GB/T 47439-2026Safety requirements for the maintenance of new energy vehicles (English PDF)

4.1 Personnel

4.1.1 High-voltage system maintenance technicians should be qualified through professional training before taking up their posts, and should obtain a special certificate for low-voltage electrical work within the electrical work category. Type of operation certificate.

4.1.2 Electrical maintenance work should be carried out by no fewer than two maintenance technicians working together, with one of them responsible for safety supervision.

4.1.3 Maintenance technicians should be familiar with the operating procedures for specialized equipment and tools used during operations, the requirements for the use of protective equipment, and other relevant procedures. Emergency response measures.

4.1.4 Maintenance technicians should be familiar with the safety information regarding the maintenance of special equipment for the vehicle models they are responsible for repairing, and should comply with electrical safety operating procedures during the work process. specification.

4.1.5 Maintenance technicians should be familiar with the escape routes of the maintenance work site.

4.2 Venue

4.2.1 Maintenance work shall be carried out in a dedicated maintenance workshop with clear directional signs.

4.2.2 The work site should be well ventilated, free of flammable, explosive or potentially dangerous materials, and the ground should be dry and free of standing water and should not be exposed to rain.

4.2.3 Safety warning signs should be set up at the work site, and the signs should be clear and complete.

4.2.4 Static electricity elimination facilities installed at the work site should be effective.

4.2.5 The work site shall be equipped with fire-fighting facilities and equipment, such as fire hydrants, fire extinguishers, and gas masks, and shall be provided with power storage batteries (hereinafter referred to as "batteries"). For disassembly and repair of batteries, a fire-fighting water tank or explosion-proof box with the appropriate size for the battery being repaired should also be provided.

4.2.6 The work site shall be equipped with electrical high voltage protection emergency equipment, such as insulating rods and fire hooks.

4.2.7 Battery assembly repair work sites should be equipped with battery transfer equipment.

4.2.8 There are gas accumulation points on the roof of the maintenance site for fuel cell electric vehicles using gaseous hydrogen (hereinafter referred to as "hydrogen fuel cell vehicles"). Explosion-proof ventilation devices and hydrogen concentration detection and alarm devices should be installed.

4.2.9 Work sites involving working at heights shall be equipped with safety facilities for working at heights, including but not limited to ladders, safety belts and their fixing devices.

5.2 Insulating gloves with a withstand voltage rating at least

1.5 times that of the operating voltage of the high-voltage system should be selected.

5.3 The appearance of the insulating tools should be inspected to ensure they are undamaged.

5.4 Safety protective equipment should be inspected for its expiration date and appearance before use. Equipment that has exceeded its expiration date should not be used. (Appearance inspection before use is required.) It should comply with the provisions of Table 1.

5.5 A work warning isolation zone should be set up according to the content of the maintenance work, and warning signs such as "No Entry" should be placed in a conspicuous position in the warning isolation zone. "Entering" "High-pressure danger".

5.6 Maintenance technicians should not wear metal jewelry and should perform static discharge before starting work.

5.7 Turn off the vehicle's main power switch. For vehicles using physical key start, properly store the removed key. For vehicles with remote start functionality... The vehicle's remote start function should be disabled. A warning sign, such as "Do Not Start" or "Starting," should be placed near the vehicle's dashboard. Operation".

5.8 Maintenance work on hydrogen fuel cell vehicles should be carried out only after the fuel cell system has been completely shut down, and the integral of hydrogen gas in the maintenance work area should be [not specified]. It should not exceed 0.4%.

5.9 Apply the parking brake to the vehicle being sent for repair. The vehicle should be securely parked in the repair bay or on the lifting platform. If parked in the repair bay, a parking device should also be placed on it. Parking wedges (such as triangular blocks).

7.3 When removing the battery from the vehicle, follow the procedure in

7.2 first, and then follow the procedure below.

a) Proceed in the following order. battery guard plate, cooling pipes, low-voltage connectors, high-voltage connectors, equipotential bonding wires, and battery box mounting bolts. When removing battery packs, if there are multiple battery packs in the vehicle, first follow the instructions in the automotive repair technical information to remove adjacent battery packs. Power off operation.

b) The output terminals and wiring harnesses of the battery high-voltage bus are sealed with plugs or insulating tape.

c) During battery lifting, hoisting, and moving operations, ensure the safety of personnel and the safe handling of the lifting, hoisting, or moving equipment. Insulation protection treatment for the battery contact surface; during battery hoisting and movement operations, the hoisting fixing points are firmly installed, and a trial hoisting test is conducted before hoisting. Certificate; Before hoisting the battery of a new energy heavy-duty truck, check the stability of the battery system frame hoisting points.

7.4 When removing assemblies (systems) or components other than the battery from the vehicle, follow the procedures in 7.2a), b), and

c) before proceeding with the following steps.

a) Operate or measure the DC high-voltage busbar positive and negative input ports of the high-voltage distribution box (box) in accordance with 7.2d), as well as the positive and negative terminals and the box body. There should be no voltage between them; if voltage exists, it should be handled in accordance with the regulations in the automotive repair technical information.

b) Disconnect the main positive and main negative connections of the battery high-voltage busbar from the high-voltage distribution box (box);

c) Measure the voltage between the high-voltage input ports on the outside of the assembly (system) or component to be repaired, and between each port and the housing. There is no voltage.

7.5 After disassembly, the battery to be repaired should be cleaned, placed securely on the repair work platform, and marked with warning signs such as "Do Not Retrieve". Touch.

7.6 When disassembling individual battery packs from a disassembled new energy heavy-duty truck battery system, the procedures outlined in the automotive maintenance technical information should be followed. Disconnect the maintenance switches for the battery pack to be removed and its adjacent battery packs.

7.7 When opening and repairing a battery, the internal high-voltage circuit should be disconnected after opening. If there is a built-in high-voltage maintenance switch, the high-voltage maintenance switch should be disconnected first. And ensure proper insulation protection.

7.8 When performing fastening, disassembly, or adjustment work on hydrogen-related devices in hydrogen fuel cell vehicles, the manual shut-off valve of the gas cylinder should be closed first, and explosion-proof tools should be used to purge the gas. Empty the pipeline with hydrogen and verify that the hydrogen volume fraction at the hydrogen vent and maintenance work area should not exceed 0.4%.

7.9 The assembly of special equipment shall be carried out in the reverse order of disassembly, unless otherwise specified in the automotive repair technical information.

8.1 Insulation Testing

8.1.1 When conducting insulation testing, maintenance technicians should wear insulating gloves and safety shoes (boots), and preferably wear eye and face protection.

8.1.2 Before using the insulation resistance tester, a short-circuit test and an open-circuit test should be performed, and the function should be normal.

8.1.3 When using an insulation resistance tester to measure the insulation resistance of the battery's positive and negative terminals to the battery case, the battery should be disconnected from the external system. High-voltage and low-voltage connection lines.

8.1.4 When performing insulation resistance measurement using the method specified in

6.2.1.2 of GB 18384-2025, it is advisable to use a single-function electrical device. Pressure gauge.

8.1.5 When using an insulation resistance tester to measure the insulation resistance of high-voltage systems other than the battery to the vehicle body and frame, the main circuit to be measured should be disconnected first. All power inputs to the system or components.

8.1.6 Before and after insulation testing of components containing capacitors during operation, the capacitors should be completely discharged.

8.2 Electrical work

8.2.1 When disassembling and assembling modules, contactors, relays, fuses, copper busbars, and other components and parts inside the battery box, maintenance technicians must ensure their physical safety. No part of the battery box or any exposed components inside the box should be touched.

8.2.2 When measuring voltage using a single person and one hand, the alligator clip of the voltmeter should first be connected to the positive or negative terminal of the circuit. Connect one end of the voltmeter probe to the other for measurement. When using both hands to measure voltage, protective covers should be added to the voltmeter probes. Take proper protective measures during measurement. No part of your body should touch any exposed high-voltage components during the measurement process.

Note. The insulation withstand voltage rating of the alligator clips should be at least

1.5 times the operating voltage of the high-voltage system being measured.

8.2.3 Voltage measurements should preferably be performed using a single-function voltmeter; when using a multimeter, the range should be confirmed before taking measurements.

8.2.4 All exposed high and low voltage metal terminals encountered during the operation should be properly protected.

8.2.5 When performing battery equalization and battery/module charging/discharging operations, the operation process should be monitored, and the charging/discharging equipment should be reliably grounded.

8.3 Hydrogen-related operations

8.3.1 Hydrogen venting operations should be carried out in open outdoor areas.

8.3.2 Before hot work is carried out on hydrogen fuel cell vehicles, hydrogen concentration should be tested to confirm that the hydrogen concentration in the pipeline or hot work area is within the safe range.

8.3.3 When performing hot work on hydrogen fuel cell vehicles, it is advisable to remove the gas cylinders, purge the relevant hydrogen-related pipelines with nitrogen, and use sealing materials to ensure proper handling. Protect the gas cylinder and store it in a designated area; or after closing the manual shut-off valve of the gas cylinder, release the hydrogen from the hydrogen-related pipelines and use baffles, asbestos cloth, etc., to protect the gas cylinder. Work should be carried out after effectively isolating hydrogen-related pipelines, valves, sensors, and other components.

8.3.4 When disassembling the gas cylinders on a hydrogen fuel cell vehicle, the gas cylinders should be emptied first.

8.4 Other Operations

8.4.1 Do not use your hands, metal or wires to touch the positive and negative terminals of high-voltage systems marked with high voltage and orange wiring harnesses at the same time.

8.4.2 Repair tools and materials should not be stored above the high-voltage system to be repaired, and metal objects should not be passed over the high-voltage system.

8.4.3 Do not use water to directly wash the vehicle's high-voltage system, charging port, electrical compartment, and radiator grille.

8.4.4 Do not forcefully plug or unplug connectors or excessively bend vehicle wiring harnesses. Clean the appearance of connectors before plugging or unplugging them.

8.4.5 If any unusual odor, noise, or audible/visual alarm occurs during maintenance, work should be stopped immediately and the issue addressed before proceeding to the next step.

8.4.6 During hoisting and moving operations, no person or part of their body should be below the object being hoisted.

8.4.7 The movement of maintenance technicians and equipment, vehicles, assemblies (systems) or components shall follow the principle of mutual exclusion. when personnel move, all parts... The parts are fixed in place; when the parts are moved, personnel are in a safe area and remain stationary.

8.4.8 When welding work is carried out near the battery, the battery should be disassembled or isolated according to the hazards posed by the welding process.

8.4.9 For vehicle body alignment work, the battery should be removed first.

8.4.10 After the maintenance work is completed, the maintenance equipment, tools, parts, etc. should be inventoried, inspected and reset.