Battery Electric Machines Fundamentals

Global Dealer Learning - Battery Electric Machine Systems Fundamentals

• This module covers the fundamentals of preventive maintenance for Battery Electric Machines (BEM) systems.
• The module includes safety briefing, purpose, reason, assessment criteria, learning outcomes, and a module conclusion.

Safety Briefing

• Includes emergency phone numbers, first aid responders, location of exits, fire extinguishers, room alerts, hazard locations, evacuation designations, storm shelters, and hazardous materials.
• There is a safety briefing to be conducted before starting the module.

Purpose

• The module's purpose is to explain preventive maintenance procedures for Battery Electric Machines (BEM) systems.

Reason

• Successful completion validates knowledge, skills, and behaviors needed for effectively and safely performing preventive maintenance on BEM system components.

Assessment Criteria

• Knowledge assessment is closed-book.
• Minimum passing score is 80%.
• Participants complete a knowledge assessment after the module.

Learning Outcomes

• Explain BEM maintenance and interval schedule.
• Describe safe shutdown procedures for BEMs.
• Perform safe shutdown procedures for BEMs.
• Identify BEM preventive maintenance locations.
• Describe BEM preventive maintenance procedures.
• Perform BEM preventive maintenance procedures.

BEM Maintenance

• Maintenance ensures reliable operation without unforeseen actions or interventions.
• Data collected during a walk-around inspection and Preventive Maintenance (PM) is used for planning and detecting potential problems.
• Maintenance programs should be executed by qualified personnel.
• Cat machine Operation and Maintenance Manuals (OMM) provide minimum maintenance standards.

Maintenance Interval Schedule

• Maintenance intervals are based on service hours or calendar time (whichever occurs first).
• Severe operating conditions may necessitate more frequent maintenance.
• Common maintenance intervals for battery electric machines include 10 hours or daily, 250 hours or monthly (PM1), 500 hours or 3 months (PM2), 1000 hours or 6 months (PM3), 2000 hours or 1 year (PM4), 5000 hours, and 6000 hours or 3 years.

Safe Shutdown

• BEM systems contain Hazardous Voltage (HaV) levels during operation and for approximately 10 minutes after shutdown.
• Do not remove covers exposing energized components or perform electrical maintenance during operation or immediately after shutdown.
• Safe shutdown procedures isolate HaV components and ensure HaV is no longer present.
• Shutdown procedures often involve checking HaV levels, lockout/tagout (LOTO) of switches or ports, disconnection of HaV cables from machine components, and verifying HaV levels are safely low.
• The procedures vary depending on the machine; be sure to consult any Operation and Maintenance Manuals for the correct method.

HaV Component Checks

• Includes checks for housing, HaV cables, grounding, battery coolant, inverter cooling fins, insulation resistance, and battery packs.
• Scheduled maintenance (e.g., every 500 hours, every 3 months) and visual inspection are important facets of component cleanliness and repair.

Battery Coolant Change

• This procedure is only performed on the R1700 XE LHD.
• Scheduled maintenance intervals for the procedure vary.
• The procedure involves draining coolant and adding new fluid to the coolant tank.

Inverter Cooling Fins

• This procedure is only performed on the 301.9 MiniHEX.
• Scheduled maintenance is recommended every 50 service hours or weekly.
• Inspect cooling fins for debris and clean as needed with compressed air or water..

Insulation Resistance Check

• This procedure is only performed on the 301.9 MiniHEX.
• Scheduled maintenance is recommended every 500 service hours or 3 months.
• This procedure tests for short circuits in the battery electric machine system's circuits and ensures proper insulation between positive, negative, and grounding leads.

Bond Check

• This procedure is only performed on the 301.9 MiniHEX.
• Scheduled maintenance is performed as needed.
• Ensures proper connection of HaV components to the machine's grounding systems.

HaV Component Cleaning

• Components like battery packs and/or onboard chargers are cleaned to prevent corrosion and ensure smooth electrical function.
• Battery terminals and surfaces are cleaned using cloth, soap, and/or detergents; pressurized water should not be used on specified components.
• Any necessary repairs to HaV cables or the 50V battery pack should be performed as needed.

Module Conclusion

• This module concludes the Battery Electric Machine (BEM) Hazardous Voltage System module.
• When used in conjunction with service manuals, this module's information helps perform preventive maintenance on BEM system components.
• Consult the Operation and Maintenance Manual (OMM) for the most up-to-date procedures and service recommendations.