IOP-407 BE-TSN

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 HAZARDS

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

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

OPERATIONAL SAFETY

OPERATIONAL SAFETY

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

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

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

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

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

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

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

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

DO’s AND DON’T’s

• DO NOT exceed the maximum capacity of the BE.

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

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

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

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

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

• DO NOT drive the BE into the end stops.

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

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

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

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

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

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

DE-ENERGIZATION

1. Fully lower the BE roller bed or position the roller bed on service stands if service requires the bed be raised. See Figures 1 & 2

Failure to properly support the roller bed when performing service under the BE could result in injury from the roller bed lowering unexpectedly.


FIGURE 1



FIGURE 2

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


FIGURE 3

3. Disconnect power to the extractor or shut off the electrical branch circuit breaker.

Failure to disconnect electrical power to the BE could result in electrical shock. Serious personal injury or death will occur.
4. Actuate all hydraulic levers in both directions to release any stored hydraulic pressure. See Figure 4.

Failure to release any stored hydraulic pressure could result in injury from:
• Escaping hydraulic fluid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section).
• Unexpected movement of hydraulic components.


FIGURE 4

LABELS & PLACARDS

GENERAL INFORMATION

SPECIFICATION DATA

Product Specifications - Imperial / Metric	BE-24-2-SLN	BE-36-2-SLN	BE-24-2-DSN	BE-36-2-DSN	BE-24-2-TSN	BE-36-2-TSN
Travel Speed	0-190 FPM / 0-1 mps		0-190 FPM / 0-1 mps		0-190 FPM / 0-1 mps
Raise - Lower Speed	0-10 FPM / 0 -.05 mps		0-16 FPM / 0-.08 mps		0-26 FPM / 0-.13 mps
Powered Roller Speed	0-37 FPM / 0-.18 mps		0-37 FPM / 0-.18 mps		0-37 FPM / 0-.18 mps
Arm Traverse Speed	0-20 FPM / 0-.10 mps		0-20 FPM / 0-.10 mps		0-20 FPM / 0-.10 mps
Arm Rotation Time	6 - 8 Seconds		6 - 8 Seconds		6 - 8 Seconds
Draw Bar Pull Vacuum (12” Round Cup)	1,000 lbs / 450 kg		1,000 lbs / 450 kg		1,000 lbs / 450 kg
Vacuum Attach Time / Release Time	< 1 sec / < 1 sec		< 1 sec / < 1 sec		< 1 sec / < 1 sec
Input Voltage	240/480 VAC/60Hz		240/480 VAC/60Hz		240/480 VAC/60Hz
AC Current Draw	13.6 / 6.8 Amps		13.6 / 6.8 Amps		27.2 / 13.6 Amps
Control Circuit Voltage	120 VAC		120 VAC		120 VAC
Hydraulic Power Unit	5 HP / 3.73 KW		5 HP / 3.73 KW		10 HP / 7.46 KW
Hydraulic Pump	8 GPM / 30 LPM		8 GPM / 30 LPM		16 GPM / 60 LPM
Power Unit	Hydraulic, Variable Displacement		Hydraulic, Variable Displacement		Hydraulic, Variable Displacement
Operating Pressure	1,500 PSI / 103 Bar		1,500 PSI / 103 Bar		1,500 PSI / 103 Bar
Vacuum Pump	1/3 HP / .25 KW		1/3 HP / .25 KW		1/3 HP / .25 KW
Vacuum	21” Hg / 0.73 kg/cm2		21” Hg / 0.73 kg/cm2		21” Hg / 0.73 kg/cm2
Full Load Capacity	10,000 lbs / 4535 kg		10,000 lbs / 4535 kg		10,000 lbs / 4535 kg
Weight (Empty)	5,300 lbs / 2404 kg	5,700 lbs / 2585 kg	5,500 lbs / 2495 kg	6,100 lbs / 2767 kg	7,500 lbs / 3402 kg	7,800 lbs / 3538 kg
Total Compartment Rollers / Powered	11/5		11/5		11/5
Guide Track	2” x 2.5” Angle / 51 mm x 64 mm		2” x 2.5” Angle / 51 mm x 64 mm		3” x 2.5” Angle / 76 mm x 64 mm
Overall Dimensions (L x W x H)	130” x 67” x 65” / 3302 mm x 1702 mm x 1651 mm	154” x 67” x 65” / 3912 mm x 1702 mm x 1651 mm	128” x 67” x 90” / 3252 mm x 1829 mm x 2286 mm	152” x 67” x 90” / 3861 mm x 1702 mm x 2286 mm	156 .5” x 67” x 158.06” / 3975 mm x 1702 mm x 4015 mm	180.5” x 67” x 158.06” / 4585 mm x 1702 mm x 4015 mm
Vacuum Arm Reach (Stand Side)	9” / 229 mm		9” / 229 mm		9” / 229 mm
Vacuum Arm Reach (Hydraulic Extension)	5” - 17” / 127 mm - 432 mm		5” - 17” / 127 mm - 432 mm		5” - 17” / 127 mm - 432 mm
Wheel Base	95.75” / 2432 mm	119.75” / 3042 mm	95.75” / 2432 mm	119.75” / 3042 mm	98” / 2489 mm	122” / 3099 mm
Drive Wheel Centerline	48” / 1219 mm		48” / 1219 mm		48” / 1219 mm
Battery Compartment Width	24” / 610 mm	36” / 915 mm	24” / 610 mm	36” / 915 mm	24” / 610 mm	36” / 915 mm
Maximum Battery Dimensions (L x W x H)	48” x 23” x 36” / 1220 mm x 580 mm x 910 mm	48” x 35” x 36” / 1220 mm x 890 mm x 910 mm	48” x 23” x 36” / 1220 mm x 580 mm x 910 mm	48” x 35” x 36” / 1220 mm x 890 mm x 910 mm	48” x 23” x 36” 1220 mm x 580 mm x 910 mm	48” x 35” x 36” / 1220 mm x 890 mm x 910 mm
Minimum Battery Width	12” / 305 mm		12” / 305 mm		12” / 305 mm
Minimum Battery Height	17.75” / 450 mm		17.75” / 450 mm		17.75” / 450 mm
Ground Clearance	.625” / 15 mm		.625” / 15 mm		.625” / 15 mm
Roller Height	6.5” Min - 26.5” Max 165 mm Min - 670 mm Max		6.5” Min - 56” Max 165 mm Min - 1420 mm Max		6.5” Min - 96” Max 165 mm Min - 2435 mm Max

Note: Specifications may vary +/- 5% due to temperature, floor considerations and operator efficiency. Values represented under normal operating conditions.

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

OPERATOR CONSOLE

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.
• 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.”
• 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.

OPERATING INSTRUCTIONS

PRE-CHANGE OUT PREPARATION

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

DISCHARGED BATTERY REMOVAL

1. Move the extractor left or right to position the center of compartment with the center of the lift truck battery compartment. (Lead roller of extractor is equipped with a centering groove. Users may find it beneficial to mark center of lift truck compartment to aid in alignment.)
2. Align the extractor’s roller compartment height with the lift truck’s battery compartment.
3. Rotate extractor arm into battery compartment aligned in Step 2.
4. Move the extractor arm toward the battery until the vacuum cup/magnet contacts the battery.

DO NOT force cup to battery after initial contact with battery is made.
5. Energize vacuum by turning selector switch to proper direction, left or right.
6. Move extractor arm away from lift truck toward center of extractor roller bed, removing discharged battery. (Battery should be pulled past first three idler rollers onto first or second powered roller.)
7. Turn off vacuum and move extractor arm away from battery 1” to 2”.
8. Rotate extractor arm out of battery compartment into opposite compartment (if empty) and center arm in carriage.
9. Move battery into center of compartment using powered rollers.

CHARGED BATTERY RETRIEVAL

1. Locate a charged battery for the appropriate type of lift truck being changed.
2. Raise battery extractor roller compartment to proper level to gain access as needed to disconnect desired battery from its charger and disengage battery safety stop.

ALWAYS be sure charging has been completed and the charger is not still charging the battery. Dangerous sparking/arcing can occur if the battery is unplugged from the charger while charging.
3. Move extractor to appropriate rack position and align empty roller compartment with the center of the battery storage rack compartment. (The battery safety stop of each compartment is the center of that compartment and should be used for alignment with the groove in the lead roller of the battery extractor compartment.)
4. Rotate arm into empty compartment (if not already positioned there.)
5. Move extractor arm toward battery until vacuum cup contacts battery.
6. Energize vacuum cup by turning selector switch to proper direction, left or right.

DO NOT force cup to battery after initial contact with battery is made.
7. Move extractor arm away from battery rack toward center of extractor roller bed, removing charged battery. (Battery should be pulled past first three idler rollers onto first or second powered roller.)
8. Turn off vacuum and move extractor arm away from battery 1” to 2”.
9. Rotate extractor arm out of battery compartment into fully vertical position.
10. Move battery into center of compartment using powered rollers.

DISCHARGED BATTERY RETURN

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

CHARGED BATTERY INSTALLATION

1. Lower extractor to fully lowered position.
2. Drive the extractor back to the lift truck and align the roller compartment containing the charged battery as performed in steps 1 and 2 of ”Discharged Battery Removal”.
3. Move the charged battery toward the lift truck compartment by moving the extractor arm out, verifying precise battery alignment.

Many batteries are a tight fit into the lift truck battery compartments. Care MUST be taken to ensure alignment is precise to avoid damage to the battery, lift truck, and/or battery extractor.
4. Adjust the extractor vertically as well as horizontally, if needed.
5. Insert battery into lift truck as far as possible using only the powered rollers.
6. Rotate extractor arm into compartment and SLOWLY push battery into lift truck. (Be sure to watch battery cables for interference.)
7. Return extractor arm to center of roller bed and lower extractor to fully lowered position. Drive extractor out of immediate area.
8. Turn off key switch, remove key from switch and carefully exit extractor.
9. Secure newly installed battery in lift truck and reconnect battery cables.
10. Return lift truck to service.

DO NOT drive the B.E. into the travel path end stops. The end stops are designed to prevent the B.E. from accidentally traveling beyond its designated travel path. Driving the B.E. into the end stops will cause the B.E. to stop suddenly, possibly causing damage to the end stop, the B.E. and/or personal injury.

MANUAL UNLOADING

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

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

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

Should the status of the BE not allow for safe vertical extraction due to position in the battery aisle, only repairs required to safely maneuver the BE to a position allowing for safe vertical extraction should be made. Once any batteries are safely unloaded, any remaining repairs can be made.

Extreme care should be taken when working under or around equipment supporting elevated loads. Unexpected movement of the equipment could cause the load and/or equipment to fall. ALWAYS be sure devices of adequate size and strength are in place to prevent any personnel working under the elevated load from being crushed. Serious personal injury or death will occur.

RECOMMENDED SPARE PARTS

Refer to the Spare Parts Kit (Pt# BE-SPKV-TS) at the beginning of Section 7 for the list of items recommended by the factory to have on hand for BE-TSN models to minimize any downtime due to minor breakdown that may occur under normal operating conditions.

Use only BHS approved replacement parts.

BHS recommends that a full maintenance inspection report similar to the one provided be done at least once a month.

Any parts found to be excessively worn or damaged should promptly be replaced unless said parts pose a safety risk to the operator and/or extractor, in which case the unit should be removed from service until the problem(s) are remedied (See Operator’s Daily Checklist.)

PARTS SECTIONS

CHASSIS

EQUALIZTION

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	HW0020	NUT-JAM-3/4-10			4
6	43097002	STUD-ANCHOR-2”		LOWER	4
7	00158001-40	CHAIN-ROLLER-#60			4

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0416	COLLAR-SHAFT-1 1/2”			4
2	43097006	KEY-3/8” X 2 3/4”			4
3	PT0224	SPROCKET-60B12 X 1 1/2”		KEYED INLINE	8
4	PT0405	FLANGE BEARING-2 BOLT-1 1/2”			4
5	HW0502	BOLT-HHCS-1/2-13 X 1 1/4”			8
6	HW0110	WASHER-LOCK-1/2”			8
7	43127001	SHAFT-EQUALIZATION		BE-24-2	2
	43327001	SHAFT-EQUALIZATION		BE-36-2	2
8	PT0503	BEARING-FLANGED LOAD-2 1/4”			8
9	HW0025	NUT-JAM-7/8-14			8

BRIDGE & CROSS BAR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HW0502	BOLT-HHCS-1/2-13 X 1 1/4”			12
2	HW0110	WASHER-LOCK-1/2”			20
3	HW0112	WASHER-FLAT-1/2”-SAE			20
4	HW0515	BOLT-HHCS-1/2-13 X 2”		FULLY THREADED	8
5	HW0007	NUT-HEX-1/2-13			8

LIFT CYLINDER CONNECTIONS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00158001-13	CHAIN-ROLLER-#80			4
2	HW0014	NUT-HEX-1-8			8
3	43897002	STUD-LIFT-INNER FRAME			4
4	PT0204	LINK-CONNECTING-#80			8
5	43897001	STUD-LIFT-OUTER FRAME			4
6	43815018	BRACKET-CYLINDER SUPPORT			4
7	SS0761	U-BOLT-CYLINDER MOUNTING			4
8	HW0108	WASHER-FLAT-3/8”-SAE			12
9	HW0107	WASHER-LOCK-3/8”			12
10	HW0005	NUT-HEX-3/8-16			8
11	HW0514	BOLT-HHCS-1/2-13 X 2 1/2”		IDLER CASTER END OF UNIT	2
	HW0504	BOLT-HHCS-1/2-13 X 2”		DRIVE WHEEL END OF UNIT	2
12	HW0110	WASHER-LOCK-1/2”			4
13	HW0112	WASHER-FLAT-1/2”-SAE			4
14	HW0402	BOLT-HHCS-3/8-16 X 1”			4
15	43822002	CLEVIS ASSEMBLY		SOLD AS ASSEMBLY ONLY	4

GUIDANCE ARM

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43017021	GUIDE ARM WELDMENT			2
2	43017025	SPACER-GUIDE ARM			4
3	PT0510	CAM ROLLER-1 3/4”			4
4	HW0115	WASHER-LOCK-3/4”			4
5	HW0011	NUT-HEX-3/4-16			4
6	HW0509	BOLT-HHCS-1/2-13 X 4 1/2”			4
7	HW0112	WASHER-FLAT-1/2”-SAE			4
8	HW0110	WASHER-LOCK-1/2”			4
9	HW0007	NUT-HEX-1/2-13			4

IDLER ROLLERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43182001	LEAD ROLLER ASSEMBLY-24”		W/ ALIGNMENT GROOVE	4
	43382001	LEAD ROLLER ASSEMBLY-36”		W/ ALIGNMENT GROOVE	4
2	43182002	IDLER ROLLER ASSEMBLY-24”			8
	43382002	IDLER ROLLER ASSEMBLY-36”			8
3	43187002	SHAFT-HEX-.75” X 25.75”			8
	43387002	SHAFT-HEX-.75” X 37.75”			8
4	43187003	SHAFT-HEX-.75” X 27.5”			4
	43387003	SHAFT-HEX-.75” X 39.5”			4
5	HW1058	PIN-HITCH			24

POWERED ROLLERS

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43182003	POWERED ROLLER-24”			10
	43382003	POWERED ROLLER-36”			10
2	43087001	JOURNAL-POWERED ROLLER			10
3	PT0404	FLANGE BEARING-3-BOLT-1”			20
4	HW0321	BOLT-HHCS-5/16-18 X 1 1/4”			60
5	HW0105	WASHER-LOCK-5/16”			60
6	HW0004	NUT-HEX-5/16-18			60
7	PT0033	SPROCKET-35B18 X 1”			16
8	00197028	KEY-1/4” X 1 1/4”			8
9	00158001-38	CHAIN-ROLLER-#35		† 49 PITCH LENGTH	4
	00158001-39	CHAIN-ROLLER-#35		51 PITCH LENGTH	4
10	PT0031	LINK-CONNECTING-#35			8
11	PT0418	COLLAR-SHAFT-1”			10
12	PT0032	LINK-OFFSET-#35		† NOT SHOWN	4

† OFFSET LINKS FOR USE WITH 49 PITCH LENGTH CHAINS ONLY.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	HC0120	MOTOR-HYDRAULIC-160CC			2
2	HW1071	KEY-WOODRUFF-#808 STD		SUPPLIED WITH ITEM 1	A/R
3	H1544	ADAPTER-#6 JICM X #10 SAEM			4
4	HW0402	BOLT-HHCS-3/8-16 X 1”			18
5	HW0107	WASHER-LOCK-3/8”			18
6	50017005	PLATE-MOTOR MOUNTING			2
7	PT0302-1	COUPLING BODY-#40 X 1”			4
8	PT0301	CHAIN-COUPLING-#40		INCL. CONNECTING PIN	2
9	00197026	KEY-1/4” X 1”			4

HOSE CARRIER

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	PT0629	CARRIER TRACK		81 LINKS REQ’D	10’
2	PT0630	BRACKET-UPPER MOUNTING		SOLD AS SET - INCL. ITEM #5	1
3	HW0212	SCREW-RHMS-#10-24 X 1/2”			2
4	SS0202	NUT-NILN-#10-24			2
5	PT0630	BRACKET-LOWER MOUNTING		SOLD AS SET - INCL. ITEM #2	1
6	HW0301	BOLT-SELF TAP “F”-1/4-20 X 1/2”			6
7	HW0303	BOLT-HHCS-1/4-20 X 1”			2
8	HW0104	WASHER-FLAT-1/4”-SAE			2
9	HW0103	WASHER-LOCK-1/4”			2
10	HW0002	NUT-HEX-1/4-20			2
11	43817056-2	BRACKET-CARRIER TRACK MOUNTING			1
12	HW0401	BOLT-HHCS-3/8-16 X 3/4”			4
13	HW0107	WASHER-LOCK-3/8”			4
14	HW0108	WASHER-FLAT-3/8”-SAE			4
15	43817057	PLATE-CARRIER TRACK SUPPORT			1
16	HW0504	BOLT-HHCS-1/2-13 X 2”			2
17	HW0110	WASHER-LOCK-1/2”			2
18	HW0112	WASHER-FLAT-1/2”-SAE			2

CABLE RETRACTOR

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	CCR-12HD	TAKE UP REEL-CARRIER TRACK			1
2	HW0403	BOLT-HHCS-3/8-16 X 1 1/4”			2
3	HW0108	WASHER-FLAT-3/8”-SAE			4
4	HW0107	WASHER-LOCK-3/8”			2
5	HW0005	NUT-HEX-3/8-16			2

OPERATOR GATE

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	43017064-2	LATCH-SWIING GATE			1
2	HW0030	BOLT-HHCS-3/8-16 X 2 1/4”			1
3	HW0031	NUT-LOCK-3/8-16			1
4	HW9000	HINGE-SPRING			1
5	HW0301	BOLT-SELF TAP ”F”-1/4-20 X 1/2”			3
6	HW1037	STOP-GATE	80092001		1
7	HW0303	BOLT-HHCS-1/4-20 X 1”	80092001		1
8	HW0104	WASHER-FLAT-1/4”-SAE	80092001	(NOT SHOWN)	1
9	HW0003	NUT-NILN-1/4-20	80092001	(NOT SHOWN)	1

GUARDS - OUTSIDE CARRIAGE

GUARDS - INNER CARRIAGE

GUARDS - LIFT CYLINDER=

EXTRACTOR ARM

VACUUM STUDS

SWING ARMS

SWING ARM STOPS

VACUUM PUMP

EXTRACTOR ARM MOUNTING

HOSE MOUNTING

ARM CYLINDER

BEARING PLATES

ROTARY ACTUATOR

CARRIER SHAFTS

DRIVE NUT ASSEMBLY

DRIVE SCREW

HOSE CARRIER PLATE

DRIVE AND IDLER CASTERS

FLOOR DRIVE ASSEMBLY

CASTERS

ELECTRICAL

AC POWER STANCHION

CONTROL PANEL

OPERATOR CONSOLE

FOOT SWITCH

GATE SWITCH

PROXIMITY SWITCH

JUNCTION BOX

JUNCTION BOX PANEL

WIRING DIAGRAMS

HYDRAULICS

POWER UNITS

RESERVOIR

VALVE ASSEMBLY

LIFT CYLINDER

LIFT CIRCUIT

CROSS PORT RELIEF

COUNTER BALANCE VALVE

TRANSITION PLATE

RETURN LINE MANIFOLD

HYDRAULIC SCHEMATICS

SERVICE AND MAINTENANCE

DAILY INSPECTION LIST

The points listed below should be visually inspected daily prior to initial start up of the Battery Extractor to ensure safe and proper operation of the unit and to help avoid unnecessary down time.

1. Walk around unit and inspect for any physical damage to machine not previously noted.

2. Verify all guards are in place.

3. Inspect the AC power feed for any damage.

4. Inspect vacuum cups for damage to cup sealing surface, backup casting, and vacuum hoses.

5. Inspect travel path and area around unit for any hydraulic oil that could be a potential repair/maintenance issue and/or safety hazard.

6. Check oil level in hydraulic reservoir at fill level gauge.

7. Check that operator safety gate and all safety switches are in proper working order.

8. Verify extractor path is free of obstructions.

9. Check roller beds for any debris and clean as required.

10. Board unit, engage system and verify all functions are operating properly and that no abnormal or unusual noises are present.

USE FORM IF-5008 WHEN PREFORMING DAILY INSPECTIONS.

OPERATOR'S DAILY CHECKLIST

RECOMMENDED LUBRICATION INTERVALS

PREVENTATIVE MAINTENANCE REPORTS

EQ CHAIN RESETTING PROCEDURE

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

Tools Required:

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

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

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

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

Step 1)

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

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

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

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

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

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

BE SURE ALL STOPS ARE CORRECTLY SEATED AS SHOWN HERE

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

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

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

FIGURE 2

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

FIGURE 3

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

FIGURE 4

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

FIGURE 5

FIGURE 6

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

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

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

Step 7)

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

FIGURE 7

FIGURE 8

SERVICE STAND INSTALLATION

TROUBLE SHOOTING GUIDE

TECH BULLETINS

PARTS KITS

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.