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Questions and Answers
What color are the HV cables that run between the inverter assembly and the alternator?
What color are the HV cables that run between the inverter assembly and the alternator?
What color are the cables that run between the inverter assembly and the alternator?
What color are the cables that run between the inverter assembly and the alternator?
What is the minimum voltage rating for the gloves that must be used when repairing a hybrid or electric vehicle?
What is the minimum voltage rating for the gloves that must be used when repairing a hybrid or electric vehicle?
What is the minimum voltage rating of HV gloves that should be used when repairing a hybrid or electric vehicle?
What is the minimum voltage rating of HV gloves that should be used when repairing a hybrid or electric vehicle?
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What type of instrument is used to check for continuity between the HV cables and the vehicle chassis?
What type of instrument is used to check for continuity between the HV cables and the vehicle chassis?
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What organization administers and coordinates the U.S. voluntary standardization and conformity assessment system?
What organization administers and coordinates the U.S. voluntary standardization and conformity assessment system?
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What type of tool is used to check for continuity between the HV cables and the vehicle chassis?
What type of tool is used to check for continuity between the HV cables and the vehicle chassis?
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What color are the warning labels used to identify HV components?
What color are the warning labels used to identify HV components?
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What organization administers and coordinates the U.S. voluntary standardization and conformity assessment system?
What organization administers and coordinates the U.S. voluntary standardization and conformity assessment system?
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What type of warning labels are used to identify high-voltage components?
What type of warning labels are used to identify high-voltage components?
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Study Notes
- High-voltage (HV) components are identified with warning labels.
- HV cables are identified by color of the plastic conduit and are indicated by the following colors: blue or yellow—up to 60 volts (not a shock hazard, but an arc will be maintained if a circuit is opened).
- When the belt starter alternator assembly is installed, the three blue cables run between the inverter assembly and the alternator.
- The yellow cable is part of the electric power steering system on a Toyota/Lexus vehicle.
- Low voltage, such as the 12–14 volts used in conventional vehicles, does not represent a shock hazard and it is safe to handle.
- Voltages between 14 and 60 volts do not present a shock hazard, but an arc can occur if a connector carrying current is opened.
- High voltage, over 60 volts, does create a shock hazard and all precautions must be adhered to prevent personal injury.
- Electric shock can occur from contact with electrically charged (“hot” or “live”) HV components, such as the battery box or electric motor.
- The HV cables can be easily identified by their distinctive orange color, and contact with them can be avoided.
- For a safe working environment, be sure the work area is clean and dry, and that HV warnings and safety cones are posted. Additional precautions, such as a roof cone or warning tape, are also recommended.
- When repairing a hybrid or electric vehicle, a clearly defined safety zone needs to be established in the area where the vehicle is being worked on.
- Before working on the HV system of a hybrid electric vehicle, ensure that HV lineman’s gloves are available. Be sure that the gloves are rated at least 1,000 volts and class “0” by ANSI/ASTM.
- The American National Standards Institute (ANSI) is a private, nonprofit organization that administers and coordinates the U.S. voluntary standardization and conformity assessment system.
- ANSI International, originally known as the American Society for Testing and Materials (ASTM), was formed over a century ago to address the need for component testing in industry.
- The Occupational Safety and Health Administration (OSHA) requirements specify that the HV gloves get inspected every six months by a qualified glove inspection laboratory.
- Leather protectors should be used to protect the HV rubber gloves from damage. Other personal protection equipment such as an insulated fiberglass pole and a 10-foot insulated blanket should be available outside the safety zone in the event of an accident.
- Hybrid and electric vehicles are equipped with electrical systems whose voltages can exceed 600 volts DC.
- A category three (CAT III) certified digital multimeter is required for making measurements on these high-voltage systems.
- The higher the category (CAT) rating of the meter, the greater the level of protection to the technician when measuring high-energy voltage.
- Under each category, there are various voltage ratings.
- A megohmmeteror insulation tester is used to check for continuity between the HV cables and the vehicle chassis.
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