Working On High Voltage Vehicles

Summary

In this tech tip, Mark from Garage Gurus explains essential safety protocols for working with hybrid and electric vehicles, which often feature high-voltage systems. He emphasizes the importance of using the right equipment, including a 1000-volt rated digital meter and high-voltage gloves, to protect against potentially lethal voltages. Mark demonstrates how to properly test the gloves for leaks and discusses the need for safety gear like rubber-soled boots and safety glasses. By following service information and using the correct tools, technicians can safely disable and work on these vehicles.

Takeaways

• 😀 Hybrid and electric vehicles are becoming more common in garages, requiring technicians to be familiar with high-voltage safety protocols.
• ⚡ The voltages in hybrid and electric vehicles can be lethal, with battery packs holding up to 300 volts DC and running as high as 500 volts during operation.
• 🛠️ To disable the high-voltage system during service, technicians need to follow specific safety procedures and have the right equipment.
• 📜 Always follow the service information instructions when disabling high-voltage systems in hybrid or electric vehicles.
• 🔌 High-voltage meters used for servicing must have a category 3 voltage rating, meaning they can endure extended connections to high-voltage systems.
• 🧤 High-voltage gloves are essential for protection, with a rubber glove providing primary protection and a leather glove worn on top for added safety.
• 📅 High-voltage gloves must be inspected before each use by checking for air retention and verifying their date code for safety.
• ⚠️ A hole in the protective gloves could allow high voltage to pass through, similar to a spark jumping out of a damaged spark plug boot.
• 👓 Safety glasses and rubber-soled boots are also required to complete the essential personal protective equipment for working with high-voltage systems.
• 🔧 Following the correct procedures and using the proper equipment ensures both technician safety and effective service when working with high-voltage systems in hybrid and electric vehicles.

Q & A

What is the primary safety concern when working with hybrid and electric vehicles?

The primary safety concern is the high voltage in the vehicle's battery pack, which can reach voltages of up to 500 volts. These voltages are lethal if not handled properly.

What is the minimum voltage rating required for the digital meter used to measure high-voltage systems?

The digital meter must have a category 3 voltage rating and be capable of handling up to 1000 volts.

What is the purpose of high-voltage gloves in vehicle maintenance?

High-voltage gloves provide essential protection from electrical shock by insulating the technician from the vehicle's electrical system while performing service procedures.

How can a technician ensure that high-voltage gloves are safe to use?

Before each use, the technician should shake air into the gloves, roll up the wrist tightly, and check if the glove holds air. If it holds air without leaking, the glove is safe to use.

What additional layer of protection should be worn over the rubber high-voltage gloves?

Leather gloves should be worn over the rubber high-voltage gloves to prevent physical damage to the rubber gloves while working on the vehicle.

Why is it necessary to follow service information procedures when disabling the high-voltage system in a hybrid or electric vehicle?

Following service information procedures ensures that the high-voltage system is safely disabled, reducing the risk of electrical shock and ensuring proper service of the vehicle.

What is the recommended voltage range for the battery packs in hybrid and electric vehicles?

Battery packs in hybrid and electric vehicles typically hold at least 300 volts DC, and the voltage can rise as high as 500 volts when the engine is running.

What type of protective footwear should technicians wear when working with high-voltage systems?

Technicians should wear rubber-soled boots, which help provide insulation and reduce the risk of electrical shock while working around high-voltage systems.

How should the high-voltage gloves be tested for safety?

The gloves should be tested by inflating them with air, ensuring that they hold the air without any leaks. If they do, the gloves are safe for use.

What is the significance of the date code on the high-voltage gloves?

The date code on the gloves indicates when they were manufactured and is used to determine when the gloves need replacement or testing, according to OSHA guidelines.