Lexus HS 250h User manual

Gasoline-Electric
Hybrid Synergy Drive
ANF10 Series

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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.

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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
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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.

Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine: 147 hp (110 kW), 2.4-liter Aluminum Alloy Engine
Electric Motors 141 hp (105 kW), Permanent Magnet Motor
Transmission: Automatic Only (electrically controlled continuously variable transaxle)
HV Battery: 244.8 Volt Sealed NiMH Battery
Curb Weight: 3,770 lbs/1,710 kg
Fuel Tank: 14.5 Us.gals/55.0 liters
Frame Material: Steel Unibody
Body Material: Steel Panels except forAluminum Hood
Seating Capacity: 5 standard
n
o
r
p
q
u
ts
p
v
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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 illuminated, 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 HS250h, 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.
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.
Instrument Cluster READY Indicator
8

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The HS250h features 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 rigidly mounted to the cabin area
floor pan cross member under the second row rear seat. The metal case is isolated from
high voltage and concealed by carpet in the cabin area.
• The HV battery pack consists of 34 low voltage (7.2 Volt) NiMH battery modules
connected in series to produce approximately 244.8 Volt. Each NiMH battery module is
non-spillable and sealed in a metal 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.
• In the unlikely event that the battery pack is overcharged, the modules vent gases directly
outside the vehicle through a vent hose.
HV Battery Pack
Battery pack voltage 244.8 V
Number of NiMH battery modules in the pack 34
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 19 x 40 x 14 in.
(471 x 1010 x 339 mm)
NiMH battery pack weight 121.2 lbs (55 kg)
Components Powered by the HV Battery Pack
• Electric Motor • Inverter/Converter
• Power Cables • A/C Compressor
• Electric Generator • DC-DC Converter
9

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued)
HV Battery Pack Recycling
• The HV battery pack is recyclable. Contact either your Lexus Distributor as mentioned on
HV battery Caution Label (see page 30) or the nearest Lexus dealer.
Auxiliary Battery
• The HS250h also contains a lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers
the vehicle electrical system similar to a conventional vehicle. As with other conventional
vehicles, the auxiliary battery is grounded to the metal chassis of the vehicle.
• The auxiliary battery is located in the engine compartment.
244.8 Volt HV Battery Pack 12 Volt Auxiliary Battery in Engine
Compartment
HV Battery Pack Mounted in Trunk
10

High 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 244.8 to 650 Volts DC. The inverter/converter creates
3-phase AC to power the motors. Power cables are routed from the inverter/converter to each
high voltage motor (front and rear electric motors, 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 n* provides short circuit protection in the HV battery pack.
• Positive and negative high voltage power cables o* connected to the HV battery pack are
controlled by 12 Volt normally open relays p*. When the vehicle is shut off, the relays
stop electricity 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 opening any orange high voltage
power cable or high voltage component.
• Both positive and negative power cables o* are insulated from the metal chassis, so there is
no possibility of electric shock when touching the metal chassis.
• 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 q*
will 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.
*Numbers apply to the illustration on the following page.
11

High Voltage Safety (Continued)
Service Plug Grip
• The high-voltage circuit is cut by removing the service plug grip (see page 15).
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)
q
o
oo
pp
n
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Precaution to be observed when dismantling the vehicle
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.
Necessary Items
• Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
• Insulating tape such as electrical tape that has a suitable electrical insulation rating.
• Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
• An electrical tester that is capable of measuring DC 750 Volts or more.
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14
Spills
The HS250h contains the same common automotive fluids used in other non-hybrid Lexus vehicles,
with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery electrolyte
is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however, is absorbed
in the cell plates and will not normally spill or leak out even if a battery module is cracked. A
catastrophic crash that would breach both the metal battery pack case and a metal battery module would
be a rare occurrence.
A caustic alkaline is at the opposite end of the pH scale from a strong acid. A safe (neutral) substance
is approximately in the middle of this scale. Adding a weak acidic mixture, such as a dilute boric acid
solution or vinegar, to the caustic alkaline electrolyte will cause the electrolyte to be neutralized. This
is similar but opposite to the use of baking soda to neutralize a lead-acid battery electrolyte spill.
A Lexus Material Safety Data Sheets (MSDS) is attached to this document.
• Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE):
• Splash shield or safety goggles. A fold down face shield is not acceptable for acid or
electrolyte spills.
• Rubber, latex or nitrile gloves.
• Apron suitable for alkaline.
• Rubber boots.
• Neutralize NiMH electrolyte.
• Use a boric acid solution or vinegar.
• Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric acid to 1
gallon of water.

Dismantling the vehicle
The following 2 pages contain general instructions for use when working on an HS250h. Read
these instructions before proceeding to the HV battery removal instructions on page 18.
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 any high voltage component.
1. Shut off the ignition (READY indicator is
off). Then disconnect the cable from the
auxiliary battery negative (-) terminal.
2. Remove the service plug grip.
(1) Disengage the 2 clips and 2 guides, and remove the battery service hole cover.
Caution:
Wear insulated gloves for the following 3 steps.
(2) Slide the handle of the service plug grip to the left.
(3) Raise the release handle of the service plug grip.
(4) Remove the service plug grip.
（１）
（2）
（3）
（4）
(5) Apply insulating tape to the socket of the service plug grip to insulate it.
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3. Carry the removed service plug grip in your pocket to prevent other staff from
accidentally reinstalling it while you are dismantling the vehicle.
4. Make other staff aware that a high-voltage system is being dismantled by using the
following sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 17).
5. If the service plug grip cannot be removed due to damage to the vehicle, remove the
IGCT No. 2 fuse (10A).
Caution:
This operation shuts off the HV system. Be sure to wear insulated gloves
because high voltage is not shut off inside the HV battery. When it is possible to
remove the service plug grip, remove it and continue the procedure.
IGCT No.2
6. After disconnecting or exposing a high-voltage connector or terminal, insulate it
immediately using insulating tape. Before disconnecting or touching a bare
high-voltage terminal, wear insulated gloves.
7. Check the HV battery and nearby area for leakage. If you find any liquid, it may be
strong alkaline electrolyte. Wear rubber
gloves and goggles and neutralize the
liquid using a saturated boric acid solution
or vinegar. Then wipe up the liquid using
waste rags etc.
8. If the electrolyte comes into contact with
your skin, wash the skin immediately using
a saturated boric acid solution or a large
amount of water. If the electrolyte
adheres to any article of clothing, take the clothing off immediately.
9. If the electrolyte comes into contact with your eye(s), call out loudly for help. Do not
rub your eye(s). Instead, wash the eye(s) with a dilute boric acid solution or a large
amount of water and seek medical care.
10. With the exception of the HV battery, remove parts by following procedures which are
similar to conventional Lexus vehicles. For the removal of the HV battery, refer to the
following pages.
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