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 MBE (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 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

LABELS & PLACARDS

GENERAL INFORMATION

SPECIFICATIONS

UNPACKING

The following instructions will guide you through the basic steps necessary to remove the MBE from its shipping skid.

The MBE drive wheel sets below the shipping skid cross boards. Use care not to damage the drive wheel when handling the unit from the operator end. See Figure 1.


FIGURE 1




1. Position the MBE in an area allowing ample space to position a lift truck on each side of the MBE.
2. Carefully remove any shrink wrap, then cut and remove all banding material securing the MBE to the shipping skid.
3. Adjust the forks of the lift trucks to be used to lift the MBE to their widest positions.
4. Postition the forks of the lift trucks directly under the arrows of the "lift point fork placement" labels on both sides of the MBE. See Figure 2.


FIGURE 2

5. Slowly insert the forks appoximately 12" under the MBE frame. See Figure 3
The MBE drive wheel sets below the shipping skid cross boards. Use care not to damage the drive wheel when handling the unit from the operator end. See Figure 1.


FIGURE 3

6. Once the forks of both lift trucks are properly positioned under the MBE, SLOWLY raise the forks of both trucks simultaneously to lift the MBE from the skid.
7. Raise the MBE until the drive wheel clears the skid and remove the skid from under the MBE.
8. SLOWY lower the MBE to the floor.
9. Lower the forks to the floor, remove the forks from under the MBE, and exit the lift trucks from the area.

OPERATING CONTROLS

D.C. CABLE CONNECTIONS

The following instructions will guide you through the basic steps necessary to charge the powerhead battery. Refer to the powerhead manual for complete instructions, warnings and safety procedures.

1. Disconnect the Extractor Input and Extractor Battery connectors.

DO NOT charge the powerhead battery with the Extractor Input connected. Damage to extractor components may occur.

2. Disconnect the Powerhead Battery connector from the Powerhead input labeled "TO DRIVE" and connect it to the Battery Charger connector labeled "TO CHARGE".

3. Plug the battery charger cord into a 110V outlet.

OPERATING INSTRUCTIONS

The following instructions will guide you through the basic steps necessary to operate and change batteries with an MBE.

Operators must be equipped with all necessary PPE and be properly trained in handling industrial lead-acid lift truck batteries.

1. If not already in place, position industrial truck (pallet or lift truck) which requires a battery change in the appropriate staging area.
2. Disconnect the battery leads and remove any battery restraints.
3. Move the MBE into position such that the battery compartment of the industrial truck is aligned with the roller compartment of the MBE.
4. Raise the battery safety stop.
5. Depress the "up" or "down" button on the control pendant to adjust the vertical height of the MBE battery compartment. Adjust the height of the MBE battery compartment with the battery compartment of the industrial truck or slightly higher. DO NOT exceed 1/4" difference.
6. Depress the “out" button to extend the extractor arm toward the battery.
7. Release the button once the vacuum cup has made contact with the battery.
DO NOT force the cup into the battery after initial contact with the battery is made.
8. Energize the vacuum by turning the switch on the control pendant "on".
9. Depress the "in" button to begin removing the battery from the industrial truck battery compartment while inspecting the vertical alignment of both battery compartments. If vertical adjustment is needed, disengage the vacuum cup prior to adjusting the height of the MBE.
10. Once the battery is entirely inside the MBE battery compartment, carefully lower the battery safety stop. Turn off the vacuum.
11. The battery may now be transported to the charging area.
12. Align the MBE with an open roller compartment in the battery charging area. Be sure to check the vertical alignment of the two roller compartments.
13. Raise the MBE battery safety stop. Lower the battery safety stop on the battery roller stand.
14. Depress the "out" button to move the battery in to the empty roller compartment.
DO NOT force the cup/magnet into the battery after the battery contacts the backstop.
15. Raise the battery safety stop on the battery roller stand and connect the battery to the appropriate charger.
16. Locate and remove a fully charged battery to be installed into the industrial truck by following the above process.
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. Many batteries are a tight fi t 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.

MANUAL UNLOADING

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

Manual unloading of the MBE is not recommended. In the event of power loss or an operational malfunction of the MBE not allowing a battery to be unloaded using normal operating procedures, only repairs required to safely maneuver the MBE to a position allowing safe unloading using normal operating procedures 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.

PARTS SECTIONS

CHASSIS

POWERED TRANSMISSION

IDLER WHEELS

CAM FOLLOWERS (INNER FRAME)

ROLLERS

SLIDE STRIPS

DROP BAR / RUBBER BUMPERS

GUARDING

HOSE CARRIER

LABELS

EXTRACTOR ARM

STANDARD EXTRACTOR ARM

VACUUM CUPS

PNEUMATICS

VACUUM PUMP

HYDRAULICS

POWER UNIT

ARM DRIVE MOTOR

CROSS PORT RELIEF VALVE

CONTROL VALVES

CYLINDER

HOSES

ELECTRICAL

CONTROL PENDANT

ENCLOSURE

SWITCHES

CABLES & CONNECTORS

ELECTRICAL SCHEMATIC

PARTS KITS

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.

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