Handling Vehicle
Handling Vehicle
Handling Vehicle
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:�[email protected]
©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.
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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.
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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.
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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.
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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�
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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.
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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.
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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".
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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
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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
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Röntgenstraße�7
85716�Unterschleißheim,�Germany