Lexus 2015 ES 300h User manual

ES300h
Gasoline-Electric
Hybrid Synergy Drive
AVV60 Series

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 theA/C compressor, electric motor, generator, and inverter/converter.
All other conventional 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.
©2012 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.

i
Table of Contents
About the ES300h hybrid ..........................................................................................................................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 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............................................................................................................................19
HV Battery Caution Label.......................................................................................................................30

About the ES300h hybrid
The ES300h joins the LS600h L, GS450h, RX450h, HS250h and CT200h 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 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 the kinetic
energy from the rear 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.
1
Deceleration Stopping
Normal Driving
Starting Acceleration
Electricity Electricity and gasoline Charging batteries
Electricity and gasoline
(additional electricity
extracted from batteries)
Engine automatically
stopped

ES300h Identification
In appearance, the 2013 model ES300h is a nearly identical to the conventional,
non-hybrid Lexus ES350 or ES250. The ES300h 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, under the right side front seat, and on the left side B pillar.
Example VIN: JTHBW1GG0D2000101
AES300h is identified by the first 8 alphanumeric characters JTHBW1GG.
Left Side Windshield Cowl, Right Side Floor and Left Side B Pillar
2

ES300h Identification (Continued)
Exterior
 * and logos on the trunk.
 logo on the front doors.
 Gasoline fuel filler door located on the left side rear quarter panel.
*: Except U.S.A. and Canada models
Exterior Left Side View
Exterior Front View


Exterior Rear View
Exterior Rear and Left Side View
Others
U.S.A. and Canada Models





3

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 or ES250.
 A switchable gauge in the instrument cluster 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.
4
Instrument Cluster View (Hybrid System Indicator)
Instrument Cluster View (Tachometer)

READY Indicator
For U.S.A.Others


For U.S.A.Others

ES300h Identification (Continued)
Engine Compartment
 2.5-liter aluminum alloy gasoline engine.
 Logo on the plastic engine cover.
 Orange colored high voltage power cables.
Engine Compartment View
Power Cables



5

6
Hybrid Component Locations & Descriptions
Component Location Description
12 Volt
Auxiliary Battery

Right Side of
Trunk A lead-acid battery that supplies power to the low voltage devices.
Hybrid Vehicle
(HV) Battery
Pack 
Trunk Area,
Mounted 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 Cables 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 motor, and generator.
Inverter/
Converter 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.
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 3-phase high voltage AC permanent magnet electric motor contained in the transaxle and drives the front
wheels.
Electric
Generator Engine Compartment 3-phase high voltage AC electric generator that is contained in the transaxle and recharges the HV battery
pack.
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 Converts 244.8 Volts from the HV battery pack to 12 Volts for low voltage vehicle power.
Fuel Tank and
Fuel Line

Undercarriage
and Left Side
and Center
The fuel tank provides gasoline via a fuel line to the
engine. The fuel line is routed along the left side and
center tunnel under the floor pan.
*Numbers in the component column apply to the illustrations on the following page.

Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine: 155 hp (116 kW), 2.5-liter Aluminum Alloy Engine (U.S.A. and Canada
Models)
158 h
p
(
118 kW
)
,
2.5-liter Aluminum Allo
y
En
g
ine
(
Others
)
Electric Motor: 141 hp (105 kW),AC Motor
Transmission: Automatic Only
HV Battery: 244.8 Volt Sealed NiMH Battery
Curb Weight: 3,660 to 3,781lbs/1,660 to 1,715 kg
Fuel Tank: 17 gals/64.35 liters (U.S.A. and Canada Models)
17 gals/65 liters (Others)
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 passenger








U.S.A. and Canada Models Others



7

Hybrid Component Locations & Descriptions (Continued)
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.
Instrument Cluster READY Indicator
8

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 trunk area
behind the rear seat. The metal case is isolated from high voltage and concealed by fabric
covers in the trunk.
• 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
NiMH battery module dimensions 10.9 x 0.8 x 4.2 in
(276 x 19.6 x 106 mm)
NiMH module weight 2.3 lbs (1.0 kg)
NiMH battery pack dimensions 32.1 x 17.5 x 12.9 in
(817 x 445 x 325 mm)
NiMH battery pack weight 102.5 lbs (46.5 kg)
Components Powered by the HV Battery Pack
• Electric Motor • Inverter/Converter
• Power Cables
• Electric Generator
• A/C Compressor
• DC-DC Converter for 12 Volt Auxiliary
Battery
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 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 trunk area. It is concealed by a fabric cover on the
left side in the rear quarter panel well.
244.8 Volt HV Battery Pack 12 Volt Auxiliary Battery Mounted in Trunk Area
HV Battery Pack Mounted in Trunk Area
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, routed along the propeller shaft and transmission tunnel 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 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 * 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 * 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)

0.0
V
olt DC 12 Volt
A
uxiliary
Battery
Hybrid Vehicle Computer

A
/C
Compressor


Electric
Generator 
Inverter/
Converter
0.0
V
olt DC
Electric
Motor

A
C
3-Phas HV Battery Assembly
Hybrid Vehicle Computer
Vol t D C
Inverter/
Converter
244.8 12 Volt
A
uxiliary
Battery
A
/C
Compressor
Electric
Generator
V
olt DC
244.8
Electric
Motor
A
C
3-Phase HV Battery Assembly
12

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.
13

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 metal 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. 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 ES300h.
Read these instructions before proceeding to the HV battery removal instructions on page 19.
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.
(1) Remove the 12 Volt auxiliary battery
cover.
(2) Disconnect the battery negative terminal.
(3) Remove the luggage compartment floor
mat.
2. Remove the luggage compartment front
trim cover.
(1) Disengage the 8 fasteners and remove the
luggage compartment front trim cover.
15

3. Remove the No. 8 hybrid vehicle battery
shield panel.
(1) Remove the 2 nuts and No. 8 hybrid
battery shield panel.
4. Remove the service plug grip.
Caution:
Wear insulated gloves for the following
4 steps.
(1) Slide the handle of the service plug grip to the right.
(2) Raise the release handle of the service plug grip
(3) Remove the service plug grip.
(4) Apply insulating tape to the socket of the service plug grip to insulate it.
5. Carry the removed service plug grip in your pocket to prevent other staff from
accidentally reinstalling it while you are dismantling the vehicle.
6. Make other staff aware that a high-voltage system is being dismantled by using
thefollowing sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 18).
7. If the service plug grip cannot be removed due to damage to the vehicle, remove the
IG2 MAIN fuse (25 A).
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.
IG2 MAIN Fuse
16