Service and Parts Business

Service Manager Bulletin
TITLE:

Volvo Electric Vehicle Technical Live Voltage Permit to Work
GROUP:

NO:

ISSUING DEPARTMENT:

CAR MARKET:

00

018

Technical Training

United States and Canada

REVISIONS:

ISSUE DATE:

STATUS DATE:

Updated MSD isolation test measurement

2021-05-21

2022-04-04

Page 1 of 5
“Right first time in Time”
Update Notes: New page 5
Volvo’s commitment to safety includes taking into consideration the safety and preparedness of our
technicians, to properly service our vehicles.
Prior to the start of any high voltage battery work being performed, a risk assessment / safety check shall
be performed. This is also known as a “Permit to Work Live Voltage”.
The Permit to Work Live Voltage document serves as an overarching communication that fully
encompasses any and all electric vehicle (EV) battery repairs such as hybrids and battery electric
vehicles. This document is not intended to replace or supersede any national, state, or local safety codes
or regulations.
This Permit to Work Live Voltage document shall be filled out by the Advanced EV technician each time
live voltage work is performed. This, for example, can include battery disconnect unit replacements, and
internal high voltage battery repairs that require the lid to be removed. It also includes times when the
repair takes more than one day to complete, and the technician returns to the vehicle on subsequent days.
Volvo recommends the retailer retain a copy of this completed document for a period of (7) years or as
required by National, State and Local ordinances, whichever is greater.
*Retention of the Permit to Work Live Voltge document is required for Warranty and Technical auditing
purposes.
Failure to produce the Permit to Work document, when requested, could result in a debit to a claim.

Produced and printed in the USA and available as an electronic document.
© 2022 VOLVO CAR USA, LLC

Service Manager Bulletin 00-018
Along with the use of the Permit to Work Live Voltage, but not all inclusive, please reference VIDA
Repair information:
Section Information > Repair > General Safety Information >3: Electrical system > 300 General Safety
information for electrically powered vehicles.
High Voltage Personal Protective Equipment (HV – PPE) Recommendations and Requirements:
•
•
•
•
•
•

Class 0 rubber gloves to be worn at all times
Leather gloves worn over Class 0* rubber gloves when removing lid or near sharp areas
Minimum Z87 face shield
No metal to be worn within the electric vehicle designated work area: including jewelry, belt
with buckles etc.
Minimum ARC2 fire retardant long-sleeved shirt or coat
Electrical hazard (EH) rated boots

All Volvo Special Tools, designated in the VIDA Repair information, are available using normal
ordering routines through Parts. Some equipment can be purchased through Wurth and the Volvo
Equipment Program.
* The terms Class 0 and ICV rating of 1,000 volts are used interchangeably.

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2022-04-04

Service Manager Bulletin 00-018
Electric Vehicle Technical Permit-to-Work Live Voltage
The Electric Vehicle Technical Permit-to-Work Live Voltage documentation and procedures must be completed by
one that has a current Volvo Advanced Electric Vehicle Technician training certification.
Section 1: Vehicle information
VIN:

Repair Order #:
LV-PTW Number:

Date:

Vehicle Type

Plugin Hybrid Electric Vehicle OR

Technician Certification Level

AEVT-PHEV Certified And/OR

Battery Electric Vehicle
AEVT-BEV Certified

Section 1B: Description of Work being Performed
RO Line Number/Letter:
Description of diagnostics /
repairs being performed:

Safety Chains:
Warning Sign:
Prohibition Sign:
Site Assessment:

Personnel CPR:

Assistance:

Gloves*:

Section 2: Safety Controls
Must be placed 360° around the vehicle and no less than 36” from
the vehicle. Distance from chains to walls/doorways meet
YES
appropriate fire code.
Warning signs applied visibly on three (3) sides around the Electric
YES
Vehicle work area (secured to safety chains)
"Must not be operated. Work in progress." The sign must be fitted
or hung fully visible on the vehicle, contact details for the person
YES
responsible must be stated.
Site verified to be free of ceiling leaks, no trip hazards, and provided
YES
with appropriate accessibility for emergency response personnel
Volvo Cars highly recommends that all personnel in the Electric Vehicle work area
are CPR certified. Identify each role and their CPR certification:
YES, the technician performing the work is CPR certified
YES, the assistant with the emergency rescue hook is CPR certified
NO, the technician performing the work is NOT CPR certified
NO, the assistant with the emergency rescue hook is NOT CPR certified
Technician assistant at electric vehicle work site is equipped with
YES
emergency hook and is Volvo Electric Vehicle Awareness trained.
Section 2B: High Voltage Personal Protective Equipment (HV-PPE)
Minimum Class 0* rated Rubber gloves with available with tester.
YES
Leather outer gloves to be worn when near sharp objects.

Protective Visor*:

Minimum Z87 rated face shield.

YES

Clothing*:

Minimum ARC2 rated Non-melting clothing being worn, long sleeve
shirt or coat

YES

2022-04-04

Page 3 of 5

Service Manager Bulletin 00-018
Section 3: Tools and Equipment
1

Company emergency response procedures and evacuation plans are known and understood

YES

2

Class 0* rated Emergency hook is available

YES

3

Voltage Tester with minmum Cat3 rating

YES

4

Approved and current Volvo diagnostic and repairs procedures available with VIDA access

YES

Volvo Cars highly recommends both a functioning and charged defibrillator as well as insulated HighVoltage tools in the Electric Vehicle work area. Identify the current status of these items:
YES, a defibrillator is available in the Electric
NO, a defibrillator is not available in the Electric
5
Vehicle work area
Vehicle work area
YES, insulated high-voltage tools are available in
NO, insulated high-voltage tools are available in
the Electric Vehicle work area
the Electric Vehicle work area
Section 4: Authorization
I confirm all the above precautions, safety requirements, tools, and equipment are available as described within
their sections. I confirm that I hold the minimum certifications for Volvo Advanced Electric Vehicle Technician
(AEVT).
Advanced Electric Vehicle Technician (AEVT) – Signature:
Print Name:

Date:

I confirm all the above precautions, safety requirements, tools, and equipment are available as described within
their sections. I confirm that I hold the minimum certifications for Volvo Electric Vehicle Awareness and will be at
the Electric Vehicle work area during the High Voltage Reduction process.
Electric Vehicle Awareness Technician (EVAT) – Signature:
Print Name:

Date:

Section 5: High Voltage Reduction
WARNING: If any steps are marked “NO”, condition must be escalated to Retailer Technical Support through TIE
1
2
3
4

5

6
1
2

VIDA procedure available
Complete MSD Isolation test on the next page
PHEV Only: Go to Step 4
BEV Only: Perform voltage drop across the Battery Disconnect Unit (BDU)
terminals. Is the voltage less than 60V?

YES
YES

NO
NO

YES

NO

Perform the battery lid removal process as per VIDA

YES

NO

PHEV Only: Remove all battery bus bars
BEV Only: Remove the ESSENTIAL COMPONENTS below
Bus Bar between modules 3 and 4
Bus Bar between modules 5 and 6
YES
Bus Bar between modules 15 and 16
Bus Bar between modules 19 and 20
Bus Bar between modules 23 and 24
Disconnect low voltage connectors on cell modules 6, 19, 23, and 25
Was High-Voltage reduction successful and is the battery ready for repairs?
YES
Section 6: Cancellation of Electric Vehicle Technical Permit-to-Work Live Voltage
Live Voltage repairs are complete per VIDA instructions and battery is ready to be
installed into the vehicle
OR
Live Voltage repairs are NOT complete

Copy of Permit to Work Live Work document has been made and will be stored for (7)
years.

NO

NO

YES
(Repairs complete)

NO
(Repairs NOT complete)

YES

Advanced Electric Vehicle Technician (AEVT) – Signature:
Print Name:

Page 4 of 5

Date:

2022-04-04

Service Manager Bulletin 00-018
MSD Isolation Testing

Using the isolation meter, the MSD adaptor, perform the following measurements:
Approximate Values
PHEV Batteries
BEV
Voltage Drop “A” to:

3 Layer

6 Mod.

27 Mod.

B

0V

0V

0V

C

0V

0V

0V

D

0V

0V

0V

E

NA

0V

0V

Chassis

NA

0V

0V

Voltage Drop “B” to:

3 Layer

6 Mod.

27 Mod.

C

0V

0V

0V

D

0V

0V

0V

E

NA

0V

~121V

Chassis

0V

0V

0V

Voltage Drop “C” to:

3 Layer

6 Mod.

27 Mod.

D

0V

0V

0V

E

NA

~190V

~176.4V

Chassis

0V

0V

0V

Voltage Drop “D” to:

3 Layer

6 Mod.

E

NA

0V

27 Mod.
MUST NOT
equal C to E

Chassis

0V

0V

0V

Voltage Drop “E” to:

3 Layer

6 Mod.

27 Mod.

Chassis

NA

0V

0V

Measured Voltage

Measured Voltage

Measured Voltage

Measured Voltage

Measured Voltage

After battery lid is removed per the Permit-to-Work, perform the below measurements:
Voltage Drop “D” to:

3 Layer

6 Mod.

27 Mod.

Cell Module C
Positive Terminal

~158.4V

NA

NA

Measured Voltage

WARNING:

Condition must be escalated to the Retailer Technical Support through TIE if the measured voltages do NOT equal
the expected values.

2022-04-04

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