2010

FUSION HYBRID
MILAN HYBRID

EMERGENCY RESPONSE GUIDE

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FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009
FOREWORD
The emergency response procedures for the Fusion Hybrid and Milan Hybrid
vehicles are similar to those for traditional gasoline-powered vehicles with the
addition of special considerations for the high-voltage electric system components.

The Fusion Hybrid or Milan Hybrid vehicles use a conventional gasoline engine in
addition to an electric motor to power the vehicle. The energy used to power the
vehicle comes from gasoline (used by the internal combustion engine) and electricity
(used by the electric motor).

• Gasoline is stored in a traditional fuel tank.

• Electricity is stored in a high-voltage battery pack.

The combination of a gasoline engine and electric motor provides for improved
performance (V6 performance with a 4-cylinder engine and electric motor),
reduced emissions and improved fuel economy. The high-voltage system is
self contained, never needing to be plugged into an electrical outlet for recharging.
The system incorporates a generator that recharges the high-voltage batteries during
cruising and braking from the engine.

The information in this guide will allow response to emergencies involving Fusion
Hybrid or Milan Hybrid vehicles to be as safe as with conventional vehicles.

The Fusion Hybrid and Milan Hybrid vehicles have been designed with many safety
features for your protection. These features help provide safe access to the vehicle
under various conditions. However, when approaching a high-voltage vehicle in
a fire, rescue or recovery situation, always follow one industry standard rule:

ALWAYS ASSUME THE VEHICLE’S

HIGH-VOLTAGE SYSTEM IS POWERED UP !

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FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009
FUSION HYBRID AND MILAN HYBRID VEHICLE IDENTIFICATION

• The Fusion Hybrid and Milan Hybrid vehicles can be easily identified by
the Ford “green leaf highway” badges located on the left and right front
doors. There is a “Hybrid” nameplate on the trunk lid that also includes
the “green leaf highway” icon.

Hybrid Nameplate Unique Hybrid

with “Green Leaf Specific Wheels
Highway” Badge on
Front Door

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FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009
 • The Fusion Hybrid and Milan Hybrid vehicles have a unique engine
appearance cover with a raised “green leaf highway” icon and HYBRID
lettering.

Unique Hybrid Engine Appearance Cover

with “Green Leaf Highway” Icon

• The 5th, 6th and 7th digits of the Vehicle Identification Number (VIN)
identify the Hybrid vehicle line.

VIN POSITIONS
5, 6 and 7 VEHICLE
P0L Fusion Hybrid — Front Wheel Drive (FWD)
M0L Milan Hybrid — Front Wheel Drive (FWD)

SAMPLE VIN
3FAD P0L30AR100001

Fusion Hybrid FWD

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FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009
HIGH-VOLTAGE ELECTRICAL DISCONNECT FEATURES

The following list describes certain features that have been incorporated into the
Hybrid vehicles that allow for either simple or automatic shutoff of the high-voltage
electrical systems.

• High-Voltage Fuse — In the event of a high-current short circuit,

the high-voltage fuse will open, disabling the high-voltage system.

• High-Voltage Interlock Circuit — Whenever a high-voltage connector

is disconnected, the high-voltage interlock circuit opens and disables
the high-voltage system.

• Ignition Key in OFF Position — Any time the ignition lock cylinder is in
the OFF position, the high-voltage system is disabled.

• High-Voltage Service Disconnect — Whenever the high-voltage

service disconnect (located behind the rear seat) is removed, the
high-voltage system is disabled. For additional information, refer to
Page 9 in this manual.

• Thermal Sensors — In the event the ignition key is left in the ON position
and the high-voltage battery temperature exceeds 60°C (140°F),
thermal sensors located near the high-voltage battery will automatically
disable the high-voltage battery.

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HIGH-VOLTAGE WARNING DECALS

• Warning decals, as shown here, will be located on components included

in the high-voltage system.

2U5A-14B218-CA

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HYBRID COMPONENT LOCATION AND IDENTIFICATION

This chart provides the location, description and basic function of the hybrid system
components. Refer to the hybrid component description on the following page.

2 1

5
4

NOTE: All high-voltage wires and harnesses are wrapped in orange-colored insulation.

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FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009
 COMPONENT LOCATION / DESCRIPTION FUNCTION
1 High-Voltage • Orange rectangle with a molded Provides means to disconnect
Service Disconnect plastic handle, about 100 mm high-voltage battery for safely
(4 in) in length. servicing vehicle.
2 High-Voltage Battery • Located behind the rear Provides high-voltage storage
275 Volts seatback. (275 V) for vehicle propulsion
requirements.
• Sealed nickel-metal hydride.
3 High-Voltage Wiring • Runs along the vehicle’s Provides physical path for
floorpan from the high-voltage high-voltage circuitry.
battery to the Electronically
Controlled Continuously
Variable Transaxle (eCVT),
to DC-to-DC converter, then the
electric A/C unit.
• All high-voltage wiring has
orange-colored insulation.
4 12-Volt Battery • Located under the hood on Provides 12-volt power for
driver side of the vehicle. vehicle accessories.
• Typical automotive 6-cell
lead/acid design.
5 Electronically • Transverse-mounted design Provides delivery of power to
Controlled similar to the non-Hybrid wheels for vehicle propulsion,
Continuously Fusion/Milan vehicles. generates electricity to re-
Variable Transaxle charge the batteries during
(eCVT) • Contains the traction motor, operation and contains
generator motor and hybrid certain hybrid electronics.
electronics.
6 DC/DC Converter • Located under the hood on Provides 12 volts of power to
the passenger side forward charge the 12-volt battery and
of the strut tower. run vehicle accessories.
7 Electric A/C • Located in the front of Provides electric A/C
Compressor the engine. operation. Replaces the
belt driven A/C compressor.

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HIGH-VOLTAGE SERVICE DISCONNECT

To gain access to the high-voltage service disconnect, the rear seat must
be lowered. The rear seat is released from the trunk area.

• Locate the seat backrest latch release levers (2) between the high-voltage
battery and the body sheet metal.

• Push the release lever toward the outboard side of the vehicle.

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HIGH-VOLTAGE BATTERY PACK

WARNING

• Removing the high-voltage service disconnect will disconnect

the high-voltage from the vehicle.

• The individual cells inside the battery pack will still be charged.

• Do not cut, weld or screw into the high-voltage battery case or

penetrate the batteries in any way.

The high-voltage battery pack is located behind the rear seatback.

• The total voltage of the battery pack is approximately 275 volts DC.

• The battery case is designed to be water resistant.

• The battery cells contain a base electrolyte (consisting of potassium

hydroxide as the dominant active ingredient) that is absorbed in a
special paper. The electrolyte will not leak from the battery under most
conditions, however, if the battery is crushed, it is possible for a small
amount (drops) of electrolyte to leak.

These warnings must be observed when working with a damaged battery:

NOTE: If possible, remove the high-voltage service disconnect.

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 1. Exposure to electrolyte could cause skin/eye irritation and/or burns. If exposed,
rinse with large amounts of water until the soapy feel is gone. Personal Protective
Equipment (PPE) such as splash shield or safety goggles, gloves (latex, rubber or
Nitrile), an apron or overcoat suitable to protect against alkaline and rubber boots
are required when handling damaged batteries. Fold-down helmet shields are not
acceptable for acid or alkaline spills.

2. If the battery is exposed to intense heat, it is possible that hydrogen could be

released from the battery. Appropriate precautions should be taken to make sure
the area is properly ventilated, such as, opening the vehicle windows or doors.

APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE

1. FOLLOW EXISTING TRAINING AND INCIDENT COMMANDER DIRECTION.
• This guide provides only supplemental information as it pertains to the
Fusion Hybrid and Milan Hybrid vehicles. The same rules apply when
approaching any potential high-voltage situation. Always follow your
high-voltage safety training. Some precautions to be taken in any
high-voltage situation include:
— Remove all jewelry (watches, necklaces and earrings). Metal objects
are conductors of electricity.
— Wear the necessary PPEs (high-voltage rubber gloves, face shield,
insulated boots, protective raincoat or apron).
— Bring the following equipment:

• Class ABC powder-type fire extinguisher

• A non-conductive object – about 1.5 m (5 ft) long – used to safely push

someone away from the vehicle if they accidentally come in contact
with high-voltage.

2. APPROACHING A DAMAGED VEHICLE.

• Disable the high-voltage electrical system using as many of the following

steps as possible:
— Secure the vehicle — place the shift lever into the PARK position.
Remove the ignition key. Block the wheels, if necessary. Removing the
ignition key or turning the key to the OFF position will disconnect the
high-voltage system.
— Disconnect the negative cable from the 12-volt battery – this will also
disable the high-voltage system.
— If possible, remove the high-voltage service disconnect (See Page 9).

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FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009
SPECIAL NOTES

• If the vehicle is on fire, use a Class ABC powder-type extinguisher to contain

and smother the flames. If water is being used, large amounts of water will
be required (e.g., from a fire hydrant) to extinguish the flames.

• If the vehicle has any exposed cables, make sure to wear high-voltage
rubber gloves and other protective clothing. Do not touch any broken or
damaged high-voltage orange cables. Treat severed cables as if they
contain high voltage.

• If the vehicle is submerged in water, do not touch any high-voltage

components or orange cables while extricating the occupant(s). Do not
remove the vehicle until you are sure the high-voltage battery is completely
discharged. A submerged high-voltage battery may produce a fizzing or
bubbling reaction. The high-voltage battery will be discharged when the
fizzing or bubbling has completely stopped.

3. IF THE HIGH-VOLTAGE BATTERY CASE HAS BEEN RUPTURED.

• Just like any other battery, hose the area down with large amounts of water.

4. MOVING DAMAGED VEHICLES — WRECKER DRIVERS.

• Turn the vehicle ignition key to the ACCESSORY position to release

the locking steering wheel.

• If possible, remove the high-voltage service disconnect.

• Follow the guidelines in the Wrecker Towing Manual.

— Front Tow: Wheel Lift (FWD)

— Rear Tow: Wheel Lift with Dolly (FWD)

— Flat bed: Front and Rear

5. SPECIAL NOTE TO SALVAGE YARDS.

• If a vehicle with a high-voltage battery is to be scrapped, the high-voltage

battery must be disposed of following all local, state/provincial and federal
guidelines.

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FCS-14265-10 2010 Fusion Hybrid, Milan Hybrid Emergency Response Guide, 02/2009