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When a hybrid or electric vehicle is involved in a collision, there is a chance that the battery and its contents are compromised. This can pose a major threat for collision repairers. As a precaution, all high-voltage batteries should be treated as though they are unstable.
As a result of a collision, vehicle components may have been pushed into the battery or high-voltage wiring harness. Technicians should avoid touching any vehicle components that come in contact with the high-voltage battery or wiring harness. The major dangers of damaged batteries and wiring are electrocution and combustion.
If the battery has been damaged or punctured, the vehicle should be isolated in a place that is at least 50 feet away from other flammable or combustible materials. This is due to some batteries being extremely difficult to extinguish once they are on fire.
The technician should also place any object that could start the engine or hybrid system away from the vehicle. This means that key fobs and high-voltage battery disconnects should be locked in a container and moved out of range from the vehicle. Always remember that once a high-voltage battery is disabled and discharged, the vehicle should never be rolled on its wheels, as this can generate voltage to the battery system.
To ensure technician safety, proper high-voltage personal protection equipment should be used, such as gloves (rubber and leather), boots, face shield, and safety glasses. Technicians should always be fully trained and read OEM high-voltage disable procedures and precautions before working on hybrid and electric vehicles.
Additional I-CAR Collision Repair News you may find helpful:
- Enhancements to OEM Hybrid and Electric Vehicle Disable Search
- How To Use The OEM Hybrid And Electric Vehicle Disable Search
- Hybrid And Electric Vehicle Article Hotspot
- Welding On A Hybrid Or Electric Vehicle
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Article validated in 2025