Installation,Use Maintenance andRepair Manual MinePowerStorageBatteries SAFETY.CAT.COM BI001953 A6474X26 February2012
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ThismanualisintendedtoprovideGENERALproductinformationfor theCaterpillarminepowerstoragebatteries.Theillustrations,descriptions,andprocedurescontainedinthispublicationapplyonlytoCaterpillarminepowerstoragebatteries.Caterpillarreservestherightto revisemodelsanddesignswithoutpriornotice.
ThisCaterpillarminepowerstoragebatterywasmanufacturedunder theguidelines,procedures,andrequirementsoftheU.S.FederalCoal MineHealthandSafetyAct,CodeofFederalRegulations,Title30, Chapter1,Subpart0,Part75forundergroundcoalmines,andother applicablenon-U.S.regulatoryagencystandards.
Atthecompletionofthemanufacturingprocess,thisbatterywasissued theappropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisbatterywithouttheconsentofCaterpillarand theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytotheinstructions,mayinvalidatetheseapprovalsandrenderthis batteryunsafetooperate.
StrictcompliancewithallFederalandStateMininglaws,regulations, andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisbattery.
Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisbattery,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourservicerepresentative immediately
Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distribution,orunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.
__________________________________________________________ BI001953
© CATERPILLAR ALLRIGHTSRESERVED
_________________________________________________ Tableofcontents A6474X26 VPSS/15 BI001953 Tableofcontents
Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual?....................1.4 Charactersandsymbols 1.5
1.
Yoursafety Yoursafety 2.3 Personnel 2.4 Operation 2.4 Installationandrepair......................................................2.4 Operatingconditions 2.5 Intendeduse 2.5 Unauthorizeduse 2.5 Safetyinstructions 2.7 Generalrules 2.7 Storageandtransport 2.7 Pre-startinspection 2.8 Operation 2.8 Maintenanceandrepair 2.9 Batteryhazards 2.10 Safetyprocedures 2.11 Federalstandards 2.11 Whilehandlingbatteries ......................................... 2.11 Whilechargingbatteries 2.12 Whilehandlingacids............................................... 2.13 Whileservicingorrepairingbatteries 2.14 Overviewofthesafetyinstructions .................................... 2.15 Chapter3:Storageandtransport 2.15 Chapter4:Installation ................................................... 2.15 Chapter5:Operation 2.15
2.
Storageandtransport Storageandtransport.............................................................3.3 Storage.................................................................................3.3 Storagemethods 3.3 Chargedandwetbatteries........................................3.3’ Chargedanddrybatteries 3.3 Transport..............................................................................3.4 Loadunits 3.4 Shipment .........................................................................3.4 Unpackinguponreceipt 3.5
3.
Tableofcontents _________________________________________________ MinePowerStorageBatteries BI001953
Installation................................................................................4.3 Pointstoobservepriortoinstallation 4.3 Whoisallowedtocarryoutinstallation? .........................4.3 Whichtoolsarerequiredforinstallation? 4.3 Notesoninstallation 4.4 Pre-installationchecklist 4.5
4. Installation
Operation..................................................................................5.3 Definitions 5.3 Descriptionsandconstruction 5.3 Charging...............................................................................5.7 Principlesofoperation 5.11 Fundamentalsofcycling................................................5.11 Ampere-hourcapacity 5.12 Voltage...........................................................................5.12 Ratedcapacity 5.12 Sulfation.........................................................................5.13 Operatingcycle 5.13 Servicelife.....................................................................5.13 Temperature 5.13 Preparationforuse.............................................................5.15 Establishingbatteryrequirements 5.15 Acidtowaterproportions 5.15 Chargedandwetbatteries 5.15 Instructionsonthemaintenance 5.17 Importantnotes 5.17 General 5.17 Specificmaintenanceinstructions 5.19 Everyshift 5.19 Weekly 5.21 Monthly 5.22 Annually 5.22 Recordkeeping 5.22 Troubleshootingprocedures 5.25 Instructionsontheadjustmentprocedures 5.29 Electrolytespecificgravity.............................................5.29 Restoringasulfatedbattery 5.30 Excessiveselfdischargecorrection ..............................5.31 Testdischarge 5.31 Replacementofparts .........................................................5.33 Purginggas 5.33 Removingintercellconnectors ......................................5.33 Removingacompletecell 5.34 Removinganelement....................................................5.34 Replacingacellinabattery 5.36 Replacingacellcover ...................................................5.37 Sealingcompoundandleadbushingdesign 5.37 Epoxysealandnutdesign 5.38 Heatbondedplasticcover-to-jardesign 5.38
5. Operation
_________________________________________________ Tableofcontents A6474X26 VPSS/15 BI001953 6. Technicaldata Tighteningtorques..................................................................6.3 7. Foryourinformation Foryourinformation...............................................................7.3 Ourservice 7.3 Serviceaddress 7.3 Rebuildfacilityaddress ...................................................7.4
applicableoperatingmanual
machinetype
Aboutthismanual
Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.
Beforestartingtowork
Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofbatteryused.
Thisoperatingmanualisintendedfor:
Minepowerleadacidstoragebatteries
SerialNo. - N/A
andisonlypermittedtobeusedforthesebatteries.
newoperationmanual
Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththebatteries.
Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.
Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.
Whoisthisoperatingmanualintendedfor?
Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthebattery.
Everypersonworkingonthefaceorintheintersectionbetweenface andentryorintheentrymustreadthisoperatingmanual.
Thisincludespersonswho:
■ areinchargeoftransport
■ performassembly/disassemblywork
■ operatethemachine
■ eliminatefaults
■ performdailyroutineworkonthefaceorintheentry
■ performmaintenancework
■ performrepairwork
supervisorypersonnelwho:
■ initiateand/or
■ supervisetheactivitiesjustindicated.
________________________________________Beforestartingtowork A6474X26 VPSS/15 1.3 BI001953
cost-effectiveness
Whatisthepurposeofthisoperatingmanual?
Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothebattery.
Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.
service safety
Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.
Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.
Beforestartingtowork ________________________________________ 1.4 MinePowerStorageBatteries BI001953
Charactersandsymbolsused
Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.
Trytomemorizethesymbolsandtheirmeanings.
DANGER!
Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.
WARNING!
Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.
CAUTION!
Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.
NOTICE!
Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothebattery ordamageintheimmediatevicinity.
IMPORTANT!
Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.
■ Itemsinlistsaremarkedwithbullets.
– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.
Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.
________________________________________Beforestartingtowork A6474X26 VPSS/15 1.5 BI001953
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
