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Handling Vehicle

The document provides information about handling BMW i vehicles for service personnel. It discusses BMW i as a new sub-brand focused on sustainable vehicles and mobility services. It outlines the high-voltage systems used in BMW i vehicles, how the components are recognized by warning stickers, and dangers associated with working on these systems. Qualification requirements are discussed to ensure safe work on hybrid and electric vehicles.

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0% found this document useful (0 votes)
45 views16 pages

Handling Vehicle

The document provides information about handling BMW i vehicles for service personnel. It discusses BMW i as a new sub-brand focused on sustainable vehicles and mobility services. It outlines the high-voltage systems used in BMW i vehicles, how the components are recognized by warning stickers, and dangers associated with working on these systems. Qualification requirements are discussed to ensure safe work on hybrid and electric vehicles.

Uploaded by

wake666
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 16

Technical�training.

Product�information.
Handling�BMW�i�Vehicles.

BMW�Service
General�information

Symbols�used

The�following�symbol�is�used�in�this�document�to�facilitate�better�comprehension�or�to�draw�attention
to�very�important�information:

Contains�important�safety�information�and�information�that�needs�to�be�observed�strictly�in�order�to
guarantee�the�smooth�operation�of�the�system.

Information�status�and�national-market�versions

BMW�Group�vehicles�meet�the�requirements�of�the�highest�safety�and�quality�standards.�Changes
in�requirements�for�environmental�protection,�customer�benefits�and�design�render�necessary
continuous�development�of�systems�and�components.�Consequently,�there�may�be�discrepancies
between�the�contents�of�this�document�and�the�vehicles�available�in�the�training�course.

This�document�basically�relates�to�the�European�version�of�left-hand�drive�vehicles.�Some�operating
elements�or�components�are�arranged�differently�in�right-hand�drive�vehicles�than�shown�in�the
graphics�in�this�document.�Further�differences�may�arise�as�the�result�of�the�equipment�specification�in
specific�markets�or�countries.

Additional�sources�of�information

Further�information�on�the�individual�topics�can�be�found�in�the�following:

• Owner's�Handbook
• Integrated�Service�Technical�Application.

Contact:�conceptinfo@bmw.de

©2013�BMW�AG,�Munich

Reprints�of�this�publication�or�its�parts�require�the�written�approval�of�BMW�AG,�Munich

The�information�contained�in�this�document�forms�an�integral�part�of�the�technical�training�of�the
BMW�Group�and�is�intended�for�the�trainer�and�participants�in�the�seminar.�Refer�to�the�latest�relevant
information�systems�of�the�BMW�Group�for�any�changes/additions�to�the�technical�data.

Information�status:�July�2013
Technical�training.
Handling�BMW�i�Vehicles.
Contents.
1. Introduction............................................................................................................................................................................................................................................ 1

2. BMW�i�in�Service..........................................................................................................................................................................................................................2
2.1. BMW�i�-�New�sub�brand�of�the�BMW�Group..............................................................................................................2
2.2. What�must�be�observed?.......................................................................................................................................................................... 3
2.2.1. High-voltage�systems�in�the�vehicle...................................................................................................... 3
2.2.2. How�are�the�high-voltage�components�recognised?................................................... 4
2.2.3. Dangers�when�handling�high-voltage�systems..................................................................... 6

3. Qualification.......................................................................................................................................................................................................................................... 7
3.1. What�prerequisites�must�employees�satisfy�in�order�to�be�able�to�perform�work
on�BMW�i�vehicles?........................................................................................................................................................................................... 7
3.2. Who�is�responsible�for�ensuring�the�prerequisites�are�satisfied�for�safe�work�on
a�hybrid�car�or�electric�vehicle?...................................................................................................................................................... 7
3.3. How�is�the�qualification�effected?...............................................................................................................................................7

4. What�still�has�to�be�observed?........................................................................................................................................................................... 8
4.1. Charging�the�high-voltage�battery............................................................................................................................................. 8
4.2. Silent�driving.................................................................................................................................................................................................................. 9
4.3. Car� wash.............................................................................................................................................................................................................................. 9
4.4. Starting�aid....................................................................................................................................................................................................................... 9
4.5. Towing�vehicle�away......................................................................................................................................................................................... 9
4.6. Procedure�after�an�accident............................................................................................................................................................. 10
Handling�BMW�i�Vehicles.
1.�Introduction.
This�product�information�bulletin�should�serve�as�a�source�of�information�and�user�guide�for�the
responsible�ptrainingersons�in�Service�(e.g.�in�the�car�dealership)�in�order�to�be�able�to�train�all
employees�in�the�company.�The�aim�of�this�information�bulletin�is�to�alert�employees�to�possible
dangers�when�handling�BMW�i�vehicles.�The�instruction�should�ideally�be�completed�directly�before
the�arrival�of�the�first�BMW�i�vehicles�in�Service�and�be�confirmed�in�writing�by�each�employee.

1
Handling�BMW�i�Vehicles.
2.�BMW�i�in�Service.
2.1.�BMW�i�-�New�sub�brand�of�the�BMW�Group
BMW�i�stands�for�visionary�vehicles�and�mobility�services,�an�inspirational�design�and�a�new
understanding�of�the�word�premium,�which�is�defined�by�sustainability.�With�BMW�i�the�BMW
Group�is�taking�a�holistic�approach:�By�incorporating�customised�vehicle�concepts,�sustainability
throughout�the�entire�value-added�chain�and�additional�mobility�services�such�as�"MyCityWay"�or
"ParkatmyHouse",�BMW�i�is�redefining�the�understanding�of�individual�mobility.

At�the�same�time,�BMW�i�is�therefore�opening�up�the�company�to�new�target�groups�and�is�further
strengthening�the�position�of�the�BMW�umbrella�brand�as�sustainable�and�future-oriented.�The�entire
value-added�chain,�be�it�a�sub�process,�supplier�or�technology,�should�make�a�positive�contribution�to
the�sustainability�balance�of�the�product�and�brand.

BMW�i3�Concept

On�the�one�hand,�there�is�the�BMW�i3,�a�Megacity�Vehicle,�which�will�be�the�first�purely�electrical
production�vehicle�of�the�BMW�Group.�The�BMW�i3�will�be�launched�on�the�market�in�the�fourth
quarter�of�2013.

On�the�other�hand,�there�is�the�BMW�i8,�which�in�its�unique�plugin�hybrid�concept�combines�a
combustion�engine�and�electric�motor�with�an�exceptional�driving�experience�and�extremely�low
consumption�and�emissions�at�the�same�time.

High-voltage�systems�are�used�in�both�models.�The�BMW�Service�personnel�will�also�perform�work
on�these�systems.�The�technical�design�ensures�that�the�high�voltages�used�do�not�pose�a�direct
danger�to�personnel.�These�are�called�intrinsically�safe�systems.�The�legal�requirements�in�Germany
and�many�other�countries�require�the�BMW�Group�(and�all�other�automobile�manufacturers)�to
provide�special�training�for�Service�personnel.�The�participants�acquire�technical�knowledge�about
high-voltage�systems�in�a�corresponding�training�course.�The�Service�personnel�are�also�informed
about�the�general�dangers�associated�with�high�voltages.�Procedures�on�avoiding�dangers�are�also
communicated.�As�a�result,�both�the�high�service�quality�and�safe�handling�of�high-voltage�systems�are
guaranteed.

2
Handling�BMW�i�Vehicles.
2.�BMW�i�in�Service.
2.2.�What�must�be�observed?

2.2.1.�High-voltage�systems�in�the�vehicle

LifeDrive�modules�and�high-voltage�components

Index Explanation
1 Life�module
2 Drive�module
3 High-voltage�battery
4 Electrical�machine�and�power�electronics

In�vehicles�with�high-voltage�systems�components�are�installed�which�are�operated�at�voltages�above
60 V�direct�current�voltage�or�30 V�AC�voltage.�The�components�in�these�vehicles�sometimes�need
high�electrical�power.�The�high-voltage�electrical�system�in�hybrid�and�electric�vehicles�works�at�direct
current�voltages�of�up�to�650�V�and�must�provide�high�electrical�energy.

3
Handling�BMW�i�Vehicles.
2.�BMW�i�in�Service.
2.2.2.�How�are�the�high-voltage�components�recognised?

High-voltage�component�warning�sticker

Each�high-voltage�component�has�on�its�housing�an�identification�that�enables�Service�personnel�and
other�vehicle�users�to�identify�intuitively�the�possible�hazards�that�can�result�from�the�high�electric
voltages�used.�The�warning�sticker�used�is�based�on�the�standard�international�warning�sign�for
dangerous�electrical�voltage.

High-voltage�cables

The�high-voltage�cables�are�a�special�case�for�identification.�As�they�may�be�a�few�metres�long,
identification�with�a�warning�sticker�at�one�or�two�places�would�not�make�sense.�The�Service�employee
could�easily�oversee�these�stickers.�Instead�all�high-voltage�cables�are�marked�in�the�orange�warning
colour.�Also�some�connectors�at�high-voltage�cables,�as�well�as�the�high-voltage�safety�connector,�can
be�in�orange.

The�manufacturers�of�hybrid�cars�and�electric�vehicles�have�agreed�on�a�uniform�identification�of�the
high-voltage�components�with�the�above-mentioned�warning�stickers�and�the�high-voltage�cables�with
the�warning�colour�orange.

4
Handling�BMW�i�Vehicles.
2.�BMW�i�in�Service.

Service�Disconnect�in�BMW�i3

The�high-voltage�safety�connector�(Service�Disconnect)�plays�an�important�role�in�the�safety�concepts
of�the�vehicle�manufacturer.�It�has�the�same�function�for�all�concepts,�i.e.�shut�down�the�high�voltage
in�the�high-voltage�system.�By�disconnecting�the�high-voltage�safety�connector�it�is�guaranteed�that
there�is�no�dangerous�voltage�at�high-voltage�components�in�the�vehicle.

Only�Service�employees�who�satisfy�all�the�prerequisites�are�permitted�to�work�on�the�designated
high-voltage�components:�suitable�qualifications,�compliance�with�the�safety�rules,�procedure
following�the�repair�instructions�to�the�letter.

Service�employees�who�have�only�received�basic�training�on�hybrid�cars�and�electric�vehicles�(such�as
through�this�product�information�bulletin)�are�not�suitably�qualified�to�perform�work�on�high-voltage
components�

5
Handling�BMW�i�Vehicles.
2.�BMW�i�in�Service.
2.2.3.�Dangers�when�handling�high-voltage�systems

Example�of�a�current�flow�through�the�human�body

All�movements�in�the�human�body�are�activated�by�electrical�control�mechanisms.�All�muscle
reactions,�such�as�the�heartbeat,�are�controlled�via�electrical�stimuli.�These�electrical�stimuli�spread
throughout�the�body�via�nerve�tracts,�similar�to�currents�in�electrical�circuits.�If�contact�is�made�with
live�high-voltage�components�a�current�flow�through�the�human�body�may�result.�Depending�on�the
duration�of�the�perfusion,�reversible�disruptions�of�the�heart�impulses�may�occur�at�direct�currents
from�roughly�30 mA.�At�even�higher�body�currents�serious�inner�burns�may�also�occur�and�it�may
cause�ventricular�fibrillation.�In�the�event�of�a�short�circuit�of�the�two�terminals�of�a�high-voltage�system
there�is�a�risk�of�a�light�arc�forming.�In�the�human�body�this�may�cause�serious�external�burns�and
dazzle�the�eyes.

6
Handling�BMW�i�Vehicles.
3.�Qualification.
3.1.�What�prerequisites�must�employees�satisfy�in�order�to�be�able
to�perform�work�on�BMW�i�vehicles?
As�long�as�the�high-voltage�system�is�OK�and�no�contact�has�to�be�made�with�the�high-voltage
components�and�high-voltage�cables,�every�Service�employee�can�perform�general�maintenance�work
on�hybrid�cars�and�electric�vehicles�(e.g.�tyre�change).�Employees�must�be�instructed�before�starting
the�work�in�order�to�become�familiar�with�the�electrical�hazards�posed�by�the�high-voltage�system.
They�must�become�acquainted�with�the�identifications�of�the�high-voltage�components�and�safe
operation�of�the�vehicle.

Work�on�the�high-voltage�components�is�strictly�forbidden�for�these�employees�

Employees�who�are�to�perform�work�on�high-voltage�components�require�an�additional�qualification.
They�are�qualified�as�an�"Expert�for�working�on�high-voltage�intrinsically�safe�vehicles�and�intrinsically
safe�high-voltage�components".�These�employees�are�then�able�to�assess�the�electrical�hazards
posed�by�the�high-voltage�system�and�define�the�protective�measures�required�for�the�high-voltage
system.�They�are�able�to�establish�the�de-energised�state�at�the�vehicle�and�ensure�this�for�the
duration�of�the�work.�The�scope�of�the�qualification�mainly�depends�on�the�educational�background
and�practical�experiences�of�the�employee.�Evidence�of�the�skills�and�knowledge�acquired�through
theoretical�and�practical�qualifications�is�required.

The�Service�employees�also�need�a�special�qualification�for�working�on�the�12 V�vehicle�electrical
system�in�conjunction�with�a�carbon�body�of�a�BMW�i�vehicle.

3.2.�Who�is�responsible�for�ensuring�the�prerequisites�are�satisfied
for�safe�work�on�a�hybrid�car�or�electric�vehicle?
The�employer�or�the�manager�instructed�by�him�is�responsible�for�occupational�safety�in�the�company.
The�work�must�be�designed�so�that�risk�to�the�life�and�health�of�employees�is�avoided.�This�also
applies�for�work�on�vehicles�with�high-voltage�components.�The�responsible�persons�must�ensure
that�only�employees�who�satisfy�the�prerequisites�mentioned�above�work�on�hybrid�cars�and�electric
vehicles�with�high-voltage�components.

If�work�needs�to�be�performed�on�the�high-voltage�components�themselves,�then�it�is�imperative
that�the�complete�system�is�in�a�de-energised�state.�Only�specially�qualified�personnel�(experts�for
working�on�high-voltage�intrinsically�safe�vehicles�and�intrinsically�safe�high-voltage�components)�are
employed�for�this�work.

3.3.�How�is�the�qualification�effected?
The�BMW�Group�provides�the�training�concept�for�the�qualification�of�Service�employees�on�"Expert
for�work�on�high-voltage�intrinsically�safe�vehicles�and�intrinsically�safe�high-voltage�components".
The�qualification�is�effected�through�online�and�face-to-face�training�courses�in�a�combination�of
theoretical�and�practical�learning�sequences.�The�training�organisation�responsible�for�your�country
will�inform�you�about�the�training�measures�and�offer�the�appropriate�training�courses.�Further
information�can�be�found�in�the�training�offer.

7
Handling�BMW�i�Vehicles.
4.�What�still�has�to�be�observed?
4.1.�Charging�the�high-voltage�battery.

Filling�the�fuel�tank�while�the�high-voltage�battery�is�charging�is�not�permitted�

When�the�charging�cable�is�connected�do�not�fill�the�fuel�tank�and�keep�a�safe�distance�from�highly
flammable�materials.�Otherwise,�in�the�event�of�an�improper�connection�or�if�the�charging�cable�is
pulled�out,�there�is�a�risk�of�personal�injury�or�material�damage�by�burning�fuel�for�example.

A�standard�charging�cable,�an�AC�rapid�charging�cable�or�a�permanently�installed�cable�at�a�charging
station�are�used�for�charging�the�high-voltage�battery�in�an�electric�vehicle.

The�charging�cable�is�automatically�locked�during�the�charging�procedure.�The�charging�procedure
must�be�completed�before�the�charging�cable�is�removed.

The�information�on�charging�the�high-voltage�battery�is�available�in�the�operating�instructions�of�the
vehicle.

Charging�the�high-voltage�battery�using�a�typical�household�power�socket�results�in�a�high�continuous
load�on�the�power�socket,�which�does�not�occur�with�other�household�appliances.�Therefore,�the
following�information�must�be�observed:

• Do�not�use�an�adapter�or�extension�cable
• After�charging�plug�the�charging�plug�into�the�vehicle�first�and�then�into�the�wall
• Avoid�tripping�hazards�and�mechanical�loads�for�charging�cables�and�power�sockets
• Do�not�insert�the�charging�plug�in�damaged�power�sockets
• Do�not�use�damaged�charging�cables
• The�charging�plug�and�charging�cable�may�be�warm�when�charging�the�high-voltage�battery.
If�they�become�too�hot,�the�power�socket�is�not�suitable�for�charging�or�the�charging�cable�is
damaged.�Stop�charging�immediately�and�have�the�power�socket�and�charging�cable�checked
by�an�electrician.
• In�the�event�of�repeated�charging�faults�or�terminations�contact�a�suitably�qualified�Service
employee.
• Only�use�power�sockets�protected�against�moisture�and�weathering
• Do�not�touch�contact�areas�of�power�sockets�with�fingers�or�objects
• Never�repair�or�modify�a�charging�cable�yourself
• Remove�cable�on�both�sides�before�cleaning.�Do�not�immerse�in�fluids.
• Do�not�go�through�a�car�wash�during�charging
• Only�charge�at�power�sockets�checked�by�an�electrician
• Observe�special�information�in�the�operating�instructions�for�charging�at�unknown�or�unfamiliar
infrastructure/power�sockets.�Set�the�charging�current�in�the�vehicle�to�"low".

8
Handling�BMW�i�Vehicles.
4.�What�still�has�to�be�observed?
4.2.�Silent�driving
The�BMW�i�vehicles�are�designed�so�that�they�can�operate�using�electrical�means�all�the�time�or
sometimes.�During�electric�driving�please�note�that�pedestrians�and�other�road�users�cannot�hear�the
usual�engine�noises�of�a�typical�conventional�engine.�Therefore�pay�particular�attention�when�parking
for�example.

4.3.�Car�wash

Washing�the�vehicle�while�the�high-voltage�battery�is�charging�is�not�permitted�

The�flap�for�the�charging�socket�must�be�closed�during�the�washing�procedure.�Otherwise,�damage
may�be�caused�to�the�vehicle�and�charging�socket.

If�the�charging�socket�is�contaminated�with�dirt�have�it�cleaned�by�suitably�qualified�personnel.
Otherwise,�there�is�a�risk�of�injury�due�to�the�high�voltage.�Regularly�remove�foreign�bodies,�e.g.�leaves
when�the�engine�compartment�lid�is�open,�in�the�area�below�the�windscreen.�Wash�the�vehicle�more
often�in�winter.�Heavy�dirt�contamination�and�road�salt�may�cause�damage�to�the�vehicle.

4.4.�Starting�aid
Do�not�bypass�or�directly�charge�the�battery�using�conventional�starting�aid.�It�is�not�possible�to
operate�the�vehicle�if�the�high-voltage�battery�and�12 V�battery�are�not�charged.�In�this�case�do�not
give�a�starting�aid�via�conventional�starting�aid,�but�connect�the�charging�cable�for�charging�the�high-
voltage�battery�to�the�vehicle.�Both�the�12 V�battery�and�the�high-voltage�battery�are�charged.

4.5.�Towing�vehicle�away.

Towing�vehicle�away

9
Handling�BMW�i�Vehicles.
4.�What�still�has�to�be�observed?

The�vehicle�cannot�be�towed�away�but�only�transported�on�a�loading�platform.�Otherwise,�damage�may
occur.

In�order�to�remove�a�stationary�vehicle�from�a�danger�area,�it�can�be�pushed�a�short�distance�at�a
maximum�speed�of�10 km/h.�The�vehicle�can�only�be�pushed�in�selector�lever�position�N.�In�the�event
of�electrical�faults�or�if�the�12 V�battery�is�not�charged,�it�may�transpire�that�it�is�not�possible�to�change
the�selector�lever�position.

4.6.�Procedure�after�an�accident
After�an�accident�do�not�touch�any�high-voltage�components�such�as�orange-coloured�high-voltage
cables�or�parts�which�have�contact�with�exposed�high-voltage�cables.�Otherwise,�there�is�a�risk�of�fatal
injury�by�an�electric�shock�due�to�the�high�voltage�of�the�system.

Do�not�make�contact�with�emerging�fluids�from�the�high-voltage�battery�as�they�may�cause�burns�on
the�skin.

If�you�are�in�an�accident�with�a�BMW�i�vehicle,�observe�the�following�additional�safety�precautions�with
regard�to�the�high-voltage�system:

• Protect�the�scene�of�an�accident
• Inform�rescue�workers,�police�or�fire�brigade�straight�away�that�it�is�a�vehicle�with�a�high-
voltage�system
• Engage�selector�lever�position�P,�actuate�the�Automatic�Hold�brake�and�switch�off�driving
readiness.
• Lock�vehicle�after�leaving�it
• Do�not�breathe�in�emerging�gases�from�the�high-voltage�system.�If�nec.�keep�your�distance
from�the�vehicle.

10
Bayerische�Motorenwerke�Aktiengesellschaft
Händlerqualifizierung�und�Training
Röntgenstraße�7
85716�Unterschleißheim,�Germany

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