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Boxcar Bully Plug Door Opener Boxcar Bully Plug Door Opener Logo
Operating Instructions for the Boxcar Bully Railcar Plug Door Opener

1. After inserting the forks fully into the pockets, The Bully should be secured to the fork truck via the safety chains.
2. Make sure the Bully hydraulic motor is plugged into the right outlet and is not plugged in the charger mode.
3. Secure the umbilical cord to the fork truck for the driver’s comfort, make sure the cord is not obstructed in the mast. Plastic ties can be used for temporary use.
4. Test the unit with the umbilical cord; familiarizing oneself with the directional values to the toggle switch.
5. The best operation is achieved when the opener drive shaft is perpendicular to the door in all directions and centered on the door handle. Use the positioning of the fork truck and the mast tilt to achieve this. Approach the door and compress the spindle approximately 3” when engaging the door.
6. Rotate the door handle in the desired direction making sure not to over rotate. When closing some doors, the cam mechanism will have excess wear and may have to be adjusted prior to closing.
7. The Bully has a push bar that extends out either side 18”. This bar may be used to aid in either opening or closing the door.
8. Once depleted, the batteries are easily recharged with the onboard charger. The plug leading from the batteries needs to be unplugged from the hydraulic pump motor and plugged into the charger. This is done on the front of the unit. The charger plug is identified by the much smaller lead wires. Then the 120V power is attached to the charger. The smart charger will test and charge the batteries as needed. Please review the detailed manufacturer information that follows later in this manual. A complete charge should be achieved in only 4 hours.
9. A routine inspection should be done on battery water level and the hydraulic fluid for the pump. The hydraulic fluid should be approximately 1” from the top. These inspections can be done as part of the routine for other battery powered equipment.
10. The electrical connections on the batteries and drive motors should be checked periodically to ensure they have not been damaged or vibrated loose. The period is dependent on the amount of use and conditions.
11. The spindle drive assembly should also be lubricated periodically to ensure free movement in and out.

The Arnold Company • 3 Harmony Lane • Trenton, Illinois 62293
800.245.7505 • Fax: 618.224.7005

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