IOP-401 BE-TS

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Triple Stack Operator Aboard Battery Extractors (BE-TS) 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 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 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.

• Persons with pacemakers (or similar type medical devices) should not operate, or be in close proximity to during operation, any BHS equipment utilizing magnetic extraction.

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.

• DO 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 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

1. 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 fully lower the roller bed when performing service to the BE could result in injury from the roller bed lowering unexpectedly.


FIGURE 1



FIGURE 2

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


FIGURE 3

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.
4. 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 uid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section). • Unexpected movement of hydraulic components.

LABELS & PLACARDS

SPECIFICATION DATA

		BE-24-2-TS	BE-36-2-TS	BE-42-2-TS
A	Overall Length	156.5"	180.5"	192.5"
B	Overall Width	72"	72"	72"
C	Overall Height (Lowered)	158.188"	158.188"	160.688"
	Overall Height (Raised w/ Overhead Guard)	182.375"	182.375"	182.375"
	Overall Height (Raised w/ Strobe & Alarm)	191.75"	191.75"	191.75"
D	Wheel Base	98"	122"	134"
E	Drive Wheel Center line	51"	51"	51"
F	Battery Compartment Width	24"	36"	42"
G	Ground Clearance	.625"	.625"	.625"
H	Minimum Roller Height	6.5"	6.5"	6.5"
I	Maximum Roller Height	96"	96"	96"
J	Operator Platform Height (Lowered/Raised)	11" / 103"	11" / 103"	11" / 103"

UNITS WITH 10 HP POWER UNIT USED PRIOR TO DECEMBER, 2014

Imperial / Metric	BE-24-2-TS	BE-36-2-TS	BE-42-2-TS
Travel Speed	0 to 190 ft/min / 0 to 0.97 m/s	0 to 190 ft/min / 0 to 0.97 m/s	0 to 190 ft/min / 0 to 0.97 m/s
Raise - Lower Speed	0 to 26 ft/min / 0 to 0.13 m/s	0 to 26 ft/min / 0 to 0.13 m/s	0 to 26 ft/min / 0 to 0.13 m/s
Powered Roller Speed	0 to 37 ft/min / 0 to 0.19 m/s	0 to 37 ft/min / 0 to 0.19 m/s	0 to 37 ft/min / 0 to 0.19 m/s
Arm Traverse Speed	0 to 20 ft/min / 0 to 0.10 m/s	0 to 20 ft/min / 0 to 0.10 m/s	0 to 20 ft/min / 0 to 0.10 m/s
Arm Rotation Time	6 s to 8 s	6 s to 8 s	6 s to 8 s
Draw Bar Pull / Vacuum (12” / 305 mm Round Cup)	1,000 lb / 454 kg	1,000 lb / 454 kg	1,000 lb / 454 kg
Draw Bar Pull Magnet*	800 lb to 1,200 lb / 363 to 544 kg	800 lb to 1,200 lb / 363 to 544 kg	800 lb to 1,200 lb / 363 to 544 kg
Vacuum Attach Time	< 1 s	< 1 s	< 1 s
Vacuum Release Time	< 1 s	< 1 s	< 1 s
Input Voltage	480 V / 3 ph / 60Hz	480 V / 3 ph / 60Hz	480 V / 3 ph / 60Hz
AC Current Draw	16.5 A	16.5 A	16.5 A
Control Circuit Voltage	120 V ac	120 V ac	120 V ac
Hydraulic Power Unit	10 hp / 7.46 kW	10 hp / 7.46 kW	10 hp / 7.46 kW
Hydraulic Pump	16 gal/min / 61 L/min	16 gal/min / 61 L/min	16 gal/min / 61 L/min
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 / 0.25 kW	1/3 hp / 0.25 kW	1/3 hp / 0.25 kW
Vacuum	21” Hg / 711 mbar	21” Hg / 711 mbar	21” Hg / 711 mbar
Full Load Capacity	10,000 lb / 4535 kg	10,000 lb / 4535 kg	10,000 lb / 4535 kg
Weight (Empty)	8,000 lb / 3629 kg	8,300 lb / 3765 kg	8,600 lb / 3901 kg
Total Compartment Rollers / Powered	11/5	11/5	11/5
Guide Track	3” x 2.5” Angle 76 mm x 64 mm	3” x 2.5” Angle 76 mm x 64 mm	3” x 2.5” Angle 76 mm x 64 mm
Overall Dimensions (L x W x H)	156.5” x 72” x 158.188” 3975 mm x 1829 mm x 4018 mm	180.5” x 72” x 158.188” 4585 mm x 1829 mm x 4018 mm	192.5” x 72” x 160.688” 4890 mm x 1829 mm x 4081 mm
Vacuum Arm Reach	4.5” to 14” / 114 mm to 356 mm	4.5” to 14” / 114 mm to 356 mm	4.5” to 14” / 114 mm to 356 mm
Vacuum Arm Reach (Hydraulic Extension)	9” to 23” / 229 mm to 584 mm	9” to 23” / 229 mm to 584 mm	9” to 23” / 229 mm to 584 mm
Magnet Arm Reach (Hydraulic Extension) Truck Side	14” to 22” / 355 mm to 559 mm	14” to 22” / 355 mm to 559 mm	14” to 22” / 355 mm to 559 mm
Wheel Base	98” / 2489 mm	122” / 3099 mm	134” / 3404 mm
Drive Wheel Center Line	51” / 1295 mm	51” / 1295 mm	51” / 1295 mm
Battery Compartment Width	24” / 610 mm	36” / 915 mm	42” / 1067 mm
Maximum Battery Dimensions (L x W x H)	48” x 23” x 34” 1219 mm x 584 mm x 864 mm	48” x 35” x 34” 1219 mm x 889 mm x 864 mm	48” x 41” x 34” 1219 mm x 1041 mm x 864 mm
Minimum Battery Width (with vacuum / magnet)	12” / 305 mm 6” / 152 mm	12” / 305 mm 6” / 152 mm	12” / 305 mm 6” / 152 mm
Minimum Battery Height	17.75” / 451 mm	17.75” / 451 mm	17.75” / 451 mm
Ground Clearance	0.63” / 16 mm	0.63” / 16 mm	0.63” / 16 mm
Roller Height	6.5” Min / 96” Max 165 mm Min / 2438 mm Max	6.5” Min / 96” Max 165 mm Min / 2438 mm Max	6.5” Min / 96” Max 165 mm Min / 2438 mm Max

UNITS WITH 20 HP POWER UNIT USED DECEMBER, 2014 TO PRESENT

Imperial / Metric	BE-24-2-TS	BE-36-2-TS	BE-42-2-TS
Travel Speed	0 to 240 ft/min / 0 to 1.22 m/s	0 to 240 ft/min / 0 to 1.22 m/s	0 to 240 ft/min / 0 to 1.22 m/s
Raise - Lower Speed	0 to 26 ft/min / 0 to 0.13 m/s	0 to 26 ft/min / 0 to 0.13 m/s	0 to 26 ft/min / 0 to 0.13 m/s
Powered Roller Speed	0 to 37 ft/min / 0 to 0.19 m/s	0 to 37 ft/min / 0 to 0.19 m/s	0 to 37 ft/min / 0 to 0.19 m/s
Arm Traverse Speed	0 to 20 ft/min / 0 to 0.10 m/s	0 to 20 ft/min / 0 to 0.10 m/s	0 to 20 ft/min / 0 to 0.10 m/s
Arm Rotation Time	6 s to 8 s	6 s to 8 s	6 s to 8 s
Draw Bar Pull / Vacuum (12” / 305 mm Round Cup)	1,000 lb / 454 kg	1,000 lb / 454 kg	1,000 lb / 454 kg
Draw Bar Pull Magnet*	800 lb to 1,200 lb / 363 to 544 kg	800 lb to 1,200 lb / 363 to 544 kg	800 lb to 1,200 lb / 363 to 544 kg
Vacuum Attach Time	< 1 s	< 1 s	< 1 s
Vacuum Release Time	< 1 s	< 1 s	< 1 s
Input Voltage	480 V / 3 ph / 60Hz	480 V / 3 ph / 60Hz	480 V / 3 ph / 60Hz
AC Current Draw	35 A	35 A	35 A
AC Current Draw w/ Electric Drive Option	42 A	42 A	42 A
Control Circuit Voltage	120 V ac	120 V ac	120 V ac
Hydraulic Power Unit	20 hp / 14.9 kW	20 hp / 14.9 kW	20 hp / 14.9 kW
Hydraulic Power Unit w/ Electric Drive Option	25 hp / 18.7 kW	25 hp / 18.7 kW	25 hp / 18.7 kW
Hydraulic Pump	22 gal/min / 83 L/min	22 gal/min / 83 L/min	22 gal/min / 83 L/min
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 / 0.25 kW	1/3 hp / 0.25 kW	1/3 hp / 0.25 kW
Vacuum	21” Hg / 711 mbar	21” Hg / 711 mbar	21” Hg / 711 mbar
Full Load Capacity	10,000 lb / 4535 kg	10,000 lb / 4535 kg	10,000 lb / 4535 kg
Weight (Empty)	8,000 lb / 3629 kg	8,300 lb / 3765 kg	8,600 lb / 3901 kg
Total Compartment Rollers / Powered	11/5	11/5	11/5
Guide Track	3” x 2.5” Angle 76 mm x 64 mm	3” x 2.5” Angle 76 mm x 64 mm	3” x 2.5” Angle 76 mm x 64 mm
Overall Dimensions (L x W x H)	156.5” x 72” x 158.188” 3975 mm x 1829 mm x 4018 mm	180.5” x 72” x 158.188” 4585 mm x 1829 mm x 4018 mm	192.5” x 72” x 160.688” 4890 mm x 1829 mm x 4081 mm
Vacuum Arm Reach	4.5” to 14” / 114 mm to 356 mm	4.5” to 14” / 114 mm to 356 mm	4.5” to 14” / 114 mm to 356 mm
Vacuum Arm Reach (Hydraulic Extension)	9” to 23” / 229 mm to 584 mm	9” to 23” / 229 mm to 584 mm	9” to 23” / 229 mm to 584 mm
Magnet Arm Reach (Hydraulic Extension) Truck Side	14” to 22” / 355 mm to 559 mm	14” to 22” / 355 mm to 559 mm	14” to 22” / 355 mm to 559 mm
Wheel Base	98” / 2489 mm	122” / 3099 mm	134” / 3404 mm
Drive Wheel Center Line	51” / 1295 mm	51” / 1295 mm	51” / 1295 mm
Battery Compartment Width	24” / 610 mm	36” / 915 mm	42” / 1067 mm
Maximum Battery Dimensions (L x W x H)	48” x 23” x 34” 1219 mm x 584 mm x 864 mm	48” x 35” x 34” 1219 mm x 889 mm x 864 mm	48” x 41” x 34” 1219 mm x 1041 mm x 864 mm
Minimum Battery Width (with vacuum / magnet)	12” / 305 mm 6” / 152 mm	12” / 305 mm 6” / 152 mm	12” / 305 mm 6” / 152 mm
Minimum Battery Height	17.75” / 451 mm	17.75” / 451 mm	17.75” / 451 mm
Ground Clearance	0.63” / 16 mm	0.63” / 16 mm	0.63” / 16 mm
Roller Height	6.5” Min / 96” Max 165 mm Min / 2438 mm Max	6.5” Min / 96” Max 165 mm Min / 2438 mm Max	6.5” Min / 96” Max 165 mm Min / 2438 mm Max

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 & INSTRUCTIONS

OPERATING CONTROLS

OPERATOR CONSOLE

NOTE: Safety devices for the machine and the machine operating area shall not be rendered inoperable or misused.

SAFETY FEATURES

Key Switch – Located on the dash (see above). Primary on/off switch to prevent unauthorized personnel from operating the BE.

Foot Switch – Must be depressed to operate the BE. Stepping off the foot switch will stop all functions immediately, locking all hydraulics in place. To resume use, depress the foot switch.

Gate Switch – The gate must be fully closed for the BE to operate.

Extractor Arm Switch – Does not permit the machine to move forward or backward unless the extractor arm is located in the center of the carriage between the indicating arrows located on the arm guard.

Powered Roller Cutout (PRC-1 or PRC-2) (if equipped) – Disengages the powered roller function when the photo eye positioned on the edge of the BE battery compartment is disrupted by a battery, requiring additional input from the operator. Pressing the "Power Roller Cutout" override button (see above) on the dash will resume powered roller operation when loading or unloading batteries from the BE carriage.

Horn (If equipped) – Button located on the dash (see above). Used to alert personnel before moving the BE.

Strobe Light (If equipped) – Located on a vertical stanchion mounted to the right rear of the operator compartment. For units equipped with optional overhead guard (OHG), the beacon is located above of the operator compartment. Beacon automatically flashes when the BE is switched on to visually notify the BE is in use.

Audible Alarm (if equipped) – Mounted in the same location as the Strobe Light. Automatically sounds when the BE is switched on to notify personnel that the BE is in use.

*Typical BE-TS operator console shown above. Position of optional controls may vary from that shown depending on model of unit, age of unit and/or combination of optional controls present.

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 (or optional magnets).

• The operator shall make certain there are no persons or obstacles in the extractor path prior to traveling forward or reverse.

• 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."

• In the event of any failure or malfunction, step off the dead-man switch and all functions will stop immediately, locking all hydraulics in place.

• 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.

• Only one key should be provided to operate the extractor.

• When leaving the machine, the operator shall turn off the key switch and remove the key to prevent unauthorized use.

• Ensure all the batteries and cables are properly stored in the battery stands prior to moving the BE.

• The BE is designed to carry only one battery in each compartment on the carriage.

• When loading the BE, position the batteries in the center of the compartments on the powered rollers to prevent any battery movement when transporting.

• Ensure there are no projections outside of the carriage before moving the BE.

OPERATING INSTRUCTIONS

PRE-CHANGE OUT PREPARATION

1. Position lift truck for change out in designated area.
2. Remove all battery restraints and disconnect battery cables following manufacturers guidelines. (Be sure to position battery cables so as not to be damaged by battery during change out.)
3. Board battery extractor and close safety gate. (Gate must be fully closed or unit will not operate.)
4. Depress foot pedal.
5. Turn key switch to "ON" position.

NOTE: If unit fails to energize after steps 2-5, verify the Emergency Stop is not depressed.

DISCHARGED BATTERY REMOVAL

1. Move extractor forward or reverse to position center of empty compartment with center of 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.)
2. Align extractor’s roller bed height with lift truck’s battery compartment.
3. Rotate extractor arm into battery compartment aligned in Step 2.
4. Move extractor arm toward battery until vacuum cup/ magnet contacts battery.
DO NOT force cup/magnet to battery after initial contact with battery is made.
5. Energize vacuum cup/magnet by turning selector switch to proper direction, left or right.
6. 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.)
7. Turn off vacuum/magnet and move extractor arm away from battery 1" to 2".
8. Rotate extractor arm out of battery compartment into opposite compartment (if empty) and center arm in carriage.
9. Move battery into center of compartment using powered rollers.

CHARGED BATTERY RETRIEVAL

1. Locate charged battery of appropriate type for lift truck being changed.
2. 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 charger is not still charging battery. Dangerous sparking/arcing can occur if battery is unplugged from charger while charging.
3. 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.)
4. Rotate arm into empty compartment (if not already positioned there.)
5. Move extractor arm toward battery until vacuum cup/ magnet contacts battery.
6. Energize vacuum cup/magnet by turning selector switch to proper direction, left or right.
DO NOT force cup/magnet to battery after initial contact with battery is made.
7. 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.)
8. Turn off vacuum/magnet and move extractor arm away from battery 1" to 2".
9. Rotate extractor arm out of battery compartment into fully vertical position.
10. Move battery into center of compartment using powered rollers.

DISCHARGED BATTERY RETURN

1. 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.
2. Return discharged battery to battery rack using powered rollers.
NOTE: 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/magnet is necessary for pushing. DO NOT activate vacuum/magnet switch. Slowly push battery into rack until fully into compartment.
3. Engage battery safety stop and connect battery to charger as required.

CHARGED BATTERY INSTALLATION

1. Lower extractor roller compartment to fully lowered position.
2. Drive extractor back to lift truck and align roller compartment containing charged battery as performed in steps 1 and 2 of "Discharged Battery Removal".
3. Move charged battery toward lift truck compartment by using powered rollers, verifying precise battery alignment.
Many batteries are a tight fit into lift truck battery compartments. Care MUST be taken to ensure alignment is precise to avoid damage to battery, lift truck, and/or battery extractor.
4. Adjust extractor vertically as well as horizontally, if needed.
5. Insert battery into lift truck as far as possible using only the powered rollers.
6. Rotate extractor arm into compartment and SLOWLY push battery into lift truck. (Be sure to watch battery cables for interference.)
7. Return extractor arm to center of roller bed and lower extractor to fully lowered position. Drive extractor out of immediate area.
8. Turn off key switch, remove key from switch and carefully exit extractor.
9. Secure newly installed battery in lift truck and reconnect battery cables.
10. Return lift truck to service.

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

CHARGED BATTERY INSTALLATION

Units equipped with optional Powered Roller Cutout, the powered roller override button must be depressed in addition to actuating the hydraulic valve when a battery disrupts the photo eye(s) at the edge of the battery compartments while using the powered rollers to transfer batteries on and off of the battery extractor.

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 or level of the inner carriage), 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.

SPARE PARTS LIST

Refer to the appropriate Spare Parts Kit (vacuum equipped units - Pt# BE-SPKV-TS, magnet equipped units - Pt# BE-SPKM- TS) at the beginning of Section 8 for the list of items recommended by the factory to have on hand for BE-TS models to minimize any downtime due to minor breakdown that may occur under normal operating conditions.

BHS also offers a supplement hose kit (Pt# 80342003) which contains an assortment of hoses allowing any hose on the extractor to be replaced immediately with a temporary hose of equal length or longer. When the extractor is back up and running, the failed hose can be taken to have an exact replacement made. Once the new hose is made and installed, the temporary hose can be returned to the kit for future use.

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.)

Note: Spare parts kits contain parts for the most current machine design/configuration. Due to continuous design and manufacturing improvements, not all the parts in the spare parts kits may be compatible with older units. Consult factory when ordering spare parts for existing units in the field to ensure part compatibility.

PARTS SECTIONS

CHASSIS

EQUALIZATION

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	00158001-14	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 IN LINE	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-81.75"		BE-24-2-TS	2
	43327001	SHAFT-EQUALIZATION-105.75"		BE-36-2-TS	2
	44327001	SHAFT-EQUALIZATION-117.75"		BE-42-2-TS	2
	44527001	SHAFT-EQUALIZATION-75.75"		BE-42-1-TS	2
8	PT0503	BEARING-FLANGED LOAD-2 1/4"		USED AFTER DEC. '03	8
	43026001	BEARING-FLANGED LOAD-2 1/4" (MACHINED)		USED PRIOR TO DEC. '03	8
9	HW0025	NUT-JAM-7/8-14			8
10	HW0117	WASHER-LOCK-7/8" (NOT SHOWN)		USED PRIOR TO AUG, '02	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
	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	43015011	GUIDE ARM WELDMENT, 2 ROLLER			2	-
2	43017025	SPACER-GUIDE ARM		†1/2" THICK	4	-
3	41215204	GUIDE ARM WELDMENT, 4 ROLLER			-	2
4	41217274	SPACER-GUIDE ARM			-	4
5	43012007	CAM ROLLER-1 3/4"			4	8
6	HW0115	WASHER-LOCK-3/4"			4	8
7	HW0011	NUT-HEX-3/4-16			4	8
8	HW0509	BOLT-HHCS-1/2-13 X 4 1/2"			4	6
9	HW0112	WASHER-FLAT-1/2"-SAE			4	6
10	HW0110	WASHER-LOCK-1/2"			4	6
11	HW0007	NUT-HEX-1/2-13			4	6
12	41215234	GUIDE ARM WELDMENT (POLY)			2
13	41217317	POLY SLIDE MOUNTING BLOCK			4
14	41217318	POLY SLIDE			4
15	HW0501	BOLT-HHCS-1/2-13 x 1			6
16	HW0110	WASHER-LOCK-1/2"			6
17	91253A546	BOLT FHSCS-1/4-20 x 1-1/2			4
18	HW0003	NUT-NILN-1/4-20			4

† OLDER UNITS EQUIPPED WITH (1) 1" THICK SPACER PER GUIDE ARM BRACKET.

IDLER ROLLERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43182001	LEAD ROLLER ASSEMBLY-24"		W/ ALIGNMENT GROOVE	4
	43382001	LEAD ROLLER ASSEMBLY-36"		W/ ALIGNMENT GROOVE	4
	43482001	LEAD ROLLER ASSEMBLY-42"		W/ ALIGNMENT GROOVE	4
2	43182002	IDLER ROLLER ASSEMBLY-24"			8
	43382002	IDLER ROLLER ASSEMBLY-36"			8
	43482002	IDLER ROLLER ASSEMBLY-42"			8
3	43187002	SHAFT-HEX-.75" X 25.75"		24" COMPARTMENTS	8
	43387002	SHAFT-HEX-.75" X 37.75"		36" COMPARTMENTS	8
	43487002	SHAFT-HEX-.75" X 43.75"		42" COMPARTMENTS	8
4	43187003	SHAFT-HEX-.75" X 27.5"		24" COMPARTMENTS	4
	43387003	SHAFT-HEX-.75" X 39.5"		36" COMPARTMENTS	4
	43487003	SHAFT-HEX-.75" X 45.5"		42" COMPARTMENTS	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
	43382003	POWERED ROLLER-36"			10
	43485003	POWERED ROLLER-42"			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	00158001-16	CHAIN-ROLLER-#35			8
10	PT0031	LINK-CONNECTING-#35			8
11	PT0418	COLLAR-SHAFT-1"			10

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	43017004	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	PT0631	BRACKET-UPPER MOUNTING			1
3	HW0212	SCREW-RHMS-#10-24 X 1/2"			2
4	SS0202	NUT-NILN-#10-24			2
5	PT0630	BRACKET-LOWER MOUNTING			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	43015004	GATE-OPERATOR			1
2	HW0407	BOLT-HHCS-3/8-16 X 2 3/4"			1
3	HW0108	WASHER-FLAT-3/8"-SAE			2
4	HW0006	NUT-NILN-3/8-16			1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43017064-2	LATCH-SWING GATE			1
2	HW0030	BOLT-HHCS-3/8-16 X 2 1/4"			1
3	HW0031	NUT-LOCK-3/8-16			1
4	N/A	HINGE-SPRING		† SEE NOTES	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		1
9	HW0003	NUT-NILN-1/4-20	80092001		1
10	HW9001	SPRING-TORSION	80292008		1
11	HW0816	SCREW-HHCS-SELF DRILLING-#10 X 3/4"	80292008		4
12	43806001	ANTI-FATIGUE MAT			1
13	43017058-2	THRESHOLD			1
14	HW0402	BOLT-HHCS-3/8-16 X 1"			2
15	HW0108	WASHER-FLAT-3/8"-SAE			4
16	HW0107	WASHER-LOCK3/8"			2
17	HW0005	NUT-HEX-3/8-16			2

† PART DISCONTINUED. SPRING HINGE MUST BE REPLACED WITH TORSION SPRING KIT

GUARDS - OUTSIDE FRAME

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43817038	GUARD-FAR END-TOP			1
2	43817037	GUARD-FAR END-MIDDLE			1
3	43817035	GUARD-FAR END-BOTTOM			1
4	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			33

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43817103	GUARD-FAR END-TOP			1
2	43817102	GUARD-FAR END-MIDDLE			1
3	43817101	GUARD-FAR END-BOTTOM			1
4	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			37

GUARDS - INNER CARRIAGE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43817041-2	GUARD-FRONT-OPERATOR CONSOLE			1
2	43817042-2	GUARD-INNER-FRAME			2
3	43014006-2	GUARD-LINEAR DRIVE SCREW			1
4	43017010-2	GUARD-SIDE-ARM CARRIER SHAFT			2
	44517002-2	GUARD-SIDE-ARM CARRIER SHAFT		† SINGLE COMP. UNITS ONLY	1
5	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			34
6	43017009-2	BRACKET-SCREW GUARD MOUNTING			2
7	HW0306	BOLT-FHSCS-1/4-20 X 1"			4
8	HW0303	BOLT-HHCS-1/4-20 X 1"			4
9	HW0104	WASHER-FLAT-1/4"-SAE			8
10	HW0103	WASHER-LOCK-1/4"			8
11	HW0002	NUT-HEX-1/4-20			4

† SINGLE COMPARTMENT GUARD REPLACES STANDARD, FAR SIDE ARM CARRIER SHAFT GUARD.

GUARDS - DASH & PLATFORM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41614004-2	DASHBOARD-OPERATOR CONSOLE			1
2	43817040	KICK PLATE-OPERATOR CONSOLE		41.5" HIGH	1
3	43817086-2	DASHBOARD-OPERATOR CONSOLE			1
4	43817088	KICK PLATE-OPERATOR CONSOLE		33.5" HIGH	1
5	43817110-2	FRAME-DASHBOARD			1
6	A/R	PLATE-DASHBOARD		† SEE NOTES	1
7	HW0060	NUT-CLIP-#10-24			12
8	SS0114	BHSC-#10-24 X 1/2"-SST			12
9	PL0602	VINYL EDGING		AT FOOT SWITCH - NOT SHOWN	1’

† CONSULT FACTORY.

GUARDS - LIFT CYLINDER

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

LABELS AND PLACARDS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00196612	LABEL-"READ INSTRUCTION MANUAL PRIOR TO USE"			1
2	00196616	LABEL-"NO RIDERS ALLOWED"			1
3	00196210	LABEL-WARNING-"OPERATION BY AUTHORIZED PERSONNEL ONLY"			1
4	43696001	PLACARD-OFF / ON			1
5	43096018	PLACARD-RACK LEVEL ASSIST		†IF EQUIPPED	1
6	43096015	PLACARD-PLATFORM RAISE / LOWER			1
7	43096010	PLACARD-HORN		†IF EQUIPPED	1
8	43096016	PLACARD-DRIVE / ARM ROTATION			1
9	43096012	PLACARD-VACUUM OFF / ON		VACUUM EQP’D UNITS ONLY	1
	43096011	PLACARD-MAGNET OFF / ON		MAG UNITS ONLY (NOT SHOWN)	1
10	43096017	PLACARD-POWERED ROLLER CUTOUT OVERRIDE		†IF EQUIPPED	1
11	43096013	PLACARD-POWERED ROLLERS / ARM TRAVERSE			1
12	00196615	LABEL-"DO NOT OPERATE WITH GUARDS REMOVED"		(1) PER SIDE OF ARM	2
13	00196633	LABEL-NOTICE-"IN LINE VACUUM FILTER..."		(1) PER SIDE (VAC UNITS ONLY)	2
14	SM-1197	LABEL-ARM POSITION ARROW			2
15	00196609	LABEL-NOTICE-"ARM MUST BE POSITIONED BETWEEN ARROWS..."			1
16	00196602	LABEL-NOTICE-"LUBRICATION POINTS ON UNDERSIDE"			2
17	00196218	LABEL-WARNING-"ELECTRICAL VOLTAGE HAZARD"		MAGNET UNITS ONLY	1
18	00196214	LABEL-WARNING-"STRONG MAGNETIC FIELD"		MAGNET UNITS ONLY	2
19	00196700	DECAL-BHS-24" X 7.875"			1

† RACK LEVEL ASSIST (LAI), HORN AND POWERED ROLLER CUTOUT (PRC) ARE OPTIONAL FEATURES. NOT ALL UNITS ARE EQUIPPED WITH THESE OPTIONS.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00196004	LABEL-CAUTION-"WATCH FOR BATTERY AND CHARGER CABLES IN TRAVEL PATH"			1
2	00196216	LABEL-WARNING-"CHAIN ENTANGLEMENT HAZARD"		(1) PER CLEVIS GUARD	4
3	00196615	LABEL-"DO NOT OPERATE WITH GUARDS REMOVED"		(1) EA. NEAR AND FAR GUARDS	4
4	00196622	LABEL-LIFT POINT		(2) EACH END	4
5	00196700	DECAL-BHS-24" X 7.875"		FAR END, NOT SHOWN	1
6	00196630	LABEL-NOTICE-HYD. OIL SPEC. (AW 68)		† NOT SHOWN	1
	00196645	LABEL-NOTICE-HYD. OIL SPEC. (AW 32)		† NOT SHOWN	1

† MOST UNITS SHIPPED PRIOR TO DECEMBER, 2014 REQUIRE AW 68 HYDRAULIC OIL. SOME UNITS SHIPPED PRIOR TO DECEMBER, 2014 SHIPPED WITH AW 32 FOR LOW TEMPERATURE APPLICATIONS.

EXTRACTOR ARM

VACUUM ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	ARM-PUSH/PULL-30"		† DISCONTINUED	1
	N/A	ARM-PUSH/PULL-36"		† DISCONTINUED	1
2	HW0509	BOLT-HHCS-1/2-13 X 4 1/2"			3
3	HW0112	WASHER-FLAT-1/2"-SAE			6
4	HW0110	WASHER-LOCK-1/2"			3
5	HW0007	NUT-HEX-1/2-13			3
6	P0505	BUSHING-RED-#6 NPT X #4 FNPT-BRASS			2
7	P0402	HOSE BARB-1/4 X #4 MNPT-BRASS			2
8	HW0428	STUD-VACUUM-3/8-16 X 5"	HW-KIT-2		8
9	HW0108	WASHER-FLAT-3/8"-SAE	HW-KIT-2		40
10	HW1001	SPRING-3/8"	HW-KIT-2		24
11	HW0006	NUT-NILN-3/8-16	HW-KIT-2		8
12	HW0424	NUT-JAM-3/8-16	HW-KIT-2		8
REF	43052006	ADJUSTABLE PUSH/PULL ARM		INCL. ITEMS 13 THRU 17	1
13	43057034	ARM BASE			1
14	43055008	VACUUM CUP MOUNT			2
15	HW0523	BOLT-HHCS-1/2-13 X 4"			2
16	HW0112	WASHER-FLAT-1/2"-SAE			4
17	HW0008	NUT-NILN-1/2-13			2

† ONE-PIECE ARMS NO LONGER AVAILABLE. MUST REPLACE WITH ADJUSTABLE ARM.

VACUUM CUPS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	VACUUM CUP-10" ROUND	00162001	† AVAILABLE IN KIT ONLY	A/R
2	00117059	PLATE-VACUUM CUP ADAPTER	00162001		1
3	HW0328	BOLT-HHCS-5/16-18 X 3/4"	00162001		4
4	P0401	ELBOW-#4 MNPT X 1/4" BARB-BRASS	00162001		1
5	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS	00162001		1
6	P0505	BUSHING-RED-#6 NPT X #4 FNPT-BRASS	00162001		1
REF	00162003	VACUUM CUP-12" 3-PC		INCL. ITEMS 7 THRU 10	A/R
7	00166001	CASTING-12" VACUUM CUP	00162003		1
8	00164001	SEAL-RUBBER-12"	00162003		1
9	00165001	PLATE-FRONT-12"	00162003		1
10	HW0311	BOLT-FHSCS-1/4-20 X 3/4"	00162003		8
REF	00162004	VACUUM CUP-10" 3-PC		INCL. ITEMS 10 THRU 13	A/R
11	00164006	CASTING-10" VACUUM CUP	00162004		1
12	00164004	SEAL-RUBBER-10"	00162004		1
13	00165002	PLATE-FRONT-10"	00162004		1

† ONE-PIECE CONSTRUCTION

SWING ARMS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	45055001	TIE PLATE-SWING ARM		BE-24-2-TS	1
	45255001	TIE PLATE-SWING ARM		BE-36-2-TS (NOT SHOWN)	1
	45355001	TIE PLATE-SWING ARM		BE-42-2-TS (NOT SHOWN)	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	43057003	CUSHION-SWING ARM			2
17	HW0306	BOLT-FHSCS-1/4-20 X 1"			4
18	43055001	STOP-SWING ARM			2
18a	43057008	SPACER-SWING ARM STOP		NOT SHOWN	2
19	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			4
20	HW0107	WASHER-LOCK-3/8"			4
21	HW0108	WASHER-FLAT-3/8"-SAE			4
22	H1565	ADAPTER-45 DEG-#6 JICM X #4 MNPT			2
23	H1600	ADAPTER-90 DEG-#6 JICM X #8 SAEM			2

† INCLUDED IN MULTIPLE KITS

SEE 2.0.2A FOR SINGLE COMPARTMENT SWING ARM STOP

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	44555001	STOP-SWING ARM			1
2	43057003	CUSHION-SWING ARM			1
3	43057008	SPACER-SWING ARM STOP			1
4	HW0306	BOLT-FHSCS-1/4-20 X 1"			2
5	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			4
6	HW0107	WASHER-LOCK-3/8"			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 FNPT-BRASS			1
5	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS			4
6	P0402	HOSE BARB-1/4" X #4 MNPT-BRASS			6
7	P0207	VALVE-VACUUM RELEASE			2
8	P0302	HOSE-VACUUM-1/4" ID		TWO 6" PIECES	1 FT
9	P0302	HOSE-VACUUM-1/4" ID		SHORT ARM SIDE	1 FT
10	P0302	HOSE-VACUUM-1/4" ID		LONG ARM SIDE	2 FT
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	E0514	CORD-16-5 SW/SOW			15 FT
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-INLINE		NOT SHOWN	2

† INCLUDED IN MULTIPLE KITS

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 FNPT			4
8	H1579	ADAPTER-90 DEG-#6 JICM X #4 MNPT			2

CARRIER SHAFTS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43057013	CARRIER SHAFT-EXTRACTOR ARM			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	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

† 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	43024001	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

ITEMS BELOW ARE REQUIRED FOR REPLACING THE LINEAR DRIVE SCREW ON UNITS WITH FRAME #’S OF 373 AND EARLIER
LINEAR DRIVE SCREW UPDATE KIT
REF	80252011	UPGRADE KIT			1
1	43024001	SCREW-LINEAR DRIVE			1
2	PT0119	SPROCKET-50B15 X 1 3/16"			1
3	43097004	KEY-1/4" X 7/8"			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
16	43057019	PLATE-COVER			2
-	43057022	SHIM-18GA		MAY NOT BE REQ’D - NOT SHOWN	2
-	43057018	TEMPLATE-BEARING MOUNT PATTERN		NOT SHOWN	1
-	43057020	SPACER PLATE		NOT SHOWN	2
-	80000015	INSTRUCTION DETAIL		NOT SHOWN	REF

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	SCREW-LINEAR DRIVE (DISCONTINUED)		SEE 80252011 UPGRADE KIT	1
2	PT0118	SPROCKET-50B12 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	43057016	BLOCK-BEARING RETAINER			2
6a	PT0414	RACE-TAPERED ROLLER BEARING		INCLUDED WITH 43057016	2
7	PT0623	SEAL-GREASE			2
8	HW0416	BOLT-SHCS-3/8-16 X 1"			8
9	PT0415	BEARING-TAPERED ROLLER			2
10	HW1050	NUT-LOCK			4
11	43057017	PLATE-COVER			2
12	HW0415	BOLT-SHCS-3/8-16 X 3/4"			8
13	PT0624	FITTING-ZERK			2

HOSE CARRIER PLATE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43915018	PLATE-HOSE CARRIER			1
2	PT0618	BRACKET-FIXED END			1
3	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			2
4	PT0617	HOSE CARRIER		20 LINKS REQ’D.	3 FT
5	PT0619	BRACKET-MOVING END			1
6	HW0303	BOLT-HHCS-1/4-20 X 1"			2
7	HW0103	WASHER-LOCK-1/4"			2
8	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"		† SEE NOTES	2
9	HW0108	WASHER-FLAT-3/8"-SAE			6
10	HW0107	WASHER-LOCK-3/8"			4
11	HW0005	NUT-HEX-3/8-16			4
12	HC0262	VALVE-CROSS PORT RELIEF		INCL. CARTRIDGES	1
12a	43846002	REPLACEMENT CARTRIDGE		†† FOR ITEM 12 (NOT SHOWN)	2
13	HW0308	BOLT-HHCS-1/4-20 X 2 1/2"			2
14	HW0104	WASHER-FLAT-1/4"-SAE			2
15	HW0103	WASHER-LOCK-1/4"			2
16	HW0002	NUT-HEX-1/4-20			2
17	H1560	ADAPTER-45 DEG-#8 JICM X #8 SAEM			4
18	E1329	JUNCTION BOX-4" X 4" X 2"		PVC - INCL. COVER	1
19	HW0212	SCREW-RHMS-#10-24 X 1/2"			4
20	HW0102	WASHER-FLAT-#10-SAE			4
21	E0623	RESTRAINT-1/2"-90 DEG		GRIP SIZE .250 TO .375	2
22	E0622	RESTRAINT-1/2"		GRIP SIZE .450 TO .560	1
23	E0617	LOCKNUT-CONDUIT-1/2"		FOR 21 & 22 (NOT SHOWN)	3
24	HW1076	BOLT-FHSCS-3/8-16 X 1"		† SEE NOTES	2

† UNITS BUILT PRIOR TO FEBRUARY, 2014 WITHOUT EXTENDED REACH OPTION USE (4) HW0403 MOUNTING BOLTS. †† CARTRIDGES ARE FOR REPLACEMENT ONLY

MAGNET EXTRACTION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41257014	TIE PLATE-SWING ARM		ALL UNITS	1
-	41655008	EXTENSION-ARM		BE-36 ONLY (NOT SHOWN)	1
-	43455001	EXTENSION-ARM		BE-42 ONLY (NOT SHOWN)	1
2	HW0603	BOLT-FHSCS-5/8-11 X 2"			4
3	HW0113	WASHER-LOCK-5/8"			4
4	HW0010	NUT-JAM-5/8-11			4
5	41655001	CARRIER TUBE-MAGNET SWING SHAFT			1
6	HW0504	BOLT-HHCS-1/2-13 X 2"			6
7	HW0112	WASHER-FLAT-1/2"-SAE			6
8	HW0110	WASHER-LOCK-1/2"			6
9	HW0007	NUT-HEX-1/2-13			6
10	41657006	SHAFT-MAGNET SWING			1
11	41698001	KEY-3/8" X 7/16"			2
12	N/A	STOP-MAGNET SWING		† DISCONTINUED	1
13	PT0430	FLANGE BEARING-4 BOLT-1 1/2"			2
14	HW0513	BOLT-HHCS-1/2-13 X 2 1/4"			8
15	HW0112	WASHER-FLAT-1/2"-SAE			16
16	HW0110	WASHER-LOCK-1/2"			8
17	HW0007	NUT-HEX-1/2-13			8
18	41655002	PLATE-MAGNET MOUNTING			2
19	41257015	BLOCK-TIGHTENER		2-PIECE ITEM	1
20	41257016	BLOCK-FIXED		2-PIECE ITEM	1
21	HW0423	BOLT-SHCS-3/8-16 X 3 1/2"			4
22	HW0006	NUT-NILN-3/8-16			4
23	HW0806	SET SCREW-3/8-16 X 2"		REPLACES SWIVEL HEAD	4
24	HW0424	NUT-JAM-3/8-16			4
25	41657017	INSULATOR-MAGNET MOUNT			2
26	HW0306	BOLT-FHSCS-1/4-20 X 1"			8
27	41657008	PAD-MAGNET SLIDE			2
28	HW0314	BOLT-FHSCS-1/4-20 X 1/2"			4

† REFER TO SECTION 2.5.1A FOR REPLACEMENT / UPGRADE PARTS

MAGNET PIVOT STOP

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	80252012	MAGNET SWING STOP KIT		INCL. ITEMS 1 THRU 6	A/R
1	43057029	PLATE-STOP			1
2	43058003	SLEEVE-STOP			2
3	43057030	SUPPORT-CABLE			2
4	PL0501	GROMMET-1/2"			2
5	HW0509	BOLT-HHCS-1/2-13 X 4 1/2"			2
6	HW0008	NUT-NILN-1/2-13			2
7	44557003	PLATE-STOP		† SINGLE COMP. UNITS ONLY	1

† FOR UNITS EQUIPPED WITH PIVOT SHAFT. SEE SECT. 2.5.1B FOR UNITS WITH INDEPENDENT MAGNET PIVOT BEARINGS.

MAGNET EXTRACTION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	43052007	MAGNET PUSH/PULL ARM ASSEMBLY		INCL. ITEMS 1 THRU 17	1
1	43055009	MAGNET PUSH/PULL ARM			1
2	43055010	MAGNET MOUNT			2
3	PT0470	BEARING-MAGNET PIVOT			2
4	HW0525	BOLT-CARRIAGE-1/2-13 X 1 1/2"			12
5	HW0524	BOLT-CARRIAGE-1/2-13 X 2"		† STOP PLATE LOCATION	4
6	HW0110	WASHER-LOCK-1/2"			16
7	HW0007	NUT-HEX-1/2-13			16
8	43058009	PLATE-ROTATION STOP			2
9	43058003	SLEEVE-STOP			2
10	43058010	SUPPORT-CABLE			2
11	PL0501	GROMMET-1/2"			2
12	HW0523	BOLT-HHCS-1/2-13 X 4"			2
13	HW0008	NUT-NILN-1/2-13			2
14	43057037	INSULATOR-BOTTOM			2
15	HW0306	BOLT-FHSCS-1/4-20 X 1"			8
16	41657008	SLIDE-MAGNET			2
17	HW0314	BOLT-FHSCS-1/4-20 X 1/2"			4
18	44558001	PLATE-ROTATION STOP		† SINGLE COMP. UNITS ONLY	2

† SINGLE COMPARTMENT STOP PLATES REQUIRE (1) ADDITIONAL 2" LONG CARRIAGE BOLT EACH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	43032008	MAGNET ASSEMBLY		INCLUDES ITEMS 1 THRU 11	A/R
1	N/A	ELECTROMAGNET-95VDC			2
2	E0314	SENSOR-PROXIMITY-30MM			2
3	N/A	GASKET-REAR		DISCONTINUED - NOT USED	2
4	41657002	COVER-PROXIMITY SENSOR HOUSING		REAR	2
5	HW1065	SCREW-SHCS-#6-32 X 3/8"			8
6	HW1066	WASHER-LOCK-#6			8
7	N/A	INDICATOR LIGHT		SEE PART #’S BELOW	2
8	E0335	RECEPTACLE-5 PIN MALE		WITH 12" LEAD	2
9	E0617	LOCKNUT-CONDUIT-1/2"			2
10	N/A	GASKET-FRONT		DISCONTINUED - NOT USED	2
11	41657003	COVER-PROXIMITY SENSOR HOUSING	80252015	FRONT	2
12	HW0138	SCREW-FHSCS-#8-32 X 3/8"	80252015		8
13	HW0433	STUD-1/2-13 X 5"	80252006	FOR UNITS WITH MAGNET PIVOT SHAFT ONLY. SEE SECTION 2.5.1 (UNITS BUILT PRIOR TO 11/01/14)	8
14	HW0007	NUT-HEX-1/2-13	80252006		8
15	HW0112	WASHER-FLAT-1/2"-SAE	80252006		40
16	HW1002	SPRING-1/2"	80252006		24
17	HW0008	NUT-NILN-1/2-13	80252006		8
18	HW0514	BOLT-HHCS-1/2-13 X 2 1/2"	80252014	FOR UNITS WITH INDEPENDENT PIVOT BEARINGS ONLY. SEE SECTION 2.5.1B (UNITS BUILT 11/01/14 TO PRESENT)	4
19	HW1002	SPRING-1/2"	80252014		4
20	HW0112	WASHER-FLAT-1/2"-SAE	80252014		8
21	HW0007	NUT-HEX-1/2-13	80252014		4
FOR EXTRACTORS (OR REPLACEMENT MAGNETS) SHIPPED PRIOR TO FEB, 2014
7	E0337	LIGHT-PILOT-RED-120 VAC/DC		INCL. LENS AND BULB	2
-	2EJ79	LAMP-REPLACEMENT-INCANDESCENT		120 VAC	A/R
FOR EXTRACTORS (OR REPLACEMENT MAGNETS) SHIPPED FROM FEB, 2014 TO PRESENT
7A	E0370	HOUSING-INDICATOR LIGHT		LENS AND LAMP NOT INCL.	A/R
7B	E0371-A	LENS-FLUTED-AMBER			A/R
7C	E0372-120	LAMP-LED		120 VAC	A/R

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E1105	JUNCTION BOX-4" X 2" X 2"		WEATHER PROOF BOX	1
2	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			2
3	E1106	COVER-JUNCTION BOX		WEATHER PROOF W/ GASKET	1
4	E0333	RECEPTACLE-9 PIN MALE		WITH 12" LEAD	1
5	E0608-1	RESTRAINT-1/2"-90 DEG		GRIP SIZE .450 TO .560	2
6	E0617	LOCKNUT-CONDUIT-1/2"			3
7	E0334	CORD-5 PIN FEMALE		WITH 36" LEAD	2
8	E0332	CORD-9 PIN FEMALE-90 DEG		WITH 36" LEAD	1
9	PL0501	GROMMET-1/2"			1
10	41657013-2	PLATE-PANEL MOUNTING		W/ SINGLE CABLE HOLE	1
11	E0334-6	CORD-5 PIN FEMALE		WITH 72" LEAD	2
12	43057038-2	PLATE-PANEL MOUNTING		W/ DUAL CABLE HOLES	1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43057021	PLATE-STIFFENER			1
2	HW0402	BOLT-HHCS-3/8-16 X 1"			12
3	HW0108	WASHER-FLAT-3/8"-SAE		(NOT SHOWN)	24
4	HW0107	WASHER-LOCK-3/8"			12
5	HW0005	NUT-HEX-3/8-16			12
6	41637001	PANEL-COMPONENT MOUNTING			1
7	HW0325	BOLT-5/16-18 X 1 3/4"-PAN HEAD			4
8	N/A	INSULATOR-THREADED FEMALE		DISCONTINUED	4
9	HW0106	WASHER-FLAT-5/16"-SAE			8
10	HW0326	NUT-NILN-5/16-18			8
11	E1016	FUSE HOLDER			1
12	HW0130	SCREW-RHMS-#8-32 X 1/2"			1
13	HW0133	WASHER-FLAT-#8-SAE			1
14	HW0132	NUT-NILN-#8-32			1
15	E0325	FUSE-7AMP-250VAC		FLM-7 OR FNM-7	1
16	PL0307	INSULATOR-MALE STUD			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41637001	PANEL-COMPONENT MOUNTING			1
2	41637002	WIRE WAY			2
3	41637003	WIRE WAY			1
4	41637004	TRACK-TERMINAL BLOCK MOUNTING			1
5	41637005	TRACK-TERMINAL BLOCK MOUNTING			1
6	HW0130	SCREW-RHMS-#8-32 X 1/2"			10
7	HW0132	WASHER-FLAT-#8-SAE			10
8	HW0133	NUT-NILN-#8-32		NOT SHOWN	16
9	E1020	TERMINAL BLOCK			12
10	E1040	END BARRIER			2
11	E1330	END ANCHOR			4
12	E1009	RECTIFIER-FULL WAVE BRIDGE			2
13	HW0135	SCREW-RHMS-#8-32 X 3/4"			2
14	E1313	SOCKET-RELAY-8 PIN			2
15	HW0139	SCREW-RHMS-#8-32 X 1 1/4"			4
16	E0331	RELAY-DPDT-110VAC		WITH INDICATOR LIGHT	2

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43055007	MOUNT-STOP-SWING ARM		† SEE NOTES	2
2	43057024	STOP-SWING ARM		BE-24	4
	43057023	STOP-SWING ARM		BE-36 & BE-42	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

† SEE SECTION 2.0.2 FOR SINGLE COMPARTMENT STOP MOUNT AND STOP

VACUUM EXTENDED REACH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41257014	TIE PLATE-SWING ARM		ALL UNITS	1
-	41655008	EXTENSION-ARM		BE-36 ONLY (NOT SHOWN)	1
-	43455001	EXTENSION-ARM		BE-42 ONLY (NOT SHOWN)	1
2	HW0504	BOLT-HHCS-1/2-13 X 2"			6
3	HW0112	WASHER-FLAT-1/2"-SAE			6
4	HW0110	WASHER-LOCK-1/2"			6
5	HW0007	NUT-HEX-1/2-13			6
6	P0301-1	HOSE-COIL-VACUUM			1
7	41257035	STANDOFF			2
8	HW1072	RESTRAINT-HOSE			2
9	HW0104	WASHER-FLAT-1/4"-SAE			2
10	HW0103	WASHER-LOCK-1/4"			2
11	HW0318	BOLT-SHCS-1/4-20 X 1 1/2"			2
12	HW0302	BOLT-HHCS-1/4-20 X 3/4"			1
13	HW0312	SCREW-SHSS-1/4-20 X 1"-CUP POINT			1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41255005	ARM-EXTENSION-VACUUM			1
2	HC0416	CYLINDER-EXTENDED REACH-VACUUM		2 1/2" X 12" CYLINDER	1
3	H1578	ADAPTER-90 DEG-#6 JICM X #6 MNPT			2
4	41257031	PIN-CLEVIS END			1
5	00197036	PIN-ROD END			1
6	HW1058	PIN-HITCH			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41255004	HOUSING-EXTENDED REACH-VACUUM			1
2	41257030	PLATE-END			1
3	HW0402	BOLT-HHCS-3/8-16 X 1"			4
4	HW0108	WASHER-FLAT-3/8"-SAE			8
5	HW0107	WASHER-LOCK-3/8"			4
6	HW0005	NUT-HEX-3/8-16			4
7	41258002	PLATE-BEARING	80258001	SIDE	2
8	41258005	PLATE-SHIM	80258001	SIDE	2
9	41258003	PLATE-BEARING	80258001	UPPER/ LOWER	2
10	41258004	PLATE-SHIM	80258001	UPPER/ LOWER	2
11	HW0812	SCREW-SHSS-1/4-20 X 5/8"-HALF DOG			28
12	HW0002	NUT-HEX-1/4-20			28

EXTENDED REACH

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 FNPT			4
8	H1579	ADAPTER-90 DEG-#6 JICM X #4 MNPT			4

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		14 LINKS REQ’D.	39"
7	PT0628	BRACKET-FIXED END			1
8	HC0262	VALVE-CROSS PORT RELIEF			1
8a	43046003	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
12a	43046005	REPLACEMENT CARTRIDGE		† FOR ITEM 12 (NOT SHOWN)	A/R
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

† CARTRIDGES ARE FOR REPLACEMENT ONLY

MAGNET EXTENDED REACH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43055011	ARM-EXTENSION-MAGNET			1
2	HC0415	CYLINDER-EXTENDED REACH-MAGNET		2 1/2" X 8" CYLINDER	1
3	H1578	ADAPTER-90 DEG-#6 JICM X #6 MNPT			2
4	43057042	PIN-CLEVIS END			1
5	43057043	PIN-ROD END			1
6	HW1132	RETAINING RING-EXTERNAL-3/4" ID			4
7	HW1043	CLAMP-CYLINDER			2
8	43057044-2	SUPPORT-CABLE			2
9	PL0501	GROMMET-1/2" ID			4
10	43058019	SUPPORT-CABLE-BAND CLAMP			2
11	HW0104	WASHER-FLAT-1/4"-SAE			4
12	HW0103	WASHER-LOCK-1/4"			2

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43055012	HOUSING-EXTENDED REACH-MAGNET			1
2	50057008	PLATE-END			1
3	HW0402	BOLT-HHCS-3/8-16 X 1"			4
4	HW0108	WASHER-FLAT-3/8"-SAE			8
5	HW0107	WASHER-LOCK-3/8"			4
6	HW0005	NUT-HEX-3/8-16			4
7	43058013	PLATE-BEARING-SIDE			2
8	43058016	PLATE-SHIM-SIDE			2
9	43058014	PLATE-BEARING-UPPER/LOWER			2
10	43058015	PLATE-SHIM-UPPER/LOWER			2
11	HW0812	SCREW-SHSS-1/4-20 X 5/8"-HALF DOG			24
12	HW0002	NUT-HEX-1/4-20			24

EXTENDED REACH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	CARRIER SHAFT-EXTRACTOR ARM		† 3-HOLE VERSION	A/R
2	PT0413	COLLAR-SHAFT-3"			4
3	50057009	PLATE-END-3 HOLE		REPLACEMENT PART ONLY	4
4	50057010	SHIM-END PLATE		††SEE NOTES	A/R
5	HW1076	BOLT-FHSCS-3/8-16 X 1"			12
6	43057045	CARRIER SHAFT-EXTRACTOR ARM		1-HOLE VERSION	2
7	43017076	PLATE-END-1 HOLE			4
8	HW0603	BOLT-FHSCS-5/8-11 X 2"			4

† 3-HOLE CARRIER SHAFT NO LONGER AVAILABLE. MUST REPLACE 3-HOLE SHAFT W/ CURRENT, 1-HOLE VERSION ALONG WITH NEW END PLATES & HARDWARE.

†† SHIM QUANTITY VARIES DUE TO MANUFACTURING TOLERANCES.

DRIVE AND IDLER WHEELS

DRIVE WHEEL MOUNTING

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW0503	BOLT-HHCS-1/2-13 X 1 1/2"			6
2	HW0504	BOLT-HHCS-1/2-13 X 2"		CYL. BRACKET BOLT ONLY	2
3	HW0110	WASHER-LOCK-1/2"			8
4	HW0112	WASHER-FLAT-1/2"-SAE			8

DRIVE WHEEL MOTORS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43822001-6B	FLOOR DRIVE ASSEMBLY (W/ 200CC MOTOR)		† SEE NOTES	2
	43822004-6B	FLOOR DRIVE ASSEMBLY (W/ 400CC MOTOR)		† SEE NOTES	2
2	43827004	PLATE-MOTOR MOUNTING			2
3	HW0416	BOLT-SHCS-3/8-16 X 1"			8
4	HW0107	WASHER-LOCK-3/8"			8
5	H1612	ADAPTER-90 DEG-#8 JICM X #10 SAEM			4
6	N/A	ROD-THREADED-1/2-13 X 7 3/4"		†† SEE NOTES	8
7	N/A	SPACER-DRIVE WHEEL-4.75" LG		†† SEE NOTES	8
8	HW0110	WASHER-LOCK-1/2"			8
9	HW0007	NUT-HEX-1/2-13			8
10	43827006	SPACER-DRIVE WHEEL-4.125" LG		MUST BE ORDERED AS SET OF 4	8
11	HW0516	BOLT-HHCS-1/2-13 X 6 1/2"			8
12	HW0112	WASHER-FLAT-1/2"-SAE			8
13	N/A	MOTOR-HYDRAULIC-200CC		††† KEYED SHAFT	-
	N/A	MOTOR-HYDRAULIC-400CC		††† KEYED SHAFT	-
14	HW1071	KEY-WOODRUFF-#808 STD			2
15	HC0124-6B	MOTOR-HYDRAULIC-200CC		† SPLINE SHAFT	2
	HC0126-6B	MOTOR-HYDRAULIC-400CC	80322003	† SPLINE SHAFT	2

† 200CC MOTORS REQUIRED FOR UNITS EQUIPPED WITH PARALLEL DRIVE CIRCUIT. 400CC MOTORS REQUIRED FOR UNITS EQUIPPED WITH SERIES DRIVE CIRCUIT. SEE SECTION 5.4 TO DETERMINE IF UNIT IS PARALLEL OR SERIES EQUIPPED AND APPROXIMATE EFFECTIVITY OF EACH TYPE.

†† PARTS OBSOLETE AND NO LONGER AVAILABLE. MUST REPLACE WITH ITEMS 10 & 11.

††† PARTS OBSOLETE AND NO LONGER AVAILABLE. MUST REPLACE WITH SPLINE DRIVE CONVERSION KIT.

NOTE: EFFECTIVITY DATES REFER TO DATES NEW EXTRACTOR UNITS ARE SHIPPED FROM THE FACTORY. REPLACEMENT PART EFFECTIVITY MAY DIFFER DUE TO FACTORY INVENTORY LEVELS AT TIME OF PARTS ORDER. CONSULT FACTORY IF UNSURE OF PARTS NEEDED.

DRIVE WHEEL BEARINGS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43825001	FRAME-FLOOR DRIVE			2
2	C0510-1	WHEEL-10" X 5"-POLY	80322001		2
3	43822003	SHAFT-WHEEL (W/ COUPLING BODY)		AVAILABLE IN MULTIPLE KITS	2
4	43897004	KEY-3/8" X 4 3/4"	80322001		2
5	PT0430	FLANGE BEARING-4 BOLT-1 1/2"	80322001		4
6	HW0504	BOLT-HHCS-1/2-13 X 2"			8
7	HW0112	WASHER-FLAT-1/2"-SAE			16
8	HW0110	WASHER-LOCK-1/2"			16
9	HW0007	NUT-HEX-1/2-13			16
10	PT0321	CHAIN-COUPLING-#50		INCL. CONNECTING PIN	2
11	N/A	COUPLING BODY-TAPER BORE-#50		† SEE NOTES	2
12	N/A	BUSHING-TAPER LOCK-1"		† SEE NOTES	2
13	HW0323	BOLT-HHCS-5/16-18 X 1"			8
14	PT0330	COUPLING BODY-#50-SPLINE BORE	80322003		2
15	HW1110	RETAINING RING-1 1/2"-HEAVY DUTY		†† AVAILABLE IN MULTIPLE KITS	2

† PARTS OBSOLETE AND NO LONGER AVAILABLE. SPLINE DRIVE CONVERSION KIT REQUIRED. REUSE OF BUSHINGS AFTER DISASSEMBLY NOT RECOMMENDED.

†† RETAINING RINGS USED ON UNITS SHIPPED AFTER 07/01/12. UNITS SHIPPED FROM 07/01/12 TO 11/01/13 ARE EQUIPPED WITH (2) RETAINING RINGS PER SHAFT - (1) ON EACH SIDE OF THE WHEEL. UNITS SHIPPED AFTER 11/01/13 ARE EQUIPPED WITH ONLY (1) SNAP RING AS SHOWN. SECOND SNAP RING IS NO LONGER USED OR REQUIRED.

NOTE: EFFECTIVITY DATES REFER TO DATES NEW EXTRACTOR UNITS ARE SHIPPED FROM THE FACTORY. REPLACEMENT PART EFFECTIVITY MAY DIFFER DUE TO FACTORY INVENTORY LEVELS AT TIME OF PARTS ORDER. CONSULT FACTORY IF UNSURE OF PARTS NEEDED.

DRIVE WHEEL ASSEMBLY

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	43822005	DRIVE WHEEL ASSEMBLY			2
1	43825003	GEARBOX DRIVE WHEEL MOUNT
2	HC0160	400CC RADIAL PISTON MOTOR
3	C0511	WHEEL-POLY-10 X 5"-FLANGE MOUNT
4	HW0514	BOLT-HHCS-1/2"-13 X 2 1/2"
5	HW0110	WASHER-LOCK-1/2"
6	HW0007	NUT HEX 1/2"-13

IDLER CASTERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	C0500-1	CASTER-RIGID-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"		FOR CYL. BRACKET POSITION	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	43835001	STANCHION-POWER			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
14	HW1051	EYE BOLT-3/16-16 X 5 1/2"			2
15	HW0126	WASHER-FLAT-3/8"-FENDER			4
16	HW0107	WASHER-LOCK-3/8"			4
17	HW0005	NUT-HEX-3/8-16			4
18	BD0010	TROLLEY-ENERGY RAIL		AERO-MOTIVE RAIL ONLY	1
19	BD0100	BRUSH-TROLLEY			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43835001	STANCHION-AC POWER			1
2	BD0030	TOW ARM-COLLECTOR TROLLEY			1
3	46838015	SPACER-BLOCK-TOW ARM			1
4	HW1054	U-BOLT-5/16-18 X 2" X 5"-SQUARE BEND			1
5	HW0150	WASHER-FLAT-5/16"-FENDER			2
6	HW0105	WASHER-LOCK-5/16"			2
7	HW0004	NUT-HEX-5/16-18			2
8	BD0031	TROLLEY-ENERGY RAIL		VAHLE RAIL ONLY	1
9	BD0040	BRUSH-PHASE			3
10	BD0041	BRUSH-GROUND			1

† SEE SECTION 4.0.1 FOR STANCHION MOUNTING HARDWARE

CONTROL PANEL

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	ENCLOSURE-CONTROL PANEL-16" X 14" X 6"		CONSULT FACTORY	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		BLANK PANEL WITHOUT HOLES	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			17
6	E0207-1	TRANSFORMER		480VAC TO 120VAC, 0.75 Kva	1
7	HW0302	BOLT-HHCS-1/4-20 X 3/4"			4
8	HW0104	WASHER-FLAT-1/4"-SAE			4
9	HW0003	NUT-NILN-1/4-20			4
10	E1023	WIREWAY		SOLD BY LENGTH	A/R
11	E1024	MOUNTING TRACK		SOLD BY LENGTH	A/R
12	E1020	TERMINAL BLOCK			16
13	E1040	END BARRIER			2
14	E1330	END ANCHOR			4
15	E0341	GROUND LUG			1
16	E0902	FUSE-6A		FLM-6	1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	ENCLOSURE-24" X 16" X 6"		CONSULT FACTORY	1
2	E0123-1	HANDLE-DISCONNECT		INCL. MOUNTING SCREWS	1
3	E0662	RESTRAINT-3/4"-LIQUIDTIGHT		INCL. LOCKNUT	1
4	E0613	RESTRAINT-3/4"		GRIP RANGE .500 TO .625	2
5	E0632	RESTRAINT-3/4"		GRIP RANGE .625 TO .750	1
6	E0618	LOCKNUT-CONDUIT-3/4"			3
7	E0661	RESTRAINT-3/4"-90 DEG-LIQUIDTIGHT		INCL. LOCKNUT	1
8	E0616	RESTRAINT-1/2"		GRIP RANGE .250 TO .375	1
9	E0622	RESTRAINT-1/2"		GRIP SIZE .450 TO .560	2
10	E0617	LOCKNUT-CONDUIT-1/2"			3
11	HW0303	BOLT-HHCS-1/4-20 X 1"			4
12	HW0104	WASHER-FLAT-1/4"-SAE			4
13	HW0103	WASHER-LOCK-1/4"			4
14	HW0002	NUT-HEX1/4-20			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	YE0506	PANEL-COMPONENT MOUNTING		BLANK PANEL WITHOUT HOLES	1
2	YE0205-1	SWITCH-DISCONNECT-80A			1
3	43036007	SHAFT-DISCONNECT			1
4	YE0409	FUSE HOLDER-SINGLE POLE			3
5	E0914	FUSE-10A		FLM-10	1
6	E0902	FUSE-6A		FLM-6	1
7	E0903	FUSE-12A		FLM-12	1
8	YE0402	TERMINAL BLOCK			17
9	YE0405	END BARRIER			2
10	YE0406	END ANCHOR			6
11	E0136	FUSE HOLDER-3 POLE			1
12	YE0901	FUSE-40A		JTD-40-ID	3
13	E1013	BASE-RELAY			1
14	E1012	RELAY-11 PIN			1
15	E0137	FUSE HOLDER-2 POLE			1
16	YE0902	FUSE-10A		KLDR-10	2
17	E0132	CONTACTOR			1
18	E0131	OVERLOAD			1
19	E1023	WIREWAY		SOLD BY LENGTH	A/R
20	E0908	MOUNTING RAIL		SOLD BY LENGTH	A/R
21	E1070	GROUND BAR-4 POSITION			1
22	E1071	GROUND BAR-7 POSITION			1
23	HW1061	SCREW-RHMS-#8-32 X 1"			3
24	HW0130	SCREW-RHMS-#8-32 X 1/2"		TRACK AND WIREWAY MOUNTING HARDWARE (NOT SHOWN)	14
25	HW0133	WASHER-FLAT-#8			14
26	HW0132	NUT-NILN-#8-32			17

TRANSFORMER

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0220	TRANSFORMER		480VAC TO 120VAC, 3kVA	1
2	E0608-1	RESTRAINT-1/2"-90 DEG		GRIP SIZE .450 - .560	2
3	E0617	LOCKNUT-CONDUIT-1/2"			2
4	HW0303	BOLT-HHCS-1/4-20 X 1"			3
5	HW0104	WASHER-FLAT-1/4"-SAE			6
6	HW0103	WASHER-LOCK-1/4"			3
7	HW0002	NUT-HEX1/4-20			3

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	E0309-1	HOUR METER		† INCL. MOUNTING HARDWARE	1
4	N/A	SWITCH-SELECTOR-3 POSITION		ON-OFF-ON, †† SEE NOTES	1
5	E0812	LEGEND PLATE-VACUUM			1
	E0812-M	LEGEND PLATE-MAGNET			1
6	N/A	CONTACT BLOCK-N/O		†† SEE NOTES	2
7	N/A	CONTACT BLOCK-N/C		†† SEE NOTES	2
8	E1083	SWITCH-SELECTOR-3 POSITION	80232001	OFF-ON-OFF	1
9	E1080	CONTACT BLOCK-N/O & N/C	80232001		2

† CURRENT HOUR METER IS 3-BOLT VERSION. REPLACEMENT OF 4-BOLT VERSION WILL REQUIRE NEW MOUNTING HOLES TO BE DRILLED.

†† PARTS NO LONGER AVAILABLE. MUST ORDER NEW SELECTOR SWITCH KIT 80232001.

FOOT SWITCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0301-1	SWITCH-FOOT OPERATED		† SEE NOTES	1
2	E0613	RESTRAINT-3/4"		GRIP RANGE .500 TO .625	1
3	E0515	CORD-14-3-SO/SOW			9’
4	HC0303	BOLT-HHCS-1/4-20 X 1"		IF EQUIPPED	2
5	HC0103	WASHER-1/4"-LOCK		IF EQUIPPED	2

† OPEN-STYLE SWITCH IS A DIRECT REPLACEMENT FOR DISCONTINUED, COVERED-STYLE SWITCH.

GATE SWITCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0312	SWITCH-PUSH BUTTON			1
2	43017041	MOUNT-GATE SWITCH			1
3	HW1077	SCREW-RHMS-#10-24 X 5/8"			2
4	HW0104	WASHER-FLAT-1/4-SAE			2
5	HW0103	WASHER-LOCK-1/4"			2
6	HW0307	BOLT-SHCS-1/4-20 X 1"			2
7	PL0502	GROMMET-3/8" I.D.			1
8	YE0305	SWITCH-ROLLER			1
9	SS0303	WASHER-FLAT-#8			2
10	SS0111	SCREW-SHCS-#8-32 X 1 1/2"			2
11	SS0203	NUT-NILN-#8-32			2
12	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	HW0341	BOLT-FHSCS-1/4-20 X 5/8"			2

120V RECEPTACLE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0611	JUNCTION BOX-4" X 2" X 2"			1
2	E0622	RESTRAINT-1/2"		GRIP SIZE .450 TO .560	1
3	E0617	LOCKNUT-CONDUIT-1/2"			1
4	E0650	RECEPTACLE-DUPLEX		†20A	1
5	E0651	COVER-RECEPTACLE-DUPLEX			1
6	E0655	RECEPTACLE-GFCI		20A	1
7	E0656	COVER-RECEPTACLE-GFCI			1
8	E0654	JUNCTION BOX-4" X 4" X 2"			1
9	E0657	COVER-RECEPTACLE-DUPLEX/GFCI			1
10	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"		MTG HARDWARE (NOT SHOWN)	A/R

† IF DUPLEX RECEPTACLE HAS SPLIT FEED (1 SET OF BLACK & WHITE WIRES FOR EACH PLUG), THE BREAK-OFF FIN MUST BE REMOVED PRIOR TO INSTALLATION.

CONSOLE ENCLOSURE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	ENCLOSURE-6" X 6" X 4 "		CONSULT FACTORY	1
2	E0622	RESTRAINT-1/2"		GRIP SIZE .450 TO .560	1
3	E0608-1	RESTRAINT-1/2"-90 DEG		GRIP SIZE .450 TO .560	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"			6
8	43817087-2	BRACKET-MOUNTING-ENCLOSURE			1
9	HW0303	BOLT-HHCS-1/4-20 X 1"		MOUNTING BRACKET HARDWARE (NOT SHOWN)	2
10	HW0104	WASHER-FLAT-1/4"-SAE			4
11	HW0103	WASHER-LOCK-1/4"			2
12	HW0002	NUT-HEX-1/4-20			2

CONSOLE ENCLOSURE 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

CONSOLE ENCLOSURE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	ENCLOSURE-8" X 8" X 4"		CONSULT FACTORY	1
2	E0616	RESTRAINT-1/2"		GRIP SIZE .250 TO .375	3
3	E0632	RESTRAINT-3/4"		GRIP RANGE .625 TO .750	1
4	E0608-1	RESTRAINT-1/2"-90 DEG		†GRIP SIZE .450 TO .560	4
5	E0623	RESTRAINT-1/2"-90 DEG		†GRIP SIZE .250 TO .375	4
6	E0617	LOCKNUT-CONDUIT-1/2"			11
7	E0618	LOCKNUT-CONDUIT-3/4"			1
8	E1349	SEAL-KNOCKOUT-1/2"		†SEE NOTES	A/R
9	43037003-2	BRACKET-MOUNTING-ENCLOSURE			1
10	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			4
11	HW0303	BOLT-HHCS-1/4-20 X 1"		MOUNTING BRACKET HARDWARE (NOT SHOWN)	2
12	HW0104	WASHER-FLAT-1/4"-SAE			4
13	HW0103	WASHER-LOCK-1/4"			2
14	HW0002	NUT-HEX-1/4-20			2

† RESTRAINTS SHOWN FOR MACHINE EQUIPPED WITH ALL AVAILABLE OPTIONS. MACHINES BUILT WITHOUT CERTAIN OPTIONS WILL HAVE KNOCKOUT SEALS (ITEM #8) INSTALLED IN PLACE OF RESTRAINTS.

CONSOLE ENCLOSURE PANEL

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0135	PANEL-COMPONENT MOUNTING		BLANK PANEL WITHOUT HOLES	1
2	E0908	MOUNTING RAIL		SOLD BY LENGTH	A/R
3	YE0402	TERMINAL BLOCK			14
4	YE0405	END BARRIER			2
5	YE0406	END ANCHOR			2
6	E1074	JUMPER-2 POLE			2
7	E0130	GROUND BAR-7 POSITION			1
8	HW1061	SCREW-RHMS-#8-32 X 1"			2
9	HW0130	SCREW-RHMS-#8-32 X 1/2"		TRACK AND WIREWAY MOUNTING HARDWARE (NOT SHOWN)	2
10	HW0133	WASHER-FLAT-#8			2
11	HW0132	NUT-NILN-#8-32			4

JUNCTION BOX

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	E0613	RESTRAINT-3/4"		GRIP SIZE .500 TO .625	4
4	E0632	RESTRAINT-3/4"		GRIP SIZE .625 TO .750	2
5	E0618	LOCKNUT-CONDUIT-3/4"			6
6	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			6

TOP MODULE JUNCTION BOX

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E1329	JUNCTION BOX-4" X 4" X 2"			1
2	E0662	RESTRAINT-3/4"-LIQUIDTIGHT		INCL. LOCKNUT	1
3	E0632	RESTRAINT-3/4"		GRIP SIZE .625 - .750	1
4	E0618	LOCKNUT-CONDUIT-3/4"			1
5	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			2

SCHEMATICS

HYDRAULICS

POWER UNIT (10 HP)

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-VANE-16 GPM		VARIABLE DISPLACEMENT	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	43846003	REPLACEMENT CARTRIDGE		†† FOR ITEM 15 (NOT SHOWN)	A/R
16	HC0318	GAUGE-PRESSURE			1
17	H0206	PLUG-#4 NPT			1
18	H1108	ADAPTER-#10 JICM X #12 SAEM			1
19	H1522	ADAPTER-#12 JICSW X #12 SAEM		† SEE NOTE	1
20	H1542	ADAPTER-#12 JICM X #12 SAEM			1
21	HC0280	VALVE-CHECK		† SEE NOTE	1
22	H1542	ADAPTER-#12 JICM X #12 SAEM		† SEE NOTE	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

† PARTS NOTED USED ON UNITS BUILT AFTER APRIL, 2001.

†† CARTRIDGES ARE FOR REPLACEMENT ONLY.

RESERVOIR (30 GAL)

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	43842001	RESERVOIR-VERTICAL-30 GAL		INCL. ITEMS 1 THRU 8	1
1	HC0542	GASKET-CHANNEL		SOLD BY LENGTH	7’
2	HC0340	GAUGE-SIGHT		W/ THERMOMETER	1
3	HC0306	STRAINER-SUCTION			1
4	HC0308	FILLER/BREATHER ASSEMBLY			1
5	HW0209	SCREW-RHMS-10-32 X 1/2"			6
6	BI0110	ELBOW-STR-90 DEG-#16 NPT			1
7	HW0402	BOLT-HHCS-3/8-16 X 1"			8
8	H0208	PLUG-#12 NPT			1
9	H1590	ADAPTER-90 DEG-#16 JICM X #16 FNPT			1
10	BI0102	ELBOW-#12 FNPT			1
11	BI0020	NIPPLE-#12 NPT X 3"			1
12	BI0301	TEE-#12 FNPT			2
13	H1502	ADAPTER-#8 JICM X #12 MNPT			1
14	BI0002	NIPPLE-CLOSE-#12 NPT			2
15	HC0307	RETURN LINE FILTER ASSEMBLY		HOUSING AND FILTER	1
16	HC0317	FILTER-RETURN LINE		REPLACEMENT FILTER	1
17	H1509	ADAPTER-#10 JICM X #12 MNPT			2
18	HW0402	BOLT-HHCS-3/8-16 X 1"		MOUNTING HARDWARE (NOT SHOWN)	4
19	HW0108	WASHER-FLAT-3/8"-SAE			8
20	HW0107	WASHER-LOCK-3/8"			4
21	HW0005	NUT-HEX-3/8-16			4

POWER UNIT (20 HP)

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0040	MOTOR-ELECTRIC-20 HP			1
2	HC0357	ADAPTER-PUMP TO MOTOR			1
3	HC0356	PUMP-PISTON-71CC			1
4	HC0358-M	COUPLING BODY-M300-1 5/8" BORE		MOTOR SIDE	1
5	HC0358-I	SPIDER-COUPLING INSERT			1
6	HC0358-P	COUPLING BODY-M300-1 1/4" BORE		PUMP SIDE	1
7	HW0602	BOLT-HHCS-5/8-11 X 2"			2
8	HW0113	WASHER-LOCK-5/8"			2
9	H1604	ADAPTER-90 DEG-#12 JICM X #10 SAEM			1
10	HC0363	ADAPTER-FLANGE-#32 NPT		INCL. O-RING	1
11	HC0240	BLOCK-CHECK VALVE		INCL. CARTRIDGE	1
12	N/A	CARTRIDGE-CHECK VALVE		† REPLACEMENT CARTRIDGE	A/R
13	H0300	ELBOW-STR-90 DEG-#4 NPT			1
14	HC0318	GAUGE-PRESSURE			1
15	HE0704	ADAPTER-SPLIT FLANGE-1"		2-PC ADAPTER, W/ O-RING	1
16	HW0108	WASHER-FLAT-3/8"-SAE			2
17	H0211	ADAPTER-#24 NPT X #12			1
18	E0661	RESTRAINT-3/4"-90 DEG-LIQUIDTIGHT			1
19	HW0513	BOLT-HHCS-1/2-13 X 2 1/4"			4
20	HW0112	WASHER-FLAT-1/2"-SAE			8
21	HW0110	WASHER-LOCK-1/2"			4
22	HW0007	NUT-HEX-1/2-13			4

† CONSULT FACTORY

RESERVOIR (45 GAL)

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	43842010	45 GAL RESERVOIR ASSEMBLY		INCL. ITEMS 1-8	A/R
1	43848005	PLATE-COVER			1
2	HC0308	FILLER/BREATHER ASSEMBLY			1
3	HW0209	SCREW-RHMS-10-32 X 1/2"			6
4	HC0340	GUAGE-SIGHT			1
5	H0208	PLUG-#12 NPT			1
6	HW0302	BOLT-HHCS-1/4-20 X 3/4			8
7	HW0104	WASHER-FLAT-1/4"			8
8	HC0361	HOUSING-FILTER			1
9	HC0354	CARTRIDGE-FILTER		10 MICRON FILTRATION	1
10	HC0362	FLANGE-SUCTION TUBE		INCL. HARDWARE	1
11	43848008	TUBE-SUCTION			1
12	H1569	ADAPTER-45 DEG-#12 JICM X #12 NPT			1
13	H0202	REDUCER-#24 SAE X #12 SAE			1
14	H1622	ADAPTER-90 DEG-#12 SAEM X #12 JICM			1
15	H1644	PLUG-#24 SAE			1
16	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			4
17	HW0107	WASHER-LOCK-3/8"			4
18	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"		MOUNTING HARDWARE (NOT SHOWN)	2
19	HW0405	BOLT-HHCS-3/8-16 X 2"			2
20	HW0108	WASHER-FLAT-3/8"-SAE			8
21	HW0107	WASHER-LOCK-3/8"			4
22	HW0005	NUT-HEX-3/8-16			4

NOTE: RVT SILICONE REQUIRED TO SEAL COVER PLATE AFTER REMOVAL.

VALVE ASSEMBLY

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	80342001	LEVER VALVE RETRO KIT		† REQ’D PRIOR TO 2006	A/R
1	HC0257	VALVE-LEVER		EFFECTIVE FROM 2006 - PRES.	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	HC0248	FIXED FLOW REGULATOR		††14 GPM	1
12	H1521	ADAPTER-#8 JICSW X #8 SAEM		††SEE NOTES	1
13	H1540	ADAPTER-#8 JICM X #8 SAEM		††SEE NOTES	1
14	43817085	PLATE-ADAPTER-VALVE		† NOT SHOWN	1
15	SS0104	BOLT-SHCS-1/4-20 X 5/8"-SST		† NOT SHOWN	4
16	SS0300	WASHER-FLAT-1/4"-SAE-SST		† NOT SHOWN	4

† KIT INCLUDES ITEMS 1 & 14-16. MINOR MODIFICATIONS TO THE DASH BOARD REQUIRED.

†† FOR UNITS SHIPPED APRIL, 2017 TO PRESENT.

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 MNPT			2
7	HC0211	VALVE-ADJUSTABLE FLOW CONTROL			2
8	H1504	ADAPTER-#6 JICM X #4 MNPT			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 FNPT			4
6	H0001	NIPPLE-#4 NPT			4
7	HC0247	FIXED FLOW REGULATOR-2.25 GPM		†SEE NOTES	4
8	H1504	ADAPTER-#6 JICM X #4 MNPT			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

† UNITS BUILT PRIOR TO JANUARY, 2017 EQUIPPED WITH ADJUSTABLE FLOW CONTROLS. FIXED FLOW REGULATORS ARE DIRECT REPLACEMENT FOR ADJUSTABLE FLOW CONTROLS.

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

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	H1507	ADAPTER-#8 JICM X #8 MNPT			1
2	H1521	ADAPTER-#8 JICSW X #8 SAEM			1
3	HC0264	VALVE-CHECK-PILOT TO OPEN			1
4	H1606	ADAPTER-90 DEG-#8 JICM X #8 SAEM			1
5	H1621	ADAPTER-#4 SAEM X #2 NPT			1
6	HC0269	VALVE-ADJUSTABLE FLOW CONTROL			1
7	H1591	ADAPTER-90 DEG-#6 JICM X #2 MNPT			1
8	H1587	ADAPTER-#6 JICSW X #4 MNPT			1
9	H1501	ADAPTER-#8 JICM X #6 MNPT			2
10	43047002	MANIFOLD-PILOT DOWN			1
11	H1579	ADAPTER-90 DEG-#6 JICM X #4 MNPT			2

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	H1612	ADAPTER-90 DEG-#8 JICM X #10 SAEM			1
5	HC0283	VALVE-COUNTER BALANCE		INCL. CARTRIDGE	1
6	43846004	CARTRIDGE-COUNTER BALANCE		REPLACEMENT CARTRIDGE	A/R
7	H1552	ADAPTER-#6 JICM X #6 SAEM			1
8	H1587	ADAPTER-#6 JICSW X #4 MNPT			1
9	H1501	ADAPTER-#8 JICM X #6 MNPT			2
10	43047002	MANIFOLD-PILOT DOWN			1
11	H1579	ADAPTER-90 DEG-#6 JICM X #4 MNPT			2

† CARTRIDGES ARE FOR REPLACEMENT ONLY

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0270	VALVE-ADJUSTABLE FLOW CONTROL		PRESSURE COMPENSATED	1
2	H0007	NIPPLE-#8 NPT			1
3	H1647	ADAPTER-90 DEG-#10 SAEM X #8 FNPT			1
4	H1680	ADAPTER-#10 JICM X #8 MNPT			1
5	H1690	ADAPTER-#10 JICSW X #10 SAEM			1
6	HC0248	FIXED FLOW REGULATOR		14 GPM	1
7	H1521	ADAPTER-#8 JICSW X #8 SAEM			2
8	H1612	ADAPTER-90 DEG-#8 JICM X #10 SAEM			1
9	H1547	ADAPTER-#8 JICM X #10 SAEM			1

CROSS PORT RELIEF

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW0308	BOLT-HHCS-1/4-20 X 2 1/2"			2
2	HW0305	BOLT-HHCS-1/4-20 X 2"			2
3	HW0104	WASHER-FLAT-1/4"-SAE			8
4	HW0103	WASHER-LOCK-1/4"			4
5	HW0002	NUT-HEX-1/4-20			4
6	43058004	PLATE-SPACER			1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0262	VALVE-CROSS PORT RELIEF		INCL. CARTRIDGES	1
2	43046002	REPLACEMENT CARTRIDGE		FOR ITEM 1	A/R
3	H1540	ADAPTER-#8 JICM X #8 SAEM			2
4	H1521	ADAPTER-#8 JICSW X #8 SAEM			3
5	H1507	ADAPTER-#8 JICM X #8 MNPT			3
6	HC0239	VALVE-ADJUSTABLE FLOW CONTROL			2
7	H1568	ADAPTER-45 DEG-#8 JICM X #8 MNPT			1
8	H1606	ADAPTER-90 DEG-#8 JICM X #8 SAEM			1
9	HC0278-TS/QS	SOLENOID-DRIVE CUTOUT			1
10	YE0501	CONNECTOR-SOLENOID		DIN 43650	1
11	43058004	PLATE-SPACER			1
12	E0611	JUNCTION BOX-4" X 2" X 2"			1
13	E0612	COVER-JUNCTION BOX			1
14	E0616	RESTRAINT-1/2"		GRIP SIZE .250 TO .375	2
15	E0617	LOCKNUT-CONDUIT-1/2"			2
16	N/A	SOLENOID-DRIVE CUTOUT		† SEE NOTES	1
17	BI0001	NIPPLE-CLOSE-#8 NPT			1

† PART OBSOLETE. MUST BE REPLACED WITH RETRO KIT PT# 80242007.

NOTE: EFFECTIVITY DATES REFER TO DATES NEW EXTRACTOR UNITS SHIPPED FROM THE FACTORY. REPLACEMENT PART EFFECTIVITY MAY DIFFER DUE TO FACTORY INVENTORY LEVELS AT TIME OF PARTS ORDER. CONSULT FACTORY IF UNSURE OF PARTS NEEDED.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	H1646	ADAPTER-90 DEG-#8 SAEM X #6 FNPT			2
2	H0805	TEE-#6 MNPT			2
3	HC0273	REGULATOR-FIXED FLOW		7.0 GPM	4
4	H1501	ADAPTER-#8 JICM X #6 MNPT			4

COUNTER BALANCE VALVE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0263	VALVE-COUNTER BALANCE			1
1a	43046004	REPLACEMENT CARTRIDGE		† FOR ITEM 1 (NOT SHOWN)	A/R
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

† CARTRIDGES ARE FOR REPLACEMENT ONLY

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" ID			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 MNPT			1
3	H1503	ADAPTER-#12 JICM X #12 MNPT			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

SCHEMATICS

STANDARD AVAILABLE OPTIONS

STROBE & ALARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0317	STROBE LIGHT			1
2	41215014	STANCHION			1
3	HW0401	BOLT-HHCS-3/8-16 X 1"			3
4	HW0107	WASHER-LOCK-3/8"			3
5	HW0108	WASHER-FLAT-3/8"			3
6	E1010	RECEPTACLE-TWIST LOCK		NOT SHOWN	1
7	E1011	PLUG-TWIST LOCK		NOT SHOWN	1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0317-A	AUDIBLE ALARM			1
2	E0654	JUNCTION BOX-4" X 4" X 2"			1
3	00117010-2	MOUNTING BRACKET			1
4	E0616	RESTRAINT-1/2"		GRIP SIZE .250 TO .375	1
5	E0617	LOCKNUT-CONDUIT-1/2"			1
6	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0362	MOUNTING BASE		INCL. RESTRAINT	1
2	E0365	TERMINAL BASE			1
3	E0363	STROBE LIGHT-AMBER-120VAC		†SEE NOTES	1
4	E0364	AUDIBLE ALARM		††SEE NOTES	1
5	SS0118	SCREW-SHCS-#8-32 X 1"			2
6	SS0303	WASHER-FLAT-#8			2
7	SS0203	NUT-NILN-#8-32			2
8	E1010	RECEPTACLE-TWIST LOCK		NOT SHOWN	1
9	E1011	PLUG-TWIST LOCK		NOT SHOWN	1

† FOR UNITS NOT EQUIPPED WITH THE AUDIBLE ALARM OPTION, A CAP (NOT SHOWN) MOUNTS ON TOP THE STROBE LIGHT IN PLACE OF THE AUDIBLE ALARM . CAP INCL. WITH BASE.

†† FOR UNITS NOT EQUIPPED WITH THE STROBE LIGHT OPTION, THE AUDIBLE ALARM MOUNTS DIRECTLY TO THE TERMINAL BASE IN PLACE OF THE STROBE LIGHT.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41235060	STACK LIGHT STANCHION		DISCONTINUED	A/R
2	HW0401	BOLT-HHCS-3/8-16 X 1"			3
3	HW0107	WASHER-LOCK-3/8"			3
4	HW0108	WASHER-FLAT-3/8"			3
REF	43032006	STANCHION ASSEMBLY		INCL. ITEMS 5 THRU 8	A/R
5	43035003	STACK LIGHT STANCHION			1
6	43037007-2	CLAMP BRACKET			1
7	HW0305	BOLT-HHCS-1/4-20 X 2"			4
8	HW0050	NUT-FLANGED-1/4-20			4
9	43037004-2	MOUNTING BRACKET		OVERHEAD GUARD ONLY	1
10	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			2

OVERHEAD GUARD

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43817119-2	GUARD-SIDE		†SEE NOTES	2
2	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			8
3	HW0104	WASHER-FLAT-1/4"-SAE			8
4	HW0406	BOLT-HHCS-3/8-16 X 2-1/2"			5
5	HW0108	WASHER-FLAT-3/8"			10
6	HW0006	NUT-NILN-3/8-16			5

† SIDE GUARDS USED ON UNITS BUILT NOVEMBER, 2013 TO PRESENT. MOUNTING HARDWARE VALID FOR ALL UNITS W/ REMOVABLE OVERHEAD GUARD.

OPERATOR SHIELD

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43814025	OPERATOR SHIELD		†SEE NOTES	1
2	HC0542	GASKET EDGING		(2) @ 38" LG, (1) @ 60" LG	136"
3	43817116-2	BRACKET-TOP			1
4	1412FSW	BOLT-SELF TAP "F"-1/4-20 X 3/4"			2
5	43817117-2	BRACKET-CENTER SUPPORT-OUTSIDE			1
6	43817118-2	BRACKET-CENTER SUPPORT-INSIDE			1
7	SS0114	SCREW-RHMS-#10-24 X 1/2"			3
8	SS0502	LANYARD-8"			2
9	SS0501	PIN-QUICK RELEASE-3/16" X 2"			2
10	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			2

† CONSULT FACTORY FOR UNITS BUILT PRIOR TO NOVEMBER, 2013 WITH PLEXIGLAS BOLTED DIRECTLY TO OVERHEAD GUARD STRUCTURE ON FRONT AND SIDES.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43717116	SHIELD-OPERATOR		†SEE NOTES	1
2	43015010	FRAME-OPERATOR SHIELD WELDMENT			1
3	43017066-2	SUPPORT-SIDE			2
4	43017065-2	SUPPORT-LOWER			1
5	43017067-2	SUPPORT-UPPER			1
6	HW0303	BOLT-HHCS-1/4-20 X 1"			16
7	HW0104	WASHER-FLAT-1/4"-SAE			32
8	HW0103	WASHER-LOCK-1/4"			16
9	HW0002	NUT-HEX-1/4-20			16
10	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			6

† CONSULT FACTORY FOR UNITS WITH PLEXIGLAS BOLTED DIRECTLY TO FRAME.

POWERED ROLLER CUTOUT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E1321A	PHOTO EYE		† POLARIZED	1
2	41217170-2	MOUNT-PHOTO EYE			1
3	HW0216	SCREW-#10-24 X 2"		††SEE NOTES	2
4	SS0202	NUT-NILN-#10-24			2
5	E1321-R	REFLECTOR			1
6	41217171	MOUNT-REFLECTOR			2
7	SS0803	SCREW-RHMS-#6-32 X 5/8"		††SEE NOTES	2
8	SS0125	BOLT-HHCS-1/4-20 X 5/8"		†††SEE NOTES	4
9	HW0103	WASHER-LOCK-1/4"			4
10	HW0104	WASHER-FLAT-1/4"-SAE			4

QUANTITIES PROVIDED ARE FOR SINGLE-SIDED (PRC-1) POWER ROLLER CUTOUT OPTION. FOR UNITS WITH DOUBLE SIDED (PRC-2) OPTION, QUANTITIES ARE DOUBLE.

† POLARIZED PHOTO EYE RECOMMENDED TO PREVENT POTENTIAL OPERATIONAL ISSUES WITH VERY SMOOTH OR SHINY BATTERY CASES.

†† PHOTO EYE & REFLECTOR MOUNTING SCREWS ARE TRIMMED TO LENGTH.

††† PHOTO EYE & REFLECTOR BRACKET MOUNTING SCREWS MAY REQUIRED TO BE GROUND FLUSH TO PREVENT INTERFERENCE WITH GUARDS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0281	SOLENOID VALVE			2
2	E0611	JUNCTION BOX-4" X 2" X 2"			1
3	E0612	COVER-JUNCTION BOX			1
4	BI0001	NIPPLE-CLOSE-#8 NPT			2
5	E0623	RESTRAINT-1/2"-90 DEG		GRIP SIZE .250 TO .375	1
6	E0617	LOCKNUT-CONDUIT-1/2"			3
7	H1600	ADAPTER-90 DEG-#6 JICM X #8 SAEM			2
8	H1546	ADAPTER-#6 JICM X #8 SAEM			2
9	HW0308	BOLT-HHCS-1/4-20 X 2 1/2"			2
10	HW0104	WASHER-FLAT-1/4"-SAE			4
11	HW0103	WASHER-LOCK-1/4"			2
12	HW0002	NUT-HEX-1/4-20			2

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0308	ACTUATOR-PUSH BUTTON			1
2	E0358	CONTACT BLOCK-N/C			1

BUTTON LOCATION ON DASH MAY VARY FROM POSITION SHOWN.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0611	JUNCTION BOX-4" X 2" X 2"			1
2	E0612	COVER-JUNCTION BOX			1
3	E0623	RESTRAINT-1/2"-90 DEG		GRIP SIZE .250 TO .375	3
4	E0616	RESTRAINT-1/2"		GRIP SIZE .250 TO .375	4
5	E0617	LOCKNUT-CONDUIT-1/2"			7
6	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"		MOUNTING BOLTS (NOT SHOWN)	4

LEVEL ASSIST (LAI)

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E1321A	PHOTO EYE			1
2	13537001-2	MOUNT-PHOTO EYE			1
3	PL0502	GROMMET			1
4	43837007	TARGET ANGLE			1
5	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			4
6	E0370	HOUSING-INDICATOR LIGHT		LENS AND LAMP NOT INCL.	1
7	E0371-A	LENS-FLUTED-AMBER			1
8	E0372-120	LAMP-LED		120 VAC	1
9	HW0152	WASHER-5/8" ID		††SEE NOTES	2
10	E1321-RT	REFLECTIVE TAPE		NOT SHOWN	A/R

† LOCATION OF INDICATOR LIGHT ON THE DASH MAY VARY FROM LOCATION SHOWN.

†† WASHERS REQUIRED FOR UNITS THAT DID NOT SHIP WITH LEVEL ASSIST OPTION FROM THE FACTORY.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0611	JUNCTION BOX-4" X 2" X 2"			1
2	E0612	COVER-JUNCTION BOX			1
3	E0623	RESTRAINT-1/2"-90 DEG		GRIP SIZE .250 TO .375	1
4	E0616	RESTRAINT-1/2"		GRIP SIZE .250 TO .375	2
5	E0617	LOCKNUT-CONDUIT-1/2"			3
6	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2'		MOUNTING BOLTS (NOT SHOWN)	2

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 PERFORMING DAILY INSPECTIONS.

OPERATOR'S DAILY CHECKLIST

RECOMMENDED BATTERY EXTRACTOR 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

RESERVOIR	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.

VACUUM EXTRACTION PLANNED MAINTENANCE INSPECTION REPORT

MAGNET 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 fl ush 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 confi rm 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

280292001-i - BATTERY EXTRACTOR SERVICE STAND INSTALLATION INSTRUCTIONS

Tools required:

• None

Notes:

• Refer to kit part # 80292001 or 80392001 for the complete bill of materials supplied.
• Remove ALL batteries from extractor prior to installation / service.
• Installation of service stands requires (2) persons plus a trained battery extractor operator to raise and lower the inner carriage. DO NOT attempt installation with less than (3) persons.

SINGLE LEVEL SERVICE STAND PROPERLY INSTALLED

IMPORTANT:

• Read and understand the Safety and De-energization Procedure TP-606 before starting this procedure.
• Read and understand these instructions completely before starting this procedure.

Procedure:

1. Have a qualified operator raise the inner carriage of the extractor to the required height for installation. For single level applications, the required height will be approximately 25" (64 cm) from the fully lowered position. For double, triple, and quad stack machines, the required height will be approximately 55" (140 cm) from the fully lowered position.
On double, triple, and quad stack battery extractors, the operator either must remain on the operator platform during service or be provided an OSHA approved method of egress. This is not applicable to single level battery extractors as the operator platform height is fixed.
2. Install the stands by engaging the top of the stand into the inner carriage cutouts. Place the bottom channel of the stand over the tube of the outer frame. The top flanges of each stand are tapered to aid in proper alignment of the stand with the inner frame. See Figures 1 & 2.


FIGURE 1



FIGURE 2

3. Once BOTH stands have been properly placed, SLOWLY lower the inner carriage while the stands are held in place.
4. Once the inner carriage is firmly seated on the service stands, verify the stands are securely installed. See Figure 3.


FIGURE 3

TROUBLESHOOTING 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 Affected: All Vacuum Equipped Units

Subject:

Vacuum cup damage and replacement.

Description:

On units which utilize vacuum extraction, the vacuum cups are the most frequently replaced items. This is due to tearing of 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 once engaged on a battery case. This causes the cup to slide along the battery case, typically leading the edge of the cup to curl or roll under. Repeatedly doing so will eventually cause damage to the cup assembly. To prevent 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 curling of the cup edge, BHS recommends a silicone type lubricant be applied on the face of the cup to help the cup slide on the battery case. Using the vacuum cup as a hook to extract the battery by “hooking” the battery eye with the back of the vacuum cup will also lead to cup and mounting hardware damage. The vacuum cup should never be used in this manner.

Repair:

Replace the vacuum cup if it has been torn or is separated from the metal backing plate. BHS offers multiple cup options with a standard mounting layout. All options are available for use on any BHS vacuum equipped extractor. For more information on available vacuum cup options, refer to Tech Tip TT-937. To find out more about proper mounting and hardware, refer to Tech Tip TT-913. These, as well as all of the latest Tech Tips, inspection forms and planned maintenance information, are available online. Go to BHS1.com and click on “Technical Literature” under the “Library” tab for the latest available information.

Vacuum cup damage due to elevation adjustment after attachment to battery

Vacuum cup and mounting hardware damage due to “hooking” battery eye with cup for extraction

MOVING AN INOPERABLE BATTERY EXTRACTOR

Tech Tip TT-902

Models Affected: All Operator Aboard Battery 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 Affected: 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 the oil life is reduced to 250 hours.

Recommendation:

BHS Battery Extractors are shipped from the factory with Shell Tellus 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 Affected: 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 uid. 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 (10 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 sleeve on powered rollers for Battery Extractors.

Description:

Due to the weight of batteries traveling on the powered rollers, the plastic sleeve 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 sleeve 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 and 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.

FIGURE 1

FIGURE 2

Recommendation:

Trimming the plastic sleeve 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.

POWERED ROLLER AFTER TRIMMING

BATTERY EXTRACTOR STIFFENER PLATE KIT

Tech Tip TT-909

Models Affected: All Operator Aboard Battery Extractors

Subject:

Proper mounting of Battery Extractor swing arm cover/stiffener plates.

Description:

The plates that cover the vacuum pump or magnet circuitry on the Battery 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 Plate installed properly

ELECTROMAGNET PERFORMANCE

Tech Tip TT-910

Models Affected: All Magnet Equipped Battery Extractors

Subject:

Without improvement of electromagnetic performance, the integrity of the battery structure, compartment configuration, and compartment roller trays can be compromised.

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
   1. 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.
   2. 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.
   3. Battery Case “Crowning”: A battery case may appear to have a flat 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.
   4. 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.
   5. 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
   1. 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 bouncing 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.
   2. 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 Affected: 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.

For the Aeromotive Energy Rail, check the tow arm and collector trolley on a regular basis to ensure proper height alignment. Verify the hardware is secure and that the tow arm is not bent. Inspect trolley alignment with the energy rail by slowly driving the Battery Extractor the length of the system while checking that the collector trolley remains in-line with the conductor housings. 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.

For the Vahle Energy Rail, the collector trolley is self-aligning when the tow arm is properly mounted. It should be inspected regularly to confirm proper height alignment, as well as ensuring the tow arm does not push against the trolley or become detached from the trolley while driving the machine.

Improper alignment of Aeromotive energy rail energy rail and trolley

Proper alignment of Aeromotive energy rail energy rail and trolley

Proper alignment of Vahle energy rail energy rail and trolley

PROPER VACUUM CUP MOUNTING

Tech Tip TT-913

Models Affected: 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 two hardware kits. The HW-KIT-1 for Automatic Transfer Carriage (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 Operator Aboard Battery Extractor (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

DRIVE WHEEL FAILURE

Tech Tip TT-917

Models Affected: All Operator Aboard Battery Extractors

Subject:

Difficulty or inability for Operator Aboard Battery Extractor (BE) to move when loaded unless pushed to start.

Description:

The BE is driven by two drive wheel assemblies. If one wheel assembly fails, it is possible for the BE to travel unloaded with little or no trouble. Once loaded however, the BE may be difficult or even impossible to start moving with out pushing it with a lift truck. Once moving, the BE may travel normally until coming to a stop where problems moving occur again.

Recommendation:

There are two different processes to check for drive wheel assembly failure.

Machine Loaded

1. Load the BE with two batteries that will produce the problem condition.
2. With someone carefully operating the drive function on the BE, examine the drive

wheel couplings for each drive wheel assembly. A flashlight will be helpful in this examination.

1. If a coupling assembly is found to be turning but the wheel is not, this indicates a

failure of the wheel/shaft connection and repair is necessary.

Machine Unloaded

1. Raise the operator’s end of the BE so that both drive wheels are slightly off the ground.
2. With someone carefully operating the drive function on the BE, examine the drive couplings and the wheels themselves for operation. A flashlight will be helpful in this examination.

Note: It is possible for a failed assembly to still turn without resistance on the wheel.

1. If both wheels appear to be turning, use a large screwdriver or small pry bar to apply pressure to the wheel. If the wheel stops turning when pressure is applied, this indicates a failure of the wheel/shaft connection and repair is necessary.

Repair:

BHS offers several options to repair the drive wheel from a Drive Wheel Repair Kit to a complete Drive Wheel Assembly. Contact the BHS Tech Support Department for the repair parts that best suit your needs.

Top View of Drive Wheel Coupling

Bottom View of Drive Wheel

LIFT CIRCUIT VELOCITY FUSE

Tech Tip TT-919

Models Affected: All Operator Aboard Battery Extractors

Subject:

All BHS Operator Aboard Battery Extractors (BE) are equipped with velocity fuses on each cylinder to prevent sudden, unexpected lowering of the battery compartment. Properly sized velocity fuses will prevent free-fall of the battery compartment in the event of a disconnected cylinder hose, hose breakage, or other component failure that would allow oil in the cylinders to be released at a rapid rate.

Description:

Velocity fuses work by sensing higher than normal oil flow rates exiting the bottom port of the cylinders. When the velocity fuse senses this higher flow, the fuse locks closed, preventing any oil from passing through the fuse. The typical time for a velocity fuse to activate is less than 0.5 second. In the event of a velocity fuse failure, the fuse will fail in the closed position.

Recommendation:

A failed velocity fuse will prevent the cylinder from lowering. If this occurs during normal operation, lowering should be stopped IMMEDIATELY to prevent damage to the BE. It may be possible to reset a locked velocity fuse by raising the carriage a few inches and then lowering it again.

The hydraulic system must be properly maintained to ensure dependable function of the velocity fuses. Proper maintenance will prevent oil contamination which can lead to potential velocity fuse failure.

Repair:

If a velocity fuse is found to be defective, BHS recommends replacing all (4) fuses.

ALWAYS properly secure the inner carriage when servicing any area under the BE, utilizing the BHS Service Stand Kit.

TECHNICAL SUPPORT

Tech Tip TT-922

24 Hour Access to BHS Technical Information

Live Phone Support: Call 1.877.BHS.4YOU (1.877.247.4968) from 8:00 a.m. - 5:00 p.m. Central Time to speak with the BHS Technical Support Team. With a combined experience of over 75 years in assembly, shipping, installation, equipment design, manual publication and quality control, the BHS Technical Support Team can answer all of your questions.

Ken Schwyhart Technical Support Coordinator schwyhart@bhs1.com

Gary Duckett After Market Parts duckett@bhs1.com

After Hours Support: Need a question answered outside of normal business hours? No problem! Just call 1.877.BHS.4YOU (1.877.247.4968), leave a message and our system will alert the on-call service technician to contact you. After hours emergency shipping via air cargo is also available.

Website Library: From available parts kits and the latest Tech Tips, to inspection forms and planned maintenance information, our website is always available. Go to BHS1.com and click on “Library” for the latest information.

DAILY INSPECTIONS

Tech Tip TT-923

Models Affected: All

Subject:

As with all machinery, proper maintenance will greatly extend the useful life of your battery handling equipment. A big part of properly maintaining any equipment is routine inspection of the equipment.

Description:

A proper daily or pre-shift inspection of the battery handling system is important for ensuring proper operation of the equipment as well as the safety of the operator(s). By inspecting the equipment and addressing any issues prior to machine operation, small repairs and adjustments can be made before major repairs are required thus avoiding possible machine failures and saving lost production due to down time.

Recommendation:

As with all material handling equipment, the battery handling equipment should be inspected prior to each use for any visual damage or defects and any required liquids should be checked for proper fill level. Any defects or damage found during the inspection should be addressed prior to operation. The equipment should also undergo scheduled Planned Maintenance (PM) which includes thorough inspection and maintenance performed by trained personnel.

A general "Daily Inspection" form as well as model specific Planned Maintenance (PM) inspection reports can be found on our website. Go to https://na.bhs1.com/media-library/technical-literature/planned-maintenance/

PARTS ORDER INFORMATION

Tech Tip TT-924

Parts ordering and transit times from BHS

BHS will accept parts orders over the phone, but in an effort to avoid possible errors and misunderstandings, a hard copy of your order is appreciated. Orders can be e-mailed to order@bhs1.com and should include a PO number, ship to address, part numbers and quantity required, and requested ship method.

BHS ships all parts orders via UPS ground unless otherwise specified. Items in stock typically ship within three (3) business days of date ordered. Expedited ground shipping is available upon request. Orders requiring same day shipping must be received before 3:00pm Central Time Zone. Orders received after 3:00pm will be processed the following business day. After hours shipping is available but is subject to additional charges.

Requested ship methods other than UPS for parcel shipments (i.e. FedEx) will incur an additional $16.00 handling fee. An account number for collect or third party billing of freight charges for non-UPS shipments must also be supplied. All UPS freight charges are prepaid/added to the invoice. Collect and 3rd party shipping are available upon request (appropriate account number must be supplied at time of order).

Once processed, all orders are confirmed via acknowledgements which are emailed daily to the primary contact on file with BHS.

Transit times shown for orders shipped via UPS ground.

Three Day Select (UPS/ORN), Two Day (UPS/BLU), Next Day (UPS/RED), Saturday and same day (next flight out) delivery are also available. Orders ship from St. Louis, MO 63132.

BE SERVICE INTERVAL

Tech Tip TT-925

Models Affected: All Operator Aboard Battery Extractors

Subject: In Tech Tip #923 we discussed the importance of Daily Inspections to properly maintain your battery handling equipment. Equally important to the Daily Inspection is proper lubrication and scheduled maintenance. This helps prevent issues and ensures optimal performance of your equipment.

Description:

Scheduled lubrication and maintenance at proper intervals can prevent unnecessary wear and tear on machine components.

• Lubricating the drive screw nut and arm carrier bearings every 50 hours (weekly) will reduce friction on the carrier shafts and allow the arm to move freely, reducing stress on the arm traverse components.
• Properly lubricating the idler casters every 200 hours (monthly) can prevent bearing failures requiring wheel replacement.
• Cleaning and oiling of the roller chains every 200 hours (monthly) can prevent rust and debris build-up. Failing to maintain the chains could lead to undue chain and sprocket wear and possible breakage.
• Changing the filter every 300 hours (twice quarterly) prevents contaminants from circulating through the system, possibly clogging ports, causing erratic machine operation.
• Changing the hydraulic fluid every 600 hours (quarterly) prevents internal component wear from fluid deterioration and contamination.
• Every 600 hours (quarterly) the equipment should also undergo scheduled Planned Maintenance (PM) which includes thorough inspection and maintenance performed by trained personnel.

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.

Recommendation:

The BE Manuals contain information on recommended service and the proper intervals in which it should be performed. The most current service information can also be found on our website. Go to BHS1.com and look for the required information in the “Technical Literature” section under the “Library” tab.

WARNING LABELS & PLACARDS

Tech Tip TT-926

Models Affected: All

Subject:

Warning labels and placards are important parts of the machine and should not be overlooked during regular maintenance. All operators and service personnel should be familiar with all labels and their meaning. Warning labels and placards should be legible at all times, and worn or damaged labels should be replaced as soon as possible.

Description:

BHS uses various types of labels and placards to convey potential hazards and operational information on our battery handling equipment.

Graphical Labels are graphic symbols within a safety sign. The shape and color of the graphical label is determined by the purpose for which it is used.

A white graphical symbol inside a blue circle indicates an action shall be taken to avoid a hazard - in this case, read and understand instruction manual prior to use.

A black graphical symbol inside a red circular band with a diagonal bar indicates an action shall not be taken - in this case, do not operate with guards or covers removed.

A black graphical symbol inside a yellow triangle with a black band indicates a potential hazard - in this case, moving chains and sprockets which can crush and cut.

Combination Labels combine a hazard severity panel with supplementary information regarding the hazard.

The hazard severity panels identify the severity of potential hazards as follows:

Notice is used to address practices not related to personal injury.

Caution used with the safety alert symbol indicates a hazardous situation, which if not avoided, can result in minor or moderate injury.

Warning used with the safety alert symbol indicates a hazardous situation, which if not avoided, can result in death or serious injury.

Danger used with the safety alert symbol indicates a hazardous situation, which if not avoided, will result in death or serious injury.

Operational Placards are used to convey actions required in machine operation such as valve handle movement and switch position.

Recommendation:

Replace any labels that are worn, illegible or missing. Visit BHS1.com to find the Label Replacement Kit for your equipment or contact BHS for more information.

Vacuum Pump and Filter Cleaning

Tech Tip TT-927

Models Affected: Models Affected: All Models Equipped with Vacuum Extraction

Subject:

Decreased performance of the vacuum pump due to dust accumulation inside the pump.

Description:

When operating in dirty or dusty environments, fine particulate can pass through the internal vacuum pump filters, causing a build up of dust inside the vacuum pump. This build up can cause the vacuum pump to operate inefficiently, eventually leading to complete loss of vacuum. This fine particulate can also clog the internal filters causing loss of vacuum.

Recommendation:

If loss of vacuum occurs and all other vacuum system components are found to be in working order, then the vacuum pump can be carefully disassembled and cleaned.

Repair:

1. Remove the vacuum pump head.
   
   Use care not to damage the gasket.
2. Remove the (2) foam filters from the head and clean using compressed air.
3. Clean the valve plate with compressed air, careful not to damage the leaf valve or valve limiter.
4. Reinstall the filters into the head and reassemble the vacuum pump.

Note: Units built after January 1, 2010 are equipped with additional in-line filters. These filters should be cleaned or replaced regularly to avoid dust build up inside the vacuum pump. The in-line filters may also be installed on units manufactured prior to 2010.

Contact the BHS Tech Support Department for more information regarding vacuum pump cleaning and/or in-line filters.

PARTS KITS

BE-TS W/ VACUUM SPARE PARTS KIT

P/N: BE-SPKV-TS

(For Units Built Dec. 2014 to Present)

QTY	PART#	DESCRIPTION	QTY	PART#	DESCRIPTION
1	00162003	VACUUM CUP ASSEMBLY-12”	1	HC0233	BRANNON LEVER VALVE
1	43822001-6B	DRIVE WHEEL ASSEMBLY (200cc)	1	HC0236	CROSS PORT RELIEF CARTRIDGE
1	80232001	SELECTOR SWITCH KIT	1	HC0257	LEVER VALVE-LIFT/LOWER
1	C0500-1	CASTER-10” X 5”-POLY	1	HC0354	OIL FILTER
1	E0314	PROXIMITY SENSOR	1	HW-KIT-2	VACUUM STUD KIT
1	E0327	KEY SWITCH	2	P0111	IN-LINE VACUUM FILTER
1	E0351	KEY SET-REPLACEMENT	4	43012007	ROLLER CROWNED SEALED
1	HC0121	100cc HYDRAULIC MOTOR	1	TP-629	HC0236 SETTING PROCEDURE

BE-TS W/ MAGNET SPARE PARTS KIT

P/N: BE-SPKM-TS

(For Units Built Dec. 2014 to Present)

QTY	PART#	DESCRIPTION	QTY	PART#	DESCRIPTION
2	41657003	COVER-PROXIMITY SENSOR	1	80252014	MAGNET STUD SPRING KIT
1	43822001-6B	DRIVE WHEEL ASSEMBLY (200cc)	1	HC0236	CROSS PORT RELIEF CARTRIDGE
1	80232001	SELECTOR SWITCH KIT	1	E0325	FUSE-MAGNET-7A
1	E0314	PROXIMITY SWITCH	1	E0370	PILOT LIGHT HOUSING
1	C0500-1	CASTER-10" X 5" POLY	1	E0371-A	PILOT LIGHT LENS (AMBER)
1	HC0121	100CC HYDRAULIC MOTOR	1	E0372-120	LAMP-120V-T2
1	HC0233	BRANNON LEVER VALVE	4	43012007	ROLLER CROWNED SEALED
1	HC0257	LEVER VALVE-LIFT/LOWER	4	HW0115	WASHER-LOCK-3/4"
1	HC0354	HYDRAULIC OIL FILTER	4	HW0011	NUT-HEX-3/4-16
1	E0327	KEY SWITCH	1	TP-629	HC0236 SETTING PROCEDURE
1	E0351	REPLACEMENT KEY SET

BATTERY EXTRACTOR BE-TS SUPPLEMENTAL HOSE KIT

P/N: 80342003

Hose Size	Hose Part #	Hose Length	Hose Ends	Hose End Part #
1/4"	HE0001	134"	#6 JIC Swivel	HE0402
1/4"	HE0001	69"	#6 JIC Swivel	HE0402
3/8"	HE0002	188"	#8 JIC Swivel	HE0502
3/8"	HE0002	86"	#8 JIC Swivel / #6 JIC Swivel	HE0502/HE0501
3/8"	HE0002	42"	#8 JIC Swivel	HE0502
3/8"	HE0002	31"	#8 JIC Swivel / #10 JIC Swivel	HE0502/HE0503
1/2"	HE0003	32"	#10 JIC Swivel / #8 JIC Swivel	HE0602/HE0601
1/2"	HE0003	7"	#10 JIC Swivel / #12 JIC Swivel	HE0602/HE0603
1/2"	HE0003	240"	#10 JIC Swivel / #12 JIC Swivel	HE0602/HE0603
1/2"	HE0003	159"	#8 JIC Swivel / #12 JIC Swivel	HE0601/HE0603
1/2"	HE0003	30"	#8 JIC Swivel	HE0601
1/2"	HE0003	10"	#10 JIC Swivel	HE0602
1/2"	HE0003	13.5"	#10 JIC Swivel / #10 SAE-90° Swivel	HE0602/HE0604
1"	HE0005	38"	#16 JIC Swivel / #20 JIC Swivel	HE0801/HE0802
3/8" Rhino	HE0006	245"	#8 JIC Swivel	HE0502
3/4" Rhino	HE0007	264"	#12 JIC Swivel	HE0701

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

10" 3 PC. VACUUM CUP ASSEMBLY

P/N: 00162004

QTY	PART#	DESCRIPTION
1	00166002	CASTING-10" VACUUM CUP
1	00165002	FRONT PLATE-10" VACUUM CUP
1	00164004	RUBBER PAD-10" VACUUM CUP
8	HW0311	BOLT-FHSCS-1/4-20 X 3/4"

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"
4	HW0424	NUT-JAM-3/8-16

BATTERY EXTRACTOR MAGNET STUD KIT

P/N: 80252006

(For Units Built Prior To Nov. 2014)

QTY	PART#	DESCRIPTION
4	HW0433	STUD-1/2-13 X 5"
4	HW0008	NUT-NILN-1/2-13
4	HW0007	NUT-HEX-1/2-13
12	HW1002	SPRING-1/2"
16	HW0111	WASHER-FLAT-1/2"
4	HW0514	Bolt-HHCS-1/2-13 X 2 1/2"

BATTERY EXTRACTOR MAGNET STUD KIT

P/N: 80252014

(For Units Built Nov. 2014 to Present)

QTY	PART#	DESCRIPTION
4	HW0514	BOLT-HHCS-1/2-13 X 2 1/2"
4	HW1002	SPRING-1/2"
8	HW0111	WASHER-FLAT-1/2"
4	HW0007	NUT-HEX-1/2-13

BE Magnet Proximity Cover Plate Kit

P/N: 80252015

QTY	PART#	DESCRIPTION
1	41657003	COVER-PROXIMITY SENSOR HOUSING
4	HW0138	SCREW-FHSCS-#8-32 X 3/8

BATTERY EXTRACTOR MAGNET PIVOT STOP RETRO KIT

P/N: 80252012

QTY	PART#	DESCRIPTION
1	43057029	STOP-PLATE
2	43058003	SLEEVE-STOP
2	43057030	SUPPORT-CABLE
2	PL0501	GROMMET-1/2"
2	HW0509	BOLT-HHCS-1/2-13 X 4 1/2"
2	HW0008	NUT-NILN-1/2-13
1	80252012-i	INSTALLATION INSTRUCTIONS

BE SWING GATE SPRING KIT

P/N: 80292008

QTY	PART#	DESCRIPTION
1	HW9001	SPRING-GATE
4	HW0816	#10-16 X 3/4" SELF DRILLING HHCS
1	80292008-i	INSTALLATION INSTRUCTIONS

BATTERY EXTRACTOR SWING ARM / STIFFENER PLATE KIT

P/N: 80252005

QTY	PART#	DESCRIPTION
1	43055002	SWING ARM-LH
1	43055004	SWING ARM-RH
2	43057021	STIFFENER-SWING ARM
12	HW0403	BOLT-HHCS-3/8"-16 X 1-1/4"
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 2	PART# PT0413	DESCRIPTION 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 SWING ARM STIFFENER PLATE KIT

P/N: 80252004

QTY 2	PART# 43057021	DESCRIPTION STIFFENER-SWING ARM
12	HW0403	BOLT-HHCS-3/8"-16 X 1-1/4"
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	C0510-1	WHEEL-POLY-10" X 5"
1	43822003	DRIVE WHEEL SHAFT
2	PT0430	FLANGE BEARING-4 BOLT-1 1/2"
1	43897004	KEY-3/8" X 4 3/4"
1	HW1110	RETAINING RING-1 1/2"

BE-TS/QS DRIVE WHEEL SHAFT KIT

P/N: 80322002

QTY	PART#	DESCRIPTION
1	43822003	DRIVE WHEEL SHAFT
1	HW1110	RETAINING RING-1 1/2"

BE-TS/QS 400CC SPLINE DRIVE CONVERSION KIT

P/N: 80322003

QTY 1	PART# HC0126-6B	DESCRIPTION MOTOR-HYDRAULIC-400CC-1" SPLINE
1	PT0330	SPROCKET-FLOOR DRIVE
1	43822003	DRIVE WHEEL SHAFT
1	PT0321	COUPLING-CHAIN-#50
1	HW1110	RETAINING RING-1 1/2"

BE-TS/QS LIFT VALVE RETRO KIT

P/N: 80342001

NOTE: FOR UNITS BUILT PRIOR TO 2006 WITH DISCONTINUED LIFT VALVE PT# HC0255

QTY	PART#	DESCRIPTION
1	HC0257	LIFT VALVE
1	43817085	ADAPTER PLATE
1	43843001	TEMPLATE
4	SS0104	SHCS-1/4-20 X 5/8"
4	SS0300	WASHER-FLAT-1/4"-SAE
1	80342001-i	INSTALLATION INSTRUCTIONS

BATTERY EXTRACTOR FLOOR DRIVE CUTOUT SOLENOID VALVE RETRO KIT

P/N: 80242007

QTY 1	PART# HC0278	DESCRIPTION SOLENOID VALVE
1	YE0501	DIN CONNECTOR
1	43058004	SPACER PLATE
1	E0611	4" X 2" X 2" JUNCTION BOX
1	E0612	JUNCTION BOX COVER
1	E0623	1/2" 90 DEG CABLE RESTRAINT
2	E0616	1/2" CABLE RESTRAINT
3	E0617	1/2" CONDUIT LOCKNUT
30"	E0504	16-2 SO CABLE
6	E0433	CRIMP CONNECTOR
2	HW0305	BOLT-HHCS-1/4-20 X 2"
4	HW0104	WASHER-FLAT-1/4"-SAE
2	HW0103	WASHER-LOCK-1/4"
2	HW0002	NUT-HEX-1/4-20
2	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"
1	80242007-i	INSTALLATION INSTRUCTIONS

BATTERY EXTRACTOR SELECTOR SWITCH KIT

P/N: 80232001

QTY	PART#	DESCRIPTION
1	E1083	SELECTOR SWITCH-3 POSITION-30MM
2	E1080	CONTACT BLOCK- N/O & N/C-30MM
2	E1046	#14 MTW - BLACK
1	E1056	#14 MTW - RED
1	E1056-1	#14 MTW - GREEN
1	E1065	#14 MTW - WHITE
6	E0433	CRIMP CONNECTOR
1	80232001-i	INSTALLATION INSTRUCTIONS

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

P/N: 80392001

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

BATTERY EXTRACTOR BE-42-1-DS/TS SERVICE STAND KIT

P/N: 80392003

NOTE: EACH STAND WEIGHS 42 LBS

QTY	PART#	DESCRIPTION
2	46815003	SERVICE STAND
1	80392003-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

STATEMENT OF WARRANTY

Statement of Warranty

Click here for details on BHS' Statement of Warranty.