IOP-407 BE-TSN

TP-606 - 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 rotate the arm onto a battery such that any part of the extractor arm, vacuum cup or magnet contacts the top of the battery.

• DO NOT allow anyone to enter the area under the carriage without the service stands properly installed.

• 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 properly support the roller bed when performing service under 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 fluid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section).
• Unexpected movement of hydraulic components.


FIGURE 4

LABELS & PLACARDS

GENERAL INFORMATION

SPECIFICATION DATA

PRE-INSTALLATION CHECK

OPERATING CONTROLS

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.

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. (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 the extractor’s roller compartment height with the lift truck’s battery compartment.
3. Rotate extractor arm into battery compartment aligned in Step 2.
4. Move the extractor arm toward the battery until the vacuum cup/magnet contacts the battery.
DO NOT force cup to battery after initial contact with battery is made.
5. Energize vacuum 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 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.

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.)