Foreword

This guide was developed to educate and assist dismantlers in the safe handling of hybrid vehicles. Hybrid dismantling procedures are similar to other non-hybrid vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the hybrid, as they may not be familiar to dismantlers.

High voltage electricity powers the A/C compressor, electric motor, generator, and inverter/converter.

All other conventional automotive electrical devices such as the headlights, radio, and gauges are powered from a separate 12 Volt auxiliary battery.

The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.

High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis of the vehicle.

By following the information in this guide, dismantlers will be able to handle Prius-electric vehicles as safely as the dismantling of a conventional non-hybrid automobile.

Precaution to be observed when dismantling the vehicle

WARNING:

• Never assume that the hybrid vehicle is shut off simply because it is silent.
  

• Assure that READY indicator is off.
  

• Remove the key from the key slot.
  

• After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.
  

• Before dismantling the high-voltage system, take measures such as wearing insulated gloves and removing the service plug to prevent electrocution.
  

• If either of the disabling steps above cannot be performed, proceed with caution as there is no assurance that the high voltage electrical system, SRS, or fuel pump is disabled.
  

• Never touch, cut, or open any orange high voltage power cable or high voltage component.
  

 Necessary items

• Protective clothing (insulated gloves, rubber gloves, safety goggles, and safety shoes).
  

• Vinyl tape for insulation
  

• Before wearing insulated the vehicle gloves, make sure that they are not cracked, ruptured, torn, or damaged in any other way. Do not wear wet insulated glove
  

Spillage

The Hybrid contains the same common automotive fluids used in other non-hybrid vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however, is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked. A catastrophic crash that would breach both the metal battery pack case and a metal battery module would be a rare occurrence.

Similar to using baking soda to neutralise a lead-acid battery electrolyte spillage, a dilute boric acid solution or vinegar is used to neutralise the NiMH battery electrolyte spillage.

Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE):

• Splash shield or safety goggles. A fold down face shield is not acceptable for acid or electrolyte spills.
  

• Rubber, latex or nitrile gloves.
  

• Apron suitable for alkaline.
  

• Rubber boots.
  

Neutralize NiMH electrolyte.

• Use a boric acid solution or vinegar.
  

• Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric acid to 1 gallon of water.
  

Dismantling a Vehicle

Remove the key from the key slot.

Disconnect the negative (-) terminal of the auxiliary battery and remove the service plug.

Remove the deck floor box rear as shown in the illustration.

Slide up the liver of the service plug. Remove the service plug grip while turning the lever to the left.

Insulate the service plug socket with insulating tape.