IOP 404 BP-MS

TP-617 - SAFETY AND DE-ENERGIZATION PROCEDURES

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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.1.
Failure to lower the inner carriage when performing service to the BTC could result in injury from the roller bed lowering unexpectedly.
2. Turn key on dashboard to the “OFF” position. See Figure 1.


FIGURE 1

3. Disconnect power to the extractor or shut off the electrical branch circuit breaker.
Failure to disconnect electrical power to the BTC could result in electrical shock.
4. Actuate all hydraulic levers in both directions to release 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

LABELS & PLACARDS

GENERAL INFORMATION

The Battery Extractor (BE) is used to remove large batteries from electric industrial trucks, which typically weigh 1000 lb to 5000 lb. It is operated by a single on-board operator. Once removed from the truck, these batteries are placed onto roller stands where the operator will connect them to a charger. A fully charged battery is then removed from the stands with the BE and inserted back into the industrial truck. The BE can raise and lower its roller bed to reach various lift truck battery compartment heights and to all levels of the battery stands. It can also travel via driven wheels along a designated travel path. It is directed along this path by a guide track mounted permanently to the floor.

SPECIFICATION DATA

Pre-Installation

BATTERY ROOM CONSIDERATIONS

It is not permitted for unauthorized persons to enter the BE travel path and its approach areas or for persons to use it for access to other areas. Entry to these zones shall be restricted to specially authorized persons who have been properly informed on and use measures provided for their safety. Each person entering a machine operating area through an open door shall ensure that the main isolator remains disconnected by means of a personal locking device such as a padlock or an equivalent device. Refer to page A.1 for a list of general safety guidelines.

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 pat

Prior to commissioning the battery extractor system into service, the "Battery Extractor System Start-up Check List" (IF-5025) shall be completed and submitted to Battery Handling Systems, Inc. A copy of this form can be found on the following page.

BE System Start-up Checklist

OPERATING CONTROLS

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 four, manually operated, hydraulic control valves and a two position selector switch which controls the magnet.

• The operator shall make certain there are no persons or obstacles in the extractor path prior to traveling forward or reverse.
• The floor drive and magnet near/far valves are moved in the direction of the function travels which they control. The lift/lower valve is pulled toward the operator for “up” and pushed away for “down.” The arm left/right valve is pulled toward the operator to move the arm to the left and pushed away to move the arm to the right.
• In the event of any failure or malfunction, step off the foot switch 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.
• 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 to prevent any battery movement when transporting.
• Ensure there are no projections outside of the carriage before moving

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 the battery during change out.)
3. Board battery extractor and depress foot pedal.
4. Turn key switch to “ON” position

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 compartment height with lift truck’s battery compartment.
3. Rotate magnet to face lift truck.
4. Move extractor arm into battery compartment aligned in Step 2.
5. Move extractor arm toward battery until magnet contacts battery.
DO NOT force cup/magnet to battery after initial contact with battery is made.
6. Energize magnet by turning selector switch on.
7. Move extractor arm away from lift truck toward center of extractor roller bed, removing discharged battery. (Battery should be pulled past the center friction stops and centered left to right in the compartment.)
8. Turn off magnet and move extractor arm away from battery 1” to 2” (25 mm to 50 mm).
9. Move extractor arm out of battery compartment into opposite compartment (if empty) and center arm in carriage.

CHARGED BATTERY RETRIEVAL

1. Locate charged battery for appropriate type of lift truck being changed.
2. 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 the magnet to face the battery to be retrieved.
5. Move arm into empty compartment (if not already positioned there.)
6. Move extractor arm toward battery until magnet contacts battery.
7. Energize magnet by turning selector switch on.
DO NOT force cup/magnet to battery after initial contact with battery is made.
8. Move extractor arm away from battery rack toward center of extractor roller bed, removing charged battery. (Battery should be pulled past the center friction stops and centered left to right in the compartment.)
9. Turn off magnet and move extractor arm away from battery 1” to 2” (25 mm to 50 mm).
10. Move extractor arm out of battery compartment.

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: No magnet is necessary for pushing. DO NOT activate 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 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 extractor arm, 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. Move extractor arm into compartment and SLOWLY push battery into lift truck. (Be sure to watch battery cables for interference.)
6. Return extractor arm to center of roller bed and lower extractor to fully lowered position. Drive extractor out of immediate area.
7. Turn off key switch, remove key from switch, and carefully exit extractor.
8. Secure newly installed battery in lift truck and reconnect battery cables.
9. 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.

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 BTC not allowing the battery to be unloaded using normal operating procedures, it is recommended the battery be removed from the BTC using certifi ed 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

Refer to the Spare Parts Kit (Pt# 80292003) at the beginning of Section 7 for the list of items recommended by the factory to have on hand for BE-MS 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

EQUALIZATION SHAFTS

EQUALIZATION CHAIN

BRIDGE

LIFT CYLINDER CONNECTIONS

ROLLER BED COMPONENTS

GUARDING

LABELS & PLACARDS

EXTRACTOR ARM

MAGNET ASSEMBLY

ARM TRAVERSE ROLLERS

ARM TRAVERSE SHAFT

ARM TRAVERSE MOTOR

ARM TRAVERSE TRACK

MAGNET ROTATION ASSEMBLY

MAGNET TRAVERSE HOUSING

MAGNET TRAVERSE SPROCKETS

MAGNET TRAVERSE CHAIN

MAGNET TRAVERSE MOTOR

HOSE & CABLE CARRIER

HOSE & CABLE CARRIER

DRIVE AND IDLER WHEELS

DRIVE WHEEL ASSEMBLY

IDLER WHEELS

ELECTRICAL

AC POWER STANCHION

CONTROL PANEL

EXTRACTOR ARM BOX (#4)

TERMINAL BLOCK #3

OPERATOR CONSOLE

FOOT SWITCH

WIRING DIAGRAMS

HYDRAULICS

POWER UNIT

RESERVOIR

CONTROL VALVES

LIFT CYLINDERS

DRIVE CIRCUIT

DISTRIBUTION MANIFOLDS

TRANSITION PLATE

HYDRAULIC SCHEMATICS

HOSE CHART

SERVICE AND MAINTENANCE

MAINTENANCE

GENERAL MAINTENANCE INFORMATION The end user is responsible for complying with all maintenance, inspection, and testing requirements.

Inspections and planned maintenance work shall be carried out in regular intervals as listed on the "Recommended Service Intervals" page.

Maintenance shall be carried out safely and so as to ensure safe functioning of the BE between maintenance intervals.

Maintenance and inspections shall only be done by people who are fully acquainted and trained to work on the BE.

Personnel must observe general safety procedures and all directions given in this manual when maintaining the BE.

Maintenance records shall be kept.

Before staring any maintenance work, make sure the main isolator is switched off and locked out. The key shall be kept in a safe place.

If it is necessary to switch on the power to the BE during maintenance, appropriate measures shall be taken to avoid hazards to all people.

Where work can take place in an area adjacent to a machine operating area, a "permit to work" system shall be used to control any access in the travel path and approach area. The permit to work system shall ensure the following:

• Only persons authorized by name, in writing, to perform specific tasks are permitted to work in the area.
• Authorization shall only be given to such persons after they have been given the appropriate and relevant training.
• Such training shall ensure that persons understand the following:
  • The nature of the hazards which can arise when the machine operating area is entered.
  • The precautions to be taken to avoid such hazards.
  • The separate and additional procedures to be followed if it is necessary to enter the machine operating area.

Work shall be carried out from safe positions. If it is not possible to perform work from such positions, staff shall be protected by other temporary measures.

Defects or damages which are found during maintenance work shall be corrected immediately or reported for repair. In the event of an obvious hazard for the operator or machine, the equipment shall be stopped immediately; the machine shall not be started again before the defect has been repaired.

An inspection should be done after any major repairs (e.g. repairs on structural components by welding). The extent of testing required is determined by the extent of repair work done.

Written records shall be kept of the results of all inspections. These records shall contain the findings of the first and subsequent periodic inspections together with those of tests after major repair and conversion work.

The hour meter reading of the next inspection shall be displayed in a clearly visible manner in the operator’s position.

DAILY INSPECTION CHECKLIST

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 magnet for damage to attaching face, cable, plug and proximity switch cover.
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 all safety switches are in proper working order.
8. Verify the extractor path is free from 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-5019 WHEN PREFORMING DAILY INSPECTIONS.

ADDRESS ALL ISSUES WITH THE PROPER PERSONNEL BEFORE PROCEEDING IF ANY OF THE ABOVE CONDITIONS ARE FOUND TO BE DEFECTIVE OR QUEST

STATEMENT OF WARRANTY

Statement of Warranty

Battery Handling Systems, Inc. and its subsidiaries and affiliates (collectively “BHS”) warrants to the original purchaser of its equipment, that the equipment shall be free from defects in material and workmanship under normal and proper use, operation, and maintenance during the applicable warranty period set forth below for the product containing the alleged defect:

• Thirteen (13) months from the 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) only.
• Ninety (90) days from the date of shipment to the original purchaser with respect to all other parts not covered above.
• Bulbs, fuses, and filters are not included in this ninety (90) day warranty, unless found to be defective prior to use or within (90) days of shipment to the original purchaser, whichever occurs first.
  BHS’s warranty obligations hereunder are contingent upon the following conditions: (1) BHS or its authorized dealer is promptly (but in no event later than thirty (30) days following the discovery of the claimed defect) notified of the defect; (2) the purchaser establishes to BHS’s reasonable satisfaction that any goods have been properly installed, maintained, and operated; (3) the purchaser returns the defective goods or any part thereof to BHS; and (4) the purchaser complies with all other warranty procedures required by BHS (such procedures are available upon request). Upon a determination by BHS that a product is defective within the above-mentioned warranty period(s), BHS may, at its exclusive option, either provide parts and labor to repair or replace said defective equipment, or grant a credit or refund of the purchase price of the defective equipment. 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 of the repaired/replaced equipment, whichever is longer.

BHS will cover normal ground freight charges such as ground UPS, common carrier, etc. for the delivery of repaired or replaced equipment or parts covered by this warranty. 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’s provision of such express delivery. Unless expressly authorized in writing by BHS, the foregoing warranty does not cover the cost of removal or reinstallation of equipment (or the cost of other activities ancillary thereto), the cost of which will be borne solely by the purchaser.

This warranty is void in the case of abuse, misuse, abnormal use, accidents, overloading, improper installation, repair, or maintenance (other than by BHS), modification of products, application of products not in accordance with the instruction manual and product application bulletins, or any other reason BHS determines that said product is not operating properly as a result of causes other than defective manufacture.

This warranty shall apply exclusively to products sold to the purchaser by BHS. BHS shall not have any liability or obligation to the purchaser, under this warranty or other- wise, with respect to any defect or failure of performance in products which are not sold or manufactured by BHS, including any such products which are commingled with or incorporated into any BHS products, or any products into which BHS products are incorporated as a system component or otherwise 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 ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MER- CHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, NON-INFRINGEMENT, OR OTHERWISE, ARE HEREBY EXPRESSLY EXCLUDED. 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’S CONSENT. FURTHER, UNDER NO CIRCUMSTANCES, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER IN WARRANTY, CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OR FOR ANY OTHER TORT OR CLAIM), SHALL BHS BE LIABLE TO THE PURCHASER OR ANYONE ELSE FOR ANY: (A) INCIDENTAL DAMAGES (EXCEPT AS SPECIFICALLY PROVIDED FOR ABOVE), OR CONSEQUENTIAL, INDIRECT, SPECIAL OR PUNITIVE DAMAGES RELATIVE TO OR ARISING FROM OR CAUSED DIRECTLY OR INDIRECTLY BY SAID PRODUCTS OR THE USE THEREOF OR ANY DEFICIENCY, DEFECT, OR INADEQUACY OF SAID PRODUCTS; OR (B) DIRECT DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE BHS EQUIPMENT GIVING RISE TO THE CLAIM OR CAUSE OF ACTION, OR AT THE ELECTION OF BHS, THE RESTORATION OR REPLACEMENT OR REPAIR OF SUCH EQUIPMENT. “CONSEQUENTIAL DAMAGES” INCLUDE, WITHOUT LIMITATION, LOST PROFITS, BUSINESS INTERRUPTION DAMAGES, LOSS OF USE DAMAGES, AND DAMAGE TO REPUTATION OR GOODWILL. This Warranty is governed by and construed in accordance with the laws of the State of Missouri, without regard to conflict of law principles. All disputes or controversies arising out of or in connection with this Warranty shall be subject to the exclusive jurisdiction of the U.S. District Court for the Eastern District of the State of Missouri and any and all process in connection with any litigation arising out of such dispute or controversy may be served by registered, certified mail, return receipt requested, outside Missouri, with the same force and effect as if service had been made in Missouri.

If part of this Warranty is held to be invalid or unenforceable, such invalidity or unenforceability shall not invalidate or render unenforceable the entire Warranty, but rather the Warranty shall be construed as if not containing the particular invalid or unenforceable provision.