MSA Ultralight User manual

caplampsystems
luminator®
powercell 81717713AH
luminator®
powercellplus 81717816AH
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 WHO
USE OR MAINTAIN THIS PRODUCT, INCLUDING THOSE WHO HAVE ANY
RESPONSIBILITY INVOLVING ITS SELECTION, APPLICATION, SERVICE,
OR REPAIR. THIS RESPIRATOR WILL PERFORM AS DESIGNED ONLY IF
USED AND MAINTAINED ACCORDING TO THE INSTRUCTIONS. OTHER-
WISE IT COULD FAIL TO PERFORM AS DESIGNED AND PERSONS WHO
RELY ON THIS PRODUCT COULD SUSTAIN SERIOUS PERSONAL INJURY
OR DEATH.
WARNING
The warranties made by MSA with respect to the product are voided if the
product is not installed, used, and serviced in accordance with the instruc-
tions in this manual. We encourage our customers to write or call for a
demonstration 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. 817184
Doc. 817184
and ML-2
Ultralight
13 AH - 817171
Ultralight
16 AH - 817172
Ultralight w/Remote
13 AH - 817169
Ultralight w/Remote
16 AH - 817170
ML-2
13 AH - 817173
ML-2
16 AH - 817174
ML-2 w/Remote
16 AH - 817176
UltralightTM
817184 8/13/99 9:42 AM Page 1

IMPORTANT
Please read and observe the Warnings
and Cautions in this manual. A WARN-
ING describes a condition that may
cause severe personal injury or death
if allowed to happen. A CAUTION
describes a condition that may cause
moderate injury or property damage if
allowed to happen.
1. An adequate mine lighting pro-
gram must include assessment
of mine lighting requirements,
integration of appropriate MSHA
regulation, selection of proper
equipment, and instruction and
training in the use, inspection
and maintenance of equipment.
(See MSHA regulations, Title 30
CFR, Part 19).
2. The cap lamp system will per-
form as designed only if used
and maintained according to the
manufacturer’s instructions.
Supervisors and users must read
and understand these instruc-
tions before trying to use or ser-
vice this product. We encourage
our customers to write or call
their MSA distributor or call MSA
Customer Service for informa-
tion on this product before using
it. To reach the nearest MSA
office, call 1-800-MSA-2222
3. This cap lamp may be used only
after proper instructions and
training in its use.
4. Do not alter, modify, or substi-
tute any components without the
approval of MSA. Such alter-
ations will void the MSHA
approval for use in a hazardous
atmosphere of methane and air
only.
5. Inspect the cap lamp and bat-
tery after each use and maintain
them according to MSA’s
instructions. Repairs must be
made by properly trained per-
sonnel only.
6. Follow MSA’s instructions for
first time and routine cap lamp
use. The battery must not be left
“on charge” indefinitely, (see
Storing Idle Batteries section).
Doing so may cause internal
gases to vent, which may lead to
accumulation of combustible
gases in the lamp room, damage
to the battery, or reduced ser-
vice life.
Failure to follow the above can
result in serious personal injury or
death.
GENERAL DESCRIPTION
The Ultralight and ML-2 Cap Lamp
System consists of a lightweight, cap
mounted headpiece powered by a
Luminator®(lead-acid) battery.
2TAL 998 (L) Rev. 2 - 817184
Ultralight™ Cap Lamp System ML-2 Cap Lamp System
TABLE OF CONTENTS
GENERAL DESCRIPTION....................................................2
Remote Power Connections................................................3
PREPARATION FOR USE....................................................3
Battery Charging..................................................................3
Routine Battery Maintenance..............................................3
Replacing Battery ...............................................................4
Remote Power Connection..................................................4
ULTRALIGHT™....................................................................5
Using the Ultralight™ Cap Lamp System............................5
MAINTENANCE ...................................................................5
Removing the Bezel.............................................................6
Installing a New Secondary Bulb.........................................6
Removing and Installing the Main Circuit Board.................6
Removing and Installing the Switch and Wiring..................7
Removing and Replacing the Cap Hook .............................7
Removing and Installing the Charging Barrel,
Charging Contact, and Contact Wire Assembly..................8
CABLE AND BATTERY COVER ASSEMBLY.......................9
Replacing the Cable ............................................................9
ML-2 CAP LAMP SYSTEM..................................................9
MAINTENANCE .................................................................11
Replacing Bulb...................................................................11
Replacing Reflector ...........................................................11
Replacing Cable.................................................................12
TROUBLESHOOTING........................................................15
WARNING
817184 8/13/99 9:42 AM Page 2

Depending on the Luminator battery
used, the cap lamp is designed to
operate at full brilliance for a minimum
of an 8-10 hour shift, with reserve
energy if needed. At the end of each
shift the battery is recharged in a sin-
gle- or multiple-station charging unit.
The Luminator Power Cell (13 AH) is
designed to operate at cycle routines
of 8-10 hours discharge/16-14 hour
recharge 5 days/week (max). If the
routines are increased, the Luminator
Power Cell Plus (16 AH) is recom-
mended. Battery charging connection
is made through the headpiece, using
either a parallel or modular charging
system. Each battery has a transpar-
ent case with molded-in electrolyte
level indicators below the filling ports.
Remote Power Connections
The Remote Power Connection allows
the Cap Lamp to be used as a power
source for an external remote device
while still operating as light source.
MSHA regulation permits this configu-
ration as long as the external remote
device current requirement does not
exceed 275 milliamps.
If using the Remote with the Ultralight
or ML-2 Cap lamps, the Luminator
Power Cell Plus 16 Ah battery is rec-
ommended, due to higher battery
demands. However, the Luminator
Power Cell 13 AH has been approved
with the Remote Power Connection
for Ultralight Cap Lamp use only.
Preparing the Ultralight and ML-2
Cap Lamps for First Time Use
Battery Charging
Every battery must be charged before
it is used for the first time. A battery
may be charged with parallel or modu-
lar systems, in either standard or low
profile racks, or in a single station
charger. Various MSA chargers and
part numbers are listed in the chart
below:
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 is
flowing, look at the meter (located
either just above or just below the
battery on rack-mounted charg-
ers). The meter needle should
swing to the far right.
Note
In some cases there will not be a
meter on the charger. See the instruc-
tions for the appropriate charger.
4. Allow the battery to remain on
charge for 24 hours.
5. As the battery charges, the meter
needle should gradually move to
the left to OFF. In other chargers,
the LED lights will indicate
charged condition.
6. Top off each cell with distilled water
if necessary (see Watering section).
Routine Battery Maintenance
1. Routine Charging on Standard
Rack and Charger. All batteries in
this category must be charged
immediately after each period of
use 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 the
instructions supplied with the
charger.
c. Check meter, the needle
should swing to right indicating
charge, (or check LED lights).
d. Allow battery to remain in the
rack until it is recharged.
(Needle of meter will return to
“OFF” or LED lights will indi-
cate charged condition).
e. To remove lamp and stop
charge, rotate the headpiece
counterclockwise to a full stop,
then lift headpiece from key and
battery form the charging rack.
Note
Batteries which do not perform satis-
factorily, should be removed from ser-
vice and cycled - charged 16 hours,
discharged 8 hours. Repeat several
times until battery responds. If battery
does not respond after three or four
cycles, it should be replaced.
f. After weekly shifts, the battery
should be placed on the
charger following the instruc-
tions included with the charg-
er, and left to charge the
remainder 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 acid
should be boost charged for 24
hours every 3 months, and imme-
diately before being placed into
regular service. Recommended
storage temperatures 32˚F to 80˚F.
3. Watering.
The electrolyte level should be
maintained between the two lines
indicated below the filling and
venting hole i.e. slightly above the
top of the battery plate.
Normally topping up should not be
necessary more often than once
every 3-4 weeks, and should
always be carried out when the
battery is fully charged. Only dis-
tilled or deionized water should be
used in topping up.
The Electrolyte is corrosive and can
cause burns. Take proper precau-
tions to avoid skin and eye contact.
Contact MSA for battery Materials
Safety Data Sheet (MSDS). Phone
1-800-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
Fill
Lines
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 your
existing Caplamp battery using
a 5/64” Allen wrench, and
keep the cover clamps and
socket dcrews for later use.
b. Lift the battery cover off the
battery.
c. Disconnect the red and black
wires from the battery termi-
nals by loosening the screws
holding the pole clamps to the
posts. Carefully remove the
clamps from the posts.
Dispose of the old battery
properly.
2. Install new battery.
a. Connect red conductor to pos-
sitive battery pole and black
conductor to negative battery
pole to insure correct polarity.
b. Tighten cable clamps with a
flat blade screwdriver.
3. Re-install the battery cover.
a. Check both ends of the battery
for the adapter clips.
Replace the battery cover. It
must fit squarely on top of the
battery. Slide a cover clamp on
each end of the battery and
cover.
Note
The mounting hole in each clamp is
slightly off-center. Install the clamp so
that the hole is below center.
b. Install the two screws and
tighten, using the 5/64” allen
wrench.
The electrolyte level of all batteries
should be checked once each week,
and after battery is charged.
Water only when battery is fully
charged. If the battery is over-
topped, there is a possibility that
electrolyte may leak out under cer-
tain conditions.
a. Fill the plastic bottle of the
MSA Filling Device (P/N 69422,
469773, or 454052) with dis-
tilled water only, and place it at
a convenient location close to
the batteries to be watered.
b. Insert the nozzle or needle of the
Filling Tube into the small hole
provided in the battery window.
Depending on the style of filling
device, squeeze the bottle or
push the needle forward.
c. Fill until the electrolyte level is
centered between the two
scribed lines below the cell
window. The battery may have
to be tilted back slightly to
allow the water to flow.
d. Repeat this procedure in adja-
cent battery cell.
Using the Remote Power
Connection
Note
If using the Remote Power Connec-
tions with the Ultralight or ML-2 Cap
Lamps, the Luminator Power Cell Plus
16 AH battery is recommended, due
to higher battery demands. However,
the Luminator Power Cell 13 AH has
been approved for use with the
Remote Power Connection with the
Ultralight cap lamp.
1. To access the battery power for an
external remote device, remove
the connector cover located on
the top of the battery. Keep the
cover for later use.
4TAL 998 (L) Rev. 2 - 817184
Battery Replacement
CAUTION
817184 8/13/99 9:42 AM Page 4

2. Slide the remote power device’s
connector onto the connector on
top of the battery until it stops.
3. At end of shift, or when finished
using the external device, remove
the external connection from the
battery top and reinstall the cover.
Place the battery on charge as
described in the Routine Battery
Maintenance section.
4. Refer to Illustrated Parts List for
replacement components.
ULTRALIGHT CAP LAMP SYSTEM
The Ultralight headpiece is made up of
the lamp-housing, which contains the
following 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 the
reflector, positioned for a tightly-
focused beam at maximum light out-
put, and then bulb and reflector are
cemented together. The main bulb
and reflector are held in the lamp-
housing by the bulb pins, which plug
into a flexible circuit board.
The secondary bulb gives enough light
for the wearer to leave the mine if the
bulb burns out. This bulb also plugs into
the lamp-housing circuit board, but
passes through the reflector. Since the
bulb is not centered in the reflector, it
does not give a bright, sharp spot.
The spring keeps the reflector tight
against 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. A
stainless steel clip holds the head-
piece firmly to the miner’s cap. A
durable, abrasion-resistant cable con-
nects the headpiece to the battery and
allows freedom of movement.
Using the Ultralight Cap Lamp
System
The on-off switch is a 3-position switch,
located on the headpiece. The center
position 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 for
maximum lighting.
2. Push the switch to the center posi-
tion to the lamp off.
3. Push the switch back all the way to
light the secondary bulb.
This bulb will not form a tight spot,
but will give enough light to leave
the mine.
If the main bulb fails to light, turn
the secondary light on, and immedi-
ately go to a well-lit area and
replace the main bulb.
MAINTENANCE OF THE
ULTRALIGHT CAP LAMP SYSTEM
HEADPIECE ASSEMBLY
Removing the Bezel (cover)
P/N 476705
1. Use a 3/32” allen wrench to thread
the two allen set screws
(P/N 634639) into the lamp-hous-
ing (P/N 486610).
Note
It is easier to remove the bezel by thread-
ing the set screws into the lamp-housing
rather 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
Battery
Cover
Battery
Cable
CAUTION
817184 8/13/99 9:42 AM Page 5

3. Inspect the O-ring (P/N 632226) in
the lamp-housing groove.
If the O-ring shows signs of wear
or damage, replace it. The O-ring
is needed to keep dust and mois-
ture out of the lamp-housing.
Installing the Bezel
1. Line up the notches in the bezel
with the tabs in the lamp-housing.
2. Press the bezel into place so that
the side holes line up with the allen
screws.
3. Use a 3/32” allen wrench to thread
the two set screws out of the lamp-
housing until the screw heads are
flush with the bezel surface.
Do not touch the bulb while it is on.
Turn the lamp off and let the bulb
cool for 2 or 3 minutes before you
touch it. These bulbs reach temper-
atures up to 400˚F and you could be
seriously burned.
Removing the Main Bulb and
Reflector 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 the
spring (P/N 632227) out of the
lamp-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-Ring
1. 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 the
groove.
Installing a new Main Bulb and
Reflector Assembly
1. 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.
Note
Check that the opening in the reflector
is on the same side of the main circuit
board as the contacts for the sec-
ondary bulb.
4. Support the flexible circuit board
with your fingers and push the
reflector gently until the pins are in
the flexible board contacts.
5. Release the spring so it is flat on
the circuit board.
Installing a new Secondary Bulb
1. 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.
6TAL 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 circuit
board 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 Board
1. Position the board so that its
straight side is on the same side of
the 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 the
bottom 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 O
Black to K Blue to B
Red to R Brown to N
Green to G
a. Line up the holes in the board
with the brass inserts into the
lamp-housing and install the
three lockwashers and screws.
Do not over-tighten screws or you
may crack the circuit board.
b. Re-install the main lamp and
reflector assembly, the spring
and the secondary bulb.
c. Re-install the bezel.
Removing the Switch and Wiring
Assembly (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 to
secure the new switch. Take care
not to damage the boot material.
5. Pull the switch and wiring out of
the lamp-housing.
Installing the Switch and Wiring
Assembly
1. Position the switch so that the
blue wire is closest to the open
end of the lamp-housing and bend
the wires so that the switch will fit
in the lamp-housing.
Be careful not to bend the switch
terminals. They may break.
2. Insert the switch toggle through
the hole in the lamp-housing.
You may have to move the switch
back and forth to fit the threaded
bushing 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 and
the secondary bulb.
6. Re-install the bezel.
7. Test the switch operation by push-
ing the toggle forward to light the
main bulb, and back to light the
secondary 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) that
hold 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 bend
the cap hook as it is removed.
Installing a new Cap Hook
1. Line up the base of the cap hook with
the grooves in the lamp-housing.
Note
The grommet portion of the cable may
have to be pushed into the base of the
lamp-housing.
2. Press the cap hook into place and
install the two screws and lock-
washers to secure it to the lamp-
housing. Be careful that you do
not bend the charging key.
Removing the Charging Barrel
(P/N 89947), Charging Contact
(P/N 89948), and Contact Wire
Assembly (P/N 484821)
1. Remove the bezel.
2. Remove the main lamp and reflec-
tor, the spring and the secondary
bulb.
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-end
of the cable and battery cover
assembly.
6. Using long-nose pliers, grasp the
charging barrel (P/N 89947) and
pull 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 Contact
Wire Assembly
1. Insert the screw into the charging
contact, then insert the screw into
the hole in the center of the lamp-
housing.
2. Temporarily, insert the charging
barrel to hold the charging contact
and screw in place.
3. Install the contact wire assembly
(white wire), the lockwasher and
the nut on the screw inside the
headpiece.
4. Remove the charging barrel and
secure the assembly by tightening
the screw.
5. To re-install the charging barrel.
a. Position the charging barrel so
that the end with the holes
faces you.
b. Turn the charging barrel until
the flat side lines up with the
charging contact and the
notch is on the right (at about
the 5 o’clock position).
c. Insert the charging barrel into
the lamp-housing and press it
in place.
6. Re-install the cable through the hole
at 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.
8TAL 998 (L) Rev. 2 - 817184
Maintenance
817184 8/13/99 9:43 AM Page 8

CABLE AND BATTERY COVER
ASSEMBLY
Replacing the Cable
1. To separate the headpiece, cable
and cover, remove battery cover
clamp screws, one on each side,
and slide cover clamps off side-
ways. Lift cover to permit access
to cable clamp screws, loosen
them, and carefully pry cable
clamps off the battery poles.
2. To separate the cable from the
cover, remove cable retaining
screws and washers, then lift the
cable away from the circular boss-
es molded in the cover and pull the
cable through the cable protector.
3. Lubricate approximately 6” length
of other end of new cable with
soapy water and insert it into the
cover by pushing each terminated
conductor, one at a time, through
the cable protector.
Continue pushing cable until 3-1/4”
of cable sheath is exposed inside
the cover. Wrap cable around and
through circular bosses molded in
the cover and press firmly to inside
top of cover. Secure in place by
assembling cable retaining wash-
ers and screws.
4. Clean any foreign matter from
each battery pole.
5. Fasten red conductor to positive
battery pole and black conductor
to negative pole to insure correct
polarity.
Tighten in a position so that cover
will sit squarely on battery top.
6. Slide on cover clamps.
Lock in place with cover clamp
screws.
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 System
Expanded 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 of
the lamp-housing, which contains the
following 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 which
permits the use of a safety filament if
the primary filament burns out. The
switch knob selects either filament.
The gasket helps seal out dust and
moisture from the headpiece.
The focusing knob adjusts the focus
to a small spot or flood light. Once
focused, it does not require further
focusing until a new bulb is installed.
The reflector makes maximum use of
light output. The hexagonal key lock
locks the headpiece to ensure that the
settings are not changed. The stain-
less steel clip attaches the headpiece
to the miner’s cap.
USING ML-2 CAP LAMP SYSTEM
The on-off switch knob is a 3 position
switch, located on the headpiece. To
operate the lamp:
1. Turn the switch knob clockwise or
counterclockwise to turn on the pri-
mary filament. The primary filament
provides the brightest beam of light.
2. Turn focusing knob to adjust the
light beam to a spot or wide beam.
3. After use, turn the switch knob
until the bulb is off.
Note
In the case of the primary filament
burning out, the safety filament may
be switched on by continuing to turn
the switch knob. Check the bulb to be
sure both filaments are in working
order before use.
ML-2 MAINTENANCE
Replacing Bulb
1. Insert 3/32” hexagon wrench into
the socket located at the bottom
of the headpiece just in front of the
charging 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 firmly
to obtain a tight seal.
7. Align the closest two grooves on
the bezel with the two grooves on
the lock cover.
8. With hexagon wrench, lock bezel
in place by making one-half turn
clockwise.
Replacing Reflector
1. Unlock the bezel and remove it
from the headpiece (as just
described for bulb replacement).
2. Remove bulb.
3. With headpiece facing up, turn
focusing knob clockwise as far as
it will go to move the reflector out-
ward and free of the headpiece.
TAL 998 (L) Rev. 2 - 817184 11
ML-2 Information
Battery
Cable
Stainless
Steel Clip
Bezel
Lens
Battery
Cover
Cable
Protector
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4. Turn the headpiece downward and
carefully shake reflector into palm
of your hand.
5. While facing headpiece, make sure
that the focusing knob has been
rotated to its extreme clockwise
position.
6. Place a new reflector into position
in the headpiece so that the two
pins extending from its yoke drop
into the slots of the metal bushing.
7. While applying a slight pressure
against the reflector edge with fin-
gers, draw the reflector inward by
rotating the focusing knob counter-
clockwise to its full stop position.
Reflector may be damaged if it is
not drawn back to its extreme stop
position within the headpiece
before the bezel is attached and
tightened.
8. Insert bulb and replace the bezel
assembly.
Replacing Cable
1. To separate the headpiece, cable
and cover, remove battery cover
clamp screws, one on each side.
Slide cover clamps off sideways.
Lift cover to permit access to
cable clamp screws, loosen them,
and carefully pry cable clamps off
the battery poles.
2. To separate the cable from the
cover, remove cable retaining
screws and washers, then lift the
cable away from the circular boss-
es molded in the cover and pull the
cable through the cable protector.
3. To separate the headpiece from
the cable, use 5/64” hexagon
wrench and remove three screws
from each side and the top of the
stainless steel clip.
Slide cap hook back along cable.
Lift rubber flap on the cable end at
the top rear of headpiece and
remove headpiece cable screws.
4. Remove cap hook from cable to
be replaced and slide it on the
new cable.
12 TAL 998 (L) Rev. 2 - 817184
Maintenance
CAUTION
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5. Fold back the rubber flap on the
molded end of the new cable, insert
headpiece cable screws through the
exposed terminals and thread them
into the threaded inserts at the top
rear of headpiece housing.
Tighten screws securely.
6. Slide cap hook into place over the
molded end of the cable and fas-
ten to the headpiece by inserting
three cap hook locking screws.
7. Lubricate approximately 6” length
of other end of new cable with
soapy water and insert it into the
cover by pushing each terminated
conductor, one at a time, through
the cable protector.
Continue pushing cable until 3-1/4”
of cable sheath is exposed inside
the cover. Wrap cable around and
through circular bosses molded in
the cover and press firmly to inside
top of cover. Secure in place by
assembling cable retaining wash-
ers and screws.
8. Clean any foreign matter form
each battery pole.
9. Fasten red conductor to positive
battery pole and black conductor to
negative pole to insure correct
polarity.
Tighten in a position so that cover
will sit squarely on battery top.
10. Slide on cover clamps.
Lock in place with cover clamp
screws.
TAL 998 (L) Rev. 2 - 817184 13
Maintenance
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14 TAL 998 (L) Rev. 2 - 817184
ML-2 Cap Lamp System
Expanded Parts Diagram
Notes
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Troubleshooting
PROBLEM CAUSE
Lamp glows dimly, flickers or fails 1. Low battery capacity
a. 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 several
times (discharge 8 hours and recharge 16 hours). Repeat this procedure 3
times. If battery does not respond, replace with a new one.
2. Loose connections
a. 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 Level
a. 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 VDC
during shift b. Check electrolyte level after charge
c. Make sure connections between headpiece and battery are good; charging
rack 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
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PITTSBURGH, PENNSYLVANIA,U.S.A.15230
Manufactured by
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