GENERAL INFORMATION CU800 Service Manual
47
connector
c. A change in meter readings indicates a poor connection. Fine and repair the problem or replace
the part. Check for wires with cracked or broken insulation
d.
2. Heat – This is another common problem with connectors or plugs that have loose or poor
connections. As these connections heat up. The connection or joint expands and separates.
Causing an open circuit. Other heat related problem occur when a component creates its own
heat as it starts to fail or go bad
a. Troubleshoot the problem to help isolate the problem or area.
b. To check a connector. Perform a continuity test as described in the appropriate service
procedure. Or under Continuity test in this chapter. Then repeat the test while heating the
ground. If the lamp comes on. The problem is the connection between the lamp and Connector
with a heat gun or hair dryer. If the meter reading was normal (continuity) when the connector
was cold, then fluctuated or read infinity when heat was applied, the connection is bad.
c. If the motor does not work, it could be motor or controller overheating due to long-term
operation, the instrument will report overheating Error of controller 0052 or overheating Error of
motor 0028. Stop and wait for the controller or motor to cool down. A change in meter readings
indicates a temperature problem.
1.19.3 Electrical Component Replacement
Most EV dealerships and parts suppliers will not accept the return of any electrical part. If you
cannot determine the exact cause of any electrical system malfunction. If you purchase a new
electrical component(s), install it, and then find that the system still does not work properly, you will
probably be unable to return the unit for a refund.
Consider any test results carefully before replacing a component that teats only slightly out of
specification, especially resistance. A number of variables can affect test results dramatically. These
include: the testing meter’s internal circuitry, ambient temperature and conditions under which the
machine has been operated. All instructions and specifications have been for accuracy: however.
Successful test results depend to a great degree upon individual accuracy.
1.19.4 Test Equipment
A test light can be constructed from a 12-volt light bulb with a pair of test leads carefully soldered
to the bulb. To check for battery voltage in a circuit, attach one lead to ground and the other lead to
various points along the circuit. The bulb lights when battery voltage is present.
A voltmeter is used in the same manner as the test light to find out if battery voltage is present in
any given circuit. The voltmeter, unlike the test light, also indicates how much voltage is present at
each test point. When using a voltmeter, attach the positive lead to the component or wire to be
checked and the negative lead to a good ground.
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