Starting and Charging: Service Precautions

REPAIR INSTRUCTION: PRECAUTION

1. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE

NOTE: The RX400h hybrid system contains a 288V high-voltage system with a strong alkali solution of potassium hydroxide. Be sure to follow the instructions to handle the system correctly. Failure to do so may result in serious injury or electrocution.

(a) Engineer must undergo special training to be able to perform high-voltage system inspection and servicing.
(b) All high-voltage wire harness connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires and components.





(c) Before inspecting or servicing the high-voltage system, be sure to follow safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while your are servicing the vehicle.

NOTE: Do not put the vehicle into the READY-on state after removing the service plug grip as the ECU may be damaged.

(d) After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.

HINT: 5 minutes are required to discharge the high-voltage condenser inside the inverter.





(e) Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves.

(f) When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit.
(g) Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.





(h) After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.

(i) The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
(j) Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers that a high-voltage system is being inspected and/or repaired.





(k) After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminal screws are firmly tightened, and that the connectors are correctly connected.
(l) Do not place the battery upside down while removing and installing it.