properly secure the battery prior to transporting the battery.

*Avoid abrupt changes in direction when transporting a battery in the MBE to prevent loss of the battery and/or loss of control of the MBE. 

*Remove MBE from service if 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 MBE.

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

* '''DO NOT''' perform any maintenance or service to the powerhead or MBE with a battery loaded on the MBE. 

*'''DO NOT''' allow anyone to ride in or on the MBE. 

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

*'''DO NOT''' travel with the stop bar in the raised position. 

*'''DO NOT'''  lower the inside frame on any person or object. 

*Disconnect the electrical connection between the MBE and the powerhead prior to charging the powerhead battery. 

*Disconnect the MBE from all power sources and engage the e-stop before attempting to perform service or maintenance to the unit. 


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

            >>As a scooter or 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 ===
The following procedure DOES NOT de-energize the powerhead of the MBE - only the lift and extraction function/ of the MBE - only the lift and extraction function/ components of the unit.  Refer to the powerhead manufaccomponents of the unit.  Refer to the powerhead manufacturers manual(s) for proper servicing procedures.

<ol>
<li>Remove the green wire from the small, positive terminal of the solenoid.  Secure the green solenoid wire so it cannot contact any other terminals, ground points, or metal parts.  See Figure 1.
</li>

[[File:IOP-350 (MBE-42) figure 1.JPG|300px|none|caption]]
FIGURE 1

<li>Depress the IN, OUT, UP, and DOWN buttons of the pendant to relieve any  stored hydraulic pressure.  See Figure 2.</li>

[[File:Warning bhs sign (1).JPG]]

'''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. '''

[[File:IOP-350 (MBE-42) figure 2.JPG|300px|none|caption]]
FIGURE 2

<li>Disconnect the DC power supply by unplugging/disconnecting the power connector/leads to the powerhead battery.  See Figure 3.</li>
[[File:Warning bhs sign (2).JPG]]

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

[[File:IOP-350 (MBE-42) figure 3.JPG|300px|none|caption]]
FIGURE 3

</ol>

=== LABELS & PLACARDS ===

[[File:IOP-350 (MBE-42) 04-11-12 TP-626(4).jpg|500px|none|border]]

==GENERAL INFORMATION==

===SPECIFICATIONS===

[[File:IOP-350 (MBE-42) 04-11-12 A1.jpg|500px|none|border]]

===UNPACKING===
The following instructions will guide you through the basic steps necessary to remove the MBE from its shipping skid.
<ol>
<pre style="color: white; background-color:#003366; width:40px;">NOTICE</pre>

'''The MBE drive wheel sets below the shipping skid cross boards.  Use care not to damage the drive wheel when handling the unit from the operator end.  See Figure 1.'''

[[File:IOP-350 (MBE-42) p10-1.JPG|300px|none|caption]]
FIGURE 1


<li>Position the MBE in an area allowing ample space to position a lift truck on each side of the MBE. </li>
<li>Carefully remove any shrink wrap, then cut and remove all banding material securing the MBE to the shipping skid. </li>
<li>Adjust the forks of the lift trucks to be used to lift the MBE to their widest positions. </li>
<li>Postition the forks of the lift trucks directly under the arrows of the "lift point fork placement" labels on both sides of the MBE.  See Figure 2. </li>

[[File:IOP-350 (MBE-42) p10-2.JPG|300px|none|caption]]
FIGURE 2

<li>Slowly insert the forks appoximately 12" under the MBE frame.  See Figure 3</li>
<pre style="color: white; background-color:#003366; width:40px;">NOTICE</pre>

'''The MBE drive wheel sets below the shipping skid cross boards.  Use care not to damage the drive wheel when handling the unit from the operator end.  See Figure 1.'''

[[File:IOP-350 (MBE-42)p10-3.JPG|300px|none|caption]]
FIGURE 3
<li>Once the forks of both lift trucks are properly positioned under the MBE, SLOWLY raise the forks of both trucks simultaneously to lift the MBE from the skid.</li>
<li>Raise the MBE until the drive wheel clears the skid and remove the skid from under the MBE.</li>
<li>SLOWY lower the MBE to the ﬂoor.</li>
<li>Lower the forks to the ﬂoor,  remove the forks from under the MBE, and exit the lift trucks from the area.</li>
</ol>

===OPERATING CONTROLS===
[[File:IOP-350 (MBE-42) 04-11-12 C1.jpg|500px|none|border]]
[[File:IOP-350 (MBE-42) 04-11-12 C2.jpg|500px|none|border]]
[[File:IOP-350 (MBE-42) p12-1.JPG|500px|none|caption]]
D.C. CABLE CONNECTIONS

The following instructions will guide you through the basic steps necessary to charge the powerhead battery.  Refer to the powerhead manual for complete instructions, warnings and safety procedures.

1. Disconnect the Extractor Input and Extractor Battery connectors.

<pre style="color: white; background-color:#003366; width:40px;">NOTICE</pre>

'''DO NOT charge the powerhead battery with the Extractor Input connected.  Damage to extractor components may occur.'''

2. Disconnect the Powerhead Battery connector from the Powerhead input labeled "TO DRIVE" and connect it to the Battery Charger connector labeled "TO CHARGE".

3. Plug the battery charger cord into a 110V outlet.

===OPERATING INSTRUCTIONS===

The following instructions will guide you through the basic steps necessary to operate and change batteries with an MBE.

Operators must be equipped with all necessary PPE and be properly trained in handling industrial lead-acid lift truck batteries.

<ol>
<li> If not already in place, position industrial truck (pallet or lift truck) which requires a battery change in the appropriate staging area.</li>
<li>Disconnect the battery leads and remove any battery restraints.</li>
<li>Move the MBE into position such that the battery compartment of the industrial truck is aligned with the roller compartment of the MBE.</li>
<li>Raise the battery safety stop.</li>
<li> Depress the "up" or "down" button on the control pendant to adjust the vertical height of the MBE battery compartment.  Adjust the height of the MBE battery compartment with the battery compartment of the industrial truck or slightly higher. '''DO NOT exceed 1/4" difference.'''</li>
<li>Depress the “out" button to extend the extractor arm toward the battery.</li>
<li>Release the button once the vacuum cup has made contact with the battery.</li>

<pre style="color: white; background-color:#003366; width:40px;">NOTICE</pre>

'''DO NOT force the cup into the battery after initial contact with the battery is made.'''
<li>Energize the vacuum by turning the switch on the control pendant "on".</li>
<li>Depress the "in" button to begin removing the battery from the industrial truck battery compartment while inspecting the vertical alignment of both battery compartments.  If vertical adjustment is needed, disengage the vacuum cup prior to adjusting the height of the MBE. </li>
<li>Once the battery is entirely inside the MBE battery compartment, carefully lower the battery safety stop.  Turn off the vacuum.</li>
<li>The battery may now be transported to the charging area.</li>
<li> Align the MBE with an open roller compartment in the battery charging area.  Be sure to check the vertical alignment of the two roller compartments.</li>
<li> Raise the MBE battery safety stop.  Lower the battery safety stop on the battery roller stand.</li>
<li> Depress the "out" button to move the battery in to the empty roller compartment.</li>

<pre style="color: white; background-color:#003366; width:40px;">NOTICE</pre>

'''DO NOT force the cup/magnet into the battery after the battery contacts the backstop.
''' 
<li>Raise the battery safety stop on the battery roller stand and connect the battery to the appropriate charger.</li>
<li>Locate and remove a fully charged battery to be installed into the industrial truck by following the above process.</li>

[[File:Warning bhs sign (1).JPG]]
'''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.'''

<pre style="color: white; background-color:#003366; width:40px;">NOTICE</pre>

'''Many batteries are a tight ﬁ t 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.''' 

</ol>


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

Manual unloading of the MBE is not recommended. In the event of power loss or an operational malfunction of the MBE not allowing a battery to be unloaded using normal operating procedures, only repairs required to safely maneuver the MBE to a position allowing safe unloading using normal operating procedures should be made.  Once any batteries are safely unloaded, any remaining repairs can be made.

[[File:Warning bhs sign (2).JPG]]

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. 

[[File:IOP-350 (MBE-42) 04-11-12 D1.jpg|500px|border]]

== PARTS SECTIONS ==

===CHASSIS ===

==== POWERED TRANSMISSION ====

[[File:IOP-350 (MBE-42) 04-11-12 1.0.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.0.1T.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.0.2.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.0.2T.jpg|500px|border]]

==== IDLER WHEELS====

[[File:IOP-350 (MBE-42) 04-11-12 1.1.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.1.1T.jpg|500px|border]]

==== CAM FOLLOWERS (INNER FRAME)====

[[File:IOP-350 (MBE-42) 04-11-12 1.2.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.2.1T.jpg|500px|border]]

==== ROLLERS====

[[File:IOP-350 (MBE-42) 04-11-12 1.3.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.3.1T.jpg|500px|border]]

==== SLIDE STRIPS====

[[File:IOP-350 (MBE-42) 04-11-12 1.4.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.4.1T.jpg|500px|border]]

==== DROP BAR / RUBBER BUMPERS====

[[File:IOP-350 (MBE-42) 04-11-12 1.5.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.5.1T.jpg|500px|border]]

==== GUARDING====

[[File:IOP-350 (MBE-42) 04-11-12 1.6.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.6.1T.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.6.2.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.6.2T.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.6.3.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.6.3T.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.6.4.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.6.4T.jpg|500px|border]]

==== HOSE CARRIER====

[[File:IOP-350 (MBE-42) 04-11-12 1.7.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.7.1T.jpg|500px|border]]

==== LABELS====

[[File:IOP-350 (MBE-42) 04-11-12 1.8.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 1.8.1T.jpg|500px|border]]


===EXTRACTOR ARM ===

====STANDARD EXTRACTOR ARM ====

[[File:IOP-350 (MBE-42) 04-11-12 2.0.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 2.0.1T.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 2.0.2.jpg|500px|border]]
[[File:IOP-350-(MBE-42)-04-11-12-49 2.02t.jpg|500px|border]]

====VACUUM CUPS ====

[[File:IOP-350 (MBE-42) 04-11-12 2.1.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 2.1.1T.jpg|500px|border]]

===  PNEUMATICS ===

====VACUUM PUMP ====

[[File:IOP-350 (MBE-42) 04-11-12 3.0.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 3.0.1T.jpg|500px|border]]

===  HYDRAULICS ===

====POWER UNIT ====

[[File:IOP-350 (MBE-42) 04-11-12 4.0.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 4.0.1T.jpg|500px|border]]


====ARM DRIVE MOTOR ====

[[File:IOP-350 (MBE-42) 04-11-12 4.1.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 4.1.1T.jpg|500px|border]]

====CROSS PORT RELIEF VALVE ====

[[File:IOP-350 (MBE-42) 04-11-12 4.2.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 4.2.1T.jpg|500px|border]]

==== CONTROL VALVES ====

[[File:IOP-350 (MBE-42) 04-11-12 4.2.2.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 4.2.2T.jpg|500px|border]]


==== CYLINDER ====

[[File:IOP-350 (MBE-42) 04-11-12 4.3.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 4.3.1T.jpg|500px|border]]

==== HOSES====

[[File:IOP-350 (MBE-42) 04-11-12 4.4.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 4.4.1T.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 PAGE 70.jpg|500px|border]]

=== ELECTRICAL ===

==== CONTROL PENDANT ====

[[File:IOP-350 (MBE-42) 04-11-12 5.0.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 5.0.1T.jpg|500px|border]]

==== ENCLOSURE ====

[[File:IOP-350 (MBE-42) 04-11-12 5.1.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 5.1.1T.jpg|500px|border]]

==== SWITCHES ====

[[File:IOP-350 (MBE-42) 04-11-12 5.2.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 5.2.1T.jpg|500px|border]]

==== CABLES & CONNECTORS ====

[[File:IOP-350 (MBE-42) 04-11-12 5.3.1.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 5.3.1T.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 5.3.2.jpg|500px|border]]
[[File:IOP-350 (MBE-42) 04-11-12 5.3.2T.jpg|500px|border]]