61 00... Safety information for handling electric/hybrid vehicles

All repair work on high-voltage components must be performed by qualified technicians  (qualification: training for work on high-voltage vehicles).

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.

• Note operating instructions for handling high-voltage battery units.
• 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.
• In the event of damage (mechanical, thermal) transition metal oxides, carbon, electrolyte solvents and their products of decomposition may be released.

  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.

• Prevent escaping substances from entering drains, pits and the sewer system.
• Collect any material that is discharged and have it disposed of according to the work instruction, wear acid-resistant protective clothing when doing so.
• Notify the fire brigade if fire breaks out, clear the area immediately and make accident scene safe.

  Attempt to extinguish the fire without putting persons in danger (suitable extinguishant: water and water foam).

• A cut 2nd emergency separation point must be repaired with a butt connector.

• Each job on the vehicle must be assigned by appropriately trained personnel. Before work is started, this electrician must place the vehicle in the operating condition required to perform the relevant activity. The qualified personnel's instructions and directions absolutely must be followed. No work may be carried out without this qualified personnel 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. no accelerator pressing and 
  5. speed < 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 qualified personnel (high-voltage safety connector Off) and secured against unauthorized return to service (padlock).
• 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. Corresponding display in instrument cluster: High-voltage system switched off 

  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. risk of serious injury or death.  Before work begins, a qualified electrician (1000 V DC) must verify that the system is de-energized using appropriate measuring devices and procedures.

  => In this case, a qualified electrician or 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.
• The vehicle must not be charged and refuelled at the same time.
• No repair work may be carried out at the high-voltage system when a combustion engine is currently running.
• The coolant pump and electric fan can be switched on automatically when terminal 15 is switched on or the high-voltage battery unit is charging. The following preliminary work must be performed prior to working on the electric fan to prevent injuries caused by an automatically activated electric fan.
  1. Disconnect any connected charging cables.
  2. Switch off terminal 15.
  3. Disconnect high-voltage system from power.
  4. Disconnect plug connections from the electric fan.

• Identifiable mechanical damage to or tampering with high-voltage components must be reported immediately to the qualified personnel 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.).
• Check all connectors and plug connections of the high-voltage components for damages after disconnecting them and/or before connecting them.
• High-voltage cables (orange coating) and their connectors and ferrules may not  be repaired. If damaged, a cable must always be replaced completely.
• High-voltage cables must not be twisted or kinked. Crushed high-voltage cables must be replaced.
• After a bending operation, the resulting bend may only be returned to its original shape. To repeat bending at the same place is not permitted.
• When working in the vicinity of high-voltage components (identified accordingly with warning stickers and orange-colored 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. The measurement (insulation measurement) is performed by the vehicle automatically and therefore manual measurement is not required.

  For a correct ground connection, the retaining elements of high-voltage components must not be painted. Follow further PAINTING NOTES .

• Removed high-voltage battery units must be stored in a manner that protects them from misuse and damage.

Potential compensation wires, high-voltage cable, and the battery earth lead of the electrical machine electronics have a safety screw connection.

• Clean contact faces and have then checked by a second person.
• Tighten down screws/bolts to specified torque.
• Have tightening torque checked by a second person.
• Both persons must document that the work has been carried out correctly in the vehicle records.