cap lamp systemsluminator®power cell 817177 13 AHluminator®power cell plus 817178 16 AH

instructions

PITTSBURGH, PENNSYLVANIA, U.S.A. 15230

Manufactured by

THIS MANUAL, INCLUDING THE WARNINGS AND CAUTIONS INSIDE,MUST BE READ AND FOLLOWED CAREFULLY BY ALL PERSONS WHOUSE OR MAINTAIN THIS PRODUCT, INCLUDING THOSE WHO HAVE ANYRESPONSIBILITY INVOLVING ITS SELECTION, APPLICATION, SERVICE,OR REPAIR. THIS RESPIRATOR WILL PERFORM AS DESIGNED ONLY IFUSED AND MAINTAINED ACCORDING TO THE INSTRUCTIONS. OTHER-WISE IT COULD FAIL TO PERFORM AS DESIGNED AND PERSONS WHORELY ON THIS PRODUCT COULD SUSTAIN SERIOUS PERSONAL INJURYOR DEATH.

WARNING

The warranties made by MSA with respect to the product are voided if theproduct is not installed, used, and serviced in accordance with the instruc-tions in this manual. We encourage our customers to write or call for ademonstration of this equipment prior to use or for any additional informa-tion relative to use or repairs. Call 1-800-MSA-2222.

TAL 998 (L) Rev. 2 © MSA 1999 Print Spec. 10000005389 (S) Mat. 817184Doc. 817184

and ML-2

Ultralight13 AH - 817171

Ultralight16 AH - 817172

Ultralight w/Remote13 AH - 817169

Ultralight w/Remote16 AH - 817170

ML-213 AH - 817173

ML-216 AH - 817174

ML-2 w/Remote16 AH - 817176Ultralight

TM

817184 8/13/99 9:42 AM Page 1

IMPORTANT

Please read and observe the Warningsand Cautions in this manual. A WARN-ING describes a condition that maycause severe personal injury or deathif allowed to happen. A CAUTIONdescribes a condition that may causemoderate injury or property damage ifallowed to happen.

1. An adequate mine lighting pro-gram must include assessmentof mine lighting requirements,integration of appropriate MSHAregulation, selection of properequipment, and instruction andtraining in the use, inspectionand maintenance of equipment.(See MSHA regulations, Title 30CFR, Part 19).

2. The cap lamp system will per-form as designed only if usedand maintained according to the

manufacturer’s instructions.Supervisors and users must readand understand these instruc-tions before trying to use or ser-vice this product. We encourageour customers to write or calltheir MSA distributor or call MSACustomer Service for informa-tion on this product before usingit. To reach the nearest MSAoffice, call 1-800-MSA-2222

3. This cap lamp may be used onlyafter proper instructions andtraining in its use.

4. Do not alter, modify, or substi-tute any components without theapproval of MSA. Such alter-ations will void the MSHAapproval for use in a hazardousatmosphere of methane and aironly.

5. Inspect the cap lamp and bat-tery after each use and maintainthem according to MSA’sinstructions. Repairs must bemade by properly trained per-

sonnel only.6. Follow MSA’s instructions for

first time and routine cap lampuse. The battery must not be left“on charge” indefinitely, (seeStoring Idle Batteries section).Doing so may cause internalgases to vent, which may lead toaccumulation of combustiblegases in the lamp room, damageto the battery, or reduced ser-vice life.

Failure to follow the above canresult in serious personal injury ordeath.

GENERAL DESCRIPTION

The Ultralight and ML-2 Cap LampSystem consists of a lightweight, capmounted headpiece powered by aLuminator® (lead-acid) battery.

2 TAL 998 (L) Rev. 2 - 817184

Ultralight™ Cap Lamp System ML-2 Cap Lamp System

TABLE OF CONTENTSGENERAL DESCRIPTION....................................................2Remote Power Connections................................................3PREPARATION FOR USE....................................................3Battery Charging..................................................................3Routine Battery Maintenance ..............................................3Replacing Battery ...............................................................4Remote Power Connection..................................................4ULTRALIGHT™....................................................................5Using the Ultralight™ Cap Lamp System............................5MAINTENANCE ...................................................................5Removing the Bezel.............................................................6Installing a New Secondary Bulb.........................................6

Removing and Installing the Main Circuit Board .................6Removing and Installing the Switch and Wiring ..................7Removing and Replacing the Cap Hook .............................7Removing and Installing the Charging Barrel,Charging Contact, and Contact Wire Assembly..................8CABLE AND BATTERY COVER ASSEMBLY.......................9Replacing the Cable ............................................................9ML-2 CAP LAMP SYSTEM..................................................9MAINTENANCE .................................................................11Replacing Bulb...................................................................11Replacing Reflector ...........................................................11Replacing Cable.................................................................12TROUBLESHOOTING........................................................15

WARNING

817184 8/13/99 9:42 AM Page 2

Depending on the Luminator batteryused, the cap lamp is designed tooperate at full brilliance for a minimumof an 8-10 hour shift, with reserveenergy if needed. At the end of eachshift the battery is recharged in a sin-gle- or multiple-station charging unit.The Luminator Power Cell (13 AH) isdesigned to operate at cycle routinesof 8-10 hours discharge/16-14 hourrecharge 5 days/week (max). If theroutines are increased, the LuminatorPower Cell Plus (16 AH) is recom-mended. Battery charging connectionis made through the headpiece, usingeither a parallel or modular chargingsystem. Each battery has a transpar-ent case with molded-in electrolytelevel indicators below the filling ports.

Remote Power ConnectionsThe Remote Power Connection allowsthe Cap Lamp to be used as a powersource for an external remote devicewhile still operating as light source.MSHA regulation permits this configu-ration as long as the external remotedevice current requirement does notexceed 275 milliamps.

If using the Remote with the Ultralightor ML-2 Cap lamps, the LuminatorPower Cell Plus 16 Ah battery is rec-ommended, due to higher batterydemands. However, the LuminatorPower Cell 13 AH has been approvedwith the Remote Power Connectionfor Ultralight Cap Lamp use only.

Preparing the Ultralight and ML-2Cap Lamps for First Time Use

Battery ChargingEvery battery must be charged beforeit is used for the first time. A batterymay be charged with parallel or modu-lar systems, in either standard or lowprofile racks, or in a single stationcharger. Various MSA chargers andpart numbers are listed in the chartbelow:1. Set power supply or charging sta-

tions to 5.0 ± .05 VDC.2. Connect the battery to the charg-

ing station, following the instruc-tions supplied with the charger.

3. To check that charging current isflowing, look at the meter (locatedeither just above or just below thebattery on rack-mounted charg-ers). The meter needle shouldswing to the far right.

NoteIn some cases there will not be ameter on the charger. See the instruc-tions for the appropriate charger.

4. Allow the battery to remain oncharge for 24 hours.

5. As the battery charges, the meterneedle should gradually move tothe left to OFF. In other chargers,the LED lights will indicatecharged condition.

6. Top off each cell with distilled waterif necessary (see Watering section).

Routine Battery Maintenance1. Routine Charging on Standard

Rack and Charger. All batteries inthis category must be chargedimmediately after each period ofuse in the following manner:a. Set power supply or charging

stations to 5.0 ± .05 VDC.b. Connect the battery to the

charging station following theinstructions supplied with thecharger.

c. Check meter, the needleshould swing to right indicatingcharge, (or check LED lights).

d. Allow battery to remain in therack until it is recharged.(Needle of meter will return to“OFF” or LED lights will indi-cate charged condition).

e. To remove lamp and stopcharge, rotate the headpiececounterclockwise to a full stop,then lift headpiece from key andbattery form the charging rack.

NoteBatteries which do not perform satis-factorily, should be removed from ser-

vice and cycled - charged 16 hours,discharged 8 hours. Repeat severaltimes until battery responds. If batterydoes not respond after three or fourcycles, it should be replaced.

f. After weekly shifts, the batteryshould be placed on thecharger following the instruc-tions included with the charg-er, and left to charge theremainder of the weekend.

g. If cap lamp needs cleaning,use a mild detergent and wipe.Do not submerge.

2. Storage of Batteries.All stored batteries with acidshould be boost charged for 24hours every 3 months, and imme-diately before being placed intoregular service. Recommendedstorage temperatures 32˚F to 80˚F.

3. Watering.The electrolyte level should bemaintained between the two linesindicated below the filling andventing hole i.e. slightly above thetop of the battery plate.

Normally topping up should not benecessary more often than onceevery 3-4 weeks, and shouldalways be carried out when thebattery is fully charged. Only dis-tilled or deionized water should beused in topping up.

The Electrolyte is corrosive and cancause burns. Take proper precau-tions to avoid skin and eye contact.Contact MSA for battery MaterialsSafety Data Sheet (MSDS). Phone1-800-MSA-2222.

TAL 998 (L) Rev. 2 - 817184 3

General Description

WARNING

Part No. Description

461891 Deluxe Charger, Single Unit, 120 VAC

466490 Charger, Modular, 6-unit, 120 VAC

466491 Charger, Modular, 10-unit, 120 VAC

464734 Charger, Modular, 40-unit, 120 VAC

464714 Charger, Modular, 60-unit, 120 VAC

463746 Charger, Standard, 40-unit, 120-VAC

463747 Charger, Standard, 60-unit, 120 VAC

MineSpot Charging Equipment

FillLines

817184 8/13/99 9:42 AM Page 3

Replacing the Battery(Ultralight and ML-2)1. Remove the battery cover.

a. Remove the cover from yourexisting Caplamp battery usinga 5/64” Allen wrench, andkeep the cover clamps andsocket dcrews for later use.

b. Lift the battery cover off thebattery.

c. Disconnect the red and blackwires from the battery termi-nals by loosening the screwsholding the pole clamps to theposts. Carefully remove theclamps from the posts.Dispose of the old batteryproperly.

2. Install new battery.a. Connect red conductor to pos-

sitive battery pole and blackconductor to negative batterypole to insure correct polarity.

b. Tighten cable clamps with aflat blade screwdriver.

3. Re-install the battery cover.a. Check both ends of the battery

for the adapter clips.

Replace the battery cover. Itmust fit squarely on top of thebattery. Slide a cover clamp oneach end of the battery andcover.

NoteThe mounting hole in each clamp isslightly off-center. Install the clamp sothat the hole is below center.

b. Install the two screws andtighten, using the 5/64” allenwrench.

The electrolyte level of all batteriesshould be checked once each week,and after battery is charged.

Water only when battery is fullycharged. If the battery is over-topped, there is a possibility thatelectrolyte may leak out under cer-tain conditions.

a. Fill the plastic bottle of theMSA Filling Device (P/N 69422,469773, or 454052) with dis-tilled water only, and place it ata convenient location close tothe batteries to be watered.

b. Insert the nozzle or needle of theFilling Tube into the small holeprovided in the battery window.Depending on the style of fillingdevice, squeeze the bottle orpush the needle forward.

c. Fill until the electrolyte level iscentered between the twoscribed lines below the cellwindow. The battery may haveto be tilted back slightly toallow the water to flow.

d. Repeat this procedure in adja-cent battery cell.

Using the Remote PowerConnection

NoteIf using the Remote Power Connec-tions with the Ultralight or ML-2 CapLamps, the Luminator Power Cell Plus16 AH battery is recommended, dueto higher battery demands. However,the Luminator Power Cell 13 AH hasbeen approved for use with theRemote Power Connection with theUltralight cap lamp.

1. To access the battery power for anexternal remote device, removethe connector cover located onthe top of the battery. Keep thecover for later use.

4 TAL 998 (L) Rev. 2 - 817184

Battery Replacement

CAUTION

817184 8/13/99 9:42 AM Page 4

2. Slide the remote power device’sconnector onto the connector ontop of the battery until it stops.

3. At end of shift, or when finishedusing the external device, removethe external connection from thebattery top and reinstall the cover.Place the battery on charge asdescribed in the Routine BatteryMaintenance section.

4. Refer to Illustrated Parts List forreplacement components.

ULTRALIGHT CAP LAMP SYSTEM

The Ultralight headpiece is made up ofthe lamp-housing, which contains thefollowing parts:— Bezel (cover);— O-ring— Main bulb and reflector assembly— Spring— secondary bulb— 3-position switch— Printed circuit board— Charging key system

Bulbs are tungsten-halogen type con-struction.

The main bulb is mounted in thereflector, positioned for a tightly-focused beam at maximum light out-put, and then bulb and reflector arecemented together. The main bulband reflector are held in the lamp-housing by the bulb pins, which pluginto a flexible circuit board.

The secondary bulb gives enough lightfor the wearer to leave the mine if thebulb burns out. This bulb also plugs intothe lamp-housing circuit board, butpasses through the reflector. Since thebulb is not centered in the reflector, itdoes not give a bright, sharp spot.

The spring keeps the reflector tightagainst the cover bezel. An O-ring,mounted in a groove in the lamp-housing, seals against the bezel to

help keep out dirt and moisture. Astainless steel clip holds the head-piece firmly to the miner’s cap. Adurable, abrasion-resistant cable con-nects the headpiece to the battery andallows freedom of movement.

Using the Ultralight Cap LampSystemThe on-off switch is a 3-position switch,located on the headpiece. The centerposition is OFF. To operate the lamp:1. Place the switch forward all the

way to light the primary bulb.

This bulb forms a tight spot formaximum lighting.

2. Push the switch to the center posi-tion to the lamp off.

3. Push the switch back all the way tolight the secondary bulb. This bulb will not form a tight spot,but will give enough light to leavethe mine.

If the main bulb fails to light, turnthe secondary light on, and immedi-ately go to a well-lit area andreplace the main bulb.

MAINTENANCE OF THEULTRALIGHT CAP LAMP SYSTEM

HEADPIECE ASSEMBLY

Removing the Bezel (cover)P/N 4767051. Use a 3/32” allen wrench to thread

the two allen set screws(P/N 634639) into the lamp-hous-ing (P/N 486610).

NoteIt is easier to remove the bezel by thread-ing the set screws into the lamp-housingrather than out of the lamp-housing.

2. Pull the bezel off the lamp-housing.

TAL 998 (L) Rev. 2 - 817184 5

Ultralight Cap Lamp System

Bezel

Reflector

Cable Protector

BatteryCover

BatteryCable

CAUTION

817184 8/13/99 9:42 AM Page 5

3. Inspect the O-ring (P/N 632226) inthe lamp-housing groove.

If the O-ring shows signs of wearor damage, replace it. The O-ringis needed to keep dust and mois-ture out of the lamp-housing.

Installing the Bezel1. Line up the notches in the bezel

with the tabs in the lamp-housing.

2. Press the bezel into place so thatthe side holes line up with the allenscrews.

3. Use a 3/32” allen wrench to threadthe two set screws out of the lamp-housing until the screw heads areflush with the bezel surface.

Do not touch the bulb while it is on.Turn the lamp off and let the bulbcool for 2 or 3 minutes before youtouch it. These bulbs reach temper-atures up to 400˚F and you could beseriously burned.

Removing the Main Bulb andReflector Assembly (P/N 480374)1. Remove the bezel.2. Gently lift the reflector and spring,

and hold the flexible circuit board.3. Gently pull the reflector until the

bulb pins are free.

4. Lift the bulb and reflector and thespring (P/N 632227) out of thelamp-housing.

Removing the Secondary Bulb(P/N 476720)1. Gently pull the bulb until the pins

are free of the circuit board.

Installing a new O-Ring1. Place a small amount of silicone

lubricant on the O-ring.2. Gently stretch the O-ring over the

lamp-housing and place it in thegroove.

Installing a new Main Bulb andReflector Assembly1. Insert the bulb and reflector into

the spring.2. Compress the spring with your fin-

gers.3. Line up the bulb pins with the con-

tacts on the flexible circuit board.

NoteCheck that the opening in the reflectoris on the same side of the main circuitboard as the contacts for the sec-ondary bulb.4. Support the flexible circuit board

with your fingers and push thereflector gently until the pins are inthe flexible board contacts.

5. Release the spring so it is flat onthe circuit board.

Installing a new Secondary Bulb1. Insert the bulb through the open-

ing in the reflector.2. Gently push the pins into the con-

tacts on the circuit board.

3. Re-install the bezel.

Removing the Main Circuit Board(P/N 484686)1. Remove the bezel.

6 TAL 998 (L) Rev. 2 - 817184

Maintenance

WARNING

817184 8/13/99 9:43 AM Page 6

2. Remove the main bulb and reflector,the spring and the secondary bulb.

3. Remove the three screws (P/N 65522) and lockwashers (P/N 54278) that hold the circuitboard in the lamp-housing.

4. Lift the board to expose the wiring.5. Pull the seven wire pins out of the

board.

Installing the new Main Circuit Board1. Position the board so that its

straight side is on the same side ofthe headpiece as the switch;a. its pins face up;b. the flexible circuit board pins

face up.

2. Insert the wires into the pins on thebottom of the main circuit board.They must be installed as follows(the letters are on the top of the

board)White to W Orange to OBlack to K Blue to BRed to R Brown to NGreen to G

a. Line up the holes in the boardwith the brass inserts into the

lamp-housing and install thethree lockwashers and screws.

Do not over-tighten screws or youmay crack the circuit board.

b. Re-install the main lamp andreflector assembly, the springand the secondary bulb.

c. Re-install the bezel.

Removing the Switch and WiringAssembly (P/N 484684)1. Remove the bezel.2. Remove the main bulb and reflector,

the spring and the secondary bulb.3. Remove the main circuit board.4. Using a wrench, loosen and

remove the boot (P/N 682390).Keep the boot; it will be used tosecure the new switch. Take carenot to damage the boot material.

5. Pull the switch and wiring out ofthe lamp-housing.

Installing the Switch and WiringAssembly1. Position the switch so that the

blue wire is closest to the open

end of the lamp-housing and bendthe wires so that the switch will fitin the lamp-housing.

Be careful not to bend the switchterminals. They may break.

2. Insert the switch toggle throughthe hole in the lamp-housing. You may have to move the switchback and forth to fit the threadedbushing into the hole.

3. Thread the boot on the switch bush-ing and tighten, using a wrench.Take care not to damage the boot.

4. Re-install the main circuit board.5. Re-install the main bulb and

reflector assembly, the spring andthe secondary bulb.

6. Re-install the bezel.7. Test the switch operation by push-

ing the toggle forward to light themain bulb, and back to light thesecondary bulb.

Removing the Cap Hook(P/N 484687)1. Use a flatblade screwdriver to

remove the two screws (P/N 65522)and lockwashers (P/N 51704) thathold the cap hook to the lamp-housing.

TAL 998 (L) Rev. 2 - 817184 7

Maintenance

CAUTION

CAUTION

817184 8/13/99 9:43 AM Page 7

2. Be careful that you do not bendthe cap hook as it is removed.

Installing a new Cap Hook1. Line up the base of the cap hook with

the grooves in the lamp-housing.

NoteThe grommet portion of the cable mayhave to be pushed into the base of thelamp-housing.

2. Press the cap hook into place andinstall the two screws and lock-washers to secure it to the lamp-housing. Be careful that you donot bend the charging key.

Removing the Charging Barrel(P/N 89947), Charging Contact(P/N 89948), and Contact WireAssembly (P/N 484821)1. Remove the bezel.2. Remove the main lamp and reflec-

tor, the spring and the secondarybulb.

3. Remove the main circuit board.4. Remove the cap hook.5. Grasp the cable below the grom-

met and pull it out of the lamp-housing.

This removes the headpiece-endof the cable and battery coverassembly.

6. Using long-nose pliers, grasp thecharging barrel (P/N 89947) andpull it out of the lamp-housing.

7. Unthread and remove the screw(P/N 633694), charging contact(P/N 89948), nut (P/N 50249), lock-washer (P/N 56874), and the con-tact wire assembly (P/N 484821)(the white wire).

Re-installing the Charging Barrel,Charging Contact, and ContactWire Assembly1. Insert the screw into the charging

contact, then insert the screw intothe hole in the center of the lamp-housing.

2. Temporarily, insert the chargingbarrel to hold the charging contactand screw in place.

3. Install the contact wire assembly(white wire), the lockwasher andthe nut on the screw inside theheadpiece.

4. Remove the charging barrel andsecure the assembly by tighteningthe screw.

5. To re-install the charging barrel.a. Position the charging barrel so

that the end with the holesfaces you.

b. Turn the charging barrel untilthe flat side lines up with thecharging contact and thenotch is on the right (at aboutthe 5 o’clock position).

c. Insert the charging barrel intothe lamp-housing and press itin place.

6. Re-install the cable through the holeat the bottom of the lamp-housing.Press the grommet in place.

7. Re-install the cap hook.8. Re-install the main circuit board.9. Re-install the main lamp and

reflector, the spring and the sec-ondary bulb.

10. Re-install the bezel.

8 TAL 998 (L) Rev. 2 - 817184

Maintenance

817184 8/13/99 9:43 AM Page 8

CABLE AND BATTERY COVERASSEMBLY

Replacing the Cable1. To separate the headpiece, cable

and cover, remove battery coverclamp screws, one on each side,and slide cover clamps off side-ways. Lift cover to permit accessto cable clamp screws, loosenthem, and carefully pry cableclamps off the battery poles.

2. To separate the cable from thecover, remove cable retainingscrews and washers, then lift thecable away from the circular boss-es molded in the cover and pull thecable through the cable protector.

3. Lubricate approximately 6” lengthof other end of new cable withsoapy water and insert it into thecover by pushing each terminatedconductor, one at a time, throughthe cable protector.

Continue pushing cable until 3-1/4”of cable sheath is exposed insidethe cover. Wrap cable around andthrough circular bosses molded inthe cover and press firmly to insidetop of cover. Secure in place byassembling cable retaining wash-ers and screws.

4. Clean any foreign matter fromeach battery pole.

5. Fasten red conductor to positivebattery pole and black conductorto negative pole to insure correctpolarity.

Tighten in a position so that coverwill sit squarely on battery top.

6. Slide on cover clamps.

Lock in place with cover clampscrews.

TAL 998 (L) Rev. 2 - 817184 9

Cable and Battery Cover Assembly

817184 8/13/99 9:43 AM Page 9

10 TAL 998 (L) Rev. 2 - 817184

Notes

Ultralight Cap Lamp SystemExpanded Parts Diagram

817184 8/13/99 9:43 AM Page 10

817184 8/13/99 9:43 AM Page 11

817184 8/13/99 9:43 AM Page 12

ML-2 INFORMATION

The ML-2 headpiece is made up ofthe lamp-housing, which contains thefollowing parts:— Bezel (cover)— Lens— Gasket— Focusing Knob— Two Filament Bulb— Reflector— Hexagonal Key Lock— Stainless steel clip— Charging circuit connection— Switch knob

The bulb is a two filament bulb whichpermits the use of a safety filament ifthe primary filament burns out. Theswitch knob selects either filament.The gasket helps seal out dust andmoisture from the headpiece.

The focusing knob adjusts the focusto a small spot or flood light. Oncefocused, it does not require furtherfocusing until a new bulb is installed.

The reflector makes maximum use oflight output. The hexagonal key locklocks the headpiece to ensure that thesettings are not changed. The stain-less steel clip attaches the headpieceto the miner’s cap.

USING ML-2 CAP LAMP SYSTEM

The on-off switch knob is a 3 positionswitch, located on the headpiece. Tooperate the lamp:1. Turn the switch knob clockwise or

counterclockwise to turn on the pri-mary filament. The primary filamentprovides the brightest beam of light.

2. Turn focusing knob to adjust thelight beam to a spot or wide beam.

3. After use, turn the switch knobuntil the bulb is off.

NoteIn the case of the primary filamentburning out, the safety filament maybe switched on by continuing to turnthe switch knob. Check the bulb to besure both filaments are in workingorder before use.

ML-2 MAINTENANCE

Replacing Bulb1. Insert 3/32” hexagon wrench into

the socket located at the bottomof the headpiece just in front of thecharging key hole.

2. Rotate wrench one-half turn coun-terclockwise to unlock the bezel.

3. Unscrew the bezel assembly.4. Remove bulb and replace with a

new one.5. Keep reflector clean and free of

fingerprints.6. Reassemble bezel assembly to

headpiece and screw down firmlyto obtain a tight seal.

7. Align the closest two grooves onthe bezel with the two grooves onthe lock cover.

8. With hexagon wrench, lock bezelin place by making one-half turnclockwise.

Replacing Reflector1. Unlock the bezel and remove it

from the headpiece (as justdescribed for bulb replacement).

2. Remove bulb.

3. With headpiece facing up, turnfocusing knob clockwise as far asit will go to move the reflector out-ward and free of the headpiece.

TAL 998 (L) Rev. 2 - 817184 11

ML-2 Information

BatteryCable

StainlessSteel Clip

Bezel

Lens

BatteryCover

CableProtector

817184 8/13/99 9:43 AM Page 13

4. Turn the headpiece downward andcarefully shake reflector into palmof your hand.

5. While facing headpiece, make surethat the focusing knob has beenrotated to its extreme clockwiseposition.

6. Place a new reflector into positionin the headpiece so that the twopins extending from its yoke dropinto the slots of the metal bushing.

7. While applying a slight pressureagainst the reflector edge with fin-gers, draw the reflector inward byrotating the focusing knob counter-clockwise to its full stop position.

Reflector may be damaged if it isnot drawn back to its extreme stopposition within the headpiecebefore the bezel is attached andtightened.

8. Insert bulb and replace the bezelassembly.

Replacing Cable1. To separate the headpiece, cable

and cover, remove battery coverclamp screws, one on each side.

Slide cover clamps off sideways.

Lift cover to permit access tocable clamp screws, loosen them,and carefully pry cable clamps offthe battery poles.

2. To separate the cable from thecover, remove cable retainingscrews and washers, then lift thecable away from the circular boss-es molded in the cover and pull thecable through the cable protector.

3. To separate the headpiece fromthe cable, use 5/64” hexagonwrench and remove three screwsfrom each side and the top of thestainless steel clip.

Slide cap hook back along cable.Lift rubber flap on the cable end atthe top rear of headpiece andremove headpiece cable screws.

4. Remove cap hook from cable tobe replaced and slide it on thenew cable.

12 TAL 998 (L) Rev. 2 - 817184

Maintenance

CAUTION

817184 8/13/99 9:44 AM Page 14

5. Fold back the rubber flap on themolded end of the new cable, insertheadpiece cable screws through theexposed terminals and thread theminto the threaded inserts at the toprear of headpiece housing.

Tighten screws securely.

6. Slide cap hook into place over themolded end of the cable and fas-ten to the headpiece by insertingthree cap hook locking screws.

7. Lubricate approximately 6” lengthof other end of new cable withsoapy water and insert it into thecover by pushing each terminated

conductor, one at a time, throughthe cable protector.

Continue pushing cable until 3-1/4”of cable sheath is exposed insidethe cover. Wrap cable around andthrough circular bosses molded inthe cover and press firmly to insidetop of cover. Secure in place byassembling cable retaining wash-ers and screws.

8. Clean any foreign matter formeach battery pole.

9. Fasten red conductor to positivebattery pole and black conductor tonegative pole to insure correctpolarity.

Tighten in a position so that coverwill sit squarely on battery top.

10. Slide on cover clamps.

Lock in place with cover clampscrews.

TAL 998 (L) Rev. 2 - 817184 13

Maintenance

817184 8/13/99 9:44 AM Page 15

14 TAL 998 (L) Rev. 2 - 817184

ML-2 Cap Lamp SystemExpanded Parts Diagram

Notes

817184 8/13/99 9:44 AM Page 16

817184 8/13/99 9:44 AM Page 17

817184 8/13/99 9:44 AM Page 18

Troubleshooting

PROBLEM CAUSE

Lamp glows dimly, flickers or fails 1. Low battery capacitya. Observe the electrolyte level in the cell windows and make certain level is

between the two scribed lines on the cell windows.b. Continuous use of battery that has not been fully charged will cause it to

lose its capacity. This may be corrected by cycling the battery severaltimes (discharge 8 hours and recharge 16 hours). Repeat this procedure 3times. If battery does not respond, replace with a new one.

2. Loose connectionsa. Gently wiggle or pry each connection on top of the battery to make sure it

is tight and working properly.b. Make certain solder connections of the circuit assembly (P/N 459739) are

fused solidly to the poles.c. Check the cables for broken conductors by twisting or pulling it at various

points along its length.d. Check the headpiece terminals and the electrical connections inside the

headpiece in the same manner as those on the battery.e. Make sure the bulb is secure and making good contact.f. If the light flickers or dims when any of the preceding items are being

checked, that item should be repaired or replaced.g. If battery appears warm on charge, this is normal and is not necessarily an

indication that anything is wrong with the battery.

3. Electrolyte Levela. Check at least once each week to see that the electrolyte level is between

the two scribed lines on the cell window.

Battery not holding a charge a. Make sure charger output is set at 5.0 ± .05 VDCduring shift b. Check electrolyte level after charge

c. Make sure connections between headpiece and battery are good; chargingrack connections are good.

d. Make sure stored batteries are boost charged before placing into service.

Battery Capacity: a. 13 AH battery recommended routing is 8-10 hour discharge/16-14 hour Loses charge during weekly use recharge, 5 days a week. Use the 16 AH Luminator battery for greater cycle

routines.b. Check charger.c. Check battery connections.

TAL 998 (L) Rev. 2 - 817184 15

817184 8/13/99 9:44 AM Page 19

PITTSBURGH, PENNSYLVANIA, U.S.A. 15230

Manufactured by

817184 8/13/99 9:44 AM Page 20