PDF Service Guide CAT DBT 488L 488-6 - 1 MB
This comprehensive guide covers operation, preventive maintenance, troubleshooting, and service for the CAT DBT 488L and 488-6 models.
It is an all-in-one resource designed for both operators and service technicians.
Following the procedures in this manual will help minimize downtime and ensure the equipment operates safely and reliably.
This document is essential for the proper care of your machinery.
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OPERATION,
PREVENTIVE MAINTENANCE,
TROUBLESHOOTING
AND SERVICE GUIDE
MODELS 488L and 488-6
THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY
INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL
INSTALLING AND OPERATING THIS EQUIPMENT.
P/N A6474X210
Revision 4, February / 07
DBT AMERICA INC. 2007
ALL RIGHTS RESERVED
--- Page 3 ---
DBT America Inc.
SAFETY PRECAUTIONS AND GUIDELINES
OVERVIEW
Before you operate, maintain or in any other way, use this unit -
READ and STUDY this guide. KNOW how to safely use the unit's controls and what you must do for safe
maintenance.
ALWAYS wear or use the proper safety items required for your personal protection.
If you have ANY QUESTIONS about the safe use or maintenance of this unit:
ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK
PRE-START INSPECTION
Read this entire guide BEFORE attempting to operate this unit. You should be familiar with the controls
and their functions before the unit is energized.
INSPECT your machine by doing a pre-operational inspection. Have any malfunctioning, broken or
missing parts corrected or replaced before use.
VERIFY that all maintenance has been performed.
VERIFY that all the instruction and safety labels are in place and readable. These are as important as
any other equipment on the machine.
CLEAN any foreign material from the operator's compartment.
THIS Model 488 Series UN-A-TRAC® was shipped from the factory equipped with a protective canopy.
This canopy MUST be securely in place before operating the unit.
STARTING
DO NOT operate any levers or pedals from outside the operator's compartment to keep the machine from
hitting you or other personnel.
FOLLOW the instructions in the STARTING PROCEDURES section of this guide (page 23).
DO NOT operate any levers or pedals if anyone is in the Hazard Zone (page 21).
BE familiar with the operation of the tape switches and be prepared for the sudden stop when the tape
switches are struck.
OPERATING
ALWAYS make sure that no person or obstruction is in your line of travel BEFORE starting the unit into
motion or in the articulation area when steering the unit.
NEVER climb onto, or climb out of the machine while it is in motion.
DO NOT operate the machine with any part of your body outside of the operator's compartment in order
to prevent body parts from being crushed between the machine and objects outside.
USE extreme caution and be observant when working in close quarters or in congested or blind-travel
areas. The warning gong should be sounded to alert personnel of your movement.
Revised 02 – 07
7 MODEL 488L AND 488-6 SERIES UN-A-TRAC®
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DBT America Inc.
FIGURE 10 – GAUGE PANEL AND DIF-LOK (OPTIONAL)
DIF-LOK PRESSURE
BRAKE PRESSURE
DIF-LOK
DIF-LOK (OPTIONAL)
The operator controlled “DIF-LOK” actuator (Figure 10) is located to the operator’s left and on the floor.
When actuated, pushed in, the differential locks are engaged in both the front and rear axles. To release
the differential lock, pull out on the push button.
GENERAL HYDRAULIC CONTROL SYSTEM INFORMATION
In the operator's compartment located to the right of the operator’s seat is a group of control levers and
gauges (Figure 11). These levers control the steering, bucket position, ejector blade position, winch
operation and battery changer system by means of a hydraulic valve bank located behind the panel to the
operator's right. The gauges include emergency brake, accumulator, and system pressure. The
hydraulic system pressure relief valve is set at the factory at 2000 psi (138 bar), and should not be
changed. Should the "SYSTEM PRESSURE" gauge (Figure 11) read more than 2250 psi (155 bar),
SHUTDOWN the Model 488-6 and call a maintenance person (see page 29 for Shutdown Procedure).
HYDRAULIC CONTROL PANEL GAUGES
GAUGE PRESSURE READING
Emergency Brake 1500 – 1800 psi (103 –124 bar)
Accumulator 1500 – 1875 psi (103 – 129 bar)
System Pressure 2250 psi (155 bar)
SHOULD EITHER GAUGE SHOW ABOVE OR BELOW THE PRESSURES
LISTED ABOVE, SHUTDOWN THE UN-A-TRAC® AND CALL A MAINTENANCE
PERSON (SEE PAGE 29 FOR SHUTDOWN PROCEDURE).
Revised 02 – 07
17 MODEL 488L AND 488-6 SERIES UN-A-TRAC®
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DBT America Inc.
TOWING A DISABLED MACHINE
IT IS NOT POSSIBLE, WITHIN THE SCOPE OF THIS GUIDE, TO ANTICIPATE
ALL POSSIBLE ARRANGEMENTS FOR TOWING A DISABLED UNIT.
BEFORE ATTEMPTING TO TOW ANY VEHICLE, YOU MUST TAKE ALL
POSSIBLE PRECAUTIONS TO PROTECT THE OPERATORS AND ANY ONE
AROUND BOTH VEHICLES FROM BEING INJURED BY EITHER THE TOWING
VEHICLE, THE TOWING DEVICES OR THE VEHICLE BEING TOWED. THE
PRIMARY TOWING DEVICE USED (CABLES, BARS, ETC.) AND THE TOWING
VEHICLE (SCOOP, TRACTOR, ETC.) MUST BE STRONG AND HEAVY
ENOUGH TO MAINTAIN CONTROL OF BOTH VEHICLES THROUGH ALL
BOTTOM CONDITIONS TO BE ENCOUNTERED AT ALL TIMES. SAFETY
CHAINS OR OTHER SAFETY DEVICES MUST BE USED IN CASE OF FAILURE
OF THE PRIMARY TOWING DEVICE. ALL OPERATORS MUST BE ALERT AT
ALL TIMES TO PREVENT EITHER UNIT FROM "RUNNING AWAY" OR
RUNNING OUT OF CONTROL DURING TOWING. THE VEHICLE TO BE
TOWED MUST BE SECURELY COUPLED TO THE TOWING VEHICLE BEFORE
THE BRAKES ARE RELEASED ON THE DISABLED UNIT. THE OPERATOR
OF THE TOWING VEHICLE MUST BE IN PLACE IN THE TOWING VEHICLE
WITH THE BRAKES APPLIED BEFORE THE BRAKES OF THE DISABLED
VEHICLE ARE RELEASED.
1. Couple the towing vehicle securely to the disabled vehicle.
2. Close the valve to tank circuit that is on the hand pump. This isolates the park brake solenoid from the
circuit.
3. Begin pumping the hand pump. The building pressure moves the shuttle valve and allows the
Automatic (Park) Brake system to be pressurized.
4. The Automatic (Park) Brake is "released" as indicated by the Brake Release gauge.
AT NO TIME DURING TOWING SHOULD ANYONE RIDE IN OR ON THE
VEHICLE BEING TOWED OR STAND IN BETWEEN THE TOWING VEHICLE
AND THE DISABLED VEHICLE.
5. Begin towing the vehicle.
6. Once the destination is reached, stop both vehicles and set the parking brake on the disabled vehicle
before removing the towing devices. The disabled vehicle should be choked in both directions at all
four wheels for additional stability. The brake is "set' by opening the valve on the hand-pump.
FAILURE TO SET THE PARKING BRAKE ON THE DISABLED VEHICLE
BEFORE REMOVING THE TOWING DEVICE COULD ALLOW THE DISABLED
VEHICLE TO ROLL AWAY UNCONTROLLED.
Revised 02 – 07
27 MODEL 488L AND 488-6 SERIES UN-A-TRAC®
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DBT America Inc.
BATTERY CHANGE PROCEDURE (GROUND LEVEL)
Two people are needed to change the battery in the UN-A-TRAC®. Since one person may step into
the Hazard Zone, the other person (operating the UN-A-TRAC®) must be very careful and look each time
before moving any levers or pedals. Take time now to refamiliarize yourself with the Hazard Zone (page
21).
1. Line up the battery end of the UN-A-TRAC® with the place where the battery is to be deposited (Figure
24) (see Starting Procedure, page 23).
FIGURE 24 – BATTERY CHANGE PROCEDURE (GROUND LEVEL)
CHARGED BATTERY JUMPER CABLES
DISCHARGED BATTERY
THE "BATTERY" CHANGE CONTROL LEVER SHOULD NEVER BE OPERATED
EXCEPT AT A BATTERY CHANGE STATION OR WHEN ITS NECESSARY TO
ADJUST THE BATTERY'S TERRAIN CLEARANCE. IF THE "BATTERY"
CHANGE CONTROL LEVER IS OPERATED IN A LOW ROOF AREA, THE
BATTERY MAY BE DAMAGED.
2. UnIatch both battery Iatch pins before placing the battery on the ground (Figure 25). If difficulty is
encountered in unlatching the latch pins, it may be necessary to gently shake the battery up and down
by using the battery "LIFT” control lever.
Revised 02 – 07
37 MODEL 488L AND 488-6 SERIES UN-A-TRAC®
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DBT America Inc.
CRITICAL TORQUE VALUES
Torque values are expressed in lubricated and dry thread values. Lubricated thread torque values
should be used any time the bolt threads are covered with oil, grease, anti-seize or thread-locking
compounds. Dry thread torque values should be used when threads are completely clean and dry.
CRITICAL BOLT TORQUE VALUES (ft./lbs.) (m-n)
LOCATION BOLT SIZE GRADE DRY LUBRICATED
Steering Cylinder Pins 7/8 NC Grade 8 N/A 460
Tire-Wheel Mounting Bolts 3/4-16UNF Grade 8 390 300
(John Deere Axle) X 2-1/2” (529 m-n) (407 m-n)
Tire-Wheel Mounting Bolts 9/16 NC Grade 8 160 120
(Meritor Axle) X 2-1/4” (217 m-n) (163 m-n)
Tire-Wheel Mounting Bolts M16 X 1.5 X 60 Class 10.9 232 217
(Kessler)
Drive Motor-to-Gearbox 3/4NC Grade 5 285 170
Mounting Bolts X 2-3/4” (387 m-n) (231 m-n)
LUBRICANTS, FLUIDS AND CAPACITIES
LOCATION TYPE OF LUBRICANT APPROXIMATE NOTES
CAPACITY
Hydraulic Oil Spec. 100-1 (John Deere or Meritor) 40 Gallons (151.5 1
Spec. 100-12 (Kessler) l)
Speed Reducer (Gearbox) Spec. 100-6 As Required
Axle Housing (Meritor) (Kessler) Spec. 100-6 As Required 2
Planetary Wheel Ends Spec. 100-6 As Required 2
(Meritor) (Kessler) Each Wheel end
Wet Disc Brakes Spec. 100-12 As Required 2
(Meritor) (Kessler) For Each Brake
John Deere Axle John Deere Hy-Gard Oil 20 Qt. (18.9 l) 5
Winch API GL-4 or 5 pints (2.36 l)
(140) Worm Gear Oil
Peragma Grade 8
SROIB Park Brake SROIB Oil 2 Qt. (1.89 l) 4
Wet Disc Brake (PT Tech) Spec. 100-1 As Required
Multi-Purpose Grease Spec. 100-3 As Required 3
Notes:
1. With ejector blade completely retracted.
2. The axle housing, brake cooling sumps, and planetary wheel end assemblies do not have a common oil source.
Each assembly must be filled separately.
Make sure the level and fill hole in the planetary wheel end cover is in the proper position. Rotate the wheel end
as required to bring the fill hole to either the 3 o'clock or 9 o'clock position.
When filling the axle housing and planetary wheel ends, allow enough time for the lubricant to fill the various
cavities and around component parts in each assembly. Continue adding oil into each assembly until the required
oil level is reached
3. Pump grease into fitting until old grease can be observed coming out of component.
4. If the SROIB brake is used as a service brake, sump oil capacity is 4 qt (3.78 l).
5. When bleeding brakes, bleed both ports at the same time.
Revised 02 – 07
47 MODEL 488L AND 488-6 SERIES UN-A-TRAC®
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DBT America Inc.
9. Check the oil level in the speed reducer (gearbox).
A. Remove the check plug from the speed reducer (gearbox) (Figure 42). The oil level should be kept
at the level of the check plug.
B. Should it be necessary to add oil, add the oil through the fill plug hole slowly until oil flows from the
check plug hole. Do not overfill the speed reducer.
C. Replace the check and fill plug.
FIGURE 42 – SPEED REDUCER (GEARBOX) OIL LEVEL
FILL PLUG
CHECK PLUG
DRAIN PLUG
10. Check the oil levels of both drive axles. (If equipped with John Deere axles, see Figure 45).
A. Park the UN-A-TRAC® on solid level ground and remove the oil level/fill plugs (Figure 43),
B. Make sure the level and fill hole in the planetary wheel end cover is in the proper position. Rotate
the wheel end as required to bring the hole to either the 3 o’clock or 9 o’clock position.
B. The oil should just barely flow out from these holes when full.
C. Should it be necessary to add oil, add the oil through the level/fill plug hole slowly, just until it starts
to run back out. Allow time for the oil to travel throughout the axle when filling.
FIGURE 43 – AXLE AND WET DISC BRAKEFILL POINTS (Meritor)
Bleeder Fill plug
Breather
Oil level
Fill plug plug
Fill/check plug
Fill/check plug
Revised 02 – 07
57 MODEL 488L AND 488-6 SERIES UN-A-TRAC®
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DBT America Inc.
The following lubricants are recommended for use in the UN-A-TRAC®. Other lubricants with
equivalent specifications may be used.
Recommended Lubricant Specification
Hydraulic Oil Texaco Rando HD68 Spec 100-1
(John Deere or Meritor)
Hydraulic Oil Mobilfluid 424 Spec 100-12
(Kessler)
Heavy-Duty, Multi-Purpose Grease Texaco EP 1 Spec 100-3
Speed Reducer (Gearbox) Oil Texaco EP-90 Gear Oil Spec 100-6
Axle Oil (Meritor or Kessler) Texaco EP-90 Gear Oil Spec 100-6
Axle Oil (John Deere) John Deere Hy-Gard Oil --------
Wet Disc Brakes (Meritor or Mobilfluid 424 Spec 100-12
Kessler)
SROIB Park Brake SROIB Oil --------
LUBRICATION CHART
CLEAN ALL EXCESS OIL AND GREASE FROM THE UN-A-TRAC® AFTER
COMPLETING MAINTENANCE PROCEDURES.
ONCE PER WEEK
The following points should be lubricated at the grease fittings with heavy-duty, multi purpose grease.
SYMBOL LOCATION
• 1. Bucket Pivot Pins (2 Places)
• 2. Bucket Lift Cylinders (Rod End)
• 3. Bucket Lift Cylinders (Base End)
• 4. Steering Cylinders (Rod End)
• 5. Steering Cylinders (Base End)
• 6. Automatic (Park) brake Caliper
• 7. Drive Line Universal Joints
• 8. Drive Line Slip Joints
• 9. Control Levers
• 10. Foot Pedals
• 11. Central Lubrication Fitting Block
• 12. Center Section Assembly
• 13. Winch
Revised 02 – 07
67 MODEL 488L AND 488-6 SERIES UN-A-TRAC®
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DBT America Inc.
MAJOR MAINTENANCE PROCEDURES
CONTACTOR TIP REPLACEMENT
1. Insure electrical power is off and allow a minimum of one minute for capacitors to discharge (see page
69).
2. Change the stationary contactor tips (Figure 53):
A. Remove the bolt that holds the old tip in place and remove the old tip.
B. Position the new tip in place and replace the bolt. Check the placement of the tip to insure that it is
correctly positioned and the bolt is tight.
C. Repeat for all stationary tips.
THE BOLTS USED TO FASTEN THE STATIONARY CONTACTOR TIPS IN
PLACE ARE SPECIALLY SIZED TO PREVENT THE CONTACTOR TIP FROM
GROUNDING TO THE CONTACTOR COIL. IF REPLACEMENT BECOMES
NECESSARY, IT IS IMPORTANT TO USE BOLTS AND WASHERS IDENTICAL
TO THE ORIGINAL ONES. ALL CONNECTIONS MUST BE TIGHT BEFORE THE
UNIT IS PUT BACK INTO SERVICE.
3. Check for grounding between the stationary tips and either terminal of the contactor coil by using a
volt/ohm meter set on R x 1. Correct any shorts if found.
4. Change the moving contactor tips (Figure 53).
A. Remove the two (2) nuts that secure the tip and remove the old tip.
B. Position the new tip and secure with new nuts. Check the placement of the tip to insure that it is
correctly positioned and the nuts are tight.
C. Repeat for all moving tips.
FIGURE 53 – CONTACTOR TIP INSPECTION AND REPLACEMENT
MOVING TIP
MOVING TIP. (TYP. 2 PLACES
STATIONARY TIP
STATIONARY TIP TYP. 2 PLACES
SINGLE-POLE CONTACTOR DOUBLE POLE CONTACTOR
Revised 02 – 07
77 MODEL 488L AND 488-6 SERIES UN-A-TRAC®
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INSTALLATION, USE
MAINTENANCE, AND REPAIR
OF MINE POWER
STORAGE BATTERIES
THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY
INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL
INSTALLING AND OPERATING THIS EQUIPMENT.
P/N A6474X26
Revision 9, February / 05
DBT AMERICA INC. 2005
ALL RIGHTS RESERVED
--- Page 13 ---
DBT America Inc.
SAFETY PRECAUTIONS AND GUIDELINES
OVERVIEW
Before you install, maintain or repair a mine service battery -
READ and STUDY this guide. KNOW how to safely use the battery and what you must do for safe
maintenance.
ALWAYS wear or use the proper safety items required for your personal protection.
If you have ANY QUESTIONS about the safe use or maintenance of this unit:
ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK
MAINTENANCE
AVOID, whenever possible, servicing, cleaning or examining the battery in congested areas.
ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the
proper location and part number of decals and plates.
DISCONNECT the battery when servicing or when welding on the battery.
BE SURE the battery area is well ventilated (clear of fumes) when it is necessary to connect battery
charger. Fumes from the battery could ignite by a spark and explode.
It is important that any procedure not specifically recommended in this guide be thoroughly evaluated
from the standpoint of safety before it is implemented.
Chapter 4 of this guide is dedicated to safety procedures that MUST be followed when using or
servicing lead-acid batteries. It is important that you read and understand the procedures
outlined in this guide, particularly those in Chapter 4.
Revised 02 – 05
7 MINE POWER STORAGE BATTERIES
--- Page 14 ---
DBT America Inc.
3. Check to make sure that all cells are properly connected and that terminal connections are tight. If
there are irregularities in the electrolyte levels or specific gravity readings, or if the battery has been in
storage for more than 30 days, it should be given a freshening charge (see Paragraph 2-10d).
4. Recheck electrolyte levels after charging and after gassing has stopped. Again take and record
specific gravity readings and electrolyte temperatures. If irregularities in electrolyte specific gravity
readings still exist, they should be adjusted as described in Paragraph 3-12.
2-5. General
Economical and dependable performance from a storage battery depends, to a great extent, upon
proper charging. Faulty charging causes a decrease in battery service life and dissatisfaction with its
performance. The selection of suitable charging equipment and methods is as important as the
application of the correct battery. A mine battery installation is completely satisfactory only when the unit,
battery, and charger operate as a smoothly functioning team. This text on chargers is for general
information and guidance only. If specific data is required on a particular type of charger, contact the
nearest sales representative.
When preparing a battery to be charged, make certain that all points of contact between the charger
and the battery are clean to assure good conductivity. Also make certain that the positive terminal of the
battery is connected to the positive terminal of the charger and, correspondingly, negative of battery to
negative of charger.
PERMANENT DAMAGE TO THE BATTERY OR CHARGER MAY RESULT IF THE
BATTERY IS CONNECTED INCORRECTLY.
2-6. Charging Principles
Charging, as applied to a storage battery, is the conversion of electrical energy into chemical energy
within the cell or battery. This restores the active materials and is accomplished by maintaining a
unidirectional current to the battery in the opposite direction to that during discharge. When a cell or
battery is said to be charged it is understood to mean fully charged. The type of battery, service
condition, time available for charging, and the variation in battery voltages will strongly influence which
charging method is best for a particular situation. Normally lead-acid batteries are recharged in 8 hours
following a full discharge. However, they can be recharged within other time periods when desirable. A
deeply discharged battery will absorb high current rates when the voltage is low. As the charge
progresses, the voltage steadily increases until it reaches gassing voltage, approximately 2.37 volts per
cell at 77 degrees F. At this point, battery chargers normally reduce charging rates automatically and
taper to finishing rates which are used to complete the charge. The battery is fully charged when nearly
all of the active material has been converted and when the specific gravity of the electrolyte and cell
voltage have reached their maximum or constant values (corrected for temperature), as indicated by
similar readings over a two or three hour period.
Batteries used in mine power applications are cycled - they are either being charged or discharged. In
most circumstances, batteries are charged after each shift of use, so they are cycled many times during
their lifetime. Incorrect charging for only a few cycles will do little harm, but if repeated day after day, the
battery's service life will be seriously shortened.
2-7. Charging Rates
Proper charging means charging the battery sufficiently without overcharging, overheating, or
excessive gassing. The charge is usually started at high amperage which is known as the starting rate.
Later during the charge, this rate of current flow is reduced to what is called the finishing rate. It is
Revised 02 – 05
17 MINE POWER STORAGE BATTERIES
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DBT America Inc.
TABLE 5 (Continued)
STORAGE BATTERY TROUBLESHOOTING CHART
SYMPTOMS PROBABLE CAUSE POSSIBLE REMEDY
BATTERY NOT 1. Battery not fully charged 1. See that battery has reached
COMPLETING FULL WORK before placed into operation. full charge specific gravity before
SHIFT placing into operation.
2. Weak, leaking, or defective 2. Repair or replace cell(s) or
cell(s) in battery. battery.
3. Grounds or shorts in the 3. Remove grounds or shorts.
battery.
4. Battery worn out and beyond 4. Replace battery with equal or
economical repair. higher capacity battery.
5. Battery too small for job. 5.
a. Replace battery with one
having higher capacity.
b. Purchase extra batteries (with
higher capacity if possible) and
change them more frequently.
6. Electrical or mechanical 6. Troubleshoot vehicle and
problem. repair.
LOW ELECTROLYTE 1. Cracked or broken jar(s). 1. Replace jar(s) and adjust
gravity.
2. Cell missed when watered. 2. More careful attention when
watering.
3. Defective or weak cell(s). 3. Repair or replace cell(s)
4. Frequent overcharge. 4. See items 1 and 2 in “Battery
Overheats During Charge.”
5. Battery not regularly watered. 5. Water battery regularly.
Revised 02 – 05
27 MINE POWER STORAGE BATTERIES
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DBT America Inc.
CHAPTER 5 – STORAGE AND SHIPMEMT
5-1. General
Follow these guidelines for those occasions when batteries must be stored, in either a wet or dry state,
and for possible reshipment to other areas.
5-2. Storage Methods
a. Charged and Wet Batteries - Lead acid batteries may be stored in a charged and wet (filled with
electrolyte) condition when necessary for periods of up to several months. During such periods they
should be stored in a clean, cool, dry, and well ventilated location away from radiators, hot air ducts, or
other sources of heat, and protected from exposure to direct sunlight. Before being stored, the battery
should be fully charged and the electrolyte brought to the proper level. Any leads should be
disconnected or insulated to prevent accidental discharge. The top of the battery should be protected
from dust, foreign matter, and moisture. Do not attempt to dismantle the battery.
If the average storage temperature is 80 degrees F. or higher, the specific gravity of the electrolyte
should be checked at least monthly. If below 80 degrees F., check gravities at least every two months.
Whenever the specific gravity, corrected to 80 degrees F., falls to 1.240 or below, the battery should be
given a freshening charge as described in Paragraph 2-10d. A freshening charge is also recommended
just before returning a battery to service.
b. Charged and Dry Batteries - New batteries are often supplied charged and dry (without electrolyte).
Batteries in this condition can remain in storage, unattended, for a period of at least two years. They
should be stored in a cool, dry place with vent caps tightly closed. Average temperatures should not
exceed 80 degrees F. Batteries should not be stored near radiators, hot air ducts, or other sources of
heat, and should be protected from exposure to direct sunlight. The top of the battery should be
protected from dust, foreign matter, and moisture. Charged and dry batteries when removed from
storage should be activated as described in Paragraph 2-4a.
5-3. Shipment
a. Charged and Wet Batteries - Depots or using organizations may make shipments of motive power
batteries in a charged and wet condition if intended for use within a period of 90 days. The battery
service weight is usually stamped into the steel tray near one of the lifting holes.
Before crating a wet battery for shipment, it should be given a freshening charge as described in
Paragraph 2-10d. A tag should be attached to both the battery and the crate showing the date of the last
charge and the specific gravity of the electrolyte at the completion of the charge. Make certain that the
battery is properly protected when crated. The receiving organization should be alerted also to the need
for a freshening charge before the battery is put into service.
b. Charged and Dry Batteries - Depots will normally make domestic and export shipments of new
batteries which usually will be in a charged and dry condition. Batteries, and the accompanying
electrolyte in separate carboys, which are intended for export shipment must be packaged in
accordance with approved methods.
WHENEVER BATTERIES ARE SHIPPED BY COMMON CARRIER, ICC
REGULATIONS WILL APPLY.
Revised 02 – 05
37 MINE POWER STORAGE BATTERIES
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DBT America
MAJOR HAZARDS
AREA HAZARD SAFEGUARDS
WHERE HAZARD CAN WHAT CAN HAPPEN IF HOW TO AVOID
OCCUR PRECAUTIONS AND THE HAZARD
SAFEGUARDS ARE NOT
OBEYED
ELECTRICAL (A.C. Input, Electrical shock could cause All electrical systems should be
Charger, Battery) irreparable injury or death. maintained by certified electricians.
The a.c. input and charger plug
should be disconnected before
servicing the charger.
Charging a battery of a size Chargers should be matched to the
different than that shown on size batteries in use at each
the charger nameplate could particular mine.
cause the battery to burst, or
cause damage to the battery
or charger.
BATTERY The battery produces lethal The battery should be maintained
amounts of power whether by qualified personnel. (Refer to
connected to the machine or DBT America Inc.
charger, or not. "INSTALLATION, USE,
MAINTENANCE, AND REPAIR OF
MINE POWER STORAGE
BATTERIES,” PART NUMBER
A6474X26, for complete
instructions).
Battery covers could fall Be sure cover supports are in place
crushing hands or arms. when working on battery.
Battery hold-down clamps Keep fingers away from hold-down
could crush fingers. clamps.
Batteries produce explosive Batteries should be well vented