I-CAR - Inter-Industry Conference on Auto Collision Repair Certified Electric Vehicle Repair Safety Questions and Answers

Question 1

A technician is preparing to disable the high-voltage system on an electric vehicle.
After turning off the ignition, removing the key fob, and disconnecting the 12V battery, what is the critical next step before physically touching any high-voltage components?

Accepted Answer

Remove the main high-voltage service disconnect plug.

Answer

Use a CAT III-rated multimeter to verify zero voltage at a high-voltage connection point.

Answer

Visually inspect all orange cables for damage.

Answer

Put on a standard pair of mechanic's gloves for protection.

Question 2

When working on or near any high-voltage component of an EV, what is the minimum class of insulated rubber gloves that is generally required according to I-CAR and industry standards?

Accepted Answer

Class 0 (1,500V DC rating)

Answer

Class 1 (11,250V DC rating)

Answer

Class 00 (750V DC rating)

Answer

Class 2 (25,500V DC rating)

Question 3

A collision-damaged EV arrives at the shop. The high-voltage battery case appears dented, and a faint, unusual sweet chemical odor is present. What is the MOST appropriate immediate course of action?

Accepted Answer

Isolate the vehicle in a designated outdoor area at least 50 feet away from any buildings or other vehicles and notify management.

Answer

Immediately push the vehicle inside the shop to begin the estimate.

Answer

Use a floor jack to lift the vehicle and get a better look at the battery.

Answer

Connect a scan tool to check for battery-related diagnostic trouble codes.

Question 4

Which of the following is the primary purpose of a "Lockout/Tagout" (LOTO) procedure when servicing an electric vehicle?

Accepted Answer

To prevent accidental re-energization of the high-voltage system while it is being serviced.

Answer

To document the technician who is working on the vehicle.

Answer

To secure the vehicle's wheels and prevent it from rolling.

Answer

To alert the vehicle's owner that high-voltage repairs are in progress.

Question 5

A technician has properly disabled an EV's high-voltage system, removed the service disconnect, and waited the manufacturer-specified time. What is the mandatory final verification step before any repair work on HV components can begin?

Accepted Answer

Perform a "live-dead-live" test with a CAT III or higher rated voltmeter to confirm zero voltage.

Answer

Check the dashboard for any warning lights.

Answer

Listen for the sound of high-voltage contactors disengaging.

Answer

Ensure the 12V battery reads below 12.0 volts.

Question 6

Which of the following safety components is designed to automatically isolate the high-voltage battery from the rest of the vehicle's systems in milliseconds if a high-voltage connector is improperly disconnected?

Accepted Answer

The High-Voltage Interlock Loop (HVIL)

Answer

The service disconnect plug

Answer

The manual maintenance switch

Answer

The pyro-fuse disconnect