Battery Electric Machine Preventive Maintenance PDF

GLOBAL DEALER LEARNING BATTERY ELECTRIC MACHINE SYSTEMS FUNDAMENTALS BATTERY ELECTRIC MACHINE PREVENTIVE MAINTENANCE MODULE 3 - TEXT REFERENCE SERVxxxx © 2024 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the “Po...

GLOBAL DEALER LEARNING BATTERY ELECTRIC MACHINE SYSTEMS FUNDAMENTALS BATTERY ELECTRIC MACHINE PREVENTIVE MAINTENANCE MODULE 3 - TEXT REFERENCE SERVxxxx © 2024 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -2- Module 3 - Preventive Maintenance TABLE OF CONTENTS SAFETY BRIEFING 3 PURPOSE 4 REASON 5 ASSESSMENT CRITERIA 6 LEARNING OUTCOMES 7 BATTERY ELECTRIC MACHINE (BEM) MAINTENANCE 8 MAINTENANCE INTERVAL SCHEDULE 9 SAFE SHUTDOWN 10 HAZARDOUS VOLTAGE COMPONENTS CHECK - HOUSING 13 HAZARDOUS VOLTAGE COMPONENTS CHECK - HAV CABLES 14 HAZARDOUS VOLTAGE COMPONENTS CHECK - GROUNDING 15 BATTERY COOLANT CHANGE 16 INVERTER COOLING FINS INSPECT / CLEAN 17 INSULATION RESISTANCE CHECK 18 BOND CHECK 19 HAZARDOUS VOLTAGE COMPONENTS CLEAN - BATTERY PACK 20 HAZARDOUS VOLTAGE COMPONENTS CLEAN - ONBOARD CHARGERS 21 PURPOSE 22 REASON 23 ASSESSMENT CRITERIA 24 LEARNING OUTCOMES 25 MODULE CONCLUSION 26 Caterpillar: Confidential Yellow SERVxxxx - 12/24 -3- Module 3 - Preventive Maintenance SAFETY BRIEFING Emergency Phone Numbers First Aid Responders Location of Exits Location of Fire Extinguisher Room Alerts or Hazards Designated Location for Evacuation Storm Shelter Hazardous Material Safely Home. Everyone. Every Day.™ 3 SAFETY BRIEFING Provide a safety briefing. Before beginning this module, the following topics will be reviewed: Emergency Phone Numbers First Aid Responders Location of Exits Location of Fire Extinguisher Room Alerts or Hazards Designated Location for Evacuation Storm Shelter Hazardous Material Safely Home. Everyone. Every Day.™ NOTE: Any system or component specifications stated in this training module are used only for training purposes. Components and specifications may change as the product evolves. Always refer to Caterpillar Service information to obtain the most current specifications when servicing Cat® products. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -4- Module 3 - Preventive Maintenance PURPOSE This module covers preventive maintenance procedures for Battery Electric Machine (BEM) systems. 4 PURPOSE Explain the purpose of this This module covers preventive maintenance procedures for Battery Electric module. Machine (BEM) systems. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -5- Module 3 - Preventive Maintenance REASON Successful completion validates the knowledge, skills, and behaviors that are required to effectively and safely perform preventive maintenance on BEM systems components. 5 REASON Explain the reason of this Successful completion validates the knowledge, skills, and behaviors that are module. required to effectively and safely perform preventive maintenance on BEM systems components. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -6- Module 3 - Preventive Maintenance ASSESSMENT CRITERIA Knowledge Assessment Closed Book Minimum passing score of 80% 6 ASSESSMENT CRITERIA Explain the assessment criteria After the completion of this module, the participant must complete a knowledge for this module. assessment with a minimum passing score of 80%. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -7- Module 3 - Preventive Maintenance LEARNING OUTCOMES After the completion of this module, the participant will be able to: 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. 7 LEARNING OUTCOMES Explain the learning outcomes of After the completion of this module, the participant will be able to: this module. Explain BEM maintenance 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. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -8- Module 3 - Preventive Maintenance BATTERY ELECTRIC MACHINE (BEM) MAINTENANCE 8 BATTERY ELECTRIC MACHINE (BEM) MAINTENANCE Identify BEM maintenance. Maintenance ensures that Cat machines will function reliably and without any unforeseen actions or interventions. The data obtained during the walk-around inspection and Preventive Maintenance (PM) is useful for planning needed services and detecting potential problems with the battery electric machine systems. It is recommended that maintenance programs be designed and executed by qualified personnel only. The instructions and recommendations found in the Operation and Maintenance Manual (OMM) of Cat machines should be read carefully and used as a basis when planning its maintenance program. Note that maintenance recommendations found in the OMM represent only a minimum level of maintenance. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -9- Module 3 - Preventive Maintenance MAINTENANCE INTERVAL SCHEDULE Common Caterpillar Maintenance Intervals: 10 service hours or daily 250 service hours or monthly (PM1) 500 service hours or 3 months (PM2) 1000 service hours or 6 months (PM3) 2000 service hours or 1 year (PM4) 5000 service hours 6000 service hours or 3 years 9 MAINTENANCE INTERVAL SCHEDULE Explain the maintenance interval When developing a Maintenance Interval Schedule (MIS), service hours or schedule. calendar time should be used (whichever occurs first) to determine the maintenance intervals. Machines that operate in severe operating conditions may require more frequent maintenance. Some parts of the machine may need maintenance under certain circumstances; otherwise, common Caterpillar maintenance intervals for machines with battery electric drives include the following: Every 10 service hours or daily Every 250 service hours or monthly (this is also known as PM1) Every 500 service hours or 3 months (this is also known as PM2) Every 1000 service hours or 6 months (this is also known as PM3) Every 2000 service hours or 1 year (this is also known as PM4) Every 5000 service hours Every 6000 service hours or 3 years Caterpillar: Confidential Yellow SERVxxxx - 12/24 -10- Module 3 - Preventive Maintenance SAFE SHUTDOWN 1 2 10 SAFE SHUTDOWN Identify safe shutdown. Battery electric machine systems contain Hazardous Voltage (HaV) levels during machine operation and for about 10 minutes after machine shutdown. Do not remove any covers that will expose energized electrical components or perform any type of electrical maintenance while the machine is operating or while the components remain energized following a machine shutdown. When an electrical service procedure on any component of battery electric machine systems must be performed after machine shutdown, always perform the safe shutdown procedure. This action verifies that HaV is no longer present in the battery electric machine systems and that the battery modules are electrically isolated from the rest of the battery system. Other situations where safe shutdown must be performed is when an enclosure housing electrical connections is part of a service procedure, or whenever an electrical or mechanical service procedure must be performed with the low voltage electrical system energized. Always refer to a Cat machine’s OMM and other service literature when following safe shutdown procedures. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -11- Module 3 - Preventive Maintenance SAFE SHUTDOWN (CONT.) 3 11 Safe Shutdown (cont.) Explain safe shutdown The general steps to a safe shutdown of a battery electric machine are the procedures. following: 1. Turn the machine OFF. If applicable, set the machine to IMMEDIATE OFF once the machine is OFF. This will immediately discharge the inverter. NOTE: The 301.9 MiniHEX does not have an IMMEDIATE OFF setting. 2. Wait for voltage to discharge in the HaV electrical system. This should typically take between 5-10 minutes. NOTE: The 301.9 MiniHEX does not require this step, since it already has a DC bus voltage of 50 VDC. 3. Verify there is less than 50 VDC on the DC bus using the monitor display before continuing with safe shutdown. 4. Verify the HaV indicator lamp(s) (1) is/are OFF. NOTE: The 301.9 MiniHEX does not have a HaV indicator lamp, since it already has a DC bus voltage of 50 VDC. 5. Perform the HaV indicator lamp test to verify the functionality of the HaV indicator lamp(s). 6. Perform Lockout/Tagout (LOTO) of the battery disconnect switch (2). 7. Disconnect the interface connector(s) between the machine harness and battery pack harness(es). NOTE: The R1700 XE LHD does not require this step, since its battery harnesses are fully integrated into its machine harness. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -12- Module 3 - Preventive Maintenance SAFE SHUTDOWN (CONT.) 4 5 12 Safe Shutdown (cont.) Continue explanation of safe 8. Remove all battery pack Manual Service Disconnects (MSDs) (3), if applicable. shutdown procedures. NOTE: The R1700 XE has 5 MSDs located on top of each of its battery boxes. The 950 GC MWL and 320 MHEX have one MSD located at the PEM of each of their battery packs. 9. Perform LOTO of all MSD ports, if applicable. 10. Verify the absence of hazardous voltage in the HaV cables (4) connecting the battery pack(s) to the HaV electrical system of the machine. NOTE: Testing locations will vary by machine. For example, the R1700 XE LHD has its voltage measured at the battery terminals (5) of its battery boxes, whereas the 301.9 MiniHEX has its voltage measured at its DC charger port. 11.Disconnect the HaV cables connecting the battery pack(s) to the HaV electrical system of the machine. Once the machine has been shut down and its battery system has been isolated, service can now be performed. Ensure the machine is not charging when any type of service is taking place on the machine. [NOTE TO AHMED: Is there any sort of LOTO to prevent charger ports from being plugged into to prevent this from happening?] Caterpillar: Confidential Yellow SERVxxxx - 12/24 -13- Module 3 - Preventive Maintenance HAV COMPONENTS CHECK - HOUSING 13 HAZARDOUS VOLTAGE COMPONENTS CHECK - HOUSING Identify the HaV component This maintenance procedure is performed on all battery electric machines. housing and enclosure checks. Scheduled maintenance is recommended every 500 service hours or 3 months. Begin by visually checking the component housings and enclosures of the BEM systems components covered in Module 2. Check for any of the following conditions: Seals that are damaged or loose Hardware or fasteners that are damaged, loose, or missing Casing dents or punctures Debris build-up Caterpillar: Confidential Yellow SERVxxxx - 12/24 -14- Module 3 - Preventive Maintenance HAV COMPONENTS CHECK - HAV CABLES 14 HAZARDOUS VOLTAGE COMPONENTS CHECK - HAV CABLES Identify the HAV cable checks. After checking the component housings and enclosures, inspect the HaV cables and HaV electrical harnesses (indicated by their orange color) of each HaV component for any of the following conditions: Cable damage or able to see cable insulation Wire clips or straps that are damaged or missing Cables with signs of rubbing, pinching, or kinking Connections that are corroded, damaged, or loose Debris build-up on or between cables Caterpillar: Confidential Yellow SERVxxxx - 12/24 -15- Module 3 - Preventive Maintenance HAV COMPONENTS CHECK - GROUNDING 1 2 15 HAZARDOUS VOLTAGE COMPONENTS CHECK - GROUNDING Identify the bonding wires and Once the HaV cables and electrical harnesses have been inspected, check the grounding wires/straps checks. bonding wires (1) and grounding wires/straps (2) of each HaV component for any of the following conditions: Wires that are corroded, damaged, or worn Connections that are corroded, damaged, or loose Wires or connections that are contaminated Cables/straps that have become separated from their cable/strap end Debris build-up If any of the conditions mentioned exist, make the necessary repairs. Debris can be cleaned by using pressurized air. Use a maximum air pressure of 205 kPa (30 psi) when cleaning debris build-up. Always refer to a Cat machine’s OMM for the most current and correct procedure. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -16- Module 3 - Preventive Maintenance BATTERY COOLANT CHANGE 1 16 BATTERY COOLANT CHANGE Explain the battery coolant This maintenance procedure is only performed on the R1700 XE LHD. Scheduled change procedure for the R1700 maintenance for this procedure has yet to be determined. XE machines. Changing the battery coolant involves removing the drain plug from the holding tank located at the bottom of the machine. Once the system is drained, new battery coolant solution is added to the shunt tank at the battery coolant tank cap (1). Always refer to a Cat machine’s OMM for the most current and correct procedure. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -17- Module 3 - Preventive Maintenance INVERTER COOLING FINS INSPECT / CLEAN 1 17 INVERTER COOLING FINS INSPECT / CLEAN Explain the procedure for inverter This maintenance procedure is only performed on the 301.9 MiniHEX. Scheduled cooling fins inspection/cleaning maintenance is recommended every 50 service hours or weekly. on the 301.9 machines. Inspect the cooling fins (1) of the inverter for debris. If significant debris build-up is found, use either compressed air or water to remove dust and other debris from the cooling fins. Always refer to a Cat machine’s OMM for the most current and correct procedure. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -18- Module 3 - Preventive Maintenance INSULATION RESISTANCE CHECK 18 INSULATION RESISTANCE CHECK Explain the procedure for This maintenance procedure is only performed on the 301.9 MiniHEX. Scheduled checking the insulation maintenance is recommended every 500 service hours or 3 months. resistance of the battery electric machine systems on the 301.9 Checking the insulation resistance of the battery electric machine systems involves machines. using a megaohm meter to perform an insulation resistance test. The test verifies that there are no short circuits in the battery electric machine systems, and that positive, negative, and earth leads all have sufficient resistances between them. Always refer to a Cat machine’s OMM for the most current and correct procedure. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -19- Module 3 - Preventive Maintenance BOND CHECK 2 1 19 BOND CHECK Explain the procedure for This maintenance procedure is only performed on the 301.9 MiniHEX. Scheduled checking the battery electric maintenance is recommended when required. machine systems bonding on the 301.9 machines. Checking the bonding of the battery electric machine systems involves using a digital milliohm meter to perform a bonding test. The test ensures that HaV components are adequately linking by measuring the resistance between the Protective Earth (PE) point (1) located below the network manager (2) at the rear of the machine and conductors located throughout the machine. Always refer to a Cat machine’s OMM for the most current and correct procedure. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -20- Module 3 - Preventive Maintenance HAV COMPONENTS CLEAN - BATTERY PACK 20 HAZARDOUS VOLTAGE COMPONENTS CLEAN - BATTERY PACK Explain the procedure for This maintenance procedure is only performed on the 301.9 MiniHEX. Scheduled cleaning the battery pack on the maintenance for this procedure has yet to be determined. 301.9 machines. Begin by inspecting the battery terminals for signs of corrosion. Clean the battery terminals and the surfaces of the batteries with a clean cloth. If necessary, soaps and/or detergents can be used to aid in the cleaning of the battery surface. NOTE: Do not use pressurized water to clean the 50V Battery Pack. Once the battery terminals and surfaces have been cleaned, inspect the HaV cables connecting the battery modules to the PEM for wear or damage. Make any necessary repairs. If necessary, replace the HaV cables and/or the 50V Battery Pack. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -21- Module 3 - Preventive Maintenance HAV COMPONENTS CLEAN - ONBOARD CHARGERS 1 21 HAZARDOUS VOLTAGE COMPONENTS CLEAN - ONBOARD CHARGERS Explain the procedure for After cleaning the 50V Battery Pack, remove the access cover to the onboard cleaning the onboard chargers. chargers beneath the machine. Inspect the onboard chargers’ fans (1) for debris. Clean the fans, if necessary. Once finished cleaning, reinstall the access cover. Always refer to a Cat machine’s OMM for the most current and correct procedure. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -22- Module 3 - Preventive Maintenance PURPOSE This module covers preventive maintenance procedures for Battery Electric Machine (BEM) systems. 22 PURPOSE Explain the purpose of this This module covers preventive maintenance procedures for Battery Electric module. Machine (BEM) systems. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -23- Module 3 - Preventive Maintenance REASON Successful completion validates the knowledge, skills, and behaviors that are required to effectively and safely perform preventive maintenance on BEM systems components. 23 REASON Explain the reason of this Successful completion validates the knowledge, skills, and behaviors that are module. required to effectively and safely perform preventive maintenance on BEM systems components. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -24- Module 3 - Preventive Maintenance ASSESSMENT CRITERIA Knowledge Assessment Closed Book Minimum passing score of 80% 24 ASSESSMENT CRITERIA Explain the assessment criteria After the completion of this module, the participant must complete a knowledge for this module. assessment with a minimum passing score of 80%. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -25- Module 3 - Preventive Maintenance LEARNING OUTCOMES After the completion of this module, the participant will be able to: 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. 25 LEARNING OUTCOMES Explain the learning outcomes of After the completion of this module, the participant will be able to: this module. Explain BEM maintenance 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. Caterpillar: Confidential Yellow SERVxxxx - 12/24 -26- Module 3 - Preventive Maintenance MODULE CONCLUSION 26 MODULE CONCLUSION Conclusion This concludes the Battery Electric Machine Hazardous Voltage System module for the Battery Electric Machine System Fundamentals course. When used in conjunction with service manuals, the information in this module will enable the participant to effectively and safely perform preventive maintenance on BEM systems components. For service recommendations, always refer to the Operation and Maintenance Manual (OMM), service manuals, and other related Cat service publications. Caterpillar: Confidential Yellow