L-SB-0046-15

September 4, 2015

Hybrid System Electrical Safety Precautions
Service
Category

General

Section

Pre-Delivery Service

Market USA

Applicability
YEAR(S)

MODEL(S)

2016

CT200H

ADDITIONAL INFORMATION

Introduction

This bulletin provides general high-voltage safety precautions for the hybrid system. The hybrid
system circuits operate with up to 650 volts. These high voltages are dangerous and can cause
severe personal injuries, burns, and electrical shock if proper safety precautions are NOT
followed. Be sure to carefully review all applicable Repair Manual procedures BEFORE
performing service.
As a policy, and to ensure safety, no Lexus dealership technician is qualified to service or repair
hybrid vehicles until Lexus course L071 has been successfully completed.
CAUTION
When servicing the high-voltage system on the 2016 CT 200h, wait AT LEAST 10 minutes after
disconnecting the service plug BEFORE touching any of the high-voltage connectors or terminals.

1

Inverter

3

Power Cable

2

Hybrid Vehicle Transaxle Assembly

4

HV Battery Assembly

© 2015 Lexus, a division of Toyota Motor Sales, USA

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L-SB-0046-15

September 4, 2015

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Hybrid System Electrical Safety Precautions
Warranty Information
OP CODE

DESCRIPTION

TIME

OFP

T1

T2

N/A

Not Applicable to Warranty

–

–

–

–

Required Tools & Equipment
SPECIAL SERVICETOOLS (SST)

PART NUMBER

QTY

00002-03100-S (Small)
Electrical Insulating Gloves*

00002-03200-M (Medium)

1

00002-03300-L (Large)
CAUTION
Always inspect Electrical Insulating Gloves before use for cracks, ruptures, tears, pinholes, or
damage. Do NOT wear if damaged.

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
* Essential SST.

Electrical Safety Precautions
CAUTION
HYBRID HIGH-VOLTAGE SAFETY NOTICE
A Lexus gas/electric hybrid vehicle has high-voltage DC and AC systems. Both DC and AC highvoltage are very dangerous and can cause personal injury, severe burns, electric shock, and even
fatal injury.
Regular Service and Repairs (Pre-Delivery Service [PDS], and Non-High-Voltage Maintenance and
Service)
Ensure that all persons performing PDS or non-high-voltage maintenance and service:
1. Follow all Caution labels attached to high-voltage parts.
2. Do NOT touch or attempt to remove or replace any high-voltage (orange-colored) wiring
and connectors.
3. Do NOT touch the orange service plug.
4. Read, understand, and follow the safety procedures in the Pre-Delivery Service Manual,
Repair Manual, and all applicable Service Bulletins for the vehicle.

© 2015 Lexus, a division of Toyota Motor Sales, USA

L-SB-0046-15

September 4, 2015

Page 3 of 3

Hybrid System Electrical Safety Precautions
Electrical Safety Precautions (Continued)
CAUTION
HYBRID HIGH-VOLTAGE SAFETY NOTICE (Continued)
High-Voltage Repairs
Ensure that all technicians performing repairs to high-voltage systems:
1. Complete the hybrid training course L071 provided at the Lexus Area office.
2. Read, understand, and follow the safety procedures in the Repair Manual and all applicable
Service Bulletins for the vehicle.
3. Use high-voltage gloves and safety glasses whenever servicing high-voltage systems.
4. After disconnecting the service plug, wait AT LEAST 10 minutes BEFORE touching any of
the high-voltage connectors or terminals.
5. Are responsible for managing the safety of any hybrid vehicle or parts they are working on.
6. Maintain a “safety zone” around their work, including using yellow caution tape and
“DO NOT TOUCH “HIGH-VOLTAGE” signs when high-voltage system repairs are to be
left unattended.
In the Event the Hybrid Vehicle Is Involved in an Accident
1. Do NOT touch any high-voltage wiring, connectors, or parts, such as the inverter or the
hybrid battery assembly.
2. Do NOT touch the potassium hydroxide electrolyte that might spill or leak from the hybrid
battery as the result of an accident. If potassium hydroxide electrolyte gets on your skin or
in your eyes, neutralize it IMMEDIATELY with a saturated boric acid solution (ratio: 80
grams boric acid to 2 liters water or alternatively, flush repeatedly with large amounts of
water).
SEEK IMMEDIATE MEDICAL ATTENTION.
3. If a vehicle fire occurs, water has been proven to be a suitable extinguishing agent.
4. See the Emergency Response Guide on the Lexus Technical Information System (TIS) or
Dealer Daily for more information.
If you have any questions, contact your District Service and Parts Manager.

For additional Caution notices, download the PDF files from Dealer Daily, Lexus Customer Services
website, Forms, and print on a color printer.

© 2015 Lexus, a division of Toyota Motor Sales, USA