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

    CAUTION:


    • This vehicle has a hybrid system that operates at voltages of up to 650 V. An organic electrolyte containing carbonic acid esters as its main component is used as the electrolyte for the HV battery. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.


    1. Technicians must undergo special training to be able to service and inspect the high-voltage system.

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

    3. When there is a problem with a wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high-voltage wire or connector.

    4. Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug grip to prevent electrocution. Carry the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

      Note

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

    5. After removing the service plug grip, wait 10 minutes before touching any of the high-voltage connectors and terminals.

      Tech Tips

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

    6. Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.

      B0049IW

      1. Place the glove on its side.

      2. Roll the opening up 2 or 3 times.

      3. Fold the opening in half to close it.

      4. Confirm that there are no air leaks.

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

    8. Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.

    9. B0049J9

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

    10. Bolts and nuts for high-voltage terminals should be tightened to the specified torque. Both insufficient and excessive torque can cause a malfunction.

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

      B0049KAE01
      *1 When performing work on the HV system, fold this sign and put it on the roof of the vehicle.

    12. After servicing the high-voltage system and before reinstalling the service plug grip, check again that you have not left any parts or tools inside, that the high-voltage terminals are firmly tightened, and that the connectors are correctly connected.

    13. When performing work involving a high-voltage circuit, use either a tool wrapped with vinyl insulation tape or an insulated tool.

    14. When installing hybrid system components such as the HV battery, make sure that the polarity of all connections is correct.

  2. ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT

    CAUTION:

    This vehicle has a hybrid system that operates at voltages of up to 650 V. An organic electrolyte containing carbonic acid esters as its main component is used as the electrolyte for the HV battery. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.


    1. Items to be prepared for the accident site


      • Protective clothing (insulated gloves, rubber gloves, goggles, organic solvent mask, safety shoes and solvent resistant apron (for organic solvent))

      • Soap

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

      • A shop rag or piece of cloth (for wiping up electrolyte)

      • Insulating tape (for insulating cables)

      • Electrical tester

    2. Actions to be taken at the accident site

      CAUTION:


      • Do not touch any bare cables that could be high-voltage cables. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.

      • 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.

      • Visually check the HV battery and surrounding area for any electrolyte leakage. Do not touch any leaked liquid because it could be organic electrolyte that contains carbonic acid esters.

      • The electrolyte is flammable. Keep all ignition sources such as open flame and hot objects away from the electrolyte.

      • Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the electrolyte is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let them lie quietly. Seek medical care.

      • If the vehicle is submerged in water, do not touch any of the high-voltage components or cables including the service plug grip, as doing so poses an electrocution hazard. Work on the vehicle only after the vehicle has been pulled out of the water.

      • If the electrolyte comes in contact with your skin, wash the area thoroughly with soap and plenty of water, and seek medical care. If the electrolyte comes in contact with an article of clothing, take it off immediately. Prolonged contact with the electrolyte may cause skin irritation.

      • If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.

      • If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless instructed by the doctor.


      1. Check the vicinity of the HV battery for any leakage of the electrolyte.

        CAUTION:

        Do not touch any leaked liquid because it could be the organic electrolyte that contains carbonic acid esters. If contact is unavoidable, wipe up the liquid using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

      2. If damage to any of the high-voltage components or cables is suspected, cut the high-voltage circuit using the following procedure.

        CAUTION:

        Be sure to wear insulated gloves, goggles and safety shoes.

        B0049JHC01
        *A for LHD *B for RHD
        *1 Compressor with Motor Assembly *2 Hybrid Vehicle Transmission Assembly
        *3 HV Floor Under Wire *4 HV Battery
        *5 Inverter with Converter Assembly *6 No. 2 Engine Room Relay Block
        *7 Auxiliary Battery *8 No. 2 Luggage Room Relay Block
        *9 No. 1 Luggage Room Relay Block *10 Sub-Battery With Control Assembly

      3. Turn the power switch off.

        Tech Tips

        If the power switch cannot be turned off, remove the J/B D-B fusible link from the No. 1 luggage room relay block. Then confirm that the READY light is not illuminated.

        B0049K4C03
        *1 No. 1 Luggage Room Relay Block *2 J/B D-B Fusible Link

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

      5. While wearing insulated gloves, remove the service plug grip.

        Note

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

    3. Moving the damaged vehicle

      Note

      When towing the vehicle, refer to the Precautions for Towing Front Wheel Drive Vehicles.

      If any of the following conditions are met, tow the vehicle away using a tow truck.


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

      • Components related to driving, the hybrid transmission or the fuel system are damaged.

      • The master warning light is on.

      • The READY light does not come on when attempting to turn the power switch on (READY).

      CAUTION:

      Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) auxiliary battery terminal and remove the service plug grip.

      Note

      Perform the procedure below if the master warning light turns on, or there are abnormal noises, unusual smells, or strong vibrations while driving:


      1. Park the vehicle in a safe place.

      2. Apply the parking brake, push the P switch and confirm that park (P) has been selected.

      3. Turn the power switch off, and disconnect the cable from the negative (-) auxiliary battery terminal.

      4. While wearing insulated gloves, remove the service plug grip.

    4. Actions required after moving the damaged vehicle


      1. Procedure

        If there is liquid on the floor, it could be organic electrolyte containing carbonic acid esters. Wipe up the liquid using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

    5. Items to be prepared (when repairing a damaged vehicle)


      • Protective clothing (insulated gloves, rubber gloves, goggles, organic solvent mask, safety shoes and solvent resistant apron (for organic solvent))

      • Soap

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

      • A shop rag or piece of cloth (for wiping up electrolyte)

      • Insulating tape (for insulating cables)

      • Electrical tester

    6. Precautions to be observed when servicing a damaged vehicle

      CAUTION:


      • Always follow the instructions to ensure safety.

      • Do not touch any bare cables that could be high-voltage cables. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.

      • Visually check the HV battery and surrounding area for any electrolyte leakage. Do not touch any leaked liquid because it could be organic electrolyte that contains carbonic acid esters.

      • The electrolyte is flammable. Keep all ignition sources such as open flame and hot objects away from the electrolyte.

      • Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the electrolyte is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let them lie quietly. Seek medical care.

      • If the electrolyte comes in contact with your skin, wash the area thoroughly with soap and plenty of water, and seek medical care. If the electrolyte comes in contact with an article of clothing, take it off immediately. Prolonged contact with the electrolyte may cause skin irritation.

      • If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.

      • If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless instructed by the doctor.


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

      2. Check the HV battery and surrounding area for any electrolyte leakage.

        CAUTION:

        Do not touch any leaked liquid because it could be the organic electrolyte that contains carbonic acid esters. If contact is unavoidable, wipe up the liquid using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

      3. Do not touch any bare cables that could be high-voltage cables. If a cable must be touched or if accidental contact is possible, perform the following: 1) wear insulated gloves and goggles, 2) measure the voltage between the cable and body ground using an electrical tester, and 3) insulate the cable using insulating tape.

      4. If damage to any of the high-voltage components or cables is suspected, cut the high-voltage circuit using the following procedure.

        CAUTION:

        Do not touch any bare cables that could be high-voltage cables. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.

      5. Turn the power switch off.

        Tech Tips

        If the power switch cannot be turned off, remove the J/B D-B fusible link from the No. 1 luggage room relay block. Then confirm that the READY light is not illuminated.

        B0049K4C03
        *1 No. 1 Luggage Room Relay Block *2 J/B D-B Fusible Link

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

      7. While wearing insulated gloves, remove the service plug grip.

        Note

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

    7. Precautions to be taken when disposing of an HV battery


      1. When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

        CAUTION:


        • Before returning the HV battery, make sure to perform Recovery Inspection.

        • Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.

        • To reduce the risk of fire, the HV battery must not be stored in an area where it will be exposed to open flame or high temperatures.

    8. Precautions to be observed when towing


      1. Tow the damaged vehicle with its front and rear wheels lifted off the ground.

        CAUTION:

        Towing the damaged vehicle with its wheels on the ground will cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.

    9. Towing with all 4 wheels on the ground

      CAUTION:


      • If the vehicle needs to be towed using a cable or chain with all 4 wheels on the ground, do not exceed 30 km/h (18 mph) and tow only for a short distance and then have the vehicle towed by a truck.

      • Turn the power switch on (IG), move the shift lever to N and confirm that neutral (N) has been selected.

      • Make sure not to turn the power switch off while the vehicle is being towed, as park (P) may be selected, which may result in damage or an accident.

      • If any abnormality in the damaged vehicle occurs during towing, stop towing immediately.

      Tech Tips

      Neutral (N) cannot be selected if the auxiliary battery is disconnected.

  3. PRECAUTIONS FOR TOWING REAR 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).

      B0049JIE18

      Note


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

      • *1: 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 apply by automatically detecting the slope of the road.

      Tech Tips

      *2: Press the electric parking brake twice to apply the parking brake with the maximum braking force.

    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 short distances below 30 km/h (18 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 the wheels on the ground, the drivetrain or vehicle may be damaged.


      1. Emergency towing procedure


        1. Turn the power switch on (IG).

        2. Depress the brake pedal and move the 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.

        • If the hybrid system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult.

        • 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.

        Tech Tips


        • Neutral (N) cannot be selected if the auxiliary battery is discharged or if it has been disconnected.

        • There is a possibility that neutral (N) cannot be selected when parts related to the electronic shift lever system are malfunctioning.

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

      B0049IF

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

        CAUTION:

        If the vehicle is towed with only the front wheels on the ground, the steering may move, causing the vehicle to become unstable.

        Note

        If the vehicle is towed with only the rear wheels on the ground, the drivetrain may overheat and be damaged.

      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.