IOP-146 PGC-PDC

TP-603 - SAFETY AND DE-ENERGIZATION PROCEDURES

Register your equipment with BHS Optima, BHS's free app.

GENERAL SAFETY

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

• Keep these instructions for future reference.

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

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

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

• PGC units shall only be used indoors in an industrial setting on a hard, nonslip, and level floor without defects including but not limited to: holes, gouges, cracks, drains or obstacles.

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

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

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

• Perform system and safety check before operating.

• Failure to follow these instructions and warnings may result in property damage, personal injury or death.

WORK AREA

• Keep work area clean and well lit. Cluttered work areas and poor lighting can lead to accidents.
• Clean up/contain any fl uid spills immediately to prevent slips or falls.
• Be aware of potential hazards when performing any service or maintenance to the unit.

SERVICE & MAINTENANCE

Service personnel shall wear Personal Protective Equipment (PPE) appropriate for the task being performed.

LOCKOUT/TAGOUT

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

LEAD-ACID BATTERIES-EXPLOSION HAZARD

Do not allow open fl ames or sparks of any kind near a battery. Highly explosive gas is generated when charging a battery that can remain in battery cells for extended periods of time after charging is complete.

• Always wear appropriate PPE including rubber apron, gloves, boots and full face shield when performing service or maintenance to any lead-acid batteries.
• Do not place metal or other conductive objects on top of battery. Arcing may occur causing damage to the battery and/or serious personal injury or death.

• Use only chargers matching the voltage and amperage of the battery being charged. Overcharging a battery can cause damage to the battery, charger and/or serious personal injury or death.
• Turn off charger before disconnecting battery from charger. Arcing between battery and charger connectors can cause damage to the connectors and/or serious personal injury or death.

OPERATIONAL SAFETY

OPERATIONAL SAFETY

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

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

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

• All users and service personnel shall be familiar with the meaning and risks associated with all data plates, warning labels, etc.

• All operators and service personnel shall be aware of potential crush and shear points while operating or servicing the PGC.

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

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

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

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

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

DO’s AND DON’T’s

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

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

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

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

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

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

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

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

• DO NOT run the PGC into the end stops.

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

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

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

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

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

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

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

• Always travel with the battery as low as possible.

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

• DO NOT lift batteries over people.

• DO NOTstep under a suspended battery.

• DO NOToperate PGC unless all persons are (and remain) clear of the suspended battery and moving gantry structure travel path.

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

• DO NOTattempt to lengthen the load chain or repair a damaged load chain.

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

• DO NOTuse the load chain as a sling or wrap the load chain around a battery.

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

• DO NOToperate PGC beyond the limits of the load chain travel.

• DO NOTleave a battery suspended by the PGC unattended unless specific precautions have been taken.

• DO NOTallow the load chain or hook to be used as an electrical or welding ground*.

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

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

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

• Ensure hoist limit switches function properly.

• Warn personnel of an approaching PGC or battery.

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

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

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

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

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

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

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

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

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

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

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

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

LIFTING DEVICE SAFETY

DO’s AND DON’T’s

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

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

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

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

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

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

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

CORRECT HAND PLACEMENT FOR MANEUVERING A MOTIONLESS BATTERY

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

INCORRECT HAND PLACEMENT FOR MANEUVERING A BATTERY