AK00015R00Y

10/31/13

Service Bulletin See Models Below

TO: DEALER PRINCIPALS, BRANCH MANAGERS, SERVICE MANAGERS, PARTS

MANAGERS and TRAINERS

SUBJECT: AC Motor Test Tips

MODELS AFFECTED: Models with AC Motors

DESCRIPTION:
The following procedures are designed to assist the technician in determining if the AC motor system is
operating properly. When testing AC motor control systems, accuracy is very important; as little as 1 to 2
volts or 3 to 5% current difference or “imbalance” between phases can indicate a problem. When testing an
AC motor system it may not be necessary to conduct all tests outlined in this document. An example would
be a motor that will not start, or surges through most of its operating RPM range, in this case connect to the
unit with a computer and ensure no codes exist and the inputs i.e. (accelerator, MLM levers, or steering) are
working as they should. Inspect the controller, motor, cables, fuses, connections, and hardware for signs of
damage, tightness, or discoloration. If any issues are found they must be addressed before proceeding. If no
above issues are found a simple CURRENT PHASE BALANCE TEST 1 will tell you if the problem is in the
AC power system or not. If all three phases have the same current then the problem is most likely some
other place; like the encoder bearing / sensor or associated wiring. Simply put, the CURRENT PHASE
BALANCE TEST 1 is easy, fast, and provides a lot of information. The other test are included if you find one
of the phases with higher or lower current then the other and further testing is needed.

Current Phase Balance Test

TEST U V W
1
2
3

Voltage Phase Balance Test

AC Voltage U-V V-W W-U
Controller
Motor

Cable Voltage Drop Test

U V W
AC Voltage

Motor Case to Field Test

U V W
Resistance
Leakage

Motor Winding Resistance Test

U-V V-W W-U
Resistance
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AC drive motor and controller testing tools needed.

DMM Digital multi meter
AC clamp-on type amp meter (Meter needs to read up to 1000 amps AC current)
Megger Meter

Using a DMM:

VOLTAGE PHASE BALANCE TEST:

The purpose of this test is to make sure the controller is outputting the same voltage to all three
phases. If the voltage is not the same “Balanced” it would indicate an issue with the controller, motor,
or the cabling between them.

It is also important to keep in mind the direction of a three phase motor is determined by the phase
sequence. This simply means interchanging the position of any two of the three power cables will
change the direction of the motor. If you’re conducting the voltage test and the reading is not making
any sense, you may need to simply move the direction lever (forward or reverse) to operate the
traction motor in the opposite direction and re-test. If you are unfamiliar with three phase motors, a
phase checker will help you determine the phase sequence until you become more familiar with them;
most phase testers are inexpensive and easy to use.

Measuring AC voltage for each of the phases at controller:

Set meter to AC voltage and connect test leads between the U and V lugs on the controller and then
stall the motor if you’re testing the drive system; or put the hydraulic system in relief if testing a
hydraulic system. Record the results in the provided worksheet (VOLTAGE PHASE BALANCE TEST)
above, then repeat the above test between (V - W) and (W-U) recording those results also. After
completing the test at the controller repeat the same test at the motor terminal lugs.
If the phases are not balanced (voltage from each phase very close) it can indicate an issue with the
controller, motor, or power cables. To determine what is causing the difference in voltage readings
conduct the following test.

Using an Amp clamp:

The purpose of this test is to make sure the controller is outputting the same current to all three
phases. If the current is not the same, “Balanced”, it would indicate an issue with the controller,
motor, or the cabling between them.

Note: When recording results from the current balance testing, use the labeling on the controller as
your reference point, not the cable labeling.

CURRENT PHASE BALANCE TEST:

Test 1:
Note: It’s very important the amp clamp be installed exactly the same way for each test. Try to
connect the clamp the same distance and orientation each time; if you do not the test readings and
test results will be affected.

Ensure power cables are connected to the controller in standard configuration as they came from the
factory. U to U, V to V, and W to W. Install the clamp around one of the power leads between the
controller and the motor. Then stall the motor if you’re testing the drive system or put the hydraulic
system in relief if testing a hydraulic system. Test one cable at a time and record the results for each
leg in the above provided space. The amp readings for each leg of the system should be very close
to each other.

If the phases are not balanced it can indicate an issue with the controller, motor or power cables. To
determine what is causing the difference in current readings conduct the following test. A low reading
on one phase would be an indication of low output from the controller or high resistance somewhere.
A high reading on one phase would be an indication of short or low resistance somewhere.
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CAUTION
Before Conducting Test 2 and 3 follow the instructions outlined in the service manual
regarding disconnecting the battery and discharging the controller capacitors before
proceeding. Failing to do so could result in injury or death. CAUTION

Test 2:
Move all the power cables at the controller one place to the right. Connect the U cable to the V
terminal, the V cable to the W terminal, and the W cable to the U terminal. After relocation is
completed conduct the same test as before as outline above (CURRENT PHASE BALANCE TEST).
Record the results for each leg in the above provided worksheet.

Test 3:
Again move all the power cables at the controller one place to the right. Connect the U cable to the W
terminal, the V cable to the U terminal, and the W cable to the V terminal. After relocation is
completed conduct the same test as before as outline above (CURRENT PHASE BALANCE TEST).
Record the results for each leg in the above provided worksheet.

After completing the tests return the cables to their proper place as they came from factory.
After conducting Current Phase Balance test one through three; review the results recorded in the
chart you filled out above. If the odd reading remains at the same controller terminal in all three tests;
this would indicate the controller is the issue.

If the odd reading moves one terminal to the right during each test, this would indicate an issue with
the power cables or the motor. Conducting the Cable voltage drop test along with the motor
resistance/ megger test will assist in determining the cause.

Using a DMM:

CABLE VOLTAGE DROP TEST:

The purpose of this test is to make sure the “voltage drop” (working resistance) of the cables and
connections are very low between the controller and motor on all three phases. If the voltage is not
the same “Balanced” it would indicate an issue with the cabling or connections between them.
Measuring the AC voltage drop of each power cables between the controller and the motor:
Set meter to AC voltage and connect test leads between the (U) lug on the controller and the (U) lug
of the motor. Stall the motor if you’re testing the drive system or put the hydraulic system in relief if
testing a hydraulic system. Record the results in the provided worksheet (CABLE VOLTAGE DROP
TEST) above, then repeat the above test for the (V and W) cables recording those results also.
The reading should be a low voltage and very close on all the cables. If one or more cable readings
are a couple or more volts higher than the others further inspection is needed on the cable and
connection on that power cable. When conducting this test it’s important to keep in mind that voltage
drop is directly related to current and resistance. Simply put, the higher the current the higher the
voltage drop for any given cable. This means the size and length of the cable also affect the voltage
drop for any given current.

MOTOR RESISTANCE TEST:

The purpose of this test is to test the insulation between the motor field windings and the case.
The preferred method would be to use a megger and not a DMM, see explanation below.
Disconnect all power cables and sensor wires from motor before testing. Connection to the motor
U,V, and W and motor case will need to be done; i.e. you will connect one meter lead to one of the
motor terminals and one the motor case, repeat for each terminal. Set meter to ohms and record
results in the provided worksheet (Motor Case To Field) above.
A reading of infinity would be expected.
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This will test the resistance of each winding.

Disconnect all power cables and sensor wires from motor before testing.
Set meter to ohms, connect meter leads between U-V, V-W, and W-U; record results in the provided
worksheet (Motor Winding Resistance Test) above.

A very low resistance between motor terminals would be expected. If all windings are not very close,
further inspection is needed. It’s important when conducting this test to keep in mind; most
inexpensive meters do not have good resolution at low resistance and simply read 0 ohms.

Using the Megger

MOTOR LEAKAGE TEST:

The purpose of this test is to test the insulation between the field windings and the motor case. A
good reading would be 2MΩ or more for ohms or 20 milliamps or less for leakage. When conducting
this test it’s important not to test the motor at a higher voltage than the winding insulation is rated. If
the insulation is rated at say 200 volts testing at 1500 volts can damage a motor that was undamaged
before testing.

You will need to follow the meter manufactures operating instruction as each meter is different
depending on the manufacturer. Some read in ohms and some in milliamps. Record results in the
provided worksheet (Motor Case To Field Test) above.

Disconnect all power cables and sensor wires from motor before testing. Connection to the motor
U,V, and W and motor case will need to be done; i.e. you will connect one meter lead to one of the
motor terminals and one the motor case, repeat for each terminal.

Why use a megger over a DMM? Simply put it takes 20 volts to bridge a .001in gap, most DMM
check resistance at less than 10 volts. If an intermittent short gap is greater than .0005 or less (a half
thousandth of an inch), a DMM will not detect it. With a megger and testing at 500 volts, the short
could be about .025in between the winding and the frame and be detected, about 500 times the
distance.

Note: After completing the above tests and work sheet (on page one) and you are unable to determine the
problem, please scan the completed first page and attach it to a Contact Management. Make sure the form is
legible!!!

Warranty Reimbursement
This Service Bulletin is for information purposes only.

Confidential - For use by NMHG employees and authorized dealers only.

Do not copy or redistribute to unauthorized parties.

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