(BE-SL & -DS) Single Level & Double Stack Operator Aboard Battery Extractors – Parts & Service Manual (IOP-400)

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Preface

This manual is to be used to service SINGLE LEVEL (BE-SL) as well as DOUBLE STACK (BE-DS) Battery Extractors.

Any views not specifically stated otherwise are of the Single Level Extractor. The parts listed are common for Single Level (BE-SL) and Double Stack (BE-DS) unless otherwise noted in the notes column of the Parts Lists. See Example Below.

ITEM	BHS PART NUMBER	DESCRIPTION	REF. KIT NO.	NOTES	NO. REQ
1	00158001-10	CHAIN-ROLLER-#60		BE-SL ONLY	4
	00158001-12	CHAIN-ROLLER-#60		BE-DS ONLY	4

For Items or Assemblies that are unique to only the SL or DS, it will be designated as such on the diagram and have a separate, corresponding parts list for that diagram.

When servicing HIGH PERFORMANCE (BE-DS-HP) models, refer to the High Performance Option section for all parts unique to High Performance Units. If a particular part is not found in the High Performance Option section, refer tot the Standard Parts Section(s) of this manual.

TP-606 – Safety & De-Energization Procedures

Operational 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.
• Failure to follow these instructions and warnings may result in property damage, personal injury or death.

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 Battery 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.

	Electromagnet Hazard Units equipped with magnetic extraction generate strong magnetic fields. Persons with pacemakers SHOULD NOT operate or be in close proximity to equipment during operation. Failure to comply with this direction could result in serious personal injury or death.

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 Lead-Acid Battery Explosion Hazard section).
• All data plates, warning labels, placards, etc. shall be in place and legible at all times. Contact BHS for re-placement 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 inside the operator 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'ts

• 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 foodstuffs
  • In a potentially explosive atmosphere

Operating Controls & Instructions

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 or press the E-stop button 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, remove the key and logout out of the IIoT (if equipped) 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 the battery during change out.)
3. Board battery extractor and close safety gate. (Gate must be fully closed or unit will not operate.)
4. Turn key switch to "ON" position.
5. Log in on the HMI display (if equipped with BE-IIoT package).
6. Depress foot pedal.

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