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新能源汽车操作安全知识概要

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新能源电动汽车操作安全知识

1
备注：1
丰田混合动力系统
特殊的车辆需要有特别的维修，保养，意外事故和灾难或援救的操作程序
2
备注：新的PRIUS的THS系统或丰田混和动力系统，他们与传统的汽车不同，使用电能和发动机来提供驱动力。
同样的，维修和保养的程序和传统的车辆 也不同，需要特别注意,避免任何可能的事故
处理被损坏的PRIUS或发生车祸或灾难的车辆时，同样要求按照特殊的程序
这里的介绍，和紧急对应指导，介绍了出现这类情况的对策
he new Prius utilises THS or Toyota Hybrid System, which differs from conventional motor vehicles by using electricity as well as gasoline to provide the drive energy.
Likewise, the servicing and maintenance procedures differ from the conventional motor vehicle and requires special care and attention to minimise any potential risks.
Handling a damaged Prius, or a vehicle that has been involved in an accident or a disaster also requires special procedures.
This presentation, along with the emergency response guide, outlines the recommended actions to be taken in these situations.
备注：2
Prius 特性
在维修PRIUS车辆时，如果采用不适当方法或在工作中疏忽对待，会造成严重电击或身体伤害的潜在危险
内有500 v 的电器零件和电路

高碱性的HV蓄电池电解液 (氢氧化钾) 
3
备注：镍金属氢化电池的额定电压为201.6V，每个单元内的电解液由氢氧化钾组成
如果错误操作，这些特性都有可能导致严重伤害甚至死亡
在动手维修PRIUS前先进行思考，不仅仅考虑到你自身的安全同时也要考虑附近人员的安全
The nickel-metal hydride battery in Prius is rated at 201,4 volts and the electrolyte within each cell is made of potassium hydroxide.
These features both have the capability to cause severe injury or death if mis-handled.
Always think before you act when dealing with Prius vehicles, not only for your own safety but the safety of anyone in the vicinity.
备注：3
紧急事件对应指导
已提供这样的印刷培训手册
认真学习手册的内容将维修中的风险降到最低
4
备注：请学习指导手册，确认自己DLR内的所有有关安全设备可以随时使用并保持状态良好状态
Please study the guide and ensure all the relevant safety equipment within your dealership is always available and in good order.
备注：4
紧急事件对应指导
维修防范也可以在修理手册RM1076E1的导言部分或车身损伤维修手册BRM124E中找到
5
备注：显然，所有的必需的操作防范可以在有关PRIUS的底盘和车身修理手册的导言部分或碰撞损伤维修手册中找到
Obviously, all the necessary handling precautions can also be found in the introduction sections of the relevant Prius body and chassis service manuals as well as the collision damage repair manual.
备注：5
高压组成部分
所有高压电线为橙色
6
备注：为了方便辨别，所有的PRIUS连接高压回路部分的电线和接头为橙色
高压回路和其它回路和车身绝缘
高压组成部分包含HV电池，驱动桥，变频器，转换器，和维修塞
To allow easy identification, all the Prius wiring and electrical harnesses that form part of the high voltage circuits are colour coded orange. 
These high voltage circuits are isolated from all other electrical circuits and the vehicles body.
The high voltage components include the HV battery, transaxle, inverter and converter and the service plug.
备注：6
警告标签
7
备注：警告标签类似图中被贴在HV电池和变频器上
他们提供了基本的警告，操作说明和回收信息
Warning labels similar to this example have been placed on the HV battery case and inverter converter assembly.
They provide basic cautions, handling instructions and recycling information.
备注：7
如果 你需要处理被损坏车辆，你必须保护好自己，以免被电击或伤害，见下面说明…….
处理被损坏车辆
8
备注：当处理被损坏车辆时，潜在的被电击或暴露在高碱性化学物质中可能不易察觉
所以，你需要总是准备好防护装备

When handling a damaged Prius, the potential for electrocution or exposure to
highly alkaline chemicals may not be obvious. Therefore, always prepare yourself with the following protective clothing.
备注：8
安全手套
适用于电工作业的绝缘橡胶
防止电解液飞溅的耐碱橡胶
9
备注：手套必须有两种独立的性能，第一：在进行任何有关高压组件或线路的操作时，需要使用橡胶制成的绝缘手套，这些手套通常被认为是电工手套，并被设计为按照澳大利亚标准如AS2225 ，能够承受650V的工作电压。
第二，抗碱性的合成橡胶手套同样需要，当工作中接触钾氢氧化物时，对人的组织有极其严重的伤害。

Two separate types of gloves are necessary, firstly, insulated gloves made from rubber materials are needed for working on any of the high voltage components or wiring circuits. These are commonly known as electrical linesmans gloves and are designed to meet certain Australian standards such as AS2225 for working voltages up to 650 volts.
Secondly, alkaline resistant synthetic rubber gloves are also needed when working with any electrolyte spillage as the potassium hydroxide electrolyte is extremely hazardous to all human tissue.
备注：9
安全防护镜＆安全鞋
防碱性类型，防止电解液的溢出
10
备注：戴上合适的眼部和足部的防护，以防止电池液的飞溅
最好的，面罩因该将所有的面部皮肤裸露部分覆盖，安全鞋也必须具有耐碱性鞋底
Suitable eye and foot protection must also be worn in the event of an electrolyte spill.
Ideally, the face mask should cover all the areas of exposed skin on the face while the safety shoes must have alkaline resistant soles.
备注：10
渗透硼酸处理方案
将 800 克的硼酸溶解在20升自来水中
中和所有溢出的HV电池电解液
11
备注：渗透硼酸处理方案被使用于中和所有电解液
处理方法是通过溶解800克的硼酸于20升自来水中
这个方法可以倒在电解液上，进行中和
A saturated boric acid solution needs to be made to neutralise any electrolyte spills. 
This solution is created by dissolving 800 grams of powered boric acid into a clean vessel containing 20 litres of tap water.
This solution can then be poured onto the spillage, allowing it to neutralise.
备注：11
红色石蕊试纸
使用试纸检查溢出的电解液是否已被中和
如果溢出的电解液仍然保持碱性，试纸会变成蓝色
12
备注：当你面对有可能是溢出电解液时，及早穿好合适的防护装置，并剥下一片红色石蕊试纸检查溢出液，如果试纸变为蓝色，溢出的液体需要使用硼酸液进行中和，
中和完成后，使用试纸再去检查溢出液，确认试纸颜色不改变
中和完毕后，使用棉布对残余液进行清理
When you are confronted with a possible electrolyte spill, wear the appropriate protective clothing mentioned earlier, and apply a strip of red litmus paper to the spill. If the litmus paper turns blue, then the spill needs to be neutralise with the saturated boric acid mixture. 
On completion, re-check the spill with red litmus paper and ensure that it does not change colour.
Once neutralised, always clean up the residue with waste cotton rag.
备注：12
灭火器
HV 蓄电池使用二氧化碳类型灭火器
无法使用少量的水灭火，但可使用大量，并持续的水去灭火
13
备注：如果PRIUS着火时，使用常规的ABC干粉灭火器灭火，这种灭火器设计使用于油或电路火灾
然而，如果只是HV电池着火，则推荐使用二氧化碳灭火器
发生大面积或大的火灾时，持续的浇水也同样适用熄灭HV电池火灾
使用少量的水，如只用一桶，是危险的，实际上将加剧HV电池火灾的程度
If Prius catches fire, use a conventional ABC type fire extinguisher designed for use on both oil and electrical fires.
However, if the HV battery itself is on fire the recommended fire extinguisher is a CO? type. 
Sand or a large, continuous supply of water is also suitable for use to extinguish a HV battery fire.
The use of a small quantity of water, such as a bucket,  can be dangerous and actually increase the intensity of a HV battery fire.
备注：13
吸水毛巾＆布
在溢出电解液被中和后，使用吸水毛巾＆布吸收多余的电解液
14
备注：用充足的吸水毛巾＆布，吸收事故中溢出的电解液是有必要的，然而，在使用这些布去吸收前，先要确认使用试纸去检查，确保所有溢出液已被中和
A supply of waste rags or toweling is necessary to soak up any spills in the event of an accident. However, always ensure that any spillage is not alkaline by testing the material with red litmus paper before attempting to soak it up.
备注：14
胶布
使用绝缘胶布覆盖所有的高压电线或端子
在 维修塞被拔出后，使用绝缘胶布包住维修塞槽
15
备注：无论何时，当高压电线或端子裸露时，必须使用绝缘胶布将裸露部分包住
同样的，在拆下维修塞后，使用绝缘胶布覆盖维修塞槽，隔开端口
当维修任何端子时，使用扭矩扳手按规定扭矩上紧防止损坏
Whenever a high voltage cable or terminal is uncovered it is necessary to insulate the exposed conductor with electrical insulation tape.
Also, after removing the service plug, cover the aperture with tape to insulate the port.
When refitting any terminal fasteners, always use a torque wrench set to the correct value to prevent damage.
备注：15
万用表
测量高压组件的电压
16
备注：要求使用高品质，多功能数字式的万用表检查高压回路中不同位置，在开始着手进行维修工作前确认所有电负荷已经接地
伏特表电压读数为0
A high quality, digital multimeter is required to check various points of the high voltage circuit to ensure that all electrical charge has grounded prior to commencing any service work. 
The voltmeter reading should be zero.
备注：16
当如下操作时，要求进行 …

进行保养或维修 
处理损坏车辆
进行事故恢复或急救工作
断开HV 系统
17
备注：为了使得受到身体伤害或电击的风险最小，处理PRIUS时将高压系统断开
这里显示了如何进行断开
现在，让我们学习如何做
 To minimise the risk of physical injury or electrocution when working on Prius vehicles always isolate the high voltage system.
This list indicates when this isolation should be done.
Now lets look at how it is done  .
备注：17
程序
将换档杆切换到P档位 
18
备注：首先，踩下刹车，按下P档按键
如果，没办法却换到P档，使用驻车档块防止车辆移动
Firstly, apply the foot brake and select P range using the select lever. 
If it is not possible to select P range for some reason, use wheel chocks to prevent the vehicle from moving.
备注：18
程序
使用驻车制动器
19
备注：踏下驻车制动器
备注：19
程序
拔下点火钥匙
20
备注：将钥匙从钥匙槽内拿开
将钥匙放在你的口袋是一个好的习惯
Remove the ignition key from the cylinder.
It is good working practice to keep the key in your pocket.
备注：20
程序
断开辅助电池的负极端子
21
备注：打开行李箱，寻找12V辅助电池，移开乘客侧装饰，断开电池的负极
固定接地线，以防止端子移动回电池负极端子
Open the boot to access the 12 volt auxiliary battery. Remove the passenger side trim and unbolt the battery negative terminal.
Position the earth strap so it cannot move back in contact with the negative terminal.
备注：21
程序
戴上绝缘手套，拆下维修塞

维修插销
22
备注：找到维修塞位置，拆下HV电池维修塞。当处理橙色高压组件和线路时，确保带着绝缘橡胶手套
将拆下的维修插销放在你的口袋中以防止其他人将它安装回车上去，并将裸露的维修塞槽使用绝缘胶布封住
Locate and remove the HV battery service plug. Always wear insulated rubber gloves when working on the orange coloured high voltage components and wiring.
Place the service plug in your pocket to prevent someone else refitting it to the vehicle and cover the exposed plug port with insulating tape.
备注：22
程序
如果因为损坏或其它的原因无法取下HV电池维修塞
在发动机室内接线盒中取下HV保险丝
23
备注：当出现意外事故或类似情况，HV电池的维修塞无法取下，可以通过将在发动机室内的HV保险丝取下，达到断开高压线路的目的
In situations where the HV battery service plug is not accessible due to accident damage or similar circumstances, it is possible to isolate the high voltage circuit by removing the HV fuse from the engine room junction block.
备注：23
移动 &amp;amp; 拖拽 Prius
如果出现如下情况，车辆必须被拖拽…
任何高压系统组件或线路损坏
制动，转向，动力分配或燃油系统被损坏
钥匙插入后， READY 灯不点亮
24
备注：当评估一辆事故损坏车辆时，只要高压线路或组件有任何问题，或刹车，转向，动力分配或燃油系统有损坏，就不可以驾驶车辆，而必须使用拖车
在拖车前，按照前面幻灯片介绍的方法断开高压系统
When assessing an accident damaged Prius, the vehicle cannot be driven and must be towed whenever any of the high voltage circuit, including components, is damaged or there is damage to any brake, steering, power delivery or fuel system component.
Before towing the vehicle, isolate the high voltage system as described in the previous slides.
备注：24
移动Prius
在移动损坏车辆完毕后，检查所有溢出的碱性电解液，使用正确、安全的设备进行中和
25
备注：一但车辆被移动，检查所有的残留溢出电解液
使用红色石蕊试纸和合适的安全设备，按照正确的方法检查全车
进行化学中和后，使用使用废弃抹布对地板表面进行清洁
 the vehicle has been moved, always check for any remaining spillage.
Check any material using the red litmus paper and proper safety equipment and treat as required.
Once chemically neutral, wipe the road surface clean with the waste rag.
备注：25
检查&amp;amp; 维修
当对THS进行检查＆维修时，必须按照以下的要求准备
不小心的操作将导致电击或严重的身体伤害
按照维修手册的程序和指导内容进行操作
26
备注：为使发生伤害或电击的风险降到最低，在着手进行HV系统的工作前，PRIUS技师必须按照后面的防范要求
To mimimise the risk of injury or electrocution, the Prius technician must take the following precautions prior to commencing work on the HV systems.
备注：26
高压线路
所有的高压线路和连接器均为橙色，以方便辨认
27
备注：记住，所有的高压线路均为橙色以方便辨认Remember, all high voltage circuit wiring is colour coded orange for easy identification.
备注：27
准备
检查并记录存储器内存有的所有DTC
断开辅助电池的负极端子
戴上经认可的安全绝缘防护手套.
28
备注：在断开辅助电池负极端子前，使用IT-Ⅱ检查所有的ECU，记录所有的DTC
Before removing the auxiliary battery terminal, record any diagnostic trouble codes by checking all ECU’s with the Intelligent Tester.
备注：28
准备
确认你的手套如下…
无破损
无潮湿或水气
是正确的类型
29
备注：在戴绝缘手套前面，总是要确认手套是干燥的，无损坏和正确的大小
Before fitting your insulated gloves, always ensure they are dry, not damaged and are the correct size.
备注：29
准备
放置警告标志在车顶上
30
备注：告诉附近的人，你在对高压系统进行作业是非常必要的，
这些可以通过放置标志，如这里的例子，放置在车顶上
It is necessary to indicate to others within the general vicinity that you are working on the high voltage system.
This is done by displaying a sign, such as this example, on the vehicle’s roof.
备注：30
维修插销的拆除
拆下维修塞，并放在自己的口袋中
将维修塞槽用绝缘胶布贴起来
31
备注：找到HV电池维修塞的位置，戴上绝缘手套拆下维修塞
确保将维修塞放在你自己的口袋中，防止在维修中被其他人安装回去
Locate and remove the HV battery service plug using insulated rubber gloves.
Always put the plug in your pocket to prevent it being refitted by someone else.
备注：31
0V检查
在开始检查前等待5 分钟
使用万用表去检查每一个相位
电压读数必须为0
端子 U
端子 V
端子 W
32
备注：一但维修塞被拆下，必需要等待5分钟，使得变频器中的电容器进行放电，才可进行作业
Once the service plug has been removed, it is necessary to wait 5 minutes before commencing work to allow the capacitors within the inverter assembly to discharge.
备注：32
隔离外露区域
始终保持使用绝缘胶布隔离高压系统的接线端或连接器
33
备注：无论何时高压连接器或线路被拆卸，始终使用绝缘胶布去隔离裸露部分
Whenever a high voltage connection or cable is removed, always tape the exposed wire with electrical tape.
备注：33
牵引Prius
断开辅助电池负极端子
34
备注：在拖车前（除了四轮着地方式外），拆开乘客侧的行李箱内的装饰物，断开辅助电池的负极
固定接线，防止负极接线移动连接负极端子
Before towing Prius(except with 4 wheels on the road), remove the passenger side boot inner trim and unbolt the negative terminal from the auxiliary battery.
Position the earth strap so it cannot move back in contact with the negative terminal.
备注：34
拖拽Prius
采用牵引前轮或四轮离地牵引方法
35
备注：正确地牵引方法是，使得前轮离地或全部平放在卡车上
牵引车辆时，使得车辆前轮转动将产生电能，如果此时车辆是损坏的，将极其危险的
The correct towing procedure is to have the front wheels elevated off the road surface, such as a flat bed truck.
Towing the vehicle and allowing the front wheels to rotate will generate electricity which is extremely dangerous if the vehicle is damaged.
备注：35
拖拽Prius
四轮着地状态拖拽车辆，必须 满足以下条件…
极低的车速 (少于 30 公里每小时)
尽可能短的距离
换入 N档
点火开关位置在 ACC
36
备注：如果车辆必须在四轮着地状态牵引，尽可能在低速情况下牵引尽可能短的距离，使用铁环连接车辆If the vehicle must be moved with all wheels on the ground, it should be for the shortest possible distance at very low speed, using the eyelet provided with the vehicle.
备注：36
跨接起动 Prius
如果12V辅助电池没有电…
主仪表 READY 灯无法点亮
车辆将无法起动
37
备注：12V的辅助电池提供电能给ECU，包含高压电路的控制系统
如果电池的电压低于8V，车辆将无法起动，主仪表READY灯无法点亮
车辆可以通过以下的方法跨接起动
The 12 volt auxiliary battery provides power to all the ECU’s including the control systems for the high voltage circuits.
If the battery voltage falls below about 8 volts, the vehicle will not start and the ready light in the combination meter will not light.   
The vehicle can be jump started using the following procedure.
备注：37
跨接起动
按下P档开关, 设置驻车制动，拔下钥匙
38
备注：按照幻灯片的描述操作来保护车辆Secure the vehicle as described on the slide.
备注：38
跨接起动
如图示，连接升压电池组
起动后，按照相反的顺序断开连接
39
备注：按照图中数字顺序所示，连接一个12V的充满电的电池，之后将PRIUS钥匙插入起动位置
当PRIUS地发动机运行时，将跨接电池按照连接顺序相反的顺序断开
Connect a fully charged 12 volt battery in the numeric order shown here, then turn the Prius ignition key to the start position.
Once the Prius engine is running, disconnect the jumper battery in the reverse order to the connecting procedure.
备注：39
预防
PRIUS车严禁使用快速充电
辅助电池只能使用相同设计功能的电池替代
不要尝试通过推或拉的方式起动
如果HV电池完全放电，则需要更换
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备注：辅助电池的充电率不可以超过3.5安培，充电的时间也必须受到监控
辅助电池不是传统的湿示铅酸电池，必须使用相同设计功能的电池来替代
尝试推或拉PRIUS将严重损坏机械部件，千万不可尝试
不可以通过任何外部电源对HV电池进行充电，如果HV电池完全放电，则需要更换
The charging rate of the auxiliary battery must never exceed three and a half ampere and the charging time must be monitored.
The auxiliary battery used in Prius is not a traditional wet cell lead acid type and must always be replaced with one of a similar design.
Trying to push or pull start Prius will cause serious mechanical damage and should never be attempted.
It is not possible to charge the HV battery by any external source and it should be replaced if it completely discharges.
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