Monday, June 9, 2014

3.3.2 Operation and Maintenance

When working on high-voltage systems, always ensure that the main switch is in the “off” position and tag it and/or lock it in that position so that no one else can turn the vehicle on.

Always assume that high-voltage electrical components are live, even when the vehicle main switch is in the off position. Use a volt meter to check before touching any electrical component.

Always use appropriate personal protective equipment, such as high-voltage gloves, when working on high-voltage systems. Follow the safety recommendations in the manufacturer’s service manual.

Never wear jewelry when working around high-voltage systems.
Always reinstall high-voltage covers and barriers. Reapply high-voltage labels if they are removed or damaged.

Do not ignore warnings from the ground fault monitoring system. Follow instructions in the service manual to isolate and repair the source of the fault. Unrepaired ground faults can cause shocks or electrocution to vehicle occupants or service technicians.

High-voltage electrical cables are designed with special shielding and insulation, and the exterior cover should be made from orange colored material. Always replace high-voltage wiring and harnesses with parts as specified by the manufacturer. Do not manufacture your own high-voltage harnesses or substitute non-approved parts.

Remember that high voltage will always be present inside a traction battery or ultracapacitor pack (if vehicle has a hybrid-electric drive system) even when the main switch is off or automatic shutdown has occurred. Special tools and procedures are required to work safely inside the battery/ultracapacitor pack. Do not open the battery/ultracapacitor pack cover unless you have been trained to work safely with live high voltage.

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