ERG Highlander

Hybrid
2010 Model
3rd Generation
© 2009 Toyota Motor Corporation
All rights reserved. This document may not be
altered without the written permission of Toyota Motor Corporation.
10 Prius ERG REV – (09/21/09)
Foreword
In May 2000 and October 2003, Toyota introduced the 1st and 2nd
generation Toyota Prius gasoline-electric hybrid vehicles in North
America. To educate and assist emergency responders in the safe
handling of Toyota Prius technology, Toyota published the 2000 and
2004 Toyota Prius Emergency Response Guides.
A body electrical system rated at 12 Volts, negative chassis ground.
Supplemental Restraint System (SRS) – dual stage frontal airbags,
front seat mounted side airbags, side curtain airbags, front seatbelt
pretensioners, and driver knee airbag.
High voltage electrical safety remains an important factor in the
emergency handling of the Prius Hybrid Synergy Drive. It is important
to recognize and understand the disabling procedures and warnings
throughout the guide.
rd
With the release of the 3 generation Toyota Prius in May 2009, a new
2010 Toyota Prius Emergency Response Guide was published for
emergency responders. While many features from the 1st and 2nd
generation Prius models are similar, emergency responders should
recognize and understand the new, updated features of the Prius
covered in this guide.
Additional topics in the guide include:
Prius identification.
Major Hybrid Synergy Drive component locations and descriptions.
Extrication, fire, recovery, and additional emergency response
information.
Roadside assistance information.
High voltage electricity powers the electric motor, generator, air
conditioning compressor and inverter/converter. All other 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 to help ensure the high voltage,
approximately 201.6 Volt, Nickel Metal Hydride (NiMH) Hybrid
Vehicle (HV) battery pack is kept safe and secure in an accident.
The Prius utilizes the following electrical systems:
Maximum 650 Volts AC
Nominal 201.6 Volts DC
Maximum 27 Volts DC
Nominal 12 Volts DC
2010 Model Year
Prius
3rd generation Prius Features:
Complete model change with a new exterior and interior design.
A boost converter in the inverter/converter that boosts the available
voltage to the electric motor to 650 Volts.
A high voltage Hybrid Vehicle (HV) battery pack rated at 201.6
Volts.
A high voltage motor driven Air Conditioning (A/C) compressor
rated at 201.6 Volts and optional remote air conditioning system.
An optional solar ventilation system rated at 27 Volts.
2004 – 2009 Model Year
Prius
This guide is intended to assist emergency responders in the safe
handling of a Prius vehicle during an incident.
NOTE:
Emergency Response Guides for Toyota hybrid and alternative fuel
vehicles may be viewed at http://techinfo.toyota.com.
-i-
Table of Contents
Page
About the Prius
1
Prius Identification
2
Hybrid Synergy Drive Component Locations & Descriptions
5
Smart Key System
8
Electronic Gearshift Selector
10
Hybrid Synergy Drive Operation
11
Hybrid Vehicle (HV) Battery Pack
12
Solar Ventilation and Remote Air Conditioning Systems
13
Low Voltage Battery
15
High Voltage Safety
16
SRS Airbags & Seat Belt Pretensioners
17
Emergency Response
19
Extrication
Fire
Overhaul
Recovering/Recycling of NiMH HV Battery Pack
Spills
First Aid
Submersion
Roadside Assistance
19
28
29
29
30
30
31
32
-ii-
About the Prius
The Prius continues into its 3rd generation as a gasoline-electric hybrid
vehicle. Hybrid Synergy Drive means that the vehicle contains a
gasoline engine and 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 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 operates in various driving modes.
During full acceleration, such as climbing a hill, both the gasoline
engine and the electric motor power the vehicle.
During light acceleration at low speeds, the vehicle is powered by
the electric motor. The gasoline engine is shut off.
During deceleration, such as when braking, the vehicle regenerates
kinetic energy from the front wheels to produce electricity that
recharges the battery pack.
During normal driving, the vehicle is powered mainly by the
gasoline engine. The gasoline engine also powers the generator to
recharge the battery pack.
While the vehicle is stopped, the gasoline engine and electric motor
are off, however the vehicle remains on and operational.
-1 -
Prius Identification
Exterior
In appearance, the 2010 model year Prius is a 5-door hatchback.
Exterior, interior, and engine compartment illustrations are provided to
assist in identification.
and
logos on the hatch.
Gasoline fuel filler door located on driver side rear quarter panel.
The alphanumeric 17 character Vehicle Identification Number (VIN) is
provided in the front windshield cowl and on the driver door pillar.
Example VIN: JTDKN3DUA82020211
JTDKN3DU
A Prius is identified by the first 8 alphanumeric characters
JTDKN3DU.
Exterior Driver Side View
Driver Side Windshield and Driver Side B Pillar
Exterior Front and Rear View
Exterior Rear and Driver Side View
-2 -
Prius Identification (Continued)
Interior
Instrument cluster (speedometer, READY light, shift position indicators,
warning lights) located in center of the dash and near the base of the
windshield.
Interior View
Instrument Cluster View
-3 -
Prius Identification (Continued)
Engine Compartment
1.8-liter aluminum alloy gasoline engine.
Logo on the plastic engine cover.
Engine Compartment View
-4 -
Hybrid Synergy Drive Component Locations &
Descriptions
Component
12 Volt
Auxiliary
Battery
Hybrid
Vehicle (HV)
Battery Pack
Power
Cables
Location
Description
Passenger Side of A lead-acid battery that supplies power to
Cargo Area
the low voltage devices.
Cargo Area,
Mounted to Cross
Member behind
Rear Seat
Undercarriage
and Engine
Compartment
Inverter/
Converter
Engine
Compartment
Gasoline
Engine
Engine
Compartment
Electric
Motor
Engine
Compartment
Electric
Generator
Engine
Compartment
201.6 Volt Nickel Metal Hydride (NiMH)
battery pack consisting of 28 low voltage
(7.2 Volt) modules connected in series.
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 3phase Alternating Current (AC) between the
inverter/converter, electric motor, and
generator.
Boosts and inverts the high voltage
electricity from the HV battery pack to 3phase AC electricity that drives the electric
motor. The inverter/converter also converts
AC electricity from the electric generator
and electric motor (regenerative braking) to
DC that recharges the HV battery pack.
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.
3-phase high voltage AC permanent magnet
electric motor contained in the front
transaxle. It is used to power the front
wheels.
3-phase high voltage AC generator that is
contained in the transaxle and recharges the
HV battery pack.
Hybrid Synergy Drive Components
Components (Top View) and High Voltage Power Cables
-5 -
Hybrid Synergy Drive Component Locations &
Descriptions (Continued)
Component
A/C
Compressor
(with
Inverter)
Fuel Tank
and Fuel Line
Location
Description
Engine
Compartment
3-phase high voltage AC electrically driven
motor compressor.
Undercarriage
and Center
The fuel tank provides gasoline via a fuel
line to the engine. The fuel line is routed
under the center of vehicle.
Fuel Tank and Fuel Line
-6 -
Hybrid Synergy Drive Component Locations &
Descriptions (Continued)
Key Specifications:
Aluminum Hood
Aluminum Hatch
Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine
Electric Motor: 80 hp (60 kW), Permanent Magnet Motor
Transmission: Automatic Only (electrically controlled
continuously variable transaxle)
HV Battery: 201.6 Volt Sealed NiMH Battery
Curb Weight: 3,080 lbs/1,397 kg
Fuel Tank: 11.9 gals/45.0 liters
Fuel Economy
Ratings: 51/48 (City/Hwy) miles/gal
4.7/4.8 (City/Hwy) liters/100 km
Frame Material: Steel Unibody
Body Material: Steel Panels except for Aluminum Hood and Hatch
Seating Capacity: 5 passenger
Steel Unibody
-7 -
Smart Key System
The Prius smart key system consists of a smart key transceiver that
communicates bi-directionally, enabling the vehicle to recognize the
smart key in proximity to the vehicle. Once recognized, the smart key
will allow the user to lock and unlock the doors without pushing smart
key buttons, and start the vehicle without inserting it into an ignition
switch.
Release Button
Smart key features:
Passive (remote) function to lock/unlock the doors and start the
vehicle.
Wireless transmitter buttons to lock/unlock all 5 doors.
Hidden metal cut key to lock/unlock the doors.
Smart Key (Fob)
Hidden Metal Cut Key for Door Lock
Unlock Touch Sensor
Door (Lock/Unlock)
There are several methods available to lock/unlock the doors.
Pushing the smart key lock button will lock all doors including the hatch.
Pushing the smart key unlock button once unlocks the driver door, twice
unlocks all doors.
Touching the sensor on the backside of the driver door exterior handle, with
the smart key in proximity to the vehicle, unlocks the driver door. Touching
the sensor on the backside of the front passenger door exterior handle, with
the smart key in proximity to the vehicle, unlocks all doors. Touching the
lock sensor on either front door, or the lock button for the hatch will lock
all doors.
Inserting the hidden metal cut key in the driver door lock and turning
clockwise once unlocks the driver door, twice unlocks all doors. To lock
all doors turn the key counter clockwise once. Only the driver door
contains an exterior door lock for the metal cut key.
Lock Touch Sensor
Driver Door Unlock Touch Sensor and
Lock Touch Sensor
Optional Hatch Lock Button
-8 -
Use the Hidden Metal Cut Key
Front Driver Door Lock
Smart Key System (Continued)
Ignition Mode
Off
Accessory
Ignition-On
Brake Pedal Depressed
Vehicle Started (READY-ON)
Malfunction
Vehicle Starting/Stopping
The smart key has replaced the conventional metal cut key, and the power
button with an integral status indicator light has replaced the ignition switch.
The smart key only needs to be in proximity to the vehicle to allow the system
to function.
Power Button Indicator Light
Off
Amber
Amber
Green
Off
Blinking Amber
With the brake pedal released, the first push of the power button operates
the accessory mode, the second push operates the ignition-on mode, and the
third push turns the ignition off again.
Ignition Mode Sequence (brake pedal released):
Vehicle Off Button Push Accessory Button Push Ignition-On
Button Push
Starting the vehicle takes priority over all other ignition modes and is
accomplished by depressing the brake pedal and pushing the power button
once. To verify the vehicle has started, check that the power button status
indicator light is off and the READY light is illuminated in the instrument
cluster.
Power Button with Integral Status
Indicator Light
Ignition Modes (Brake Pedal Released)
Starting Sequence
(Brake Pedal Depressed)
Smart Key Recognition
(When Smart Key Battery is Dead)
If the internal smart key battery is dead, use the following method to start
the vehicle.
1. Touch the Toyota emblem side of the smart key to the power button.
2. Within the 5 seconds after the buzzer sounds, push the power button
with the brake pedal depressed (the READY light will illuminate).
Once the vehicle has started and is on and operational (READY-ON), the
vehicle is shut off by bringing the vehicle to a complete stop and then
depressing the power button once.
To shut off the vehicle before coming to a stop in an emergency, push and
hold down the power button for more than 3 seconds. This procedure may
be useful at an accident scene in which the READY indicator is on, Park
cannot be selected, and the drive wheels remain in motion.
-9 -
Electronic Gearshift Selector
The Prius electronic gearshift selector is a momentary select shift-bywire system that engages the transaxle in Reverse, Neutral, Drive, or
engine Brake modes.
These modes may only be engaged while the vehicle is on and operational
(READY-on), except for Neutral which may also be engaged while in the
ignition-on mode. After selecting the gear position R, N, D, or B the
transaxle remains in that position, identified on the instrument cluster, but
the shift selector returns to a default position. To select Neutral, it is
necessary to hold the shift selector in the N position for approximately 0.5
seconds.
Default
Position
Unlike a conventional vehicle, the electronic shift selector does not contain
a park position. Instead, a separate P switch located above the shift selector
engages the park (P) position.
Electronic Gearshift Selector and P Switch
When the vehicle is stopped, regardless of shift selector position, the
electro-mechanical parking pawl is engaged to lock the transaxle into park
by either depressing the P switch or pushing the power button to shut off
the vehicle.
Being electronic, the gearshift selector and the park systems depend on the
low voltage 12 Volt auxiliary battery for power. If the 12 Volt auxiliary
battery is discharged or disconnected, the vehicle cannot be started and
cannot be shifted out of park.
Indicates
Gear Position
Instrument Cluster Gear Position Indicator
-10-
Hybrid Synergy Drive Operation
Once the READY indicator is illuminated in the instrument cluster, the
vehicle may be driven. However, the gasoline engine does not idle like a
typical automobile and will start and stop automatically. It is important
to recognize and understand the READY indicator provided in the
instrument cluster. When lit, it informs the driver that the vehicle is on
and operational even though the gasoline engine may be off and the
engine compartment is silent.
Vehicle Operation
With the Prius, the gasoline engine may stop and start at any time while the
READY indicator is on.
Instrument Cluster READY Indicator
Never assume that the vehicle is shut off just because the engine is off.
Always look for the READY indicator status. The vehicle is shut off when
the READY indicator and instrument cluster lights are off.
The vehicle may be powered by:
1. The electric motor only.
2. The gasoline engine only.
3. A combination of both the electric motor and the gasoline engine.
The vehicle computer determines the mode in which the vehicle operates in
order to improve fuel economy and reduce emissions. Three new features
on the 2010 Prius are EV (Electric Vehicle) mode, Power mode and ECO
(Economy) mode:
1. EV Mode: When activated, and certain conditions have been met,
2.
3.
the vehicle operates with the electric motor powered by the HV
battery.
ECO Mode: When activated, this mode helps enhance fuel
economy on trips that involve frequent braking and acceleration.
Power Mode: When activated, power mode optimizes acceleration
feel by increasing the power output more quickly at the beginning
of accelerator pedal operation.
EV Drive Mode Switch/Economy Drive Mode Switch/Power Mode Switch
-11-
Hybrid Vehicle (HV) Battery Pack
Components Powered by the HV Battery Pack
The Prius features a high voltage Hybrid Vehicle (HV) battery pack that
contains sealed Nickel Metal Hydride (NiMH) battery modules.
Front Electric Motor
Power Cables
Electric Generator
HV Battery Pack
The HV battery pack is enclosed in a metal case and is rigidly mounted to
the cargo area floor pan cross member behind the rear seat. The metal case
is isolated from high voltage and concealed by carpet in the cabin area.
Inverter/Converter
A/C Compressor
HV Battery Pack Recycling
The HV battery pack is recyclable. Contact the nearest Toyota dealer or:
The HV battery pack consists of 28 low voltage (7.2 Volt) NiMH battery
modules connected in series to produce approximately 201.6 Volts. Each
NiMH battery module is non-spillable and in a sealed case.
United States: (800) 331-4331
Canada: (888) TOYOTA 8 [(888) 869-6828]
The electrolyte used in the NiMH battery module is an alkaline mixture of
potassium and sodium hydroxide. The electrolyte is absorbed into the
battery cell plates and will not normally leak, even in a collision.
HV Battery Pack
Battery pack voltage
Number of NiMH battery modules in the pack
NiMH battery module voltage
NiMH battery module dimensions
NiMH module weight
NiMH battery pack dimensions
NiMH battery pack weight
201.6 V
28
7.2 V
11.2 x 0.8 x 4.6 in
(285 x 19.6 x 117.8 mm)
2.3 lbs (1.04 kg)
11.7 x 23.2 x 0.42 in
(297 x 590 x 10.7 mm)
90 lbs (41 kg)
HV Battery Pack
-12-
Solar Ventilation and Remote Air Conditioning Systems
Solar Panel
Two newly available options on the 2010 Prius are the solar ventilation
system and the remote air conditioning system. These systems are
provided to enhance occupant comfort by lowering the inside cabin
temperature while the vehicle is shut off and parked.
Solar Panel
Wiring
Solar Ventilation System
The solar ventilation system uses energy provided by a solar panel built into the
roof to operate the blower fan contained within the air conditioning system.
This allows ventilation of the vehicle interior when the vehicle is parked in
direct sunlight.
Glass
The solar panel is located on the roof above the rear passenger space, as shown
in the illustration. It consists of 36 poly crystalline silicon solar cells connected
in series, and is primarily constructed from glass, potting material, silicon,
silver and aluminum compounds, and a back sheet.
Potting Material
(Ethylene Vinyl Acetate Resin)
Back Sheet (Polyvinyl Fluoride Resin)
Optional Solar Panel
The solar panel generates a nominal 60 Watts of electricity, and although the
voltage and current output vary by temperature and sunlight intensity, the panel
does not produce high voltage. For example, the solar panel output is 22 Volts
on an average sunny day (77oF, 25oC) and has a maximum output of 27 Volts in
sub zero temperatures (-22oF, -30oC). The maximum current of 3.6 Amps
occurs at full sunlight intensity.
Safety Concerns
The Prius solar panel is similar to the ones used in residential or commercial
buildings except it does not operate at high voltage and does not use storage
batteries.
Since voltage is generated when the solar panel is exposed to sunlight, the
output wire may be energized even after the vehicle is shut off and the 12 Volt
auxiliary battery is disconnected. Current will only flow if the solar ventilation
blower fan circuit is turned on.
The solar panel output wire is not electrically connected to the 12 Volt auxiliary
battery, SRS airbags, or the HV battery pack. The solar panel output will not
back feed power to these circuits.
Breaking or cutting the solar panel is generally not a hazard except for injury
that may occur from material fragments.
-13-
Solar Cell (Silicon, Silver and
Aluminum Compounds)
Solar Ventilation and Remote Air Conditioning Systems
(Continued)
Optional Remote Air Conditioning System
System Disabling:
To disable the remote air conditioning system, first shut off the vehicle by
pushing the power button if necessary and ensuring that the READY indicator
and instrument cluster lights are off. Second, disconnect the 12 Volt auxiliary
battery. After performing these two steps, the remote air conditioning system
will be disabled and will not activate even if the smart key A/C button is pushed.
The remote air conditioning system is similar to a remote engine start system
used in a conventional gasoline vehicle to precondition the vehicle interior
while the vehicle is parked. Unlike a conventional gasoline vehicle, the Prius
does not start the gasoline engine. Instead it utilizes the energy stored in the
High Voltage HV battery pack to operate the high voltage air conditioning
compressor to cool the vehicle interior. The system is activated remotely by
pushing the smart key A/C button and will operate for up to three minutes when
certain conditions are met.
Safety Concerns
Since the operation of the remote air conditioning system allows high voltage
electrical flow, it is important to recognize how the system is activated,
deactivated, and disabled.
A/C Button
System Activation:
When the remote air conditioning system is activated, high voltage cables are
energized and high voltage electricity flows from the HV battery pack to the air
conditioning compressor. The system is operating when all of the following
conditions occur:
All doors are locked.
The instrument cluster lights are on, but the READY indicator light is
off.
Air is flowing from the interior vehicle vents, and the blower fan noise
may be heard.
Optional Remote Air Conditioning System A/C Button
Air
Conditioning
Compressor
System Deactivation:
When the system is deactivated, the high voltage cables are de-energized and
high voltage electrical flow stops from the HV battery pack. The system is
deactivated when any one of the following conditions occur:
After about 3 minutes of operation.
When the HV battery pack charge level is low.
When a door is opened, the hood is opened, or the brake pedal is
depressed.
When the smart key A/C button is pushed twice within 3 seconds.
When conditions for operation are not met.
12 Volt Auxiliary
Battery
High Voltage Flow
HV Battery
Remote Air Conditioning System Operation (READY Indicator Off)
-14-
Low Voltage Battery
Auxiliary Battery
The Prius contains a sealed lead-acid 12 Volt battery. The 12 Volt
auxiliary battery powers the vehicle’s electrical system similar to a
conventional vehicle. As with conventional vehicles, the negative terminal
of the auxiliary battery is grounded to the metal chassis of the vehicle.
The auxiliary battery is located in the cargo area. It is concealed by a fabric
cover on the passenger side in the rear quarter panel well.
NOTE:
An under hood label shows the location of the HV battery (traction battery)
and 12 Volt auxiliary battery.
Remove Center Deck Board
Remove Center Auxiliary Box
Battery Cover
12 Volt Auxiliary Battery Mounted in
Cargo Area
Battery Location Label
-15-
High Voltage Safety
A ground fault monitor continuously monitors for high voltage leakage
to the metal chassis while the vehicle is running. If a malfunction is
detected, the hybrid vehicle computer will illuminate the master warning
light
in the instrument cluster and indicate “Check Hybrid System” on
the multi-information display.
The HV battery pack powers the high voltage electrical system with DC
electricity. Positive and negative orange colored high voltage power cables are
routed from the battery pack, under the vehicle floor pan, to the
inverter/converter. The inverter/converter contains a circuit that boosts the HV
battery voltage from 201.6 to 650 Volts DC. The inverter/converter creates 3phase AC to power the motor. Power cables are routed from the
inverter/converter to each high voltage motor (electric motor, electric generator,
and A/C compressor). The following systems are intended to help keep
occupants in the vehicle and emergency responders safe from high voltage
electricity:
High Voltage Safety System
A high voltage fuse
pack.
provides short circuit protection in the HV battery
Positive and negative high voltage power cables connected to the HV
battery pack are controlled by 12 Volt normally open relays . When the
vehicle is shut off, the relays stop electrical flow from leaving the HV
battery pack.
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
WARNING:
The high voltage system may remain powered for up to 10 minutes after
the vehicle is shut off or disabled. To prevent serious injury or death
from severe burns or electric shock, avoid touching, cutting, or
breaching any orange high voltage power cable or high voltage
component.
Both positive and negative power cables are insulated from the metal
body. High voltage electricity flows through these cables and not through
the metal vehicle body. The metal vehicle body is safe to touch because it is
insulated from the high voltage components.
High Voltage Safety System – Vehicle On and Operational (READY-ON)
-16-
SRS Airbags & Seat Belt Pretensioners
Standard Equipment
Electronic frontal impact sensors (2) are mounted in the engine
compartment as illustrated.
Front seat belt pretensioners are mounted near the base of the B-pillars .
A frontal dual stage driver airbag is mounted in the steering wheel hub.
A frontal twin-chamber shaped dual stage passenger airbag is integrated
into the dashboard and deploys through the top of the dashboard.
The SRS computer , which contains an impact sensor, is mounted on the
floor pan underneath the instrument panel, forward of the shift lever.
Front electronic side impact sensors (2) are mounted near the base of the Bpillars.
Rear electronic side impact sensors (2) are mounted near the base of the Cpillars.
Front seat side airbags are mounted in the front seatbacks.
Side curtain airbags are mounted along the outer edge inside the roof
rails.
Driver knee airbag is mounted on the lower portion of the dash.
Active (mechanical non-pyrotechnic) front seat headrests (see description
on page 27).
Electronic Impact Sensors and Side Airbags
Side Curtain Airbag
Inflators
Optional Equipment
The optional pre-collision safety system contains a radar sensory
system, occupant seat sensor, and an electric motor-pyrotechnic
pretensioner system. During a pre-collision event, an electric motor in
the pretensioners retracts the front seatbelts. When conditions stabilize
the electric motor will reverse itself. When the airbags deploy, the
pyrotechnic pretensioners function normally.
WARNING:
The SRS may remain powered for up to 90 seconds after the vehicle is
shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS components.
Standard Frontal Airbags, Seat Belt Pretensioners, Knee Airbag, Side Curtain
Airbags
-17-
SRS Airbags & Seat Belt Pretensioners (Continued)
NOTE:
The front seatback mounted side airbags and the side curtain airbags may
deploy independently of each other.
The knee airbag is designed to deploy simultaneously with the frontal airbag.
The Prius is equipped with a standard front passenger occupant
classification system that may prohibit the deployment of the front
passenger frontal airbag, front seatback mounted side airbag, and seat belt
pretensioners. If the passenger occupant classification system prohibits
deployment during an SRS event, the passenger SRS will not re-arm nor
deploy.
Side Airbag Sensor
Front Seat Side Airbag
Front Seat Belt
Pretensioner
Side Curtain Airbag
Rear Side
Airbag Sensor
Passenger Frontal Airbag
Frontal, Knee, Front Seatback Mounted Side, Side Curtain Airbags.
Front Airbag
Sensors
Knee Airbag
Rear Side
Airbag Sensor
Driver Frontal Airbag
Front Seat Side Airbag
Front Seat Belt
Pretensioner
Side Curtain Airbag
Side Airbag Sensor
SRS System Diagram
Driver Knee Airbag and Inflator
-18-
Emergency Response
On arrival, emergency responders should follow their standard
operating procedures for vehicle incidents. Emergencies involving the
Prius may be handled like other automobiles except as noted in these
guidelines for Extrication, Fire, Overhaul, Recovery, Spills, First Aid,
and Submersion.
U.S.A. Canada
WARNING:
Never assume the Prius is shut off simply because it is silent.
Always observe the instrument cluster for the READY indicator
status to verify whether the vehicle is on or shut off. The vehicle
and optional remote air conditioning system are shut off when the
READY indicator is off and the instrument cluster lights are out.
Failure to shut off and disable the vehicle before emergency
response procedures are performed may result in serious injury or
death from the unintentional deployment of the SRS or severe burns
and electric shock from the high voltage electrical system.
Chock Wheels
Extrication
Immobilize Vehicle
Chock wheels and set the parking brake.
Push the P switch to engage park.
Disable Vehicle
Performing either of the following two procedures will shut the
vehicle off and disable the HV battery pack, SRS, gasoline fuel pump,
and optional remote air conditioning system.
P Switch
-19-
Set Parking Brake
Emergency Response (Continued)
Extrication (Continued)
Procedure #1
1.
2.
3.
4.
5.
Confirm the status of the READY indicator in the instrument
cluster. If the READY indicator is illuminated, the vehicle is on
and operational.
Shut off the vehicle by pushing the power button once.
The vehicle is already shut off if the instrument cluster lights are
not illuminated. Do not push the power button because the
vehicle may start.
If the smart key is easily accessible, keep it at least 16 feet (5
meters) away from the vehicle.
Disconnect the 12 Volt auxiliary battery under the cover in the
cargo area to prevent accidental restarting of the vehicle and
operation of the optional remote air conditioning system.
Hatch Opener Switch
-20-
Shut Off Vehicle (READY-OFF)
Open Hatch Door
Remove Center Deck Board
Remove Center Auxiliary Box
Remove Auxiliary Battery Cover
12 Volt Auxiliary Battery in Cargo
Area
Emergency Response (Continued)
Extrication (Continued)
Procedure #2 (Alternate if power button is inaccessible)
1.
2.
3.
4.
Open the hood.
Remove the fuse box cover.
Remove the IGCT fuse (30A green colored) and AM2 fuse
(7.5A orange colored) in the engine compartment fuse box (refer
to illustration). If the correct fuse cannot be recognized, pull all
fuses in the fuse box.
Disconnect the 12 Volt auxiliary battery under the cover in the
cargo area.
Remote Hood Release
NOTE:
Before disconnecting the 12 Volt auxiliary battery, if necessary,
lower the windows, unlock the doors and open the hatch as required.
Once the 12 Volt auxiliary battery is disconnected, power controls
will not operate.
Hood Latch Release
AM2 fuse (7.5A Orange)
WARNING:
The high voltage system may remain powered for up to 10 minutes
after the vehicle is shut off or disabled. To prevent serious injury
or death from severe burns or electric shock, avoid touching,
cutting, or breaching any orange high voltage power cable or high
voltage component.
The SRS may remain powered for up to 90 seconds after the vehicle
is shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS
components.
If none of the disabling procedures can be performed, proceed with
caution as there is no assurance that the high voltage electrical
system, SRS, fuel pump, or optional remote air conditioning system
are disabled.
IGCT fuse (30A Green)
-21-
Remove Fuse Box Cover
IGCT and AM2 Fuse Location in
Engine Compartment Fuse Box
Remove Battery Cover
12 Volt Auxiliary Battery in Cargo
Area
Emergency Response (Continued)
Extrication (Continued)
Stabilize Vehicle
Crib at (4) points directly under the front and rear pillars.
Do not place cribbing under the high voltage power cables, exhaust
system, or fuel system.
NOTE:
The Prius is equipped with a tire pressure warning system that by
design prevents pulling the metal valve stem with integral transmitter
from the wheel. Snapping the valve stem with pliers or removing the
valve cap and Schrader valve will release the air in the tire.
Metal Valve Stem with Integral
Transmitter
Access Patients
Glass Removal
Use normal glass removal procedures as required.
SRS Awareness
Responders need to be cautious when working in close proximity
to undeployed airbags and seat belt pretensioners. Front dual
stage airbags automatically ignite both stages within a fraction of
a second.
Cribbing Points
Door Removal/Displacement
Doors can be removed by conventional rescue tools such as hand,
electric, and hydraulic tools. In certain situations, it may be
easier to pry back the vehicle body to expose and unbolt the
hinges.
Cribbing Points
-22-
Metal Valve Stem with Integral
Transmitter Installed on Wheel
Emergency Response (Continued)
Extrication (Continued)
Removable Area
Roof Removal
The Prius is equipped with side curtain airbags. If the side
curtain airbags are undeployed, total roof removal is not
recommended. This is to avoid breaching the side curtain airbags,
inflators, and wiring harness. Patient access through the roof can
be performed by cutting the roof center section inboard of the
roof rails as illustrated.
Side Curtain Airbag Inflators
Removable Area
Prius models equipped with the optional solar panel have an
output wire bundled with the side curtain airbag wire harness
routed along the driver side C-pillar as shown in the illustration.
This output wire is energized when the solar panel surface is
exposed to light energy, and similar to a 12 Volt battery positive
cable, it cannot be shut off or isolated until it reaches the control
computer under the dashboard.
Side Curtain Airbag Inflators
Cutting the roof center section may result in cutting into the
optional solar panel and energized output wire. Wear personal
protective equipment to prevent exposure to broken glass,
material fragments, and dust.
Roof Removal Area
Side Curtain Airbag
Wire Harness
NOTE:
The 27 Volt maximum solar panel output wire has a higher arc
potential than 12 Volt wires.
Solar Panel Output Wire
Noise Filter
Solar Panel Output
Wire & Side Curtain
Airbag Wire Bundle
SRS Computer
Solar Panel Output Wire and Side Curtain Airbag Wire Bundle Routing
-23-
Emergency Response (Continued)
Extrication (Continued)
If the driver side curtain airbag is undeployed, avoid cutting the
shaded area shown in the illustration. If this area is cut, there is a
slight possibility of shorting the side curtain airbag harness and
the solar panel energized output wire, resulting in airbag
deployment. If cutting this area is unavoidable, manually disable
the solar panel output wire using one or both of the following
recommendations.
Disable solar panel output by covering the entire panel with a
material that blocks sunlight. Debris bags or salvage covers
have been effective for disabling the solar panel output when
two layers, either two separate layers, or one layer folded
over the other, are used. Make sure the material is free of
holes or tears that would allow sunlight through, and block
the entire solar panel since even a small amount of sunlight
will allow the solar panel to generate power.
Avoid Cutting Shaded Area
NOTE:
Once the solar panel is disabled, the output in the energized wire
drops immediately.
Disable by Covering the Entire Solar Panel
-24-
Emergency Response (Continued)
Extrication (Continued)
Disconnect/Cut Here (red or blue output wire):
Disable solar panel output by disconnecting or cutting the
solar panel energized output wire. Remove the headliner
above the driver side rear passenger area. Identify the red or
blue output wire from under the solar panel as illustrated.
Disconnect the connector or cut the red or blue wire to
disable power output.
Red Output
Wire
Blue Output
Wire
Noise
Filter
NOTE:
The 27 Volt maximum solar panel output wire has a higher arc
potential than 12 Volt wires.
If neither of the above recommendations can be performed, keep
away from the side curtain airbag deployment zone area along the
driver and passenger side window as shown in the illustration.
Solar Panel
Front
Disable Solar Panel Energized Output Wire (Headliner Removed)
Dash Displacement
The Prius is equipped with side curtain airbags. When
undeployed, total roof removal is not recommended. This is to
avoid breaching the side curtain airbags, inflators, SRS harnesses,
and optional solar panel energized wire. As an alternative, dash
displacement may be performed by using a Modified Dash Roll.
Side Curtain Airbag Deployment Area
-25-
Emergency Response (Continued)
Extrication (Continued)
Rescue Lift Air Bags
Responders should not place cribbing or rescue lift air bags under
the high voltage power cables, exhaust system, or fuel system.
Repositioning Steering Wheel and Front Seats
Telescopic steering wheel and seat controls are shown in the
illustrations.
Tilt and Telescoping Control
Front Seat Controls
-26-
Emergency Response (Continued)
Extrication (Continued)
Active Headrest Removal
The Prius is equipped with active front headrests, located in both front
seatbacks. The active headrests are mechanical non-pyrotechnic
head supports that are designed to reduce neck injuries in the
event of a rear collision.
Headrest
Upper Unit
Cable
Lower Unit
No special methods are required to remove the headrests. Push
the release button and lift to remove the headrest.
Active Front Headrest
Mirror Cross Section
NOTE:
The Prius is equipped with an optional electrochromic auto
dimming rear view mirror. The mirror contains a minimal
amount of transparent gel sealed between two glass plates that
will not normally leak.
Sealed Electrochromic Coating
Electrochromic Auto Dimming Rear View Mirror
-27-
Emergency Response (Continued)
Fire
Offensive Fire Attack
Normally, flooding an NiMH HV battery pack with copious amounts
of water at a safe distance will effectively control the HV battery pack
fire by cooling the adjacent NiMH battery modules to a point below
their ignition temperature. The remaining modules on fire, if not
extinguished by the water, will burn themselves out.
Approach and extinguish a fire using proper vehicle fire fighting practices as
recommended by NFPA, IFSTA, or the National Fire Academy (USA).
Extinguishing Agent
Water has been proven to be a suitable extinguishing agent.
Initial Fire Attack
Perform a fast, aggressive fire attack.
Divert the runoff from entering watershed areas.
Attack teams may not be able to identify a Prius until the fire has
been knocked down and overhaul operations have commenced.
However, flooding the Prius HV battery pack is not recommended
due to the battery case design and location preventing the responder
from properly applying water through the available vent openings
safely. Therefore, it is recommended that the incident commander
allow the Prius HV battery pack to burn itself out.
Fire in the HV Battery Pack
Should a fire occur in the NiMH HV battery pack, attack crews
should utilize a water stream or fog pattern to extinguish any fire
within the vehicle except for the HV battery pack.
Defensive Fire Attack
If the decision has been made to fight the fire using a defensive attack,
the fire attack crew should pull back a safe distance and allow the
NiMH battery modules to burn themselves out. During this defensive
operation, fire crews may utilize a water stream or fog pattern to
protect exposures or to control the path of smoke.
WARNING:
The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is
damaging to human tissues. To avoid injury by coming in contact
with the electrolyte, wear proper personal protective equipment.
The battery modules are contained within a metal case and
accessibility is limited.
To avoid serious injury or death from severe burns or electric
shock, never breach or remove the high voltage battery pack cover
under any circumstance including fire.
Fire involving the Optional Solar Panel
The solar panel is constructed of materials commonly used in
household electronic devices. Should a fire occur involving the solar
roof panel, extinguish it using water.
When allowed to burn themselves out, the Prius NiMH battery
modules burn rapidly and can quickly be reduced to ashes except for
the metal.
-28-
Emergency Response (Continued)
NOTE:
Before disconnecting the 12 Volt auxiliary battery, if necessary,
lower the windows, unlock the doors and open the hatch as required.
Once the 12 Volt auxiliary battery is disconnected, power controls
will not operate.
Overhaul
During overhaul, immobilize and disable the vehicle if not already done.
Refer to illustrations on page 19, 20, and 21. The HV battery cover should
never be breached or removed under any circumstances including fire. Doing
so may result in severe electrical burns, shock, or electrocution.
WARNING:
Immobilize Vehicle
Chock wheels and set the parking brake.
Push the P switch to engage park.
The high voltage system may remain powered for up to 10 minutes
after the vehicle is shut off or disabled. To prevent serious injury or
death from severe burns or electric shock, avoid touching, cutting, or
breaching any orange high voltage power cable or high voltage
component.
The SRS may remain powered for up to 90 seconds after the vehicle is
shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS components.
If none of the disabling procedures can be performed, proceed with
caution as there is no assurance that the high voltage electrical system,
SRS, fuel pump or optional remote air conditioning are disabled.
Disable Vehicle
Performing either of the following two procedures will shut the
vehicle off and disable the HV battery pack, SRS, fuel pump and
optional remote air conditioning.
Procedure #1
1.
2.
3.
4.
5.
Confirm the status of the READY indicator in the instrument
cluster. If the READY indicator is illuminated, the vehicle is on
and operational.
Shut off the vehicle by pushing the power button once.
The vehicle is already shut off if the instrument cluster lights are
not illuminated. Do not push the power button because the
vehicle may start.
If the smart key is easily accessible, keep it at least 16 feet (5
meters) away from the vehicle.
Disconnect the 12 Volt auxiliary battery under the cover in the
cargo area to prevent accidental restarting of the vehicle and
operation of the optional remote air conditioning system.
Recovering/Recycling of NiMH HV Battery Pack
Clean up of the HV battery pack can be accomplished by the vehicle recovery
crew without further concern of runoff or spillage. For information regarding
recycling of the HV battery pack, contact the nearest Toyota dealer, or:
United States: (800) 331-4331
Canada: (888) TOYOTA 8 [(888) 869-6828]
Procedure #2 (Alternate if power button is inaccessible)
1.
2.
3.
Open the hood and remove the fuse box cover.
Remove the IGCT fuse (30A green colored) and AM2 fuse
(7.5A orange colored) in the engine compartment fuse box as
illustrated on page 21. If the correct fuse cannot be recognized,
pull all fuses in the fuse box.
Disconnect the 12 Volt auxiliary battery under the cover in the
cargo area.
-29-
Emergency Response (Continued)
First Aid
Spills
Emergency responders may not be familiar with NiMH electrolyte exposure
when rendering aid to a patient. Exposure to the electrolyte is unlikely except
in a catastrophic crash or through improper handling. Utilize the following
guidelines in the event of exposure.
The Prius contains the same common automotive fluids used in other nonhybrid Toyota 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 battery module would be a rare occurrence.
WARNING:
The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is
damaging to human tissues. To avoid injury by coming in contact with
the electrolyte, wear proper personal protective equipment.
Similar to the use of baking soda to neutralize a lead-acid battery electrolyte
spill, a dilute boric acid solution or vinegar can be used to neutralize a NiMH
battery electrolyte spill.
Wear Personal Protective Equipment (PPE)
Splash shield or safety goggles. Fold down helmet shields are not
acceptable for acid or electrolyte spills.
Rubber, latex or nitrile gloves.
Apron suitable for alkaline.
Rubber boots.
NOTE:
Electrolyte leakage from the HV battery pack is unlikely due to its
construction and the amount of available electrolyte contained within the
NiMH modules. Any spillage would not warrant a declaration as a hazardous
material incident. Responders should follow the recommendations as outlined
in this emergency response guide.
Absorption
Perform gross decontamination by removing affected clothing and
properly disposing of the garments.
Rinse the affected areas with water for 20 minutes.
Transport patients to the nearest emergency medical care facility.
In an emergency, manufacturer’s Material Safety Data Sheets (MSDS) are
available by contacting:
United States: CHEMTREC at (800) 424-9300
Canada: CANUTEC at *666 or (613) 996-6666 (collect)
Inhalation in Non-Fire Situations
No toxic gases are emitted under normal conditions.
Handle NiMH electrolyte spills using the following Personal Protective
Equipment (PPE):
Splash shield or safety goggles. Fold down helmet shields are not
acceptable for acid or electrolyte spills.
Rubber, latex or nitrile gloves.
Apron suitable for alkaline.
Rubber boots.
Inhalation in Fire Situations
Toxic gases are given off as by-products of combustion. All
responders in the Hot Zone should wear the proper PPE for fire
fighting including SCBA.
Move a patient from the hazardous environment to a safe area and
administer oxygen.
Transport patients to the nearest emergency medical care facility.
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.
Ingestion
If NiMH electrolyte is ingested, do not induce vomiting.
Allow the patient to drink large quantities of water to dilute the
electrolyte (never give water to an unconscious person).
-30-
Emergency Response (Continued)
First Aid (Continued)
If vomiting occurs spontaneously, keep the patient’s head lowered
and forward to reduce the risk of asphyxiation.
Transport patients to the nearest emergency medical care facility.
The solar panel is constructed of glass, potting material, silicon, silver and
aluminum compounds, and a back sheet. If the panel is compromised, wear
personal protective equipment to prevent exposure to broken glass, material
fragments and dust. In a fire, wear SCBA to prevent breathing toxic gases.
Seek medical attention in the event of exposure to smoke from a burning solar
roof panel.
Submersion
A submerged hybrid vehicle does not have high voltage potential on the metal
vehicle body, and is safe to touch.
Access Patients
Responders can access the patient and perform normal extrication
procedures. High voltage orange color coded power cables and high
voltage components should never be touched, cut, or breached.
Vehicle Recovery
If a hybrid vehicle is fully or partially submerged in water, emergency
responders may not be able to determine if the vehicle has been
automatically disabled. The Prius may be handled by following these
recommendations:
1.
2.
3.
Remove the vehicle from the water.
Drain the water from the vehicle if possible.
Follow the immobilizing and disabling procedures on page 19,
20, and 21.
-31-
Roadside Assistance
The Prius utilizes an electronic gearshift selector and an electronic P
position switch for park. If the 12 Volt auxiliary battery is discharged
or disconnected, the vehicle cannot be started nor can it be shifted out
of park. If discharged, the 12 Volt auxiliary battery can be jump started
to allow vehicle starting and shifting out of park. Most other roadside
assistance operations may be handled like conventional Toyota vehicles.
Towing
The Prius is a front wheel drive vehicle and it must be towed with the front
wheels off the ground. Failure to do so may cause serious damage to Hybrid
Synergy Drive components.
The vehicle may be shifted out of Park into Neutral by turning the
ignition-on and READY-on modes. To select Neutral, it is necessary to
hold the shift selector in the N position for approximately 0.5 seconds.
Starting Vehicle
Move Gearshift to Desired Position
Towing Eyelet Mounting Location
Eyelet Installation
If the 12 Volt auxiliary battery is discharged, the vehicle will not start and
shifting out of park is not possible. There is no manual override except to
jump start the vehicle, refer to the Jump Starting on page 35.
If a tow truck is not available, in an emergency the vehicle may be
temporarily towed using a cable or chain secured to the emergency towing
eyelet or rear tow hook. This should only be attempted on hard, paved
roads for short distances at below 19 mph (30 km/h). The eyelet is
located with the tools in the cargo area of the vehicle, refer to the
illustration on page 34.
Rear Hook
Rear Hook Location
-32-
Roadside Assistance (Continued)
Electric Hatch Opener
The Prius is equipped with an electric hatch opener. In the event of 12 Volt
power loss, the hatch cannot be opened from the outside of the vehicle.
Hatch Opener Switch
Electric Hatch Opener Switch
The electric hatch can be opened manually using the release as shown in the
illustration.
Back Hatch, Viewed
from Inside Vehicle
Manual Hatch Release
-33-
Roadside Assistance (Continued)
Spare Tire
The jack, tools, towing eyelet and spare tire are provided as shown.
Towing
Eyelet, Jack
and Tools
Tools, Jack, Towing Eyelet and Spare Tire in the Cargo Area
-34-
Roadside Assistance (Continued)
Jump Starting
The 12 Volt auxiliary battery may be jump started if the vehicle does not start
and the instrument cluster gauges are dim or off after depressing the brake
pedal and pushing the power button.
The 12 Volt auxiliary battery is located in the cargo area. If the 12 Volt
auxiliary battery is discharged, the rear hatch cannot be opened. Instead, the
vehicle can be jump started by accessing the remote positive 12 Volt auxiliary
battery terminal in the engine compartment fuse box.
Remote Hood Release
Hood Latch Release
Remove Fuse Box Cover
Open Positive Terminal Cover
Open the hood, remove the fuse box cover, and open the positive terminal
cover.
Connect the positive jumper cable to the positive terminal.
Connect the negative jumper cable to a solid ground.
Place the smart key in proximity to the interior of the vehicle, depress the
brake pedal, and push the power button.
NOTE:
If the vehicle does not recognize the smart key after connecting the
booster battery to the vehicle, open and close the driver door when the
vehicle is shut off.
Positive Terminal
Ground
If the smart key internal battery is dead, touch the Toyota emblem side of
the smart key to the power button during the start sequence. See the
instructions and illustrations on page 9 for more details.
The high voltage HV battery pack cannot be jump started.
Immobilizer
The Prius is equipped with a standard immobilizer system.
The vehicle can be started only with a registered smart key.
Jumper Cable Connections
-35-
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