Hybrid Precaution
FOR ALL OF VEHICLESPRECAUTION
1. PRECAUTIONS FOR HIGH- VOLTAGE CIRCUIT INSPECTION AND SERVICE
a. Engineers to be engaged in inspection and servicing related to high- voltage systems should undergo special training.
b. All the high-voltage wire harness connectors are colored orange: the HV battery and other high-voltage components are identified by the High Voltage caution labels. Do not carelessly touch these wires and components.
c. Before inspecting or servicing the high-voltage system, be sure to take measures such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while you are servicing the vehicle.
d. After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.
HINT: The 5 minutes are required to discharge the high-voltage condenser inside the inverter.
e. Before wearing insulated gloves, make sure that they are not cracked, reptured, torn, or damaged in any other way. Do not wear wet insulated gloves.
f. When servicing the vehicle, do not wear a metal object like a mechanical pencil or scale that may drop accidentally and cause a short circuit.
g. Before touching a bare high-voltage terminal, wear insulated gloves and ensure that the terminal is not charged with electricity (approx. 0 V) using an electrical tester.
h. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.
i. The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive tightening torque can cause failure.
j. Call other engineers attention to the vehicle which highvoltage system is being inspected or repaired by hanging a High Voltage Operation in Progress. Do Not Touch sign.
k. After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminal screws are firmly tightened, and that the connectors are correctly engaged.
2. PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT
The PRIUS,automatically turns the engine ON and OFF when the ignition switch is set to the ON position provided that the READY light on the instrument panel is it.
Before inspecting or servicing the engine compartment, therefore, remove the ignition switch key.
3. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED
a. Actions to be taken when the auxiliary battery is depleted
HINT:
The following phenomena indicate that the auxiliary battery is depleted:
- No display appears on the instrument panel when you turn the ignition switch to the ON position.
- The hybrid system does not start.
- The headlights are dark.
- The sound from the horn is weak.
NOTE: Never use a quick charger.
1. Move the shift lever to the P range, and engage the parking brake.
2. Remove the ignition key plate from the ignition switch.
3. Using a booster cable, connect the 12 V battery of the rescue vehicle and auxiliary battery of the stalled vehicle, as shown in the illustration.
4. Start the engine of the rescue vehicle and run the engine at a speed slightly higher than the idling speed for 5 minutes to charge the auxiliary battery of the stalled vehicle.
5. Turn the ignition switch of the stalled vehicle to the START position to start the hybrid system.
If the hybrid system fails to start and the master and HV battery warning lights come on, the HV battery may have been discharged.
6. Disconnect the booster cable in the reverse way of the connection procedure.
NOTE: If the auxiliary battery needs to be replaced, replace it only with a 12 V battery specially designed for the use of the PRIUS.
b. Actions to be taken when HV battery is depleted
NOTE: Leaving a vehicle alone for 2 - 3 months may cause electric discharge from HV battery. When this happens, replace the HV battery.
4. INSPECTION MODE
HINT:
- The PRIUS automatically stops the engine while the vehicle is stopped with the engine warmed up and battery well charged if the A/C compressor operation is not required. Therefore, even if the vehicle stops for any reason such as a check of ignition timing, the inspection mode should be activated when continuous operation of the engine is required.
- The PRIUS has a skid control as traction control function. When the wheel speed of the front wheels exceeds that of the rear wheels, this function restrains the wheel speed of the front wheels. It is necessary to activate the inspection mode and reset the skid control when turning only the front wheels using a speedometer tester.
Activation inspection mode (Without using a hand-held tester)
1. Perform the following (2) through (6) within 60 sec.
2. Turn the ignition switch ON from OFF.
3. With the shift lever in P range, fully depress the accelerator pedal 2 times.
4. With the shift lever in N range, fully depress the accelerator pedal 2 times.
5. With the shift lever in P range, fully depress the accelerator pedal 2 times.
6. Activate the inspecting mode and check that the hybrid system error warning light on the multi-center display flashes.
7. Turning the ignition switch to START starts the engine's continuous operation.
NOTE:
- The idling speed in the inspection mode is approx. 1,000 rpm. The number of revolutions will increase up to 1,500 rpm if the accelerator pedal is depressed to a degree of less than 60%, and up to 2,250 rpm in a case of 60% or more.
- If a diagnosis code is recorded when entering the inspection mode, the master warning light and the error warning light on the multi-center display is lit.
- When the master warning light is lit during operation in the inspection mode, deactivate the inspection mode and inspect the diagnosed area.
HINT: When continuous operation of the engine is required for such as an exhaust leakage inspection, it is advisable as an easier way to turn ON the FULL switch of the air conditioner.
5. SPECIAL NOTES FOR VEHICLE INSPECTION
a. Vehicle conditions
1. Before activating the service mode, turn the air conditioner off, start the engine with the shift lever at P range, and check that the engine stops within several seconds after starting. (Engine warm up check)
2. Activate the service mode and inspect the vehicle. The shift position for each test is as follows:
3. Reset the service mode immediately after completion of inspection.
NOTE: Traveling on a road without resetting the service mode may damage the transaxle.
b. Special notes for speedometer test
NOTE: Rapid starting or quick acceleration/deceleration based on the speedometer tester without load setting may damage the transaxle.
1. Depress the accelerator pedal slowly and gradually accelerate at the time of measurement.
2. After the measurement, use the brake to decelerate gradually and stop.
c. Special note for using the chassis dynamometer Always set an appropriate load before starting the test.
NOTE: Rapid starting or quick acceleration/deceleration with insufficient load may damage the transaxle.
6. ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT
a. Items to be prepared (For operation at the site of accident)
- Protective clothing (Insulated gloves, rubber gloves, goggles, and safety shoes)
- Saturated boric acid solution 20 L (Procure 800 g of boric acid powder, put it into a container, and dissolve it in water.)
- Red litmus paper
- ABC fire extinguisher (Applicable to both oil flames and electrical flames)
- Waste rags or old towels (For wiping off the electrolyte)
- Vinyl tape (For insulating cable)
- Electrical tester
b. Actions to be taken at the place of accident
1. Wear insulated or rubber gloves, goggles and safety shoes.
2. Do not touch a bare cable that could be a high-voltage cable. If you need to touch it, or if you have a danger of making an accidental contact, wear insulated gloves, measure the voltage between the cable and body ground using an electrical tester, and insulate the cable using vinyl tape.
3. If the vehicle catches fire, use a ABC fire extinguisher to extinguish the fire. Trying to extinguish the fire using only a small amount of water can be more dangerous than effective: either use a greater amount of water from a fire hydrant or wait for the fire fighters.
4. If the vehicle is partially submerged in water, do not touch the service plug or any of the high-voltage components and cables because of the danger of electrocution. If you need to touch them, do so only after pulling the vehicle completely out of water.
5. Check the HV battery and nearby area for any leakage of the electrolyte. Do not touch any leaking liquid because it could be the highly alkaline electrolyte. If you need to wipe it off (using rags etc.), do so only after completing the following procedure: wear the rubber gloves and goggles, neutralize the electrolyte with saturated boric acid solution, and finally apply a red litmus paper to make sure that it does not turn blue.
6. If a damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.
- Move the shift lever to the P range and engage the parking brake.
- Remove the ignition key. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.
- Remove the service plug with the insulated gloves on.
If service plug cannot be removed due to damage to the rear portion of the vehicle, remove the HV fuse or IGCT relay instead.
c. Moving the damaged vehicle
HINT: If any of the following applies, tow the vehicle away using a tow truck lorry.
- One or more of the high-voltage components and cables is damaged.
- The driving, traction, or fuel system is damaged.
- The READY light is not lit when you turn ignition key to the ON position.
NOTE:
- Before towing the vehicle away using a break down lorry, disconnect the cable from the negative (-) terminal of the auxiliary battery and remove the service plug. Only if none of the above applies and you see no problems that might affect the driving operation, you are allowed to drive the vehicle away from the place of accident.
- Preform the procedure below if the READY light goes off or you detect an abnormal noise, abnormal smell, or strong vibration while traveling:
1. Park the vehicle in a safe place.
2. Move the shift lever to the P range and engage the parking brake.
3. Disconnect the cable from the negative (-) terminal of the auxiliary battery.
4. Remove the service plug with insulated gloves on.
d. Actions required after moving the damaged vehicle If you see any liquid on the road surface, it could be the leakage of the highly alkaline electrolyte. Wearing rubber gloves and goggles, apply a red litmus paper to the liquid. If the litmus paper turns blue, neutralize the liquid using the saturated boric acid solution and reapply a red litmus paper to make sure that it does not turn blue. Then wipe the liquid off from the road surface using waste rags, etc.
e. Items to be prepared (When repairing damaged vehicles)
- Protective clothing (Insulated gloves, rubber gloves, goggles, and safety shoes)
- Saturated boric acid solution 20 L (Procure 800 g of boric acid powder, put it into a container, and dissolve it in water.)
- Red litmus paper
- Waste rags or old towels (For wiping off the electrolyte)
- Vinyl tape (For insulating cable)
- Electrical tester
f. Precautions to be observed when servicing the damaged vehicle:
1. Wear insulated or rubber gloves, goggles, and safety shoes.
2. Do not touch a bare cable that could be a high-voltage cable. If you need to touch it, or if you have a danger of making an accidental contact, wear insulated gloves, measure the voltage between the cable and the body ground using an electrical tester, and insulate the cable using a vinyl tape.
3. Check the HV battery and nearby area for leakage. If you find any liquid, it could be the leakage of the highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply a red litmus paper to the leak. If the litmus paper turns blue, neutralize the liquid using the saturated boric acid solution and reapply a red litmus paper to make sure that it does not turn blue. Then wipe the liquid off using waste rags etc.
4. If the electrolyte adheres to your skin, wash the skin immediately using the saturated boric acid solution or large amounts of water. If the electrolyte adheres to an article of clothing, take it off immediately.
5. If the electrolyte comes into contact with your eyes, call out loudly for help. Do not rub your eyes but wash them with the saturated boric acid solution or large amounts of water and seek medical care.
6. If a damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below:
- Move the shift lever to the P range and engage the parking brake.
- Remove the ignition key. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.
- Wear insulated gloves, and then remove the service plug.
- If you cannot remove the service plug due to damage to the rear portion of the vehicle, remove the HV fuse or IGCT relay instead.
g. Precautions to be taken when disposing of the vehicle When scrapping the vehicle, remove the HV battery from the vehicle and return it through the route specified by the manufacturer. The same applies to any damaged HV battery.
h. Precautions to be observed when towing Tow the damaged vehicle with its front wheels or its front and rear wheels lifted off the ground.
NOTE: Towing the damaged vehicle with its front wheels on the ground may cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.
i. Towing with 4 wheels on the ground
NOTE:
- If you have to tow the damaged vehicle using a rope, do it at a speed below 30 km/h. Such towing operation is allowed only to cover very short distance, such as the distance to a tow truck lorry, for example.
- Set the ignition switch to the ACC position and shift lever to the N range.
- If you detect any abnormality in the damaged vehicle during the towing operation, stop the towing operation immediately.
j. Towing eyelet
1. Install the hook.
2. Hook a rope onto the illustrated point for towing.