Battery Electric Machines Fundamentals

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Questions and Answers

What is one of the learning outcomes of this module?

Implement corrective actions for system failures.

Describe BEM maintenance interval schedule. (correct)

Perform advanced diagnostics on electrical systems.

Analyze battery performance metrics.

Which procedure must participants be able to perform after completing this module?

Perform safe shutdown procedures for BEMs. (correct)

Conduct energy audits for battery systems.

Engage in troubleshooting of hydraulic systems.

Perform preventive maintenance for other machinery types.

Where should participants look for service recommendations after this module?

Peer-reviewed journals on machinery.

Online forums for equipment users.

Manufacturer's marketing brochures.

Operation and Maintenance Manual (OMM). (correct)

What should participants be able to identify regarding BEM systems?

Preventive maintenance locations. Signup and view all the answers

What is a key aspect of performing preventive maintenance on BEM systems?

Describing BEM preventive maintenance procedures. Signup and view all the answers

What is one of the primary focuses of the preventive maintenance module?

Ensuring safe shutdown procedures Signup and view all the answers

Which component is specifically mentioned as needing an inspection or cleaning?

Inverter cooling fins Signup and view all the answers

What is a critical safety procedure regarding hazardous voltage components?

Safety lockout procedure Signup and view all the answers

During maintenance, what should be checked in relation to battery housings?

Hazardous voltage components Signup and view all the answers

What should be done to maintain insulation resistance?

Conduct insulation resistance checks Signup and view all the answers

What type of maintenance is indicated by the term 'bond check'?

Electrical connection integrity Signup and view all the answers

Which of the following is part of the maintenance interval schedule?

Routine hazardous component checks Signup and view all the answers

What is the purpose of changing battery coolant?

To enhance thermal conductivity Signup and view all the answers

What is the recommended interval for checking the insulation resistance of the 301.9 machines?

Every 500 service hours or 3 months Signup and view all the answers

What tool is used to perform the insulation resistance test on the 301.9 machines?

Megaohm meter Signup and view all the answers

What does the insulation resistance test verify in the battery electric machine systems?

No short circuits and sufficient resistances Signup and view all the answers

When is the bonding check for the battery electric machine systems performed?

Only when required Signup and view all the answers

Which meter is used for checking the bonding in the 301.9 machines?

Digital milliohm meter Signup and view all the answers

Where is the Protective Earth (PE) point located for bonding checks?

At the rear of the machine below the network manager Signup and view all the answers

What is the purpose of measuring resistance during the bonding check?

To ensure adequate linking of HV components Signup and view all the answers

What is the primary purpose of the preventive maintenance module for Battery Electric Machines (BEM)?

To cover maintenance procedures for BEM systems Signup and view all the answers

Why should a Cat machine's OMM be referred to during maintenance procedures?

To obtain the most current and correct procedure Signup and view all the answers

What does successful completion of this module validate?

Skills required to perform preventive maintenance on BEM components Signup and view all the answers

What is the minimum passing score for the knowledge assessment in this module?

80% Signup and view all the answers

Which of the following is NOT listed as a learning outcome for this module?

Perform electrical system upgrades Signup and view all the answers

What type of knowledge assessment format is used in this module?

Closed Book Signup and view all the answers

Which procedure is part of the learning outcomes for this module?

Perform safe shutdown procedures for BEMs Signup and view all the answers

What is the primary focus of the preventive maintenance procedures outlined in the module?

Specific procedures for Battery Electric Machines Signup and view all the answers

Which of the following is a component of the assessment criteria for this module?

Completing a knowledge assessment with a minimum passing score Signup and view all the answers

Which of the following conditions may indicate that HaV cables are in need of inspection?

Cable damage or visible insulation Signup and view all the answers

What should be checked regarding wire clips or straps during the HaV component inspection?

They should be undamaged and present Signup and view all the answers

In the inspection process, what is a sign of improper electrical connections in HaV components?

Connections that are corroded or loose Signup and view all the answers

What type of debris management method is acceptable for cleaning HaV cables?

Using pressurized air at a maximum of 205 kPa Signup and view all the answers

What condition requires immediate repair when inspecting bonding wires and grounding straps?

Wires that are corroded or worn Signup and view all the answers

What is a key indicator that grounding connections need attention during inspection?

Connections that are contaminated or damaged Signup and view all the answers

During the inspection, what should be done if any of the highlighted problems with HaV components are detected?

Make the necessary repairs immediately Signup and view all the answers

What should not be present on HaV cables and harnesses when performing an inspection?

Signs of kinking or pinching Signup and view all the answers

What is the first step in the safe shutdown procedure for a battery electric machine?

Turn the machine OFF and, if applicable, set it to IMMEDIATE OFF. Signup and view all the answers

How long should you typically wait for the voltage to discharge in the HaV electrical system?

5-10 minutes Signup and view all the answers

What voltage should be verified on the DC bus before continuing with the safe shutdown?

Less than 50 VDC Signup and view all the answers

Which step is required to ensure the functionality of the HaV indicator lamp(s)?

Perform the HaV indicator lamp test. Signup and view all the answers

What is the purpose of Lockout/Tagout (LOTO) in the safe shutdown procedure?

To prevent accidental reconnection of the battery disconnect switch. Signup and view all the answers

Which of the following steps is NOT required for the 301.9 MiniHEX during safe shutdown?

Wait for voltage to discharge in the HaV electrical system. Signup and view all the answers

What should you do after confirming that the HaV indicator lamp(s) is OFF?

Perform Lockout/Tagout of the battery disconnect switch. Signup and view all the answers

What is one of the key notes specific to the R1700 XE LHD in the safe shutdown process?

It does not require disconnecting the interface connector(s). Signup and view all the answers

Study Notes

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.

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Description

This quiz covers the fundamental concepts of preventive maintenance for Battery Electric Machines (BEM) systems. It includes essential safety protocols and assessment criteria necessary for effectively maintaining BEM system components. Successfully completing this module validates the skills and knowledge required in this field.