i-MiEV accident and emergency rescue manual AU900183€¦ · i-MiEV has been designed so the high...

i-MiEV

Accident and Emergency

Rescue Manual (2010 MY vehicle)

Copyright © Mitsubishi Motors Australia Limited Part number AU900183, October 2010

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Introduction

This manual provides safety instructions that need to be followed when rescuing the passengers from the vehicle after an accident and describes how to handle the damaged vehicle.

Failure to follow these instructions and especially the warnings and cautions may result in serious injury such as an electrical shock due to the high voltage battery installed on i-MiEV.

Please read and understand this manual carefully for your and the passengers safety.

Throughout this manual the words WARNING, CAUTION and NOTE appear.

These serve as reminders to be especially careful. Failure to follow instructions could result in personal injury or

damage to your vehicle.

Indicates a strong possibility of severe personal injury or death if instructions are not followed.

Means hazards or unsafe practices that could cause minor personal injury or damage to your vehicle.

NOTE: gives helpful information.


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Table of contents

1. Safety precautions for handling high voltage.(1) Isolation from the high voltage circuit (2) Disconnection of the high voltage circuit (3) Precautions when rescuing passengers

2. Exterior and interior features to identify i-MiEV. (1) Exterior (2) Interior (3) Chassis number

3. Handling the vehicle at an accident site. (1) Required tools and equipment (2) Precautions at the accident site

4. Passenger rescue procedures. (1) Preparation (2) Case 1:

Not necessary to cut the vehicle body or isolate the high voltage circuit (3) Case 2:

Cutting the vehicle body is necessary and isolating the high voltage circuit is possible (4) Case 3:

Cutting the vehicle body is necessary and because of an emergency situation it is not possible to wait for isolating the high voltage circuit. Or in case the orange-coloured high voltage wiring cables are exposed.

(5) Case 4: Submerged vehicle.

(6) Case 5: Re-inverting a rolled vehicle.

(7) Case 6: Vehicle fire.

5. Detail working procedures (1) Procedure to disconnect the high voltage circuit. (2) Procedure to fill the main battery with water. (3) Transportation of a damaged vehicle. (4) Vehicle dimensions and precautions for transporting a damaged vehicle.


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1. Safety precaution for handling high voltage. Since i-MiEV has a high voltage circuit with a 330V Lithium-ion battery for the electric motor unit and other components, it is necessary to ensure “isolation” and “cut off” from the high voltage circuit in order to prevent the risk of electric shock before handling the vehicle.

(1) Isolation from the high voltage circuit

1) The high voltage circuit is insulated from the vehicle body.

2) All high voltage components are covered by cases/covers and the high voltage wiring cables can be distinguished from the normal wiring harness by their orange coloured insulation.

3) All the high voltage component cases are insulated from the high voltage circuit inside.

(2) Disconnection of the high voltage circuit i-MiEV has been designed so the high voltage current supplied from the main battery can be isolated. This is required when it is necessary to isolate the high voltage circuit, e.g. during vehicle inspection, maintenance and /or traffic accidents.

<High Voltage disconnection method>

System

Case

Manual method Automatic method

Service plug Electric motor switch

(Ignition switch) linked Collision sensing

Normal usage X

Inspection and

maintenance X X

Crash X

i-MiEV is equipped with 4 collision sensors to determine when an accident (front, side or rear collision) has occurred, including the severity of the accident. The high voltage circuits can be automatically isolated from within the main battery (by opening the high voltage contactors) if the crash/impact is severe enough to cause damage to the high voltage components (wiring, components, main battery, etc.).

(3) Precautions when rescuing passengers

CAUTION; Please handle the vehicle in accordance with the instructions provided throughout this manual to reduce the risk of injury from electric shock.

Points to note are:

1) This vehicle uses a 330V high voltage circuit.

2) Main battery uses an electrolyte made of a flammable “Carbonate ester solution with lithium salt”. The possibility of a high volume electrolyte leak as a result of main battery damage is reduced by soaking the electrolyte into an unwoven fabric as part of the construction.


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2. Exterior and interior features to identify i-MiEV. All i-MiEV vehicles sold in Australia by Mitsubishi Motors Australia Ltd have a high voltage circuit with a

330V Lithium-ion battery for the electric motor unit and other components. Please handle using the

appropriate Personal Protective Equipment (PPE) and only the methods described in this manual.

WARNING; Use insulated Personal Protective Equipment (PPE) (rubber insulating gloves, rubber soled insulating shoes and insulated pants/jacket: rated to a minimum of 400V voltage resistance or PPE that meets relevant Australian Standards), when contact with the vehicle body is possible.

(1) Exterior

1) Rear

Absence of exhaust pipe

Absence of exhaust pipe

i-MiEV does not have an exhaust pipe.


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(2) Interior Gear shift panel

Instrument panel

Instrument panel

An energy usage indicator is located in the i-MiEV instrument panel. A state of charge gauge is also installed top LHS.

P R N D

ECO B

Gear shift panel

The indication on the panel is different.


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(3) Chassis number The Chassis number is stamped on the body inside of quarter trim in the luggage area as well on the

Caution plate at the centre pillar of at the passenger’s side.

・Caution plate (Center pillar of passenger’s side)

The first 4 digits of Chassis Number are “HA3W” for i-MiEV.

･Chassis number (Inside of quarter trim in luggage area)

The first 4 digits are “HA3W” for i-MiEV.

Quarter trim lower

Chassis number stamp

HA3W-0000010


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3. Handling the vehicle at the accident site. The following precautions need to be observed when you handle the vehicle at an accident site. (1) Required tools and equipment

Items marked ★ must be available and used. The other items to be available, if necessary.

1) ★ Insulating protection/PPE (minimum 400V voltage resistance or relevant Australian Standards). Rubber insulating gloves and rubber sole insulating shoes (as a minimum, pants and jacket also recommended). For prevention of electric shock while working from high voltage circuit/s.

2) ★ Double-end-wrench （size 10 x 12mm）. To be used to loosen: 1. Remove the 2x12mm nuts fastening the cover to access and unplug the service plug. 2. Disconnect the auxiliary battery negative terminal (10mm).

3) Solvent resistance gloves (or heavy-duty rubber gloves) and eye protection. For use when the electrolyte is leaking from the main battery.

4) Absorption mat, sand. For absorbing any electrolyte leakage. An absorption mat (that is effective to absorb fuel and/or oil) and/or sand need to be available.

5) Fire extinguisher. Fire extinguisher that is suitable for flammable liquid and/or electrical equipment fires is required.

6) Circuit tester. For voltage measurement in case the electric circuit is damaged.

7) Insulating plastic tape. For insulating the electric circuit and tools if these are damaged.

(2) Precautions at the accident site

WARNING; Use insulated Personal Protective Equipment (PPE) (Rubber insulating gloves and rubber sole insulating shoes as a minimum: rated to a minimum of 400V voltage resistance or meeting relevant Australian Standards), in case contact with the vehicle body is possible.

1) Always wear insulated Personal Protective Equipment (PPE) while working.

2) Do not directly touch any exposed high voltage wiring cables, any disconnected or protective covers or high voltage components that might be damaged.

3) If you find fluid leaking from under the main battery, it could possibly be the flammable electrolyte from the main battery assembly. Wear solvent resistance gloves (or heavy-duty rubber gloves) and eye protection (in addition to the insulated PPE requirements described above), then absorb the liquid with an absorption mat or sand. The electrolyte is clear & colourless with a slightly sweet odour. It has similar viscosity to water.

WARNING;

If the electrolyte comes in contact with your skin, flush with water immediately. If the electrolyte gets into your eyes, don’t rub your eyes and flush with a large quantity of water immediately.

4) If there is a possibility that high voltage components and wiring are damaged, cut off the high voltage circuit according to the instructions in Case 2 (page 10). For the location of high voltage components and wiring cables refer to Case 3 sections ① and ② (pages 11 & 12).

WARNING; Do not leave the vehicle unattended if the accident scene or vehicle is not safe for bystanders. When emergency work has been completed and attendants will be leaving the damaged vehicle at the accident scene, please advise any bystanders of the danger by installing a warning sign explaining “HIGH VOLTAGE” condition exists. (Please refer the example on page 19).


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4. The procedure to rescue passengers. There could be a serious risk of electric shock to the passengers and the rescuer if handled incorrectly.

WARNING; Use insulated Personal Protective Equipment (PPE) (Rubber insulating gloves and rubber sole insulating shoes as a minimum: rated to a minimum of 400V voltage resistance or meeting the relevant Australian Standards), in case contact with the vehicle body is possible.

Do not touch any high voltage components or wiring cables. Immediately cut off the high voltage circuit if possible using the procedure described in “Procedure to disconnect the high voltage circuit” on page 14. Ensure the gear selector lever is in the “P (Park)” position, apply the park brakes and place wheel chocks as required. NOTE: when the auxiliary battery is removed, the electric tailgate release will not operate to allow the tailgate to be opened.

Rescue requirement

Not necessary to cut either the vehicle body or isolate the high voltage circuit.

Go to Case 1 – page 9.

Cutting the vehicle body is necessary and isolating the high voltage circuit is possible.


Cutting the vehicle body is necessary and because of an emergency situation it is not possible to wait for isolating the high voltage circuit.

Or

In case the orange-coloured high voltage wiring cables are exposed.


Vehicle is immersed in water (submerged vehicle). Go to Case 4 – page 13.

Re-inverting a rolled vehicle. Go to Case 5 – page 13.

Vehicle fire. Go to Case 6 – page 13.

(1) Case 1. Not necessary to cut the vehicle body or isolate the high voltage circuit. Check the vehicle damage to assess if high voltage components or wiring has been damaged. Orange-coloured wiring cables indicate the high voltage circuits and cables. Once high voltage wiring cables are checked and are not exposed, it is safe to start appropriate rescue actions.

If it is necessary to remove window glass and/or doors, use the same process as would be used for an ordinary vehicle.

CAUTION; When an orange-coloured wiring cable is exposed or high voltage components have been damaged, refer to Case 2 (page 10). If cutting the vehicle body is necessary for rescue operations, refer to Case 2 (page 10) or Case 3 (page 11) as applicable.


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(2) Case 2 Cutting the vehicle body is necessary and preparation to isolate the high voltage circuit is possible.

1) Disconnect the high voltage circuit using one of the following methods: (For disconnecting the high voltage electricity current supplied from the main battery)

① Turn the electric motor power switch (ignition switch) on steering column to the “LOCK” position.

② Remove the fuse for the “Power control unit” from the fuse box under the bonnet.

Refer to Procedure to disconnect the high voltage circuit on page 14.

* Where both methods are not possible, go to Case 3 on page 11.

2) Wait at least one minute after completing Step 1, and then disconnect the auxiliary battery negative terminal. This will disconnect the power to the SRS airbags system.

* If this is not possible, go to Case 3 on page 11.

CAUTION; SRS-ECU condensers retain the required voltage for approximately 1 minute after disconnection of the power supply (auxiliary battery). This means airbag deployment function is still possible. If you proceed to the next step without waiting for this time period, there is potential for a serious injury due to an inadvertent airbag deployment (inflation).

3) Wait at least 5 minutes after completing Step 2 above before removing the service plug to isolate the high voltage current inside the main battery.

*If steps 1), 2) and 3) above are not possible, go to Case 3 on page 11.

WARNING; If the service plug is removed without observing the proper procedure above, it could cause injury to rescuers due to the flying pieces of melted metal of service plug terminal, caused by short circuit.

4) Wait an additional 5 minutes after completing Step 3 above before commencing any appropriate rescue actions, such as cutting the vehicle body.

WARNING; There are some high voltage components and wiring cables which retain high voltage for approximately 5 minutes after removing the service plug. When it is necessary to cut the high voltage components and wiring cable, wait for at least 5 minutes after removing the service plug before cutting the vehicle body. Never cut the main battery itself. Refer to Case 3 (page 11 and 12) for location of main battery.


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(3) Case 3. Cutting the vehicle body is necessary and because of an emergency situation, it is not possible to wait for isolating the high voltage circuit. Or In case the orange-coloured high voltage wiring cables are exposed.

・Pre-checking Cut the vehicle body after carefully checking through step ① to ③.

① Precautions when cutting the vehicle body WARNING; Use an appropriate cutting machine that will not cause sparks; otherwise it could cause serious injury to passengers and rescuers. In addition, avoid cutting in the area shown below (shaded) and touching any exposed orange-coloured electric wiring cable/s (refer to cable locations on the page 12). Before cutting the body, where possible isolate the high voltage by carrying out the “procedure to disconnect the high voltage circuits” on page 14.

② Cutting in areas that could cause electric shock;

Do not cut in the areas shown in the illustration below (shaded areas).

It is possible to cut the vehicle body (except in the locations around the main battery itself,

high voltage cables and components – shaded areas below), without waiting to disconnect

the high voltage circuits. Ensure the vehicle is cut above the charging connection points on

the “C” pillars, the seat belt pre-tensioners “C” pillars and through the “A” pillars – above the

shaded areas as shown. WARNING; Never cut the main battery or in the area of the main battery. Only cut the vehicle in the areas not coloured (shaded) in the illustration below.

Do not cut in the areas coloured (shaded), to prevent the risk of high voltage electric shock.（The bottom view shows the condition when the under cover is removed.）


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③ Location of the high voltage components and wiring cables are as shown in the figure below.

④ SRS airbags system (location of airbags and related wiring harness) are located as show in the figure below:

Main battery

Service plug High voltage connector

Electric motor

On board charger / DC-DC converter

High voltage connector

Heater

A/C compressor

EMCU

Front impact sensor

Pretensioner （Built in retractor） Side detect sensor

Rear detect sensor

Passenger side airbag module

Driver side airbag module Warning lamp

Clock spring

Diagnosis connector Floor harness

SRS-ECU

Floor harness


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(4) Case 4. Submerged vehicle. Check the vehicle for damage first. If you find serious damage on the vehicle and find the main battery deformed/damaged or battery internals exposed, wear insulating protection, handle carefully and avoid touching the main battery.

WARNING; After removing the vehicle from the water and draining the water from the cabin, remove the service plug whilst wearing insulated Personal Protective Equipment (PPE) (rubber insulating gloves, rubber soled insulating shoes: rated to a minimum of 400V voltage resistance or relevant Australian Standards). Then fill up the main battery with water via the main battery’s cooling duct (refer to “Procedure to fill the main battery with water” on page 16) using de-ionised water. As electrolytical generated hydrogen will be produced within the main battery internals for approximately 72 hours after filling with water, the vehicle should be kept in a well-ventilated area located outside to prevent the risk of fire. If seawater penetrates the main battery, thoroughly flush the seawater out of the main battery using de-ionised water under pressure.

(5) Case 5. Re-inverting a rolled vehicle. Check that there are no projections on the road that might damage the main battery and re-right the vehicle slowly and carefully, avoiding contact with the main battery under the floor.

・The bottom view Coloured area shows main battery (with under covers removed).

Case 6. Vehicle fire. In case of a vehicle fire, inform fire department immediately and start extinguishing the fire if possible.

1) By fire extinguisher Use a fire extinguisher type which is suitable for flammable liquid or electrical equipment fires.

2) By water - NEVER EXTINGUSH BY SMALL VOLUME OF WATER. It is quite dangerous.

WARNING; Never extinguish with a small quantity of water, always use a large quantity or volume of water – for example from a fire hydrant, otherwise wait until the fire service/department arrives.


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5. Detail working procedures. (1) Procedure to disconnect the high voltage circuit.

Always wear Personal Protective Equipment (PPE) while working.

1) Kill the electric motor unit by turning the electric motor switch (ignition switch) on the steering column to the “LOCK” position.

If it is impossible to turn off the electric motor switch, remove the “Power control unit” fuse (No.7 15A fuse shown in below figure) from the fuse box under the bonnet. If you cannot find the fuse, remove all fuses and relays in the fuse box.

2) Disconnect auxiliary battery negative terminal. Disconnect auxiliary battery negative terminal using a 10mm spanner by following the procedure below. This isolates the electricity supply to the SRS airbags system.

① Remove the auxiliary battery cover under the bonnet.

② Disconnect negative terminal from auxiliary battery.

12V Battery

Tab


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3) Procedure to remove the service plug. Wearing Personal Protective Equipment (PPE), remove the service plug by the following procedure to disconnect the high voltage circuit in the main battery.

WARNING; There are some high voltage components and wiring cables that retain high voltage for up to 5 minutes after removing the service plug. When it is necessary to disconnect high voltage components and wiring cable, wait at least 5 minutes after disconnecting the high voltage circuit. (Refer to the procedure for cutting the vehicle body and to rescue passengers in Case 2 - page 10 or Case 3 - page 11).

① Slide the front passenger seat to its rear most position and roll up the carpet under the seat. ② Remove the service lid or cover (12mm nuts x 2).

③ Whilst wearing Personal Protective Equipment, unplug the service plug. i Pull up the lever of the service plug.

ii Pull up the service plug to unplug and remove.

WARNING; The person who removes the service plug must retain it (or place in a secure place under their control), in order to prevent it from being mistakenly reinstalled.

Before leaving the vehicle unattended, the service lid should be reinstalled and secured (were possible) to prevent any accidental contact. Do not reinstall the service plug.

Nut

Service lid

Service plug

Front end of passenger’s seat

Slit of carpet

Service lid

Velcro tape

Front side of vehicle

Service plug

Lever

Service plug


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(2) Procedure to fill the main battery with water.

1) Cut the floor carpet under/in front of the front passenger seat.

2) Detach the main battery’s cooling duct. NOTE: if it is impossible to detach, break it by a pry bar or similar tool.

3) Fill up the main battery with water through the hole for the cooling duct (as shown below) into the main battery.

(3) Transportation of a damaged vehicle.

You can drive a damaged vehicle for transportation purpose provided there is no significant damage to the vehicle. Do not drive if any of the following concerns are evident:

High voltage components and/or wiring cables are damaged. Electric motor (electric motor unit), transmission, brakes, suspension, and/or tyres are damaged. Oil and/or cooling water is leaking. “READY” indicator lamp (meaning ready to drive) does not illuminate in the instrument panel

after turning on the electric motor switch (ignition switch), with setting the selector lever to “P (Parking)” position and applying the foot brake.

If the “READY” indicator lamp turns off and/or EV related warning lamps turn on in the instrument panel, or if you find an abnormal noise, smell and/or strong vibration from the vehicle during driving, the following procedure should be carried out:

1) Stop the vehicle as soon as possible in a safe location. 2) Set the selector lever to “P (Parking)” position and apply park brake. 3) Turn off the electric motor switch (ignition switch) to the “LOCK” position. 4) Disconnect auxiliary battery negative terminal (at least 1 minute later). 5) Whilst wearing Personal Protective Equipment (PPE), remove the service plug (at least 5

minutes later after disconnecting the auxiliary battery negative terminal).

(4) When driving a damaged vehicle is not possible, the vehicle should be transported by tow truck after turning the electric motor switch (ignition switch) to the “LOCK” position, disconnecting the auxiliary battery negative terminal (at least 1 minute later) and removing the service plug (at least 5 minutes after disconnecting the auxiliary battery negative terminal). Transport the vehicle as per “Vehicle dimensions and precautions for transporting a damaged vehicle” on page 17.

WARNING; Always wear suitable Personal Protective Equipment when removing the service plug!

Battery cooling ductopening


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(5) Vehicle dimensions and precautions for transporting a damaged vehicle. 1) Vehicle major dimension

Overall length 3,395 mm

Overall width 1,475 mm

Overall height 1,610 mm

Wheelbase 2,250 mm

Minimum road clearance 150 mm

Weight 1,100 kg

2) Transportation of a damaged vehicle. When a tow truck is used for the transportation of a damaged vehicle, all four wheels must be elevated. WARNING; If the damaged vehicle is carried with the rear wheels on the ground, it could cause vehicle fire due to a short circuit by the electricity generated from the electric motor (electric motor unit) through driving the rear wheels on the ground.

Carrying method Remarks

○

Lift up all wheels Carry the vehicle with setting the selector lever to “P (Parking)” position and applying the park brake.

×

Lift up either front or real wheel

Carrying the vehicle with rear wheels on the ground could cause vehicle fire due to short circuit by the electricity generated from the electric motor (electric motor unit) through driving the rear wheels on the ground.

Do not carry the vehicle with keeping rear wheel lifted up (or hang), because this transportation method is unstable.

×

Hang either front or real wheel

・ Figure shows examples of carrying statement.

・ When loading the vehicle on the carrier, please handle carefully so that the vehicle is not damaged further.


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3) Towing by tow rope WARNING; Depending on the vehicle damage, carrying the vehicle with the rear wheels on the ground may cause vehicle fire due to short circuit by the electricity generated from the electric motor (electric motor unit). If there is no alternative to towing the vehicle using a tow rope, the vehicle speed must not exceed 30km/h and the distance must be minimized. While towing, set the selector lever to “N (Neutral)” position.

① Set the tow rope on the towing hook of the body as shown.

② While towing, turn on the electric motor unit if possible. If this is not possible, turn on the electric motor switch (ignition switch) to ACC. If the auxiliary battery is disconnected, turn on the electric motor switch (ignition switch) to ACC, utilizing the emergency key.

③ The regulations concerning towing may differ from state or territory. It is recommended that you obey the regulations of the area where you are towing the vehicle.

CAUTION;

When the electric motor unit is stopped, the brake efficiency is reduced and steering effort increases. If the electric motor switch (ignition switch) is in the “LOCK” position, it is impossible to use the steering due to the steering lock function - this could cause an accident. The driver of the towed vehicle must keep an eye on the stop lamps of the towing vehicle carefully and ensure tension is maintained in the tow rope at all times.

④ Set the selector lever to the “N (Neutral)” position.

⑤ Turn on the hazard lamps to provide a warning to other road users.

WARNING;

Prevent driving in such a way that may cause high tension in the tow rope and towing hook as this could cause tow rope breakage, vehicle damage and the potential to cause serious injury to bystanders.

・ Please tow carefully taking precautions not to increase the damage to the vehicle.

・ If an abnormal noise, smell and/or strong vibration are observed from the vehicle while towing, stop towing immediately.


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It is recommended that a warning sign (example provided above) is fixed to or on the vehicle during any

emergency work on the vehicle. A sign that complies with any local legislation or meets relevant Australian

Standards should be used.


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