Lexus GS450h Emergency Response Guide

Lexus GS450h Emergency Response Guide
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Hybrid 2006 Model
Emergency Response Guide
© 2006 Toyota 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.
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FOREWORD
• The body electrical system rated at
12-Volts negative chassis ground.
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.
• 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.
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.
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.
The GS450h utilises the following electrical
systems:
• Maximum 650-Volts AC
By following the information in this guide,
emergency responders should be able to safely
perform a rescue involving the Lexus GS450h
hybrid vehicle.
• 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.
2006 GS450h
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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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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.
❶
During light acceleration at low speeds, the
vehicle is powered by the electric motor.
The petrol engine is shut off.
❷
During normal driving, the vehicle is powered
mainly by the petrol engine. The petrol engine
also powers the generator to recharge the
battery pack.
❸
During full acceleration, such as climbing a hill,
both the petrol engine and the electric motor
power the vehicle.
❹
During deceleration, such as when braking, the
vehicle regenerates the kinetic energy from the
rear wheels to produce electricity that recharges
the battery pack.
❺
While 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.
Left Hand Side
Windshield
Engine Compartment
Cowl
The alphanumeric 17 character Vehicle
Identification Number (VIN) is provided in the front
windshield cowl, driver door pillar, and engine
compartment.
Example VIN: JTHBC96S105000149
Base of Driver Side B Pillar
A GS450h is identified by the first 6 alphanumeric
characters JTHBC69S.
VIN Plate Locations
Exterior
❶
logos on the
rear luggage
compartment lid.
❷
logos on the rear
door moulding.
❸
Exterior Front View
Petrol fuel filler door located on the driver side
rear quarter panel.
❶
Exterior Rear View
Exterior Rear and Passenger Side View
Exterior Driver Side View
–2–
❷
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GS450h IDENTIFICATION
Interior
❹
The 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.
❺
In 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.
Interior View
Engine Compartment
❺
❹
❻
3.5- litre aluminum alloy petrol engine.
❼
Logos on the plastic engine cover.
❼
Instrument Cluster View
❻
Logo on Cover
❻
Engine Compartment View
–3–
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HYBRID SYNERGY DRIVE COMPONENT
LOCATIONS AND DESCRIPTIONS
COMPONENT
LOCATION
12-Volt ❶
Luggage
Auxiliary Battery Compartment
❶
❷
➒
❸
❹
❻ ❼
Hybrid ❷
Vehicle (HV)
Battery Pack
❺
➒
❶
❷
288-Volt Nickel Metal
Hydride (NiMH) battery
pack consisting of 40
low voltage (7.2-Volt)
modules connected
in series.
Under Carriage
and Engine
Compartment
Orange coloured power
supply cables carry highvoltage 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/
Converter ❹
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.
Petrol ❺
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 ❻
Generator
Transmission
3-phase high-voltage
AC generator that is
contained in the
transmission and
recharges the HV
battery pack.
Electric ❼
Motor
Transmission
3-phase high-voltage
AC permanent magnet
electric motor contained
in the transmission and
drives the rear wheels
through the propeller
shaft.
Power ❸
Cables
❹
❸
❻❼
❺
❽
A lead-acid battery
that supplies power to
the low voltage devices.
Luggage
Compartment
Area, Mounted
to Cross Member
and behind Rear
Seat
❽
Hybrid Synergy Drive Components
DESCRIPTION
Components (Top View) and High Voltage
Power Cables
–4–
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HYBRID SYNERGY DRIVE COMPONENT
LOCATIONS AND DESCRIPTIONS
COMPONENT
A/C ❽
Compressor
❿
DC-DC ➒
Converter
Fuel Tank ❿
and Fuel
Lines
LOCATION
DESCRIPTION
Engine
Compartment
3-phase high voltage AC
electrically driven motor
compressor.
Luggage
Compartment
under HV Battery
Pack
Converts 288-Volts from
the HV battery pack to
12-Volts for low voltage
vehicle power.
Undercarriage,
Driver Side
and Centre
The fuel tank provides
petrol via fuel lines to
the engine. The fuel
lines are routed along
the driver side and
centre tunnel under the
floor pan.
Fuel Tank and Fuel Lines
Key Specifications
Steel Unibody
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
Fuel Tank:
65 litres
Frame Material: Steel Unibody
Body Material:
–5–
Steel Panels
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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:
Smart Key
• 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.
Hidden Metal Cut Key For Door Lock
Unlock Touch
Sensor
Lock
Button
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.
Hidden Metal Cut Key For Door Lock
–6–
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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.
Power Button with Integral
Status Indicator Light
Ignition Mode Sequence (Brake pedal released):
Vehicle Off
Button Push
Accessory
Button Push
Ignition-On
Button Push
Ignition Modes (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.
Starting Sequence
(Brake Pedal Depressed)
• 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.
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
Required Distance
10mm (0.39 in)
Smart Key Recognition
(When Smart Key Battery is Discharged)
–7–
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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.
Instrument cluster READY Indicator
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–
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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
288-Volt 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.
HV Battery Pack
Mounted in Luggage Compartment
• 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
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
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–
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LOW VOLTAGE BATTERIES
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.
12-Volt Auxiliary Battery Mounted in
Luggage Compartment
• 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.
Front
Optional Active Stabiliser
Suspension System Battery
Optional 12-Volt Battery for Active
Stabiliser Suspension System
• 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:
Auxiliary
Battery
Optional
Battery
Low Voltage Batteries in
Luggage Compartment
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.
– 10 –
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HIGH VOLTAGE SAFETY
❷
❸
❷
❷
❸
❶
❹
High Voltage Safety System – Vehicle Shut
Off (READY-OFF)
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
High Voltage Safety System – Vehicle On
and Operational (READY-ON)
• A high voltage fuse ❶ provides short circuit
protection in the HV battery pack.
• Positive and negative high voltage power cables
❷ connected 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.
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 ❷ are
insulated from the metal chassis, so there is no
possibility of electric shock when touching the
metal chassis.
• A ground-fault monitor ❹ continuously
monitors for high voltage leakage to the metal
chassis while the vehicle is running. If a
malfunction is detected, the hybrid vehicle
computer ❹ will illuminate the master warning
light
in the instrument cluster and indicate
"CHECK HYBRID SYSTEM" on the multiinformation display.
• The HV battery pack relays will automatically
open to stop electricity flow in a collision
sufficient to activate the SRS.
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HIGH VOLTAGE SAFETY
EPS
Computer
EPS
Assist
Motor
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.
37-Volt EPS
NOTE:
37-Volt AC has a higher arc potential than the
normal 12-Volt DC.
HID Low Beam
Headlight
High Intensity Discharge
Headlights
Projector Type HID Low Beam 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.
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.
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SRS AIRBAGS & SEAT BELT PRETENSIONERS
Standard Equipment
Frontal, Seat Side, Curtain, and
Knee Airbag
Driver Side Knee Airbags
• Electronic frontal impact sensors (2) are
mounted in the engine compartment ❶ as
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 ❸ is
mounted in the steering wheel hub.
• A frontal dual stage airbag for the front
passenger ❹ is integrated into the dashboard
and deploys through the top of the dashboard.
• The SRS computer ❺ is 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 ❽ are mounted
in the front seats.
• Side curtain airbags ➒ are mounted along the
outer edge inside the roof rails.
• Front knee airbags ❿ are 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:
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
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.
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SRS AIRBAGS & SEAT BELT PRETENSIONERS
➒
Side Curtain Airbag Inflator in Roof Rail
❻
➒
❽
❿
❹
❸
❼
❺
❽
❻
❶
Electronic Impact Sensors, Front and Optional
Rear Seat Side Airbags
❷
❿
❷
Standard Frontal Airbags, Seat Belt Pretensioners,
Knee Airbags, and Side Curtain Airbags.
System Diagram
– 14 –
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EMERGENCY RESPONSE
Chock Wheels
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.
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.
Set Parking Brake
• 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.
Shift Lever in Park
Extrication
•
Immobilise Vehicle
Chock wheels and set the parking brake.
Move the shift lever to the Park position.
•
Disable Vehicle
Shut Off Vehicle (READY-Off)
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.
Luggage
Compartment
Opener Button
2. If the READY indicator is illuminated, the
vehicle is on and operational. Shut off
the vehicle by pushing the power
button once.
12-Volt Auxiliary
Battery in Luggage
Compartment
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.
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EMERGENCY RESPONSE
Extrication (Continued)
Remote Hood
Release
NOTE:
Before disconnecting the 12-Volt auxiliary
battery, if necessary, reposition the power
seats and tilt/telescoping steering wheel,
lower the windows, unlock the doors, open
the luggage compartment and the fuel door
as required. A manual fuel door release is
located in the luggage compartment (see
illustration in the Roadside Assistance
section page 24). Once the 12-Volt auxiliary
battery is disconnected power controls will
not operate.
Hood Latch
Release
Procedure #2 (Alternate if power
button is inaccessible)
1. Disconnect the 12-Volt auxiliary battery in
the luggage compartment.
2. Remove the engine compartment covers.
3. Remove the driver side fuse box cover.
4. Remove the IGCT No. 1 fuse (20A yellow
coloured) in the engine compartment
junction block as illustrated. If the correct
fuse cannot be recognised, pull all of the
fuses in the fuse block.
Remove Engine Compartment Covers
Procedure #3 (Alternate if power button
and engine compartment are
inaccessible)
1. Remove the RH J/B-B fuse (30A green
coloured) in the luggage compartment
near the auxiliary battery positive post as
illustrated. If the correct fuse cannot be
recognised, pull all three fuses.
2. Disconnect the 12-Volt auxiliary battery in
the luggage compartment.
Remove Fuse Box Cover
IGCT
No. 1
Fuse
RH J/B-B Fuse
(30 A Green)
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.
• 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.
12-Volt Auxiliary
Battery + Post
IGCT No. 1 Fuse
Location in Engine
Compartment
Fuse Box
RH J/B-B Fuse in
Luggage Compartment
near the Auxiliary
Battery Positive Post
• If none of the disabling procedures can be
performed, proceed with caution as there is no
assurance that the high voltage electrical system,
SRS, or fuel pump are disabled.
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Page 17
EMERGENCY RESPONSE
Extrication (Continued)
•
Stabilise Vehicle
Check/stabilise at (4) points directly under
the front and rear pillars.
Do not place blocks under the high voltage
power cables, exhaust system, or fuel
system.
Chocking Points
Chocking /Stabilising Points
•
Access Patients
Glass Removal
Use normal glass removal procedures
as required.
Chocking/ Stabilising Points
Underbody View
SRS Curtain
Airbag
SRS Curtain
Airbag
SRS Awareness
Responders need to be cautious when
working in close proximity to undeployed
airbags and seat belt pretensioners. Front
dual stage airbags automatically ignite both
stages within a fraction of a second.
Door Removal/Displacement
Doors can be removed by conventional
rescue tools such as hand, electric, and
hydraulic tools. In certain situations, it may
be easier to pry back the vehicle body to
expose and unbolt the hinges.
Roof Removal
The GS450h contains side curtain airbags.
If undeployed, it is not recommended to
remove or to displace the roof. The side
curtain airbags may be identified as
illustrated.
SRS Side
Airbag
SRS Knee
Airbag
Front Seat Side, Side Curtain, and
Knee Airbag Identifiers.
Dash Displacement
The GS450h contains side curtain airbags.
Do not remove or displace the roof during a
dash displacement to avoid cutting into
undeployed airbags or inflators. As an
alternative, dash displacement may be
performed by using a Modified Dash Roll.
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Page 18
EMERGENCY RESPONSE
Extrication (Continued)
Rescue Lift Air Bags
Responders should not place chocks or
rescue lift air bags under the high voltage
power cables, exhaust system, or
fuel system.
Repositioning Steering Wheel and Seat
Power tilt/telescopic steering wheel and seat
controls are shown in the illustration.
Power Tilt and Telescoping Controls
Power Front Seat Controls
NOTE:
The GS450h driver seat is equipped with a
power seat slide linked headrest.
Repositioning the seat and/or headrest
removal must be done prior to 12-Volt
auxiliary battery disconnect. Unlike the
passenger seat, the driver seat has a hidden
release button located under the seat fabric
as illustrated.
Fire
Approach and extinguish a fire using proper vehicle
fire fighting practices.
•
Extinguishing Agent
Water has been proven to be a suitable
extinguishing agent.
•
Initial Fire Attack
Perform a fast, aggressive fire attack.
Divert the runoff from entering watershed
areas.
Attack teams may not be able to identify a
GS450h until the fire has been knocked down
and overhaul operations have commenced.
Driver Headrest Hidden Release Button
•
Fire in the HV Battery Pack
Should a fire occur in the NiMH HV battery
pack, attack crews should utilise a water
stream or fog pattern to extinguish any fire
within the luggage compartment except for
the HV battery pack.
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Page 19
EMERGENCY RESPONSE
WARNING:
• The NIMH battery electrolyte is a caustic alkaline (pH 13.5) that is
damaging to human tissues. To avoid injury by coming in contact with the
electrolyte, wear proper personal protective equipment.
• The battery modules are contained within a metal case and accessibility
is limited.
• To avoid serious injury or death from severe burns or electric shock, never
breach or remove the high voltage battery pack cover under any
circumstance including fire.
When allowed to burn themselves out, the GS450h NiMH
battery modules burn rapidly and can quickly be reduced to
ashes except for the metal.
Offensive Fire Attack
Normally flooding a NiMH HV battery pack with copious
amounts of water at a safe distance will effectively control the
HV battery pack fire by cooling the adjacent NiMH battery
modules to a point below their ignition temperature. The
remaining modules on fire, if not extinguished by the water, will
burn themselves out.
However, flooding the GS450h HV battery pack is not
recommended due to the battery case design and location
preventing the responder from properly applying water through
the available vent openings safely. Therefore, it is
recommended that the incident commander allow the GS450h
HV battery pack to burn itself out.
Defensive Fire Attack
If the decision has been made to fight the fire using a defensive
attack, the fire attack crew should pull back a safe distance and
allow the NiMH battery modules to burn themselves out.
During this defensive operation, fire crews may utilise a water
stream or fog pattern to protect exposures or to control the path
of smoke.
Overhaul
During overhaul, immobilise and disable the vehicle if not already
done. See illustrations on page 15. The HV battery cover should never
be breached or removed under any circumstances including fire.
Doing so may result in severe electrical burns, shock, or electrocution.
•
Immobilise Vehicle
Chock wheels and set the parking brake.
Move the shift lever to the Park position.
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Page 20
EMERGENCY RESPONSE
•
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.
Procedure #2 (Alternate if power button is inaccessible)
1. Disconnect the 12-Volt auxiliary battery in the luggage
compartment.
2. Remove the engine compartment covers.
3. Remove the driver side fuse box cover.
4. Remove the IGCT No. 1 fuse (20A yellow coloured) in the
engine compartment junction block as illustrated on page 16.
If the correct fuse cannot be recognised, pull all of the fuses
in the fuse block.
Procedure #3 (Alternate if power button and engine
compartment are inaccessible)
1. Remove the RH J/B-B fuse (30A green coloured) in the
luggage compartment near the auxiliary battery positive
post as illustrated on page 16. If the correct fuse cannot be
recognised, pull all three fuses.
2. Disconnect the 12-Volt auxiliary battery in the luggage
compartment.
Recovery/Recycling of NiMH HV
Battery Pack
Clean up of the HV battery pack can be accomplished by the vehicle
recovery crew without further concern of runoff or spillage.
For information regarding recycling of the HV battery pack, contact the
nearest Lexus dealer or Lexus Australia.
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Page 21
EMERGENCY RESPONSE
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.
• 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.
• If none of the disabling procedures can be performed, proceed with
caution as there is no assurance that the high voltage electrical system,
SRS, or fuel pump are disabled.
Spills
The GS450h contains the same common automotive fluids used in
other non-hybrid Lexus vehicles, with the exception of 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 the plastic battery module would be a rare occurrence.
Similar to the use of baking soda to neutralise a lead-acid battery
electrolyte spill, a dilute boric acid solution or vinegar can be used to
neutralise a NiMH battery electrolyte spill.
NOTE:
Electrolyte leakage from the HV battery pack is unlikely due to its
construction and the amount of available electrolyte contained within
the NiMH modules. Any spillage would not warrant a declaration as a
hazardous material incident. Responders should follow the
recommendations as outlined in this emergency response guide.
In an emergency, check the Material Safety Data Sheets (MSDS)
on page 26.
•
Handle NiMH electrolyte spills using the following
Personal Protective Equipment (PPE):
Splash shield or safety goggles. Fold down helmet shields are
not acceptable for acid or electrolyte spills.
Rubber, latex or nitrile gloves.
Apron suitable for alkaline.
Rubber boots.
•
Neutralise NiMH Electrolyte
Use a boric acid solution or vinegar.
Boric acid solution - 800 grams boric acid to 20 litres water.
– 21 –
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Page 22
EMERGENCY RESPONSE
First Aid
Emergency responders may not be familiar with a NiMH electrolyte
exposure when rendering aid to a patient. Exposure to the electrolyte
is unlikely except in a catastrophic crash or through improper
handling. Utilise the following guidelines in the event of exposure.
WARNING:
The NIMH battery electrolyte is a caustic alkaline (pH 13.5) that is damaging
to human tissues. To avoid injury by coming in contact with the electrolyte,
wear proper personal protective equipment.
•
Wear Personal Protective Equipment (PPE)
Splash shield or safety goggles. Fold down helmet shields are
not acceptable for acid or electrolyte spills.
Rubber, latex or nitrile gloves.
Apron suitable for alkaline.
Rubber boots.
•
Absorption
Perform gross decontamination by removing affected clothing
and properly disposing of the garments.
Rinse the affected areas with water for 20 minutes.
Transport patients to the nearest emergency medical care facility.
•
Inhalation in Non-Fire Situations
No toxic gases are emitted under normal conditions.
•
Inhalation in Fire Situations
Toxic gases are given off as by-products of combustion.
All responders in the Hot Zone should wear the proper PPE for
fire fighting including SCBA.
Move a patient from the hazardous environment to a safe area
and administer oxygen.
Transport patients to the nearest emergency medical care facility.
•
Ingestion
Do not induce vomiting.
Allow a patient to drink large quantities of water to dilute
electrolyte (Never give water to an unconscious person).
If vomiting occurs spontaneously, keep the patient’s head
lowered and forward to reduce the risk of asphyxiation.
Transport patients to the nearest emergency medical care facility.
Submersion
When fully or partially submersed a GS450h can be safely handled by
following these recommendations:
• Remove the vehicle from the water.
• Drain the water from the vehicle if possible.
• Follow the immobilising and disabling procedures on page 15.
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Page 23
ROADSIDE ASSISTANCE
Lexus GS450h roadside assistance may be handled
like conventional Lexus vehicles except as noted in
the following pages.
Lexus Roadside Assistance is available during the
basic warranty period by contacting:
Lexus Drivecare: 1800 253 987
Shift Lever
Gated Shift Lever
Similar to most Lexus vehicles, the GS450h uses
a gated shift lever as shown in the illustration.
However, the GS450h shift lever includes an
S position for 6 levels of engine braking.
Towing
The GS450h is a rear drive vehicle and it must be
towed with the rear wheels off the ground. Failure
to do so may cause serious damage to the Hybrid
System Drive components.
• A flat bed trailer is the preferred method
of towing.
Remove Shift Lock Release Cover
• When towing the vehicle with the front wheels
on the ground, be sure to release the steering
lock by turning the ignition-on.
• The vehicle may be shifted out of Park into
Neutral by turning the ignition-on, depressing
the brake, then moving the gated shift lever
to N.
• If the shift lever cannot be moved out of Park, a
shift lock release button is provided near the
shift lever as shown in the illustration.
Push in Shift Lock Release
• 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. This should only be attempted on hard,
paved roads for short distances at low speeds.
– 23 –
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Page 24
ROADSIDE ASSISTANCE
Electric Luggage Compartment Opener
The GS450h is equipped with an electric luggage
compartment opener. In the event of 12-Volt power
loss, the luggage compartment can be opened with
the metal cut key hidden in the smart key.
Electric Fuel Door Opener
The GS450h is equipped with an electric fuel door
opener. In the event of 12-Volt power loss, the fuel
door can only be opened using the manual release
located inside the luggage compartment.
Luggage
Compartment
Opener Switch
Fuel Door
Opener Switch
Spare Tyre
The jack, tools, and spare tyre are provided in the
luggage compartment as illustrated.
Fuel Door and Luggage Compartment
Opener Switches
Manual Luggage Compartment Opening
with the Metal Cut Key
Manual Luggage Compartment Opening
with the Metal Cut Key
Tools and Spare Tyre in the
Luggage Compartment
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Page 25
ROADSIDE ASSISTANCE
Jump Starting
The 12-Volt auxiliary battery may be jump started if
the vehicle does not start and the instrument
cluster gauges are dim or off after depressing the
brake pedal and pushing the power button.
12-Volt Auxiliary
Battery
Clip
The 12-Volt auxiliary battery is located in the
luggage compartment. The luggage compartment
opener will not operate if the auxiliary battery is
discharged. Instead use the metal cut key hidden in
the smart key to open the luggage compartment.
• Open the luggage compartment, and remove
the 12-Volt auxiliary battery cover on the
left hand side.
• Connect the positive jumper cable to the
positive battery post.
• Connect the negative jumper cable to the
negative battery post.
• Place the smart key inside the vehicle, depress
the brake pedal, and push the start button.
Battery only for active stabiliser
suspension (if fitted)
Jumper Cable Connections
NOTES:
If the vehicle does not recognise the smart key
after connecting the booster battery to the
vehicle, open and close the driver door when
the vehicle is shut off.
If the smart key internal battery is discharged,
hold the smart key next to the power button
(within 10 mm) during the start sequence.
• The high-voltage HV battery pack cannot be
jump-started.
• Never use a ‘Quick Charger’ or ‘Booster Pack’ to
jump-start the vehicle.
• If the auxiliary battery needs to be replaced,
replace it only with 12-Volt battery specially
designed for use in the GS450h.
Immobiliser and Anti-Theft Alarm
The GS450h is equipped with an immobiliser
system and an anti-theft alarm as standard
equipment.
• The vehicle can be started only with a registered
smart key.
• To disarm the anti-theft alarm, unlock the door
by using the smart key button, hidden metal cut
key, or using the door handle touch sensor.
Engaging the ignition-on mode or starting the
vehicle will also disarm the anti-theft alarm.
– 25 –
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Page 26
PRODUCT SAFETY DATA SHEET
1. Product and Company Identification
Name of Product
Prismatic Nickel Metal-hydride Battery (module)
Model name
EV-MP6R5R02 (GEN II)
Company name
Panasonic EV Energy Co., Ltd.
Address
555,Sakaijyuku,Kosai-City, Shizuoka, 431-0452 Japan
Division
Engineering Department
Telephone/ Fax
+81-53-577-3112 / +81-53-577-3114
Issue date / Revised date
Issue date Oct 31st, 2003
Issue number
p0054
2. Substance Identification (Main substances of Prismatic Nickel Metal-hydride Battery [module])
Substance
Nickel Hydroxide
CAS No.
12054-48-7
Substance
Hydrogen storage alloy
CAS No
Not specified
Substance
Alkaline solution
Potassium hydroxide (Substance in alkaline solution)
1310-58-3
(1) Positive
(2) Negative
(3) Electrolyte
CAS No.
3. Hazardous and Toxicity Class
(1) Class Name
Not applicable.
(2) Hazard
No hazard in-normal situations.
However, heat generation and/or alkaline electrolyte leakage may occur in
the event of positive/negative terminal short circuiting by metallic or highly
conductive objects.
(3) Toxicity
No toxicity in-normal situations.
In the event of a burning battery pack, there is a possibility that an alkaline
mixed gas may be emitted, which may in turn irritate eyes, nose,
and/or throat.
If the battery is stored for very long time periods, electrolyte and/or metal
materials may leak and result in surface soil pollution.
4. First Aid Measures
In the event of alkaline electrolyte and/or alkaline mixed gas leakage.
(1) Eye contact
Contact may cause corneal injury and blindness.
Wash eyes with large amounts of running water for at least 15 minutes.
Seek medical treatment immediately.
If appropriate actions are not taken, eye disorders may result.
(2) Skin contact
Wash the contact area with plenty of water and seek medical
treatment immediately.
Clothing, shoes, and socks, etc. which have come into contact with
alkaline electrolyte should be taken off immediately.
If appropriate actions are not taken, skin inflammation may occur.
(3) Inhalation
Move the exposed person to fresh air area immediately.
Cover up the affected person with a blanket.
Seek medical treatment immediately.
(4) Swallowing
Do not induce vomiting.
Seek medical treatment immediately.
– 26 –
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Page 27
PRODUCT SAFETY DATA SHEET
5. Fire Fighting Measures
(1) Firefighting measures
and extinguisher
(1) Use powder-type ABC extinguisher.
(2) When corrosive gas could be generated in the event of fire fighting,
use appropriate breathing apparatus.
(3) Extinguishing a fire with a large amount of water may be an
effective method.
However, this should be considered as a supplementary means.
If there are no readily available large amounts of water, use dry sand
instead; as the application of only a small amount of water may
temporarily act as an accelerant and affect the fire adversely while the
hydrogen storage alloy is burning.
(4) Remove the flammable materials from the fire.
(5) If fire occurs nearby to batteries, move them to a safe place.
(2) Possibility of fire and explosion
(1) Fire may occur when:
Short circuit-induced arcing occurs.
A large current is applied to a module or a cell.
(2) Explosion may occur when:
The battery is contained in a hermetic container, since oxygen and/or
hydrogen may be generated by the battery. The battery itself will not
explode in normal conditions.
(3) Fire and explosion may occur when:
The battery is over-charged or over-discharged. The battery is over
100 deg C.
The battery is in a hermetic container with an ignition source nearby
and overcharge or overdischarge occurs.
6. Measures for electrolyte leakage
When the alkaline electrolyte leaks from battery.
(1) Wipe off with a towel.
(2) Keep away from flames.
(3) Protective glasses and rubber gloves should be worn.
7. Handling and Storage
(1) No short circuit
Short circuit should be prevented since heat generation and/or fire
may result.
(2) No disassembly and reconstruction
The battery should not be disassembled and/or reconstructed for the
following reasons:
• If a cell is disassembled, alkaline electrolyte may leak.
• If a module is disassembled, short circuiting may occur.
• If a module is disassembled, cells will be damaged and alkaline
electrolyte may leak.
(3) No over-charge or over-discharge
Battery should not be over-charged or over-discharged to prevent possible
oxygen and/or hydrogen generation.
(4) No usage in hermetic container
Battery should not be used in a hermetic container since the container may
explode due to gas generated from the battery.
8. Exposure Control
When alkaline electrolyte leakage from the battery occurs, necessary
action should be taken as follows:
(1) Acceptable concentration
Not specified in Japanese Industrial Hygienic association and ACGIH.
(2) Facilities
(1) Ventilation should be considered. Limited exhaust device or other
ventilation device should be used.
(2) Exhaust system or exhaust hole is required when the battery is used
in a container.
(3) Prevention measures
Safety glasses, mask, and gloves should be worn.
– 27 –
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Page 28
PRODUCT SAFETY DATA SHEET
9. Physical and Chemical Properties
(1) Appearance
The nickel hydrogen battery (cell and module) is contained within a plastic
resin case.
The module geometry is basically a thin rectangular trapezoid. A fixed
voltage value cannot be specified.
10. Hazardous Information
As indicated in Sections 3 and 5.
11. Toxicological Information
In the event of alkaline electrolyte leakage.
(1) Acute toxicity
(2) Stimulation
LD50 2g/kg oral rat (based on material safety data sheet of
liquid potassium hydroxide).
Inflammation of the cornea can be caused from scratching/rubbing
one’s eyes.
Exposure for extended time periods can irritate bronchial tubes and eyes.
12. Transport Information
(1) Battery terminal should be packaged to prevent external short circuits.
Batteries should not be allowed to contact each other as prevention
against short circuiting when packaged.
(2) There should be a marking on the package that indicates that Nickel
Hydrogen Storage batteries are contained.
There should be a ”Non-spillable” marking for international shipment.
(Refer to Section 14).
(3) Packaging should be stable and durable enough to protect batteries from
vibration, shock, dropping and stacking.
Batteries should not fall down and/or be allowed to be inverted/tilted
during shipping.
(4) Packaging should not become wet (rain and/or dew, etc), during storage
and shipping.
(5) Keep away from fire/flame during storage and shipping, and do not store
batteries in a hot environment.
NOTE: One example of storage in a hot environment is that of exposing a
vehicle with a battery installed in very hot weather for a long time.
13. Disposal
(1) Battery should be disposed in accordance with provisions of vehicle
manufacturer or dealer.
(2) Domestic waste disposal is not allowed.
14. Regulatory Information
(1) Hazardous Materials Transportation
(Hazardous shipping transportation
and storage regulation)
15. Others
(1) DOT (Department of Transportation)
• UN Number
2800
• Classes
8
• Special Provision
49 CFR 173.159(d)
(2) IATA (International Air Transport Association)
• UN Number
2800
• Classes
8
• Special Provision
A67
Not specified.
– 28 –
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