Isolation From Supply Prior To Performing Maintenance Tasks On Hybrid Vehicles
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Specific qualifications are required for carrying out the maintenance tasks listed here.
The qualification of the person performing the task is shown in the table.
The table also shows whether or not the vehicle must be isolated from the power supply in order to perform the task.
- Only HVTs are permitted to isolate the high-voltage system from the power supply.
- The Eip is permitted to perform defined items of work according to instructions and under the supervision of the HVT.
- Work on high-voltage components must only be performed following isolation of the high-voltage system from the power supply by the HVT.
- All work on high-voltage vehicles must only be performed by persons who are at least qualified as Eips.
- When performing each task on a high-voltage vehicle, the high-voltage components in the task/work area must be inspected visually.
- The high-voltage cables must not be extensively bent or kinked.
- Anything anomalous or unclear must be reported to the HVT or the high-voltage expert (HVE).
- All work specified here refers to the removal and installation or replacement of the individual components.
- For regular maintenance work, the high-voltage system does not need to be isolated from the power supply.
Definition of isolating the HV system from the power supply applies to isolating the system from the power supply at the high-voltage battery (rear) and power electronics (front)
- 1. Isolate from power supply
- 2. Ensure that system cannot be switched back on again
- 3. Verify safe isolation from power supply
Definition of minimum qualification:
Eip = Electrically instructed person
- The Eip may perform general work and maintenance tasks on a high-voltage vehicle as well as mechanical work on the isolated high-voltage system on instruction from the HVT.
HVT = High-voltage technician
- The high-voltage technician's qualifications authorise him to do the same as an Eip. The HVT is additionally authorised to perform certified measurements to verify isolation of the high-voltage system from the power supply. The HVT is authorised to do the following work on the isolated high-voltage system.
- 1. Isolate from power supply
- 2. Ensure that system cannot be switched back on again
- 3. Verify and document safe isolation from power supply
- 4. Delegate work on the isolated high-voltage system to the Eip
- 5. Start the vehicle and complete the relevant documentation
HVE = High-voltage expert
- The HVE has additional knowledge to that of the HVT and is solely authorised to isolate the high-voltage system in the vehicle from the power supply, in the event that the HVT is not able to do this using the conventional tools and measurements.
- If the authorisation of the HVT to perform work on the high-voltage system is terminated, the HVE must continue the work.
- The task of the HVE is exclusively to isolate the high-voltage system from the power supply, if this cannot be performed using the conventional equipment or methods of the HVT.
Work on the high-voltage system
| When Working On The Following Components: | Minimum Qualification: |
| Isolate the high-voltage system from the power supply | HVT |
| When working on the following components | Is the high-voltage system isolated from the power supply by the HVT before starting work? | Minimum Qualifications: | |||||
| Yes | No | ||||||
| Electric machine with decoupler | X(2) | Eip | |||||
| Power electronics | X(2) | Eip | |||||
| Service disconnector | X | HVT | |||||
| Rear pilot line connector | X | HVT | |||||
| Front pilot line connector | X | HVT | |||||
| High-voltage line from power electronics to air-conditioning compressor | X(2) | Eip | |||||
| High-voltage line from power electronics to electric machine | X(2) | Eip | |||||
| High-voltage line from hybrid battery to power electronics | X(2) | Eip | |||||
| Removing and installing high-voltage battery | X(1) | Eip | |||||
| Charging high-voltage battery | X | HVT | |||||
| High-voltage battery control unit | X(1) | HVT | |||||
| Fan on high-voltage battery | X(1) | Eip | |||||
| Air extraction duct on high-voltage battery | X(1) | Eip | |||||
| Air supply for the high-voltage battery fans | X | Eip | |||||
| Electric air-conditioner compressor | X(2) | Eip | |||||
| Pressure regulator for decoupler | X | Eip | |||||
| Decoupler | X(2) | Eip | |||||
| Pressure line for decoupler | X(2) | Eip | |||||
| Brake fluid for decoupler | X | Eip | |||||
| Equipotential bonding lines | X | Eip | |||||
| Work on the coolant system of the high-voltage components | X | Eip | |||||
| Measurement at insulation resistors | X(2) | HVT | |||||
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Conventional work in the vicinity of high-voltage components
| When Working on the following components | Is the high-voltage system isolated from the power supply by the HVT before starting work? | Minimum Qualifications | |||||
| Yes | No | ||||||
| Removing and installing design cover | X | Eip | |||||
| Spark Plugs | X | Eip | |||||
| Left catalytic converter | X(1) | Eip | |||||
| Right catalytic converter | X | Eip | |||||
| Exhaust system | X | Eip | |||||
| Cardan shaft | X | Eip | |||||
| Removing and installing engine with transmission | X(2) | Eip | |||||
| Removing and installing engine | X(2) | Eip | |||||
| Removing and installing transmission | X(2) | Eip | |||||
| Auxiliary hydraulic pump for transmission oil (12 V) | X | Eip | |||||
| Transfer Gear | X | Eip | |||||
| Fuel Tank | X(1) | Eip | |||||
| Front unit carrier | X | Eip | |||||
| Rear axle housing | X | Eip | |||||
| Underbody panelling | X | Eip | |||||
| Welding work (covering high-voltage components and then carrying out visual inspection) | X | Eip | |||||
| Body repair work (using straightening bench) | X(2) | Eip | |||||
| Body repair work (assembly work and dent removal) | X | Eip | |||||
| Working close to high-voltage components and high-voltage lines using cutting, deforming and sharp-edged tools or heat sources, such as welding, soldering, hot air and thermal bonding | X(1) | Eip | |||||
| Removing and installing left and right headlights | X | Eip | |||||
| Removing and installing headlight bulbs | X | Eip | |||||
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General Work
| When Working on the following components | Is the high-voltage system isolated from the power supply by the HVT before starting work? | Minimum Qualifications | |||||
| Yes | No | ||||||
| Removing and installing 12 volt battery | X | Eip | |||||
| Removing and installing general control units and electric battery (12 V) | X | Eip | |||||
| Draining and filling fluids (coolant and oils) | X | Eip | |||||
| Removing refrigerant by suction, evacuating and filling | X(1) | Eip | |||||
| Refrigerant line directly on air-conditioning compressor | X(2) | Eip | |||||
| Air conditioning performance test (for checking the pressure transmitter, using air conditioning service unit) | X | Eip | |||||
| Refrigerant line in peripheral vehicle equipment (work that is not directly on the air-conditioning compressor, without opening the refrigerant circuit, e.g. loosening and securing refrigerant lines). | X | Eip | |||||
| Work in the engine/chassis area for which the cover plate on the power electronics must be removed. | X | Eip | |||||
| Work in the engine area for which the cover plate must be removed and lines must be disconnected at the power electronics. | X(2) | HVT | |||||
| Work for which the engine is raised by up to approx. 20 cm (e.g. engine mountings). | X(1) | Eip | |||||
| Hydraulic pump for steering (12 V) | X | Eip | |||||
| Electric vacuum pump (12 V) | X | Eip | |||||
| Emissions inspection | X | Eip | |||||
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