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 theA/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, approximately 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......................................................................................................................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............................................................................................................................20
HV Battery Caution Label.......................................................................................................................37

1
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 Normal Driving Acceleration Deceleration Stopping
Electricity Electricity and gasoline Electricity and gasoline
(additional electricity
extracted from batteries)
Charging batteries Engine automatically
stopped

2
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

3
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 Side View






4
RC300h 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 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.
Interior View
Combination Meter View
READY Indicato
r


for O
p
titron Meter for TFT LCD Meter

READY Indicato
r

5
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




6
Hybrid Component Locations & Descriptions
Component Description
12 Volt Auxiliary Battery
Supplies electricity to the electrical components.
Hybrid Vehicle (HV)
Battery Pack 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.
Power Cables Connects the HV battery, inverter with converter assembly, hybrid
vehicle transmission assembly and compressor with motor assembly.
Inverter/
Converter

DC-DC
Converter 
for 12 Volt
Auxiliary
Battery
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.
Motor
Generator
ECU
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.
Boost
Converter 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).
Inverter Converts the direct current from the boost converter into alternating
current for generator (MG1) and motor (MG2), and vice versa (from
AC to DC).
Gasoline Engine 
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.
Electric Motor
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.
Electric Generator Generator (MG1), which is driven by the engine, generates
high-voltage electricity in order to operate motor (MG2) and charge
the HV battery. Also, it functions as a starter to start the engine.
A/C Compressor
(with inverter) 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.
Fuel Tank and Fuel Line
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.

7
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 / 3,825 to 3,913 lbs (except Europe)
Fuel Tank: 66 liters /17.4 gals
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 4 passenger

















for LHD
for RHD


for LHD
for RHD


8
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.
Combination Meter READY Indicator
for O
p
titron Meter for TFT LCD Meter

9
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 230.4 V
Number of NiMH battery modules in the pack 32
NiMH battery module voltage 7.2 V
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

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 (see page 37) or the nearest Lexus dealer.
Auxiliary Battery
The RC300h also 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 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 fabric
cover on the left side in the luggage compartment.
230.4 Volt HV Battery Pack 12 Volt Auxiliary Battery Mounted in Luggage Compartment Area
(Left Side)
HV Battery Pack Mounted in Luggage Compartment 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 230.4 to 650 Volts DC. The inverter/converter creates 3-phase AC
to power the motors. Power cables are routed from the inverter/converter to each high voltage
motors (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 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 * 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.

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
HV Battery Pack
Hybrid Vehicle Computer
Hybrid Vehicle Computer
Volts DC
Volts DC
A/C
Compressor
A/C
Compressor
Electric
Generator
Electric
Generator
Electric
Motor
230.4
0 Volts AC
3-Phase
650 Volts
AC Max
3-Phase
Inverter/
Converter
Inverter/
Converter
230.4
Volts DC 12 Volts
Auxiliary
Battery
12 Volts
Auxiliary
Battery
Volts DC
0.0
➊
➋
➋
❸❸
➍
Electric
Motor
0.0

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 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.

14
Spills
The RC300h 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.

15
Dismantling the vehicle
The following 4 pages contain general instructions for use when working on an RC300h.
Read these instructions before proceeding to the HV battery removal instructions on page 20.
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) Disengage the 5 claws and 4 guides to
remove the luggage battery service hole
cover LH.
(2) Loosen the nut, and disconnect the cable
from the negative (-) auxiliary battery
terminal.
2. Remove the No. 5 HV battery shield panel.
(1) Remove the No. 1 luggage compartment trim
cover.
.
(2) Remove the 6 clips.

16
(3) Disengage the 3 guides and remove the
luggage compartment trim box.
(4) Remove the 3 nuts and No. 5 HV battery
shield panel from the HV battery.
3. Remove the service plug grip.
Caution:
・Wear insulated gloves.
・Do not inspect or service the high voltage system with the service plug grip installed.
・To prevent electric shock, make sure to remove the service plug grip to cut off the
high voltage circuit before servicing the vehicle.
・To prevent electric shock, make sure to wait at least 10 minutes after removing the
service plug grip to fully discharge the high voltage capacitor inside the inverter
with converter assembly.
・Keep the removed service plug grip in your pocket to prevent other technicians from
accidentally reconnecting it while you are servicing the vehicle.
・To prevent electric shock, make sure to remove the service plug grip to cut off the
high voltage circuit before servicing the vehicle.
・Place a "HIGH VOLTAGE WORK IN PROGRESS. DO NOT TOUCH." sign, in order to
prevent other technicians from accidentally reconnecting the power while work is in
progress.
Notice:
・After removing the service plug grip, turning the power switch on (READY) may cause a
malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.
・Do not touch the terminals of the service plug grip.