CAUTION! Reduce risk of personal injury from electrical shock, burns, and damage to any electrical components by always disconnecting 12 and 42 volt system batteries when performing service procedures under the vehicle hood, within or around energy storage box, and /or related to hybrid vehicle systems.

Hybrid vehicles use a conventional gasoline engine in addition to an electric motor to power the vehicle. The energy used to power the vehicle must be stored. Gasoline for the internal combustion engine is stored in the fuel tank, and electricity is stored in a high voltage battery pack. The combination of a gasoline engine and electric drive provides for improved performance, reduced emissions and most importantly – improved fuel economy. The system is self-contained,
so you never have to plug a hybrid in to recharge the batteries.

Whenever you approach a high voltage vehicle in a Fire, Rescue, or Recovery situation you must always follow one cardinal rule:

Always Assume The Vehicle is Powered Up!

The following information was referenced from the Ford Motor Company, and specifically addresses the Ford Escape Hybrid vehicle. Other vehicle manufacturers, such as Honda, also produce Hybrid vehicles. The manufacturers should be consulted before addressing training needs for their vehicles. In any case, this should be viewed as supplemental information, and standard precautions for high voltage situations must be followed.

Hybrid Vehicle Identification – Unique Hybrid labels are located in several places on the vehicle, such as the hood, tailgate and front doors. The left rear quarter glass contains a high voltage battery air intake. They also have a unique under hood appearance. The engine cover has a hybrid label for easy identification. The Ford VIN will show “U95” or “U96” in the fifth, sixth and seventh positions.

Design Features – There are two inertia switches, front and rear, designed to disconnect high voltage and fuel in the event of an accident. The high voltage system is disconnected any time the vehicle ignition key is turned to the off position. The high voltage system is disconnected any time the High Voltage Service Disconnect Switch, located on top of the High Voltage Battery, is removed. In case of a short circuit, a fuse will open and disable the electrical power. If the battery temperature exceeds 140 degrees, the system will automatically disconnect. Any time a wiring connector is disconnected, an interlock circuit disables the system.

Batteries – The batteries are located underneath the carpet in the rear of the vehicle. There are 250 individual cells that resemble the size D flashlight batteries, contained in a stainless steel case, and they are designed to be water resistant. In case these batteries are ruptured, skin and eye protection should be used.

When approaching a damaged high voltage vehicle, follow the precautions in any high voltage emergency situation. This includes:

• Remove all jewelry and metal objects, as they are conductors of
  electricity.
• Wear all the necessary protective clothing.
• Bring a Class ABC type fire extinguisher.
• Use a nonconductive object to safely push someone away from the
  vehicle if they accidentally come into contact with high voltage.

Once at the vehicle:

• Secure it by blocking the wheels if necessary, and put the shift lever
  into Park. Removing the ignition key or turning it to the Off position will
  disconnect the high voltage system.
• Disconnect the negative cable from the 12-volt battery.
• If possible, remove the High Voltage Disconnect Switch.

Special Notes:

• If the vehicle is on fire, use Class ABC powder type extinguishers to
  contain and smother the flames. If water is to be used, use large
  amounts.
• If the vehicle has any exposed cables, make sure you are wearing
  insulated gloves and other protective clothing. Do not touch any broken
  or damaged orange cables. Treat any severed lines as if they contain
  high voltage.
• If the battery case has been ruptured, treat it like any other battery –
  hose the area down with large amounts of water.

Flashpoint
Spring 2006