Hazardous Substances and High Voltage Isolation Procedure

Purpose. This procedure explains how workers handle, store and dispose of hazardous substances and how technicians isolate hybrid and battery electric vehicles before high-voltage work.

1.Hazardous substances register

Every chemical held on site must be listed in the Hazardous Substances Register with a current safety data sheet no more than five years old. The parts team must not accept a new product until the safety data sheet has been filed and the product added to the register.

2.Handling and storage

Workers must read the safety data sheet before first use and must wear the personal protective equipment it specifies. Fuels and solvents are stored in the flammable liquids cabinet. Oils and coolant are stored in the bunded area. Aerosols are stored away from heat. Containers must be labelled with the product name and hazard pictograms.

3.Brake dust, exhaust and battery acid

Brake assemblies must be cleaned with the wet method or a brake washer, never with compressed air. Engines must not be run in a bay unless the exhaust extraction hose is fitted. Battery acid spills must be neutralised with the bicarbonate kit and reported.

4.High voltage vehicle isolation

Before any work on the high-voltage system of a hybrid or battery electric vehicle, an authorised technician must move the vehicle to the isolated bay, place the high-voltage barrier and warning sign, remove the service plug or disconnect in the manufacturer sequence, wait the discharge period the repair information states and verify zero voltage with a rated meter. The service plug is kept on the technician's person or in the locked box.

• Only technicians on the high-voltage list
• Insulated gloves tested before each use and inspected for damage
• Rescue hook and insulated mat in place
• Zero voltage verified and recorded on the repair order
• Vehicle reinitialised and checked before release

5.Damaged batteries

A high-voltage battery that is damaged, swollen, leaking or warm must be treated as an emergency. The technician must evacuate the bay, notify the Service Manager, place the vehicle in the outdoor quarantine area if it is safe to move and contact the manufacturer technical line. The incident must be recorded in the Incident and Hazard Register.

6.Disposal

Waste substances are disposed of under the Environmental Management and Waste Policy through licensed contractors only.