GB/T 44510-2024 English PDF (GB/T44510-2024)

GB/T 44510-2024: Technical requirement for maintenance and repair of new energy vehicle
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GB/T 44510-2024
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.180
CCS R 16
Technical requirement for maintenance and repair of new
energy vehicle
ISSUED ON: SEPTEMBER 29, 2024
IMPLEMENTED ON: JANUARY 01, 2025
Issued by: State Administration for Market Regulation;
Standardization Administration of the People's Republic of China.
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative references ... 4
3 Terms and definitions ... 4
4 General requirements ... 5
5 Safety requirements ... 6
6 Maintenance work items and requirements ... 8
7 Technical requirements for repair and completion ... 15
Technical requirement for maintenance and repair of new
energy vehicle
1 Scope
This document specifies the general requirements, safety requirements, maintenance
work items and requirements, as well as repair and completion technical requirements
for maintenance and repair of new energy vehicle.
This document is applicable to the repair and maintenance of pure electric vehicles,
plug-in hybrid electric vehicles, and fuel cell electric vehicles using gaseous hydrogen.
Other types of new energy vehicles shall follow the same procedures.
2 Normative references
The following referenced documents are indispensable for the application of this
document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
GB/T 2900.41, Electrotechnical terminology -- Primary and secondary cells and
batteries
GB/T 3798, Technical requirements for completion and acceptance of vehicle
overhaul
GB/T 5624, Motor vehicle maintenance and repair terms
GB/T 18344, Specification for the inspection and maintenance of motor vehicle
GB 18384, Electric vehicles safety requirements
GB/T 19596, Terminology of electric vehicles
GB/T 24548, Fuel cell electric vehicles -- Terminology
GB/T 24549, Fuel cell electric vehicles -- Safety requirements
3 Terms and definitions
For the purposes of this document, the terms and definitions defined in GB/T 2900.41,
GB/T 5624, GB/T 19596, GB/T 24548 as well as the followings apply.
4.3 Routine equipment maintenance shall be carried out in accordance with the
provisions of GB/T 18344. Routine equipment repair shall be carried out in accordance
with the provisions of GB/T 3798.
4.4 The maintenance cycle of special equipment shall be determined in accordance with
the requirements of the maintenance technical information published by the automobile
manufacturer (hereinafter referred to as "automobile maintenance technical
information"), combined with the vehicle type, vehicle operating conditions, mileage,
road conditions and years of use.
4.5 The daily maintenance items of special equipment and the maintenance items under
different maintenance cycles shall be determined according to the automobile
maintenance technical information and Chapter 6.
4.6 When performing periodic maintenance, the special equipment shall first be enter-
factory inspected using a diagnostic instrument or special testing equipment. The fault
code shall be read. The additional operation items of the special equipment shall be
determined based on the vehicle technical condition reported by the driver.
4.7 The technical requirements for the maintenance of each system component involved
in the maintenance process of the special equipment shall comply with the provisions
of Chapter 7. If the automobile manufacturer has special requirements, they shall
comply with the provisions in the automobile maintenance technical information.
4.8 The power battery shall be balanced according to the cycle and method specified in
the vehicle maintenance technical information.
5 Safety requirements
5.1 New energy vehicle repair and periodic maintenance operations shall be carried out
in dedicated sites. The site shall be dry and well ventilated, with warning isolation areas
and warning signs. Non-repair and maintenance personnel shall not enter.
5.2 During the repair and periodic maintenance of fuel cell electric vehicles (hereinafter
referred to as "hydrogen fuel vehicles") that use gaseous hydrogen, there are places on
the top of the site where gas is easily accumulated, and explosion-proof exhaust devices
and hydrogen concentration detection alarm devices shall be installed.
5.3 New energy vehicle repair and periodic maintenance operation areas shall be
equipped with fire-fighting and electrical high voltage protection emergency equipment
according to the vehicle model, including but not limited to gas masks, insulating rods,
fire hooks and appropriate fire-fighting facilities and equipment.
5.4 Personnel performing high voltage power system repair and periodic maintenance
shall obtain a low voltage electrician special operations operator certificate.
5.5 Personnel who repair and perform periodic maintenance on special equipment shall
undergo professional training and be qualified before taking up their posts.
5.6 High voltage power system repair and periodic maintenance operations shall be
performed by at least two persons. The operators shall comply with the electrical safety
operation regulations.
5.7 Workers who repair and periodically maintain special equipment shall discharge
static electricity before operation. They shall wear safety protection equipment. They
shall use working tools with insulation protection function. They shall not wear metal
accessories when working. Safety protection equipment shall include but not be limited
to insulating gloves (with a withstand voltage level of more than 1000 V), insulating
shoes (boots), eye protection, and safety helmets. Safety protection equipment and
working tools shall be intact and have effective insulation.
5.8 Before high voltage power system repair and periodic maintenance, the vehicle shall
be powered off in the following order: turn off the vehicle power main control switch,
disconnect the positive and negative poles of the auxiliary battery or turn off the
auxiliary battery switch handle, and turn off the high voltage maintenance switch (or
the order specified in the vehicle maintenance technical information). Confirm that the
positive and negative pole voltages of the power battery high voltage output line system
are lower than 36 V. Maintenance can only be performed after the insulation resistance
value meets the requirements of the vehicle maintenance technical information.
5.9 After high voltage components are disconnected, the exposed high voltage terminals
shall be insulated and protected.
5.10 After high voltage power system repair and periodic maintenance are completed,
the vehicle shall be powered on and reset in the reverse order of powering off the vehicle
(or the order specified in the vehicle maintenance technical information).
5.11 The repair and periodic maintenance of hydrogen fuel cell vehicles shall also meet
the following requirements:
a) After the fuel cell system is completely shut down;
b) When tightening, disassembling, or adjusting the hydrogen pipeline of a hydrogen
fuel cell vehicle, first power off the vehicle. Close the manual shut-off valve of
the gas cylinder. Use explosion-proof tools to drain the fuel from the hydrogen
supply pipeline;
c) During hot work, hydrogen concentration detection shall be carried out to ensure
that the hydrogen gas volume in the pipeline or hot work area is within a safe
range;
d) When performing hot work near gas cylinders, first remove the gas cylinders and
purge the relevant hydrogen-related pipelines with nitrogen. Use sealing products
fault alarm information.
7.2 Power battery system
7.2.1 Appearance
7.2.1.1 The power battery shall be securely fixed in the box. The surface shall be flat,
dry, free of dirt and leakage, and with clear and correct markings. The battery modules
shall be neatly arranged and reliably connected.
7.2.1.2 The positive and negative connectors shall be connected correctly and sealed
properly. The high voltage busbar, connectors and wiring harness shall not be deformed,
loose, overheated, burned, or damaged.
7.2.1.3 The battery pack safety valve shall be free of damage and blockage.
7.2.1.4 The battery pack, battery bracket, lifting lugs, filter, cooling fan, etc. shall be
fixed in good condition.
7.2.1.5 The battery pack shall be clean on the outside, free of abnormal deformation,
bumps and damage, smoke, odor, and leakage. There shall be no water or dust inside.
7.2.1.6 The external poles of the battery pack shall be free of oxidation, arcing, sparking,
and burning. The pole plugs and sockets shall not be worn or burned. The poles and
pole seat protective covers shall be complete and intact. The external pole seat of the
battery box shall be reliably connected, and there shall be no sparking and burning
under high voltage.
7.2.1.7 The thermal insulation material on the inner edge of the battery pack shall not
fall off or be damaged.
7.2.1.8 The battery pack shall have a nameplate and warning signs on its outer surface.
If the battery pack’s external power cable and control cable interfaces do not have a
function to prevent wrong insertion, they shall be clearly marked.
7.2.1.9 For battery packs fixed with locking devices, the mechanical lock’s unlocking,
locking, and unlocking handles shall rotate smoothly. When the unlocking handle is
pressed, the mechanical lock shall be locked in the correct position.
7.2.1.10 The hatch cover of the power battery compartment shall be locked normally
and without deformation.
7.2.1.11 Rubber gaskets, pressure plates, anti-collision steel pipes, anti-scratch iron
plates, sealing strips, insulating materials, etc. shall be intact.
7.2.1.12 The guide rail bearings of the quick-change power battery box shall be
complete. Each bearing shall roll smoothly. The guide rail shall not be deformed.
7.2.1.13 The high voltage maintenance switch shall not be loose, heated, burned or
deformed. There shall be no jamming when plugging, unplugging, or switching on and
off.
7.2.2 Performance
7.2.2.1 Single batteries (battery cells) shall not be overcharged or over-discharged.
7.2.2.2 The consistency of single batteries (battery cell packs) shall comply with the
provisions of the vehicle maintenance technical information.
7.2.2.3 The fuse shall not be blown. The relay shall not be stuck.
7.2.2.4 The insulation resistance value shall comply with the requirements of the
vehicle maintenance technical information.
7.2.3 Cooling system
7.2.3.1 The cooling system shall be clean and dry.
7.2.3.2 The cooling pipeline shall be fixed reliably. There shall be no leakage at the
connection between the cooling hose and the hard pipe. There shall be no interference
in the layout of the pipeline.
7.2.3.3 The coolant shall be added between the upper and lower limits of the liquid level
markings.
7.2.3.4 The cooling system shall operate normally without abnormal noise.
7.3 Drive motor system
7.3.1 Drive motor
7.3.1.1 The surface of the drive motor housing shall be clean, dry, and free of leakage
or cracks.
7.3.1.2 The drive motor shall be firmly fixed.
7.3.1.3 The terminal wiring or connector shall be firm and not loose.
7.3.1.4 The wire screw sleeve shall be assembled in place without damage or falling off.
7.3.1.5 The three-phase high voltage connection copper busbar shall not be damaged or
burned.
7.3.1.6 There shall be no crooked, withdrawn, or broken pins in the low-voltage socket.
7.3.1.7 The sealing ring shall not be damaged or lost. There shall be no oil leakage.
vehicle maintenance technical information.
7.4.2 High voltage distribution box
7.4.2.1 The distribution box shall be clean and dry.
7.4.2.2 The distribution box shall be firmly fixed and not loose.
7.4.2.3 The circuit breaker shall work properly. The fuse shall not change color due to
high temperature.
7.4.2.4 The insulation resistance value of the high voltage part shall comply with the
provisions of the vehicle maintenance technical information.
7.4.3 High voltage connector
7.4.3.1 The high voltage connector housing shall be free of corrosion and damage. The
inside of the connector shall be clean and dry.
7.4.3.2 The high voltage connector shall be installed securely without any loosening,
damage, deformation, or corrosion. The sealing ring shall not fall out of the sheath.
7.4.3.3 The conductive parts of high voltage connectors shall be free from oxidation,
abnormal heating, and ablation.
7.4.3.4 The high voltage connector shall be plugged in properly without being loose.
7.4.3.5 The insulation resistance value shall comply with the requirements of the
vehicle maintenance technical information.
7.4.4 High voltage maintenance switch
7.4.4.1 The high voltage maintenance switch shall not be loose, heated, burned or
deformed.
7.4.4.2 The high voltage maintenance switch shall not be stuck when plugging in,
unplugging, or switching on and off.
7.4.5 Power converter
7.4.5.1 Each terminal post shall be fixed securely and its surface shall be clean and dry.
7.4.5.2 The connection terminals shall not be loose or exposed.
7.4.5.3 The insulation resistance value of the high voltage part and the output voltage
value of the power converter shall comply with the provisions of the vehicle
maintenance technical information.
7.4.6 On-board charger
7.4.6.1 The surface of the charger shall be clean and dry.
7.4.6.2 The charging connection shall be normal. The charging protection shall be
effective.
7.4.6.3 The insulation resistance value of the high voltage part shall comply with the
provisions of the vehicle maintenance technical information.
7.4.7 Charging socket
7.4.7.1 The protective cover and its locking buckle shall be intact and not damaged. The
interior shall be clean. The waterproof ring shall not be damaged or fall off.
7.4.7.2 The charging socket shall be firmly fixed and not loose. The conductive parts
shall not be oxidized, abnormally heated, or ablated.
7.4.7.3 The...