Electrical - Safety Precautions

PRODUCT GENERAL INFORMATION
PG005-01

April 27, 2001

Title:
PRIUS ELECTRICAL SAFETY PRECAUTIONS

Models:
'01 Prius

Introduction

This bulletin provides general high voltage safely precautions for the Toyota Hybrid System (THS) used in the Prius. THS operates with 274 volt DC and AC circuits. These high voltages are dangerous and can cause severe personal injuries, burns, and electrical shock if proper safety precautions are not followed. Always follow the Repair Manual procedures before attempting service on the Prius.

Applicable Vehicles

^ 2001 model year Prius vehicles.





Warranty Information

Electrical Safety Precautions

^ Only technicians who have successfully completed the Toyota Technical Training Class 071 are qualified to perform service on the Toyota Hybrid System.





^ All high voltage wiring harnesses and connectors are orange in color.

^ High voltage components are identified by either High Voltage caution labels or orange wire harness connections.

^ When servicing the Prius, remove metal objects that will conduct electricity such as a pocket screwdriver, mechanical pencil, or ruler that may drop accidentally and cause a short circuit.

^ Before servicing the high voltage Systems, turn the ignition key off, wear insulated gloves, and remove the service plug. Carry the removed service plug in your pocket to prevent others from reinstalling it while you are servicing the vehicle.





^ Always check for cracks, tears, or holes in your insulated gloves, Insulated gloves are available through Toyota Special Service Tools at 1-800-933-8335. Part numbers are as shown:

^ After removing the service plug, wait 5 minutes for the high voltage capacitor to discharge. Then, verify the terminal or connector to be worked on is at 0 volts before beginning repair.

^ After disconnecting or exposing a high voltage connector or terminal, insulate it immediately using electrical tape.

^ The screw or bolt of a high voltage terminal should be tightened firmly to the specified torque. Either insufficient or excessive tightening torque may cause failure.

^ As a safe practice, whenever a high voltage assembly or component is being repaired, place a "Caution: High Voltage. Do Not Touch During Operation" sign on the vehicle to warn others.

^ After servicing the high voltage system and before reinstalling the service plug, check again that no components, parts, or tools were left inside, the high voltage terminals were properly torqued, and the connectors were properly set.





^ The Toyota Prius Publications shown are available for purchase via non-parts ordering.