control module. On some hybrids, the disconnect is pulled
out to produce an open circuit between the battery pack
and the power control module. With other designs, the dis-
connect has a switch that is rotated to provide an open in
the battery pack circuit.
Hybrid high-voltage disconnects are usually located near
the battery pack in the trunk, under the seat, on the side of a
seat under a trim panel, or other similar location, Figure 5-21.
Warning: In order to avoid electric shock, wait
at least five minutes after removing the hybrid
power disconnect plug before working on high
voltage circuits. It can take up to five minutes for HV
capacitors in the inverter circuit to discharge fully.
High-Voltage Buffer Zone
When working on a hybrid, set up a high voltage buffer
zone of about three feet (one meter) around the perimeter of
the vehicle. Keep steel workbenches, large metal equipment,
or any other potential conductor of electricity away from the
vehicle while working. This buffer zone helps you avoid
touching high voltage and any conductor with your body.
Summary
A service facility can be a safe and enjoyable place to
work if safety rules are followed. However, if safety regula-
tions are not followed, the shop can be a very dangerous
place to work. Always make sure you are using approved,
safe practices when working on a vehicle.
You must prevent fires, explosions, chemical burns, elec-
tric shocks, and other physical injuries. Constantly think about
what you are doing and take corrective action when needed.
Hazardous wastes are often generated in the service facility.
These wastes are regulated by the Resource Conservation and
Recovery Act and must be disposed of properly. A material data
safety sheet provides information about a chemical or substance,
such as common reactions and treatments for overexposure.
Hybrid vehicles generate extreme electrical energy.
Therefore, specific safety rules have been developed that
must be followed during servicing. These rules address
how to tow the vehicle, how to disconnect power supplies,
and what clothing to wear to increase safety.
Chapter 5 Shop Safety 121
Service plug
A
B
C
Service plug
Glove
Figure 5-21. Hybrid power disconnects can be difficult to locate. A—This disconnect plug is located in the trunk of the vehicle.
B—Here you must rotate a locking switch before you can remove the fuse disconnect. C—This disconnect plug is located on the
side of the rear seat, under a piece of plastic trim. (Ford and Toyota)