AARC EV & Hybrid Vehicle Processing 2 — Questions and Answers
Question 1: What is the primary reason high-voltage EV battery packs must be stored separately from other vehicle fluids at a recycling facility?
- To prevent thermal runaway ignition near flammable materials (Correct answer)
- To comply with EPA noise regulations
- To allow easier barcode scanning
- To maintain warranty documentation
Correct answer: To prevent thermal runaway ignition near flammable materials
Thermal runaway in damaged lithium-ion cells can ignite nearby flammable fluids, so segregated storage is required for fire safety.
Question 2: When a hybrid vehicle's nickel-metal hydride (NiMH) battery is being removed, what fluid hazard is also present inside the battery module?
- Sulfuric acid electrolyte
- Potassium hydroxide electrolyte (Correct answer)
- Lithium hexafluorophosphate
- Ethylene glycol
Correct answer: Potassium hydroxide electrolyte
NiMH batteries use an alkaline potassium hydroxide electrolyte that is corrosive and can cause chemical burns.
Question 3: Which color coding is federally recognized to indicate high-voltage components and wiring in hybrid and electric vehicles?
- Red
- Orange (Correct answer)
- Blue
- Yellow
Correct answer: Orange
SAE J1772 and OEM standards use orange to identify high-voltage cables and components in hybrid and EV systems.
Question 4: A technician measures 48 V between the HV bus bars after the service disconnect has been removed. What is the most likely cause?
- Normal capacitor bleed-down in progress (Correct answer)
- The measurement tool is faulty
- A second battery pack is still energized
- The 12 V auxiliary battery is interfering
Correct answer: Normal capacitor bleed-down in progress
Inverter capacitors retain charge briefly after disconnect removal; technicians must wait for full bleed-down before touching HV components.
Question 5: Under RCRA regulations, spent lithium-ion batteries from EVs are classified as which type of waste when sent off-site for recycling?
- Universal waste (Correct answer)
- Hazardous waste Class D
- Municipal solid waste
- Special nuclear material
Correct answer: Universal waste
EPA's Universal Waste Rule covers lithium batteries, simplifying management requirements compared to full hazardous waste regulations.
Question 6: What personal protective equipment is specifically required when disabling a high-voltage battery system in a flood-damaged EV?
- Steel-toed boots and hard hat
- Class 0 or higher rated rubber insulating gloves and face shield (Correct answer)
- Chemical splash goggles only
- Cut-resistant gloves and safety glasses
Correct answer: Class 0 or higher rated rubber insulating gloves and face shield
Class 0 insulating gloves (rated ≥1,000 V) and a face shield protect against electric shock and arc flash during HV system work.
Question 7: Which recycling partner certification should an AARC-certified recycler verify before transferring end-of-life EV battery packs?
- ISO 9001 quality management
- R2v3 or e-Stewards certification (Correct answer)
- CARB emissions compliance
- NHTSA crash-test approval
Correct answer: R2v3 or e-Stewards certification
R2v3 (Responsible Recycling) and e-Stewards are industry standards that verify downstream battery recyclers handle materials responsibly.
AARC EV & Hybrid Vehicle Processing 2
What is the primary reason high-voltage EV battery packs must be stored separately from other vehicle fluids at a recycling facility?