Safety instructions on handling hybrid cars (Cooper Convertible)

Please observe the current version!  Safety instructions for handling electric vehicles and hybrid vehicles

1. Qualification: 

   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.

2. Identification: 

   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.

3. Rules of conduct/protective measures: 
   • Note operating instructions for handling high-voltage battery units.
   • 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.

     Attempt to extinguish the fire without putting persons in danger (suitable extinguishing agent: water and water foam).

   • A cut 2nd emergency separation point must be repaired with a butt connector.
4. Measures before starting work: 

   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.

   • 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: 
     1. seat belt buckle unlocked and 
     2. the driver's door is open and 
     3. no brake activated and 
     4. the accelerator pedal is not activated and 
     5. 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:

     1. Corresponding display in the KOMBI High-voltage system deactivated  or

   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!  Before work begins, a qualified electrician (1000 V AC) must verify that the system is de-energized using appropriate measuring devices and procedures.

   => 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 heating may lead to sporadic launches of the electric fan (switch-on request from 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.

   5. Measures during/after activities: 

   • 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:  When the "Power Electronic Box Cover" is removed, the high-voltage system is not permitted to be activated. The high-voltage safety plug must only be used when the "Power Electronic Box Cover" is completely installed.
   • High-voltage cables (orange coating) and their connectors and stop parts may not be repaired. If damaged, a cable must always be replaced completely.
   • When working in the vicinity of high-voltage components (identified accordingly with warning signs and orange-colored coating), protect these components against damage.
   • The specified work steps in the repair instructions must be adhered to exactly.
   • High-voltage components and their holders must be screwed/bolted to the defined tightening torque. Tightening torques and tightening specifications must be observed.
   • Connecting high-voltage components to body ground is crucial to safety for reasons of potential equalization. For this reason, it is prohibited to operate any high-voltage components without them being correctly connected to body ground. The measurements (insulation/potential equalization measurement) are performed automatically by the vehicle. Manual measurement is not therefore necessary.

     For a correct earthing connection, the retaining elements of high-voltage components must not be painted. Follow further painting notes.

   • Removed high-boltage battery units must be stored in a manner that protects them from misuse and damage.
   • Damaged or no longer legible warning signs on high-voltage components must always be replaced.

   6. Potential compensation: 

   Potential equalization lines, high-voltage cables and the battery negative lead to the EME are fitted with safety screws.

   • 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.