High-Voltage Safety and De-Energization

Hybrid and electric vehicles operate at 200-800 volts DC—lethal levels that can cause cardiac arrest, severe burns, and arc flash injuries. All high-voltage cables are sheathed in standardized orange conduit per SAE J1673 to provide visual warning. The battery pack, inverter, electric motor, onboard charger, and DC-DC converter are all part of the high-voltage circuit. Before any service involving these components, the technician must de-energize the system and verify zero voltage. No exceptions—even seemingly minor tasks like removing a seat (some EVs route HV cables under seats) require verification.