CAT Super Service Battery Charger Operation Manual BI016811 - PDF DOWNLOAD

BI016811

BI016811 A6474X233 February 2013

Operation Manual Super Service Battery Charger

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• 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

BI016811

BI016811

This manual is intended to provide GENERAL product information for the Super Service battery charger. The illustrations, descriptions and procedures contained in this publication apply only to this unit. The manufacturer reserves the right to revise models and designs without prior notice.

This battery charger was manufactured under the guidelines, procedures and requirements of the appropriate regulatory agency standards. At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of the manufacturer and these regulatory agencies, or any repair or replacement of parts contrary to the manufacturer’ s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all local and national laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

 2013 ALL RIGHTS RESERVED

BI016811

BI016811

Table of Contents

Table of contents 1. About this manual About this manual ......................................................................1.3 Before starting to work ............................................................1.3 Who is this operating manual intended for?............................1.3 What is the purpose of this operating manual?.......................1.4 Characters and symbols used.................................................1.5

2. Your safety Your safety ..................................................................................2.3 Personnel ................................................................................2.4 Operation ...........................................................................2.4 Installation and repair.........................................................2.4 Operating conditions ...............................................................2.5 Intended use ......................................................................2.5 Unauthorized use ...............................................................2.5 Safety instructions ...................................................................2.7 Storage and transport ........................................................2.9 Installation and start-up......................................................2.9 Operation .........................................................................2.10 Maintenance and repair ...................................................2.10 Overview of the safety instructions .......................................2.13

3. Storage and transport Storage and transport ................................................................3.3 Storage....................................................................................3.3 Storage of the machine and spare parts............................3.3 Transport .................................................................................3.4 Load units; dimensions and weights ..................................3.4 Before transport .................................................................3.5

4. Installation Installation...................................................................................4.3 Points to observe prior to installation ......................................4.3 Who is allowed to carry out installation?............................4.3 Which tools are required for installation?...........................4.3 Notes on installation...........................................................4.3 Pre-installation check list ...................................................4.5 General information ...........................................................4.5

A6474X233

REV 03

BI016811

Table of Contents

BI016811 Safety features .................................................................. 4.7 Location ............................................................................. 4.5 Overview of the battery charger............................................ 4.11

5. Operation Operation .................................................................................... 5.3 How to operate the battery charger ........................................ 5.3 Who is allowed to operate the battery charger?................ 5.3 When can charging be started? ........................................ 5.3 Controls and indicators ........................................................... 5.4 Battery charging procedure .................................................... 5.7 Charging ............................................................................ 5.3 Equalizing charge .............................................................. 5.3 Operating instructions........................................................ 5.3 Watering ............................................................................ 5.3 Cleaning............................................................................. 5.3 Shut down procedure............................................................ 5.12 Display fault messages......................................................... 5.12 Electrical system ................................................................... 5.15 Input and output ratings ........................................................ 5.15 D.C. voltage ....................................................................... 5.3 A.C. voltage ....................................................................... 5.3 Troubleshooting .................................................................... 5.15 General inspection............................................................. 5.3 Service information............................................................ 5.3 Troubleshooting and replacing silicon diodes ................... 5.3 Checking capacitors .......................................................... 5.3

6. Technical data Technical data ............................................................................ 6.3 Components of the battery charger ........................................ 6.3 Technical data sheet ......................................................... 6.3 Tightening torques ................................................................ 6.19

7. For your information For your information.................................................................. 7.3 Our service.............................................................................. 7.3 Service address ................................................................. 7.3 Rebuild facility address...................................................... 7.4

Super Service Battery Charger

BI016811

BI016811

1

About this manual

BI016811

BI016811

BI016811

Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual

Machine type

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for: Model Super Service Battery Charger Serial No.: N/A and is only permitted to be used for equipment of this type.

The operating manual must be accessible at all times to all persons working on or with the unit.

It should, if possible, always be available at the place of operation.

new operation manual

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the unit.

Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who:  are in charge of transport  perform assembly / disassembly work  operate the machine  eliminate faults  perform daily routine work on the face or in the entry  perform maintenance work  perform repair work supervisory personnel who:  initiate and/or  supervise the activities just indicated.

A6474X233

REV 03

1.3

BI016811

Before starting to work

BI016811

What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the unit.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

1.4

service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety”with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

Super Service Battery Charger

BI016811

BI016811

Before starting to work

Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations. 

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

 Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

A6474X233

REV 03

1.5

BI016811

Before starting to work

1.6

BI016811

Super Service Battery Charger

BI016811

BI016811

2

Your safety

BI016811

BI016811

BI016811

Personnel

Your safety This chapter provides vital information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The battery charger has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the unit. All modifications and changes must be approved by the manufacturer.

Use only original spare parts. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations:

   further operating manuals

A6474X233

of the mine. of the mines inspector and of the mining supervisory authorities

Please read also the operating manuals for the batteries to be charged and equipment to be operated carefully and thoroughly. Clarify any questions before starting work.

REV 03

2.3

BI016811

Personnel

BI016811

Personnel Operation The battery charger may only be operated by qualified, trained personnel. training

The battery charger is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the

 

electrics, operation

and must be able to prove this knowledge.

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on:

 

safety components the electrics

may only be carried out by service engineers or by specially qualified personnel of the mine.

2.4

Super Service Battery Charger

BI016811

BI016811

Operating conditions

Operating conditions Intended use The battery charger has been designed and manufactured purely for recharging of mine power storage batteries.

Intended uses include:



the recharging of mine power storage batteries that are specified on the charger nameplate.

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the charger.



the recharging of other types of batteries not specified on the charger nameplate.

The manufacturer accepts no liability for any damage resulting from any such unauthorized use.

A6474X233

REV 03

2.5

BI016811

Operating conditions

2.6

BI016811

Super Service Battery Charger

BI016811

BI016811

Safety instructions

Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

personal equipment

Always wear your personal protective equipment. This also includes eye and clothing protection.

Inform your colleagues of:

   safety equipment

your exact location. the work you are performing. the time that you will probably require.

Start the unit only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the optical start-up warnings of the unit.

symbol plates emergency stop

lock-out

Observe the symbol plates on the unit.

Press the EMERGENCY STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Lock-out and disconnect the power system while performing:

   cordon off working area

A6474X233

maintenance work inspection work repair work

Cordon off your working area widely for the battery charger.

REV 03

2.7

BI016811

Safety instructions

BI016811

Personal precautions    

  

    

2.8

Have someone within range of your voice or close enough to come to your aid when you work near a battery Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery If the battery electrolyte contacts skin or clothing, wash immediately with soap and water. If the electrolyte enters the eye, immediately flood the eye with running cold water for at least ten (10) minutes and get medical attention immediately Never smoke or allow a spark or flame in vicinity of a battery Avoid dropping metal tools onto a battery. They may spark or short circuit the battery or other electrical parts that could cause an explosion Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery. A battery can produce a short circuit current high enough to weld a ring or the like to metal, causing a severe burn Never charge a frozen battery If it is necessary to remove the battery connections, always remove the grounded terminal from the battery first. Make sure all loads are disconnected and unit is off, so as not to cause an arc Be sure the area around the battery is well ventilated while the battery is being charged When cleaning battery terminals, be careful to keep corrosion from coming in contact with the eyes Study all the battery manufacturer's specific precautions such as do not remove cell caps while charging, recommended rates of charge, and maintenance procedures

Super Service Battery Charger

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• 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