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Elements and Performance Criteria

  1. Prepare to diagnose and repair BEV high voltage traction motor
  2. Diagnose traction motor
  3. Repair traction motor
  4. Complete work processes
  5. Prepare to diagnose and repair BEV high voltage traction motor
  6. Diagnose traction motor
  7. Repair traction motor
  8. Complete work processes

Range Statement

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 in 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:

using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and HV insulating mat with Australian standards rating

identifying and using fire safety equipment as appropriate

using the ‘one hand rule’

following live system warning tags and signs

depowering the vehicle

isolating the HV RESS electrical supply

stabilising the 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

scan tool

oscilloscope

residual voltage tester, if specified in original equipment manufacturer (OEM) test requirements.

Environmental requirements must include:

procedures for trapping, storing and disposing of waste released from high voltage traction motors.



Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing HV traction motors in BEVs, including procedures for:

identifying hazards and controlling risks associated with:

working with high voltages in 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:

using personal protective equipment (PPE), including electrical safety gloves with 1000 volt rating and high voltage (HV) insulating mat with Australian standards rating

identifying and using fire safety equipment as appropriate

using the ‘one hand rule’

following live system warning tags and signs

depowering the vehicle

isolating the HV rechargeable energy storage system (RESS) electrical supply

stabilising the vehicle electrical system

environmental requirements, including procedures for trapping, storing and disposing of waste released from high voltage traction motors

key requirements of AS 5732 Electric vehicle operations: Maintenance and repair

operating principles of HV BEVs and associated components, including:

motor generators

types of batteries

battery charging

application, purpose and operation of HV traction motors and components, including:

direct current (DC) motor generators

alternating current (AC) motor generators

diagnostic testing procedures for battery electric vehicle systems, including:

accessing and interpreting scan tool system data, including:

diagnostic trouble codes (DTCs)

live data

freeze frame data

waveforms

using diagnostic flow charts

testing electrical systems, including procedures for:

accessing electrical terminals and using test probes without damaging connectors, fuse holders or wiring

determining damage to traction motor windings

checking insulation resistance of traction motor windings

checking routing and damage to HV cabling

conducting vehicle dynamic and static tests

analysing abnormal noise

analysing component failure

repair procedures for traction motor speed control systems, including:

tightening connections

replacing faulty or damaged cable connections

removing and replacing faulty or damaged components

removing and replacing the traction motor

post-repair testing procedures for BEVs, including:

DTC clearing procedures

checking for electrical connector mating

static and dynamic performance tests of traction motors.