Operation Specification For New Energy Vehicle Safety Maintenance
1) High-voltage parts identification: The orange wire harnesses of the whole vehicle are all high-
voltage cables.
2) High-voltage parts: power battery pack, high-voltage distributor box, on-board charger, drive
motor controller and DC-DC assembly, electric power assembly, integrated compressor, PTC
heater, service switch.
3) When servicing the high voltage system, the vehicle power supply must be OFF (and the
vehicle in a non-charging state) and the service switch must be unplugged; after the
emergency service switch is unplugged, it should be kept by a full-time custodian who ensures
that it is not plugged in by anyone during the servicing process.
NOTE: When it is necessary to service or replace the high voltage distributor box, the
positive and negative high voltage connector clip connecting the battery packs should be
carefully unplugged and the exposed wire ends should be wrapped with insulating tape to avoid
electric shock.
4) After disconnecting the emergency service switch for 5 minutes, a multimeter should be used
to measure the high-tension loop to ensure that there is no electricity before servicing the high
voltage system.
4-1) Measure the voltage between the positive terminal of the battery pack and the body to initially
determine if there is an electric leakage. If the inspected voltage is more than or equal to 50V,
which indicates that the battery pack is leaking, the operation should be stopped immediately;
4-2) When measure the high voltage with multimeter, pay attention to choose the correct
measuring span, the accuracy of the multimeter for inspecting is not less than 0.5 level, and it
is required to have DC voltage measuring gear, the range is not less than or equal to 600V,
and comply with the principle of "one-handed operation";
4-3) A test pen line of the multimeter used is equipped with insulated alligator clips (required to
withstand voltage of 3KV, overcurrent capacity of more than 5A), clip to a terminal of the circuit
with a clip during the measurement, and then use another test pen connected to the terminal
to be measured to measure the readings. Only one hand can hold the test pen during each
measurement; it is strictly prohibited to touch the metal part of the test pen during the
measurement process.
5) The service switch is not assembled during low-voltage debugging, and the assembly of the
service switch must be directed by a full-time custodian during high-voltage debugging.
6) High-voltage debugging must be debugged under the premise of good low-voltage debugging
to facilitate the judgment of whether the battery has a leakage, if any leakage should be
checked in a timely manner, not high-voltage debugging.
7) When disassembling the battery pack assembly, first of all, connect the high-voltage distributor
box to the high-voltage wiring harness plugs with insulating tape, do not damage the wiring
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