Lexus HS 250h User manual

Gasoline-Electric
Hybrid Synergy Drive
ANF10 Series

ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Lexus HS250h
gasoline-electric hybrid vehicles. HS250h dismantling procedures are similar to other non-hybrid
Lexus vehicles with the exception of the high voltage electrical system. It is important to recognize
and understand the high voltage electrical system features and specifications of the Lexus HS250h, as
they may not be familiar to dismantlers.
High voltage electricity powers theA/C compressor, electric motors, generator, and inverter/converter.
All other conventional 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
HS250h to help ensure the high voltage, approximately 244.8 Volt, Nickel Metal Hydride (NiMH)
Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in
some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell
plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.
Additional topics contained in the guide include:
• Lexus HS250h identification.
• Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle HS250h-electric vehicles
as safely as the dismantling of a conventional non-hybrid automobile.
©2009 Toyota Motor Corporation
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.

iii
Table of Contents
About the HS250h......................................................................................................................................1
HS250h Identification................................................................................................................................2
Exterior .........................................................................................................................................................3
HS250h Identification (Continued)..........................................................................................................4
Interior...........................................................................................................................................................4
Engine Compartment....................................................................................................................................5
Hybrid Component Locations & Descriptions........................................................................................6
Specifications................................................................................................................................................7
Lexus Hybrid Drive Operation.................................................................................................................8
Vehicle Operation..........................................................................................................................................8
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery.....................................................................9
HV Battery Pack............................................................................................................................................9
Components Powered by the HV Battery Pack.............................................................................................9
HV Battery Pack Recycling.........................................................................................................................10
Auxiliary Battery..........................................................................................................................................10
High Voltage Safety .................................................................................................................................11
High Voltage Safety System........................................................................................................................11
Service Plug Grip........................................................................................................................................12
Precaution to be observed when dismantling the vehicle.....................................................................13
Necessary Items.........................................................................................................................................13
Spills..........................................................................................................................................................14
Dismantling the vehicle...........................................................................................................................15
Removal of HV battery ...........................................................................................................................18
HV Battery Caution Label ...........................................................................................................................30

About the HS250h
The HS250h sedan joins the LS 600h L, RX 450h and GS 450h 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 HS250h 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 HS250h operates in various driving
modes.
nDuring light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.
oDuring normal driving, the vehicle is powered mainly by the gasoline engine. The
gasoline engine also powers the generator to recharge the battery pack.
pDuring full acceleration, such as climbing a hill, both the gasoline engine and the
electric motor power the vehicle.
qDuring deceleration, such as when braking, the vehicle regenerates the kinetic
energy from the wheels to produce electricity that recharges the battery pack.
rWhile the vehicle is stopped, the gasoline engine and electric motor are off, however
the vehicle remains on and operational.
r
1

HS250h Identification
In appearance, the 2010 model year HS250h 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: JTHBB1BAA82020211
An HS250h is identified by the first 8 alphanumeric characters
JTHBB1BA.
Driver Side Windshield cowl and Driver Side B Pillar
2

HS250h Identification (Continued)
Exterior
nlogo on the back door.
ologo on the rear door moldings.
Exterior Driver Side View
Exterior Front and Rear View
Exterior Rear and Driver Side View
o
n
n
o
3

HS250h Identification (Continued)
Interior
pInstrument cluster (speedometer, power meter, READY light, shift position indicators,
warning lights) located in the dash behind the steering wheel.
Hint:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not
illuminated.
Interior View of Front Door Sill/Scuff Plate
Instrument Cluster View
p
p
4

HS250h Identification (Continued)
Engine Compartment
q2.4-liter aluminum alloy gasoline engine.
rLEXUS HYBRID DRIVE logo on the plastic engine cover.
sOrange colored high voltage power cables.
Engine Compartment View
Power Cables
r
q
s
5

6
Hybrid Component Locations & Descriptions
Component Location Description
12 Volt nAuxiliary
Battery Trunk Passenger
Side A lead-acid battery that supplies power to the low voltage devices.
Hybrid oVehicle
(HV) Battery Pack
Trunk Area,
Mounted to
Cross Member
and behind
Rear Seat
244.8 Volt Nickel Metal Hydride (NiMH) battery pack
consisting of 34 low voltage (7.2 Volt) modules
connected in series.
Power pCables
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 motors, and generator.
Inverter/
Converter q
Engine
Compartment Boosts and inverts the high voltage electricity from the HV battery pack to 3-phaseAC electricity that drives the
electric motors. The inverter/converter also converts
AC electricity from the electric generator and electric
motors (regenerative braking) to DC that recharges the
HV battery pack.
Gasoline r
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.
Electrics
Motor
Engine
Compartment 3-phase high voltageAC permanent magnet electric motor contained in the front transaxle. It is used to
power the front wheels.
Electric t
Generator Engine
Compartment 3-phase high voltageAC generator that is contained in the transaxle and recharges the HV battery pack.
A/C Compressor
(with Inverter) uEngine
Compartment 3-phase high voltage AC electrically driven motor compressor.
Fuel Tank and Fuel
Line v
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.
*Numbers in the component column apply to the illustrations on the following page.