For the truck to function correctly, the electrical system and the motor windings for the truck chassis must have sufficient insulation resistance. Insulation resistance must be tested in accordance with EN 1175-1 (DIN VDE 0117-1) using an approved and calibrated insulation measuring device.
The insulation resistance of the truck must be tested at regular intervals as part of the regular testing in accordance with FEM 4.004 (formerly the UVV accident prevention regulations). The insulation resistance of the motor windings must only be tested during repairs to the motor or if there is a malfunction on the truck.
Different regulations may apply in other countries.
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CAUTION
Electronic controls and components can be destroyed if the test voltage of the insulation measuring device is too high.
The test voltage of the insulation measuring device used for the insulation testing of the truck and the traction battery must be set to 100 V.
Do not touch the insulation measuring device terminals during testing.
The insulation resistance of the truck, the drive battery and the motor windings must be tested individually.
Insulation testing for the truck
100 V test voltage
NOTE
The emergency stop switch must not be switched off during insulation testing. An unpainted, clean area must be selected as a reference measurement point on the chassis (preferably screw head A). Controllers and plug connectors do not have to be disconnected before the measurement.
The insulation resistance for the following measurements must be ≥ 80 kΩ (≥ 1 kΩ/V).
The reference point for the following measurements is the screw head (A) .
Measuring points
(1) Main negative
(2) to the traction output module (terminal 14 behind contactor contact K1)
(3) Supply L+ (connecting bolt 1)
(4) to the pump motor output module (terminal 24 behind contactor contact K1)
Additional measurement points at the contactor for the active charging ventilation unit (if fitted).
Measuring points
(6) to the emergency stop toggle switch (terminal 14 behind contactor contact 9K96)
(7) Charging supply (terminal 13 in front of contactor contact 9K96)
Traction battery insulation resistance
100 V test voltage
The insulation resistance of the disconnected, filled and charged battery must be ≥ 4 kΩ (≥ 50 Ω/V).
➢ Measurement 1 from battery female connector Plus to chassis
➢ Measurement 2 from battery female connector Minus to chassis
Insulation resistance of motor windings (≥ 20 MΩ)
250 V test voltage
The insulation resistance of the disconnected motor windings to the motor housing must be ≥ 20 MΩ (test duration 3 sec.)
➢ Measurement 1 from motor connection U to motor housing
➢ Measurement 2 from motor connection V to motor housing
➢ Measurement 3 from motor connection W to motor housing
More service information,please refer to:Linde Forklift Truck Repair