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.
2
TAL 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
