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Mitsubishi MOTORS Outlander PHEV Procedures Manual
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Mitsubishi MOTORS Outlander PHEV Procedures Manual

Mitsubishi MOTORS Outlander PHEV Procedures Manual

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Outlander PHEV
Emergency Procedure
Manual

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Summary of Contents for Mitsubishi MOTORS Outlander PHEV

  • Page 1 Outlander PHEV Emergency Procedure Manual...
  • Page 2 It may differ according to the sales classification; refer to the sales catalogue Mitsubishi Motors reserves the right to make changes in design and specification and/or to make additions to or improvements in this product without obligation to install them on products previously manufactured.
  • Page 3 1． Safety precaution for handling high voltage (1) Isolation from the high voltage circuit (2) Disconnection of the high voltage circuit (3) Precautions when rescuing passengers 2． High voltage components layout (1) High-voltage component and wiring harness locations (2) SRS airbag system 3．...
  • Page 4 1． Safety precaution for handling high voltage The Outlander is equipped with a lithium-ion battery of max. voltage 300 V. This is used to activate the electric motor unit and some components such as air conditioning. Before rescue work can begin, 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.
  • Page 5 2. High-voltage component location (1) High-voltage component and wiring harness locations High voltage components and wiring cables are located as shown in the figure below. EV charger cable Rear motor (electric motor unit) cable (quick charger) <Option> EV charger cable Drive battery rear cable AC compressor cable On-board charger (OBC) and DC-DC...
  • Page 6 3. Features on vehicle exterior Outlander PHEV shares one vehicle body with models with petrol engine. Therefore, their exteriors are very similar. If you find any of the following features which can identify Outlander PHEV, always wear appropriate Personal Protective Equipment (PPE). WARNING;...
  • Page 7 3) Feature in the engine compartment and centre pillar ①, ② and ③: Chassis number is stamped on the hood, the centre pillar and the cowl top panel ④ "PLUG-IN-HYBRID EV" logo ①Vehicle information code plate The vehicle information code plate is riveted to the food.
  • Page 8 "GG2W" in the Chassis number. Ex) Chassis number stamp: Europe : JMAXDGG2WEZ000001 JMBXDGG2WEZ000001 Australia and New Zealand : JMFXDGG2WEZ000001 ④"PLUG-IN-HYBRID EV" logo If "PLUG-IN-HYBRID EV" logo is hown on the power drive unit (PDU) cover, the vehicle must be Outlander PHEV.
  • Page 9 4. What is necessary at the accident site You have to observe the followings: (1) Required tools, etc. at the accident site The items marked by ★ are essential. The other items should be available and used as necessary. 1) ★Protective clothing (rated to a minimum of 400 V voltage resistance) ・Rubber insulating gloves and rubber soled insulating shoes Protects service technician from high voltage.
  • Page 10 (3) Safety measures at the accident site WARNING; Use insulating Personal Protective Equipment (PPE) (Rubber insulating gloves, Rubber soled insulating shoes: rated to a minimum of 400V voltage resistance) when you may touch the vehicle body directly or indirectly. 1) Always wear appropriate Personal Protective Equipment (PPE). 2) Never directly touch any exposed orange-coloured high voltage wiring cables (cutoff or break a plastic jacket), or high voltage components that might be damaged.
  • Page 11 Reference) Fluids used in this vehicle Unit name Designation Colour Engine to fuel tank Petrol Light orange Engine Engine oil Dark brown Electric motor and generator CVT fluid Blue-green Transaxle (transmission) Cooling fluid Coolant Blue-green Heater fluid Coolant Blue-green Brake Brake fluid Clear &...
  • Page 12 (*: Hybrid vehicle has both an internal combustion engine engine and an electric drive vehicles. motor/battery) Is the damaged vehicle Mitsubishi Outlander PHEV? Follow emergency For how to identify, refer to procedures for the relevant this manual vehicle.
  • Page 13 5. Preparation of rescue operation Failure to follow these instructions may result in serious injury such as electric shock. Do not touch high voltage wires or components. Isolate high voltage circuits as necessary. WARNING; Use insulating Personal Protective Equipment (PPE) (Rubber insulating gloves, Rubber soled insulating shoes: rated to a minimum of 400V voltage resistance) when you may touch the vehicle body directly or indirectly.
  • Page 14 Procedures to rescue passengers START START START START Can you turn off the Is it necessary to cut the electric motor switch? To Case-A1 vehicle body? Can you take approx. 10 minutes to shut down the high voltage circuit? To Case-A3 Can you turn off the electric motor switch or pull To Case-A3 out the "power control unit"...
  • Page 15 Case-A1: It is not necessary to cut the vehicle body and the high voltage components are intact Orange-coloured wiring cables indicate high voltage components. Confirm that no high voltage wires are exposed, and then turn off the electric motor switch to rescue passengers. If the window glasses or the doors must be removed, observe the same procedure as for the conventional models.
  • Page 16 Case-A2: It is necessary to cut the vehicle body, but immediate rescue is not essential (About 10 minutes are required before actual rescue work can begin.). Alternatively, the orange-coloured high voltage cables are exposed. 1) Carry out any of the following two operations: This will disconnect the high-voltage electric current supplied from the drive battery.
  • Page 17 2) Wait at least one minute before proceeding to the next step. Hybrid system will be deactivated during this waiting time. WARNING; The condenser in the SRS-ECU retains the voltage required for deploying the air bags for approx. one minute. If you start the service operation before that one minute elapses, the air bags may be deployed, causing serious injuries.
  • Page 18 ① Remove the service lid cover in the footwell under the middle of the second seat. (four clips) Use a 10-mm open end wrench to remove the service lid. （four nuts) ② Wear Personal Protective Equipment (PPE) and remove the service plug. - Release the lock lever on the service plug.
  • Page 19 Case-A3: It is necessary to cut the vehicle body and immediate rescue is essential or the orange-coloured high voltage cables are exposed - Preliminary confirmation Read this page and "2. High voltage component location" before cutting the vehicle body. WARNING; Use a hydraulic cutter or a suitable tool which does not generate sparks to cut the vehicle body.
  • Page 20 Notes on how to handle the damaged vehicle (1) Procedures to rescue passengers Case-B1 Are there any sparks, smoke or flames in Vehicle fire or around the vehicle? Check circumstances below checking under the vehicle? ・ Electrolyte is leaking from the drive Case-B2 battery.
  • Page 21 （ （ （ （ 2 2 2 2 ） ） ） ） Case-B1: Vehicle fire In case of vehicle fire, alert fire department immediately and start extinguishing the fire using the following procedures where possible. CAUTION; Failure to follow these instructions may result in serious injury such as electric shock: 1) The drive battery is designed to prevent a substantial amount of electrolyte from leaking from the drive battery just in case it is broken.
  • Page 22 Case-B2: Electrolyte leaks from the drive battery CAUTION; Failure to follow these instructions may result in serious injury such as electric shock: 1) The drive battery is designed to prevent a substantial amount of electrolyte from leaking from the drive battery just in case it is broken. However, if you handle the battery improperly, serious injury such as electric shock may be caused.
  • Page 23 （4） Case-B3: The drive battery is severely damaged If the drive battery is severely damaged, the drive battery must be discharged to avoid electric shock and fires. Follow the instruction below to discharge the drive battery. CAUTION; Failure to follow these instructions may result in serious injury such as electric shock: ・The drive battery is designed to prevent a substantial amount of electrolyte from leaking from the drive battery just in case it is broken.
  • Page 24 Discharging procedure: WARNING; Never fill seawater or any water containing salt. This can result in sudden electrolysing, which generates a large volume of flammable hydrogen gas. Electrolysis of water produces hydrogen inside the drive battery for approximately 84 hours after it is submerged in water. To reduce the risk of fire, follow these instructions: - Keep the vehicle in an outside well-ventilated area.
  • Page 25 Step 7 ★. Make sure to use water not containing salt, such as tap water, well water or pond water, to prevent harmful reactions. Keep pouring a sufficient volume of water, such as from a fire hydrant or a tap. DO NOT attempt to extinguish the fire with a small amount of water.
  • Page 26 How to drain water from the drive battery: Step 1. Wait for at least approx. 84 hours (3.5 days), and then drain water from the pool. Step 2. Use a 12-mm wrench to remove the service hole lids on the bottom of the drive battery and drain the drive battery.
  • Page 27 （5） Case-B4: Submerged vehicle When a vehicle is submerged, there may be water ingress in the drive battery. Always follow the procedure below: 1) Procedure ① Rescue operation Inspect the vehicle for damage. If the vehicle is severely damaged, the drive battery is deformed, broken or exposed (or you cannot evaluate how severely the drive battery is damaged), wear insulated Personal Protective Equipment (PPE) and carry out the rescue operation while taking care not to touch the drive battery.
  • Page 28 2) How to fill water into the drive battery ① Remove the service lid cover in the footwell under the middle of the second seat. （Four clips） ② Remove the plug on the service lid. ③Fill water not containing salt, such as tap water, well water or pond water through the plug opening on the service lid fully.
  • Page 29 that order on the bottom of the drain plug. Then hold them using a jack. MB992947: RUBBER, DRAIN PLUG MB992946: COVER, DRAIN PLUG Reference）MB992947: RUBBER, DRAIN PLUG Silicone rubber sheet: approx. 70 x 70 x 3 mm MB992946: COVER, DRAIN PLUG Base for the silicone rubber sheet Drain plug MB992947: RUBBER, DRAIN PLUG...
  • Page 30 3) How to drain the filled water Use a 12-mm wrench to remove the service hole lids on the bottom of the drive battery and drain the drive battery. CAUTION; ・To drain the drive battery, always observe the specified procedure (removal of the service hole lids).
  • Page 31 （6）Case-B5: Before righting a rolled over vehicle Inspect the area for debris or objects that could damage the drive battery when the vehicle is righted. Right the vehicle slowly, taking care not to contact or damage the battery. If fuel leaks, observe the same procedure as for the conventional petrol models. WARNING;...
  • Page 32 6. Vehicle specifications and precautions on how to transport the damaged vehicle (1) Vehicle specifications Total length 4,655 mm Total width 1,800 mm Total height 1,680 mm Wheelbase 2,670 mm Minimum ground 190 mm height Vehicle weight 1,872 kg (2) If the vehicle can be driven You can drive the damaged vehicle for transportation purpose if all of the four conditions below are satisfied and there is no significant damage to the vehicle.
  • Page 33 (3) Transportation of the accident vehicle by tow truck If the vehicle body or the suspension is damaged due to an accident, transport the vehicle on a flatbed truck or tow the vehicle with all wheels off the ground. WARNING; ・Take care not to touch any exposed orange-coloured high voltage wiring cables (cutoff or break a plastic jacket), or high voltage components that might be damaged.
  • Page 34 (4) Towing by tow rope If there is no other alternative (e.g, moving the vehicle to a flatbed truck due to lack of fuel), and you must tow the vehicle using a tow rope, the vehicle speed must not exceed 30 km/h and the towing distance must be minimized.
  • Page 35 ・How to deactivate the radar cruise control system (ACC) When the power supply mode of the electric motor switch is turned on, the ACC will NOT be activated (default setting). The ACC indicator in the multi-information display informs the driver whether the ACC is activated or deactivated.
  • Page 36 ③ Move the selector lever to the N (neutral) position. ④ Turn on the hazard warning lamps to alert other road users. ⑤ The regulations concerning towing may differ from country to country. It isrecommended that you obey the regulations of the area where you are towing the vehicle.
  • Page 37 *Before any high voltage work commences, place this signboard on the roof of vehicle after folding on the dotted line.
  • Page 38 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 local regulation should be used.