Lexus 2015 ES 300h User manual

E
G
L
E
S
G
asoli
n
L
exus
H
3
0
n
e-
E
le
c
H
ybri
d
0
0
h
c
tric
d
Drive
h
AXZH10
S
S
eries

ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Lexus ES300h
gasoline-electric hybrid vehicles. ES300h 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 ES300h, as
they may not be familiar to dismantlers.
High voltage electricity powers the electric motor, generator, Air Conditioning (A/C) compressor and
inverter/converter. All other automotive electrical devices such as the head lights, radio, and gauges
are powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into
the ES300h 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 ES300h identification.
Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle ES300h hybrid-electric
vehicles as safely as the dismantling of a conventional gasoline engine automobile.
2018 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 ES300h.........................................................................................................................................1
ES300h Identification...................................................................................................................................2
Exterior .........................................................................................................................................................3
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 andAuxiliary 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 a vehicle .................................................................................................................................15
Removal of HV battery ..............................................................................................................................20

1
About the ES300h
The ES300h 4-door sedan joins the 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 ES300h 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 ES300h operates in various driving
modes.
During light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.
During normal driving, the vehicle is powered mainly by the gasoline engine.
The gasoline engine also powers the generator to recharge the battery pack and to
drive the motor.
During full acceleration, such as climbing a hill, both the gasoline engine and the
electric motor power the vehicle.
During deceleration, such as when braking, the vehicle regenerates kinetic energy
from the front wheels to produce electricity that recharges the battery pack.
While the vehicle is stopped, the gasoline engine and electric motor are off, however
the vehicle remains on and operational.
Starting Normal Driving Acceleration Deceleration Stopping
Electricity Electricity and gasoline Electricity and gasoline
(additional electricity
extracted from batteries)
Charging batteries Engine automatically
stopped

2
ES300h Identification
In appearance, the 2019 model year ES300h is nearly identical to the conventional, non-hybrid
Lexus ES350/260/250/200. The ES300h is a 4-door sedan. Exterior, interior, and engine
compartment illustrations are provided to assist in identification.
The alphanumeric 15 character Vehicle Identification Number (VIN) is provided in the left side
windshield cowl, under the right side front seat, on the left side B pillar (except China) and on
the right side B pillar (for China).
Example VIN: JTHB21B12000101 or JTHB71B12000101
An ES300h is identified by the first 8 alphanumeric characters
JTHB21B1 or JTHB71B1.
Left Side Windshield Cowl, Under the Right Side Front Seat and Left Side B Pillar
(except China)
Left Side Windshield Cowl, Under the Right Side Front Seat and Right Side B Pillar
(for China)

3
ES300h Identification (Continued)
Exterior
ES300h logo on the luggage compartment door.
logos on the each rear door.
Gasoline fuel filler door located on the left side rear quarter panel.
Exterior Front and Left Side View
Exterior Rear and Left Side View





4
ES300h Identification (Continued)
Interior
The instrument cluster (hybrid system indicator, READY indicator, and warning lights)
located in the dash behind the steering wheel, is different than the one on the conventional,
non-hybrid ES350/260/250/200.
A switchable gauge in the combination meter showing either a hybrid system indicator or a
tachometer depending on driving mode.
Notice:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not
illuminated.
Interior View
Combination Meter View
READY Indicator



READY Indicator 
except F Sport for F Sport
This illustration is for an LHD model

ES3
0
Engi
 2.
5
 L
o
 O
r
0
0h Ident
ne Compar
t
5
-liter alumi
o
go on the e
n
r
ange colore
ification
(
t
ment
num alloy g
a
n
gine cover.
d high volta
g
(
Continu
e
a
soline engi
n
g
e power ca
b
Engi
n

5
e
d)
n
e.
b
les.
n
e Compartm
e
Power Cabl
e


e
nt View
e
s
This ill
u
stration is fo
r
r an LHD m
o
o
del

6
Hybrid Component Locations & Descriptions
Component Location Description
12 Volt Auxiliary
Battery Luggage
Compartment Supplies electricity to the electrical components.
Hybrid Vehicle
(HV) Battery
Pack
Cabin Area,
Mounted Under
Rear Seat
•Supplies electrical power to MG1 and MG2 in
accordance with the driving conditions of the vehicle.
•Recharged by MG1 and MG2 in accordance with the
SOC and the driving conditions of the vehicle.
Power Cables Undercarriage and
Engine
Compartment
Connects the HV battery, inverter with converter
assembly, hybrid vehicle transaxle assembly and
compressor with motor assembly.
Inverter/
Converter Engine Compartment •Converts the direct current from the boost converter
into alternating current for MG1 and MG2, and vice
versa (from AC to DC).
•Boosts the HV battery nominal voltage of DC 244.8 V
up to a maximum voltage of DC 650 V and vice versa
(steps down DC 650 V to DC 244.8 V).
Gasoline 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 Motor Engine
Compartment •MG2, which is driven by electrical power from MG1
and the HV battery, generates motive force for the drive
wheels.
•During braking, or when the accelerator pedal is not
depressed, it generates high-voltage electricity to recharge
the HV battery.
Electric Generator
Engine
Compartment MG1, which is driven by the engine, generates high-voltage electricity in order to operate MG2 and
charge the HV battery. Also, it functions as a starter to
start the engine.
A/C Compressor
(with Inverter) Engine Compartment 3-phase high voltage AC electrically driven motor compressor.
DC-DC Converter
for 12 Volt
Auxiliary Battery

Engine
Compartment Steps down the HV battery nominal voltage of DC 244.8 V to approximately DC 14 V in order to supply electricity
to the electrical components, as well as to recharge the
auxiliary battery.
Fuel Tank and Fuel
Line 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.

7
Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine: 131 kW, 2.5-literAluminum Alloy Engine
Electric Motor: 88 kW, Permanent Magnet Motor
Transmission: Automatic Only
HV Battery: 244.8 Volt Sealed NiMH Battery
Curb Weight: 3,693 – 3,836 lbs / 1,675 - 1,740 kg
Fuel Tank: 49.3 – 50.0 liters / 13.0 – 13.2 Us. gals / 10.8 – 11.0 Imp. gals
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 passenger


















8
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 ES300h, 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. A combination of both the electric motor and the gasoline engine.
Combination Meter READY Indicator
except F Sport for F Sport

9
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The ES300h 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
under the 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 Volts. 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.
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
Components Powered by the HV Battery Pack
Electric Motor Inverter/Converter
Power Cables A/C Compressor
Electric Generator
DC-DC Converter for 12 Volt Auxiliary Battery

10
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 or the nearest Lexus dealer.
Auxiliary Battery
The ES300h contains a sealed 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 negative terminal of the auxiliary battery is
grounded to the metal chassis of the vehicle.
The auxiliary battery is located in the luggage compartment area. It is concealed by a
plastic cover on the left side in the battery compartment.
244.8 Volt HV Battery Pack 12 Volt Auxiliary Battery Mounted in Luggage Compartment Area
(Right Side)
HV Battery Pack Mounted in Cabin Area

11
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 motor. Power cables are routed from the inverter/converter to each
high voltage motor (electric motor, 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 * provides short circuit protection in the HV battery pack.
Positive and negative high voltage power cables * connected to the HV battery pack are
controlled by 12 Volt normally open relays *. When the vehicle is shut off, the relays
stop electrical 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 breaching any orange high
voltage power cable or high voltage component.
Both positive and negative power cables * are insulated from the metal body. High
voltage electricity flows through these cables and not through the metal vehicle body. The
metal vehicle body is safe to touch because it is insulated from the high voltage
components.
A ground fault monitor in the hybrid vehicle computer * continuously monitors for high
voltage leakage to the metal chassis while the vehicle is running. If a malfunction is
detected, the hybrid vehicle computer * will illuminate the master warning light in
the instrument cluster and a message indicating that the hybrid system is malfunctioning
will be displayed on the multi-information display.
The HV battery pack relays will automatically open to stop electrical flow in a collision
sufficient to activate the SRS.
*Numbers apply to the illustration on the following page.

12
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)
HV Battery Pack
Hybrid Vehicle Computer
Volts DC
A/C
Compressor
Electric
Generator
Electric
Motor
0 Volts AC
3-Phase
Inverter/
Converter
12 Volts
Auxiliary
Battery
Volts DC
0.0
➊
➋
➋
❸❸
➍
0.0
HV Battery Pack
Hybrid Vehicle Computer
Volts DC
A/C
Compressor
Electric
Generator
244.8
650 Volts
AC Max
3-Phase
Inverter/
Converter
244.8
Volts DC
12 Volts
Auxiliary
Battery
Electric
Motor

13
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 breaching 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.

14
Spills
The ES300h 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 Product Safety Data Sheets (PSDS) is attached to this document.
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.
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.

Dis
m
The
f
Rea
d
S
1.
n
(
(
m
antlin
g
f
ollowing 4
p
d
these instru
WARNI
N
・ The
h
minu
t
serio
u
touc
h
cable
S
hut off the
n
egative au
Turn b
a
(
1)
cover
R
Loosen
(
2)
from th
e
termina
a vehicle
p
ages contai
n
ctions befor
e
N
G:
h
igh volta
g
t
es after t
h
u
s injury
o
h
ing, cutti
n
or any hi
g
ignition (
R
xiliary batt
e
a
ck the lugg
a
R
H as shown
the nut, and
e
negative (-
l.
n
general in
s
e
proceedin
g
g
e syste
m
h
e vehicl
e
o
r death f
r
n
g, or bre
a
g
h voltag
e
R
EADY ind
i
e
ry termina
l
a
ge compart
m
in the illust
r
disconnect
t
) auxiliary b
15
s
tructions fo
r
g
to the HV
b
m
may rem
e
is shut
o
r
om seve
r
a
chin
g
a
n
e
compo
n
i
cator is of
f
l.
m
ent trim
r
ation.
t
he cable
b
attery
r
use when
w
b
attery remo
v
ain powe
r
o
ff or disa
b
r
e burns
o
n
y orange
n
ent.
f
). Then dis
c
w
orking on a
n
v
al instructi
o
r
ed for up
b
led. To
o
r electric
high volt
a
c
onnect ca
b
n
ES300h.
o
ns on page
2
to 10
prevent
shock, a
v
a
ge powe
r
b
le from
2
0.
v
oid
r

R
2.
(
(
(
R
3.
C
•
•
•
R
emove bat
t
(
1) Remov
e
(
2) Diseng
a
illustrat
i
(
3) Diseng
a
service
h
illustrat
i
R
emove ser
v
C
aution:
Be sure t
Do not in
voltage s
grip inst
a
To reduc
e
make su
r
grip to c
u
before s
e
t
ery servic
e
e
the clip.
a
ge the 7 cla
w
i
on.
a
ge the guid
e
h
ole cover a
s
i
on.
v
ice plug g
r
o wear ins
spect or s
e
ystem wit
h
a
lled.
e
the risk
o
r
e to remo
v
u
t off the h
i
e
rvicing th
e
e
hole cover
w
s as shown
e
to remove t
s
shown in t
h
r
ip
ulated glo
v
e
rvice the
h
h
the servi
c
o
f electric
s
v
e the serv
i
gh voltag
e
e
vehicle.
16
r
in the
t
he battery
h
e
v
es.
high
c
e plug
s
hock,
v
ice plug
e
circuit