KTM AVL HV SAFETY 2000 Owner's Manual
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KTM AVL HV SAFETY 2000 Owner's Manual

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OWNER'S MANUAL
2015
AVL HV SAFETY 2000
Art. no. 3206226en

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  • Page 1 OWNER'S MANUAL 2015 AVL HV SAFETY 2000 Art. no. 3206226en...
  • Page 3 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.

  • Page 4: Table Of Contents

    SAFETY ADVICE..........5 Use definition – intended use....5 Fire hazard ........5 IMPORTANT NOTES........6 Handling a KTM PowerPack following an accident ........6 Securing workplaces in the workshop ... 7 ZERO POTENTIAL ......... 8 Determining that the KTM PowerPack is at zero potential ......

  • Page 5: Means Of Representation 1

    Indicates an unexpected reaction (e.g. of a work step or a function). Identifies work requiring expert knowledge and technical understanding. In the interest of your own safety, only have these jobs performed by correspondingly trained KTM technical person- nel. All work identified by this symbol requires a level 1 qualification for high-voltage systems. Only this qualification authorizes you to perform non-electro-technical work on a vehicle or on units with a high-voltage system.

  • Page 6: Formats Used

    1 MEANS OF REPRESENTATION Formats used The typographical formats used in this 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: Safety Advice 2

    Contact the KTM customer service immediately if major damage to the rechargeable lithium-ion bat- tery (KTM PowerPack) has occurred. There is no particular fire hazard for this vehicle when the rechargeable lithium-ion battery (KTM PowerPack) is intact. However, should the vehicle catch fire, inform the fire brigade responsible that an electric vehicle with a...

  • Page 8: Important Notes

    Causes of fire are reduced to the greatest possible extent by means of analyses and the measures derived from them during development and production. – If a KTM PowerPack catches fire, the metallic lithium will also burn and continue burning even without a sup- ply of ambient air. –...

  • Page 9: Securing Workplaces In The Workshop

    IMPORTANT NOTES 3 Recommended extinguishing agents: – Depending on the location of use, large quantities of water or foam and, if available, sand or metal fire extin- guisher. – Internal short-circuits resulting in overheating and fire cannot be completely precluded regardless of the time which has elapsed since the damage.

  • Page 10: Zero Potential

    – Select "Zero-potential". – 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: –...

  • Page 11: Ascertaining That The Discharge Plug Is At Zero Potential

    ZERO POTENTIAL 4 – Measure the voltage between the specified points. High-voltage plug for KTM PowerPack FV pin 1 – High- voltage plug for KTM PowerPack FV pin gnd < 40 V » If the specified value is not reached: –...
  • Page 12 4 ZERO POTENTIAL – Measure the voltage between the specified points. Battery discharge plug FU pin 1 – Battery discharge plug FU pin 2 < 40 V » If the specified value is not reached: – Discharge intermediate circuit capacitors. 310409-51 –...

  • Page 13: Ascertaining That The Motor Electronics Control Unit Is At Zero Potential

    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) –...
  • Page 14 4 ZERO POTENTIAL – Measure the voltage between the specified points. Measuring point HV+ – Measuring point HV− < 40 V » If the specified value is not reached: – Discharge the intermediate circuit capacitors (motor removed). – Clean the sealing surface. Info Sealant on the contact surface between the motor housing and the measurement tip can falsify...
  • Page 15 ZERO POTENTIAL 4 – 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). 310414-51...

  • Page 16: Insulation Measurement

    – Select "Insulation measurement". – 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: –...

  • Page 17: Performing An Insulation Measurement On The Discharge Plug

    INSULATION MEASUREMENT 5 – Measure the resistance between the specified points. High-voltage plug for KTM PowerPack FV pin 1 – High- voltage plug for KTM PowerPack FV pin gnd Value as per HV Safety » If the specified value is not reached: –...
  • Page 18 5 INSULATION MEASUREMENT – 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. 310409-51 –...

  • Page 19: Performing An Insulation Measurement On The Motor Electronics Control Unit

    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) –...
  • Page 20 Perform an insulation measurement on the stator. p. 20) – Change the motor electronics control unit. Last measure if none of the documented causes leads to elimination of the fault – Contact KTM customer service and send in the motor. 310413-51...

  • Page 21: Performing An Insulation Measurement On The High-Voltage Wiring Harness

    Change the motor electronics control unit. Last measure if none of the documented causes leads to elimination of the fault – Contact KTM customer service and send in the motor. 310414-51 Performing an insulation measurement on the high-voltage wiring harness Warning Risk of injury The measuring points could be live.

  • Page 22: Performing An Insulation Measurement On The Stator

    Performing an insulation measurement on the stator 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. – Remove screws 310389-10...
  • Page 23 Value as per HV Safety » If the specified value is not reached: – Contact KTM customer service and send in the motor. – Measure the resistance between the specified points. Measuring point WB – Measuring point Motor case Value as per HV Safety »...
  • Page 24 Value as per HV Safety » If the specified value is not reached: – Contact KTM customer service and send in the motor. 310393-51 – Measure the resistance between the specified points. Measuring point UA – Measuring point Motor case Value as per HV Safety »...

  • Page 25: Equipotential Bonding Check 6

    EQUIPOTENTIAL BONDING CHECK 6 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 removed. –...
  • Page 26 Battery discharge plug FU pin gnd – Measuring point Motor case < 0.1 Ω » If the specified value is not reached: – Contact KTM customer service. 310416-51 – Measure the resistance between the specified points. Battery discharge plug FU pin gnd – Measuring point Motor case <...

  • Page 27: Performing An Equipotential

    EQUIPOTENTIAL BONDING CHECK 6 – Measure the resistance between the specified points. High-voltage 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.
  • Page 28 6 EQUIPOTENTIAL BONDING CHECK – Measure the resistance between the specified points. Measuring point KTM PowerPack housing – Measuring point Frame < 0.1 Ω » If the specified value is not reached: – Contact KTM customer service. 310405-51 – Measure the resistance between the specified points.

  • Page 29: Index

    Intended use ......5 KTM PowerPack accident, handling following ....6 Securing workplaces in the workshop .
  • Page 30 *3206226en* 3206226en 11/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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