Application
This unit describes the performance outcomes required to diagnose and repair faults in the high voltage (HV) rechargeable energy storage system (RESS) of hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs). It involves preparing for the task, selecting the correct diagnostic procedure, carrying out the diagnosis and repair, performing post-repair testing, and completing workplace processes and documentation. Importance is placed in the unit on applying electrical safety procedures when working on HV RESS.
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.
Elements and Performance Criteria
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 diagnose and repair HV RESS | 1.1 Job requirements are determined from workplace instructions 1.2 Diagnostic information is accessed and interpreted 1.3 Diagnostic options are analysed and those most appropriate to the circumstances are selected 1.4 Hazards associated with the work are identified and risks are managed according to safety requirements and AS 5732 Electric vehicle operations - Maintenance and repair 1.5 Diagnostic tools and equipment are selected and checked for serviceability |
2. Diagnose RESS | 2.1 Diagnostic tests are carried out according to manufacturer specifications, workplace procedures and safety requirements 2.2 Faults are identified from diagnostic test results and causes of faults are determined 2.3 Diagnosis findings and recommendations for required repairs or adjustments are reported according to workplace procedures |
3. Repair RESS | 3.1 Repair information is accessed and interpreted 3.2 Repair options are analysed and those most appropriate to the circumstances are selected 3.3 Repair tools, equipment and materials are selected and checked 3.4 RESS service plug or manual service disconnect is located and isolated to depower vehicle HV RESS according to manufacturer specifications 3.5 RESS and components are replaced, repaired or adjusted as required according to manufacturer specifications, workplace procedures, safety and environmental requirements, and without causing damage to components or systems 3.6 RESS service plug or manual service disconnect are reconnected and vehicle is reactivated 3.7 Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified |
4. Complete work processes | 4.1 Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use 4.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 4.3 Tools and equipment are checked and stored and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures 4.4 Workplace documentation is processed according to workplace procedures |
Evidence of Performance
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:
diagnose and repair high voltage (HV) rechargeable energy storage systems (RESS) in two different hybrid electric vehicles (HEVs) or plug-in hybrid electric vehicles (PHEVs) to correct performance deficiencies.
Evidence of Knowledge
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 RESS in HEVs and PHEVs, including procedures for:
identifying hazards and controlling risks associated with:
working with high voltages on HEV and PHEV 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
environmental requirements, including procedures for trapping, storing and disposing of waste released during repair procedures
requirements of AS 5732 Electric vehicle operations - Maintenance and repair
operating principles of HV RESS in HEVs and PHEVs, including:
battery pack construction, including:
battery types
battery internal resistance
battery pack system, including:
charging characteristics
open circuit cells
reverse polarisation
series cell configuration
strapping and layout
application, purpose and operation of RESS, including:
HV battery charger and direct current (DC) to DC converter
battery management system (BMS)
power distribution unit (PDU)
diagnostic testing procedures for HV RESS in HEVs and PHEVs, including:
accessing and interpreting scan tool system data, including:
diagnostic trouble codes (DTCs)
live data
freeze frame data
waveforms
using diagnostic flow charts
electrical system testing, including procedures for:
accessing electrical terminals and using test probes without damaging connectors, fuse holders or wiring
testing controller input and output signals and waveforms
vehicle dynamic and static testing procedures
analysing abnormal noise
analysing component failure
RESS cooling system testing
repair procedures for RESS, including:
tightening connections
replacing faulty or damaged cable connections
removing and replacing faulty or damaged components
removing and replacing motor controller
post-repair testing procedures for BEV, including:
DTC clearing procedures
checking for electrical connector mating
performance testing RESS.
Assessment Conditions
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 RESS in HEVs and PHEVs that they have repaired, 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 for HEV or PHEV RESS
AS 5732 Electric vehicle operations - Maintenance and repair
two different HEVs or PHEVs RESS and associated components accessible for diagnosis and repair or replacement activities
electrical diagnostic equipment appropriate to the HEVs or PHEVs being diagnosed and repaired, including:
digital multimeter with Cat III 1000 volt rating
insulation tester
residual voltage tester, if specified in original equipment manufacturer (OEM) specifications
scan tool
oscilloscope
tools, equipment and materials appropriate for repairing HEV or PHEV RESS and their components.
Foundation Skills
This section describes those language, literacy, numeracy and employment skills that are essential to performance and are not explicit in the performance criteria.
Skills | Description |
Learning skills to: | locate appropriate sources of information efficiently. |
Reading skills to: | interpret text, symbols and wiring diagrams in diagnostic and repair information in manufacturer specifications, and workplace instructions and procedures. |
Writing skills to: | legibly and accurately fill out workplace documentation when reporting diagnostic findings, making repair recommendations, and recording parts and material used. |
Oral communication skills to: | clarify instructions report diagnostic findings and make repair recommendations. |
Numeracy skills to: | match electrical components and part identification numbers to workplace instructions, vehicle and component part lists, and manufacturer specifications interpret vehicle electrical measurements and readings on digital and analogue gauges measure voltage, current and resistance and use basic mathematical operations, including addition and subtraction, to calculate deviations from manufacturer specifications. |
Planning and organising skills to: | plan own work requirements and prioritise actions to achieve required outcomes and ensure tasks are completed within workplace timeframes. |
Technology skills to: | use specialised tools. |
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 HEV and PHEV 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 oscilloscope. |
Environmental requirements must include: | procedures for trapping, storing and disposing of waste produced during repair procedures. |
Sectors
Technical - Hybrid Vehicle and Battery Electric Vehicle
Competency Field
Electrical