AURETH002 - Service and maintain battery electric vehicles
Assessor Resource
AURETH002 Service and maintain battery electric vehicles
Assessment tool
Version 1.0 Issue Date: April 2024
This unit describes the performance outcomes required to service and maintain battery electric vehicles (BEVs). It involves working with automotive electrical components, maintaining rechargeable energy storage systems (RESS), and performing basic tests on electric drive motors. Importance is placed in the unit on applying high voltage (HV) RESS and separated extra low voltage (SELV) electrical safety procedures.
It applies to those working in the automotive service and repair industry.
No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.
You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)
Evidence Required
List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.
Elements
Elements describe the essential outcomes.
Performance Criteria
Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.
1. Prepare to service and maintain BEV
1.1 Job requirements are determined from workplace instructions
1.2 Workplace procedures and manufacturer specifications are accessed and interpreted
1.3 Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair
1.4 Tools and equipment are selected and checked for serviceability
2. Test RESS and drive motor system operation
2.1 Diagnostic equipment is used to retrieve system parameters and information
2.2 RESS and vehicle drive motor system are tested for correct operation according to manufacturer specifications
2.3 Problems associated with performance of RESS or drive motor system are identified and reported according to workplace procedures
3. Deactivate vehicle RESS
3.1 Vehicle is depowered according to manufacturer specifications and workplace procedures
3.2 Vehicle is identified with warning tag or sign to indicate potential hazards
3.3 SELV supply is located and disconnected according to manufacturer specifications
3.4 RESS service plug or manual service disconnect is located and removed to depower vehicle HV RESS according to manufacturer specifications
3.5 Vehicle is stabilised and checked for zero residual voltage according to manufacturer procedures
3.6 RESS service plug or manual service disconnect is secured and retained to prevent refitting by third party
4. Check drive motor and associated components
4.1 Electrical drive motor is checked to confirm condition
4.2 Problems associated with performance of electric drive motor and associated components are identified
4.3 Corrective action required to achieve optimum motor performance is reported according to workplace procedures
5. Check associated electrical subsystems and components
5.1 Condition and operation of associated electrical subsystems and components are checked
5.2 Problems associated with performance of electrical subsystems and components are identified
5.3 Required corrective action is reported according to workplace procedures
6. Reinitialise vehicle RESS
6.1 SELV and RESS service plug or manual service disconnect are reconnected in correct order, and vehicle is reactivated
6.2 Diagnostic test equipment is used to check and recalibrate subsystems affected by depower process as required
6.3 RESS and vehicle subsystems are checked for correct operation
6.4 Post-service testing is carried out to ensure correct and safe operation of BEV, any reported problems are resolved, and no other problems are present
7. Complete work processes
7.1 Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use
7.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
7.3 Tools and equipment are checked and stored and any faulty equipment is identified, tagged and isolated according to workplace procedures
7.4 Workplace documentation is processed according to workplace procedures
Before competency can be determined, individuals must demonstrate they can perform the following according to the standard defined in the unit’s elements, performance criteria, range of conditions and foundation skills:
safely test, service and maintain two different battery electric vehicles (BEVs).
Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to servicing and maintaining BEVs, including procedures for:
identifying hazards and controlling risks associated with:
working with high voltages on BEV electrical systems
wearing jewellery while working around high electrical currents
determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions when:
using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and Australian standards rated high voltage (HV) insulating mat
identifying and using firefighting equipment as appropriate
using the ‘one hand’ rule
following live system warning tags and signs
depowering vehicle
isolating HV rechargeable energy storage system (RESS) electrical supply
stabilising vehicle electrical system
requirements of AS 5732 Electric vehicle operations - Maintenance and repair
key components of BEVs and their functions
RESS battery construction, including:
battery internal resistance
battery types
terminal corrosion
terminal resistance
key components of RESS theory, including:
cell failure theory
charging characteristics
open circuit cells
reverse polarisation
series cell configuration
strapping and layout
battery charger characteristics and operation, including battery cooling system and refrigerant flow through RESS
battery management system (BMS) theory
power distribution unit (PDU) operation.
Assessors must satisfy NVR/AQTF assessor requirements.
Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.
Assessment must include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the BEVs they have serviced and maintained, e.g. repair orders.
Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.
The following resources must be made available:
automotive repair workplace or simulated workplace
PPE, including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat
manufacturer specifications and service procedures for the BEVs being worked on
AS 5732 Electric vehicle operations - Maintenance and repair
two different operational BEVs requiring service and maintenance
electrical test equipment appropriate to BEVs being serviced, including:
digital multimeter with Cat III 1000 volt rating
insulation tester
residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements
scan tool
tools, equipment and materials appropriate for testing, servicing and maintaining BEVs.
Submission Requirements
List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here
Assessment task 1: [title] Due date:
(add new lines for each of the assessment tasks)
Assessment Tasks
Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.
Elements
Elements describe the essential outcomes.
Performance Criteria
Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.
1. Prepare to service and maintain BEV
1.1 Job requirements are determined from workplace instructions
1.2 Workplace procedures and manufacturer specifications are accessed and interpreted
1.3 Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair
1.4 Tools and equipment are selected and checked for serviceability
2. Test RESS and drive motor system operation
2.1 Diagnostic equipment is used to retrieve system parameters and information
2.2 RESS and vehicle drive motor system are tested for correct operation according to manufacturer specifications
2.3 Problems associated with performance of RESS or drive motor system are identified and reported according to workplace procedures
3. Deactivate vehicle RESS
3.1 Vehicle is depowered according to manufacturer specifications and workplace procedures
3.2 Vehicle is identified with warning tag or sign to indicate potential hazards
3.3 SELV supply is located and disconnected according to manufacturer specifications
3.4 RESS service plug or manual service disconnect is located and removed to depower vehicle HV RESS according to manufacturer specifications
3.5 Vehicle is stabilised and checked for zero residual voltage according to manufacturer procedures
3.6 RESS service plug or manual service disconnect is secured and retained to prevent refitting by third party
4. Check drive motor and associated components
4.1 Electrical drive motor is checked to confirm condition
4.2 Problems associated with performance of electric drive motor and associated components are identified
4.3 Corrective action required to achieve optimum motor performance is reported according to workplace procedures
5. Check associated electrical subsystems and components
5.1 Condition and operation of associated electrical subsystems and components are checked
5.2 Problems associated with performance of electrical subsystems and components are identified
5.3 Required corrective action is reported according to workplace procedures
6. Reinitialise vehicle RESS
6.1 SELV and RESS service plug or manual service disconnect are reconnected in correct order, and vehicle is reactivated
6.2 Diagnostic test equipment is used to check and recalibrate subsystems affected by depower process as required
6.3 RESS and vehicle subsystems are checked for correct operation
6.4 Post-service testing is carried out to ensure correct and safe operation of BEV, any reported problems are resolved, and no other problems are present
7. Complete work processes
7.1 Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use
7.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
7.3 Tools and equipment are checked and stored and any faulty equipment is identified, tagged and isolated according to workplace procedures
7.4 Workplace documentation is processed according to workplace procedures
This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.
Safety requirements must include:
work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for:
identifying hazards and controlling risks associated with:
working with high voltages on BEV electrical systems
wearing jewellery while working around high electrical currents
determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions when:
using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat
identifying and using firefighting equipment as appropriate
using the ‘one hand’ rule
following live system warning tags and signs
depowering vehicle
isolating HV RESS electrical supply
stabilising vehicle electrical system.
Tools and equipment must include:
those specified in the specific vehicle service maintenance procedures, including:
digital multimeter with Cat III 1000 volt rating
insulation tester
residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements
scan tool.
Corrective action must include:
tightening connections
balancing state of charge
replacing faulty or damaged cable connections
removing and replacing faulty or damaged components.
Before competency can be determined, individuals must demonstrate they can perform the following according to the standard defined in the unit’s elements, performance criteria, range of conditions and foundation skills:
safely test, service and maintain two different battery electric vehicles (BEVs).
Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to servicing and maintaining BEVs, including procedures for:
identifying hazards and controlling risks associated with:
working with high voltages on BEV electrical systems
wearing jewellery while working around high electrical currents
determining appropriate procedures for minimising risk associated with hazards, including applying electrical safety precautions when:
using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and Australian standards rated high voltage (HV) insulating mat
identifying and using firefighting equipment as appropriate
using the ‘one hand’ rule
following live system warning tags and signs
depowering vehicle
isolating HV rechargeable energy storage system (RESS) electrical supply
stabilising vehicle electrical system
requirements of AS 5732 Electric vehicle operations - Maintenance and repair
key components of BEVs and their functions
RESS battery construction, including:
battery internal resistance
battery types
terminal corrosion
terminal resistance
key components of RESS theory, including:
cell failure theory
charging characteristics
open circuit cells
reverse polarisation
series cell configuration
strapping and layout
battery charger characteristics and operation, including battery cooling system and refrigerant flow through RESS
battery management system (BMS) theory
power distribution unit (PDU) operation.
Assessors must satisfy NVR/AQTF assessor requirements.
Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.
Assessment must include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the BEVs they have serviced and maintained, e.g. repair orders.
Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.
The following resources must be made available:
automotive repair workplace or simulated workplace
PPE, including electrical safety gloves with 1000 volt rating and Australian standards rated HV insulating mat
manufacturer specifications and service procedures for the BEVs being worked on
AS 5732 Electric vehicle operations - Maintenance and repair
two different operational BEVs requiring service and maintenance
electrical test equipment appropriate to BEVs being serviced, including:
digital multimeter with Cat III 1000 volt rating
insulation tester
residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements
scan tool
tools, equipment and materials appropriate for testing, servicing and maintaining BEVs.
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.
Observation Checklist
Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice
Yes
No
Comments/feedback
Job requirements are determined from workplace instructions
Workplace procedures and manufacturer specifications are accessed and interpreted
Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair
Tools and equipment are selected and checked for serviceability
Diagnostic equipment is used to retrieve system parameters and information
RESS and vehicle drive motor system are tested for correct operation according to manufacturer specifications
Problems associated with performance of RESS or drive motor system are identified and reported according to workplace procedures
Vehicle is depowered according to manufacturer specifications and workplace procedures
Vehicle is identified with warning tag or sign to indicate potential hazards
SELV supply is located and disconnected according to manufacturer specifications
RESS service plug or manual service disconnect is located and removed to depower vehicle HV RESS according to manufacturer specifications
Vehicle is stabilised and checked for zero residual voltage according to manufacturer procedures
RESS service plug or manual service disconnect is secured and retained to prevent refitting by third party
Electrical drive motor is checked to confirm condition
Problems associated with performance of electric drive motor and associated components are identified
Corrective action required to achieve optimum motor performance is reported according to workplace procedures
Condition and operation of associated electrical subsystems and components are checked
Problems associated with performance of electrical subsystems and components are identified
Required corrective action is reported according to workplace procedures
SELV and RESS service plug or manual service disconnect are reconnected in correct order, and vehicle is reactivated
Diagnostic test equipment is used to check and recalibrate subsystems affected by depower process as required
RESS and vehicle subsystems are checked for correct operation
Post-service testing is carried out to ensure correct and safe operation of BEV, any reported problems are resolved, and no other problems are present
Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
Tools and equipment are checked and stored and any faulty equipment is identified, tagged and isolated according to workplace procedures
Workplace documentation is processed according to workplace procedures
Job requirements are determined from workplace instructions
Workplace procedures and manufacturer specifications are accessed and interpreted
Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair
Tools and equipment are selected and checked for serviceability
Diagnostic equipment is used to retrieve system parameters and information
RESS and vehicle drive motor system are tested for correct operation according to manufacturer specifications
Problems associated with performance of RESS or drive motor system are identified and reported according to workplace procedures
Vehicle is depowered according to manufacturer specifications and workplace procedures
Vehicle is identified with warning tag or sign to indicate potential hazards
SELV supply is located and disconnected according to manufacturer specifications
RESS service plug or manual service disconnect is located and removed to depower vehicle HV RESS according to manufacturer specifications
Vehicle is stabilised and checked for zero residual voltage according to manufacturer procedures
RESS service plug or manual service disconnect is secured and retained to prevent refitting by third party
Electrical drive motor is checked to confirm condition
Problems associated with performance of electric drive motor and associated components are identified
Corrective action required to achieve optimum motor performance is reported according to workplace procedures
Condition and operation of associated electrical subsystems and components are checked
Problems associated with performance of electrical subsystems and components are identified
Required corrective action is reported according to workplace procedures
SELV and RESS service plug or manual service disconnect are reconnected in correct order, and vehicle is reactivated
Diagnostic test equipment is used to check and recalibrate subsystems affected by depower process as required
RESS and vehicle subsystems are checked for correct operation
Post-service testing is carried out to ensure correct and safe operation of BEV, any reported problems are resolved, and no other problems are present
Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
Tools and equipment are checked and stored and any faulty equipment is identified, tagged and isolated according to workplace procedures
Workplace documentation is processed according to workplace procedures
Forms
Assessment Cover Sheet
AURETH002 - Service and maintain battery electric vehicles
Assessment task 1: [title]
Student name:
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I declare that the assessment tasks submitted for this unit are my own work.
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Result: Competent Not yet competent
Feedback to student
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Assessment Record Sheet
AURETH002 - Service and maintain battery electric vehicles
Student name:
Student ID:
Assessment task 1: [title] Result: Competent Not yet competent
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Feedback to student:
Overall assessment result: Competent Not yet competent