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Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Toyota RAV4 EV
electric vehicles. RAV4 EV dismantling procedures are similar to other non-electric 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 RAV4 EV electric vehicle, as
they may not be familiar to dismantlers.
High voltage electricity powers the electric motor, DC/DC converter, battery coolant heater, air
conditioning (A/C) compressor, cabin coolant heater and inverter. All other automotive electrical
devices such as the head lights, radio, and gauges are powered from a separate 12 Volt auxiliary battery.
Numerous safeguards have been designed into the RAV4 EV to help ensure the high voltage,
approximately 386 Volt, Lithium-ion (Li-ion) Electric Vehicle (EV) battery assembly is kept safe and
secure in an accident.
The
Li-ion EV battery assembly 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.
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 RAV4 EV identification.
• Major electric vehicle component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle RAV4 EV electric vehicles
as safely as the dismantling of a conventional non-electric automobile.
© 2012 Toyota Motor Corporation
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.
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