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OperationManual BatteryChargerwithDigitalDisplay Models5,6,8,10,12,14and16 SAFETY.CAT.COM BI001975 A6474X230 October2012

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ThismanualisintendedtoprovideGENERALproductinformationfor BatteryChargers.Theillustrations,descriptionsandprocedurescontainedinthispublicationapplyonlytoTHESEchargers.Caterpillarreservestherighttorevisemodelsanddesignswithoutpriornotice.

ThisBatteryChargerwasmanufacturedundertheguidelines,proceduresandrequirementsoftheU.S.FederalCoalMineHealthand SafetyAct,CodeofFederalRegulations,Title30,Chapter1,Subpart0, Part75forundergroundcoalmines,andotherapplicablenon-U.S. regulatoryagencystandards.

Atthecompletionofthemanufacturingprocess,thisunitwasissuedthe appropriateapprovalnumbersandnameplatesindicatingitmetthe technicalrequirementsoftheseregulatoryagencies.Anychangetothe designorstructureofthisunit,withouttheconsentofCaterpillar,and theseregulatoryagencies,oranyrepairorreplacementofpartscontrarytotheinstructions,mayinvalidatetheseapprovalsandrenderthis unitunsafetooperate.

StrictcompliancewithallFederalandStateMininglaws,regulations andpracticesregardingthesafeoperationandmaintenanceofundergroundminingequipmentandstrictadherencetotheinstructionsinthis manualisnecessaryforthepersonalsafetyofthoseworkingonor aroundthisunit.

Whilethismanualattemptstoanticipatethemostimportantoperations andmaintenanceneedsforthisunit,unforeseencircumstancesmay arisethathavenotbeenaddressedinthismanual.Ifanyconcernsor questionsarise,pleasecontactyourServiceRepresentative immediately

Thisworkcontainsinformationprotectedundertradesecretandother intellectualpropertylaws,andisprotectedundertheU.S.Copyright Actof1976,asamended.Thisworkisprovidedunderlicenseandthe licenseisnon-transferable.Distributionandaccessislimitedonlyto authorizedpersonnel.Disclosure,reproduction,distributionorunauthorizedusemaybeaviolationoffederalandstatelawsandmaysubjecttheunauthorizedusertocriminalliability.

© CATERPILLAR ALLRIGHTSRESERVED

__________________________________________________________ BI001975

_________________________________________________ Tableofcontents A6474X230 REV04 BI001975 Tableofcontents

Aboutthismanual Aboutthismanual 1.3 Beforestartingtowork 1.3 Whoisthisoperatingmanualintendedfor? 1.3 Whatisthepurposeofthisoperatingmanual?....................1.4 Charactersandsymbols 1.5

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 Generalprecautions 2.8 Riskofexplosivegasses 2.8 Personalprecautions 2.9 Preparingtochargeprecautions 2.9 Unitlocationprecautions 2.10 Majorhazards 2.10 Storageandtransport 2.11 Installationandstart-up................................................. 2.12 Operation 2.12 Maintenanceandrepair................................................. 2.12 Overviewofthesafetyinstructions 2.15 Chapter2:Yoursafety................................................... 2.15 Chapter3:Storageandtransport 2.15 Chapter4:Installation ................................................... 2.15 Chapter5:Operation 2.16 Chapter6:Technicaldata............................................. 2.16

Storageandtransport Storageandtransport.............................................................3.3 Storage 3.3 Storageofthemachineandspareparts.........................3.3 Transport 3.4 Loadunits;dimensionsandweights ...............................3.4 Beforetransport 3.4

Installation Installation ...............................................................................4.3 Pointstoobservepriortoinstallation...................................4.3 Whoisallowedtocarryoutinstallation? 4.3

Tableofcontents _________________________________________________ BatteryChargerwithDigitalDisplay BI001975 Whichtoolsarerequiredforinstallation? 4.3 Notesoninstallation 4.3 Pre-installationchecklist 4.4 Generalinformation 4.5 Safetyfeatures 4.6 Standardfeatures............................................................4.8 Environmentalratings 4.8 Ratingsandspecifications 4.9 Minimumwiresize 4.10 Electricalconnectionsandfieldwiring...........................4.11 Groundintegrity(optional) 4.12

Operation Operation..................................................................................5.3 Howtooperatethebatterycharger 5.3 Whoisallowedtooperatethebatterycharger 5.3 Whencanchargingbestarted?.......................................5.3 Controlsandindicators 5.4 Startupprocedure 5.5 Faultcodes 5.6 Adjustments..........................................................................5.7 Circuitoperation 5.7 Instructionsonthemaintenance ........................................5.13 Importantnotes 5.13 Beforemaintenance.......................................................5.13 Generalmaintenanceprocedures 5.14 Troubleshootingprocedures...............................................5.15 Generalinspection 5.15 Serviceinformation........................................................5.15 Troubleshootinginformation 5.16 Groundshortcircuittest.................................................5.17 Troubleshootingandreplacingpowersilicondiodes 5.17 Checkingcapacitors 5.18

Technicaldata Technicaldata .........................................................................6.3 Componentsofthebatterycharger 6.3

Foryourinformation Foryourinformation...............................................................7.3 Ourservice ...........................................................................7.3 Serviceaddress 7.3 Rebuildfacilityaddress....................................................7.4

_______________________________________________________________ 1 Aboutthismanual BI001975

_______________________________________________________________ BI001975

applicableoperatingmanual machinetype

Aboutthismanual

Thischapterprovidesimportantinformationmakingiteasierforyouto usethismanual.Youwillalsobegiveninformationonthestructureof themanualandthesymbolsandcharactersused.

Beforestartingtowork

Takecaretoensurethattheoperatingmanualavailabletoyouisapplicableforthetypeofequipmentormachineused.

Thisoperatingmanualisintendedfor:

BUC - Models5,6,8,10,12,14,and16BatteryChargers SerialNo.:N/A

andisonlypermittedtobeusedforequipmentofthistype.

newoperationmanual

Theoperatingmanualmustbeaccessibleatalltimestoallpersons workingonorwiththemachine.Itshould,ifpossible,alwaysbeavailableattheplaceofoperation.

Sendforanewoperationmanualimmediatelyifthepresentmanualis nolongercompleteorhasbecomeillegible.

Whoisthisoperatingmanualintendedfor?

Thisoperatingmanualisintendedforthosepersonswhoworkwithor onthebatterycharger.

Everypersonworkingonthefaceorintheintersectionbetweenface andentryorintheentrymustreadthisoperatingmanual.

Thisincludespersonswho:

■ areinchargeoftransport

■ preparetheriseheading

■ performassembly/disassemblywork

■ operatethebatterycharger

■ eliminatefaults

■ performdailyroutineworkonthefaceorintheentry

■ performmaintenancework

■ performrepairwork

supervisorypersonnelwho:

■ initiateand/or

■ supervisetheactivitiesjustindicated.

___________________________________________ Beforestartingtowork A6474X230 REV04 1.3 BI001975

cost-effectiveness

Whatisthepurposeofthisoperatingmanual?

Thisoperatingmanualisintendedtohelpyouworkefficientlyand safelywithourproduct.Itcontainsimportantinformationonalltheactivitiesrelatedtothebatterycharger.

Readthisoperatingmanualcompletelyandatease.Payspecialattentiontothesafetyinstructions.Trytomemorizetheappearanceandthe meaningofthesafetyandinstructionsymbols.

service safety

Ifanydetailsarenotclearlyunderstood,pleasecontactourservicedepartment.Ourserviceaddressisgiveninthechaptertitled“Foryour information”.

Readthechapter“Foryoursafety”withspecialattention.Thechapter containsimportantinformationindicatingpossiblehazards.Observe theinformationgivenandfollowtheproceduralinstructions.

Beforestartingtowork____________________________________________ 1.4 BatteryChargerwithDigitalDisplay BI001975

Charactersandsymbolsused

Thefollowingcharactersandsymbolsareusedforsafetyinstructions andimportantinformationintheoperatingmanual.

Trytomemorizethesymbolsandtheirmeanings.

DANGER!

Pointsinthetextmarkedwiththissymboldrawyourattentionto immediatelyimpendingdanger.Possibleconsequencesare: veryseriousinjuryorevendeath.

WARNING!

Thesepointscontaininformationondangeroussituations.Possibleconsequencesare:veryseriousinjuryorevendeath.

CAUTION!

Thissymboldrawsattentiontodangeroussituations.Possible consequencesare:lighttomoderatelyseriousinjuriesandmachinedamage.

NOTICE!

Pointsinthetextmarkedwiththissymboldrawattentiontoharmfulsituations.Possibleconsequencesare:damagetothemachineordamageintheimmediatevicinity.

IMPORTANT!

Pointsinthetextmarkedwiththissymbolcontainusefultipsand informationintendedtofacilitateworkforyou.Theydonotwarn aboutharmfulordangeroussituations.

■ Itemsinlistsaremarkedwithbullets.

– Pointsinsub-listsaremarkedwithalongdashatthestartof theline.

 Pointsintextmarkedinthiswaydescribeindividualoperations. Followtheseinstructionsstepbystep.Theywillhelpyoucarryout yourworkfasterandmoreimportantly,safer.

___________________________________________ Beforestartingtowork A6474X230 REV04 1.5 BI001975

Beforestartingtowork____________________________________________ 1.6 BatteryChargerwithDigitalDisplay BI001975

_______________________________________________________________

BI001975

2 Yoursafety

_______________________________________________________________ BI001975

stateoftheart

Yoursafety

Thischapterprovidesvitalinformationforyoursafety.

Payspecialattentiontothischapter.Thesafetyinstructionsandrules ofprocedurewillhelpyoutoavoidhazardoussituationsandtoperform thenecessaryworkassafelyaspossible.

Thebatterychargerhasbeenmanufacturedinaccordancewiththe stateoftheartandgenerallyrecognizedsafetystandardsandregulations.Youandotherscanneverthelessbeexposedtodangerous situationse.g.asaresultofenvironmentalinfluences,batterycharger damageoroperatorerrors.

Donotmakeanyalterationsormodificationswhichcouldimpairthe safetyofthemachine.Allmodificationsandchangesmustbeapproved.

Useonlyoriginalspareparts.Notethattheuseofpartsfromother manufacturerswillvoidtheguarantee.

Inadditiontothisoperatingmanual,besuretoobservetherespective legalprovisionsandregulationsinyourcountry.

Observethesafetyandaccidentpreventionregulations:

■ ofthemine,

■ oftheMineInspector,and

■ oftheminingsupervisoryauthorities.

______________________________________________________ Personnel A6474X230 REV04 2.3 BI001975

Personnel

Operation

Thebatterychargermayonlybeoperatedbyqualified,trainedpersonnelwhocanprovideproofofhavingbeentrainedonthisunit.Reading oftheoperationmanual,especiallythechapteronsafety,shallconstituteapartofthistraining.

Youmusthaveadequateknowledgeofthe

■ mechanics,

■ electrics,and

■ operation andmustbeabletoprovethisknowledge.

Installationandrepair

Asafundamentalrule,installationandrepairworkmayonlybecarried outbypersonnelwhohavebeenadequatelytrainedfortheseparticular requirements.

Installationandrepairworkon:

■ safetycomponents

■ theelectrics mayonlybecarriedoutbyserviceengineersorbyspeciallyqualified personnelofthemine.

Personnel ______________________________________________________ 2.4 BatteryChargerwithDigitalDisplay BI001975

training

Operatingconditions

Intendeduse

Thebatterychargerhasbeendesignedandmanufacturedpurelyfor therechargingofminepowerstoragebatteries.

Intendedusesinclude:

■ therechargingofminepowerstoragebatteriesthatarespecified onthechargernameplate.

Unauthorizeduse

Applicationsnotexpresslylistedasintendedusesareunauthorized usesandarenotallowedtobeperformedwiththecharger.

■ therechargingofothertypesofbatteriesnotspecifiedonthe chargernameplate.

Themanufactureracceptsnoliabilityforanydamageresultingfrom anysuchunauthorizeduse.

_____________________________________________Operatingconditions A6474X230 REV04 2.5 BI001975

Operatingconditions _____________________________________________ 2.6 BatteryChargerwithDigitalDisplay BI001975

general noiseemissions

Safetyinstructions

Generalrules

Alwaysworkwithfullconcentration. Familiarizeyourselfwithyourworkingenvironment.

Alwayswearyourpersonalprotectiveequipment.Thisalsoincludes earprotectorsasthenoiseemittedbyotherequipmentintheareamay attimesexceed85db(A).

Informyourcolleaguesof:

■ yourexactlocation,

■ theworkyouareperforming,and

■ thetimethatyouwillprobablyrequire.

safetyequipment

Startthebatterychargeronlywhenitisinagoodandsafeoperating conditionandallprotectivedevices,e.g.EMERGENCYSTOPdevices, covers,etc.arecorrectlyinstalled.

Observetheacousticandopticalstart-upwarningsofthemachine.

symbolplates emergencystop lock-out

Observethesymbolplatesonthemachine.

Pressthe“EMERGENCYSTOP”switchimmediatelyintheeventof faultorirregularitiesinoperation.Reportanypeculiaritytoyoursuperiorsothatnecessarymeasurescanbetakenimmediately.

Lock-outanddisconnectthepowersystemwhileperforming:

■ maintenancework,

■ inspectionwork,and

■ repairwork.

cordonoffworkingarea

Cordonoffyourworkingareawidelyfortheunit.

_______________________________________________Safetyinstructions A6474X230 REV04 2.7 BI001975

Generalprecautions

■ Savetheseinstructions.Thismanualcontainsimportantsafetyand operatinginstructions.Beforeusingthisequipment,readallinstructionsandcautionarymarkingson(1)unit,(2)battery,and(3) productusingthebattery.

■ Toreducetheriskofinjuryand/ordamagetothebatteries,useonly thetypeofbatteriesspecifiedonthechargernameplate.

■ Donotexposeequipmenttorainorsnow.

■ Donotoperateequipmentifithasreceivedasharpblow,been dropped,orotherwisedamagedinanyway;takeittoaqualified servicetechnician.

■ Donotdisassemblethisunit;takeittoaqualifiedservicetechnician whenserviceorrepairisrequired.Incorrectre-assemblymayresultinariskofelectricshockorfire.

■ Toreducetheriskofelectricshock,disconnectthisunitfromthe ACsupply,batteries,andloadsbeforeattemptinganymaintenance orcleaning.Turningoffthecontrolswillnotreducetherisk.

Riskofexplosivegases

WARNING!

Thereisariskofexplosivegasesandworkinginthevicinityofa batteryisdangerous.Somebatteriesgenerateexplosivegases duringnormalbatteryoperation.Forthisreason,itisoftheutmostimportancethateachtimebeforeusingthisunit,youread thismanualandfollowtheinstructionsexactly.

■ Toreducetheriskofbatteryexplosion,followtheinstructionspublishedbythebatterymanufacturerandthemanufacturerofany equipmentyouintendtouseinthevicinityofthebattery.Review cautionarymarkingsonallproducts.

_______________________________________________ 2.8 BatteryChargerwithDigitalDisplay BI001975