Hybrid Drive Systems: Service Precautions

61 00 ... Safety Information On Handling Hybrid Cars

Hybrid cars have a high-voltage electrical system, in respect of which special safety regulations must be observed:

1. Qualification:
All repair work on high-voltage component may only be performed by specially trained electricians (qualification: electrician for high-voltage systems in intrinsically safe vehicles). 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 stickers 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:

- Water must be used as an extinguishant for vehicle and/or battery fire.
- Do not under any circumstances touch open high-voltage cables and high-voltage components on damaged vehicle before shutting down the high-voltage electrical system.
- Danger to life from damaged high-voltage battery unit due to escaping fluids (electrolyte), noxious vapours and risk of burning due to possibly impending thermal events.

Appropriate protective gear must be used.

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

4. Measures before starting work:

- Each job on the vehicle must be assigned by an appropriately trained electrician. Before work is started, this electrician must place the vehicle in the operating condition required to perform the relevant activity. This electrician's instructions and directions absolutely must be followed. No work may be carried out without this electrician being consulted first.
- 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 less than 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 an electrician (high-voltage safety connector Off) and secured against unauthorized return to service (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. the corresponding display appears in the instrument panel Hybrid system switched off

or

2. the safety battery terminal (SBK) is activated

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 diagnosis 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. Danger to life. 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 carry out any work whatsoever on high-voltage components while the batteries are 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.

5. Measures during/after activities:
- Identifiable mechanical damage to or tampering with high-voltage components must be reported immediately to the electrician in charge.
- When carrying out any work on the high-voltage system, it is prohibited to drive externally all the drive train components (wheels, gearbox, 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 connector may only be used if the "Power Electronic Box Cover" is fully installed.
- High-voltage cables (orange coating) and their connectors and ferrules 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 stickers and orange-coloured 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 equipotential bonding. For this reason, it is prohibited to operate any high-voltage components without them being correctly connected to body ground.

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

- Removed energy accumulators must be stored in a manner that protects them from misuse and damage.