IOP-407 BE-TSN

TP-606 - SAFETY AND DE-ENERGIZATION PROCEDURES

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GENERAL SAFETY

• Read and understand all instructions and warnings before using or servicing this equipment.

• Keep these instructions for future reference.

• Battery Extractor (BE) units shall only be operated by suitable persons of at least 18 years of age, who have been trained in the proper and safe operation of the BE and expressly certified/charged, in writing, by the user or their representative.

• Only one person is permitted to travel on the BE at any time.

• BE units shall only be used indoors in an industrial setting on a hard, nonslip, and level floor without defects including but not limited to holes, gouges, cracks, drains or obstacles comprised of concrete or other suitable industrial material meeting the minimum requirements specified by BHS as well as any local requirements.

• A licensed structural engineer should be consulted prior to installing a BE on any building level other than the ground floor.

• BE units are not designed to be shipped or transported after initial delivery.

WORK AREA

• Keep work area clean and well lit. Cluttered work areas and poor lighting can lead to accidents.
• Clean up/contain any fluid spills immediately to prevent slips or falls.
• Be aware of potential hazards when performing any service or maintenance to the unit.

SERVICE & MAINTENANCE

Service personnel shall wear Personal Protective Equipment (PPE) appropriate for the task being performed.

LOCKOUT/TAGOUT

Lockout/tagout the BE per your corporate policy, if damaged or not functioning properly. Lockout/tagout and de-energize all systems prior to performing any maintenance or service to unit.

LEAD-ACID BATTERIES-EXPLOSION HAZARD

Do not allow open flames or sparks of any kind near a battery. Highly explosive gas is generated when charging a battery that can remain in battery cells for extended periods of time after charging is complete.

• Always wear appropriate PPE including rubber apron, gloves, boots and full face shield when performing service or maintenance to any lead-acid batteries.

• Do not place metal or other conductive objects on top of battery. Arcing may occur causing damage to the battery and/or serious personal injury or death.

• Use only chargers matching the voltage and amperage of the battery being charged. Overcharging a battery can cause damage to the battery, charger and/or serious personal injury or death.

• Turn off charger before disconnecting battery from charger. Arcing between battery and charger connectors can cause damage to the connectors and/or serious personal injury or death.

HYDRAULIC HAZARD

AVOID HIGH PRESSURE FLUIDS-Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. DO NOT use your hand.

Any fluid injected into the skin under high pressure should be considered a serious medical emergency despite an initial normal appearance of the skin. There will be a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately.

OPERATIONAL SAFETY

OPERATIONAL SAFETY

• Only personnel trained in the proper and safe operation of BE units may operate or service the BE.

• Operators shall wear appropriate PPE suitable for working with industrial lead-acid batteries while operating the BE (see prior page).

• All data plates, warning labels, placards, etc shall be in place and legible at all times. Contact BHS for replacement data plates, warning labels, placards or instructions.

• All users and service personnel shall be familiar with the meaning and risks associated with all data plates, warning labels, etc.

• All operators and service personnel shall be aware of potential crush and shear points while operating or servicing the BE.

• Keep hands and arms out of the battery compartment while operating the BE.

• Remove BE from service if damaged, defective, or operating improperly (or becomes such while operating) until repairs can be made to correct any problem(s).

• All operators shall be aware of the location of the end stops in the travel path to prevent driving the BE into the end stops.

DO’s AND DON’T’s

• DO NOT exceed the maximum capacity of the BE.

• DO NOT modify or fit the BE with attachments without prior, written approval from BHS.

• DO NOT perform any maintenance or service to the BE with a battery loaded on the BE.

• DO NOT allow anyone to ride in or on the BE.

• DO NOT operate the BE with any guard or cover removed unless required for maintenance or repair.

• Disconnect the BE from all power sources before attempting to perform service or maintenance to the unit.

• DO NOT drive the BE into the end stops.

• DO NOT operate the BE if disengaged from the guidance track.

• DO NOT allow a battery to exit the BE when a lift truck or battery stand is not present to accept the battery.

• DO NOT rotate the arm onto a battery such that any part of the extractor arm, vacuum cup or magnet contacts the top of the battery.

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

• DO NOT use the BE in a manner for which it is not intended. Some examples of prohibited use are but not limited to:

           >>To transport people 
           >>As a vehicle jack
           >>To lift loads greater than its rated load capacity
           >>Where unintentional movement may exist
           >>Having direct contact with foodstuff
           >>In a potentially explosive atmosphere

DE-ENERGIZATION

1. Fully lower the BE roller bed or position the roller bed on service stands if service requires the bed be raised. See Figures 1 & 2
Failure to properly support the roller bed when performing service under the BE could result in injury from the roller bed lowering unexpectedly.


FIGURE 1



FIGURE 2

2. Turn key on dashboard to the “OFF” position. See Figure 3.


FIGURE 3

3. Disconnect power to the extractor or shut off the electrical branch circuit breaker.
Failure to disconnect electrical power to the BE could result in electrical shock. Serious personal injury or death will occur.
4. Actuate all hydraulic levers in both directions to release any stored hydraulic pressure. See Figure 4.
Failure to release any stored hydraulic pressure could result in injury from:
• Escaping hydraulic fluid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section).
• Unexpected movement of hydraulic components.


FIGURE 4

LABELS & PLACARDS

GENERAL INFORMATION

SPECIFICATION DATA

PRE-INSTALLATION CHECK

OPERATING CONTROLS

OPERATING INSTRUCTIONS

PRE-CHANGE OUT PREPARATION

1. Position the lift truck for change out in the designated change out area.
2. Remove all battery restraints and disconnect the battery cables following the manufacturer's guidelines. (Be sure to position the battery cables so as not to be damaged by the battery during change out.)
3. Board the battery extractor and close the safety gate. (The gate must be fully closed or the unit will not operate.)
4. Depress the foot pedal.
5. Turn the key switch to the “ON” position.

DISCHARGED BATTERY REMOVAL

1. Move the extractor left or right to position the center of compartment with the center of the lift truck battery compartment. (Lead roller of extractor is equipped with a centering groove. Users may find it beneficial to mark center of lift truck compartment to aid in alignment.)
2. Align the extractor’s roller compartment height with the lift truck’s battery compartment.
3. Rotate extractor arm into battery compartment aligned in Step 2.
4. Move the extractor arm toward the battery until the vacuum cup/magnet contacts the battery.
DO NOT force cup to battery after initial contact with battery is made.
5. Energize vacuum by turning selector switch to proper direction, left or right.
6. Move extractor arm away from lift truck toward center of extractor roller bed, removing discharged battery. (Battery should be pulled past first three idler rollers onto first or second powered roller.)
7. Turn off vacuum and move extractor arm away from battery 1” to 2”.
8. Rotate extractor arm out of battery compartment into opposite compartment (if empty) and center arm in carriage.
9. Move battery into center of compartment using powered rollers.

CHARGED BATTERY RETRIEVAL

1. Locate a charged battery for the appropriate type of lift truck being changed.
2. Raise battery extractor roller compartment to proper level to gain access as needed to disconnect desired battery from its charger and disengage 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 extractor to appropriate rack position and align empty roller compartment with the center of the battery storage rack compartment. (The battery safety stop of each compartment is the center of that compartment and should be used for alignment with the groove in the lead roller of the battery extractor compartment.)
4. Rotate arm into empty compartment (if not already positioned there.)
5. Move extractor arm toward battery until vacuum cup contacts battery.
6. Energize vacuum cup by turning selector switch to proper direction, left or right.
DO NOT force cup to battery after initial contact with battery is made.
7. Move extractor arm away from battery rack toward center of extractor roller bed, removing charged battery. (Battery should be pulled past first three idler rollers onto first or second powered roller.)
8. Turn off vacuum and move extractor arm away from battery 1” to 2”.
9. Rotate extractor arm out of battery compartment into fully vertical position.
10. Move battery into center of compartment using powered rollers.

OPERATING INSTRUCTIONS

DISCHARGED BATTERY RETURN

1. If required, adjust extractor compartment height to battery rack level with open battery compartment. Drive extractor to align roller compartment containing discharged battery with open battery compartment.
2. Return discharged battery to battery rack using powered rollers.
NOTE: In most instances, batteries can be deposited into battery racks in one motion using only powered rollers. When this does not work, the battery may need slight assistance from extractor arm. To do this, rotate arm into compartment such as one would if removing battery from rack. If extractor is vacuum equipped, position top edge of cup slightly higher than edge of battery (or over lifting eye if so equipped) to prevent cup from adhering to battery - No vacuum is necessary for pushing. DO NOT activate vacuum switch. Slowly push battery into rack until fully into compartment.
3. Engage the battery safety stop and connect the battery to the charger as required.

CHARGED BATTERY INSTALLATION

1. Lower extractor to fully lowered position.
2. 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”.
3. 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.
4. Adjust the extractor vertically as well as horizontally, if needed.
5. Insert battery into lift truck as far as possible using only the powered rollers.
6. Rotate extractor arm into compartment and SLOWLY push battery into lift truck. (Be sure to watch battery cables for interference.)
7. Return extractor arm to center of roller bed and lower extractor to fully lowered position. Drive extractor out of immediate area.
8. Turn off key switch, remove key from switch and carefully exit extractor.
9. Secure newly installed battery in lift truck and reconnect battery cables.
10. Return lift truck to service.
DO NOT drive the B.E. into the travel path end stops. The end stops are designed to prevent the B.E. from accidentally traveling beyond its designated travel path. Driving the B.E. into the end stops will cause the B.E. to stop suddenly, possibly causing damage to the end stop, the B.E. 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.

RECOMMENDED SPARE PARTS

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

EQUALIZTION

BRIDGE & CROSS BAR

LIFT CYLINDER CONNECTIONS

GUIDANCE ARM

IDLER ROLLERS

POWERED ROLLERS

HOSE CARRIER

CABLE RETRACTOR

OPERATOR GATE

GUARDS - OUTSIDE CARRIAGE

GUARDS - INNER CARRIAGE

GUARDS - LIFT CYLINDER=

EXTRACTOR ARM

VACUUM STUDS

SWING ARMS

SWING ARM STOPS

VACUUM PUMP

EXTRACTOR ARM MOUNTING

HOSE MOUNTING

ARM CYLINDER

BEARING PLATES

ROTARY ACTUATOR

CARRIER SHAFTS

DRIVE NUT ASSEMBLY

DRIVE SCREW

HOSE CARRIER PLATE

DRIVE AND IDLER CASTERS

FLOOR DRIVE ASSEMBLY

CASTERS

ELECTRICAL

AC POWER STANCHION

CONTROL PANEL

File:IOP-407 BE-TSN (03-30-12)4.1.2.jpg File:IOP-407 BE-TSN (03-30-12)4.1.2T.jpg

OPERATOR CONSOLE

FOOT SWITCH

GATE SWITCH

PROXIMITY SWITCH

JUNCTION BOX

JUNCTION BOX PANEL

File:IOP-407 BE-TSN (03-30-12)4.4.3.jpg

WIRING DIAGRAMS

HYDRAULICS

POWER UNIT

RESERVOIR

VALVE ASSEMBLY

LIFT CYLINDER

LIFT CIRCUIT

CROSS PORT RELIEF

COUNTER BALANCE VALVE

TRANSITION PLATE

RETURN LINE MANIFOLD

HYDRAULIC SCHEMATICS

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

RECOMMENDED LUBRICATION INTERVALS

PREVENTATIVE MAINTENANCE REPORTS

EQ CHAIN RESETTING PROCEDURE

These instructions outline the procedures for replacing or resetting the equalization chains on single, double, and triple stack battery extractors.

Tools Required:

1 - Large standard screw driver 1 - 1/8” Allen key

1 - 5/32” Allen key 2 - 1 1/8” End wrenches

1 - 3/16” Allen key 1 - Needle nose pliers

1 - Steel ruler 1 - 80292002 EQ. adjustment stop kit

Step 1)

You will need to remove the inner and outer frame guards to access the lower studs to ease the adjustment process. The next step is to level the inner frame of the extractor using the 80292002 equalization adjustment stop kit.

NOTE: THIS PROCESS REQUIRES THE EXTRACTOR TO BE FULLY UNLOADED. BE SURE TO POSITION THE BATTERY EXTRACTOR IN A LEVEL AREA OF THE FLOOR.

Installation of the equalization adjustment stop kit requires (4) persons plus a trained battery extractor operator to raise and lower the extractor from the operator platform.

First, have the operator raise the extractor approximately 30” from the fully lowered position. Next, have (4) persons install a service stop in each corner of the roller beds as shown in the following photos.

Be sure that the word “UP” and the etched arrow are pointing toward the top of the machine.

Once all four stops have been installed as shown, have the operator slowly lower the platform until the roller bed is firmly seated against all (4) stops.

BE SURE ALL STOPS ARE CORRECTLY SEATED AS SHOWN HERE

Step 2) If you are replacing or adjusting existing EQ chains at this point you will need to remove the hex nuts and lock washers from the upper EQ chain studs and lower the chains. Retain the hex nuts and lock washers for reassembly. Remove and discard the master links from the upper and lower EQ chain studs and remove the chain from the studs.

NOTE: If the equalization chains are being reset due to a master link failure, it is recommended that the stud where the master link failed be replaced at this time.

Step 3) Thread the lower EQ chain studs into the frame until they are flush with the bottom of the frame then turn an additional one half turn with the holes aligned front to back. (See figure 2)

FIGURE 2

Step 4) Attach the # 60 EQ chains to the upper and lower studs using the new #60 master links and lay chains in the frame until all 4 chains are reattached. Be sure the hex nut is threaded down near the master link. (See Figure 3)

FIGURE 3

Step 5) Align the EQ shafts so that the key stocks are in the 2 o’clock position. This will bring the set screws on the sprockets to the top of the sprocket when the inner frame is lowered. (See Figure 4)

FIGURE 4

Starting with the inside #60 EQ chain, route the chain over the sprocket directly above the lower EQ chain stud and then under the inside sprocket on the opposite EQ shaft. (See Figures 4 & 5) Be sure to take out as much slack as possible between the sprockets. Then attach the upper EQ Chain Stud to the top cross bar. (See Figure 6)

FIGURE 5

FIGURE 6

Next route the outer chain over the outer EQ sprocket and under the outer sprocket on the opposite EQ shaft and attach the upper stud to the top cross bar. Repeat this process for the opposite side of the extractor. Do not tighten the upper EQ stud adjusting nuts at this time. Be sure a lock washer is installed between the top cross bar and lower hex nut. (See figure 6)

Adjust the lower stud up or down to take the slack out of the equalization chain between the lower stud and the sprocket. It will probably be necessary to use a large standard screwdriver to get the fi nal chain over the sprocket. NOTE: It is recommended that the operator end is done fi rst since it has more obstacles hindering complete and easy access.

Step 6) Once all the chains have been installed you should now tighten the upper hex nuts on the upper studs until it takes about 10 pounds of force to produce ¼” deflection in the middle of the vertical section of the EQ chain. Tighten the lower hex nut on the upper cross bar studs to lock the studs in position.

Step 7)

Using a steel ruler measure the distance of the chain at the lower stud to the inside frame and set the distance of the corresponding sprocket to that distance. (See figures 7 and 8) Repeat this process for the remaining 3 sprockets. Raise and lower the inner frame several times and listen for any chain popping noise to confirm the sprockets are in line with the lower studs. If there is no popping noise then tighten the set screws on the sprockets and slide the clamp collars against the outside sprocket and tighten the clamp collars.

FIGURE 7

FIGURE 8

SERVICE STAND INSTALLATION

PARTS KITS