Hybrid and EV High Voltage Safety Service Checklist

This hybrid and EV high voltage safety service checklist ensures all technicians follow mandatory safety procedures when servicing vehicles with high voltage electrical systems. HV systems in hybrid and EV vehicles operate at 200-800 volts DC - enough to cause cardiac arrest from brief contact. Only technicians with documented HV safety training should service HV components. Aligned with OSHA 29 CFR 1910.333 electrical safety standards, NFPA 70E arc flash requirements, and OEM HV safety procedur

Industry: Automotive Service / EV Service
Frequency: Every HV System Service / Any Work Near Orange HV Cables
Estimated Time: 20-30 minutes
Role: OEM-Certified HV Technician / Master EV Technician
Total Items: 28
Compliance: OSHA 29 CFR 1910.333 (Electrical Safety Work Practices), NFPA 70E (Electrical Safety in the Workplace), SAE J1772 EV Connector Standard, IEC 61851 EV Charging Safety, OEM HV Safety Training Certification Requirements

PPE and Technician Qualification

Verify technician qualification and correct PPE before any HV work begins.

Technician holds valid OEM or OSHA-recognized HV safety certification for this vehicle system?
Class 0 or Class 00 insulating rubber gloves worn and within inspection and test date?
Rubber gloves air-tested for pinhole leaks by rolling cuff and inflating before use?
Arc-flash rated face shield or safety glasses worn when working near energized HV components?
All metal jewelry, rings, and watches removed before HV service begins?

High Voltage System Isolation

Isolate HV system before any service to prevent electrocution.

HV service plug (manual service disconnect) removed and locked out per OEM procedure?
Lockout/tagout device applied to service plug port to prevent accidental reconnection?
Required wait time after service plug removal observed (5-15 minutes for capacitor discharge)?
HV bus voltage measured with CATIII-rated multimeter and confirmed below 60V before touching HV components?
All orange HV cables and connectors inspected for damage and no contact with orange cables during service?

Insulation Resistance and System Integrity

Verify HV system insulation integrity to identify leakage before returning to service.

Insulation resistance test performed with megohmmeter confirming adequate resistance (minimum 10 megaohm)?
No HV system isolation fault codes in HV battery, inverter, or BMS module?
HV ready indicator / charge indicator behavior verified as normal after service plug reinstallation?
No voltage detected between HV terminals and vehicle chassis (isolation check)?
HV interlock loop (HVIL) continuity confirmed - system refuses to operate if interlock is broken?

Return to Service Verification

Verify complete HV system function before returning vehicle to customer.

Service plug reinstalled with audible click in correct orientation?
Vehicle achieves READY mode with no HV warning lights?
HV system charges, propels, and regenerates normally on test drive?
No HV battery, inverter, or powertrain warning lights after service and test drive?
All HV access covers, shields, and underbody panels reinstalled and secured?

HV Safety Documentation and Emergency Preparedness

Document HV service and ensure emergency response preparedness.

All HV service work documented including technician certification number and safety procedures followed?
OEM emergency response guide available in shop for first responders if HV incident occurs?
Shop arc flash safety plan documented and technicians trained per NFPA 70E?
Class D or appropriate dry chemical fire extinguisher accessible in HV work area?
Customer advised not to expose HV components to flood water and to call specialist if HV warning appears?
HV technician certification documentation on file in shop records?
Shop HV liability insurance and emergency response procedures reviewed annually?
All technicians who service HV vehicles have completed OEM or OSHA-recognized HV safety training within last 3 years?

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Why Use This Hybrid and EV High Voltage Safety Service Checklist?

This hybrid and ev high voltage safety service checklist helps automotive service / ev service teams maintain compliance and operational excellence. Designed for oem-certified hv technician / master ev technician professionals, this checklist covers 28 critical inspection points across 5 sections. Recommended frequency: every hv system service / any work near orange hv cables.

Ensures compliance with OSHA 29 CFR 1910.333 (Electrical Safety Work Practices), NFPA 70E (Electrical Safety in the Workplace), SAE J1772 EV Connector Standard, IEC 61851 EV Charging Safety, OEM HV Safety Training Certification Requirements, UK BS IEC 17409 EV Safety Standards, India AIS-138 BEV and HEV Safety Standards. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Hybrid and EV High Voltage Safety Service Checklist cover?

This checklist covers 28 inspection items across 5 sections: PPE and Technician Qualification, High Voltage System Isolation, Insulation Resistance and System Integrity, Return to Service Verification, HV Safety Documentation and Emergency Preparedness. It is designed for automotive service / ev service operations and compliance.

How often should this checklist be completed?

This checklist should be completed every hv system service / any work near orange hv cables. Each completion takes approximately 20-30 minutes.

Who should use this Hybrid and EV High Voltage Safety Service Checklist?

This checklist is designed for OEM-Certified HV Technician / Master EV Technician professionals in the automotive service / ev 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.