IOP-050 SP BTC (Spanish)

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Battery Transfer Carriage (BTC) Parts & Service Manual

TP-619 - PROCEDIMINETOS DE SEGURIDAD Y DES-ENERGIZACION

INFORMACION GENERAL

El carro de transferencia de batería (BTC) se utiliza para extraer baterías grandes de camiones industriales eléctricos.

Una persona en la parte trasera del BTC puede maniobrar libremente sobre las ruedas al empujar / tirar de las manijas de la unidad o hacia los lados a lo largo de un recorrido designado por una persona a cada lado de la unidad empujando / jalando una manija de la unidad.

El BTC puede ser uno de los tres posibles tipos / opciones de funcionamiento:

1. Unidad totalmente mecánica - La unidad se sube y baja usando un gato hidráulico manual ubicado en la parte posterior de la unidad. La batería es manipulada por A) un cabrestante manual ubicado en la parte trasera de la unidad que está conectado a la batería y retraído, tirando de la batería hacia la unidad mientras la empuja físicamente de la unidad o B) un brazo extractor que se mueve hacia adentro y hacia afuera usando una rueda de mano ubicada en la parte posterior izquierda de la unidad para empujar o tirar de la batería dentro y fuera de la unidad.
2. Unidad totalmente eléctrica - La unidad tiene una unidad de energía hidráulica totalmente cerrada, autónoma y con alimentación eléctrica ubicada en la parte posterior derecha de la unidad. La energía es suministrada por una batería de 12VDC ubicada en la parte posterior izquierda de la unidad. La unidad de potencia proporciona potencia para elevar la unidad utilizando un cilindro hidráulico y potencia para mover el brazo extractor hacia adentro y hacia afuera utilizando un motor hidráulico. Las funciones de elevación y extracción están controladas por válvulas de palanca manuales individuales ubicadas dentro de la carcasa de la unidad de potencia. Esta unidad puede estar equipada con una extracción de vacío opcional que tiene una bomba de vacío ubicada entre las empuñaduras en la parte posterior de la unidad alimentada por la batería de CC.
3. Unidad parcialmente eléctrica - La unidad es una combinación de extracción mecánica y elevación eléctrica o extracción eléctrica y elevación mecánica. El funcionamiento de esta unidad es una combinación de cada tipo mencionado anteriormente.

SEGURIDAD GENERAL

• Lea y comprenda todas las instrucciones y advertencias antes de usar o reparar este equipo.

• Guarde estas instrucciones para referencia futura.

• Las unidades de Battery Transfer Carriage (BTC)solo se deben usar en interiores en un entorno industrial en un piso duro, antideslizante y nivelado sin defectos que incluyan, entre otros, agujeros, ranuras, grietas, desagües u obstáculos compuestos de concreto u otro material industrial adecuado.

• Las fuerzas requeridas para operar el BTC varían con el peso de la carga, las condiciones del piso y las condiciones del carro.

• Las unidades BTC no están diseñadas para ser enviadas o transportadas después de la entrega inicial.

• Se debe consultar a un ingeniero estructural con licencia antes de instalar un BTC en cualquier nivel del edificio que no sea la planta baja.

• Realice verificacion del sistema y seguridad antes de su operacion

• El incumplimiento de estas instrucciones y advertencias puede provocar daños a la propiedad, lesiones personales o la muerte.

AREA DE TRABAJO

• Mantenga el área de trabajo limpia y bien iluminada. Las áreas de trabajo desordenadas e iluminación deficiente pueden provocar accidentes.
• Limpie / contenga cualquier derrame de líquido de inmediato para evitar resbalones o caídas.
• Tenga en cuenta los posibles riesgos al realizar cualquier servicio o mantenimiento a la unidad.

SERVICIO Y MANTENIMIENTO

El personal de mantenimiento debe usar equipo de protección personal (EPP) apropiado para la tarea que se realiza.

BLOQUEO/ETIQUETADO

Bloquee / etiquete el BTC según su política corporativa, si está dañado o no funciona correctamente. Bloquee / etiquete y desenergice todos los sistemas antes de realizar cualquier mantenimiento o servicio a la unidad.

PELIGRO DE EXPLOSIONES DE BATERIAS DE PLOMOACIDO

No permita llamas abiertas ni chispas de ningún tipo cerca de una batería. Se genera gas altamente explosivo cuando se carga una batería que puede permanecer en las celdas de la batería durante períodos prolongados después de que se completa la carga.

• Siempre use equipo de protección personal apropiado, incluyendo delantal de goma, guantes, botas y careta completa cuando realice el servicio o mantenimiento de cualquier bateria de ácido de plomo

• No coloque metal u otros objetos conductores sobre la batería. Se pueden producir arcos que causan daños a la batería y / o lesiones personales graves o la muerte.

• Utilice solo cargadores que coincidan con el voltaje y el amperaje de la batería que se está cargando. Sobrecargar una batería puede causar daños a la batería, el cargador y/ o lesiones personales graves o la muerte.

• Apague el cargador antes de desconectar la batería del cargador. La formación de un arco entre los conectores de la batería y el cargador puede causar daños a los conectores y / o lesiones personales graves o la muerte.

RIESGOS HIDRAULICOS

EVITE FLUIDOS DE ALTA PRESIÓN - El escape de liquido bajo presion penetrar la piel y causar lesionesngraves. Libere la presion antes de desconectar las lineas hidraulicas. Mantenga las manos y cuerpo alejados de los orificios que expulsan los fluidos de alta presion. use un pedazo de carton o papel para buscar fugas. NO use sus manos.

Cualquier fluido inyectado en la piel bajo alta presión debe considerarse una emergencia médica grave a pesar de una apariencia inicial normal de la piel. Habrá un inicio tardío del dolor y puede ocurrir un daño tisular grave. Se debe buscar atención médica de inmediato.

SEGURIDAD OPERACIONAL

SEGURIDAD OPERACIONAL

• Solo el personal capacitado en el funcionamiento correcto y seguro de las unidades BTC puede operar o dar servicio al BTC.

• Los operadores deberán usar equipos de proteccion personal apropiado adecuado para trabajar con baterías de plomo-ácido industriales mientras operan el BTC (ver página anterior).

• Todas las placas de datos, etiquetas de advertencia, carteles, etc. deberán estar en su lugar y ser legibles en todo momento. Póngase en contacto con BHS para obtener placas de datos de reemplazo, etiquetas de advertencia, carteles o instrucciones.

• Todos los usuarios y el personal de servicio deben estar familiarizados con el significado y los riesgos asociados con todas las placas de datos, etiquetas de advertencia, etc.

• Todos los operadores y el personal de servicio deben estar al tanto de los posibles puntos de aplastamiento y corte al operar o dar servicio al BTC, incluidas las ruedas y los frenos.

• BTC debe operarse en un área con niveles de luz ambiental de al menos 50 lux.

• Mantenga las manos y los brazos fuera del compartimento de la batería mientras opera el BTC.

• Active los topes de seguridad para las baterias y asegure apropiadamente la bateria antes de ser transportada.

• Conecte el gancho y la cadena (si está equipado) a la batería antes de transportar la batería.

• Evite cambios bruscos de dirección cuando transporte una batería en el BTC para evitar la pérdida de la batería y / o la pérdida de control del BTC.

• Retire el BTC del servicio si está dañado, defectuoso o si funciona incorrectamente (o se vuelve así durante el funcionamiento) hasta que se puedan hacer reparaciones para corregir cualquier problema.

QUE HACER Y QUE NO HACER:

• NO exceda la capacidad máxima del BTC.

• NO modifique ni ajuste el BTC con archivos adjuntos sin la aprobación previa por escrito de BHS.

• NO realice ningún tipo de mantenimiento o servicio al BTC con una batería cargada en el BTC.

• NO permita que nadie viaje en o sobre el BTC.

• NO opere el BTC con ninguna protección o cubierta removida a menos que sea necesario para mantenimiento o reparación.

• Desconecte la batería (si está equipada) antes de intentar realizar servicio o mantenimiento al BTC.

• NO use el BTC de una manera para la cual no está destinado. Algunos ejemplos de uso prohibido están, pero no se limitan a:

 » Como scooter o para transportar personas
 » Como un gato de vehículo
 » Para levantar cargas mayores que su capacidad de carga nominal
 » Donde pueda existir movimiento involuntario
 » Tener contacto directo con alimentos.
 » En una atmósfera potencialmente explosiva

DES-ENERGIZACION

BTC/BTC-MPP:

1. Gire la manija de liberación de la bomba en sentido contra reloj para bajar el carro interior y liberar la presión hidráulica. Vea Figura 1

Si no se baja el carro interior cuando se realiza el servicio al BTC, podrían producirse lesiones si la cama de rodillos se baja inesperadamente.


FIGURA 1

BTC-MPPEL/MPPEE/MPPAE:

1. Desenchufe el cargador de batería (si está equipado).
2. Desconecte el cable positivo del borne de la batería. Asegure el cable positivo para que no pueda tocar el borne positivo de la batería. Ver Figura 2.

Si no se desconecta la alimentación eléctrica al BTC, se podrían producir descargas eléctricas.


FIGURA 2

3. Cicle las válvulas manuales varias veces para aliviar la presión hidráulica almacenada. Ver Figura 3.

Si no se libera la presión hidráulica almacenada, podrían producirse lesiones por: Fluido hidráulico que escapa bajo alta presión (ver PELIGROS HIDRÁULICOS en la sección de SEGURIDAD GENERAL). Movimiento inesperado de componentes hidráulicos.


FIGURA 3

ETIQUETAS Y ROTULOS

INFORMACION GENERAL

NUMERO DE MODELO Y OPCIONES

ANCHO DEL COMPARTIMIENTO DE RODILLOS

18 = Ancho del Compartimiento de 18"

24 = Ancho del Compartimiento de 24"

30 = Ancho del Compartimiento de 30"

METODO DE EXTRACCION / LEVANTAMIENTO 1

MPP = Empuje y Extraccion Mecanica - Levantamiento Mecanico
MPPEL = Empuje y Extraccion Mecanica - Levantamiento Electrico
MPPEE = Empuje y Extraccion Electrico - Levantamiento Mecanico

MPPAE = Empuje y Extraccion Electrico - Levantamiento Electrico (Todo Electrico)

VIGA DE EXTENSION Y CAMA DE RODILLOS EXTENDIDA 2

CAN-7 = 7" de Extension de la Viga en la parte Superior, No Extension de la Cama de Rodillos
CAN-7-6 = 7" de Extension de la Viga en la parte Superior, 6" de Extension de la Cama de Rodillos
CAN-14-6 = 14" de Extension de la Viga en la parte Superior, 6" Extension de la Cama de Rodillos

OPCIONES ADICIONALES

RB-OPT = Topes de Goma

TM = Montaje de Riel (usado en conjunto con una pista guia opcional)
PA = Brazo de Empuje de Extension (Solo para Modelos con Gancho y Cadena)

VAC = Extraccion con Aspiradora

CHGR = Cargador Autonomo (Solo para Modelos Electricos)
RGD = Protectores de Goma

EC = Capacidad Extra (Incrementa la Capacidad a 3400 lbs) 3

NS = Opcion No-Estandar 3

1 1 Si el metodo de extraccion o levantamiento no esta en la lista (por ejemplo, MPP, MPPAE, etc.) la unidad esta equipada con un winch de mano y levantamiento mecanico.

2 2 Si no hay ninguna opcion de viga de extension en la lista (por ejemplo, CAN-7) La unidad es considerada "Estandar" sin ninguna estension de brazo o cama de rodillos.

3 3 Consulte la fabrica por unidades con opciones EC o NS ya que los componentes pueden ser completamente unicos el equipo en particular.

SPECIFICATIONS

Product Specifications - Imperial / Metric

	MPPAE	MPPEL	MPPEE	MPP
Max. Load Capacity 1	3,000 lb / 1360 kg	3,000 lb / 1360 kg	3,000 lb / 1360 kg	3,000 lb / 1360 kg
Voltage Requirement	12 VDC	12 VDC	12 VDC	N/A
Hydraulic Pump	1.3 GPM / 4.6 LPM	1.3 GPM / 4.6 LPM	1.3 GPM / 4.6 LPM	N/A
Extractor Arm Travel Speed	0 - 20 FPM / 0-.10 m/s	N/A	0 - 20 FPM / 0-.10 m/s	N/A
Battery Attachment	Hook & Chain	Hook & Chain	Hook & Chain	Hook & Chain
Optional Vacuum	Yes	N/A	Yes	N/A
Primary Drive Reduction	N/A	4.5 to 1	N/A	4.5 to 1
Primary Drive Chain Size	#50	#50	#50	# 50
Roller Diameter	2.4” / 61 mm	2.4” / 61 mm	2.4” / 61 mm	2.4” / 61 mm
Roller Shaft Size	7/16” / 11 mm Hex (Model 18) 7/16” / 11 mm Hex (Model 24) 3/4” / 19 mm Hex (Model 30)	7/16” / 11 mm Hex (Model 18) 7/16” / 11 mm Hex (Model 24) 3/4” / 19 mm Hex (Model 30)	7/16” / 11 mm Hex (Model 18) 7/16” / 11 mm Hex (Model 24) 3/4” / 19 mm Hex (Model 30)	7/16” / 11 mm Hex (Model 18) 7/16” / 11 mm Hex (Model 24) 3/4” / 19 mm Hex (Model 30)
Maximum Battery Width	17” / 430 mm 23” / 580 mm 29” / 735 mm	17” / 430 mm 23” / 580 mm 29” / 735 mm	17” / 430 mm 23” / 580 mm 29” / 735 mm	17” / 430 mm 23” / 580 mm 29” / 735 mm
Battery Length	25” to 39.75” 635 to 1010 mm	25” to 39.75” 635 to 1010 mm	25” to 39.75” 635 to 1010 mm	25” to 39.75” 635 to 1010 mm
Min. Battery Height	20” / 500 mm	20” / 500 mm	20” / 500 mm	20” / 500 mm
Overall Length2	67” / 1700 mm	67” / 1700 mm	67” / 1700 mm	67” / 1700 mm
Overall Width	46.5” / 1180 mm (Model 18) 52.5” / 1335 mm (Model 24) 58.5” / 1485 mm (Model 30)	46.5” / 1180 mm (Model 18) 52.5” / 1335 mm (Model 24) 58.5” / 1485 mm (Model 30)	46.5” / 1180 mm (Model 18) 52.5” / 1335 mm (Model 24) 58.5” / 1485 mm (Model 30)	38.5” / 975 mm (Model 18) 44.5” / 1130 mm (Model 24) 50.5” / 1280 mm (Model 30)
Overall Height	65.5” / 1665 mm	65.5” / 1665 mm	65.5” / 1665 mm	65.5” / 1665 mm
Roller Height Service Range	5.5” - 21.5” 140 - 545 mm	5.5” - 21.5” 140 - 545 mm	5.5” - 23.5” 140 - 595 mm	5.5” - 23.5” 140 - 595 mm
Roller Width (Nominal)	18” / 445 mm (Model 18) 24” / 610 mm (Model 24) 30” / 760 mm (Model 30)	18” / 445 mm (Model 18) 24” / 610 mm (Model 24) 30” / 760 mm (Model 30)	18” / 445 mm (Model 18) 24” / 610 mm (Model 24) 30” / 760 mm (Model 30)	18” / 445 mm (Model 18) 24” / 610 mm (Model 24) 30” / 760 mm (Model 30)
Extended Arm Reach3 (Beyond Roller Bed)	6” / 152 mm	6” / 152 mm	6” / 152 mm	6” / 152 mm
Service Weight (unloaded)	1050 lb / 480 kg (Model 18) 1128 lb / 515 kg (Model 24) 1135 lb / 520 kg (Model 30)	945 lb / 430 kg (Model 18) 960 lb / 440 kg (Model 24) 1090 lb / 500 kg (Model 30)	850 lb / 390 kg (Model 18) 934 lb / 425 kg Model 24) 1060 lb / 485 kg (Model 30)	718 lb / 330 kg (Model 18) 748 lb / 340 kg (Model 24) 960 lb / 440 kg (Model 30)

1. Maximum Load Capacity based on 39” Battery Length

2. Not including cantilever or roller bed extension options

3. Not including any roller bed extension options

INSTALACION

Lo siguiente describe el procedimiento de instalacion basico para el BTC battery transfer carriage.

1. Una vez que el carro se ha retirado de la paleta de envío, los frenos de piso deben ser instalados. El freno de piso es instalado en la parte inferior del marco en el lado del operador por debajo del cilindro de levantamiento con los tornillos suministrados. Ver Figuras 1 - 3.
Notas: Los modelos de BTC-30 tienen dos frenos de piso. El freno de piso debe ser usado solo cuando la unidad no esta en uso.


FIGURA 1



FIGURA 2



FIGURA 3

2. Asegure que el cilindro de elevación esté alineado correctamente con el agujero ubicado en la parte inferior del marco interno. Esto garantizará la seguridad, incluso la elevación. Consulte la Figura 4.


FIGURA 4




3. Unidades Electricas solamente:Desatornille el soporte del winchey vuelva a colocarlo hacia la parte posterior de la unidad. Consulte la Figura 5


FIGURA 5

4. Unidades Electricas solamente:Conecte el cable positivo con el terminal positivo de la baterias. Ver Figura 6.
Nota: La bateria debe desconectarse antes de cargarla.


FIGURA 6

5. El carro ya está listo para usar.

OPERATING CONTROLS

The following is a brief operational overview of the BTC.

EXTRACTION CONTROLS
• Winch Extraction - Rotate the winch handle counterclockwise to extend the winch strap and rotate the winch handle clockwise to retract the winch strap. Winch direction is changed by switching the lever at the rear of the winch. See Figure 7


FIGURE 7

• Mechanical Extraction - Turn the hand wheel counterclockwise to extend the extractor arm toward the lift truck or battery stand and clockwise to retract the extractor arm. See Figure 8. Note: The extractor arm latch must be raised to move the arm when fully retracted. See Figure 9.


FIGURE 8



FIGURE 9

• Electric Extraction - With the green power button depressed, push the extraction valve handle to the right to extend the extractor arm toward the lift truck or battery stand and push the valve handle to the left to retract the extractor arm. See Figure 10.


FIGURE 10

• Vacuum (if equipped) - Pull up the vacuum switch to energize the vacuum pump and push down to de-energize the vacuum pump.
LIFT CONTROLS
• Mechanical Lift - Insert the jack handle into the jack handle socket and pump the jack handle up and down to raise the inner carriage. To lower the inner carriage, slowly turn the release handle located at the base of the manual jack counterclockwise. Turn the release handle clockwise to stop lowering the inner carriage. See Figures 11 & 12.


FIGURE 11



FIGURE 12

• Electric Lift - With the green power button depressed, push the lift valve handle to the left to raise the inner carriage and push the valve handle to the right to lower the inner carriage. See Figure 13.


FIGURE 13

BRAKES

• Vector Brakes - The vector brakes are used when transferring batteries from the BTC to the industrial truck or battery stand. To engage the vector brake, lift the release handle up and slide it forward allowing the vector brake to lower to the floor. To disengage, lift the release handle up until the notch in the release handle is allowed to move rearward, locking the brake in the raised position. See Figures 14 & 15.


FIGURE 14



FIGURE 15

• Floor Lock - The floor lock is to be used any time the BTC is left unattended. DO NOT use the floor lock during the change out process. To engage the fl oor lock, press down on the pedal with your foot. To disengage, press either of the two release tabs on the side of the floor lock with your foot. See Figure 16.


FIGURE 16

OPERATIONAL TEST

After the initial installation has been completed or any service to the unit has been performed, an operational test should be conducted to ensure proper functions of the unit prior to returning the BTC back into service.

• Extractor Arm - Verify proper arm travel by slowly moving the extractor arm fully in and out of the battery compartment.
• Lift - Verify proper lift by slowly raising and lowering the inner carriage through the entire lift range.
• Vector Brakes - Verify operation by engaging and disengaging the vector brake to ensure smooth operation and verify complete contact of the brake pad with the floor. While engaged, carefully pull rearward on the cart to ensure proper engagement of the vector brakes.
Note: When unloaded, it is normal for the front casters of the carriage to lift off the floor as the vector brakes engage.
• Floor Lock - Verify operation by engaging the floor lock and ensure the carriage cannot move when pushed or pulled with moderate force.
• Vacuum (if equipped) - Verify the vacuum pump energizes and there is suction at the vacuum port of the vacuum cup.

OPERATING INSTRUCTIONS

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

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 BTC into position such that the roller compartment of the BTC is aligned with the battery compartment of the industrial truck.
4. Verify the battery safety stop at the end of the BTC roller bed is in the down position.
5. Adjust the vertical height of the BTC battery compartment to the battery compartment of the industrial truck or slightly higher. [DO NOT exceed 1/4" difference.].
6. Once the proper height is achieved, the extractor arm can be moved toward the lift truck battery.
   Hook and Chain - Stop the extractor arm approximately 3" - 4" from the battery.
   Vacuum Extraction - Bring the vacuum cup in contact with the battery. DO NOT force the extractor arm into the battery once contact is made.
7. For hook and chain units, attach the hook securely through the lifting eye of the battery and ensure full engagement. See Figure 17. For vacuum units, energize the vacuum.


FIGURE 17

8. Slowly begin removing the battery from the industrial truck battery compartment while inspecting the vertical alignment of both battery compartments. If vertical adjustment is required, disengage the vacuum cup (if equipped) prior to adjusting the height of the BTC.
9. Once the battery is entirely inside the BTC battery compartment, move the battery safety stop to the upright position. For electric units, secure the battery for transport by moving the battery forward using the extractor arm to “pin” the battery between the extractor arm and battery stop to prevent the battery from rocking front to back. If equipped, turn off the vacuum.
10. The battery may now be transported to the charging area.
    Note: When possible, always push carriage so as to not create a hazard should you slip while pulling the carriage. Batteries are heavy and could cause personal injury under such conditions.
11. Align the BTC with an open roller compartment in the battery charging area.
12. Adjust the vertical height as needed for alignment with the battery stand.
13. Engage both vector brakes.
14. Lower the battery safety stop at the front of the carriage.
15. Slowly move the battery from the BTC into the battery stand. For vacuum equipped units, it is not necessary to energize the vacuum for this step.
16. After transfer, raise the battery stop on the stand and disconnect the hook from the battery. DO NOT force the extractor arm into the battery after the battery is completely in the stand.
17. Reposition the BTC at the location of the newly charged battery to be installed in the lift truck.
18. The above process can be used to remove a battery from the roller stand to be installed into the industrial truck.
19. After completing battery changes, the floor lock(s) should be engaged prior to leaving the BTC unattended.
As with all material handling equipment, the transfer carriage should be inspected prior to each use for any visual damage. It should also undergo a routine inspection by trained maintenance personnel to verify and maintain the load capacity of the unit.

MANUAL UNLOADING

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

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

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

If certified and approved vertical extraction methods and/or devices are not available and the unit’s casters and lift/lower functions operate normally, the battery may be unloaded by hand as follows:

1. Move the BTC into position such that the roller compartment of the BTC is aligned with an empty battery stand roller compartment. Verify the battery safety stop(s) of the empty roller compartment is in the down position.

2. Engage the vector brakes on both sides of the BTC.

3. Adjust the vertical height of the BTC roller compartment with the empty roller compartment or slightly higher. DO NOT exceed 1/4” difference. Verify the battery safety stop(s) at the end of the BTC roller bed is in the down position.

4. Carefully push the battery by hand from the BTC into the battery stand. Move the battery safety stop(s) of the battery stand to the up position.

Hand position should be carefully selected to prevent accidental crushing. Maintain a secure footing to prevent slips, trips or falls.

OPERATOR’S DAILY CHECKLIST

SERVICE & MAINTENANCE

The following items are recommended by the factory to have on hand for BTC models to minimize any downtime due to minor breakdown that may occur under normal operating conditions.

BHS PART NUMBER	DESCRIPTION	QTY	REFERENCE SECTION	NOTES
80122001	CASTER KIT	1	1.0.1	BTC-18 & 24 UNITS
80122002	CASTER KIT	1	1.0.1	BTC-30 UNITS
80152002	HAND WHEEL KIT	1	1.1.1
80052005	SLIDE BLOCK KIT	1	1.1.3
80812001	BATTERY STOP KIT	1	1.2.1
08092001	HOOK AND CHAIN ASSEMBLY	1	2.0.1
E0009-2	SOLENOID-12VDC	1	3.0.1	ELECTRIC UNITS ONLY
80032001	PUSH BUTTON ASSEMBLY	1	4.1.1
E0302	SWITCH-PULL	1	5.5.1	VACUUM UNITS ONLY
00162001	VACUUM CUP-10"	1	5.5.3
HW-KIT-1	STUD KIT-VACUUM	1	5.5.3
P0301-1	HOSE-COIL-VACUUM	1	5.5.3

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.)

“READY” STATUS INDICATOR LIGHT

BTC electric motors are protected by an internal thermal switch. If the motor gets too hot, the switch will open so the motor will not operate. When this happens the green light will not be lit. This switch will reset automatically and the light will be lit again when the motor has cooled sufficiently.

The unit is “Ready” for use when the green light is lit. If the light is not lit, check the following:

1. Verify the battery voltage is the same as listed on the serial plate.

2. Verify the correct polarity at the light terminals.

If both these items are correct, then the thermal switch may have opened. Let the motor cool for about 30 minutes and check the green light again. If the green light does not come on, call for service.

HYDRAULIC SYSTEM

For electric units, the reservoir should be fi lled within 1" of the top of the reservoir with approximately 0.8 Gal / 3.0 L of Chevron hydraulic oil AW ISO 32 or equivalent ISO 32 grade hydraulic oil with anti-wear additives and foam suppressant.

NOTE: It is not necessary to bleed the system after filling the unit.

DISPOSAL OF WASTE MATERIAL

Dispose of all fluids and waste according to local regulations.

BTC SERIES PLANNED MAINTENANCE INSPECTION REPORT

PARTS SECTIONS

CHASSIS

CASTERS & FLOOR LOCK

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	C0020	CASTER-6" X 2"-SWIVEL	†		2
2	C0015	CASTER-6" X 2"-RIGID	†		2
3	C0010-1	FLOOR LOCK	†	BTC-18 & 24	1
				BTC-30 ONLY	2
4	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"	†	BTC-18 & 24	20
				BTC-30 ONLY	24
5	HW0108	WASHER-FLAT-3/8"-SAE	†	BTC-18 & 24	20
				BTC-30 ONLY	24
6	HW0107	WASHER-LOCK-3/8"	†	BTC-18 & 24	20
				BTC-30 ONLY	24
7	HW0005	NUT-HEX-3/8-16	†	BTC-18 & 24	20
				BTC-30 ONLY	24

† INCLUDED IN MULTIPLE KITS

VECTOR BRAKE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	VB	VECTOR BRAKE ASSEMBLY		HANDLE SOLD SEPARATELY	2
1	05017023-2	MOUNT-VECTOR BRAKE			2
2	05017025-2	ARM-VECTOR BRAKE			4
3	05012004-B	BRAKE PAD ASSEMBLY		LOWER SHOE W/ RUBBER PAD	2
4	05017085-3	HANDLE-LHS			1
	05017085-4	HANDLE-RHS			1
5	HW0423	BOLT-HHCS-3/8-16 X 3 1/2"			8
6	HW1003	SPRING-TORSION			2
7	HW0006	NUT-NILN-3/8-16			8
8	HW0402	BOLT-HHCS-3/8-16 X 1"			4
9	HW0108	WASHER-FLAT-3/8"-SAE			4
10	HW0107	WASHER-LOCK-3/8"			4
11	HW0005	NUT-HEX-3/8-16			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	80112001	VECTOR BRAKE KIT		INCL. ITEMS 1-11	A/R
1	05017023-2	MOUNT-VECTOR BRAKE	80112001		2
2	05017025-2	ARM-VECTOR BRAKE	80112001		4
3	05012004-B	BRAKE PAD ASSEMBLY	80112001	LOWER SHOE W/ RUBBER PAD	2
4	05017026	CLASP-VECTOR BRAKE	80112001		2
5	05018010	PIN-PIVOT	80112001		4
6	HW1003	SPRING-TORSION	80112001		2
7	HW1007	CLIP RING-STAR-3/8"	80112001		8
8	HW0423	BOLT-HHCS-3/8-16 X 3 1/2"	80112001		4
9	HW0006	NUT-NILN-3/8-16	80112001		4
10	HW1008	BOLT-SHOULDER-5/16-18 X 1/2"	80112001	3/8" DIA. SHOULDER	2
11	HW0004	NUT-HEX-5/16-18	80112001		2

NOTE: VECTOR BRAKES REPLACEMENT KITS SHIPPED ASSEMBLED FOR ONE SIDE ONLY. TO MOUNT ON OPPOSITE SIDE OF UNIT, MOVE CLASP TO OPPOSITE SIDE OF VECTOR BRAKE ASSEMBLY (CLASP SHOULD BE ON OUTER SIDE OF VECTOR BRAKE ASSEMBLY ONCE INSTALLED.)

SPROCKETS & SHAFTS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05017045	COVER-HAND WHEEL	80152002		1
2	HW0301	BOLT-SELF-TAP "F"-1/4-20 X 1/2"	80152002		2
3	05026001	HAND WHEEL	80152002		1
4	HW0317	BOLT-HHCS-1/4-20 X 3 1/2"	80152002		1
5	HW0104	WASHER-FLAT-1/4"-SAE	80152002		1
6	HW0003	NUT-NILN-1/4-20	80152002		1
7	PT0105	SPROCKET-5010 X 5/8"		INCLUDES SET SCREWS	1
8	PT0109	SPROCKET-5045 X 1"		INCLUDES SET SCREWS	1
9	00158001-6	CHAIN-ROLLER-#50			1
10	PT0102	LINK-CONNECTING-#50			1
11	05027002	SHAFT-HAND WHEEL	80152002		1
12	00197017	KEY-3/16" X 1"	80152002		1
13	00197018	KEY-1/4" X 1 1/2"		ONE EACH SIDE	2
14	PT0403	FLANGE BEARING-4 BOLT-5/8"			2
15	HW0405	BOLT-HHCS-3/8-16 X 2"			4
16	HW0108	WASHER-FLAT-3/8"-SAE			8
17	HW0107	WASHER-LOCK-3/8"			4
18	HW0005	NUT-HEX-3/8-16			4
19	05027001	SHAFT-DRIVE-BTC-18		MPP & MPPEL (MECHANICAL EXTRACT)	1
	05127001	SHAFT-DRIVE-BTC-24
	05227001	SHAFT-DRIVE-BTC-30
	05027003	SHAFT-DRIVE-BTC-18		MPPEE & MPPAE (ELECTRIC EXTRACT)
	05127002	SHAFT-DRIVE-BTC-24
	05227003	SHAFT-DRIVE-BTC-30
20	PT0302-1	COUPLING BODY-#40 X 1"			2
21	PT0301	CHAIN-COUPLING		INCL. CONNECTING PIN	1
22	HW1071	KEY-WOODRUFF-#808 STD		INCL. WITH MOTOR	A/R

BEARINGS & SPROCKETS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0107	SPROCKET-5015 X1"			2
2	00197018	KEY-1/4" X 1 1/2"		ONE EACH SIDE	2
3	PT0401	BEARING-PILLOW BLOCK-1"			2
4	HW0405	BOLT-HHCS-3/8-16 X 2"			4
5	HW0108	WASHER-FLAT-3/8"-SAE			8
6	HW0107	WASHER-LOCK-3/8"			4
7	HW0005	NUT-HEX-3/8-16			4
8	PT0111	SPROCKET-IDLER-50A15 X 5/8"			2
9	HW0603	BOLT-FHSCS-5/8-11 X 2"			2
10	HW0114	WASHER-FLAT-5/8"-SAE			8
11	HW0010	NUT-JAM-5/8-11			2

ARM & CHAIN ATTACHMENT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05057006	PLATE-TOP			2
2	00158001-7	CHAIN-ROLLER-#50		STANDARD BTC	2
	00158001-8	CHAIN-ROLLER-#50		BTC-CAN-7
	00158001-9	CHAIN-ROLLER-#50		BTC-CAN-14
3	PT0104	LINK-OFFSET-#50			2
4	PT0102	LINK-CONNECTING-#50			4
5	05057005	BLOCK-PULL	80052002		2
6	HW0307	BOLT-SHCS-1/4-20 X 1"	80052002		4
7	HW0103	WASHER-LOCK-1/4"	80052002		4
8	05056002	BLOCK-SLIDE	80052005		2
9	05057004	PLATE-BOTTOM	80052005		2
10	HW0407	BOLT-HHCS-3/8-16 X 2 3/4"	80052005		6
11	HW0409	BOLT-FHSCS-3/8-16 X 2"	80052005		2
12	HW0108	WASHER-FLAT-3/8"-SAE	80052005		14
13	HW0006	NUT-NILN-3/8-16	80052005		8

CAM FOLLOWERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0501	CAM FOLLOWER			4
2	HW0115	WASHER-LOCK-3/4"			4
3	HW0011	NUT-HEX-3/4-16			4

EQUALIZATION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05127003	SHAFT-LIFT EQUALIZATION		BTC-24	1
	05227002	SHAFT-LIFT EQUALIZATION		BTC-30
2	PT0401	BEARING-PILLOW BLOCK-1"			2
3	PT0606	SPUR GEAR-1"		22 TOOTH	2
4	00197019	KEY-1/4" X 1 3/8"			2
5	00197022	SHIM-BEARING			2
6	HW0404	BOLT-HHCS-3/8-16 X 1 1/2"			4
7	HW0108	WASHER-FLAT-3/8"-SAE			4
8	HW0107	WASHER-LOCK-3/8"			4
9	HW0005	NUT-HEX-3/8-16			4

ROLLERS & BATTERY STOP

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00182003	ROLLER ASSEMBLY-BTC-18			6
	00182005	ROLLER ASSEMBLY-BTC-24
	05282001	ROLLER ASSEMBLY-BTC-30
2	00187044	SHAFT-HEX-.438" X 20"		BTC-18	6
	00187045	SHAFT-HEX-.438" X 26"		BTC-24
	05287001	SHAFT-HEX-.75" X 32"		BTC-30
3	HW1014-1	PIN-HITCH		FOR USE WITH .438" HEX SHAFT	12
	HW1058	PIN-HITCH		FOR USE WITH .75" HEX SHAFT
4	00194001	STOP-BATTERY	80812001		1
5	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"	80812001		1
6	HW0006	NUT-NILN-3/8-16	80812001		1

PRIMARY GUARDING

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05017087-2	GUARD-CHAIN-LHS		STANDARD BTC	1
	05017097-2	GUARD-CHAIN-LHS		BTC-CAN-7
	05017098-2	GUARD-CHAIN-LHS		BTC-CAN-14
2	05015011-2	GUARD-CHAIN-RHS		STANDARD BTC	1
	05015021-2	GUARD-CHAIN-RHS		BTC-CAN-7
	05115013-2	GUARD-CHAIN-RHS		BTC-CAN-14
3	05015009	GUARD-HAND WHEEL-PRIMARY			1
4	05017086-2	GUARD-HAND WHEEL-LOWER			1
5	05115018	GUARD-EQUALIZATION SHAFT			2
6	05017045	COVER-HAND WHEEL			1
7	HW0301	BOLT-SELF-TAP "F"-1/4-20 X 1/2"			21
8	PL0401	CAP-END			2

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05017087-2	GUARD-CHAIN-LHS		STANDARD BTC	1
	05017097-2	GUARD-CHAIN-LHS		BTC-CAN-7
	05017098-2	GUARD-CHAIN-LHS		BTC-CAN-14
2	05015010-2	GUARD-CHAIN-RHS		STANDARD BTC	1
	05015020-2	GUARD-CHAIN-RHS		BTC-CAN-7
	05115012-2	GUARD-CHAIN-RHS		BTC-CAN-14
3	05017077-2	GUARD-MOTOR			1
4	05017070-2	COVER-POWER UNIT			1
5	05017067-2	GUARD-POWER UNIT			1
6	HW0303	BOLT-HHCS-1/4-20 X 1"			8
7	HW0104	WASHER-LOCK-1/4"			8
8	05115018	GUARD-EQUALIZATION SHAFT			2
9	HW0301	BOLT-SELF-TAP "F"-1/4-20 X 1/2"			14
10	PL0401	CAP-END			2

LABELS & DECALS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00196216	LABEL-WARNING-"CHAIN ENTANGLEMENT HAZARD"		LARGE	4
2	00196217	LABEL-WARNING-"GEAR ENTANGLEMENT HAZARD"			2
3	00196724	LABEL-CAPACITY-”CAPACITY 3,000 LBS”			1
4	00196219	LABEL-WARNING-"ELECTRICAL VOLTAGE HAZARD"			1
5	00196613	LABEL-"CONSULT MANUAL FOR TECHNI- CAL PROCEDURE"			1
6	00196615	LABEL-"DO NOT OPERATE WITH GUARDS REMOVED"			1
7	00196612	LABEL-"READ INSTRUCTION MANUAL PRIOR TO USE"			1
8	08096007	PLACARD-EXTRACTOR ARM IN/OUT		ELECTRIC EXTRACTION UNITS	1
9	08096008	PLACARD-POWER: PUSH & HOLD			1
10	05096006	PLACARD-CARRIAGE RAISE/LOWER			1
11	00196215	LABEL-WARNING-"CHAIN ENTANGLEMENT HAZARD"		SMALL	1
12	05096007	PLACARD-EXTRACTOR ARM IN/OUT		MECHANICAL PUSH/PULL UNITS	1
13	00196701	DECAL-BHS-12" X 3.875"			2

EXTRACTOR ARM

WINCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0601	WINCH			1
2	PT0602	STRAP-WINCH		INCLUDES HOOK	1
3	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			2
4	HW0108	WASHER-FLAT-3/8"-SAE			6
5	HW0107	WASHER-LOCK-3/8"			6
6	HW0005	NUT-HEX-3/8-16			6
7	05015006	MOUNT-WINCH			1
8	HW0404	BOLT-HHCS-3/8-16 X 1 1/2"			4

EXTRACTOR ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05055001	EXTRACTOR ARM-BTC-18			1
	05155001	EXTRACTOR ARM-BTC-24
	08155001	EXTRACTOR ARM-BTC-30
2	08092001	HOOK AND CHAIN ASSEMBLY			1
3	05057007	PAD-PUSH			1
4	HW0413	BOLT-FHSMS-3/8-16 X 1 1/4"			2
5	HW0107	WASHER-LOCK-3/8"			2
6	HW0005	NUT-HEX-3/8-16			2
7	08617006	LATCH-EXTRACTOR ARM		MECHANICAL PUSH/PULL UNITS ONLY	1
8	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			1

HYDRAULICS

POWER UNIT

MONARCH POWER UNITS - EFFECTIVE: 03/06 TO PRESENT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	HC0002-4	POWER UNIT ASSEMBLY-12VDC			1
1	E0029	MOTOR-12VDC-ISKRA		† SEE NOTES	1
2	E0009-2	SOLENOID			1
3	H1008	ADAPTER-RED-#6 SAEM X #4 FNPT			2
4	H0600	TEE-MALE RUN-#4 NPT			1
5	HC0318	GAUGE-PRESSURE		INCL. WITH POWER UNIT ASSY	1
6	HW0107	WASHER-LOCK-3/8"			2
7	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			2
8	E0030	BRUSH KIT (ISKRA MOTOR)		NOT SHOWN	1
	HC0534	BRUSH KIT (BOSCH MOTOR)			1
9	-	THERMAL SWITCH		†† SEE NOTES	1

NOTE:

† BOSCH MOTOR NO LONGER AVAILABLE. ISKRA MOTOR IS DIRECT REPLACEMENT FOR BOSCH MOTOR.

††INTERNAL OF MOTOR. CONSULT FACTORY

BARNES POWER UNIT - EFFECTIVE: 02/02 TO 03/06

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	N/A	POWER UNIT ASSEMBLY-12VDC		††† SEE NOTES	-
1	N/A	MOTOR-12VDC-HALDEX		††† SEE NOTES	-
2	E0009-2	SOLENOID			1
8	HC0512	BRUSH KIT (HALDEX MOTOR)		NOT SHOWN	1

FENNER POWER UNIT - EFFECTIVE PRIOR TO 02/02

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
REF	N/A	POWER UNIT ASSEMBLY-12VDC		††† SEE NOTES	-
1	N/A	MOTOR-12VDC		††† SEE NOTES	-
2	E0009-2	SOLENOID-12VDC			1
8	N/A	BRUSH KIT-12VDC		††† SEE NOTES	-

††† MUST ORDER NEW MONARCH POWER UNIT TO REPLACE BARNES OR FENNER POWER UNIT.

EXTRACTOR ARM MOTOR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0120	MOTOR-HYDRAULIC-160CC			1
2	HW1071	KEY-WOODRUFF-#808 STD		INCL. WITH MOTOR	A/R
3	H1002	BUSHING-RED-#10 SAEM X #4 FNPT			2
4	HW0402	BOLT-HHCS-3/8-16 X 1"			4
5	HW0107	WASHER-LOCK-3/8"			4
6	HW0806	SCREW-SHSS-3/8-16 X 2"			2
7	HW0006	NUT-NILN-3/8-16			2

CONTROL VALVES

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0201	MANUAL VALVE	80042002		1
REF	08046001	MODIFIED VALVE HANDLE ASSEMBLY	80042002	INCL. ITEMS 2 & 3	1
2	N/A	VALVE HANDLE-MODIFIED	†		1
3	N/A	BALL-HANDLE	†		1
4	H1303	ADAPTER-90 DEG-#6 JICM X #8 NPTM	80042002		4
5	H0201	BUSHING-RED-#8 NPTM X #4 FNPT			1
6	H0600	TEE-MALE RUN-#4 NPT			1
7	H0300	ELBOW-STR-90 DEG-#4 NPT			1
8	HC0218	VALVE-CHECK			1
9	HW0106	WASHER-FLAT-5/16"-SAE			3
10	HW0322	BOLT-HHCS-5/16-18 X 2"			3
11	HW0105	WASHER-LOCK-5/16"			3
12	HW0004	NUT-HEX-5/16-18			3

† INCLUDED IN MULTIPLE KITS

PILOT-TO-OPEN VALVE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0209	VALVE-PTO			1
2	H0201	BUSHING-RED-#8 MNPT X #4 FNPT			2
3	H0600	TEE-MALE RUN-#4 NPT			1
4	H0700	TEE-BRANCH-#4 NPT			1
5	HW0405	BOLT-HHCS-3/8-16 X 2"			2
6	HW0107	WASHER-LOCK-3/8"			2
7	HW0005	NUT-HEX-3/8-16			2

HOSES

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00142001-87	HOSE-HYDRAULIC-54"-JICSW X MNPTSW		MPPEE & MPPAE	2
2	00142001-27	HOSE-HYDRAULIC-40"-MNPT X MNPTSW		MPPEL & MPPAE	2
3	00142001-85	HOSE-HYDRAULIC-13"-MNPT X MNPTSW		MPPEL & MPPAE	2
4	00142001-86	HOSE-HYDRAULIC-13"-JICSW X MNPT		ALL	2
5	00142001-17	HOSE-HYDRAULIC-30"-JICSW X MNPT		MPPEL & MPPAE	1
6	00142001-24	HOSE-HYDRAULIC-36"-JICSW X JICSW		MPPAE ONLY	1

MANUAL JACK

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05046003	MANUAL JACK		HANDLE SOLD SEPARATELY	1
2	HW0303	BOLT-HHCS-1/4-20 X 1"			2
3	HW0104	WASHER-FLAT-1/4"-SAE			4
4	HW0103	WASHER-LOCK-1/4"			2
5	HW0002	NUT-HEX-1/4-20			2
6	HC0414	JACK HANDLE			1

MANUAL JACK REPAIR PARTS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	-	O-RING		AVAILABLE IN REPAIR KIT ONLY	1
2	-	O-RING		AVAILABLE IN REPAIR KIT ONLY	1
3	-	FILLER PLUG		AVAILABLE IN REPAIR KIT ONLY	1
4	-	GASKET		AVAILABLE IN REPAIR KIT ONLY	1
5	-	BACK-UP RING		AVAILABLE IN REPAIR KIT ONLY	1
6	-	U-CUP		AVAILABLE IN REPAIR KIT ONLY	1
7	-	BACK-UP RING		AVAILABLE IN REPAIR KIT ONLY	1
8	-	O-RING		AVAILABLE IN REPAIR KIT ONLY	1
9	HC0412	RELEASE HANDLE			1
10	HC0413	SCREW-RELEASE HANDLE			1
11	HC0411	RELEASE VALVE			1
12	-	SEAL		AVAILABLE IN REPAIR KIT ONLY	1
13	HC0519	CARTRIDGE			1
14	-	SEAL		AVAILABLE IN REPAIR KIT ONLY	1
15	HC0522	FILTER			1
16	HC0406	PUMP CYLINDER			1
17	-	SEAL		AVAILABLE IN REPAIR KIT ONLY	1
18	-	O-RING		AVAILABLE IN REPAIR KIT ONLY	1
19	HC0525	PUMP PISTON			1
20	HC0526	PIN			2
21	HC0528	HANDLE SOCKET			1
22	HC0529	RETAINING PIN			2
REF	HC0405	REPAIR KIT			A/R

HYDRAULIC CYLINDER

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0402	CYLINDER-LIFT			1
2	00197035	PIN-CYLINDER			1
3	HW1058	PIN-HITCH			2
4	H0303	ELBOW-STR-90 DEG-#6 NPTM X #4 FNPT			2
5	H0001	NIPPLE-#4 NPT			1
6	HC0211	VALVE-ADJUSTABLE FLOW CONTROL			1

HYDRAULIC SCHEMATICS

ELECTRICAL

BATTERY & CABLES

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0416	BATTERY-12VDC			1
2	05032003	CABLE-BATTERY-76"		BTC-18 & 24	1
	05032004	CABLE-BATTERY-84"		BTC-30
3	E1103-1	COVER-TERMINAL-RED			1
4	05032005	CABLE-GROUND-BATTERY			1
5	E1104-1	COVER-TERMINAL-BLACK			1
6	05032006	CABLE-GROUND-POWER UNIT			1
7	HW0105	WASHER-LOCK-5/16"			2
8	HW0004	NUT-HEX-5/16-18			2
9	HW0402	BOLT-HHCS-3/8-16 X 1"			1
10	HW0108	WASHER-FLAT-3/8"-SAE			1
11	HW0107	WASHER-LOCK-3/8"			1
12	HW0005	NUT-HEX-3/8-16			1

OPERATOR CONSOLE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E1361	LIGHT-INDICATOR-12VDC			1
2	E0308	ACTUATOR-PUSH BUTTON	80032001		1
3	E0307	CONTACT BLOCK-N/O	80032001		1
4	PL0501	GROMMET-1/2" I.D.			A/R

ELECTRICAL SCHEMATICS

STANDARD OPTIONS

RUBBER BUMPERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW1037	BUMPER-RUBBER-RECESSED	80092001		2
2	HW0303	BOLT-HHCS-1/4-20 X 1"	80092001		2
3	HW0104	WASHER-FLAT-1/4"-SAE	80092001		2
4	HW0003	NUT-NILN-1/4-20	80092001		2

TRACK MOUNT

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	C0015	CASTER-6" X 2"-RIGID			2
2	HW0403	BOLT-HHCS-3/8-16 X 1 1/4"			8
3	HW0108	WASHER-FLAT-3/8"-SAE			8
4	HW0107	WASHER-LOCK-3/8"			8
5	HW0005	NUT-HEX-3/8-16			8
6	C0080	CASTER-6" X 3"-DUAL FLANGED			2
7	HW0504	BOLT-HHCS-1/2-13 X 2"			8
8	HW0112	WASHER-FLAT-1/2"-SAE			16
9	HW0110	WASHER-LOCK-1/2"			8
10	HW0007	NUT-HEX-1/2"			8

PUSH ARM EXTENSION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05015036	EXTENSION-PUSH PAD			1
2	05057010	PAD-PUSH			1
3	HW0413	BOLT-FHSMS-3/8-16 X 1 1/4"			2
4	HW0107	WASHER-LOCK-3/8"			2
5	HW0005	NUT-HEX-3/8-16			2
6	HW0402	BOLT-HHCS-3/8-16 X 1"			2
7	HW0108	WASHER-FLAT-3/8"-SAE			2
8	HW0006	NUT-NILN-3/8-16			2

COMPARTMENT EXTENSION

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1a	00182007	ROLLER ASSEMBLY-14.563"		†	1
1b	00182003	ROLLER ASSEMBLY-18.563"		†
1c	43182002	ROLLER ASSEMBLY-23.875"		†
2a	00187012	SHAFT-HEX-.438" X 16.125"		††	1
2b	00187044	SHAFT-HEX-.438" X 20"		††
2c	43187002	SHAFT-HEX-.75" X 25.75"		††
3	HW1014-1	PIN-HITCH		FOR USE WITH .438" HEX SHAFT	2
	HW1058	PIN-HITCH		FOR USE WITH .75" HEX SHAFT

† THE ROLLERS LISTED ABOVE ARE THE MOST COMMON ROLLERS USED IN COMPARTMENT EXTENSIONS. IF YOUR UNIT IS EQUIPPED WITH A ROLLER OTHER THAN THOSE LISTED, MEASURE THE INSIDE WIDTH OF THE COMPARTMENT EXTENSION (SEE DETAIL A) AND CONSULT THE FACTORY.

†† HEX SHAFT LETTER “a” IS TO BE USED WITH ROLLER “a”, HEX SHAFT “b” WITH ROLLER “b” ETC

SECONDARY GUARDING

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	05317156	GUARD-CHAIN-RUBBER		STANDARD BTC	2
	05017103	GUARD-CHAIN-RUBBER		BTC-CAN-7
	05017105	GUARD-CHAIN-RUBBER		BTC-CAN-14
2	05317155	RETAINER-RUBBER GUARD		STANDARD BTC	2
	05017102	RETAINER-RUBBER GUARD		BTC-CAN-7
	05017104	RETAINER-RUBBER GUARD		BTC-CAN-14
3	HW0301	BOLT-SELF-TAP "F"-1/4-20 X 1/2"			16

VACUUM SWITCH

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0302	SWITCH-PULL		6-28VDC, 75 AMP	1
2	08096005	PLACARD-VACUUM-ON/OFF			1
3	E0611	JUNCTION BOX-4" X 2" X 2"			1
4	E0612	COVER-JUNCTION BOX			1
5	E0624	CONNECTOR-1/2"		INCLUDES LOCK NUT	3
6	HW0301	BOLT-SELF-TAP "F"-1/4-20 X 1/2"			2
7	00196218	LABEL-WARNING-"ELECTRICAL VOLTAGE HAZARD"			1

VACUUM PUMP

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	P0001	PUMP-VACUUM-12VDC	80062001		1
2	P0205	VALVE-VACUUM RELEASE-12VDC	80062001		1
3	P0503	NIPPLE-#4 NPT-BRASS	80062001		1
4	P0506	ELBOW-STR-90 DEG-#4 NPT-BRASS	80062001		1
5	P0208	FILTER-HIGH FLOW	80062001		1
6	P0402	HOSE BARB-1/4" X #4 NPT-BRASS			2
7	05167001-2	MOUNT-VACUUM PUMP			1
8	HW0206	SCREW-RHMS-#10-32 X 3/4"			4
9	HW0101	WASHER-LOCK-#10			4
10	E0611	JUNCTION BOX-4" X 2" X 2"			1
11	E0612	COVER-JUNCTION BOX			1
12	E0624	CONNECTOR-1/2"		INCLUDES LOCK NUT	2
13	HW0301	BOLT-SELF-TAP "F"-1/4-20 X 1/2"			2
14	HW0003	NUT-NILN-1/4-20			2
15	00196218	LABEL-WARNING-"ELECTRICAL VOLTAGE HAZARD"			1
16	HW0303	BOLT-HHCS-1/4-20 X 1"			4
17	HW0104	WASHER-FLAT-1/4"-SAE			4
18	HW0105	WASHER-LOCK-1/4"			4
19	HW0002	NUT-HEX-1/4-20			4
20	P0302	HOSE-VACUUM -1/4" I.D.		SOLD BY LENGTH	A/R

VACUUM ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	N/A	VACUUM CUP-250 mm	00162001	AVAILABLE IN KIT ONLY	1
2	00117059	PLATE-VACUUM CUP ADAPTER	00162001		1
3	HW0328	BOLT-HHCS-5/16-18 X 3/4"	00162001		4
4	P0505	BUSHING-RED-#6 NPT X #4 FNPT-BRASS	00162001		1
5	HW0427	STUD-VACUUM-3/8-16 X 4"	HW-KIT-1		4
6	HW0108	WASHER-FLAT-3/8"-SAE	HW-KIT-1		32
7	HW1001	SPRING-3/8"	HW-KIT-1		8
8	HW0006	NUT-NILN-3/8-16	HW-KIT-1		4
9	05055002	EXTRACTOR ARM-BTC-18			1
	05155002	EXTRACTOR ARM-BTC-24
	05255001	EXTRACTOR ARM-BTC-30
10	P0301-1	HOSE-COIL-VACUUM			1

SELF CONTAINED CHARGER

<td style="width:216pt;border-top-style:solid;border-top-width:1pt;border-top-color:#231F20;border-left-style:solid;border-left-width:1pt;border-left-color:#231F20;border-bottom-style:solid;border-bottom-width:1pt;border-bottom

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	E0209	CHARGER-12VDC / 25A			1
2	05217007	MOUNT-CHARGER			1
3	HW0303	BOLT-HHCS-1/4-20 X 1"			6
4	HW0104	WASHER-FLAT-1/4"-SAE			12
5	HW0103	WASHER-LOCK-1/4"			6
6	HW0002