IOP-350 (MBE-42)

TP-626 - SAFETY AND DE-ENERGIZATION PROCEDURES

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GENERAL INFORMATION

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

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

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

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

GENERAL SAFETY

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

• Keep these instructions for future reference.

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

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

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

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

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

• Perform system and safety check before operating.

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

WORK AREA

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

SERVICE & MAINTENANCE

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

LOCKOUT/TAGOUT

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

LEAD-ACID BATTERIES-EXPLOSION HAZARD

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

• Always wear appropriate PPE including rubber apron, gloves, boots and full face shield when performing service or maintenance to any lead-acid batteries.

• Do not place metal or other conductive objects on top of battery. Arcing may occur causing damage to the battery and/or serious personal injury or death.

• Use only chargers matching the voltage and amperage of the battery being charged. Overcharging a battery can cause damage to the battery, charger and/or serious personal injury or death.

• Turn off charger before disconnecting battery from charger. Arcing between battery and charger connectors can cause damage to the connectors and/or serious personal injury or death.

BATTERY WASH WATER HAZARDS

HYDRAULIC HAZARD

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

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

OPERATIONAL SAFETY

OPERATIONAL SAFETY

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

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

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

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

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

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

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

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

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

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

DO’s AND DON’T’s

• DO NOT exceed the maximum capacity of MBE.

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

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

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

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

• DO NOT travel with the stop bar in the raised position.

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

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

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

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

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

DE-ENERGIZATION

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

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


FIGURE 1

2. Depress the IN, OUT, UP, and DOWN buttons of the pendant to relieve any stored hydraulic pressure. See Figure 2.
Failure to release any stored hydraulic pressure could result in injury from: *Escaping hydraulic fluid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section). *Unexpected movement of hydraulic components.


FIGURE 2

3. Disconnect the DC power supply by unplugging/disconnecting the power connector/leads to the powerhead battery. See Figure 3.
Failure to disconnect electrical power to the MBE could result in electrical shock. Serious personal injury or death will occur.


FIGURE 3