Fault Guide

over the methane head the low alarm display LED on the display will light up as a warning but the engine keeps running. If a 1.25% or higher calibrated test gas is passed over the methane sensor, the low and high alarm display LEDs and the run solenoid display LED on the display will light up and the engine will shutdown. 5) Remove the cap to allow fresh air to pass over the sensor: The sensor will continue checking for methane. Once no methane is registered the high and low warning display

LEDs will go out, the solenoid will power up and the run solenoid display LED on the display will go out leaving only the charge failure display LED on. Pilot air pressure is then supplied to the shut off valve. The engine is now ready to be restarted.

FAULT DIAGNOSIS GUIDE

The electronic shutdown system is designed to stop the engine whenever something endangers the machine or the operator. There can be various such events. If the engine suddenly stops, the display LEDs will probably indicate what is wrong. With the electronic shutdown system switched on and the engine not running, the oil pressure, the coolant circulation, the solenoid and the charging display LEDs must be on, so ignore them. They are only important when the engine is running. Following examples of fault diagnosis: 1) Engine stops, all display LEDs go out: This is likely to be a wire break in the power supply line or in the start/reset line. 2) Engine stops, some display LEDs are still on: This may be due to a fault in the solenoid circuit. The solenoid display LED will be on when the engine has stopped, but if the on/off toggle switch is toggled (i.e. electronic shutdown system powered down and up again), the solenoid display LED on the display should go out after 17 seconds. If it does not, the fault is in the solenoid wiring or in the solenoid itself. 3) Engine stops, some display LEDs are still on: Look for a display LED that should not be on, because the stop is likely to be due to one of the field sensors tripping. Check which display LED is on beside the four that signal the engine has stopped. The electronic shutdown system does not differentiate between a sensor signaling alarm and its wire or connection breaking. First check whether the alarm is valid (is engine or gas temperature high or coolant low etc.). A display LED may also be flashing. This means that the fault is in the wire to the relevant sensor, e.g. a short between the wires, and a short to frame. If a display LED is flashing, examine the appropriate wire. 4) Engine stops, some display LEDs are still on: Look for a display LED that should not be on. If there is not one, trouble is likely to be due to either the oil pressure or the coolant circulation sensors. Toggle the on/off toggle switch and try starting the engine again. The engine should run for about 25 seconds even if there is no oil pressure and/or no coolant circulation. Watch the oil pressure gauge. If that is in order but the engine still stops after 25 seconds, it is likely that coolant circulation has stopped. 5) Engine stops, one or both methane alarms flash: This means that either the methane detector itself is faulty, or its cable is damaged. 6) Engine keeps running, but all display LEDs flash: This means that the battery voltage is low. Attention to the battery and charging is required.

FAULT CAUSE REMEDY

Engine stops and all LEDs go out. Wire break battery supply line. Wire break between electronic shutdown system start/reset pressure switch and main control board. Check and replace damaged cables.

Engine stops and all LEDs go out. Internal electronics problem with main control assembly. Remove and replace main control assembly and return to Bucyrus for repair.

Engine stops methane high and low alarm LEDs flashing. Faulty methane sensor or cabling. Check cable to methane sensor if it is OK replace the methane sensor and return the damaged sensor to Bucyrus for repair.

Engine stops some LEDs flashing. Valid alarm shutdown due to engine problems.

Damaged cable to a particular field sensor or damaged field sensor. Check which LED is on. There will always be some LEDs on with the engine off and the electronic shutdown system on (charge failure, engine oil pressure, run solenoid and exhaust coolant flow). If a LED for a field sensor other than the above is on check for engine fault. If no fault found with engine check field sensor and its cable and replace if damaged

Engine stops some LEDs flashing Valid alarm shutdown due to engine problems.

Damaged cable to a particular field sensor or damaged field sensor Check which LED is on. If the LEDs that are on should be on when the engine is not running then there is likely to be a problem either with the engine oil pressure or exhaust coolant flow. First check coolant level in heat exchanger cooling system and the engine oil level. If OK reset the electronic shutdown system and start the engine. The engine will run for 25 seconds before the hold of timer turns off. Once the engine has started check the oil pressure if OK but the engine shuts down after 25 seconds there is a problem with the oil pressure sensor or the coolant sensor or their cables. Replace as necessary.

Engine starts and runs for a few seconds and the start LED is on. Engine start pressure not switching the timers on in the main control assembly Check air pressure at the engine start pressure switch. Check switch and its cable, if damaged replace.

Engine runs but all LEDs are flashing. Battery is flat and needs to be replaced. Remove and replace IS battery.

Solenoid LED will not turn off. Solenoid or its cable is damaged. Check cable and solenoid, if damaged replace.

Methane low alarm LED is on. Methane in the surrounding air has reached the low alarm level. This is normal operation.

Engine runs charge failure LED on. No charging current for battery from alternator. Check to see if alternator is supplying enough current (the charge failure LED may flicker when engine is at idle). Check fuses in the flameproof alternator barrier assembly. These fuses will blow if the alternator is running over current. The fuses will blow if the alternator puts out more than 15.7 volts continuously. Fuses mainly blow due to a sudden power spike. Replace fuses, repair alternator if not running in the correct parameters

Solenoid LED turns off but the engine will not start If this happens the solenoid ports are more than likely blocked Check to see if air is passing through the solenoid. If not remove hose fittings and clean gauze filter or replace. If air still does not pass through the solenoid, replace solenoid and return blocked solenoid to Bucyrus for repair