Toyota Prius NHW20 Series Bedienungsanleitung

Gasoline-Electric

Hybrid Synergy Drive

NHW20 Series

Foreword

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

Toyota Prius gasoline-electric hybrid vehicle. Prius dismantling procedures are similar to

other 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 as they may not be familiar to dismantlers.

High voltage electricity powers an electric motor, generator, electric inverter compressor

(for air conditioner) and inverter. All other conventional automotive electrical devices

such as the headlights, radio, and gauges are powered from a separate 12-Volt battery.

Numerous safeguards have been designed into the Prius to help ensure the high voltage,

approximately 201-Volts, Nickel Metal Hydride (Nigh) Hybrid Vehicle (HV) battery pack is

kept safe and secure in an accident.

The Nigh HV battery pack contains sealed batteries that are similar to rechargeable

batteries used in laptop computers, cell phones, 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 identification.

•Major hybrid component locations and descriptions.

By following the information in this guide, dismantlers will be able to handle the Prius

hybrid-electric vehicle as safely as the dismantling of a conventional gasoline engine

automobile.

reproduced or copied, in whole or in part, without

the written permission of Toyota Motor

Corporation

iii

Table of Contents

ABOUT THE PRIUS................................................................................................................... 1

PRIUS IDENTIFICATION ........................................................................................................... 2

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

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

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

HYBRID COMPONENT LOCATIONS & DESCRIPTIONS......................................................... 6

Specifications....................................................................................................................................................6

GASOLINE-ELECTRIC HYBRID VEHICLE 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....................................................................................................................................................11

PRECAUTION TO BE OBSERVED WHEN DISMANTLING THE VEHICLE ........................... 13

Necessary items.............................................................................................................................................13

SPILLAGE................................................................................................................................ 14

DISMANTLING A VEHICLE..................................................................................................... 15

REMOVAL OF HV BATTERY................................................................................................... 18

HV battery removal.........................................................................................................................................18

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

About the Prius

The Toyota Prius (NHW20 Series) is a gasoline-electric hybrid vehicle sold in the

world since September 2003. Gasoline-electric hybrid means the vehicle contains a

gasoline engine and an electric motor for power. Two energy 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 increased fuel economy and

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

the battery pack; so, unlike a pure all electric vehicles, the Prius 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 illustrations demonstrate how the Prius operates in various driving

modes.

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

The gasoline engine is shut off.

During normal driving, the vehicle is powered mainly by the gasoline engine.

The gasoline engine is also used to recharge the battery pack.

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

electric motor power the vehicle.

During deceleration, such as braking, the vehicle regenerates the kinetic energy

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

While the vehicle is stopped, the gasoline engine and electric motor are off;

however the vehicle remains on and operational.



Prius Identification

In appearance, the Prius is similar to a 5 door hatch back. Exterior,

interior, and engine compartment illustrations are provided to assist in the

identification.

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

the front windshield cowl and driver door post.

Example VIN: JTDKB22U840020208

(A Prius is identified by the first 6 alphanumeric characters JTDKB2)

VIN Plate Locations

Exterior



Hybrid Synergy Drive

PRIUS

logos on trunk.

Gasoline fuel filler door located on left side quarter panel.

Toyota logo on the hood.

Exterior Rear & Left Side View

Exterior Left Side View

Exterior Front View



Hybrid

Synergy

Drive





Prius Identification (Continued)

Interior

Center cluster mounted automatic transmission shift selector lever.

Instrument cluster (speedometer, fuel gauge and warning lights) located in the

dash and near the base of the windshield.

LCD monitor (fuel consumption and radio controls) located below the

instrument cluster.

Interior View

Instrument Cluster & LCD Monitor





[

Engine Compartment

1.5 liter aluminum alloy gasoline engine.

High voltage inverter with the

Toyota Synergy Drive

logo on the cover.

Orange colored high voltage power cables.

Toyota Synergy Drive

Logo on

Inverter

Engine Compartment







Hybrid Component Locations & Descriptions

Component Location Description

12-Volt Auxiliary

Battery 

Luggage, RH Side Low voltage lead-acid battery that controls all

electrical equipment except electric motor generator

and inverter.

Hybrid Vehicle

(HV) Battery

Pack 

Luggage, Mounted

to Cross Member &

Behind Rear Seat

201.6-Volts Nickel Metal Hydride (NiMH) battery pack

consisting of 28 low voltage (7.2-volts) modules

connected in series.

Power Cables



Under Carriage &

Engine

Compartment

Orange colored power cables carry high voltage

Direct Current (DC) between the HV battery pack and

inverter. Also carry 3 phase Alternating Current (AC)

between inverter, motor, and generator.

InverterEngine

Compartment

Converts 200V DC electricity from HV battery pack

into 500V DC electricity that drives the electric motor.

Also, converts AC from electric generator and motor

(regenerative braking) into DC that recharges HV

battery pack.

Gasoline

Engine 

Engine

Compartment

Provides two functions: 1) powers vehicle; 2) powers

generator to recharge HV battery pack. Engine is

started and stopped under control of vehicle

computer.

Electric Motor



Engine

Compartment

3 Phase AC permanent magnetic electric motor

contained in transaxle. Used to power the vehicle.

Electric

Generator 

Engine

Compartment

3 Phase AC generator contained in transaxle. Used to

recharge HV battery pack.

Fuel Tank 

and Fuel Lines

Undercarriage, RH

Side

Fuel tank provides gasoline via a single fuel line to the

engine. The fuel line is routed along RH side under

the floor pan.

Specifications

Gasoline Engine: 1.5 liter Aluminum Alloy Engine

NorthAmerica: 57KW (76hp). Europe , Australia and others: 57KW (77PS)

Electric Motor: 50 KW (68 PS), Permanent Magnet Motor

Transmission: Automatic Only

HV Battery: 201.6-Volts Sealed NiMH

Curb Weight: NorthAmerica: 1,310 Kg (2890lbs), Europe: 1,300 kg,Australia: 1,295kg

Fuel Tank: 45 litters / 11.9 gals

Frame Material: Steel Unibody & Steel Body Panels and Aluminum engine food/back door

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