IOP-402 BE-QS

TP-625 - SAFETY AND DE-ENERGIZATION PROCEURES

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GENERAL INFORMATION

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

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

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 fully lower the roller bed when performing service to the BE could result in injury from the roller bed lowering unexpectedly.

FIGURE 1

FIGURE 2

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

FIGURE 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.

Actuate all hydraulic levers in both directions to release any stored hydraulic pressure. See Figure 4.

LABELS & PLACARDS

SPECIFICATION DATA

PRE-INSTALLATION CHECK

FLOOR CONDITIONS

The floor is the single most critical area of the battery room. A bad floor can cause significant issues with the installation as well as downtime and maintenance problems with the extractor. The floor should be verified as to its minimum thickness and strength with user. As noted on the drawing, the specific requirement of flatness for your particular type of system is listed. Below is a chart stating floor requirements. If possible, especially on double stack and higher systems, a digital level should be used to shoot the grade for compliance with the specification. The floor should also be inspected for severe cracks or excessively wide expansion joints in the travel path of the machine. If floor drains are present, they must not have a grade to the opening that encroaches into the travel path.

F-min is a rating method used to evaluate the flatness and levelness of a floor designated as "defined travel path". For example, an F-min rating of 60 means that there is no more than .129" of variation in the transverse axis (wheels left to right) and .287" variation in the longitudinal axis (front to back) on the equipment.

To avoid potential damage to drive wheel assemblies, guide track, structural components, guide rollers and issues with the inner frame equalization the "defined travel path" of the Battery Extractor should meet or exceed the recommended F-min specification. See chart below for the model specifications

OPERATING CONTROLS & INSTRUCTIONS

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. The machine key must be used to reset the emergency stop.

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.

Gate Switch – The gate must be fully closed for the BE to operate.

Extractor Arm Switch – Does not permit the machine to move forward or backward unless the extractor arm is located in the center of the carriage between the indicating arrows located on the arm guard.

Powered Roller Cutout – Disengages the powered roller function when the photo eye positioned on the edge of the BE battery compartment is disrupted by a battery, requiring additional input from the operator. Pressing the "Power Roller Cutout" override button (see above) on the dash will resume powered roller operation when loading or unloading batteries from the BE carriage.

Horn (If equipped) – Button located on the dash (see above). Used to alert personnel before moving the BE.

Strobe Light (If equipped) – Located on a vertical stanchion mounted to the right rear of the operator compartment. For units equipped with optional overhead guard (OHG), the beacon is located above of the operator compartment. Beacon automatically flashes when the BE is switched on.

Audible Alarm (if equipped) – Located in the same spot as the Strobe Light. Automatically sounds when the BE is switched on.

OPERATION OVERVIEW

• All operators should be familiar with the operator console of the extractor before performing any battery changes. The controls of the console are simple and well marked. It consists of six, manually operated, hydraulic control valves and a three position selector switch which controls the left and right vacuum cups (or optional magnets).

• The operator shall make certain there are no persons or obstacles in the extractor path prior to traveling forward or reverse.

• 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 dead-man switch and all functions will stop immediately, locking all hydraulics in place.

• The extractor arm must be in the center of the carriage or the unit will not travel forward or reverse.

• To ensure smooth operation, all valve movements should be made in a slow, deliberate motion.

• Only one key should be provided to operate the extractor.

• When leaving the machine, the operator shall turn off the key switch and remove the key to prevent unauthorized use.

• Ensure all the batteries and cables are properly stored in the battery stands prior to moving the BE.

• The BE is designed to carry only one battery in each compartment on the carriage.

• When loading the BE, position the batteries in the center of the compartments on the powered rollers to prevent any battery movement when transporting.

• Ensure there are no projections outside of the carriage before moving the BE.

OPERATING INSTRUCTIONS

PRE-CHANGE OUT PREPARATION

Position lift truck for change out in designated area.
Remove all battery restraints and disconnect battery cables following manufacturers guidelines. (Be sure to position battery cables so as not to be damaged by battery during change out.)
Mount battery extractor and close safety gate. (Gate must be fully closed or unit will not operate.)
Secure safety lanyard to safety harness.
Depress foot-operated pedal. (Dead-man switch) 6. Turn key switch to "ON" position.

NOTE: If unit fails to energize after steps 2-5, verify the Emergency Stop is not depressed.

DISCHARGED BATTERY REMOVAL

Move extractor forward or reverse to position center of empty compartment with center of 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.)
Align extractor’s roller bed height with lift truck’s battery compartment.
Rotate extractor arm into battery compartment aligned in Step 2.
Move extractor arm toward battery until vacuum cup/ magnet contacts battery.
Energize vacuum cup/magnet by turning selector switch to proper direction, left or right.

DO NOT force cup/magnet to battery after initial contact with battery is made.

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.)
Turn off vacuum/magnet and move extractor arm away from battery 1" to 2".
Rotate extractor arm out of battery compartment into opposite compartment (if empty) and center arm in carriage.
Depress powered roller override button and move battery into center of compartment using powered rollers.

CHARGED BATTERY RETRIEVAL

Locate charged battery of appropriate type for lift truck being changed.
Move extractor to appropriate rack position and align empty roller compartment horizontally with center of bottom battery storage rack compartment. (Battery safety stop of each compartment is center of that compartment and should be used for alignment with groove in lead roller of battery extractor compartment.)
#Raise battery extractor roller compartment to proper level to gain access as needed to disconnect battery from charger.

ALWAYS be sure charging has been completed and charger is not still charging battery. Dangerous sparking can occur if battery is unplugged from charger under these conditions.

Adjust roller compartment height to battery being retrieved.
Rotate arm into empty compartment (if not already positioned there.)
Move extractor arm toward battery until vacuum cup/ magnet contacts battery.
Energize vacuum cup/magnet by turning selector switch to proper direction, left or right.

DO NOT force cup/magnet to battery after initial contact with battery is made.

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.)
Turn off vacuum/magnet and move extractor arm away from battery 1" to 2".
Rotate extractor arm out of battery compartment into fully vertical position.
Depress powered roller override button and move battery into center of compartment using powered rollers.

DISCHARGED BATTERY RETURN

While remaining at current battery compartment height, drive extractor to align roller compartment containing discharged battery with open battery compartment left by extraction of charged battery.
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/magnet is necessary for pushing. DO NOT activate vacuum/magnet switch. Slowly push battery into rack until fully into compartment.

Engage battery safety stop and connect battery to charger as required.

CHARGED BATTERY INSTALLATION

Lower extractor roller compartment to fully lowered position.
Return extractor back to lift truck and align roller compartment containing charged battery as performed in steps 1 & 2 of "Discharged Battery Removal".
Move charged battery toward lift truck compartment by using powered rollers, verifying precise battery alignment.

Many batteries are a tight t into lift truck battery compartments. Care MUST be taken to ensure alignment is precise to avoid damage to battery, lift truck, and/or battery extractor.

Adjust extractor vertically as well as horizontally, if needed.
Insert battery into lift truck as far as possible using only the powered rollers.
Rotate extractor arm into compartment and SLOWLY push battery into lift truck. (Be sure to watch battery cables for interference.)
Drive extractor out of immediate area and carefully dismount the extractor.
Secure newly installed battery in lift truck and reconnect battery cables.
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.

SPARE PARTS LIST

Refer to the appropriate Spare Parts Kit (vacuum equipped units - Pt# BE-SPKV-QS, magnet equipped units - Pt# BE-SPKM-QS) at the beginning of Section 8 for the list of items recommended by the factory to have on hand for BE-QS models to minimize any downtime due to minor breakdown that may occur under normal operating conditions.

BHS also offers a supplement hose kit (Pt# 80442001) which contains an assortment of hoses allowing any hose on the extractor to be replaced immediately with a temporary hose of equal length or longer. When the extractor is back up and running, the failed hose can be taken to have an exact replacement made. Once the new hose is made and installed, the temporary hose can be returned to the kit for future use.

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.)

Note: Spare parts kits contain parts for the most current machine design/configuration. Due to continuous design and manufacturing improvements, not all the parts in the spare parts kits may be compatible with older units. Consult factory when ordering spare parts for existing units in the field to ensure part compatibility.

PARTS SECTIONS

CHASSIS

EQUALIZATION

TOP BRIDGE

LIFT CYLINDER CHAINS

LIFT CYLINDER MOUNTING

LOWER GUIDANCE ARMS

UPPER GUIDANCE ARMS

IDLER ROLLERS

POWERED ROLLERS

HOSE CARRIER

CABLE RETRACTOR

HOSE CARRIER SUPPORT

OPERATOR GATE

GUARDS - OUTSIDE FRAME

GUARDS - INNER CARRIAGE

GUARDS - DASH & PLATFORM

GUARDS - LIFT CYLINDER

OVERHEAD GUARD

LABELS AND PLACARDS

EXTRACTOR ARM

VACUUM ARM

VACUUM CUPS

SWING ARMS

VACUUM PUMP

ROTARY ACTUATOR

CARRIER SHAFTS

DRIVE NUT ASSEMBLY

DRIVE SCREW

HOSE CARRIER PLATE

MAGNET EXTRACTION

MAGNET PIVOT STOP

MAGNET EXTRACTION

VACUUM EXTENDED REACH

EXTENDED REACH

MAGNET EXTENDED REACH

EXTENDED REACH

DRIVE AND IDLER CASTERS

DRIVE WHEEL MOUNTING

DRIVE WHEEL ASSEMBLY

DRIVE WHEEL BEARINGS

DRIVE WHEEL ASSEMBLY

IDLER CASTERS

ELECTRICAL

AC POWER STANCHION

CONTROL PANEL

MAG STARTER & DISCONNECT

TRANSFORMER

KEY SWITCH & HOUR METER

OPERATOR CONSOLE

GATE & FOOT SWITCH

PROXIMITY SWITCH

POWERED ROLLER CUTOUT

JUNCTION BOX

JUNCTION BOX PANEL

JUNCTION BOX

120V RECEPTACLE

SCHEMATICS

HYDRAULICS

POWER UNIT & RESERVOIR

RESERVOIR CHECK VALVE

POWER UNIT (25 HP)

RESERVOIR (60 GAL)

RESERVOIR SUCTION HOSE

VALVE ASSEMBLY

LIFT CYLINDER

NON-INTER FLOW MANIFOLD

DOWN-SPEED VALVES

PILOT DOWN MANIFOLD

CROSS PORT RELIEF

COUNTER BALANCE VALVE

TRANSITION PLATE

HYDRAULIC DISTRIBUTION

TRAVELING HOSE TRANSITION

HYDRAULIC HOSE PAN

SCHEMATICS

STANDARD OPTIONS

STROBE & ALARM

LEVEL ASSIST (LAI)

OPERATOR SHIELD

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.

Walk around unit and inspect for any physical damage to machine not previously noted.
Verify all guards are in place.
Inspect the AC power feed for any damage.
Inspect vacuum cups for damage to cup sealing surface, backup casting, and vacuum hoses.
Inspect travel path and area around unit for any hydraulic oil that could be a potential repair/maintenance issue and/or safety hazard.
Check oil level in hydraulic reservoir at fill level gauge.
Check that operator safety gate and all safety switches are in proper working order.
Verify extractor path is free of obstructions.
Check roller beds for any debris and clean as required.
Board unit, engage system and verify all functions are operating properly and that no abnormal or unusual noises are present.