Hybrid and EV High-Voltage Battery Inspection Checklist

This hybrid and EV high-voltage battery inspection checklist ensures safe and thorough assessment of battery pack health, cooling system function, and electrical isolation integrity. HV systems in hybrids and EVs operate at 100-800V DC - fatal at any contact. Aligned with OSHA 29 CFR 1910.137 electrical PPE standards, SAE J1772 EV standards, ASE L3 certification, and OEM HV battery diagnostic protocols.

Industry: Automotive Service - Electric and Hybrid Vehicles
Frequency: Annually / Per Battery Warning / Every 30,000 Miles
Estimated Time: 45-90 minutes
Role: ASE L3-Certified EV/Hybrid Technician
Total Items: 27
Compliance: OSHA 29 CFR 1910.137 (Electrical PPE), SAE J1772/J1773 Electric Vehicle Standards, NFPA 70E Electrical Safety in the Workplace, ASE L3 Hybrid/Electric Vehicle Certification, IEC 62133 Battery Safety Standard

HV Safety Setup and Lockout

Mandatory HV safety procedures before any battery inspection. Fatal voltage present.

HV-rated insulating gloves (Class 0 minimum) inspected and donned?
Only IEC 60900-rated insulated tools used for all HV system work?
HV service disconnect (MSD) removed and secured per OEM procedure?
HV bus voltage confirmed 0V with CAT III or IV voltmeter after MSD removal?
HV caution signage on vehicle to prevent accidental energization by others?

Physical Battery Pack Inspection

Inspect battery pack for damage, leaks, and mounting integrity.

Battery enclosure free from impact damage, deformation, or puncture?
No battery coolant leaks from cooling plates or hose connections?
Battery vent paths unobstructed and vent tubes undamaged?
Battery pack mounting hardware fully torqued with no loose or missing fasteners?
All HV orange cable conduits undamaged with no abrasion, pinching, or heat damage?
No corrosion on battery terminals or visible HV connectors?

State of Health and Cell Balance

Assess battery pack health with OEM diagnostic tools.

Battery State of Health (SOH) tested via OEM scan tool or approved battery analyzer?
SOH result within acceptable range per OEM specification?
Cell voltage balance within OEM specification (typically within 50-100mV between modules)?
No active Battery Management System fault codes present?
Battery warranty status checked - federal minimum 8 year/100,000 miles for capacity?

Thermal Management System

Verify cooling maintains battery within safe operating temperature range.

Battery coolant level correct and condition acceptable?
Battery cooling fan or pump operational and responsive to temperature changes?
Battery temperature sensors reading within acceptable range?
Battery air intake vents inside cabin clear and unobstructed?
No thermal management fault codes present?

HV Isolation Testing and System Restoration

Verify isolation integrity and restore HV system safely.

HV system isolation resistance tested and within specification (over 500 ohms per volt)?
No isolation fault codes after restoration?
MSD reinstalled correctly and locked per OEM procedure?
Vehicle Ready mode confirmed with no warnings after MSD reinstall?
HV PPE inspected and stored correctly after service?
HV battery inspection documented with SOH result, all fault codes, and findings?

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Why Use This Hybrid and EV High-Voltage Battery Inspection Checklist?

This hybrid and ev high-voltage battery inspection checklist helps automotive service - electric and hybrid vehicles teams maintain compliance and operational excellence. Designed for ase l3-certified ev/hybrid technician professionals, this checklist covers 27 critical inspection points across 5 sections. Recommended frequency: annually / per battery warning / every 30,000 miles.

Ensures compliance with OSHA 29 CFR 1910.137 (Electrical PPE), SAE J1772/J1773 Electric Vehicle Standards, NFPA 70E Electrical Safety in the Workplace, ASE L3 Hybrid/Electric Vehicle Certification, IEC 62133 Battery Safety Standard, UK PAS 1899 EV Battery Safety, India AIS-138 BIS EV Battery Standards. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Hybrid and EV High-Voltage Battery Inspection Checklist cover?

This checklist covers 27 inspection items across 5 sections: HV Safety Setup and Lockout, Physical Battery Pack Inspection, State of Health and Cell Balance, Thermal Management System, HV Isolation Testing and System Restoration. It is designed for automotive service - electric and hybrid vehicles operations and compliance.

How often should this checklist be completed?

This checklist should be completed annually / per battery warning / every 30,000 miles. Each completion takes approximately 45-90 minutes.

Who should use this Hybrid and EV High-Voltage Battery Inspection Checklist?

This checklist is designed for ASE L3-Certified EV/Hybrid Technician professionals in the automotive service - electric and hybrid vehicles 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.