GENERAL INFORMATION CU800 Service Manual
49
1.19.8 Insulation Tester
The insulation tester can be used to check whether the 76.8V system of the motor has leakage
and series current, its own power source is able to output 50V to 1000V DC high voltage to detects
the insulation resistance between the power supplies of the electrical parts. Insulation test from 0.01
MΩ to 10 GΩ can help to judge whether the system is leaking.
If the 76.8V system of electric motor leaks electricity in series, the battery pack will be powered
off, the EV will not go, and the instrument will report insulation Error, at this time, the insulation tester
should be used to remove the Error.
WARNING
Danger High Voltage
High voltage electrical hazard may cause serious injuries and be life-threatening. The user
must wear insulating gloves when using. Irrelevant personnel are not allowed to approach
the test area during the test.
Instructions:
Test 76.8V voltage system for leakage
1. Pull out the ignition key.
2. Unplug the battery pack 76.8V output cable
connector. Unplug the controller signal connector.
3. Rotate the meter voltage adjust knob until the
needle and 100V mark align.
4. Disconnect the harness of 76.8V electric
appliance with possible leakage.
5. The black probe is clamped on the power
supply of 76.8V electric appliance with possible
leakage like controller B+, Red probe on the
conductive part of the frame.
6. Press test button. If the insulation resistance
is greater than 0.1MΩ, it is qualified.
7. Repeat step 4 / 5 / 6 to check whether the
76.8V electrical parts leak, and replace the
76.8V electrical parts that leak.
1.19.9 Jumper Wire
A jumper wire is a simple way to bypass a potential problem and isolate it to a particular point in a
circuit. If a faulty circuit works properly with a jumper wire installed, an open exists between the two
jumper points in the circuit.
To troubleshoot with a jumper wire, fist use the wire to determine if the problem is on the ground
side or the load side of a device. Test the ground by connecting a jumper between the lamp and a
good ground. If the lamp does not come on with the jumper installed. The lamp’s connection to
ground is good so the problem is between the lamp and the power source.
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