Lexus CT200h Hybrid 2011 User manual

Hybrid
2011 Model
© 2010 Toyota Motor Corporation
All rights reserved. This document may not be
altered without the written permission of Toyota Motor Corporation.
10 Lexus CT200h ERG REV – (02/07/11)

-i-
Foreword
In December 2010, Lexus released the 2011 Lexus CT200h gasoline-
electric hybrid vehicle in North America. To educate and assist
emergency responders in the safe handling of the CT200h hybrid
technology, Lexus published this CT200h Emergency Response Guide.
High voltage electricity powers the electric motor, generator, air
conditioning compressor and inverter/converter. All other automotive
electrical devices such as the headlights, radio, and gauges are powered
from a separate 12 Volt auxiliary battery. Numerous safeguards have
been designed into the CT200h to help ensure the high voltage,
approximately 201.6 Volt, Nickel Metal Hydride (NiMH) Hybrid
Vehicle (HV) battery pack is kept safe and secure in an accident.
The CT200h utilizes the following electrical systems:
Maximum 650 Volts AC
Nominal 201.6 Volts DC
Maximum 27 Volts DC
Nominal 12 Volts DC
CT200h Features:
A boost converter in the inverter/converter that boosts the available
voltage to the electric motor to 650 Volts.
A high voltage Hybrid Vehicle (HV) battery pack rated at 201.6
Volts.
A high voltage motor driven Air Conditioning (A/C) compressor
rated at 201.6 Volts.
A body electrical system rated at 12 Volts, negative chassis ground.
Supplemental Restraint System (SRS) - dual stage frontal airbags,
front knee airbags, front seat side airbags, side curtain airbags and
front seat belt pretensioners.
An Electric Power Steering (EPS) assist motor rated at 27 Volts.
High voltage electrical safety remains an important factor in the
emergency handling of the CT200h Lexus Hybrid Drive. It is
important to recognize and understand the disabling procedures and
warnings throughout the guide.
Additional topics in the guide include:
CT200h identification.
Major Lexus Hybrid Drive component locations and descriptions.
Extrication, fire, recovery, and additional emergency response
information.
Roadside assistance information.
2011 Model Year CT200h
This guide is intended to assist emergency responders in the safe
handling of a CT200h vehicle during an incident.
NOTE:
Emergency Response Guides for Lexus hybrid vehicles may be viewed at
http://techinfo.lexus.com.

-ii-
Table of Contents Page
About the CT200h 1
CT200h Identification 2
Lexus Hybrid Drive Component Locations & Descriptions 5
SmartKeySystem 8
Electronic Shift Selector 10
Lexus Hybrid Drive Operation 11
Hybrid Vehicle (HV) Battery Pack 12
27VoltSystem 13
Low Voltage Battery 14
High Voltage Safety 15
SRS Airbags & Seat Belt Pretensioners 16
Emergency Response 18
Extrication 18
Fire 24
Overhaul 25
Recovering/Recycling of NiMH HV Battery Pack 25
Spills 26
First Aid 26
Submersion 27
Roadside Assistance 28

About the CT200h
The CT200h 5-door hatchback joins the LS600h L, RX450h, GS450h
and HS250h as a hybrid model for Lexus. Lexus Hybrid Drive means
that the vehicle contains a gasoline engine and an electric motor for
power. The two hybrid power sources are stored on board the vehicle:
1. Gasoline stored in the fuel tank for the gasoline engine.
2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack
for the electric motor.
The result of combining these two power sources is improved fuel
economy and reduced emissions. The gasoline engine also powers an
electric generator to recharge the battery pack; unlike a pure all electric
vehicle, the CT200h never needs to be recharged from an external
electric power source.
Depending on the driving conditions one or both sources are used to
power the vehicle. The following illustration demonstrates how the
CT200h operates in various driving modes.
During light acceleration at low speeds, the vehicle is powered by
the electric motor. The gasoline engine is shut off.
During normal driving, the vehicle is powered mainly by the
gasoline engine. The gasoline engine also powers the generator to
recharge the battery pack.
During full acceleration, such as climbing a hill, both the gasoline
engine and the electric motor power the vehicle.
During deceleration, such as when braking, the vehicle regenerates
kinetic energy from the front wheels to produce electricity that
recharges the battery pack.
While the vehicle is stopped, the gasoline engine and electric motor
are off, however the vehicle remains on and operational.
-1-

CT200h IdentificationCT200h Identification
In appearance, the 2011 model year CT200h is a 5-door hatchback.
Exterior, interior, and engine compartment illustrations are provided to
assist in identification.
In appearance, the 2011 model year CT200h is a 5-door hatchback.
Exterior, interior, and engine compartment illustrations are provided to
assist in identification.
The alphanumeric 17 character Vehicle Identification Number (VIN) is
provided in the front windshield cowl and on the driver side B pillar.
The alphanumeric 17 character Vehicle Identification Number (VIN) is
provided in the front windshield cowl and on the driver side B pillar.
Example VIN: JTHKD5BHExample VIN: JTHKD5BH0C2000101
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ACT200h is identified by the first 8 alphanumeric characters
JTHKD5BH.
Driver Side Windshield Cowl, Passenger Side Floor and Driver Side B Pillar
Exterior
logo on the hatch.
logo on both the rear door panels.
Gasoline fuel filler door located on driver side rear quarter panel.
Exterior Driver Side View
Exterior Front and Rear View
Exterior Rear and Driver Side View







CT200h Identification (Continued)CT200h Identification (Continued)
InteriorInterior
Instrument cluster (speedometer, READY indicator, shift position
indicators, warning lights) located in the dash behind the steering wheel.
-3-
A switchable gauge in the instrument cluster showing either a hybrid
system indicator or a tachometer depending on driving mode.
NOTE:
If the vehicle is shut off, the instrument cluster gauges will be “blacked
out”, not illuminated.
Interior View
Instrument Cluster View
Hybrid System Indicator and Tachometer

READY Indicator
Tachometer Hybrid System Indicator


CT200h Identification (Continued)CT200h Identification (Continued)
Engine CompartmentEngine Compartment
-4-
1.8-liter aluminum alloy gasoline engine.
Logo on the plastic engine cover.
Engine Compartment View



Lexus Hybrid Drive Component Locations & DescriptionsLexus Hybrid Drive Component Locations & Descriptions
-5-
Component Location Description
12 Volt 
Auxiliary
Battery
Passenger Side of
Cargo Area A lead-acid battery that supplies power to the low voltage devices.
Hybrid 
Vehicle (HV)
Battery Pack
Cargo Area,
Mounted to Cross
Member behind
Rear Seat
201.6 Volt Nickel Metal Hydride (NiMH)
battery pack consisting of 28 low voltage
(7.2 Volt) modules connected in series.
Power 
Cables Undercarriage and Engine
Compartment
Orange colored power cables carry high
voltage Direct Current (DC) between the
HV battery pack, inverter/converter, and
A/C compressor. These cables also carry 3-
phase Alternating Current (AC) between the
inverter/converter, electric motor, and
generator.
Inverter/
Converter Engine Compartment Boosts and inverts the high voltage electricity from the HV battery pack to 3-
phase AC electricity that drives the electric
motor. The inverter/converter also converts
AC electricity from the electric generator
and electric motor (regenerative braking) to
DC that recharges the HV battery pack.
Gasoline 
Engine Engine Compartment Provides two functions: 1) Powers vehicle.
2) Powers generator to recharge the HV
battery pack.
The engine is started and stopped under
control of the vehicle computer.
Electric
Motor Engine Compartment 3-phase high voltage AC permanent magnet electric motor contained in the front
transaxle. It is used to power the front
wheels.
Electric 
Generator Engine Compartment 3-phase high voltage AC generator that is contained in the transaxle and recharges the
HV battery pack.
Lexus Hybrid Drive Components



 


Components (Top View) and High Voltage Power Cables








Lexus Hybrid Drive Component Locations & Descriptions
(Continued)
Lexus Hybrid Drive Component Locations & Descriptions
(Continued)
-6-
Component Location Description
A/C
Compressor
(with
Inverter) 
Engine
Compartment 3-phase high voltage AC electrically driven motor compressor.
Fuel Tank
and Fuel Line

Undercarriage
and Center The fuel tank provides gasoline via a fuel line to the engine. The fuel line is routed
under the center of vehicle.
Fuel Tank and Fuel Line


Lexus Hybrid Drive Component Locations & Descriptions
(Continued)
Lexus Hybrid Drive Component Locations & Descriptions
(Continued)
Key Specifications:Key Specifications:
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Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine
Electric Motor: 80 hp (60 kW), Permanent Magnet Motor
Transmission: Automatic Only (electrically controlled
continuously variable transaxle)
HV Battery: 201.6 Volt Sealed NiMH Battery
Curb Weight: 3,230 lbs/1,465 kg
Fuel Tank: 11.9 gals/45.0 liters
Fuel Economy
Ratings: 43/40 (City/Hwy) miles/gal
4.5/4.8 (City/Hwy) liters/100 km
Frame Material: Steel Unibody
Body Material: Steel Panels except for Aluminum Hood and Hatch
Seating Capacity: 5 passenger
Steel Unibody
Aluminum Hatch
Aluminum Hood

S
-8-
mart Key System
The CT200h smart key system consists of a smart key transceiver that
communicates bi-directionally, enabling the vehicle to recognize the
smart key in proximity to the vehicle. Once recognized, the smart key
will allow the user to lock and unlock the doors without pushing smart
key buttons, and start the vehicle without inserting it into an ignition
switch.
Smart key features:
Passive (remote) function to lock/unlock the doors and start the
vehicle.
Wireless transmitter buttons to lock/unlock all 5 doors.
Hidden metal cut key to lock/unlock the doors and glove box.
The CT200h is equipped with 2 types of smart keys:
Smart key (fob)
Card smart key (optional)
The card smart key is designed to be stored in a wallet and has all the
same functions as the smart key (fob), except push buttons.
Door (Lock/Unlock)
There are several methods available to lock/unlock the doors.
Pushing the smart key lock button will lock all doors. Pushing the smart
key unlock button once unlocks the driver door, twice unlocks all doors.
Touching the sensor on the backside of the driver door exterior handle, with
the smart key in proximity to the vehicle, unlocks the driver door. Touching
the sensor on the backside of the front passenger door exterior handle, with
the smart key in proximity to the vehicle, unlocks all doors. Touching the
lock touch sensor on either front door, or pushing the hatch lock button will
lock all doors.
Inserting the hidden metal cut key in the driver door lock and turning
clockwise once unlocks the driver door, twice unlocks all doors. To lock
all doors turn the key counter clockwise once. Only the driver door
contains an exterior door lock for the metal cut key.
Smart Key (Fob) Hidden Metal Cut Key for Door Lock
Optional Card Smart Key and Hidden
Metal Cut Key for Door Lock Driver Door Unlock Touch Sensor and Lock Touch Sensor
Front Driver Door Lock Hatch Lock Button
Release Button
Unlock Touch Sensor
Release Button
Lock Touch Sensor
Use the Hidden Metal Cut Key

Smart Key System (Continued)Smart Key System (Continued)
-9-
Vehicle Starting/StoppingVehicle Starting/Stopping
The smart key has replaced the conventional metal cut key, and the power
button with an integral status indicator light has replaced the ignition switch.
The smart key only needs to be in proximity to the vehicle to allow the system
to function.
With the brake pedal released, the first push of the power button operates
the accessory mode, the second push operates the ignition-on mode, and the
third push turns the ignition off again.
Ignition Mode Sequence (brake pedal released):
Starting the vehicle takes priority over all other ignition modes and is
accomplished by depressing the brake pedal and pushing the power button
once. To verify the vehicle has started, check that the power button status
indicator light is off and the READY light is illuminated in the instrument
cluster.
If the internal smart key battery is dead, use the following method to start
the vehicle.
1. Touch the Lexus emblem side of the smart key to the power button.
2. Within the 10 seconds after the buzzer sounds, push the power button
with the brake pedal depressed (the READY light will illuminate).
Once the vehicle has started and is on and operational (READY-ON), the
vehicle is shut off by bringing the vehicle to a complete stop and then
depressing the power button once.
To shut off the vehicle before coming to a stop in an emergency, push and
hold down the power button for more than 3 seconds. This procedure may
be useful at an accident scene in which the READY indicator is on, park
(P) cannot be selected, and the drive wheels remain in motion.
Ignition Mode Power Button Indicator Light
Off Off
Accessory Amber
Ignition-On Amber
Brake Pedal Depressed Green
Vehicle Started (READY-ON) Off
Malfunction Blinking Amber
Power Button with Integral Status
Indicator Light Ignition Modes (Brake Pedal Released)
Starting Sequence
(Brake Pedal Depressed) Smart Key Recognition (When Smart Key Battery is Dead)
Accessor
y
Ignition-On
Vehicle Off Button Push Button Push
Button Push
Optional Card Smart Key

-10-
Electronic Shift Selector
The CT200h electronic shift selector is a momentary select shift-by-wire
system that can be used to select reverse (R), neutral (N), drive (D), or
engine brake (B) states.
These states may only be selected while the vehicle is on and operational
(READY-on), except for neutral (N) which may also be selected while in
the ignition-on mode. After R, N, D, or B is selected, the transaxle remains
in that state, identified on the instrument cluster, but the shift selector
returns to the home position. To select neutral (N), it is necessary to hold
the shift selector in the N position for approximately 0.5 seconds.
Unlike a conventional vehicle, the electronic shift selector does not contain
a park (P) position. Instead, a separate Pswitch located below the shift
selector selects park (P).
When the vehicle is stopped, regardless of shift state, the electro-
mechanical parking lock pawl is engaged to lock the transaxle into park (P)
by either pressing the P switch or pressing the power button to shut off the
vehicle.
Being electronic, the shift selector and park (P) systems depend on the low
voltage 12 Volt auxiliary battery for power. If the 12 Volt auxiliary battery
is discharged or disconnected, the vehicle cannot be started and cannot be
shifted into or out of park (P). There is no manual override except to
reconnect the auxiliary battery or jump start the vehicle, refer to Jump
Starting on page 31.
Electronic Shift Selector and P Switch
Instrument Cluster Shift State Indicator
Home
Position
Illuminates
Indicates Selected State

Lexus Hybrid Drive Operation
Once the READY indicator is illuminated in the instrument cluster, the
vehicle may be driven. However, the gasoline engine does not idle like a
typical automobile and will start and stop automatically. It is important
to recognize and understand the READY indicator provided in the
instrument cluster. When lit, it informs the driver that the vehicle is on
and operational even though the gasoline engine may be off and the
engine compartment is silent.
Vehicle Operation
With the CT200h, the gasoline engine may stop and start at any time while
the READY indicator is on.
Never assume that the vehicle is shut off just because the engine is off.
Always look for the READY indicator status. The vehicle is shut off when
the READY indicator is off.
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The vehicle may be powered by:
1. The electric motor only.
2. The gasoline engine only.
3. A combination of both the electric motor and the gasoline engine.
The vehicle computer determines how the vehicle operates in order to
improve fuel economy and reduce emissions. Three features on the 2011
CT200h are EV (Electric Vehicle) mode, Sport mode and ECO (Economy)
mode:
1. EV Mode: When activated, and certain conditions have been met,
the vehicle operates with the electric motor powered by the HV
battery.
2. ECO Mode: Compared to Normal mode, when activated, ECO
mode helps enhance fuel economy on trips that involve frequent
braking and acceleration.
3. Sport Mode: Compared to Normal mode, when activated, Sport
mode optimizes acceleration feel by increasing the power output
more quickly at the beginning of accelerator pedal operation.
When Sport mode is selected, the tachometer is displayed in the
instrument cluster instead of the Hybrid System Indicator.
Instrument Cluster READY Indicator
EV Drive Mode Switch and Dial-type Normal, ECO and Sport Switch

Hybrid Vehicle (HV) Battery Pack
The CT200h features a high voltage Hybrid Vehicle (HV) battery pack
that contains sealed Nickel Metal Hydride (NiMH) battery modules.
HV Battery Pack
The HV battery assembly is enclosed in a metal case and is rigidly mounted
to the cross member in the cargo area behind the rear seat. The metal case
is isolated from high voltage and concealed by a carpeted panel in the cabin
area.
The HV battery pack consists of 28 low voltage (7.2 Volt) NiMH battery
modules connected in series to produce approximately 201.6 Volts. Each
NiMH battery module is non-spillable and in a sealed case.
The electrolyte used in the NiMH battery module is an alkaline mixture of
potassium and sodium hydroxide. The electrolyte is absorbed into the
battery cell plates and will not normally leak, even in a collision.
-12-
HV Battery Pack
Battery pack voltage 201.6 V
Number of NiMH battery modules in pack 28
NiMH battery module voltage 7.2 V
NiMH battery module dimensions 5 x 1 x 11 in
(118 x 20 x 276 mm)
NiMH module weight 2.3 lbs (1.04 kg)
NiMH battery pack dimensions 15 x 40 x 9 in
(387 x 1011 x 225 mm)
NiMH battery pack weight 90 lbs (41 kg)
Note: Values in inches have been rounded
Components Powered by the HV Battery Pack
HV Battery Pack Recycling
The HV battery pack is recyclable. Contact the nearest Lexus dealer or:
United States: [phone], Canada: [phone]
HV Battery Pack

Electric Motor

Inverter/Converter
Power Cables A/C Compressor
Electric Generator

27 Volt System27 Volt System
The CT200h is equipped with a 27 Volt AC assist motor for the Electric Power
Steering (EPS) system. The EPS computer generates 27 Volts from the 12 Volt
system. The 27 Volt wires are isolated from the metal chassis and routed a
short distance from the EPS computer to the EPS assist motor in the steering
column.
The CT200h is equipped with a 27 Volt AC assist motor for the Electric Power
Steering (EPS) system. The EPS computer generates 27 Volts from the 12 Volt
system. The 27 Volt wires are isolated from the metal chassis and routed a
short distance from the EPS computer to the EPS assist motor in the steering
column.
-13-
NOTE:NOTE:
27 Volts AC has a higher arc potential than 12 Volts DC.27 Volts AC has a higher arc potential than 12 Volts DC.
27 Volt Electric Power Steering System
Electric Power
Steering ECU
Assist Motor

L
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ow Voltage Battery
Auxiliary Battery
The CT200h contains a sealed lead-acid 12 Volt battery. The 12 Volt
auxiliary battery powers the vehicle’s electrical system similar to a
conventional vehicle. As with conventional vehicles, the negative terminal
of the auxiliary battery is grounded to the metal chassis of the vehicle.
The auxiliary battery is located in the cargo area. It is concealed by a fabric
cover on the passenger side in the rear quarter panel well.
NOTE:
An under hood label shows the location of the HV battery (traction battery)
and 12 Volt auxiliary battery.
Open Center and Right Side Auxiliary
Box Remove Center and Right Side Auxiliary Box
Remove Battery Cover 12 Volt Auxiliary Battery Mounted in
Cargo Area
Battery Location Label

H
-15-
igh Voltage Safety
The HV battery pack powers the high voltage electrical system with DC
electricity. Positive and negative orange colored high voltage power cables are
routed from the battery pack, under the vehicle floor pan, to the
inverter/converter. The inverter/converter contains a circuit that boosts the HV
battery voltage from 201.6 to 650 Volts DC. The inverter/converter creates 3-
phase AC to power the motor. Power cables are routed from the
inverter/converter to each high voltage motor (electric motor, electric generator,
and A/C compressor). The following systems are intended to help keep
occupants in the vehicle and emergency responders safe from high voltage
electricity:
High Voltage Safety System
A high voltage fuse provides short circuit protection in the HV battery
pack.
Positive and negative high voltage power cables connected to the HV
battery pack are controlled by 12 Volt normally open relays . When the
vehicle is shut off, the relays stop electrical flow from leaving the HV
battery pack.
WARNING:
The high voltage system may remain powered for up to 10 minutes after
the vehicle is shut off or disabled. To prevent serious injury or death
from severe burns or electric shock, avoid touching, cutting, or
breaching any orange high voltage power cable or high voltage
component.
Both positive and negative power cables are insulated from the
metal body. High voltage electricity flows through these cables and
not through the metal vehicle body. The metal vehicle body is safe to
touch because it is insulated from the high voltage component.
A ground fault monitor continuously monitors for high voltage leakage
to the metal chassis while the vehicle is running. If a malfunction is
detected, the hybrid vehicle computer will illuminate the master warning
light in the instrument cluster and indicate “Check Hybrid System” on
the multi-information display.
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)
Hybrid Vehicle Computer

00 12 Volt
Auxiliary
Battery
Volt DC

A/C
Compressor
Inverter/ Electric
Generator 

Converter
00
Electric
Moto
r
Volt DC

AC HV Battery Assembly
3-Phase
Hybrid Vehicle Computer
12 Volt
Auxiliary
Battery
Volt DC
201.6
A/C
Compressor
Electric
Generator Inverter/
Converter
HV Battery Assembly
Volt DC
201.6
Electric
Moto
r
AC
3-Phase

SRS Airbags & Seat Belt PretensionersSRS Airbags & Seat Belt Pretensioners
Standard EquipmentStandard Equipment
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Electronic frontal impact sensors (2) are mounted in the engine
compartment as illustrated.
Front seat belt pretensioners are mounted near the base of the B-pillars .
A frontal dual stage driver airbag is mounted in the steering wheel hub.
A frontal twin-chamber shaped dual stage passenger airbag is integrated
into the dashboard and deploys through the top of the dashboard.
The SRS computer , which contains an impact sensor, is mounted on the
floor pan underneath the instrument panel.
Front electronic side impact sensors (2) are mounted near the base of the B-
pillars. 
Rear electronic side impact sensors (2) are mounted near the base of the C-
pillars. 
Front seat side airbags are mounted in the front seatbacks.
Side curtain airbags are mounted along the outer edge inside the roof
rails.
Front knee airbags (2) are mounted on the lower portion of the dash.
Front door electronic side impact sensors (2) are mounted inside the base of
the front doors.
Optional Equipment
The optional pre-collision safety system contains a radar sensory
system, occupant seat sensor, and an electric motor-pyrotechnic
pretensioner system. During a pre-collision event, an electric motor in
the pretensioners retracts the front seatbelts. When conditions stabilize
the electric motor will reverse itself. When the airbags deploy, or as
necessary, the pyrotechnic pretensioners function normally.
WARNING:
The SRS may remain powered for up to 90 seconds after the vehicle is
shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS components.
Electronic Impact Sensors and Side Airbags
Standard Frontal Airbags, Seat Belt Pretensioners, Front Knee Airbags, Side
Curtain Airbags







Side Curtain Airbag
Inflators








Frontal, Knee, Front Seatback Mounted Side, Side Curtain Airbags
Driver Knee Airbag and Inflator
-17-
SRS Airbags & Seat Belt Pretensioners (Continued)SRS Airbags & Seat Belt Pretensioners (Continued)
NOTE:NOTE:
The front seatback mounted side airbags and the side curtain airbags may
deploy independently of each other.
The front seatback mounted side airbags and the side curtain airbags may
deploy independently of each other.
The knee airbags deploy simultaneously with the frontal airbags.The knee airbags deploy simultaneously with the frontal airbags.
The CT200h is equipped with a standard front passenger occupant
classification system that may prohibit the deployment of the front
passenger frontal airbag, knee airbag, seatback mounted side airbag, and
seat belt pretensioner. If the passenger occupant classification system
prohibits deployment during an SRS event, the passenger SRS will not re-
arm nor deploy.
The CT200h is equipped with a standard front passenger occupant
classification system that may prohibit the deployment of the front
passenger frontal airbag, knee airbag, seatback mounted side airbag, and
seat belt pretensioner. If the passenger occupant classification system
prohibits deployment during an SRS event, the passenger SRS will not re-
arm nor deploy.
Electronic side impact sensors are installed in each front door to aid in side
collision detection accuracy.
Electronic side impact sensors are installed in each front door to aid in side
collision detection accuracy.
SRS System Diagram
Passenger Frontal Airbag
Front Seat Side Airbag
Front Door Side
Airba
g
Senso
r
Side Airbag Sensor Side Curtain Airbag
Front Seat Belt
Pretensioner
Front Airbag
Sensors
Knee Airbag
Front Seat Side Airbag
Driver Frontal Airbag
Side Airbag Sensor Side Curtain Airbag
Front Seat Belt
Pretensioner
Front Door Side
Airba
g
Senso
r
Rear Side
Airbag Sensor
Rear Side
Airbag Sensor