IOP-402 BE-QS

TP-625 - SAFETY AND DE-ENERGIZATION PROCEURES

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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.

DO’s AND DON’T’s

• DO NOT exceed the maximum capacity of the BE.

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

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

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

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

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

• DO NOT drive the BE into the end stops.

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

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

• DO NOT 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.


FIGURE 2

4. To de-energize the entire BE, including the electrical enclosure,disconnect power to the BE 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.
5. Actuate all hydraulic levers in both directions to release any stored hydraulic pressure. See Figure 3.
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 3

LABELS & PLACARDS

GENERAL INFORMATION

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.

Emergency Stop – Located on the dash (see above). Will stop all functions immediately, locking all hydraulics in place. To use, press down on the red button.

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. (Not shown)

Gate Switch – The gate must be fully closed for the BE to operate. (Not shown)

OPERATION OVERVIEW

• The controls consist of three, manually operated, hydraulic control valves and a selector switch which controls the vacuum cup or magnet.

• 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 foot switch or press the emergency stop button and all functions will stop immediately, locking all hydraulics in place.

• To ensure smooth operation, all valve movements should be made in a slow, deliberate motion.

OPERATING INSTRUCTIONS

PRE-CHANGE OUT PREPARATION

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

DISCHARGED BATTERY REMOVAL

1. Move the extractor left or right to position the center of compartment with the center of the lift truck battery compartment.
2. Align the extractor’s roller compartment height with the lift truck’s battery compartment.
3. Move the extractor arm toward the battery until the vacuum cup/magnet contacts the battery.
DO NOT force the cup/magnet to the battery after initial contact with the battery is made.
4. Energize the vacuum/magnet by turning the selector switch on.
5. Move the extractor arm away from the lift truck back into the battery compartment, removing the discharged battery fully into the extractor compartment.
6. Turn of the vacuum/magnet.

DISCHARGED BATTERY RETURN

1. Move the extractor left or right to position the center of the compartment with center of an empty battery rack compartment.
2. If required, adjust the extractor compartment height to the empty battery compartment.
3. Move the battery fully into the empty battery compartment by moving the extractor arm out.
DO NOT force the cup/magnet into the battery after the battery contacts the backstop.
4. Engage the battery safety stop and connect the battery to the charger as required.

CHARGED BATTERY RETRIEVAL

1. Locate a charged battery for the appropriate type of lift truck being changed.
2. Disconnect the desired battery from its charger and disengage the battery safety stop.
ALWAYS be sure charging has been completed and the charger is not still charging the battery. Dangerous sparking/arcing can occur if the battery is unplugged from the charger while charging.
3. Move the extractor left or right to position the center of compartment with the center of the battery compartment.
4. If required, adjust the extractor compartment height to the battery rack level.
5. Move the extractor arm toward the battery until the vacuum cup/magnet contacts the battery.
DO NOT force the cup/magnet to the battery after initial contact with the battery is made.
6. Energize the vacuum cup/magnet by turning the selector switch on.
7. Move the extractor arm away from the battery rack back into the battery compartment, removing the charged battery fully into the extractor compartment.
8. Turn off the vacuum/magnet.

OPERATING INSTRUCTIONS

CHARGED BATTERY INSTALLATION

1. Drive the extractor back to the lift truck and align the roller compartment containing the charged battery as performed in steps 1 and 2 of ”Discharged Battery Removal”.
2. Move the charged battery toward the lift truck compartment by moving the extractor arm out, verifying precise battery alignment.
Many batteries are a tight fit into the lift truck battery compartments. Care MUST be taken to ensure alignment is precise to avoid damage to the battery, lift truck, and/or battery extractor.
3. Adjust the extractor vertically as well as horizontally, if needed.
4. Fully insert the charged battery into the lift truck.
DO NOT force the cup/magnet into the battery after the battery is fully inserted into the lift truck.
5. Retract the extractor arm into the extractor compartment.
6. Fully lower the extractor. Drive the extractor out of the immediate area.
7. Turn off the key switch, remove the key from the switch and carefully exit the extractor.
8. Secure the newly installed battery in the lift truck and reconnect the battery cables.
9. Return the 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.

MANUAL UNLOADING

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

In the event of power loss or an operational malfunction of the BE not allowing a battery to be unloaded using normal operating procedures, it is recommended a battery be removed from the BE using certified and approved vertical extraction methods and devices.

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

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

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

SPARE PARTS LIST

Refer to the Spare Parts Kit (BE-SPKV-SS or BE-SPKM-SS) at the beginning of Section 9 for the list of items recommended by the factory to have on hand for BE-36-1-SS models to minimize any downtime due to minor breakdown that may occur under normal operating conditions.

Use only BHS approved replacement parts.

BHS recommends that a full maintenance inspection report similar to the one provided be done at least once a month.

Any parts found to be excessively worn or damaged should promptly be replaced unless said parts pose a safety risk to the operator and/or extractor, in which case the unit should be removed from service until the problem(s) are remedied (See Operator’s Daily Checklist.)

PARTS SECTIONS

CHASSIS

CAM FOLLOWERS

CROSS BAR

OPERATOR CONSOLE & GATE

OPERATOR PLATFORM

TRACK GUIDANCE

POWER TRANSMISSION

ROLLERS

GUARDS

DRIVE AND IDLER WHEELS

DRIVE WHEEL ASSEMBLY

IDLER CASTERS

ELECTRICAL

MOUNTING HARDWARE

OPERATOR CONSOLE

GATE SWITCH

AC POWER STANCHION

CONTROL PANEL

JUNCTION BOX

MAGNET CORDS

MAGNET CONTROL BOX

MAGNET ASSEMBLY

ELECTRICAL DIAGRAMS

HYDRAULICS

CONTROL VALVES

HYDRAULIC HOSES

RESERVOIR

LIFT CYLINDER

EXTRACTOR ARM MOTOR

POWER UNIT

MISC. COMPONENTS

HYDRAULICS DIAGRAMS

EXTRACTOR ARM

VACUUM CUP HARDWARE

VACUUM CUPS

EXTRACTOR ARM

PNEUMATICS

VACUUM PUMP

LABELS AND DECALS

OPERATOR CONSOLE

INSIDE CHASSIS

OUTSIDE CHASSIS

ELECTRICAL ENCLOSURES

MAGNET ENCLOSURE

SERVICE AND MAINTENANCE

DAILY INSPECTION LIST

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

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

2. Verify all guards are in place.

3. Inspect the AC power feed for any damage.

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

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

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

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

8. Verify extractor path is free of obstructions.

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

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

USE FORM IF-5008 WHEN PREFORMING DAILY INSPECTIONS.

OPERATOR'S DAILY CHECKLIST

LUBRICATION INTERVALS

PARTS KITS

STATEMENT OF WARRANTY AND LIABILITY

STATEMENT OF WARRANTY AND LIABILITY

Battery Handling Systems, Inc., or its subsidiary that sells the equipment (BHS) warrants to the original purchaser of its equipment, that the equipment will be free from defects in material and workmanship under normal and proper use, operation and maintenance for a period of 13 months from date of shipment to the original purchaser with respect to: frames, weldments, electric drives, motors (except brushes), motor driven pumps, valves, and drive wheel assemblies (except wheels).

The above warranty will remain in effect with respect to all other parts for a period of ninety (90) days after shipment. Bulbs, fuses and filters are not warranted unless found to be defective prior to use or ninety (90) days after shipment, whichever occurs first.

BHS will, at its option, either provide parts and labor to repair or replace, or grant a credit or refund of the purchase price of, any equipment or part which is determined by BHS to be defective within the above mentioned warranty period, provided BHS’ procedures for warranty claims are followed. These procedures are set forth on the reverse side hereof and are also available upon request. Repaired or replacement equipment and parts will carry the foregoing warranty for the remainder of the original warranty period or ninety (90) days from the date of shipment, whichever is longer.

BHS will also cover normal ground freight charges such as ground UPS, common carrier, etc. The cost of any express delivery, if requested, will be the sole responsibility of the purchaser, and the purchaser agrees to provide its account number with its preferred carrier to BHS or to pay the entire cost of express delivery as a condition of BHS’ provision of such express delivery. Unless authorized in writing by BHS, the foregoing warranty does not cover the cost of removal or reinstallation (or the cost of other activities ancillary thereto), the cost of which will be borne solely by the purchaser.

A claimed defect must be discovered during the applicable warranty period, and notice of any claimed defect must be reported immediately to BHS or an authorized dealer prior to repair, replacement or refund or credit in accordance with the BHS warranty and warranty procedures, but in no event more than thirty (30) days after discovery of the claimed defect.

BHS’ warranty does not cover incidents of abuse, misuse, accidents, overloading, improper installation, repair or maintenance (other than by BHS), or application of products not in accordance with the instruction manual and product application bulletins. BHS’ warranty does not cover incidents or defects where the equipment has been modified or used in conjunction with other products without the prior written approval of BHS.

This warranty does not cover accessories and attachments not manufactured by BHS. The original manufacturer’s warranty, if any, for such accessories or attachments takes precedence and all claims shall be directed to their respective manufacturers.

ANY LITIGATION TO ENFORCE THE FOREGOING WARRANTY MUST BE COMMENCED NO LATER THAN ONE (1) YEAR AFTER DISCOVERY REASONABLY SHOULD HAVE BEEN MADE OF ANY FACTS OR OTHER INFORMATION SUGGESTING THE EXISTENCE OF A PRODUCT FAILURE OR A PRODUCT DEFECT. THE WARRANTY SET FORTH HEREIN IS THE COMPLETE AND ENTIRE WARRANTY MADE BY BHS, AND THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, NON-INFRINGEMENT OR OTHERWISE, MADE BY BHS. NO PERSON IS AUTHORIZED TO MAKE ANY OTHER OR ADDITIONAL WARRANTY ON BEHALF OF BHS. THE RIGHT TO REPAIR, REPLACEMENT OR CREDIT/REFUND, AS SET FORTH HEREIN, IS THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF THE ABOVE WARRANTY. BHS SHALL NOT BE LIABLE FOR CHARGES OR EXPENSES OF ANY NATURE UNDER THE FOREGOING WARRANTY INCURRED WITHOUT BHS’ CONSENT. FURTHERMORE, UNDER NO CIRCUMSTANCES, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER IN WARRANTY, CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT, OR OTHERWISE), WILL BHS BE LIABLE FOR: (A) INCIDENTAL DAMAGES (EXCEPT AS SPECIFICALLY PROVIDED FOR ABOVE), OR CONSEQUENTIAL, INDIRECT, SPECIAL OR PUNITIVE DAMAGES; OR (B) DIRECT DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE BHS EQUIPMENT GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. “CONSEQUENTIAL DAMAGES” INCLUDE, WITHOUT LIMITATION, LOST PROFITS, BUSINESS INTERRUPTION DAMAGES, LOSS OF USE DAMAGES AND DAMAGE TO REPUTATION OR GOODWILL.

Warranty Procedures

WARRANTY PROCEDURES

Please refer to Battery Handling Systems, Inc.’s Statement of Warranty and Liability (which is set forth on the reverse side hereof or available upon request) for a complete description of BHS’ warranty. In the event of conflict between BHS’ warranty and these procedures, the warranty will control.

Battery Handling Systems, Inc.’s warranty policy is intended to protect original purchasers who submit valid claims, as well as to identify and eliminate claims where product failure is the result of customer abuse, neglect or misapplication.

Step 1: Gather Information The following information must be provided immediately.

• A description of the product that includes, at a minimum, the model, serial number, and hour meter reading (if applicable).

• Customer name, location, and contact information including phone number.

• Installation date, installation provider (dealer), servicing dealer, and selling dealer.

• Any prior repairs, modification, or adjustments.

Step 2: Contact BHS

Contact BHS at: Toll Free: 1.877.247.4968 Local: 1.314.890.0953 Fax: 1.314.423.5948 Email: service@bhs1.com

Step 3: Authorization

BHS will authorize further evaluation, repair, or replacement. A warranty claim form indicating BHS prior authorization for any such action will be issued to claimant. The completed warranty claim form must be submitted with any request for warranty credit.

Step 4: Request RGA Number

• Suspected defective parts must be returned to BHS under an issued Return Goods Authorization (RGA) number.
• BHS will specify the proper disposition of the parts through the issue of an RGA number.
• Return shipment method will also be specified at time of RGA issue. RGAs are good for thirty (30) days from date issued; no credit will be issued for items returned after the RGA has expired.

Step 5: Claim Warranty

• Submit Warranty Claim forms and supporting documents to: Battery Handling Systems, Inc.

P.O. Box 28990 St. Louis, MO 63132

Fax: 1.314.423.5948

Email: service@bhs1.com

• Labor allowance hours are determined by our engineering staff.
• Actual travel time, labor time, and parts costs must be indicated as separate items as provided on the form.

Step 6: BHS will process warranty claim and notify purchaser of final disposition.

1.877.BHS-4YOU

www.bhs1.com