IOP-403 BE-36-1-SS

TP-625 - SAFETY AND DE-ENERGIZATION PROCEURES

Register your equipment with BHS Optima, BHS's free app.

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 fully lower the roller bed when performing service to the BE 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. To de-energize components external to the electrical enclosure, turn the disconnect switch on the enclosure to the “OFF” position. See Figure 2.
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 off 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

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0505	CAM ROLLER-2 1/4"			4
2	HW0124	WASHER-SHIM-7/8" I.D. X 1-3/8 O.D" X .075"			AR
3	HW0117	WASHER-LOCK-7/8"			4
4	HW0013	NUT-HEX-7/8-14			4
5	PT0507	BEARING-FLANGED LOAD-3"			4
6	05517060	SHIM-SQUARE-.075"			AR
7	HW0142	WASHER-LOCK-1 1/4"			4
8	HW0141	NUT-HEX-1 1/4-12			4

CROSS BAR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05615008	BAR-TOP CROSS			1
2	HW0411	BOLT-HHCS-3/8-16 X 4 1/2"			4
3	HW0108	WASHER-FLAT-3/8"-SAE			8
4	HW0107	WASHER-LOCK-3/8"			4
5	HW0005	NUT-HEX-3/8-16			4

OPERATOR CONSOLE & GATE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05517012-2	COVER-CONSOLE			1
2	HW0301	BOLT-SELF TAP "F"-1/4-20 X 1/2"			4
3	05617032-2	BRACKET-MOUNTING-LOWER			2
4	HW0005	NUT-HEX-3/8-16			10
5	HW0107	WASHER-LOCK-3/8"			10
6	HW0108	WASHER-FLAT-3/8"-SAE			12
7	HW0407	BOLT-HHCS-3/8-16 X 2-3/4"			6
8	HW0402	BOLT-HHCS-3/8-16 X 1"			4
9	05617031-2	BRACKET-MOUNTING-UPPER			2
10	43015004	GATE-OPERATOR			1
11	HW0006	NUT-NILN-3/8-16			1
12	HW0408	BOLT-HHCS-3/8-16 X 3-1/4"			1

OPERATOR PLATFORM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW0403	BOLT-HHCS 3/8-16 X 1-1/4"			8
2	HW0108	WASHER-FLAT-3/8"-SAE			16
3	HW0107	WASHER-LOCK-3/8"			8
4	HW0005	NUT-HEX-3/8-16			8

TRACK GUIDANCE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05615016	GUIDE ARM WELDMENT			2
2	05617047	SUPPORT PLATE			2
3	HW0503	BOLT-HHCS-1/2-13 X 1-1/2"			4
4	HW0112	WASHER-FLAT-1/2"-SAE			8
5	HW0110	WASHER-LOCK-1/2"			4
6	HW0007	NUT-HEX-1/2-13			4
7	PT0510	CAM ROLLER-1 3/4"			4
8	HW0115	WASHER-LOCK-3/4"			4
9	HW0011	NUT-HEX-3/4-16			4

POWER TRANSMISSION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0111	HB50A15 X 5/8" IDLER PITCH PART			2
2	HW0010	NUT-JAM-5/8-11			2
3	HW0114	WASHER-FLAT-5/8"-SAE			A/R
4	HW0603	BOLT-FHSCS-5/8-11 X 2"			2
5	05517033	STOP-EXTRACTOR ARM			2
6	HW0425	BOLT-HHCS-3/8-16 X 1-1/4"		GRADE 8	4
7	HW0107	WASHER-LOCK-3/8"			4
8	PT0402	BEARING-PILLOW BLOCK-1"			4
9	08027002	SHIM-PILLOW BLOCK-14 GA		.075" THICK	AR AR
	08027003	SHIM-PILLOW BLOCK-10 GA		.135" THICK
10	08017021	ROD-THREADED-3/8-16 X 3-1/2"			8
11	HW0108	WASHER-FLAT-3/8"-SAE			8
12	HW0006	NUT-NILN-3/8-16			8
13	PT0107	SPROCKET-5015 X 1"			2
14	00197028	KEY-1/4" X 1-1/4"			3
15	05627001	DRIVE SHAFT			1
16	PT0108	SPROCKET-5024 X 1"			1
17	00158001-24	CHAIN-ROLLER-#50			1
18	PT0102	LINK-CONNECTING-#50			1

ROLLERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	08282001	ROLLER ASSEMBLY		INCLUDES BEARINGS	6
2	08287001	SHAFT-HEX-.75" X 38"			6
3	HW1058	PIN-HITCH			12

GUARDS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05615007	DASHBOARD			1
2	05615005-3	GUARD-CHAIN-LHS			1
3	05615005-4	GUARD-CHAIN-RHS			1
4	HW0301	BOLT-SELF-TAP “F”-1/4-20 X 1/2"			10

DRIVE AND IDLER WHEELS

DRIVE WHEEL ASSEMBLY

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05522007	FLOOR DRIVE ASSEMBLY			1
2	HW0502	BOLT-HHCS 1/2-13 X 1-1/4"			4
3	HW0112	WASHER-FLAT-1/2"-SAE			8
4	HW0110	WASHER-LOCK-1/2"			16
5	43715012	FRAME-FLOOR DRIVE			1
6	C0050-1	WHEEL-8" X 3"-POLY	80222001		1
7	43727008	SHAFT-WHEEL	80222001		1
8	43097005	KEY-1/4" X 3"	80222001		1
9	00197028	KEY-1/4" X 1-1/4"	80222001		1
10	PT0406	FLANGE BEARING-4 BOLT-1 3/16"	80222001	ALLOY CASTING	2
11	HW0504	BOLT-HHCS-1/2-13 X 2"			4
12	HW0007	NUT-HEX-1/2-13			12
13	43727007	SPACER-DRIVE WHEEL			4
14	43797001	ROD-THREADED-1/2-13 X 7"			4
15	43726004	COUPLING BODY-TAPER BORE-#50	80222001		2
16	PT0321	CHAIN-COUPLING-#50		INCL. CONNECTING PIN	1
17	43726003	BUSHING-TAPER LOCK-1 3/16"	80222001	† SHAFT SIDE	1
18	43726002	BUSHING-TAPER LOCK-1"		† MOTOR SIDE	1
19	HW0323	BOLT-HHCS-5/16-18 X 1"	80222001		8
20	43727006	PLATE-MOTOR MOUNTING			1
21	HW0402	BOLT-HHCS-3/8-16 X 1"			4
22	HW0107	WASHER-LOCK-3/8"			4
23	HC0120	MOTOR-HYDRAULIC-160CC			1
24	H1544	ADAPTER-#6 JICM X #10 SAEM			2

† REUSE OF BUSHINGS AFTER DISASSEMBLY NOT RECOMMENDED.

IDLER CASTERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	C0220	CASTER-8" X 3"-POLY			2
	C0080	CASTER-6" X 3"-DUAL FLANGED		FOR UNITS WITH FLAT TRACK	2
2	05517048	SHIM-1/4"			A/R
3	HW0007	NUT-HEX-1/2-13			12
4	HW0110	WASHER-LOCK-1/2"			12
5	HW0112	WASHER-FLAT-1/2"-SAE			24
6	HW0504	BOLT-HHCS-1/2-13 X 2"			12
7	C0220	CASTER-8" X 3"-POLY			1

ELECTRICAL

MOUNTING HARDWARE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW0321	BOLT-HHCS-5/16-18 X 1-1/4"			4
2	HW0106	WASHER-FLAT-5/16"-SAE			8
3	HW0105	WASHER-LOCK-5/16"			4
4	HW0004	NUT-HEX-5/16-18			4
5	HW0002	NUT-HEX-1/4-20			4
6	HW0103	WASHER-LOCK-1/4"			4
7	HW0104	WASHER-FLAT-1/4"-SAE			8
8	HW0303	BOLT-HHCS-1/4-20 X 1"			4

OPERATOR CONSOLE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E1126	SWITCH-SELECTOR-2 POSITION		OFF-ON	1
2	E1006	CONTACT BLOCK-N/O			1
3	E1007	CONTACT BLOCK-N/C			1
4	E1310	SWITCH-EMERGENCY STOP			1
5	E0309	HOUR METER		INCL. MOUNTING HARDWARE	1
6	E1315	PLATE-LEGEND-EMERGENCY STOP			1
7	E0327	SWITCH-KEY		INCL. 2 KEYS	1
8	E0351	KEY-REPLACEMENT SET		INCLUDES 2 KEYS	A/R

GATE SWITCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0301-1	SWITCH-FOOT OPERATED			1
2	E0312	SWITCH-GATE			1
3	HW0307	BOLT-SHCS-1/4-20 X 1"			2
4	E0627	BASE-MOUNTING-TIE WRAP			1
5	E0611	BOX-JUNCTION			1
6	E0612	COVER-BOX-JUNCTION			1
7	E0616	RESTRAINT-1/2"		GRIP SIZE .250" TO .375"	2
8	E0622	RESTRAINT-1/2"		GRIP SIZE .450" TO .560"	1
9	PL0502	GROMMET-3/8" I.D.			1
10	43017041	MOUNT-GATE SWITCH			1
11	HW0307	BOLT-SHCS-1/4-20 X 1"			2
12	HW0103	WASHER-LOCK-1/4”			2
13	HW0104	WASHER-FLAT-1/4-SAE			2

AC POWER STANCHION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05535001	STANCHION-POWER			1
2	E0630	GRIP-CABLE SUPPORT		GRIP SIZE .500" TO .620"	1
3	E0629	SPRING-SHOCK			1
4	E0612	COVER-JUNCTION BOX		INCLUDED WITH ITEM 1	1
5	E0622	RESTRAINT-1/2"		GRIP SIZE .450" TO .560"	1
6	E0617	LOCKNUT-CONDUIT-1/2"			1
7	E0624	CONNECTOR-1/2"			1
8	E0501	CORD-14-4-SO			7'
9	HW1030	U-BOLT-3/8-16 X 2" X 5"-SQUARE BEND			1
10	HW0005	NUT-HEX-3/8-16			4
11	HW0107	WASHER-LOCK-3/8"			4
12	HW0108	WASHER-FLAT-3/8"-SAE			6
13	05517047	RETAINER-STANCHION			1
14	HW0411	BOLT-HHCS-3/8-16 X 4-1/2"			2

CONTROL PANEL

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	X350057	FUSE		4 AMP, CLASS CC, TIME DELAY	2
2	-	SCREW-MOUNTING-SUB PANEL		INCL. WITH ITEM 13	15
3	-	WASHER		INCL. WITH ITEM 13	15
4	E0122-1	BASE-DISCONNECT			1
5	05636004	SHAFT-DISCONNECT			1
6	05638001	TRACK-DISCONNECT			1
7	E0341	GROUND LUG			1
8	05636001	MAGNETIC STARTER			1
9	05636010-1	TRANSFORMER			1
10	05638002	WIREWAY-7 3/8"			1
11	05638003	WIREWAY-7 5/8"			1
12	05638004	WIREWAY-12 3/4"			1
13	05636002	PANEL-COMPONENT MOUNTING			1
14	E1330	END STOP-TERMINAL			4
15	E1020	TERMINAL BLOCK-MEDIUM			8
16	E1040	END TERMINAL-MEDIUM			2
17	05638005	TRACK-MOUNTING-TERMINAL BLOCK			1
18	E0902	FUSE		6 AMP, MIDGET, TIME DELAY	1
19	05636010-2	BLOCK-FUSE TRANSFORMER			1
20	E0613	RESTRAINT-3/4"		GRIP SIZE .500" TO .625"	2
21	E0618	LOCKNUT-CONDUIT-3/4"			2
22	E0608-1	RESTRAINT-1/2"-90 DEG		GRIP SIZE .450" TO .560"	1
23	E0617	LOCKNUT-CONDUIT-1/2"			1
24	E0123-1	HANDLE-DISCONNECT		NOT SHOWN	1

JUNCTION BOX

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05636006	JUNCTION BOX			1
2	HW0301	BOLT-SELF-TAP “F”-1/4-20 X 1/2"			4
3	-	SCREW-MOUNTING-SUB PANEL		INCL. WITH ITEM 1	4
4	E0341	GROUND LUG			1
5	05636005	PANEL-COMPONENT MOUNTING			1
6	E1330	END STOP-TERMINAL			2
7	E1022	TERMINAL BLOCK-SMALL			12
8	E1021	END TERMINAL-SMALL			2
9	05638006	TRACK-MOUNTING TERMINAL BLOCK			1
10	E0616	RESTRAINT-1/2"		GRIP SIZE .250" TO .375"	4
11	E0617	LOCKNUT-CONDUIT-1/2"			5
12	E0623	RESTRAINT-1/2"-90 DEG		GRIP SIZE .250" TO .375"	1
13	E0613	RESTRAINT-3/4"		GRIP SIZE .500" TO .625"	1
14	E0618	LOCKNUT-CONDUIT-3/4"			1
15	E1334	RECEPTACLE-FLANGED-2 POLE		15 AMP	1
16	HW0132	NUT-NILN-#8-32			4
17	HW0130	SCREW-RHMS-#8-32 X 1/2"			4

MAGNET CORDS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	41632003	MAGNET ASSEMBLY			1
2	05636007	CABLE-SUPPLY POWER MAGNET			1
3	E0622	RESTRAINT-1/2"		GRIP SIZE .450" TO .560"	2
4	E0617	LOCKNUT-CONDUIT-1/2"			4
5	05632002	CONTROL BOX-MAGNET			1
6	HW0301	BOLT-SELF-TAP “F”-1/4-20 X 1/2"			4
7	E0608-1	RESTRAINT-1/2"-90 DEG		GRIP SIZE .450" TO .560"	2
8	05637011	CORD-COIIL		14-3 CONDUCTOR SIZE	1
9	E0501	CORD-14-4-SO			A/R
10	E0611	BOX-JUNCTION-4" X 2" X 2"			1
11	E0612	COVER-JUNCTION BOX			1

MAGNET CONTROL BOX

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	05632002	MAGNET CONTROL BOX ASSEMBLY			1
1	E1313	SOCKET-RELAY			1
2	E0331	RELAY-CONTROL			1
3	E1009	BRIDGE RECTIFIER-FULL WAVE			1
4	E0622	RESTRAINT-1/2"		GRIP SIZE .450 TO .560	1
5	E0608-1	RESTRAINT-1/2"-90 DEG		GRIP SIZE .450 TO .560	1
6	E0617	LOCKNUT-CONDUIT-1/2"			2
7	E1020	TERMINAL BLOCK-MEDIUM			6
8	E1040	END TERMNINAL			2
9	E1330	END STOP-TERMINAL			4

MAGNET ASSEMBLY

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	41632003	MAGNET ASSEMBLY		INCLUDES ITEMS 1-16	A/R
1	HW0433	STUD-1/2-13 X 5"	80252006		4
2	HW0007	NUT-HEX-1/2-13	80252006		4
3	HW0112	WASHER-FLAT-1/2"-SAE	80252006		12
4	HW1002	SPRING-1/2"	80252006		12
5	HW0008	NUT-NILN-1/2-13	80252006		4
6	41657003	COVER-PROXIMITY SENSOR HOUSING		FRONT	1
7	HW0138	SCREW-FHSCS-#8-32 X 3/8"			4
8	N/A	GASKET-FRONT		DISCONTINUED	1
9	N/A	GASKET-REAR		DISCONTINUED	1
10	41657002	COVER-PROXIMITY SENSOR HOUSING		REAR	1
11	HW1066	WASHER-LOCK-#6			4
12	HW1065	SCREW-SHCS-#6-32 X 3/8"			4
13	E0337	PILOT LIGHT-RED		110VAC/DC	1
14	E0335	RECEPTACLE-5 PIN MALE		WITH 12" LEAD	1
15	E0617	LOCKNUT-CONDUIT-1/2"			1
16	E0314	PROXIMITY SENSOR			1

ELECTRICAL DIAGRAMS

HYDRAULICS

CONTROL VALVES

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	05542038	EXTRACTOR ARM VALVE ASSEMBLY			1
1	HC0201	MANUAL VALVE		MUST REUSE EXISTING HANDLE	1
2	H1303	ADAPTER-90 DEG-#6 JICM X #8 NPTM			2
3	H0305	ELBOW-STR-90 DEG-#8 NPTM X #6 FNPT			2
4	H1501	ADAPTER-#8 JICM X #6 NPTM			2
REF	05542039	LIFT VALVE ASSEMBLY			1
1	HC0201	MANUAL VALVE		MUST REUSE EXISTING HANDLE	1
2	H1303	ADAPTER-90 DEG-#6 JICM X #8 NPTM			1
3	H0305	ELBOW-STR-90 DEG-#8 NPTM X #6 FNPT			1
4	H1501	ADAPTER-#8 JICM X #6 NPTM			1
5	H1507	ADAPTER-#8 JICM X # 8 NPTM			1
6	H0201	BUSHING-RED-#8 NPTM X #4 FNPT			1
7	H0300	ELBOW-STR-90 DEG-#4 NPT			1
8	HC0218	VALVE-CHECK			1
9	H1504	ADAPTER-#6 JICM X #4 NPTM			1
REF	05542040	DRIVE VALVE ASSEMBLY			1
1	HC0201	MANUAL VALVE		MUST REUSE EXISTING HANDLE	1
2	H1303	ADAPTER-90 DEG-#6 JICM X #8 NPTM			2
3	H0305	ELBOW-STR-90 DEG-#8 NPTM X #6 FNPT			1
4	H1501	ADAPTER-#8 JICM X #6 NPTM			1
5	H1507	ADAPTER-#8 JICM X # 8 NPTM			1

VALVE MOUNTING HARDWARE (NOT SHOWN)

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	HW0322	BOLT-HHCS-5/16-18 X 2"			9
REF	HW0106	WASHER-FLAT-5/16"-SAE			18
REF	HW0105	WASHER-LOCK-5/16"			9
REF	HW0004	NUT-HEX-5/16-18			9

HYDRAULIC HOSES

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	-	VALVE ASSEMBLY-EXTRACTOR ARM		SEE SECTION 4.0.1	1
2	-	VALVE ASSEMBLY-LIFT		SEE SECTION 4.0.1	1
3	-	VALVE ASSEMBLY-DRIVE		SEE SECTION 4.0.1	1
4	00142001-4	HOSE-HYDRAULIC-1/4" X 15.25"			1
5	00142001-2	HOSE-HYDRAULIC-1/4" X 13"			1
6	00142002-1	HOSE-HYDRAULIC-3/8" X 12.875"		(Bal. shown in Fig. 4.1.2 - Item 2)	1
7	00142001-6	HOSE-HYDRAULIC-1/4" X 21.5"		(Bal. shown in Fig. 4.1.2 - Item 4)	1
8	00142001-21	HOSE-HYDRAULIC-1/4" X 35.5"		(Bal. shown in Fig. 4.5 - Item 4)	1
9	00142001-23	HOSE-HYDRAULIC-1/4" X 37.5"		(Bal. shown in Fig. 4.5 - Item 3)	1
10	H1565	ADAPTER-45 DEG-#6 JICM X #4 NPTM			1
11	H1504	ADAPTER-#6 JICM X #4 NPTM			1
12	H0100	COUPLING-#4 NPT			2
13	H0021	NUT-BULKHEAD-#6 JIC			2
14	H0020	UNION-BULKHEAD-45 DEG-# JICM			2
15	00142001-11	HOSE-HYDRAULIC-1/4" X 26.5"		(Bal. shown in Fig. 4.1.2 - Item 7)	1
16	00142002-2	HOSE-HYDRAULIC-3/8" X 13.125"			1
17	00142001-2	HOSE-HYDRAULIC-1/4" X 13"		(Bal. shown in Fig. 4.1.2 - Item 8)	2
18	00142002-13	HOSE-HYDRAULIC-3/8" X 35.875"		(Bal. shown in Fig. 4.5 - Item 20)	1

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	-	VALVE ASSEMBLY-EXTRACTOR ARM		SEE SECTION 4.0.1	1
2	-	VALVE ASSEMBLY-LIFT		SEE SECTION 4.0.1	1
3	-	VALVE ASSEMBLY-DRIVE		SEE SECTION 4.0.1	1
4	00142001-4	HOSE-HYDRAULIC-1/4" X 15.25"			1
5	00142001-2	HOSE-HYDRAULIC-1/4" X 13"			1
6	00142002-1	HOSE-HYDRAULIC-3/8" X 12.875"		(Bal. shown in Fig. 4.1.2 - Item 2)	1
7	00142001-6	HOSE-HYDRAULIC-1/4" X 21.5"		(Bal. shown in Fig. 4.1.2 - Item 4)	1
8	00142001-21	HOSE-HYDRAULIC-1/4" X 35.5"		(Bal. shown in Fig. 4.5 - Item 4)	1
9	00142001-23	HOSE-HYDRAULIC-1/4" X 37.5"		(Bal. shown in Fig. 4.5 - Item 3)	1
10	H1565	ADAPTER-45 DEG-#6 JICM X #4 NPTM			1
11	H1504	ADAPTER-#6 JICM X #4 NPTM			1
12	H0100	COUPLING-#4 NPT			2
13	H0021	NUT-BULKHEAD-#6 JIC			2
14	H0020	UNION-BULKHEAD-45 DEG-# JICM			2
15	00142001-11	HOSE-HYDRAULIC-1/4" X 26.5"		(Bal. shown in Fig. 4.1.2 - Item 7)	1
16	00142002-2	HOSE-HYDRAULIC-3/8" X 13.125"			1
17	00142001-2	HOSE-HYDRAULIC-1/4" X 13"		(Bal. shown in Fig. 4.1.2 - Item 8)	2
18	00142002-13	HOSE-HYDRAULIC-3/8" X 35.875"		(Bal. shown in Fig. 4.5 - Item 20)	1

RESERVOIR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	05642002	RESERVOIR ASSEMBLY		COMPLETE RESERVOIR ASSY	1
1	HC0542	GASKET		SOLD BY LENGTH	A/R
2	HC0340	GAUGE-SIGHT		W/ THERMOMETER	1
3	HC0306	STRAINER-SUCTION			1
4	HC0308	FILLER/BREATHER ASSEMBLY		INCLUDES GASKETS	1
5	HW0209	SCREW-RHMS-10-32 X 1/2"			6
6	BI0104	ELBOW-RED-90 DEG-#16 NPTF X #12 NPTF			1
7	BI0003	NIPPLE-CLOSE-#16			1
8	HW0402	BOLT-HHCS-3/8-16 X 1"			10
9	H0208	PLUG-#12 NPT			1
10	BI0102	ELBOW-90 DEG-#12 NPT			2
11	BI0002	NIPPLE-CLOSE-#12 NPT			2
12	HC0307	RETURN LINE FILTER ASSEMBLY		HOUSING AND FILTER	1
13	HC0317	FILTER-RETURN LINE		REPLACEMENT FILTER	1
14	41247001	MANIFOLD-RETURN LINE			1
15	H1502	ADAPTER-#8 JICM X #12 NPTM			2
16	H1506	ADAPTER-#6 JICM X #6 NPTM			1
17	HC0403-2	PLUG-#6 NPT			1
18	H1507	ADAPTER-#8 JICM X #6 NPTM			1
19	HW0402	BOLT-HHCS-3/8-16 X 1"			4
20	HW0108	WASHER-FLAT-3/8"-SAE			8
21	HW0107	WASHER-LOCK-3/8"			4
22	HW0005	NUT-HEX-3/8-16			4
23	00142003-19	HOSE ASSY-HYDR-1/2"-30.063”		(Bal. shown in Fig. 4.5 - Item 22)	REF
24	00142002-11	HOSE ASSY-HYDR-3/8”-32.875”		(Bal. shown in Fig. 4.5 - Item 21)	REF
25	00142002-19	HOSE ASSY-HYDR-3/8”-54.875”		(Bal. shown in Fig. 4.1.2 - Item 1)	REF
26	00142001-7	HOSE ASSY-HYDR-1/4”-22.5”		(Bal. shown in Fig. 4.2 - Item 5)	REF

LIFT CYLINDER

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0403	CYLINDER-LIFT			1
2	00142001-26	HOSE-HYDRAULIC-1/4" X 41.5"		(Bal. shown in Fig. 4.1 - Item 6)	REF
3	00142001-29	HOSE-HYDRAULIC-1/4" X 44.5"		(Bal. shown in Fig. 4.1 - Item 3)	REF
4	00197036	PIN-CYLINDER-LOWER			1
5	HW1058	PIN-HITCH			4
6	00197035	PIN-CYLINDER-UPPER			1
7	H0302	ELBOW-STR-90 DEG-#6 NPT			1
8	HC0426-1	VELOCITY FUSE			1
9	H1578	ADAPTER-#6 JICM X #6 NPTM			1

EXTRACTOR ARM MOTOR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0102	MOTOR-HYDRAULIC-125 CC		(Bal. shown in Fig 5.0, Item 19)	1
2	H1544	ADAPTER-#6 JICM X #10 SAEM			2
3	00142001-23	HOSE-HYDRAULIC-1/4" X 37.5"		(Bal. shown in Fig. 4.1.1 - Item 9)	REF
4	00142001-21	HOSE-HYDRAULIC-1/4" X 35.5"		(Bal. shown in Fig. 4.1.1 - Item 8)	REF
5	PT0106-1	SPROCKET-5012 X 1"			1
6	05045001	MOUNT-MOTOR			1
7	05615015	COVER-SPROCKET			1
8	HW0006	NUT-NILN-3/8-16			6
9	HW0107	WASHER-LOCK-3/8"			2
10	HW0108	WASHER-FLAT-3/8"-SAE			10
11	HW0403	BOLT-HHCS-3/8-16 X 1-1/4"			4
12	HW0406	BOLT-HHCS-3/8-16 X 2-1/2"		FULL THREAD	2

POWER UNIT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0002	MOTOR-ELECTRIC-2 HP		USED PRIOR TO 12/17/04	1
	E0023	MOTOR-ELECTRIC-2 HP		USED 12/17/04 - PRESENT	1
2	E0622	RESTRAINT-1/2"		GRIP SIZE .450" TO .560"	1
3	E0617	LOCKNUT-CONDUIT-1/2"			1
4	N/A	ADAPTER		† USED PRIOR TO 12/17/04	1
	HC0352	ADAPTER		USED 12/17/04 - PRESENT	1
5	HC0314	COUPLING BODY-5/8" (MOTOR SIDE)		ALL UNITS	1
6	HC0316	SPIDER-COUPLING INSERT			1
7	05526001	COUPLING BODY-1/2" (PUMP SIDE)		USED PRIOR TO 12/17/04	1
	HC0351	COUPLING BODY-5/8" (PUMP SIDE)		USED 12/17/04 - PRESENT	1
8	HW0402	BOLT-HHCS-3/8-16 X 1"			4
9	HW0107	WASHER-LOCK-3/8"			4
10	N/A	PUMP-GEAR		† USED PRIOR TO 12/17/04	1
	HC0350	PUMP-GEAR		USED 12/17/04 - PRESENT	1
11	H1521	ADAPTER-#8 JICSW X #8 SAEM			1
12	H1610	ADAPTER-90 DEG-#10 JICM X #10 SAEM			1
13	HC0261	VALVE-MAIN SYSTEM PRESSURE			1
14	H1606	ADAPTER-90 DEG-#8 JICM X #8 SAEM			1
15	H0206	PLUG-#4 NPT			1
16	HC0318	GAUGE-PRESSURE		0-3000 LBS	1
17	H1560	ADAPTER-45 DEG-#8 JICM X #8 SAEM			1
18	HW0416	BOLT-SHCS-3/8-16 X 1"			2
19	HW0107	WASHER-LOCK-3/8"			2
20	00142002-13	HOSE-HYDRAULIC-3/8" X 35.875"		(Bal. shown in Fig. 4.1.1 - Item 18)	REF
21	00142002-11	HOSE-HYDRAULIC-3/8" X 32.875"		(Bal. shown in Fig. 4.2 - Item 24)	REF
22	00142003-19	HOSE-HYDRAULIC-1/2" X 30.063"		(Bal. shown in Fig. 4.2 - Item 23)	REF
23	H1540	ADAPTER-#8 JICM X #8 SAEM			1

† PARTS NO LONGER AVAILABLE. MUST ORDER NEW PUMP & MOTOR ASSEMBLY.

MISC. COMPONENTS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	PILOT-TO-OPEN VALVE SUB ASSEMBLY		† SEE NOTE	REF
2	N/A	VALVE-CHECK-PILOT TO OPEN		† SEE NOTE	1
3	H1553	ADAPTER-# 6 JICM X #4-SAEM			1
4	H1000	ADAPTER-#8 SAEM X #4 NPTF			2
5	H1585	ADAPTER-90 DEG-#6 JICSW X #4 NPTM			2
6	H1504	ADAPTER-#6 JICM X #4 NPTM			2
7	H0100	COUPLING-#4 NPT			1
8	H1620	TEE-MALE BRANCH-#6 JICM X #4 NPTM			1
9	N/A	1/4” NEEDLE VALVE		† SEE NOTE	1
10	H1587	ADAPTER-#6 JICSW X #4 NPTM			1
11	H1635	TEE-#6 JICM			1
12	05542034	DUAL CROSS PORT RELIEF VALVE SUB ASSY			REF
13	HC0262	VALVE-CROSS PORT RELIEF			1
14	H1546	ADAPTER-#6 JICM X #8 SAEM			4
15	HC0236	REPLACEMENT CARTRIDGE		FOR ITEM 13	A/R

† PARTS NO LONGER AVAILABLE. MUST ORDER NEW COUNTER BALANCE VALVE SUB ASSEMBLY. SEE SECTION 4.6.2

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	05642005	COUNTER BALANCE VALVE SUB ASSY		INCL. ITEMS 1-8	A/R
1	HC0282	VALVE-COUNTER BALANCE			1
2	H1605	ADAPTER-90 DEG-#6 JICM X #10 SAEM			1
3	H1587	ADAPTER-#6 JICSW X #4 NPTM			2
4	HC0213	VALVE-NEEDLE-1/4"			1
5	H1620	TEE-BRANCH-#6 JICM X #4 NPT			2
6	H1544	ADAPTER-#6 JICM X #10 SAEM			1
7	H1615	ADAPTER-90 DEG-#6 JICM X #6 SAEM			1
8	H0100	COUPLING-#4 NPTF			1

HYDRAULICS DIAGRAMS

EXTRACTOR ARM

VACUUM CUP HARDWARE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	P0505	BUSHING-RED-#6 NPT X #4 NPTF-BRASS			1
2	P0301-1	HOSE-COIL-VACUUM			1
3	HW0006	NUT-NILN-3/8-16	HW-KIT-1		4
4	HW0108	WASHER-FLAT-3/8"-SAE	HW-KIT-1		16
5	HW1001	SPRING-3/8"	HW-KIT-1		8
6	HW0427	STUD-VACUUM-3/8-16 X 4"	HW-KIT-1		4

VACUUM CUPS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	P0110	VACUUM CUP-12" ROUND		† SEE NOTES	1
	N/A	VACUUM CUP-10" ROUND	00162001	† AVAILABLE AS KIT ONLY	1
2	00117059	PLATE-VACUUM CUP ADAPTER	00162001		1
3	HW0328	BOLT-HHCS-5/16-18 X 3/4"	00162001		4
4	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS	00162001		1
5	P0505	BUSHING-RED-#6 NPT X #4 NPTF-BRASS	00162001		1
REF	00162003	12" VACUUM CUP ASSEMBLY		INCL. ITEMS 6-9	1
6	00166001	CASTING-12" VACUUM CUP	00162003		1
7	00164001	SEAL-RUBBER	00162003		1
8	00165001	PLATE-FRONT	00162003		1
9	HW0311	BOLT-FHSCS-1/4-20 X 5/8"	00162003		8

EXTRACTOR ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05655001	EXTRACTOR ARM ASSY- VACUUM			1
	05355010	EXTRACTOR ARM ASSY- MAGNET			1
2	05657001	CROSS BAR			1
3	HW0425	BOLT-HHCS-3/8-16 X 1-1/4"		GRADE 8	4
4	HW0107	WASHER-LOCK-3/8"			4
5	43026001	BEARING-FLANGED LOAD-2 1/4"			4
6	HW0013	NUT-HEX-7/8-14			4
7	HW0117	WASHER-LOCK-7/8"			4
8	HW0124	WASHER-SHIM-7/8" I.D. X 1-3/8 O.D" X .075"			AR
9	PT0102	LINK-CONNECTING-#50			4
10	00158001-25	CHAIN-ROLLER-#50			2

PNEUMATICS

VACUUM PUMP

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	P0005	PUMP-VACUUM			1
2	P0207	VALVE-VACUUM RELEASE			1
3	P0503	NIPPLE-#4 NPT-BRASS			1
4	P0506	ELBOW-STR-90 DEG-#4 NPTF-BRASS			1
5	P0208	FILTER- HIGH FLOW			1
6	HW0104	WASHER-FLAT-1/4"-SAE			4
7	HW0101	WASHER-LOCK-#10			4
8	HW0206	SCREW-RHMS-#10-32 X 3/4"			4
9	P0111	FILTER-INLINE		NOT SHOWN	1

LABELS AND DECALS

OPERATOR CONSOLE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43696001	PLACARD-POWER-OFF/ON			1
2	08096007	PLACARD-EXTRACTOR ARM IN/OUT			1
3	05096006	PLACARD-CARRIAGE-RAISE/LOWER			1
4	43696003	PLACARD-MAGNET-OFF/ON		MAGNET EQUIPPED UNITS	1
	05696001	PLACARD-VACUUM-OFF/ON		VACUUM EQUIPPED UNITS	1
5	E1315	LEGEND PLATE-EMERGENCY STOP			1
6	08096007	PLACARD-DRIVE			1
7	00196700	DECAL-BHS-7.875" X 24"			1
8	00196612	LABEL-"READ INSTRUCTION MANUAL PRIOR TO USE"			1
9	00196615	LABEL-"DO NOT OPERATE WITH GUARDS REMOVED"			1

INSIDE CHASSIS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00196210	LABEL-WARNING-"OPERATION BY AUTHO- RIZED AND TRAINED PERSONNEL ONLY"			1
2	00196407	LABEL-CAUTION-"WATCH FOR BATTERY OR CHARGER CABLES IN TRAVEL PATH"			1
3	00196616	LABEL-"NO RIDERS"			1
4	00196222	LABEL-WARNING-"CRUSH HAZARD"			2
5	00196215	LABEL-WARNING-"CHAIN ENTANGLEMENT HAZARD"		SMALL	2
6	00196216	LABEL-WARNING-"CHAIN ENTANGLEMENT HAZARD"		LARGE	2

OUTSIDE CHASSIS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00196407	LABEL-WARNING-"KEEP HANDS CLEAR"			2

ELECTRICAL ENCLOSURES

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00196404	LABEL-DANGER-"120 VOLTS"			1
2	00196401	LABEL-DANGER-"480 VOLTS"			1
3	00196408	LABEL-DANGER-"DISCONNECT POWER BEFORE SERVICING UNIT"			1
4	00196702	DECAL-BHS-4.5" X 1.5"			1

MAGNET ENCLOSURE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00196219	LABEL-WARNING-"ELECTRICAL VOLTAGE HAZARD"			1
2	00196214	LABEL-WARNING-"STRONG MAGNETIC FIELD"			1

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

	# OF PLACES	NORMAL	EXTREME
1. Lubricate grease fittings using #2 lithium based grease
A. Idler casters	3 places	200 hrs	100 hrs
B. Drive wheel bearings	2 places	†	500 hrs
2. Wipe off and lubricate chains using light machine oil	3 places	200 hrs	100 hrs
3. Change return line hydraulic fluid filter (BHS PT# HC0317)	1 place	250 hrs	125 hrs
4. Change hydraulic fluid (Chevron AW 68 or equivalent)	-	500 hrs	250 hrs
5. Complete preventative maintenance (P.M.) (Use form IF-5030)	-	500 hrs	250 hrs

† Under normal operating conditions, sealed mounted bearings do not need to be lubricated unless the extractor is washed down with a power washer or other high pressure wash.

ENVIRONMENTAL CONDITIONS

• NORMAL - Typical warehouse environment with average ambient temperatures and minimal temperature variations.
• EXTREME - Excessively dirty environment; high heat and humidity or very low temperature (cooler or freezer applications);

• DO NOT over lubricate mounted bearings. They are sealed and shielded bearings. Over lubricating may breach the seals of these bearings.
• DO NOT allow hydraulic fl uid temperature to exceed 140 degrees.

BE-36-1-SS Planned Maintenance Inspection Report

TROUBLESHOOTING GUIDE

PROBLEM/SYMPTOM	PROBABLE CAUSE	SOLUTION
Hydraulic power unit does not operate. No electric to power unit motor.	No AC power to unit. Overload on motor contactor tripped. Gate switch not actuated. Foot switch not engaged.	Check fuses, circuit breaker or disconnects. Check reset button on contactor. Make sure operator gate is engaging switch. Check foot switch for obstruction.
Power unit runs but no pressure reading at gauge and/or no functions move.	AC input in reverse phase. Motor is running backwards. Main system relief valve stuck open or defective. Coupling between motor and pump damaged or defective.	Reverse any two of the three hot lines to unit. Check relief valve cartridge for debris. Replace as required. Inspect coupling assembly. Replace as required.
Floor drive moves but is sluggish and stalls when unit is loaded at certain points	Uneven floor conditions. High/low spots. Excessive wheel wear. Wheel shaft to motor coupling in drive wheel assembly defective or damaged. Debris lodged under extractor. Bent or damaged guidance track	Check flatness of floor. Check guidance track for scraping of guide arm on top of angle. Replace poly wheels as required. Inspect drive assembly while under load to see if shafts and couplings are moving in unison. Repair as required. Inspect under unit and remove debris as required. Repair or replace guide track as required.

Tech Tips

Vacuum Cup Replacement

Tech Tip TT-901

Models Effected: All Vacuum Equipped Extractors

Subject:

Vacuum Cup Replacement for Battery Extractor Systems.

Description:

Vacuum cups are the most frequently replaced items on a battery extractor. This is due to damage of the cup by way of tearing the sealing edge of the cup, separation of the rubber from the metal backing plate, or bending/breaking the metal backing plate.

Recommendation:

When extracting a lift truck battery from either a lift truck or a charging stand, DO NOT change the elevation of the roller bed, or rotate the extractor arm while engaged on a battery case. This causes the cup to slide along the battery case leading to the edge of the cup curling or rolling under and eventually leading to the damage of the cup assembly. To eliminate this from happening, verification of the roller bed height and extractor arm position is critical prior to engaging the cup to the battery case. To help reduce the problem of the cup edge curling under, we recommend a silicone type lubricant applied on the face of the cup to help the cup slide on the battery case.

Repair:

If the vacuum cup has been torn or separated from the metal backing plate, the cup will need to be replaced. BHS offers three cup options with a standard mounting layout. All three options are available for use on any BHS vacuum equipped extractor.

10" REPLACEMENT CUP
P/N: 00162001
STANDARD ON ATC-24 UNITS WITH VACUUM EXTRACTION.

12" REPLACEMENT CUP
P/N: P0110
STANDARD ON ATC UNITS 30" AND ABOVE

3 PIECE, 12" REPLACEMENT CUP
P/N: 00162003
CURRENT STANDARD ON BE UNITS. ALLOWS REPLACEMENT OF RUBBER PAD ONLY.

Moving an Inoperable Battery Extractor

Tech Tip TT-902

Models Effected: All Man-on-Board Extractors

Subject:

Proper procedure for moving a Battery Extractor without AC power to energize the machine.

Description:

It may be necessary to move the Battery Extractor when AC power is unavailable. This could be due to a lack of AC power at the time of install, a problem with the AC power feed, or other such instances. Regardless of the circumstances, special precautions must be taken in order to ensure no damage occurs to the drive wheel motors. DO NOT push the Battery Extractor once it is removed from the shipping skid. Pushing the battery extractor may damage the drive motor seals; thus voiding the warranty.

Recommendation:

Raise the drive wheels so that they do not contact the floor. The drive wheels are typically located at the operator’s end of the machine. Using a forklift to raise this end of the machine while moving the Battery Extractor, will prevent damage to the drive wheel motors. If the machine was moved improperly and damage has occurred, replacement of the hydraulic motors may be necessary.

INCORRECT
Pushing Extractor

CORRECT
Raising Extractor

Hydraulic Systems and Temperature Extremes

Tech Tip TT-903

Models Effected: All Hydraulic Systems

Subject:

Operating temperatures of a hydraulic system have a direct effect on oil, components, and the overall performance of the system. Temperature extremes, whether high or low, can create conditions that will break down the oil and cause component failure well before their anticipated life span.

Description:

Low Temperature increases the viscosity, or thickness, of the oil; this forces the pump to work harder pulling the oil on the inlet side. In some instances, the air dissolved in the oil will desorb and form air bubbles. These bubbles can implode violently inside the pump as it tries to compress this bubbly oil on the high-pressure side causing vibration and sounding as if marbles are inside the pump (cavitation). These implosions actually destroy the internal parts of the pump and the micro-particles are then carried throughout the system to cause additional damage to components downstream.

High Temperature decreases oil viscosity. This thinner oil causes excess wear on moving components. As the oil thins, it loses its lubricating value, which increases friction and creates more heat. This cycle continues until the oil becomes burnt and oxidized, giving it a brown color and burnt smell. At this point the oil is of no value and only damages the system. As long as the system remains below 140° F, the breakdown rate of the oil is minimized. Every 15°F over 140° F decreases the life of the oil by 50%. If the oil has an expected life of 1000 hours and the system runs at 170°F, even intermittently, the oil life is reduced to 250 hours.

Recommendation: BHS systems are shipped from the factory with Chevron AW-68 oil. This provides low temperature performance when ambient temperatures are as low as 60° F. For applications where the temperature may be consistently lower than that, we offer AW-32 oil for ambient temperatures down to 40° F. This application may be found in a refrigerated warehouse.

Be aware of your oil temperature. High temperature extremes are typically caused by a problem within the system that must be addressed as soon as possible to avoid further damage to the oil and components.

BHS recommends hydraulic oil be changed every 500 hours under normal conditions and filters be changed at least every 250 hours of operation. Oil sampling and testing can be very helpful in determining a proper maintenance schedule for your application and environment, or if a change in viscosity is needed.

Hydraulic Oil Cleanliness

Tech Tip TT-904

Models Effected: All Hydraulic Systems

Subject:

One of the most common factors of poor performance and damage to a hydraulic system is also one of the easiest to avoid - dirty hydraulic fluid. Although invisible to the naked eye, germ size particles at high counts are detrimental to the performance of close tolerance valves and system components. A single large particle or an accumulation of small particles may cause valve control to become erratic. The presence of many small particles also leads to shortened pump, motor, and actuator life by causing accelerated wear to seals and bearings.

Description:

Contamination enters a system in many ways. The following are some of the most common:

• Built In Contamination – Typical built-in contaminants include metal burrs, dust, lint from rags, and sealant which can be introduced into the system during the assembly process.
• New Oil – New oil is not necessarily clean oil and should be pre-filtered before it is put into the machine. Improperly cleaned reservoirs contain contaminants that mix with the new oil and are recirculated into the system.
• Environmental Contamination – Dust, dirt, and other airborne contaminants typically found in manufacturing environments can enter a system through exposed cylinder rods. Removal of any cap, cover, plug or line connection will expose a system to environmental contaminants.
• Generated Contamination – Even the best maintained machine in the cleanest environment will have contamination introduced from the normal wear of components and degradation of oil. Exposure to the sources described above will accelerate the generation of contaminants.

Recommendation:

Proper monitoring and maintenance of system fl uids can improve operating performance more than any other single factor. BHS recommends to change oil fi lters (20 micron or better) at least every 250 hours of operation and to change hydraulic oil every 500 hours under normal conditions. Oil sampling and testing can be very helpful in determining a proper maintenance schedule for your application and environment.

PARTS KITS

BE-36-1-SS W/ VACUUM SPARE PARTS KIT

P/N: BE-SPKV-SS

QTY	PART#	DESCRIPTION
1	00162003	VACUUM CUP ASSEMBLY-12"
1	05522007	DRIVE WHEEL ASSEMBLY
1	E1126	SELECTOR SWITCH
1	E1006	CONTACT BLOCK-N/O
1	C0220	CASTER-8" X 3"-POLY
1	E0327	KEY SWITCH
1	E0351	KEY SET-REPLACEMENT
4	PT0510	GUIDANCE CAM ROLLERS
4	HW0115	WASHER-LOCK-3/4"
4	HW0011	NUT-HEX-3/4-16
1	HC0317	OIL FILTER
1	HW-KIT-1	VACUUM STUD KIT
1	P0301-1	VACUUM HOSE
1	HC0236	CROSS PORT RELIEF CARTRIDGE

10" VACUUM CUP ASSEMBLY

P/N: 00162001

QTY	PART#	DESCRIPTION
1	N/A	10" VACUUM CUP
1	00117059	PLATE-ADAPTER-VACUUM CUP
4	HW0328	BOLT-HHCS-5/16-18 X 3/4"
1	P0505	BUSHING-RED-#6 NPT X #4 FNPT-BRASS
1	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS
1	P0401	ELBOW-#4 NPTM X 1/4" BARB-BRASS
24	HW0108	WASHER-FLAT-3/8"-SAE

BATTERY EXTRACTOR
12" VACUUM CUP ASSEMBLY

P/N: 00162003

QTY	PART#	DESCRIPTION
1	00166001	CASTING-12" VACUUM CUP
1	00165001	FRONT PLATE-12" VACUUM CUP
1	00164001	RUBBER PAD-12" VACUUM CUP
8	HW0311	BOLT-FHSCS-1/4-20 X 3/4"

ATC / BTC VACUUM STUD SPRING KIT

P/N: HW-KIT-1

QTY	PART#	DESCRIPTION
4	HW0006	NUT-NILN-3/8-16
16	HW0108	WASHER-FLAT-3/8"-SAE
4	HW0427	STUD-3/8-16 X 4"
8	HW1001	SPRING-3/8"

BATTERY EXTRACTOR
MAGNET STUD KIT

P/N: 80252006

QTY	PART#	DESCRIPTION
4	HW0433	STUD-1/2-13 X 5"
4	HW0008	NUT-NILN-1/2-13
4	HW0007	NUT-HEX-1/2-13
12	HW1002	SPRING-1/2"
16	HW0111	WASHER-FLAT-1/2"

BE-SL/DS DRIVE WHEEL REPAIR KIT

P/N: 80222001

QTY	PART#	DESCRIPTION
1	C0050-1	WHEEL-8" X 3"-POLY
1	43727008	SHAFT-WHEEL
2	PT0406	FLANGE BEARING-4 BOLT-1 3/16"
1	43097005	KEY-1/4" X 3"
1	00197028	KEY-1/4" X 1 1/4"
1	*43726003	BUSHING-FLOOR DRIVE-1 3/16"
1	*43726004	SPROCKET-FLOOR DRIVE
4	*HW0323	BOLT-HHCS-5/16-18 X 1"

*PARTS SHOWN ASSEMBLED

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:

Phone: 1.877.247.4968
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.