Isolation From Power Supply Prior To Performing Maintenance Tasks On E-Hybrid Vehicles
WARNING: This page is about a different variant/trim than selected.
Information
Observe the following specifications for all the work described:
- Country-specific, national, legal and official regulations,
- Local restrictions and export restrictions,
- Manufacturer specifications from component and vehicle manufacturers,
- Component-specific specifications.
These strict specifications apply in particular to:
- Storage, installation and removal, transport and disposal of vehicles, assemblies, operating materials and auxiliary materials,
- Handling defective and potentially hazardous vehicles as well as assemblies,
- Handling battery electric vehicles and high-voltage components.
Consider relevant and qualified sources of information such as local authorities, competent importer, associations and specialized websites for this purpose. Only deliver items to be disposed of to authorized reception points.
These regulations to be complied with have to be checked, observed and, if necessary, documented by the person responsible for the vehicle for all life phases and work.
Information
Specific qualifications are required for carrying out the maintenance tasks listed here.
The minimum 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 tasks according to instructions and under the supervision of the HVT.
- Work on and around 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 an eip.
- 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.
Information
Definition of isolating high-voltage system from power supply:
- Isolate system from power supply
- Ensure that system cannot be switched back on again
- Verify absence of electric charge
Information
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 de-energized high-voltage system on instruction from the HVT.
HVT = High Voltage Technician
- The high voltage technician's qualifications authorize him to do the same as an eip. The HVT is additionally authorized to perform certified measurements to verify isolation of the high-voltage system from the power supply. The HVT is authorized to do the following work on the isolated high-voltage system.
- Isolate system from power supply
- Ensure that system cannot be switched back on again
- Verify and document safe isolation from power supply
- Delegate work on the isolated high-voltage system to the eip
- 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 authorized 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 authorization 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 deactivate the high-voltage system 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 high-voltage system from power supply | HVT | ||
| When working on the following components | Get the HVT to isolate the high-voltage system from the power supply before starting work? | Minimum qualification: | |
| yes | no | ||
| Electric machine with decoupler | X | Eip1 | |
| Power electronics | X | Eip1 | |
| 12 V service disconnector | X | HVT | |
| Removing and installing HV battery | X | HVT | |
| Removing and installing HV battery control unit | X | HVT | |
| Cooling line outside of HV battery | X | Eip | |
| Cooling plates in the HV battery | X | HVE | |
| Removing and installing E-box | X | HVT | |
| High-voltage lines | X | Eip1 | |
| Charging socket | X | Eip1 | |
| High-voltage charger | X | Eip1 | |
| Electric passenger compartment heater | X | Eip1 | |
| Evaporator, HV valve block | X | Eip1 | |
| Front-axle carrier reinforcement | X | Eip1 | |
| Electric air-conditioning compressor | X | Eip1 | |
| Pressure regulator for decoupler | X | Eip | |
| Equipotential bonding lines | X | HVT | |
| Work on the underbody if the HV lines at the power electronics must be disconnected. | X | Eip1 | |
| Work on the coolant system with high-voltage components | X | Eip | |
| Measurement of insulation resistances | X | HVT | |
| Measurement at pilot line (HV interlock) | X | HVT |
Conventional work close to high-voltage components
| When working on the following components | Get the HVT to isolate the high-voltage system from the power supply before starting work? | Minimum qualification | |
|---|---|---|---|
| yes | no | ||
| Removing and installing design cover | X | Eip | |
| Spark plugs | X | Eip | |
| Left catalytic converter | X | Eip | |
| Right catalytic converter | X | Eip | |
| Exhaust system | X | Eip | |
| Cardan shaft | X | Eip | |
| Removing and installing engine with transmission | X | Eip1 | |
| Removing and installing engine | X | Eip1 | |
| Removing and installing transmission | X | Eip | |
| Fuel tank | X | Eip | |
| Front unit carrier | X | Eip | |
| Power-steering gear | X | Eip | |
| Rear axle housing | X | Eip1 | |
| 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 | Eip | |
| Body repair work (assembly work and dent removal) | X | Eip | |
| Working close to high-voltage components and high-voltage lines using lathe cutting, molding and sharp-edged tools or heat sources, such as welding, soldering, hot air and thermal bonding | X | Eip | |
| Removing and installing left headlight | X | Eip | |
| Removing and installing right headlight | X | Eip | |
| Removing and installing headlight lamps | X | Eip | |
| Removing and installing front stabilizer (PDCC) | X | Eip | |
| Removing and installing rear stabilizer with ePDCC | X | Eip | |
| Removing and installing ePDCC control unit | X | Eip |
General work
| When working on the following components: | Get the HVT to isolate the high-voltage system from the power supply before starting work? | Minimum qualification: | |
|---|---|---|---|
| yes | no | ||
| Removing and installing 12V battery | X | Eip | |
| Removing and installing 12 V control units or 12 V components | X | Eip | |
| Removing and installing 48 V auxiliary battery | X | Eip | |
| Removing and installing 48 V voltage converter | X | Eip | |
| Draining and filling fluids (coolant and oils) | X | Eip | |
| Removing refrigerant by suction, evacuating and filling | X | Eip | |
| Removing and installing A/C lines on electric air-conditioning compressor | X | Eip | |
| A/C lines in peripheral vehicle equipment (work that is not carried out directly on the air-conditioning compressor, without opening the refrigerant circuit, e.g. loosening and securing refrigerant lines). | X | Eip | |
| Air conditioning performance test (for checking the pressure transmitter, using air conditioning service unit) | X | Eip | |
| Work on the underbody close to where HV lines and/or HV components are installed. | X | Eip1 | |
| Work in the engine area close to where HV lines and/or HV components are installed. | X | Eip1 | |
| Work for which the engine must be raised (e.g. removing and installing engine mount). | X | Eip | |
| Power-steering gear | X | Eip | |
| Brake booster | X | Eip | |
| Emissions inspection | X | Eip |
Eip 1 AHVT must disconnect and connect the HV lines on the affected components.