Lexus GS 450h 2006 User manual

© 2006Toyota Motor Corporation Australia Limited.
All rights reserved. This document may not be reproduced or copied, in whole or in part,
without the written permission of Toyota Motor Corporation Australia Limited.
Publication No.TSO0603-00.
Hybrid 2006 Model
Emergency Response Guide
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i
FOREWORD
In May 2006, Lexus will release the Lexus
GS450h petrol-electric hybrid vehicle in
Australia. Except where noted in this guide,
basic vehicle systems and features for the
GS450h are the same as those on the
conventional, non-hybrid, Lexus GS430/300.
This GS450h Emergency Response Guide has
been published to educate and assist
emergency responders in the safe handling of
the GS450h hybrid technology.
High voltage electricity powers the electric
motor, generator, A/C compressor, and
inverter/converter. All other automotive
electrical devices such as the headlights, power
steering, horn, radio, and gauges are powered
from a separate 12-Volt battery. Numerous
safeguards have been designed into the
GS450h to help ensure the high voltage,
approximately 288-Volts, Nickel Metal Hydride
(NiMH) Hybrid Vehicle (HV) battery pack is kept
safe and secure in an accident.
The GS450h utilises the following electrical
systems:
•Maximum 650-Volts AC
•Nominal 288-Volts DC
•Maximum 37-Volts AC / DC
•Nominal 12-Volts DC
GS450h Features:
•First Hybrid Synergy Drive to utilise rear
wheel drive exclusively.
•A boost converter in the inverter
assembly that boosts to 650-Volts the
available voltage to the electric
motor.
•The high voltage hybrid
vehicle battery pack is
rated at 288-Volts.
•A high voltage electric
motor driven air
conditioning compressor
rated at 288-Volts.
•High voltage High Intensity Discharge
(HID) headlights.
•A high voltage Electric Power Steering
(EPS) assist motor rated at 37-Volts.
•The body electrical system rated at
12-Volts negative chassis ground.
•Supplemental Restraint System (SRS) -
dual stage frontal airbags, front knee
airbags, front seat and optional rear seat
side airbags, side curtain airbags, and
front seat belt pretensioners.
High voltage electrical safety is an important
factor in the emergency handling of the
GS450h Hybrid Synergy Drive system. It is
important to recognise and understand the
disabling procedures and warnings throughout
the guide.
Additional topics in the guide include:
•Lexus GS450h identification.
•Major Hybrid Synergy Drive component
locations and descriptions.
•Extrication, fire, recovery, and additional
emergency response information.
•Roadside assistance information.
By following the information in this guide,
emergency responders should be able to safely
perform a rescue involving the Lexus GS450h
hybrid vehicle.
2006 GS450h
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iii
TABLE OF CONTENTS
About the GS450h................................................................................................................................. 1
GS450h Identification ........................................................................................................................... 2
Hybrid Synergy Drive Component Locations and Descriptions ....................................................... 5
Smart Entry System and Push-Button Start........................................................................................6
Hybrid Synergy Drive Operation ......................................................................................................... 8
Hybrid Vehicle (HV) Battery Pack ......................................................................................................... 9
Low Voltage Batteries ........................................................................................................................... 10
High Voltage Safety............................................................................................................................... 11
SRS Airbags and Seat Belt Pretensioners........................................................................................... 13
Emergency Response ........................................................................................................................... 15
Extrication .................................................................................................................................... 15
Fire ................................................................................................................................................ 18
Overhaul ....................................................................................................................................... 19
Recovery/Recycling of the NiMH HV Battery Pack .................................................................... 20
Spills ............................................................................................................................................. 21
First Aid......................................................................................................................................... 22
Submersion.................................................................................................................................. 22
Roadside Assistance ............................................................................................................................. 23
Product Safety Data Sheet.................................................................................................................... 26
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iv
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ABOUT THE GS450h
The GS450h sedan is the first hybrid model for
Lexus in Australia. Hybrid Synergy Drive means
that the vehicle contains a petrol engine and an
electric motor for power. The two hybrid power
sources are stored on board the vehicle:
1. Petrol stored in the fuel tank for the
petrol 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 petrol engine also powers an electric generator
to recharge the battery pack; unlike a pure all
electric vehicle, the GS450h 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
GS450h operates in various driving modes.
❶During light acceleration at low speeds, the
vehicle is powered by the electric motor.
The petrol engine is shut off.
❷During normal driving, the vehicle is powered
mainly by the petrol engine. The petrol engine
also powers the generator to recharge the
battery pack.
❸During full acceleration, such as climbing a hill,
both the petrol engine and the electric motor
power the vehicle.
❹During deceleration, such as when braking, the
vehicle regenerates the kinetic energy from the
rear wheels to produce electricity that recharges
the battery pack.
❺While the vehicle is stopped, the petrol engine
and electric motor are off, however the vehicle
remains on and operational.
– 1 –
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GS450h IDENTIFICATION
In appearance, the 2006 GS450h is nearly identical
to the conventional, non-hybrid Lexus GS430/300.
The GS450h is a 4-door sedan. 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, driver door pillar, and engine
compartment.
Example VIN: JTHBC96S105000149
A GS450h is identified by the first 6 alphanumeric
characters JTHBC69S.
Exterior
logos on the
rear luggage
compartment lid.
logos on the rear
door moulding.
❸Petrol fuel filler door located on the driver side
rear quarter panel.
– 2 –
Exterior Front View
Exterior Rear View
Exterior Driver Side View
Exterior Rear and Passenger Side View
VIN Plate Locations
❶
❷
Left Hand Side
Windshield
Engine Compartment
Cowl
Base of Driver Side B Pillar
❶❷
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GS450h IDENTIFICATION
Interior
❹The instrument cluster (speedometer, fuel
gauge, warning lights) located in the dash
behind the steering wheel, is different than the
one on the conventional, non-hybrid GS430/300.
❺In place of a tachometer, a power meter
showing kW output is used.
NOTE:
If the vehicle is shut off, the instrument cluster
gauges will be "blacked out," not illuminated.
Engine Compartment
❻3.5- litre aluminum alloy petrol engine.
❼Logos on the plastic engine cover.
– 3 –
Interior View
Instrument Cluster View
Logo on Cover
Engine Compartment View
❹
❺
❻
❻
❼
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HYBRID SYNERGY DRIVE COMPONENT
LOCATIONS AND DESCRIPTIONS
COMPONENT LOCATION DESCRIPTION
12-Volt
❶
Luggage A lead-acid battery
Auxiliary Battery Compartment that supplies power to
the low voltage devices.
Hybrid
❷
Luggage 288-Volt Nickel Metal
Vehicle (HV) Compartment Hydride (NiMH) battery
Battery Pack Area, Mounted pack consisting of 40
to Cross Member low voltage (7.2-Volt)
and behind Rear modules connected
Seat in series.
Power
❸
Under Carriage Orange coloured power
Cables and Engine supply cables carry high-
Compartment 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, electrical
motor, and generator.
Inverter/ Engine Boosts and inverts the
Converter
❹
Compartment 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.
Petrol
❺
Engine Provides two functions:
Engine Compartment 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
❻
Transmission 3-phase high-voltage
Generator AC generator that is
contained in the
transmission and
recharges the HV
battery pack.
Electric
❼
Transmission 3-phase high-voltage
Motor AC permanent magnet
electric motor contained
in the transmission and
drives the rear wheels
through the propeller
shaft.
– 4 –
Hybrid Synergy Drive Components
❶❷
❸
❹
❺
❻❼
❽
➒
Components (Top View) and High Voltage
Power Cables
❶❷
❸
❹
❺
❻❼
❽
➒
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HYBRID SYNERGY DRIVE COMPONENT
LOCATIONS AND DESCRIPTIONS
Key Specifications
Petrol Engine: (218 kW), 3.5- litre Aluminum
Alloy Engine
Electric Motor: (147 kw), Permanent Magnet
Motor
Transmission: Automatic Only
HV Battery: 288-Volt Sealed NiMH Battery
Curb Weight: 1,875 kg
FuelTank: 65 litres
Frame Material: Steel Unibody
Body Material: Steel Panels
– 5 –
FuelTank and Fuel Lines
Steel Unibody
COMPONENT LOCATION DESCRIPTION
A/C
❽
Engine 3-phase high voltage AC
Compressor Compartment electrically driven motor
compressor.
DC-DC
➒
Luggage Converts 288-Volts from
Converter Compartment the HV battery pack to
under HV Battery 12-Volts for low voltage
Pack vehicle power.
FuelTank
❿
Undercarriage, The fuel tank provides
and Fuel Driver Side petrol via fuel lines to
Lines and Centre the engine. The fuel
lines are routed along
the driver side and
centre tunnel under the
floor pan.
❿
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SMART ENTRY SYSTEM AND
PUSH-BUTTON START
The GS450h smart entry system consists of a smart
key transceiver that communicates bi-directionally
enabling the vehicle to recognise the smart key in
close proximity to the vehicle. Once recognised,
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 to lock/unlock the doors.
•Hidden metal cut key to lock/unlock the doors
from the exterior door lock.
Door (Lock/Unlock)
Three methods are available to lock/unlock
the doors.
1. Pushing wireless smart key lock/unlock buttons.
2. Touching the sensor on the backside of any
exterior door handle, with the smart key in close
proximity to the vehicle, unlock the doors.
Pushing the lock button on any exterior door
handle locks the doors.
3. Inserting the hidden metal cut key in the drivers
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.
– 6 –
Smart Key
Hidden Metal Cut Key For Door Lock
Hidden Metal Cut Key For Door Lock
Lock
Button
UnlockTouch
Sensor
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SMART ENTRY SYSTEM AND
PUSH-BUTTON START
Vehicle 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.
•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, 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 discharged, it
cannot communicate with the vehicle. In order
for the vehicle to recognise the smart key, the
driver must hold the smart key next to the
power button while pushing the power button.
•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,
placing the gearshift lever in Park, and then
depressing the power button once.
– 7 –
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 Discharged)
Required Distance
10mm (0.39 in)
Vehicle Off Accessory Ignition-On
Button Push Button Push
Button Push
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
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HYBRID SYNERGY DRIVE OPERATION
Once the READY indicator is illuminated in the
instrument cluster, the vehicle may be driven.
However, the petrol engine does not idle like a
typical vehicle and will start and stop automatically.
It is important to recognise 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
petrol engine may be off and the engine
compartment is silent.
Vehicle Operation
•With the GS450h, the petrol 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.
•The vehicle may be powered by:
1. The electric motor only.
2. The petrol engine only.
3. A combination of both the electric motor
and the petrol engine.
•The vehicle computer determines the mode in
which the vehicle operates to improve fuel
economy and reduce emissions. The driver
cannot manually select the mode.
– 8 –
Instrument cluster READY Indicator
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HYBRID VEHICLE (HV) BATTERY PACK
The GS450h contains a high voltage, Hybrid Vehicle
(HV) battery pack that contains sealed Nickel Metal
Hydride (NiMH) battery modules.
HV Battery Pack
•The HV battery pack is enclosed in a metal case
and is securely mounted in the luggage
compartment area behind the rear seat.
The metal case is isolated from high voltage
and concealed by fabric covers.
•The HV battery pack consists of 40 low voltage
(7.2-Volt) NiMH battery modules connected in
series to produce approximately 288-Volts.
Each NiMH battery module is non-spillable and
sealed in a plastic 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 forms a gel that
will not normally leak, even in a collision.
•In the unlikely event that the battery pack is
overcharged, the modules vent gases directly
outside the vehicle through a vent hose.
Components Powered by the HV Battery Pack
•Electric Motor •Power Cables
•Inverter/Converter •DC-DC Converter
•A/C Compressor •Electric Generator
HV Battery Pack Recycling
•The HV battery pack is recyclable. Contact the
nearest Lexus dealer or Lexus Australia.
– 9 –
HV BATTERY PACK
Battery pack voltage 288-Volts
Number of NiMH battery
modules in the pack 40
NiMH battery module voltage 7.2-Volts
NiMH battery
module dimensions 118x20x276mm
NiMH module weight 1.0kg
NiMH battery
pack dimensions 333x952x484mm
Battery pack weight 69kg
288-Volt HV Battery Pack
HV Battery Pack
Mounted in Luggage Compartment
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LOW VOLTAGE BATTERIES
– 10 –
The Auxiliary Battery
•The GS450h contains a 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 auxiliary battery is grounded to the
metal chassis of the vehicle.
•The auxiliary battery is located in luggage
compartment. It is concealed by a fabric cover
on the passenger side in the rear quarter
panel well.
Optional Active Stabiliser
Suspension System Battery
•The GS450h may be optionally equipped with
an active stabiliser suspension system powered
by a separate 12-Volt lead-acid battery. Similar
to the auxiliary battery, the 12-Volt active
stabiliser suspension system battery is
grounded to the metal chassis of the vehicle.
•When equipped with the optional active
stabiliser suspension system, the GS450h is
equipped with run-flat tyres, and no spare tyre.
The active stabiliser suspension system battery
is located in the luggage compartment, and
concealed under deck fabric and tool tray in the
spare tyre well.
NOTE:
The 12-Volt battery for the optional active stabiliser
suspension system does not power the vehicle’s
low voltage system. Responders need to identify
and distinguish the auxiliary battery from the active
stabiliser suspension system battery. When in
doubt, during power disconnect, disable both
12-Volt batteries in the luggage compartment.
12-Volt Auxiliary Battery Mounted in
Luggage Compartment
Optional 12-Volt Battery for Active
Stabiliser Suspension System
Low Voltage Batteries in
Luggage Compartment
Optional
Battery
Auxiliary
Battery
Front
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The HV battery pack powers the high-voltage
electrical system with DC electricity. Positive and
negative orange coloured high voltage power
cables are routed from the battery pack, under the
vehicle floor pan, routed along the passenger side
propeller shaft and transmission tunnel to the
inverter/converter. The inverter/converter contains a
circuit that boosts the HV battery voltage from 288
to 650-Volts DC. The inverter creates 3-phase AC to
power the motor and generator located in the
transmission. Power cables are routed from the
inverter to each high-voltage motor (electrical
motor, electric generator, and A/C compressor).
The following systems keep occupants in the
vehicle and emergency responders safe from high
voltage electricity:
High Voltage Safety System
•A high voltage fuse ❶provides short circuit
protection in the HV battery pack.
•Positive and negative high voltage power cables
❷connected to the HV battery pack are
controlled by 12-Volt normally open relays ❸.
When the vehicle is shut off, the relays stop
electricity flow from leaving the HV battery pack.
•Both positive and negative power cables ❷are
insulated from the metal chassis, so there is no
possibility of electric shock when touching the
metal chassis.
•A ground-fault monitor ❹continuously
monitors for high voltage leakage to the metal
chassis while the vehicle is running. If a
malfunction is detected, the hybrid vehicle
computer ❹will illuminate the master warning
light in the instrument cluster and indicate
"CHECK HYBRID SYSTEM" on the multi-
information display.
•The HV battery pack relays will automatically
open to stop electricity flow in a collision
sufficient to activate the SRS.
HIGH VOLTAGE SAFETY
– 11 –
High Voltage Safety System – Vehicle Shut
Off (READY-OFF)
High Voltage Safety System – Vehicle On
and Operational (READY-ON)
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 opening any orange high voltage power
cable or high voltage component.
❶
❷
❷
❷
❸
❸
❹
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HIGH VOLTAGE SAFETY
– 12 –
Electronic Power Steering
System
The GS450h is equipped with a 37-Volt AC assist
motor for the Electric Power Steering (EPS) system.
The EPS computer generates 37-Volts from the
12-Volt system. The 37-Volt wires are isolated from
the metal chassis and are routed a short distance
from the EPS computer to the EPS assist motor in
the engine compartment.
NOTE:
37-Volt AC has a higher arc potential than the
normal 12-Volt DC.
High Intensity Discharge
Headlights
Similar to conventional, non-hybrid, Lexus vehicles,
the GS450h is equipped with low beam projector
type High Intensity Discharge (HID) headlights.
The light control unit, located inside the headlight
assembly, contains a high voltage generator circuit
that momentarily boosts 12-Volts to 22-kV that is
applied to the bulb when the headlights are turned
on. Once illuminated, the voltage drops to
approximately 45-Volts.
37-Volt EPS
ProjectorType HID Low Beam Headlights
WARNING:
High voltage is applied to the HID bulb socket when
the low beam headlights are turned on. To avoid
serious injury or death by electric shock do not
touch the bulb socket when the headlights are
turned on.
EPS
Computer
EPS
Assist
Motor
HID Low Beam
Headlight
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SRS AIRBAGS & SEAT BELT PRETENSIONERS
– 13 –
Frontal, Seat Side, Curtain, and
Knee Airbag
Driver Side Knee Airbags
Standard Equipment
•Electronic frontal impact sensors (2) are
mounted in the engine compartment ❶as
illustrated on the following page.
•Front seat belt pretensioners are mounted near
the base of the B-pillar ❷.
•A frontal dual stage airbag for the driver ❸is
mounted in the steering wheel hub.
•A frontal dual stage airbag for the front
passenger ❹is integrated into the dashboard
and deploys through the top of the dashboard.
•The SRS computer ❺is mounted on the floor
pan underneath the centre console. It also
contains an impact sensor.
•Front electronic side impact sensors (2) are
mounted near the base of the B-pillars ❻.
•Rear electronic side impact sensors (2) are
mounted near the base of the C-pillars ❼.
•Front seat side impact airbags ❽are mounted
in the front seats.
•Side curtain airbags ➒are mounted along the
outer edge inside the roof rails.
•Front knee airbags ❿are mounted on the
driver side and passenger side lower portion
of the dash.
Optional Equipment
•Rear seat side impact airbags mounted in the
rear seats are optional equipment.
•A pre-crash safety system containing 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 slack in the front
seatbelts. When conditions stabilise the electric
motor will reverse itself. When the airbags
deploy, the pyrotechnic pretensioners
function normally.
NOTES:
The front seat side impact airbags and the side
curtain airbags may deploy independently of
each other.
The knee airbags deploy simultaneously with the
frontal airbags and seat belt pretensioners.
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
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SRS AIRBAGS & SEAT BELT PRETENSIONERS
– 14 –
Side Curtain Airbag Inflator in Roof Rail
Electronic Impact Sensors, Front and Optional
Rear Seat Side Airbags
Standard Frontal Airbags, Seat Belt Pretensioners,
Knee Airbags, and Side Curtain Airbags.
System Diagram
➒
❶
❼
❽
❽
➒
❻
❻
❷
❺
❸
❹
❿
❷
❿
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EMERGENCY RESPONSE
– 15 –
On arrival, emergency responders should follow
their standard operating procedures for vehicle
incidents. Emergencies involving the GS450h may
be handled like other automobiles except as noted
in these guidelines for Extrication, Fire, Overhaul,
Recovery, Spills, First Aid, and Submersion.
Extrication
•Immobilise Vehicle
Chock wheels and set the parking brake.
Move the shift lever to the Park position.
•Disable Vehicle
Performing any one of the following three
procedures will shut the vehicle off and
disable the HV battery pack, SRS, and
petrol fuel pump.
Procedure #1
1. Confirm the status of READY indicator in
the instrument cluster.
2. If the READY indicator is illuminated, the
vehicle is on and operational. Shut off
the vehicle by pushing the power
button once.
3. The vehicle is already shut off if the
instrument cluster lights and the READY
indicator are not illuminated. Do not
push the power button because the
vehicle may start.
4. Keep the smart key at least 5 metres
away from the vehicle.
5. If the smart key cannot be found,
disconnect the 12-Volt auxiliary battery in
the luggage compartment.
WARNING:
•Never assume the GS450h is shut off simply
because it is silent.
•Always observe the instrument cluster for the
READY indicator status to verify whether the
vehicle is on or shut off. The vehicle is shut off
when the READY indicator is off.
•Failure to shut off the vehicle before emergency
response procedures are performed may result
in serious injury or death from the unintentional
deployment of the SRS or severe burns
and electric shock from the high voltage
electrical system.
Chock Wheels
Set Parking Brake
Shut Off Vehicle (READY-Off)
Luggage
Compartment
Opener Button
12-Volt Auxiliary
Battery in Luggage
Compartment
Shift Lever in Park
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