Toyota Prius c Bedienungsanleitung

Gasoline-Electric

Hybrid Synergy Drive

NHP10 Series

Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota Prius c

gasoline-electric hybrid vehicles. Prius c dismantling procedures are similar to other non-hybrid

Toyota 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 Toyota Prius c hybrid,

as they may not be familiar to dismantlers.

High voltage electricity powers theA/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. Numerous safeguards have been designed into the

Prius c to help ensure the high voltage, approximately 144 Volt, Nickel Metal Hydride (NiMH) Hybrid

Vehicle (HV) battery pack is kept safe and secure in an accident.

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.

Additional topics contained in the guide include:

• Toyota Prius c identification.

• Major hybrid component locations and descriptions.

By following the information in this guide, dismantlers will be able to handle Prius c-electric vehicles as

safely as the dismantling of a conventional non-hybrid automobile.

copied, in whole or in part, without the written permission

of Toyota Motor Corporation.

iii

Table of Contents

About the Prius c..........................................................................................................................................1

Prius c Identification....................................................................................................................................2

Exterior .........................................................................................................................................................3

Interior...........................................................................................................................................................4

Engine Compartment....................................................................................................................................5

Hybrid Component Locations & Descriptions...........................................................................................6

Specifications................................................................................................................................................7

Hybrid Synergy Drive Operation................................................................................................................8

Vehicle Operation..........................................................................................................................................8

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery........................................................................9

HV Battery Pack............................................................................................................................................9

Components Powered by the HV Battery Pack.............................................................................................9

HV Battery Pack Recycling.........................................................................................................................10

Auxiliary Battery..........................................................................................................................................10

High Voltage Safety ....................................................................................................................................11

High Voltage Safety System........................................................................................................................11

Service Plug Grip........................................................................................................................................12

Precaution to be observed when dismantling the vehicle........................................................................13

Necessary Items.........................................................................................................................................13

Spills.............................................................................................................................................................14

Dismantling the vehicle..............................................................................................................................15

Removal of HV battery ..............................................................................................................................18

HV Battery Caution Label.........................................................................................................................25

About the Prius c

The Prius c hatchback joins the PRIUS, CAMRY hybrid and HIGHLANDER hybrid as

a hybrid model for Toyota. Hybrid Synergy Drive means that the vehicle contains a

gasoline engine and an electric motor for power. The two hybrid power sources are

stored on board the vehicle:

1. Gasoline stored in the fuel tank for the gasoline engine.

2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the

electric motor.

The result of combining these two power sources is improved fuel economy and

reduced emissions. The gasoline engine also powers an electric generator to recharge

the battery pack; unlike a pure all electric vehicle, the Prius c never needs to be

recharged from an external electric power source.

Depending on the driving conditions one or both sources are used to power the vehicle.

The following illustration demonstrates how the Prius c operates in various driving

modes.

nDuring light acceleration at low speeds, the vehicle is powered by the electric motor.

The gasoline engine is shut off.

oDuring normal driving, the vehicle is powered mainly by the gasoline engine. The

gasoline engine also powers the generator to charge the battery pack and to drive the

electric motor.

pDuring full acceleration, such as climbing a hill, both the gasoline engine and the

electric motor power the vehicle.

qDuring deceleration, such as when braking, the vehicle regenerates the kinetic

energy from the wheels to produce electricity that recharges the battery pack.

rWhile the vehicle is stopped, the gasoline engine and electric motor are off, however

the vehicle remains on and operational.

rStopping

oNormal Driving

nStarting p

Acceleration

Deceleration

Electricity Electricity and gasoline

Charging batteries

Electricity and gasoline

(additional electricity

extracted from batteries)

Engine automatically

stopped

Prius c Identification

In appearance, the 2012 model Prius c is a 5-door hatchback. Exterior, interior, and engine

compartment illustrations are provided to assist in identification.

The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front

windshield cowl*, right side floor and on the left side B pillar.

*: Models for U.S.A. and Canada

Example VIN:

JTDKDTB30C3000101 (U.S.A., Canada)

JTDKD3B30C3000101 (Others)

APrius c is identified by the first 8 alphanumeric characters JTDKDTB3 or JTDKD3B3.

Left Side Windshield*, Right Side Floor and Left Side Door Pillar

*: Models for U.S.A. and Canada

Prius c Identification (Continued)

Exterior

nand logos on the back door.

ologo on each front fender.

Exterior Left Side View

xterior Front View

Exterior Rear View

Exterior Rear and Left Side View

Others:

U.S.A. and Canada:

Others:

U.S.A. and Canada:

Prius c Identification (Continued)

Interior

pInstrument cluster (speedometer, READY light, shift state indicators, warning lights) located

in center of the dash and near the base of the windshield.

Hint:

If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not

illuminated.

Interior View of Front Door Sill/Scuff Plate

Instrument Cluster View

READY Indicator

Prius c Identification (Continued)

Engine Compartment

q1.8-liter aluminum alloy gasoline engine.

rLogo on the plastic engine cover.

sOrange colored high voltage power cables.

Engine Compartment View

Power Cables

Hybrid Component Locations & Descriptions

Component Location Description

12 Volt n

Auxiliary Battery Under Right

Side Rear Seat A lead-acid battery that supplies power to the low voltage

devices.

Hybrid oVehicle

(HV) Battery Pack Mounted to

Cross Member

Under Rear

Seat

144 Volt Nickel Metal Hydride (NiMH) battery pack

consisting of 20 low voltage (7.2 Volt) modules connected

in series.

Power pCables Undercarriage and

Engine

Compartment

Orange colored power cables carry high voltage Direct

Current (DC) between the HV battery pack,

inverter/converter, and A/C compressor. These cables

also carry 3-phase Alternating Current (AC) between the

inverter/converter, electric motor, and generator.

Inverter/

Converter qEngine

Compartment Boosts and inverts the high voltage electricity from the

HV battery pack to 3-phaseAC electricity that drives the

electric motors. The inverter/converter also converts AC

electricity from the electric generator and electric motors

(regenerative braking) to DC that recharges the HV

battery pack.

Gasoline r

Engine Engine

Compartment Provides two functions:

1) Powers vehicle.

2) Powers generator to recharge the HV battery pack.

The engine is started and stopped under control of the

vehicle computer.

Electrics

Motor Engine

Compartment 3-phase high voltageAC permanent magnet electric motor

contained in the front transaxle. It is used to power the

front wheels.

Electric t

Generator Engine

Compartment 3-phase high voltageAC generator that is contained in the

transaxle and recharges the HV battery pack.

A/C Compressor

(with Inverter) uEngine

Compartment 3-phase high voltage AC electrically driven motor

compressor.

Fuel Tank and Fuel

Line vUndercarriage and

Center The fuel tank provides gasoline via a fuel line to the

engine. The fuel line is routed under the center of

vehicle.

*Numbers in the component column apply to the illustrations on the following page.

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