Safety instructions on handling hybrid or electric vehicles

All repair work on high-voltage components may only be performed by specially trained personnel  (qualification: Work on high-voltage inherently save vehicles) must be performed by qualified technicians. Each hybrid car requires additional vehicle specific training with training achievement controls.

Required training is offered by the BMW Training Academy.

Observe warning notices  on high-voltage components. When replacing individual high-voltage components, check if warning signs are present. Independently attaching warnings is only allowed on the locations provided for them. Use only approved and appropriately identified original new parts.

Note operating instructions for handling high-voltage battery units.

Before beginning work, a visual inspection of the high-voltage components to be processed must be done.

Do not under any circumstances touch open high-voltage cables and high-voltage components on a vehicle involved in an accident before shutting down the high-voltage electrical system.

In the event of damage (mechanical, thermal) transition metal oxides, Carbon Fiber Reinforced Plastic, electrolyte solvents and their decomposition products may be released.

Suitable acid-resistant protective clothing/equipment must therefore be used when handling the vehicle!

• Hand protection: Gloves
• Eye protection: Safety goggles

Damaged high-voltage battery units must be stored in an acid-resistant drip pan in a location in the open that is protected against the weather (sun, rain) and secured against unauthorized access. Do not inhale leakage gasses.

Prevent leakage substances from entering drains, pits and the sewer system.

Collect any material that is discharged and have it disposed of according to the work instruction, wear acid-resistant protective clothing when doing so.

Notify the fire brigade if fire breaks out, clear the area immediately and make accident scene safe.

A cut 2nd emergency separation point must be repaired with a butt connector.

Each job on the vehicle must be assigned by appropriately trained personnel. Before work is started, this electrician must place the vehicle in the operating condition required to perform the relevant activity. The qualified personnel's instructions and directions absolutely must be followed. No work may be carried out without this qualified personnel being consulted first  .

Required training is offered by the BMW Training Academy. It is not  permitted to work on the high voltage system or on high voltage components while the engine is running.

The readiness to drive must be ended before shutting off the voltage of the high-voltage system. The readiness to drive is ended when the driver is absent only under the following conditions:

• seat belt buckle unlocked and 
• the driver's door is open and 
• no brake activated and 
• the accelerator pedal is not activated and 
• Speed < 3 km/h (2 mph)

Work on live high-voltage components is expressly prohibited. Before each operation on the high-voltage system, the system must be isolated from the power supply by qualified personnel (high-voltage safety connector Off) and secured against unauthorized recommissioning (padlock).

After each deactivation of the high-voltage system, it is essential to observe a waiting period  of at least 10 seconds  prior to further work.

Before beginning work, it is mandatory to check that the equipment is de-energized and is protected against being energized again.

Work is only permitted to begin if:

Display in the KOMBI High-voltage system deactivated  .

When a high-voltage warning is active (indicator light, Check Control, etc.), it is essential to determine and eliminate the cause of this warning via the diagnostic system before continuing with any other work.

If it cannot be definitively established that the equipment is de-energized  , work is not permitted to begin. Mortal hazard!  A qualified electrician must verify that the system is de-energized 1000 V AC with suitable measuring devices/measuring procedures before work can commence.

=> In this case, Technical Support must be contacted! 

Do not perform any work on the vehicle while it is charging. Before starting work, disconnect the charging cable from the vehicle.

Battery charging may result in heating of the high-voltage battery unit. This may cause the electric fan to start running (switch on request of the electric fan). Therefore, work in the vicinity of the electric fan during the charging procedure is prohibited. Ensure freedom of movement of the battery charge lines in the vicinity of the electric fan.

Identifiable mechanical damage to or tampering with high-voltage components must be reported immediately to the qualified personnel in charge.

When carrying out any work on the high-voltage system, it is prohibited to externally drive all the drivetrain components (wheels, transmission, drive shafts, etc.).

E72 only: It is not permitted to activate the high-voltage system when the "Power Electronic Box cover" has been removed. The high-voltage safety plug must be used with a mounted "Power Electronic Box cover" only.

High-voltage cables (orange coating) as well as their connectors and stop parts may not  be repaired. If the cable is damaged, it must always be completely replaced.

In the event of external contamination of the high-voltage components (high-voltage connector, high-voltage battery unit, drive unit...), the affected areas must be carefully cleaned after checking the cause.

• Spirit
• Windshield cleaner
• Glass cleaner
• Distilled water
• Vacuum cleaner with plastic top

When working in the vicinity of high-voltage components (marked accordingly with information stickers and/or orange coating), the high-voltage system must be disconnected from the power supply and these must be protected from damage.

The steps specified in the repair instructions must be followed exactly.

High-voltage components and their holders must be screwed/bolted to the defined tightening torque. Tightening torques and tightening specifications must be observed.

The connection of high-voltage components to the body ground is safety-relevant because of the potential equalization. Operating a high-voltage component without a correct connection to the body ground is therefore prohibited. Checking the potential equalization screw connection using the two person principle is imperative.

For a correct ground connection, mounting elements of high-voltage components must not be painted. For more information, refer to the repair instructions: Painting notes  .

Removed high-voltage battery units must be stored in a manner that protects them from misuse and damage.

Damaged or illegible warning signs on high-voltage components must always be replaced.

Potential compensation wires, high-voltage cables and the battery ground lead on the electrical machine electronics have a safety screw connection.

• Clean contact faces and have then checked by a second person.
• Tighten down screws/bolts to specified torque.
• Have tightening torque checked by a second person.
• Both persons must document that the work has been carried out correctly in the vehicle records.