WORK NOTICES AND PRECAUTIONS NOTICE FOR HYBRID SYSTEM

Refer to the LEXUS Repair Manual for each work procedure.


  1. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE


    1. Engineers must undergo special training to be able to perform high-voltage system inspection and servicing.

    2. All high-voltage wire harnesses are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires and components.

    3. Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

      Note

      After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.

    4. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

      A003QH0E02

      Tech Tips

      Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

    5. Be sure to install the service plug before starting the hybrid system. Starting the hybrid system with the service plug removed may damage the vehicle.

    6. A003QI9E01
      *1 DO NOT WEAR!

      Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves.

    7. When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit.

    8. Before touching a bare high-voltage terminal, wear insulated gloves and use an electrical tester to ensure that the terminal is not charged with electricity (approximately 0 V).

    9. A003QR4

      After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.

    10. The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.

    11. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION." sign to notify other engineers that a high-voltage system is being inspected and/or repaired.

    12. Do not place the HV battery upside down while removing and installing it.

    13. After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminal screws are firmly tightened, and that the connectors are correctly connected.

      A003QON

  2. ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT


    1. Items to be prepared for operation at the site of the accident.


      • Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)

      • Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)

      • Red litmus paper

      • ABC fire extinguisher (effective against both oil flames and electrical flames)

      • Shop rags (for wiping off electrolyte)

      • Vinyl tape (for insulating cables)

      • Electrical tester

    2. Actions to be taken at the accident site.


      1. Wear insulated or rubber gloves, goggles and safety shoes.

      2. Do not touch a bare cable that could be a high voltage cable. If the cable must be touched or if accidental contact is unavoidable, follow these instructions: 1) wear insulated or rubber gloves and goggles, 2) measure the voltage between the cable and the body ground using an electrical tester, and 3) insulate the cable using vinyl tape.

      3. If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters.

      4. Visually check the HV battery and immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be a highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then, wipe the neutralized liquid with a shop rag.

      5. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.

        A003QJ1E02
        *1 Inverter with Converter Assembly
        *2 HV Battery
        *3 Frame Wire
        *4 Hybrid Transmission
        A003QICE02
        for RHD
        *1 Inverter with Converter Assembly
        *2 HV Battery
        *3 Frame Wire
        *4 Hybrid Transmission

        1. Move the shift lever to the P position and engage the parking brake.

        2. Remove the key from the vehicle. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.

        3. Remove the service plug while wearing insulated gloves.

          A003QH0E02

        CAUTION:

        Do not turn the power switch ON (READY) while removing the service plug.

        Note


        • A003QPIE02
          *1 IG2 Relay

        • If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the IG2 relay from the engine room No. 2 junction block instead.

        • If the correct relay cannot be recognized, pull both relays in the fuse box.

    3. Moving the damaged vehicle

      Tech Tips

      If any of the following applies, tow the vehicle away using a tow truck.


      • One or more of the high-voltage components and cables are damaged.

      • The driving, traction, or fuel system is damaged.

      • A003QOB

        The READY light is not illuminated when you start the engine.

      Note


      • Tow the damaged vehicle with its front and rear wheels lifted off the ground. In an emergency where a tow truck is not available, the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet. Also, make sure that the following conditions are met: 1) the towing should only be performed on paved roads for short distances at low speeds; 2) a driver must be in the vehicle to steer and operate the brakes; and 3) the vehicle's wheels, drive train, axles, steering and brakes must be operating normally.

      • Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) terminal of the auxiliary battery and remove the service plug. Only if none of the above applies and there are no problems that might affect driving, drive the vehicle away from the accident site to a safe place nearby.

      • Perform the procedure below if the READY light turns OFF, or there are abnormal noises, unusual smells, or strong vibrations while driving:


        1. Park the vehicle in a safe place.

        2. Move the shift lever to the P position and engage the parking brake.

        3. Disconnect the cable from the negative (-) terminal of the auxiliary battery.

        4. Remove the service plug while wearing insulated gloves.

    4. Actions required after moving the damaged vehicle. If you see any liquid on the road surface, it could be a highly alkaline electrolyte leakage.

      Wear rubber gloves and goggles, and apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then wipe the neutralized liquid with a shop rag.

    5. Items to be prepared (when repairing damaged vehicles).


      • Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)

      • Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)

      • Red litmus paper

      • Shop rags (for wiping off the electrolyte)

      • Vinyl tape (for insulating cables)

      • Electrical tester

    6. Precautions to be observed when servicing the damaged vehicle.


      1. Wear insulated or rubber gloves, goggles, and safety shoes.

      2. Do not touch a bare cable that could be a high voltage cable. If the cable must be touched or if accidental contact is unavoidable, follow these instructions: 1) wear insulated or rubber gloves and goggles, 2) measure the voltage between the cable and the body ground using an electrical tester, and 3) insulate the cable using vinyl tape.

      3. Check the HV battery and immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be a highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then wipe the neutralized liquid with a shop rag.

      4. If the electrolyte adheres to your skin, wash the skin immediately using saturated boric acid solution or a large amount of water. If the electrolyte adheres to an article of clothing, take the clothing off immediately.

      5. If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them with a large amount of water and seek medical care immediately.

      6. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.


        1. Move the shift lever to the P position and engage the parking brake.

        2. Remove the key from the vehicle. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.

        3. Wear insulated gloves, and then remove the service plug.

        Note

        If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the IG2 relay from the engine room No. 2 junction block instead.

    7. Precautions to be taken when disposing of the vehicle.

      When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. The same applies to any damaged HV battery.

    8. After removing the battery, keep it away from water. Water may heat the battery, which results in a fire.

    9. Do not tow the vehicle with its 4 wheels on the ground.

      Note

      In an emergency where a tow truck is not available, the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet. Also, make sure that the following conditions are met: 1) the towing should only be performed on paved roads for short distances at low speeds; 2) a driver must be in the vehicle to steer and operate the brakes; and 3) the vehicle's wheels, drive train, axles, steering and brakes must be operating normally.

  3. PRECAUTIONS FOR TOWING ALL WHEEL DRIVE VEHICLES


    1. Use one of the following methods to tow the vehicle.

    2. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).

      A003QR1E13
      Text in Illustration
      *1

      Note

      If the vehicle is tilted after parking on a level surface, the braking force may be insufficient as the electric parking brake determines how much braking force to using the yaw rate sensor value for the slope of the road.

      		 *2

      Tech Tips

      Press the electric parking brake switch twice to apply the parking brake with the maximum braking force.

      Note

      Do not use any towing method other than those shown above.

    3. 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(s).

      This should only be attempted on hard surfaced roads for distances of less than 80 km, and at speeds below 5 km/h (3 mph).

      A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition.

      Note

      If the towing speed or distance exceeds the above limits, or the vehicle is towed in a backward direction with any of the wheels on the ground, the drivetrain may be damaged.


      1. Emergency towing procedure


        1. Turn the power switch ON (IG).

        2. Depress the brake pedal and move the transmission shift lever to N.

        3. Release the parking brake.

        4. Release the brake pedal slowly.

        Note


        • Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.

        • Do not turn off the power switch. Turning off the power switch may result in engagement of the steering lock, resulting in a hazardous situation or accident.

    4. The towing methods shown below are dangerous and can damage the vehicle, so do not use them.

      A003QKX

      1. Do not tow the vehicle with only 2 wheels on the ground.

        Note

        If the vehicle is towed with only the 2 wheels on the ground, the drivetrain may overheat and be damaged or the wheels may come off the dollies.

      2. Do not use a sling-type towing method either from the front or rear.

        Note

        If a sling-type tow truck is used, damage may occur to the vehicle body.