Hybrid Drive Systems: Service Precautions
High Voltage Electrical System General Warnings
• Always check with the importer before performing any work on the hybrid system should there be any questions regarding the terms "technician trained in electrical systems", "high voltage technician", "high voltage expert"" or hybrid systems.
Before beginning work on the high voltage system, a high voltage technician, refer to , must disable the high voltage system. Refer to => [ High Voltage System, Disabling ] High Voltage System, Disabling.
For a list of work requiring the high voltage system to be disabled,
Read and follow the information below when disabling the high voltage injury to reduce the risk of fatal injury
• Only a qualified technician (high voltage technician) should disable the high voltage electrical system.
• The high voltage technician makes sure the system is disabled and cannot turn on again.
• The high voltage technician makes sure the system cannot turn on again by safekeeping the key, the service plug and the pilot line cable.
• The high voltage technician puts a sign on the vehicle saying the voltage is disabled.
• Only technicians who are specially trained in electrical systems may perform work on vehicles with a high voltage electrical system (for example a maintenance service, changing a tire, working on the convenience system electronics). If there is any uncertainty, discuss with the responsible high voltage technician.
• A high voltage technician must disable the system before any work can be performed on the high voltage electrical system or any other service work to the body.
• Only a High Voltage Expert (HVE) may perform repairs to the vehicle if it is not possible to disable the high voltage electrical system.
• Individuals with electrical medical equipment must not work on vehicles with a high voltage electrical system. Examples of electrical medical equipment include pain medication pumps, implanted heart defibrillators, pacemakers, insulin pumps and hearing aids.
Working with high voltage cables
• Do not support yourself or lay tools on the high voltage cable or on any of its components.
• Do not work near any high voltage components and cables with any cutting, crimping or sharp edged tools.
• When working near high voltage components and high voltage cables, do not use tools that generate heat, that have sharp edges or that are used for cutting or shaping, such as welding, soldering, hot air or thermal adhesive equipment.
• Do not excessively bend or flex high voltage cables.
• Always contact a high voltage technician if there are questions or if something is not clearly understood.
• Check the contact surfaces on the potential equalization cables before installation.
• The contact surfaces must be clean. There must be no rust or grease on them.
• If necessary, clean the contact surfaces using the contact surface cleaning set (VAS 6410).
Observe the Following Precautions When Working on the High Voltage System
• Only technicians who are trained in electrical systems should work on hybrid vehicles.
• When working on a hybrid vehicle, always visually inspect the hybrid components in the area where the work is being performed.
• Do not excessively bend or flex high voltage cables.
• Always contact a high voltage technician or a high voltage expert specializing in electrical systems if anything unusual occurs or if anything is unclear.
• When working near high voltage components and high voltage cables, do not use tools that generate heat, that have sharp edges or that are used for cutting or shaping, such as welding, soldering, hot air or thermal adhesive equipment.
• All the work described is referencing removing, installing and replacing the individual components.
Working On The High Voltage System
Conventional Work Near High Voltage Components
General Work
Qualification Explanation
