Checklist for high voltage safety in electric and hybrid cars

Use this checklist with every repair task where the high-voltage system on an electric or hybrid car is to be disconnected, or where the battery pack may be damaged. Always follow the manufacturer's specific repair instructions rather than general rules of thumb.

§Before work begins

• 01Identify the car make and model, and find the specific disconnection procedure in the manufacturer's repair manual.
• 02Confirm that the performing employee has relevant certification for high-voltage work.
• 03Cordon off and mark the work area clearly.
• 04Switch off the ignition and remove the key/key card from the car's reach.
• 05Follow the manufacturer's prescribed sequence for disconnecting service ports.
• 06Observe the manufacturer's specified discharge time so capacitors can be discharged.
• 07Put on insulating gloves (correct class) and use only insulating, approved tools.

§Safety measurement before work

• 01Measure the voltage between the relevant poles with a calibrated measuring instrument of suitable safety class.
• 02Confirm that the voltage is below the safe limit before work continues.
• 03Document the measurement (time, value, person performing) in the case papers.
• 04Only begin the repair when the measurement has been confirmed and documented.

§For suspected damaged battery pack

• 01Perform visual inspection for deformation, smell or leakage.
• 02Place the car in a quarantine zone at distance from other vehicles and buildings when cell damage is suspected.
• 03Contact the manufacturer or specialist before the battery pack is touched further.
• 04Confirm that the workshop has fire extinguishing equipment suitable for lithium battery fires nearby.