Lexus RC300h User Manual
RC300h
Gasoline-Electric
Lexus Hybrid Drive
AVC10 Series
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Lexus RC300h
gasoline-electric hybrid vehicles. RC300h 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 RC300h, as they
may not be familiar to dismantlers.
High voltage electricity powers the A/C compressor, electric motors, 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
RC300h to help ensure the high voltage, ap proximately 230.4 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 RC300h identification.
Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle RC300h hybrid-electric
vehicles as safely as the dismantling of a conventional gasoline engine automobile.
2015 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.
Table of Contents
About the RC300h ...................................................................................................................................... 1
RC300h 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 ...................................................................................................................... 1 1
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 ............................................................................................................................ 20
HV Battery Caution Label ....................................................................................................................... 37
About the RC300h
The RC300h 2-door coupe joins the hybrid model for Lexus Hybrid Drive means that
the vehicle contains a gasoline engine and 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 RC300h 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 RC300h 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.
Starting
Electricity Electricity and gasoline
Normal Driving
Acceleration Deceleration
Electricity and gasoline
(additional electricity
extracted from batteries)
1
Charging batteries
Stopping
Engine automatically
stopped
RC300h Identification
In appearance, the 2015 model year RC300h is nearly identical to the conventional,
non-hybrid Lexus RC350/300/200t. The RC300h is a 2-door coupe. 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, engine compartment cowl and on the left side B pillar.
Example VIN: JTHHH5BC5000101
An RC300h is identified by the first 8 alphanumeric characters JTHHH5BC.
Left Side Windshield Cowl, Engine Compartment Cowl and Left Side B Pillar
2
RC300h Identification (Continued)
Exterior
RC300h logo on the luggage compartment door.
logos on the rocker molding.
Gasoline fuel filler door located on the left side rear quarter panel.
Exterior Front and Left Side View
Exterior Rear and Left Sid e View
3
RC300h Identification (Continued)
r
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 RC350/300/200t.
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.
READY Indicato
Interior V ie w
READY Indicator
for Optitron Meter
Combination Meter View
4
for TFT LCD Meter
RC300h Identification (Continued)
Engine Compartment
2.5-liter aluminum alloy gasoline engine.
Logo on the engine cover.
Orange colored high voltage power cables.
Engine Compartment View
Power Cables
5
Hybrid Component Locations & Descriptions
Component Description
12 Volt Auxiliary Battery
Hybrid Vehicle (HV)
Battery Pack
Power Cables Connects the HV battery, inverter with converter assembly, hybrid
Inverter/
Converter
Gasoline Engine
Electric Motor
Electric Generator Generator (MG1), which is driven by the engine, generates
A/C Compressor
(with inverter)
Fuel Tank and Fuel Line The fuel tank provides gasoline via a fuel line to the engine. The fuel
*Numbers in the component column apply to the illustrations on the following page.
DC-DC
Converter
for 12 Volt
Auxiliary
Battery
Motor
Generator
ECU
Boost
Converter
Inverter Converts the direct current from the boost converter into alternating
Supplies electricity to the electrical components.
Supplies electrical power to generator (MG1) and motor (MG2) in
accordance with the driving conditions of the vehicle.
Recharged by generator (MG1) and motor (MG2) in accordance
with the SOC and the driving conditions of the vehicle.
vehicle transmission assembly and compressor with motor assembly.
Steps down the HV battery nominal voltage of DC 230.4 V to
approximately DC 14 V in order to supply electricity to the electrical
components, as well as to recharge the auxiliary battery.
Controls the inverter and boost converter in accordance with the
signals received from the hybrid vehicle control ECU assembly , thus
operating generator (MG1) and motor (MG2) as either a generator or
motor.
Boosts the HV battery nominal voltage of DC 230.4 V up to a
maximum voltage of DC 650 V and vice versa (steps down DC 650 V
to DC 230.4 V).
current for generator (MG1) and motor (MG2), and vice versa (from
AC to DC).
The 2AR-FSE engine is a high-expansion ratio Atkinson cycle engine
which is compatible with the hybrid system and which generates drive
force for driving and energy for electricity generation.
Motor (MG2), which is driven by electrical power from generator
(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.
high-voltage electricity in order to operate motor (MG2) and charge
the HV battery. Also, it functions as a starter to start the engine.
Is driven at a speed calculated by the air conditioning amplifier
assembly, receives drive requests from the hybrid vehicle control ECU
and takes in, compresses and discharges refrigerant.
line is routed along the left side and center tunnel under the floor pan.
6
Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine: 133 kW, 2.5-liter Aluminum Alloy Engine
Electric Motor: 162 kW, Permanent Magnet Motor (for Hong Kong)
164 kW, Permanent Magnet Motor (except Hong Kong)
Transmission: Automatic Only
HV Battery: 230.4 Volt Sealed NiMH Battery
Curb Weight: 1,725 to 1,775 kg / 3,803 to 3,913 lbs (for Europe)
1,735 to 1,775 kg /
Fuel Tank: 66 liters /17.4 gals
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 4 passenger
for LHD
3,825 to 3,913 lbs (except Europe)
for RHD
for LHD
for RHD
7
Lexus Hybrid Drive Operation
Once the READY indicator is illuminated in the combination meter, 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 RC300h, 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.
for Optitron Meter
Combination Meter READY Indicator
8
for TFT LCD Meter
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The RC300h 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 luggage
compartment area. The metal case is isolated from high voltage and concealed by fabric
covers in the cabin area.
The HV battery pack consists of 32 low voltage (7.2 Volt) NiMH battery modules
connected in series to produce approximately 230.4 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
Number of NiMH battery modules in the pack
NiMH battery module voltage
Components Powered by the HV Battery Pack
Electric Motor
Power Cables
A/C Compressor
Electric Generator
Inverter/Converter
- DC-DC Converter for 12 Volt Auxiliary Battery
230.4 V
32
7.2 V
9
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