Battery Electric Vehicle Service Pre-Job Inspection

Pre-job inspection for battery electric vehicle service to verify high-voltage hazard controls, PPE, lockout/tagout, and vehicle isolation before work begins.

Job Scope and Authorization

• Work order identifies BEV service task and vehicle
  Verify the work order matches the vehicle make/model, VIN or unit number, and the specific service to be performed.
• Technician is qualified for high-voltage BEV service
  Confirm the person performing the work is trained and authorized for high-voltage systems and energy control procedures.
• Service area is controlled and free of unauthorized personnel
  Verify the work area is restricted to authorized personnel only and that bystanders are kept clear.

High-Voltage Hazard Controls

• High-voltage warning labels and orange cabling are intact and visible
  Inspect for damaged, missing, or obscured high-voltage labels, covers, or orange cables indicating energized circuits.
• No visible damage, swelling, leakage, or odor from battery pack or HV components
  Check the battery enclosure, connectors, and exposed high-voltage components for physical damage, electrolyte leakage, heat, smoke, or unusual odor.
• Appropriate insulated tools and voltage-rated test equipment are available
  Confirm insulated hand tools and properly rated meters/test leads are present and suitable for the task.
• Work area has required barriers, signs, or cones in place
  Verify the area is marked to prevent unintended entry and to warn of high-voltage service activity.

PPE Verification

• Voltage-rated gloves are available and within inspection date
  Verify insulating gloves are the correct class for the task and have current inspection status.
• Leather protectors and required glove liners are available
  Confirm the required outer protectors and any specified liners are present and in usable condition.
• Arc-rated face and body protection is available as required by task
  Verify face shield, safety glasses, and arc-rated clothing are selected based on the job hazard assessment and manufacturer guidance.
• PPE is clean, undamaged, and properly donned
  Check for tears, contamination, cracks, or other defects and confirm PPE is being worn correctly.

Lockout/Tagout and Vehicle Isolation

• Vehicle is placed in the correct safe state per manufacturer procedure
  Confirm ignition is off, key/fob is controlled, and the vehicle is in the required state before isolation begins.
• 12V and high-voltage isolation steps completed
  Verify the required disconnect, service plug, or shutdown steps have been completed per OEM procedure before any high-voltage work.
• Lockout/tagout devices applied and identified
  Confirm locks, tags, and any required group lock devices are applied to the energy isolation points and identify the authorized employee(s).
• Stored energy has been discharged and verified zero energy state
  Verify waiting period, discharge, and test-for-zero-voltage steps are completed using the approved procedure and meter.
• Vehicle cannot roll, move, or be energized unexpectedly
  Confirm wheels are chocked or otherwise secured if required, and that the vehicle is protected from inadvertent movement or restart.

Pre-Work Verification and Sign-Off

• Pre-job hazards and controls reviewed with the team
  Confirm the technician or crew reviewed the hazards, controls, emergency response steps, and stop-work authority.
• Inspection completed and approved to begin work
  Final authorization to proceed after all critical items have passed.
• Inspector signature