IOP-402 BE-QS

TP-606 - SAFETY AND DE-ENERGIZATION PROCEDURES

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.

• Persons with pacemakers (or similar type medical devices) should not operate, or be in close proximity to during operation, any BHS equipment utilizing magnetic extraction.

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 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

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 uid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section). • Unexpected movement of hydraulic components.

LABELS & PLACARDS

SPECIFICATION DATA

		BE-24-2-QS	BE-36-2-QS	BE-42-2-QS
A	Overall Length	168"	192"	204"
B	Overall Width	74"	74"	74"
C	Overall Height (Lowered)	206"	206"	206"
	Overall Height (Raised)	223"	223"	223"
	Overall Height (Raised w/ Strobe & Alarm)	232"	232"	232"
D	Wheel Base	109"	133"	145"
E	Drive Wheel Center Line	51"	51"	51"
F	Battery Compartment Width	24"	36"	42"
G	Ground Clearance	.625"	.625"	.625"
H	Minimum Roller Height	6.5"	6.5"	6.5"
I	Maximum Roller Height	136.75"	136.75"	136.75"
J	Operator Platform Height (Lowered/Raised)	11" / 145"	11" / 145"	11" / 145"

QUAD STACK

SPECIFICATIONS (IMPERIAL / METRIC)

	BE-24-2-QS	BE-36-2-QS	BE-42-2-QS
Travel Speed	0 to 240 ft/min / 0 to 1.22 m/s	0 to 240 ft/min / 0 to 1.22 m/s	0 to 240 ft/min / 0 to 1.22 m/s
Raise - Lower Speed	0 to 26 ft/min / 0 to 0.13 m/s	0 to 26 ft/min / 0 to 0.13 m/s	0 to 26 ft/min / 0 to 0.13 m/s
Powered Roller Speed	0 to 37 ft/min / 0 to 0.19 m/s	0 to 37 ft/min / 0 to 0.19 m/s	0 to 37 ft/min / 0 to 0.19 m/s
Arm Traverse Speed	0 to 24 ft/min / 0 to 0.12 m/s	0 to 24 ft/min / 0 to 0.12 m/s	0 to 24 ft/min / 0 to 0.12 m/s
Arm Rotation Time	6 s to 8 s	6 s to 8 s	6 s to 8 s
Draw Bar Pull / Vacuum (12” / 305 mm Round Cup)	1,000 lb / 454 kg	1,000 lb / 454 kg	1,000 lb / 454 kg
Draw Bar Pull Magnet*	800 lb to 1,200 lb / 363 kg to 544 kg	800 lb to 1,200 lb / 363 kg to 544 kg	800 lb to 1,200 lb / 363 kg to 544 kg
Vacuum Attach Time	< 1 s	< 1 s	< 1 s
Vacuum Release Time	< 1 s	< 1 s	< 1 s
Input Voltage	480 V / 3 ph / 60Hz	480 V / 3 ph / 60Hz	480 V / 3 ph / 60Hz
AC Current Draw	45 A	45 A	45 A
AC Current Draw w/ Electric Drive Option	52 A	52 A	52 A
Control Circuit Voltage	120 V ac	120 V ac	120 V ac
Hydraulic Power Unit	25 hp / 18.7 kW	25 hp / 18.7 kW	25 hp / 18.7 kW
Hydraulic Power Unit w/ Electric Drive Option	30 hp / 22.4 kW	30 hp / 22.4 kW	30 hp / 22.4 kW
Hydraulic Pump	36 gal/min / 136 L/min	36 gal/min / 136 L/min	36 gal/min / 136 L/min
Power Unit	Hydraulic, Variable Displacement	Hydraulic, Variable Displacement	Hydraulic, Variable Displacement
Operating Pressure	1,200 psi / 76 bar	1,200 psi / 76 bar	1,200 psi / 76 bar
Vacuum Pump	1/3 hp / 0.25 kW	1/3 hp / 0.25 kW	1/3 hp / 0.25 kW
Vacuum	21” Hg / 711 mbar	21” Hg / 711 mbar	21” Hg / 711 mbar
Full Load Capacity	10,000 lb / 4535 kg	10,000 lb / 4535 kg	10,000 lb / 4535 kg
Weight (Empty)	9,660 lb / 4382 kg	9,960 lb / 4518 kg	10,940 lb / 4962 kg
Total Compartment Rollers / Powered	11/5	11/5	11/5
Guide Track	3” x 2.5” Angle 76 mm x 64 mm	3” x 2.5” Angle 76 mm x 64 mm	3” x 2.5” Angle 76 mm x 64 mm
Overall Dimensions (L x W x H)	168” x 74” x 223” 4267 mm x 1880 mm x 5665 mm	192” x 74” x 223” 4877 mm x 1880 mm x 5665 mm	204” x 74” x 223” 5182 mm x 1880 mm x 5665 mm
Vacuum Arm Reach	3.5” to 13” / 89 mm to 330 mm	3.5” to 13” / 89 mm to 330 mm	3.5” to 13” / 89 mm to 330 mm
Vacuum Arm Reach (Hydraulic Extension)	9” to 23” / 229 mm to 584 mm	9” to 23” / 229 mm to 584 mm	9” to 23” / 229 mm to 584 mm
Magnet Arm Reach (Hydraulic Extension) Truck Side	14” to 22” / 355 mm to 559 mm	14” to 22” / 355 mm to 559 mm	14” to 22” / 355 mm to 559 mm
Wheel Base	109” / 2769 mm	133” / 3378 mm	145” / 3683 mm
Drive Wheel Centerline	51” / 1295 mm	51” / 1295 mm	51” / 1295 mm
Battery Compartment Width	24” / 610 mm	36” / 915 mm	42” / 1067 mm
Maximum Battery Dimensions (L x W x H)	48” x 23” x 34” 1219 mm x 584 mm x 864 mm	48” x 35” x 34” 1219 mm x 889 mm x 864 mm	48” x 41” x 34” 1219 mm x 1041 mm x 864 mm
Minimum Battery Width (with vacuum / magnet)	12” / 305 mm 6” / 152 mm	12” / 305 mm 6” / 152 mm	12” / 305 mm 6” / 152 mm
Minimum Battery Height	17.75” / 451 mm	17.75” / 451 mm	17.75” / 451 mm
Ground Clearance	0.63” / 16 mm	0.63” / 16 mm	0.63” / 16 mm
Roller Height	6.5” Min / 136.75” Max 165 mm Min / 3473 mm Max	6.5” Min / 136.75” Max 165 mm Min / 3473 mm Max	6.5” Min / 136.75” Max 165 mm Min / 3473 mm Max

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

Model	F-Min	+/- Longitudinal	+/- Transverse	Slope Defect
SL, DS	40	.287"	.192"	.096"
TS	60	.186"	.129"	.066"
QS	85	.131"	.091"	.047"

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

1. Position lift truck for change out in designated area.
2. 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.)
3. Mount battery extractor and close safety gate. (Gate must be fully closed or unit will not operate.)
4. Secure safety lanyard to safety harness.
5. 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

1. 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.)
2. Align extractor’s roller bed height with lift truck’s battery compartment.
3. Rotate extractor arm into battery compartment aligned in Step 2.
4. Move extractor arm toward battery until vacuum cup/ magnet contacts battery.
5. 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.
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/magnet 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. Depress powered roller override button and move battery into center of compartment using powered rollers.

CHARGED BATTERY RETRIEVAL

1. Locate charged battery of appropriate type for lift truck being changed.
2. 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.)
3. 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.
4. Adjust roller compartment height to battery being retrieved.
5. Rotate arm into empty compartment (if not already positioned there.)
6. Move extractor arm toward battery until vacuum cup/ magnet contacts battery.
7. 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.
8. 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.)
9. Turn off vacuum/magnet and move extractor arm away from battery 1" to 2".
10. Rotate extractor arm out of battery compartment into fully vertical position.
11. Depress powered roller override button and move battery into center of compartment using powered rollers.

DISCHARGED BATTERY RETURN

1. 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.
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/magnet is necessary for pushing. DO NOT activate vacuum/magnet switch. Slowly push battery into rack until fully into compartment.
3. Engage battery safety stop and connect battery to charger as required.

CHARGED BATTERY INSTALLATION

1. Lower extractor roller compartment to fully lowered position.
2. Return extractor back to lift truck and align roller compartment containing charged battery as performed in steps 1 & 2 of "Discharged Battery Removal".
3. Move charged battery toward lift truck compartment by using powered rollers, verifying precise battery alignment.
Many batteries are a tight fit 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.
4. Adjust 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. Drive extractor out of immediate area and carefully dismount the extractor.
8. Secure newly installed battery in lift truck and reconnect battery cables.
9. 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

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0222	LINK-CONNECTING-#60			8
2	HW0017	NUT-HEX-3/4-10			8
3	HW0115	WASHER-LOCK-3/4"			4
4	43097001	STUD-ANCHOR-5"		UPPER	4
5	43097002	STUD-ANCHOR-2"		LOWER	4
6	00158001-27	CHAIN-ROLLER-#60			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0503	BEARING-FLANGED LOAD-2 1/4"			8
2	HW0025	NUT-JAM-7/8-14			8
3	PT0416	COLLAR-SHAFT-1 1/2"			4
4	43097006	KEY-3/8" X 2 3/4"			4
5	PT0224	SPROCKET-60B12 X 1 1/2"		KEYED IN LINE	8
6	PT0405	FLANGE BEARING-2 BOLT-1 1/2"			4
7	HW0502	BOLT-HHCS-1/2-13 X 1 1/4"			8
8	HW0110	WASHER-LOCK-1/2"			8
9	47027001	SHAFT-EQUALIZATION-84.75"		BE-24-2-QS	2
	47227001	SHAFT-EQUALIZATION-108.75"		BE-36-2-QS	2
	47327001	SHAFT-EQUALIZATION-120.75"		BE-42-2-QS	2

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.

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 PERFORMING DAILY INSPECTIONS.

OPERATOR'S DAILY CHECKLIST

RECOMMENDED BATTERY EXTRACTOR LUBRICATION INTERVALS

VACUUM EXTRACTION PLANNED MAINTENANCE INSPECTION REPORT

MAGNET EXTRACTION PLANNED MAINTENANCE INSPECTION REPORT

EQUALIZATION CHAIN

INSTALLATION / RESETTING PROCEDURES

P/N: 80292002-I

E.Q. CHAIN RESETTING

BATTERY EXTRACTOR SERVICE STAND INSTALLATION INSTRUCTIONS

TROUBLESHOOTING GUIDE

TECH BULLETINS

VACUUM CUP REPLACEMENT

Tech Tip TT-901

Models Affected: All Vacuum Equipped Units

Subject:

Vacuum cup damage and replacement.

Description:

On units which utilize vacuum extraction, the vacuum cups are the most frequently replaced items. This is due to tearing of 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 once engaged on a battery case. This causes the cup to slide along the battery case, typically leading the edge of the cup to curl or roll under. Repeatedly doing so will eventually cause damage to the cup assembly. To prevent 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 curling of the cup edge, BHS recommends a silicone type lubricant be applied on the face of the cup to help the cup slide on the battery case. Using the vacuum cup as a hook to extract the battery by “hooking” the battery eye with the back of the vacuum cup will also lead to cup and mounting hardware damage. The vacuum cup should never be used in this manner.

Repair:

Replace the vacuum cup if it has been torn or is separated from the metal backing plate. BHS offers multiple cup options with a standard mounting layout. All options are available for use on any BHS vacuum equipped extractor. For more information on available vacuum cup options, refer to Tech Tip TT-937. To find out more about proper mounting and hardware, refer to Tech Tip TT-913. These, as well as all of the latest Tech Tips, inspection forms and planned maintenance information, are available online. Go to BHS1.com and click on “Technical Literature” under the “Library” tab for the latest available information.

Vacuum cup damage due to elevation adjustment after attachment to battery

Vacuum cup and mounting hardware damage due to “hooking” battery eye with cup for extraction

MOVING AN INOPERABLE BATTERY EXTRACTOR

Tech Tip TT-902

Models Affected: All Operator Aboard Battery 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 Affected: 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 the oil life is reduced to 250 hours.

Recommendation:

BHS Battery Extractors are shipped from the factory with Shell Tellus 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 Affected: 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 uid. 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 fluids can improve operating performance more than any other single factor. BHS recommends to change oil filters (10 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.

TRIMMING POWERED ROLLERS

Tech Tip TT-905

Models Affected: BE-SL, DS, TS, & QS Models

Subject:

Trimming the plastic sleeve on powered rollers for Battery Extractors.

Description:

Due to the weight of batteries traveling on the powered rollers, the plastic sleeve on the rollers may extrude or become elongated, much like rolling a piece of clay between your hand and a table. Over time the plastic sleeve of the powered rollers will be forced toward the end of the rollers, eventually coming in contact with the frame of the roller bed. See Figures 1 and 2. Once in contact with the frame, the rollers become more difficult to turn, causing excessive strain on the power roller components. Left uncorrected, the rollers will become bound against the frame and damage to components will occur.

FIGURE 1

FIGURE 2

Recommendation:

Trimming the plastic sleeve on the powered rollers as part of a regularly scheduled preventative maintenance program will keep the plastic from contacting the frame. With the right tools and proper instruction, trimming the powered rollers is a quick and easy, two person procedure.

Repair:

BHS offers a Power Roller Trim Kit (P/N 80282001) which contains the trimming tool along with detailed instructions to properly and safely trim the powered rollers.

POWERED ROLLER AFTER TRIMMING

BATTERY EXTRACTOR STIFFENER PLATE KIT

Tech Tip TT-909

Models Affected: All Operator Aboard Battery Extractors

Subject:

Proper mounting of Battery Extractor swing arm cover/stiffener plates.

Description:

The plates that cover the vacuum pump or magnet circuitry on the Battery Extractor should be properly mounted and secured. These plates not only protect the components in the extractor arm, but are part of the overall structure of the extractor swing arms. Improper plate mounting increases the chance of damage to the extractor swing arms due to excessive flexing.

Recommendation:

It is important that both plates be properly mounted and secured on the extractor swing arms at all times during Battery Extractor (BE) operation. Install and secure new cover/stiffener plates if the current cover/stiffener plates are missing or damaged. In addition, replace any damaged or missing mounting hardware.

Repair:

If only new plates and hardware are required, BHS offers a Swing Arm Stiffener Plate Kit (P/N 80252004) to replace damaged or missing components. If the extractor swing arms need replacement along with the covers/stiffener plates, contact the BHS Tech Support Department for additional kits to best suit your needs.

Cover/Stiffener Plates & Hardware missing

Cover/Stiffener Plate installed properly

ELECTROMAGNET PERFORMANCE

Tech Tip TT-910

Models Affected: All Magnet Equipped Battery Extractors

Subject:

Without improvement of electromagnetic performance, the integrity of the battery structure, compartment configuration, and compartment roller trays can be compromised.

Description:

There are several conditions that can adversely effect the pulling power of electromagnets. The following are some of the most common issues and steps that should be taken to address these issues (if applicable).

1. BATTERY CONDITION/STRUCTURE
   1. Paint: A battery that has several thick coats of paint or a chipped and deteriorating coat of paint can cause a drastic reduction in magnet performance.
      Corrective Action: Remove any excess layers of paint to yield a smooth contact area for the magnet.
   2. Decals: Decals of any kind that are in the contact area of the magnet can cause a drastic reduction in magnet performance. Even the thinnest of decals can cause problems.
      Corrective Action: Remove any decals in the contact area of the magnet.
   3. Battery Case “Crowning”: A battery case may appear to have a flat surface, but in reality have a slight outward bow or “crown” to it – even a brand new battery. This “crown” will reduce the contact area of the magnet to the battery case and can cause a drastic reduction in magnet performance.
      Corrective Action: A thicker plate of steel may be welded to the battery case to give a flatter surface for the magnet to attach. Check with the battery manufacturer prior to performing any welding or modification to a battery.
   4. Battery Case Thickness: The battery case thickness can play a large part in magnet performance. A thin battery case may be too shallow for the field of the magnet to attach, causing a reduction in magnet performance. Also, a thinner case battery can lead to the previously mentioned condition of “crowning” while extraction is taking place, causing the magnet to prematurely release.
      Corrective Action: A thicker plate may be welded to the battery case to give a deeper field area for the magnet to attach and eliminate the “crowning” effect during extraction. Check with the battery manufacturer prior to performing any welding or modification to a battery.
   5. Case Bottom: If a battery has a very dirty and/or rough and corroded bottom, it can cause an increase in friction when pulling from slide strips or an increase in rolling resistance when pulling from a roller compartment.
      Corrective Action: A thorough neutralizing and cleaning of the bottom of the battery is required. It is recommended the battery be scraped to remove as much scale, rust, and corrosion as possible. The battery should then be recoated with a good quality acid resistant enamel. This will greatly reduce friction and help extend the life of all components making contact with the bottom of the battery.
2. BATTERY COMPARTMENT CONFIGURATION
   1. Slide Strips: The most common impact on magnet performance when using slide strips is the number of slides in the compartment. All lift truck batteries have a natural “crown” to the bottom of the battery cases. When trucks are equipped with (3) slide strips, the majority of the battery weight rests on the center slide strip. This concentration of weight along with a battery bouncing around for an entire work shift, causes the slide strip to cold-flow or conform to the irregularities of the bottom of the battery case. When this occurs, an excessive amount of force is necessary to start battery movement to overcome the increased friction between the battery case and the slide strip.
      Corrective Action: In some instances, the center slide strip can be removed to allow for even distribution of the battery weight on the two remaining slide strips. Check with the lift truck manufacturer prior to performing any modifications to the lift truck.
   2. Compartment Roller Trays: The condition of the roller compartment of a lift truck can effect magnet performance. Dirty or corroded rollers, damaged rollers or missing rollers combined with poor condition of the battery case bottom can cause a decrease in magnet performance.
      Corrective Action: Maintenance to and/or replacement of rollers or roller trays should be performed.

COLLECTOR TROLLEY ALIGNMENT

Tech Tip TT-911

Models Affected: All Energy Rail Powered Equipment

Subject:

Proper installation and maintenance of the energy rail, collector trolley, and tow arm.

Description:

Proper alignment of the tow arm and collector trolley with the energy rail is critical and should be inspected regularly. Improper alignment of the trolley/tow arm with the energy rail will cause side loading of the trolley resulting in uneven brush wear. This uneven wear will result in premature failure of the brushes which could cause intermittent machine operation requiring replacement of the brushes or collector trolley.

Recommendation:

The tow arm and collector trolley must be properly aligned with the energy rail.

For the Aeromotive Energy Rail, check the tow arm and collector trolley on a regular basis to ensure proper height alignment. Verify the hardware is secure and that the tow arm is not bent. Inspect trolley alignment with the energy rail by slowly driving the Battery Extractor the length of the system while checking that the collector trolley remains in-line with the conductor housings. Adjust the collector trolley/tow arm mounting or energy rail as required. Note that a straight energy rail is not necessarily properly aligned. Variances in floor levelness may require the energy rail to be adjusted to align with the trolley in some areas.

For the Vahle Energy Rail, the collector trolley is self-aligning when the tow arm is properly mounted. It should be inspected regularly to confirm proper height alignment, as well as ensuring the tow arm does not push against the trolley or become detached from the trolley while driving the machine.

Improper alignment of Aeromotive energy rail energy rail and trolley

Proper alignment of Aeromotive energy rail energy rail and trolley

Proper alignment of Vahle energy rail energy rail and trolley

PROPER VACUUM CUP MOUNTING

Tech Tip TT-913

Models Affected: All BHS Units with Vacuum Extraction

Subject:

Proper vacuum cup mounting is important for efficient operation as well as reducing risk of damage.

Description:

Loose, missing, or damaged vacuum cup mounting hardware can allow the vacuum cup to pull off-line or diagonally. This may cause the cup to disengage from the battery case during extraction creating lost time and unsafe situations. Improperly mounted hardware can also cause damage to the extractor arm as the stud threads can deform the inside of the mounting holes.

Recommendation:

Vacuum cup hardware should be monitored daily as part of a daily inspection. Inspect for proper tightness. The springs should be snug without being compressed while allowing a 1/4” pitch to the vacuum cup. Also inspect for damaged or missing hardware and replace as required.

BHS offers two hardware kits. The HW-KIT-1 for Automatic Transfer Carriage (ATC) units with vacuum extraction contains (4) 4” studs and (8) springs along with the required nuts and washers for installation. The HW-KIT-2 for Operator Aboard Battery Extractor (BE) units with vacuum extraction contains (4) 5” studs and (12) springs as well as required nuts and washers. Proper installation of either kit requires that the studs be tightened securely into the vacuum cup or adapter plate (10” cups only). See photos below for proper installation of washers and springs. The nuts should then be installed and tightened until the springs are just tight enough that they cannot be moved by hand. The nuts on the lower studs should then be tightened additionally to supply a 1/4” forward pitch to the vacuum cup.

Hardware kits contain all hardware required for mounting one vacuum cup HW-KIT-2 (BE units) shown

Proper installation of HW-KIT-1 (ATC units) 10" vacuum cup shown

Proper installation of HW-KIT-2 (BE units) 12" vacuum cup shown

DRIVE WHEEL FAILURE

Tech Tip TT-917

Models Affected: All Operator Aboard Battery Extractors

Subject:

Difficulty or inability for Operator Aboard Battery Extractor (BE) to move when loaded unless pushed to start.

Description:

The BE is driven by two drive wheel assemblies. If one wheel assembly fails, it is possible for the BE to travel unloaded with little or no trouble. Once loaded however, the BE may be difficult or even impossible to start moving with out pushing it with a lift truck. Once moving, the BE may travel normally until coming to a stop where problems moving occur again.

Recommendation:

There are two different processes to check for drive wheel assembly failure.

Machine Loaded

1. Load the BE with two batteries that will produce the problem condition.
2. With someone carefully operating the drive function on the BE, examine the drive

wheel couplings for each drive wheel assembly. A flashlight will be helpful in this examination.

1. If a coupling assembly is found to be turning but the wheel is not, this indicates a

failure of the wheel/shaft connection and repair is necessary.

Machine Unloaded

1. Raise the operator’s end of the BE so that both drive wheels are slightly off the ground.
2. With someone carefully operating the drive function on the BE, examine the drive couplings and the wheels themselves for operation. A flashlight will be helpful in this examination.

Note: It is possible for a failed assembly to still turn without resistance on the wheel.

1. If both wheels appear to be turning, use a large screwdriver or small pry bar to apply pressure to the wheel. If the wheel stops turning when pressure is applied, this indicates a failure of the wheel/shaft connection and repair is necessary.

Repair:

BHS offers several options to repair the drive wheel from a Drive Wheel Repair Kit to a complete Drive Wheel Assembly. Contact the BHS Tech Support Department for the repair parts that best suit your needs.

Top View of Drive Wheel Coupling

Bottom View of Drive Wheel

LIFT CIRCUIT VELOCITY FUSE

Tech Tip TT-919

Models Affected: All Operator Aboard Battery Extractors

Subject:

All BHS Operator Aboard Battery Extractors (BE) are equipped with velocity fuses on each cylinder to prevent sudden, unexpected lowering of the battery compartment. Properly sized velocity fuses will prevent free-fall of the battery compartment in the event of a disconnected cylinder hose, hose breakage, or other component failure that would allow oil in the cylinders to be released at a rapid rate.

Description:

Velocity fuses work by sensing higher than normal oil flow rates exiting the bottom port of the cylinders. When the velocity fuse senses this higher flow, the fuse locks closed, preventing any oil from passing through the fuse. The typical time for a velocity fuse to activate is less than 0.5 second. In the event of a velocity fuse failure, the fuse will fail in the closed position.

Recommendation:

A failed velocity fuse will prevent the cylinder from lowering. If this occurs during normal operation, lowering should be stopped IMMEDIATELY to prevent damage to the BE. It may be possible to reset a locked velocity fuse by raising the carriage a few inches and then lowering it again.

The hydraulic system must be properly maintained to ensure dependable function of the velocity fuses. Proper maintenance will prevent oil contamination which can lead to potential velocity fuse failure.

Repair:

If a velocity fuse is found to be defective, BHS recommends replacing all (4) fuses.

ALWAYS properly secure the inner carriage when servicing any area under the BE, utilizing the BHS Service Stand Kit.

TECHNICAL SUPPORT

Tech Tip TT-922

24 Hour Access to BHS Technical Information

Live Phone Support: Call 1.877.BHS.4YOU (1.877.247.4968) from 8:00 a.m. - 5:00 p.m. Central Time to speak with the BHS Technical Support Team. With a combined experience of over 75 years in assembly, shipping, installation, equipment design, manual publication and quality control, the BHS Technical Support Team can answer all of your questions.

Ken Schwyhart Technical Support Coordinator schwyhart@bhs1.com

Gary Duckett After Market Parts duckett@bhs1.com

After Hours Support: Need a question answered outside of normal business hours? No problem! Just call 1.877.BHS.4YOU (1.877.247.4968), leave a message and our system will alert the on-call service technician to contact you. After hours emergency shipping via air cargo is also available.

Website Library: From available parts kits and the latest Tech Tips, to inspection forms and planned maintenance information, our website is always available. Go to BHS1.com and click on “Library” for the latest information.

DAILY INSPECTIONS

Tech Tip TT-923

Models Affected: All

Subject:

As with all machinery, proper maintenance will greatly extend the useful life of your battery handling equipment. A big part of properly maintaining any equipment is routine inspection of the equipment.

Description:

A proper daily or pre-shift inspection of the battery handling system is important for ensuring proper operation of the equipment as well as the safety of the operator(s). By inspecting the equipment and addressing any issues prior to machine operation, small repairs and adjustments can be made before major repairs are required thus avoiding possible machine failures and saving lost production due to down time.

Recommendation:

As with all material handling equipment, the battery handling equipment should be inspected prior to each use for any visual damage or defects and any required liquids should be checked for proper fill level. Any defects or damage found during the inspection should be addressed prior to operation. The equipment should also undergo scheduled Planned Maintenance (PM) which includes thorough inspection and maintenance performed by trained personnel.

A general "Daily Inspection" form as well as model specific Planned Maintenance (PM) inspection reports can be found on our website. Go to https://na.bhs1.com/media-library/technical-literature/planned-maintenance/

PARTS ORDER INFORMATION

Tech Tip TT-924

Parts ordering and transit times from BHS

BHS will accept parts orders over the phone, but in an effort to avoid possible errors and misunderstandings, a hard copy of your order is appreciated. Orders can be e-mailed to order@bhs1.com and should include a PO number, ship to address, part numbers and quantity required, and requested ship method.

BHS ships all parts orders via UPS ground unless otherwise specified. Items in stock typically ship within three (3) business days of date ordered. Expedited ground shipping is available upon request. Orders requiring same day shipping must be received before 3:00pm Central Time Zone. Orders received after 3:00pm will be processed the following business day. After hours shipping is available but is subject to additional charges.

Requested ship methods other than UPS for parcel shipments (i.e. FedEx) will incur an additional $16.00 handling fee. An account number for collect or third party billing of freight charges for non-UPS shipments must also be supplied. All UPS freight charges are prepaid/added to the invoice. Collect and 3rd party shipping are available upon request (appropriate account number must be supplied at time of order).

Once processed, all orders are confirmed via acknowledgements which are emailed daily to the primary contact on file with BHS.

Transit times shown for orders shipped via UPS ground.

Three Day Select (UPS/ORN), Two Day (UPS/BLU), Next Day (UPS/RED), Saturday and same day (next flight out) delivery are also available. Orders ship from St. Louis, MO 63132.

BE SERVICE INTERVAL

Tech Tip TT-925

Models Affected: All Operator Aboard Battery Extractors

Subject: In Tech Tip #923 we discussed the importance of Daily Inspections to properly maintain your battery handling equipment. Equally important to the Daily Inspection is proper lubrication and scheduled maintenance. This helps prevent issues and ensures optimal performance of your equipment.

Description:

Scheduled lubrication and maintenance at proper intervals can prevent unnecessary wear and tear on machine components.

• Lubricating the drive screw nut and arm carrier bearings every 50 hours (weekly) will reduce friction on the carrier shafts and allow the arm to move freely, reducing stress on the arm traverse components.
• Properly lubricating the idler casters every 200 hours (monthly) can prevent bearing failures requiring wheel replacement.
• Cleaning and oiling of the roller chains every 200 hours (monthly) can prevent rust and debris build-up. Failing to maintain the chains could lead to undue chain and sprocket wear and possible breakage.
• Changing the filter every 300 hours (twice quarterly) prevents contaminants from circulating through the system, possibly clogging ports, causing erratic machine operation.
• Changing the hydraulic fluid every 600 hours (quarterly) prevents internal component wear from fluid deterioration and contamination.
• Every 600 hours (quarterly) the equipment should also undergo scheduled Planned Maintenance (PM) which includes thorough inspection and maintenance performed by trained personnel.

These recommendations are based on average use in a typical warehouse environment and may be adjusted based on individual circumstances. Dusty and/or extreme hot/cold environments may require more frequent lubrication.

BHS recommends implementing an oil sampling and analysis program to monitor hydraulic fluid condition and determine when hydraulic fluid changes are required. The fluid analysis program should be a continuous process and all results should be evaluated. Changes in the condition of the hydraulic system may indicate component wear, fluid deterioration and contamination.

Recommendation:

The BE Manuals contain information on recommended service and the proper intervals in which it should be performed. The most current service information can also be found on our website. Go to BHS1.com and look for the required information in the “Technical Literature” section under the “Library” tab.

WARNING LABELS & PLACARDS

Tech Tip TT-926

Models Affected: All

Subject:

Warning labels and placards are important parts of the machine and should not be overlooked during regular maintenance. All operators and service personnel should be familiar with all labels and their meaning. Warning labels and placards should be legible at all times, and worn or damaged labels should be replaced as soon as possible.

Description:

BHS uses various types of labels and placards to convey potential hazards and operational information on our battery handling equipment.

Graphical Labels are graphic symbols within a safety sign. The shape and color of the graphical label is determined by the purpose for which it is used.

A white graphical symbol inside a blue circle indicates an action shall be taken to avoid a hazard - in this case, read and understand instruction manual prior to use.

A black graphical symbol inside a red circular band with a diagonal bar indicates an action shall not be taken - in this case, do not operate with guards or covers removed.

A black graphical symbol inside a yellow triangle with a black band indicates a potential hazard - in this case, moving chains and sprockets which can crush and cut.

Combination Labels combine a hazard severity panel with supplementary information regarding the hazard.

The hazard severity panels identify the severity of potential hazards as follows:

Notice is used to address practices not related to personal injury.

Caution used with the safety alert symbol indicates a hazardous situation, which if not avoided, can result in minor or moderate injury.

Warning used with the safety alert symbol indicates a hazardous situation, which if not avoided, can result in death or serious injury.

Danger used with the safety alert symbol indicates a hazardous situation, which if not avoided, will result in death or serious injury.

Operational Placards are used to convey actions required in machine operation such as valve handle movement and switch position.

Recommendation:

Replace any labels that are worn, illegible or missing. Visit BHS1.com to find the Label Replacement Kit for your equipment or contact BHS for more information.

Vacuum Pump and Filter Cleaning

Tech Tip TT-927

Models Affected: Models Affected: All Models Equipped with Vacuum Extraction

Subject:

Decreased performance of the vacuum pump due to dust accumulation inside the pump.

Description:

When operating in dirty or dusty environments, fine particulate can pass through the internal vacuum pump filters, causing a build up of dust inside the vacuum pump. This build up can cause the vacuum pump to operate inefficiently, eventually leading to complete loss of vacuum. This fine particulate can also clog the internal filters causing loss of vacuum.

Recommendation:

If loss of vacuum occurs and all other vacuum system components are found to be in working order, then the vacuum pump can be carefully disassembled and cleaned.

Repair:

1. Remove the vacuum pump head.
   
   Use care not to damage the gasket.
2. Remove the (2) foam filters from the head and clean using compressed air.
3. Clean the valve plate with compressed air, careful not to damage the leaf valve or valve limiter.
4. Reinstall the filters into the head and reassemble the vacuum pump.

Note: Units built after January 1, 2010 are equipped with additional in-line filters. These filters should be cleaned or replaced regularly to avoid dust build up inside the vacuum pump. The in-line filters may also be installed on units manufactured prior to 2010.

Contact the BHS Tech Support Department for more information regarding vacuum pump cleaning and/or in-line filters.

PARTS KITS

BE-QS W/ VACUUM SPARE PARTS KIT

P/N: BE-SPKV-QS

(For Units Built Dec. 2014 to Present)

BE-QS W/ MAGNET SPARE PARTS KIT

P/N: BE-SPKM-QS

(For Units Built Dec. 2014 to Present)

10" VACUUM CUP ASSEMBLY

P/N: 00162001

10" 3 PC. VACUUM CUP ASSEMBLY

P/N: 00162004

BATTERY EXTRACTOR 12" VACUUM CUP ASSEMBLY

P/N: 00162003

BATTERY EXTRACTOR SWING ARM / STIFFENER PLATE KIT

P/N: 80252005

BATTERY EXTRACTOR SWING ARM STIFFENER PLATE KIT

P/N: 80252004

BATTERY EXTRACTOR BE SWING ARM REPLACEMENT KIT

P/N: 80252001

BATTERY EXTRACTOR LINEAR SLIDE BLOCK KIT

P/N: 80252002

BATTERY EXTRACTOR LEAD SCREW DRIVE NUT KIT

P/N: 80252003

BE-TS/QS DRIVE WHEEL REPAIR KIT

P/N: 80322001

BATTERY EXTRACTOR SELECTOR SWITCH KIT

P/N: 80232001

BATTERY EXTRACTOR VACUUM STUD SPRING KIT

P/N: HW-KIT-2

BATTERY EXTRACTOR MAGNET STUD KIT

P/N: 80252006

(For Units Built Prior To Nov. 2014)

BATTERY EXTRACTOR BE SERVICE STAND KIT - DOUBLE, TRIPLE, & QUAD STACK MACHINES

P/N: 80392001

BE-QS EQUALIZATION ADJUSTMENT STOP KIT

P/N: 80492001

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.