Hybrid and Electric Vehicle High Voltage Safety Inspection Checklist

This hybrid/electric vehicle high voltage safety inspection checklist ensures technician safety when servicing vehicles with high voltage systems (typically 200-800 volts). Electrocution from improper HV system service is fatal. Aligned with SAE J1766 hybrid vehicle safety standards, OSHA 29 CFR 1910 Subpart S electrical safety requirements, and OEM hybrid service safety protocols. Only properly trained and insulated technicians should perform HV system work.

Industry: Automotive Service
Frequency: Before Any Hybrid/EV Service
Estimated Time: 15-25 minutes
Role: Hybrid/EV Certified Technician
Total Items: 28
Compliance: SAE J1766 (Hybrid Electric Vehicle Electrical Safety), OSHA 29 CFR 1910 Subpart S (Electrical Safety), NFPA 70E (Electrical Safety in the Workplace), OEM Hybrid/EV Service Safety Protocols, SAE J2954 (Wireless EV Charging)

Technician Training and Personal Protective Equipment

Verify technician qualifications and proper PPE before any HV system work.

Technician hybrid/EV certification current and specific to this vehicle manufacturer?
Class 0 (1,000V) or higher insulated electrical gloves available and in date (6-month inspection)?
Arc-rated face shield and safety glasses worn for all HV disconnect operations?
Insulated hand tools (1,000V rated minimum) available for HV system work?
All metal jewelry, watches, and rings removed from technician before HV work begins?

High Voltage System Isolation and Verification

Properly isolate HV system and verify zero voltage before beginning service.

HV service disconnect plug removed per OEM procedure and stored away from vehicle?
Required capacitor discharge wait time observed after disconnect (typically 5-15 minutes per OEM)?
Service plug lockout/tagout applied to prevent accidental reconnection during service?
HV system voltage verified at zero volts with CAT III rated multimeter before touching any orange cables?
12V auxiliary battery disconnected negative terminal first per OEM recommendation?

High Voltage Cable and Connector Inspection

Inspect HV cables and connectors for damage that could cause arc flash or electrocution.

All orange high voltage cables intact with no visible damage, cuts, or abrasion to insulation?
HV connectors fully seated and locked with no corrosion on terminals?
No evidence of HV coolant leaks (pink or blue coolant on or near HV battery or inverter)?
HV cable routing correct with proper separation from 12V wiring and exhaust components?
All HV component shields and protective covers intact and properly installed?

HV Battery Pack and Cooling System

Inspect HV battery pack condition and dedicated cooling system integrity.

HV battery case structurally intact with no cracks, impact damage, or swelling?
HV battery cooling air vents clear and unobstructed (typically in rear seat or cargo area)?
HV cooling system fluid level correct in dedicated HV coolant reservoir?
HV battery cooling pump operating correctly with no unusual noise?
No evidence of collision damage to HV battery mounting or underbody protection?

High Voltage Interlock Testing and Service Completion

Test HV interlock system and complete post-service safety verification.

HV interlock loop continuity tested and functioning correctly?
No high voltage system fault codes stored after service completion?
HV service plug reinstalled correctly with positive click engagement?
Vehicle enters READY mode normally with no warning lights related to HV system?
All HV shields, covers, and protective components reinstalled before vehicle movement?
Complete HV system service documented with safety procedures followed and verification testing performed?
Technician hybrid/EV certification verified and documented on repair order?
All HV warning labels and orange safety markings intact and visible after service?

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Why Use This Hybrid and Electric Vehicle High Voltage Safety Inspection Checklist?

This hybrid and electric vehicle high voltage safety inspection checklist helps automotive service teams maintain compliance and operational excellence. Designed for hybrid/ev certified technician professionals, this checklist covers 28 critical inspection points across 5 sections. Recommended frequency: before any hybrid/ev service.

Ensures compliance with SAE J1766 (Hybrid Electric Vehicle Electrical Safety), OSHA 29 CFR 1910 Subpart S (Electrical Safety), NFPA 70E (Electrical Safety in the Workplace), OEM Hybrid/EV Service Safety Protocols, SAE J2954 (Wireless EV Charging), UK IET Wiring Regulations for EV Charging, India AIS-138 Electric Vehicle Safety Requirements. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Hybrid and Electric Vehicle High Voltage Safety Inspection Checklist cover?

This checklist covers 28 inspection items across 5 sections: Technician Training and Personal Protective Equipment, High Voltage System Isolation and Verification, High Voltage Cable and Connector Inspection, HV Battery Pack and Cooling System, High Voltage Interlock Testing and Service Completion. It is designed for automotive service operations and compliance.

How often should this checklist be completed?

This checklist should be completed before any hybrid/ev service. Each completion takes approximately 15-25 minutes.

Who should use this Hybrid and Electric Vehicle High Voltage Safety Inspection Checklist?

This checklist is designed for Hybrid/EV Certified Technician professionals in the automotive service industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.