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KTM AVL HV SAFETY 2000, Owner'S Manual, Page: 18 / 30

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KTM AVL HV SAFETY 2000 Owner'S Manual Download Page 18

5 INSULATION MEASUREMENT

16

310409-51

–

Measure the voltage between the specified points.
Battery discharge plug

FU

pin

1

–

Battery discharge

plug

FU

pin

2

< 10 V

» If the specified value is not reached:

–

Discharge intermediate circuit capacitors.

310410-51

–

Measure the resistance between the specified points.
Battery discharge plug

FU

pin

1

–

Measuring point

Motor case

Value as per

HV Safety

» If the specified value is not reached:

–

Perform an insulation measurement on the motor elec-
tronics control unit.

(

p. 17)

Summary of Contents for AVL HV SAFETY 2000

Page 1: ...OWNER S MANUAL 2015 AVL HV SAFETY 2000 Art no 3206226en ...

Page 2: ......

Page 3: ... adapt these to local conditions as well as to stop produc tion of a particular model without prior notice KTM accepts no liability for delivery options deviations from fig ures and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2018 KTM Sportmotorcycle GmbH Mattighofen Austria All rights reserved Re...

Page 4: ...scertaining that the motor electronics control unit is at zero potential 11 5 INSULATION MEASUREMENT 14 5 1 Performing an insulation measurement on the KTM PowerPack 14 5 2 Performing an insulation measurement on the discharge plug 15 5 3 Performing an insulation measurement on the motor electronics control unit 17 5 4 Performing an insulation measurement on the high voltage wiring harness 19 5 5 ...

Page 5: ...k on a vehicle or on units with a high voltage system All work identified by this symbol requires a level 2 qualification for high voltage systems Only this qualification authorizes you to de energize the electrical system and perform electro technical work in a de energized state All work identified by this symbol requires a level 3 qualification for high voltage systems Only this qualification a...

Page 6: ...s document are explained below Proprietary name Indicates a proprietary name Name Indicates a protected name Brand Indicates a brand available on the open market Underlined terms Refer to technical details of the vehicle or indicate technical terms which are explained in the glossary ...

Page 7: ...tly only 2 2 Fire hazard Warning Fire hazard Damaged rechargeable lithium ion batteries KTM PowerPacks present a fire hazard Massive mechanical damage may cause an internal cell short circuit and as a consequence may cause the battery to self ignite Contact the KTM customer service immediately if major damage to the rechargeable lithium ion bat tery KTM PowerPack has occurred There is no particula...

Page 8: ...in the motor case and in the KTM PowerPack is indicated by the orange insula tion Before beginning work on the vehicle the main switch on the right of the handlebar must be switched off Numerous vehicle crash tests that extend beyond the scope of the legal and consumer protection require ments have demonstrated that the KTM PowerPack guarantees a high level of safety even in the event of accidents...

Page 9: ...n es wird gearbeitet Ort Datum Entfernen des Schildes nur durch 402258 01 Safety equipment must be worn at all times when working on the vehicle The workplace for the vehicle must be clearly marked and be equipped with safety measures Floor mat 70029006000 Safety gloves 70029007000 Inner glove liners 70029008000 Warning tape 70029015000 Safety helmet 70029003000 Safety mask 70029004000 Holder for ...

Page 10: ... Prepare the special tool for measurement AVL DITEST HV Safety 2000 70029068000 Start software HV Safety Select Zero potential 310406 51 Measure the voltage between the specified points High voltage plug for KTM PowerPack FV pin 1 High voltage plug for KTM PowerPack FV pin 2 40 V If the specified value is not reached Contact KTM customer service Secure the KTM PowerPack in the transport and quar a...

Page 11: ...ge plug for KTM PowerPack FV pin 2 High voltage plug for KTM PowerPack FV pin gnd 40 V If the specified value is not reached Contact KTM customer service Secure the KTM PowerPack in the transport and quar antine box if necessary Transport system 70029020000 4 2 Ascertaining that the discharge plug is at zero potential Warning Risk of injury The measuring points could be live Use personal protectiv...

Page 12: ...tery discharge plug FU pin 2 40 V If the specified value is not reached Discharge intermediate circuit capacitors 310410 51 Measure the voltage between the specified points Battery discharge plug FU pin 1 Measuring point Motor case 40 V If the specified value is not reached Discharge intermediate circuit capacitors ...

Page 13: ...circuit capacitors 4 3 Ascertaining that the motor electronics control unit is at zero potential Warning Risk of injury The measuring points could be live Use personal protective clothing and comply with the safety measures Condition The KTM PowerPack and motor have been removed Prepare the special tool for measurement AVL DITEST HV Safety 2000 70029068000 Start software HV Safety Select Zero pote...

Page 14: ...diate circuit capacitors motor removed Clean the sealing surface Info Sealant on the contact surface between the motor housing and the measurement tip can falsify measurements 310413 51 Measure the voltage between the specified points Measuring point HV Measuring point Motor case 40 V If the specified value is not reached Discharge the intermediate circuit capacitors motor removed ...

Page 15: ...L 4 13 310414 51 Measure the voltage between the specified points Measuring point HV Measuring point Motor case 40 V If the specified value is not reached Discharge the intermediate circuit capacitors motor removed ...

Page 16: ...ed Prepare the special tool for measurement AVL DITEST HV Safety 2000 70029068000 Start software HV Safety Select Insulation measurement 310406 51 Measure the voltage between the specified points High voltage plug for KTM PowerPack FV pin 1 High voltage plug for KTM PowerPack FV pin 2 10 V If the specified value is not reached Contact KTM customer service Secure the KTM PowerPack in the transport ...

Page 17: ...ltage plug for KTM PowerPack FV pin 2 High voltage plug for KTM PowerPack FV pin gnd Value as per HV Safety If the specified value is not reached Contact KTM customer service Secure the KTM PowerPack in the transport and quar antine box if necessary Transport system 70029020000 5 2 Performing an insulation measurement on the discharge plug Warning Risk of injury The measuring points could be live ...

Page 18: ...n 2 10 V If the specified value is not reached Discharge intermediate circuit capacitors 310410 51 Measure the resistance between the specified points Battery discharge plug FU pin 1 Measuring point Motor case Value as per HV Safety If the specified value is not reached Perform an insulation measurement on the motor elec tronics control unit p 17 ...

Page 19: ...nt on the motor elec tronics control unit p 17 5 3 Performing an insulation measurement on the motor electronics control unit Warning Risk of injury The measuring points could be live Use personal protective clothing and comply with the safety measures Condition The KTM PowerPack and motor have been removed Prepare the special tool for measurement AVL DITEST HV Safety 2000 70029068000 Start softwa...

Page 20: ...and the measurement tip can falsify measurements 310413 51 Measure the resistance between the specified points Measuring point HV Measuring point Motor case Value as per HV Safety If the specified value is not reached Perform an insulation measurement on the high voltage wiring harness p 19 Perform an insulation measurement on the stator p 20 Change the motor electronics control unit Last measure ...

Page 21: ...omer service and send in the motor 5 4 Performing an insulation measurement on the high voltage wiring harness Warning Risk of injury The measuring points could be live Use personal protective clothing and comply with the safety measures Condition The KTM PowerPack and motor have been removed 310386 10 Remove screws 1 310397 10 Prepare the special tool for measurement AVL DITEST HV Safety 2000 700...

Page 22: ...fety If the specified value is not reached Change the high voltage wiring harness 310388 51 Measure the resistance between the specified points Measuring point HV Measuring point Motor case Value as per HV Safety If the specified value is not reached Change the high voltage wiring harness 5 5 Performing an insulation measurement on the stator Warning Risk of injury The measuring points could be li...

Page 23: ...e motor housing and the measurement tip can falsify measurements Measure the resistance between the specified points Measuring point WA Measuring point Motor case Value as per HV Safety If the specified value is not reached Contact KTM customer service and send in the motor 310391 51 Measure the resistance between the specified points Measuring point WB Measuring point Motor case Value as per HV S...

Page 24: ...otor 310394 51 Measure the resistance between the specified points Measuring point UA Measuring point Motor case Value as per HV Safety If the specified value is not reached Contact KTM customer service and send in the motor 310395 51 Measure the resistance between the specified points Measuring point UB Measuring point Motor case Value as per HV Safety If the specified value is not reached Contac...

Page 25: ... with the safety measures Condition The KTM PowerPack has been removed Prepare the special tool for measurement AVL DITEST HV Safety 2000 70029068000 Start software HV Safety Select Equipotential bonding check 310415 51 Measure the resistance between the specified points Battery discharge plug FU pin gnd Measuring point Motor case 0 1 Ω If the specified value is not reached Contact KTM customer se...

Page 26: ...e plug FU pin gnd Measuring point Motor case 0 1 Ω If the specified value is not reached Contact KTM customer service 310417 51 Measure the resistance between the specified points Battery discharge plug FU pin gnd Measuring point Motor case 0 1 Ω If the specified value is not reached Contact KTM customer service ...

Page 27: ... plug for KTM PowerPack FV pin gnd Measuring point KTM PowerPack housing 0 1 Ω If the specified value is not reached Contact KTM customer service 6 2 Performing an equipotential bonding check KTM PowerPack installed Warning Risk of injury The measuring points could be live Use personal protective clothing and comply with the safety measures Condition The KTM PowerPack has been installed Prepare th...

Page 28: ...t KTM customer service D06120 10 Measure the resistance between the specified points Measuring point Power plug Measuring point KTM PowerPack housing 0 1 Ω If the specified value is not reached Contact KTM customer service D06119 10 Measure the resistance between the specified points Measuring point Power plug Measuring point Frame 0 1 Ω If the specified value is not reached Contact KTM customer s...

Page 29: ... 23 25 F Fire hazard 5 I Insulation measurement performing 14 15 17 19 20 Intended use 5 K KTM PowerPack accident handling following 6 S Securing workplaces in the workshop 7 U Use definition 5 Z Zero potential ascertaining 8 9 ascertaining motor removed 11 ...

Page 30: ... 3206226en 3206226en 11 2018 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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