Safety Precautions for Hybrid/Electric Vehicles


Very high tensions occur on hybrid and electric vehicles. Due to voltage flashover on damaged components, such as marten damage or touching live components, the risk of electric shock is likely. High voltage at or in the vehicle can lead to death in case of inattention. Therefore regard the following: Only the following qualified employees are allowed to de-energize the high-voltage system: High-voltage technician Skilled electrician for predetermined operations – Hybrid or electric vehicles respectively Skilled electrician Place and attach warning signs and warning tapes. Check the high-voltage system and the high-voltage cables for damage (visual inspection). De-energizing the high-voltage system: Switch off ignition. Disconnect the service disconnect plug. Remove the fuse. Securing the high-voltage system against re-activation: Remove the vehicle key and keep it in a safe place. Keep the service disconnect plug in a safe place or secure the battery master switch against re-activation. Insulate the battery master switch, the plug connections etc. with dummy plugs, covering caps or insulating tape with the corresponding warning notice. Check the de-energized state with a voltage tester. Even with disconnected high voltage, residual voltage can still be present. Ground and short-circuit the high-voltage system (necessary only if voltage is higher than 1000 V). Voltage below 1000 V: Cover the parts which are close to the system or which are energized e.g. with insulating cloth, hoses or plastic coverings. Voltage higher than 1000 V: Cover the parts with insulating plates/protective panels specially developed for this purpose so that sufficient protection against contact to adjacent parts is ensured. Regard the following before re-energizing the high-voltage system: All tools and utilities are removed from the hybrid/electric vehicle. Remove the grounding and short circuit of the high-voltage system. Do not touch any of the cables now. Attach the protective paneling that has been removed before. Remove the protective measures at the switching system.

Very high tensions occur on hybrid and electric vehicles. Due to voltage flashover on damaged components, such as marten damage or touching live components, the risk of electric shock is likely. High voltage at or in the vehicle can lead to death in case of inattention. Therefore regard the following:

Only the following qualified employees are allowed to de-energize the high-voltage system:

High-voltage technician
Skilled electrician for predetermined operations – Hybrid or electric vehicles respectively
Skilled electrician

Place and attach warning signs and warning tapes.
Check the high-voltage system and the high-voltage cables for damage (visual inspection).
De-energizing the high-voltage system:

Switch off ignition.
Disconnect the service disconnect plug.
Remove the fuse.

Securing the high-voltage system against re-activation:

Remove the vehicle key and keep it in a safe place.
Keep the service disconnect plug in a safe place or secure the battery master switch against re-activation.
Insulate the battery master switch, the plug connections etc. with dummy plugs, covering caps or insulating tape with the corresponding warning notice.

Check the de-energized state with a voltage tester. Even with disconnected high voltage, residual voltage can still be present.
Ground and short-circuit the high-voltage system (necessary only if voltage is higher than 1000 V).
Voltage below 1000 V: Cover the parts which are close to the system or which are energized e.g. with insulating cloth, hoses or plastic coverings. Voltage higher than 1000 V: Cover the parts with insulating plates/protective panels specially developed for this purpose so that sufficient protection against contact to adjacent parts is ensured.
Regard the following before re-energizing the high-voltage system:

All tools and utilities are removed from the hybrid/electric vehicle.
Remove the grounding and short circuit of the high-voltage system. Do not touch any of the cables now.
Attach the protective paneling that has been removed before.
Remove the protective measures at the switching system.