PRODUCT INFORMATION
ELECTRIC VEHICLE
i-MiEV
E BOOK ONLINE LINK
Please copy, click LINK or QR Code attach to open the EBOOK
CONFIDENTIAL
BY ARTAS
Contents
0. General
0-1 Background of development ——–—————————————————————–———— 1
0-2 Model code —————–—————————————————————————————– 3
1. Product features
1-0 Product features general —————–————————————————————————— 4
1-1 Component layouts ——————————–—————————————————————— 4
1-2 Main components ————–———–————————————————————————— 5
1-3 Driving performance ———————————————————————————————– 6
1-4 Driving distance —–———————————————————————————————— 6
1-5 CO2 gas emission ———————————————————————————————— 7
1-6 Coal oil consumption ——————————————————————————————— 7
1-7 Advantage of Electric vehicle [Well to Wheel] ————————————————————–— 8
1-8 Exterior noise level —————–—–——–——-———————————————————– 8
2. EV System
2-1 Power unit ———–——————————–——–———————————————————— 9
2-2-1 Electric Motor [for driving] —————–———-–——–—————————————————— 10
2-2-2 Electric Motor [for driving] :Structure ———————————————————————— 10
2-2-3 Electric Motor [for driving] :Principle ——————————————–—–———————– 11
2-2-4 Resolver [Rotor angle sensor] ——————————————–———————————— 11
2-3-1 MCU [Motor Control Unit] ————————————————————————————— 12
2-3-2 Fundamental of AC->DC Inverter —–————————————————————————— 12
2-3-3 Inner structure of Inverter ————————–——-—————————————————— 13
2-3-4 Inverter Control ——————–———————-———————————————————– 13
2-4-1 OBC [On Board Charger unit and DC / DC converter] ————————–————————— 14
2-4-2 Charging system [Normal Charge] ————–——-—————–————————————– 15
2-4-3 Charging system [Quick Charge] ———————–—————————————————— 16
2-4-4 Charging Lid & Connector ————————————————————————————— 17
2-4-5 Household power circuit general [For general Japanese family house] —————————— 18
2-4-6 Circuit breaker box for Household power circuit [For general Japanese family house] ———– 18
3. Battery
3-1-1 Lithium-ion battery ———————————————————————————————— 19
3-1-2 What is Lithium-ion battery ———–—————————————————————————– 19
3-1-3 Structure of battery unit —–———————————————————————————— 20
3-1-4 Contactors ———–—————————-——————————————————————– 20
3-1-5 Balance control among each cells —–————————————————————————– 21
4. Cooling system
4-1 Cooling system for Motor unit ———————————————————-———————— 22
4-2-1 Cooling system for Battery unit —————————————————————————— 23
4-2-2 Cooling system for Battery unit [Outline of Function] ————————————————— 23
4-2-3 Cooling system for Battery unit [A/C Blower fan control] ——————–-————————— 24
5. Total vehicle management and control system
5-1 Total vehicle management and control [MiEV Operating System] ———————————— 25
5-2 MiEV OS: System configuration ——————————–—-—————————————— 25
5-3 MiEV OS: Fail safe system —————–——————————————————————– 26
5-4 MiEV OS: Protective control for the battery pack ———————–———————————– 26
5-5 MiEV OS: Over current protection control —————————————————————— 27
5-6 MiEV OS: Overvoltage cutoff control ———————————————————————— 27
5-7 Driving Selector Lever ——————————–———————————-————————— 28
5-8 Jerk restraining control —–——–———-———————————————————————- 28
5-9 Traction Control System ————–—-———————————————————————— 29
5-10 Safety features while DC 330V battery charging ———————————————————- 29
5-11 EV-ECU control modes —————————————————————————————- 30
5-12 MCU control modes ——————————————————————————————— 31
6. Transmission
6-1 Transmission general ————–-—————————————————————————- 32
6-2 Shift position sensor ————–————————-——————————————————- 32
7. Brakes
7-1 Brake system general —–—————————————————-————————————- 33
7-2-1 Brake system: Electrical motor driven vacuum pump ———–———————————-——— 33
7-2-2 Brake system: Negative pressure for brake booster ———–————-—————————— 34
–———–———————————————————
7-2-3 Brake system: Negative pressure control 34
8. Chassis electrical
8-1-1 ECU network ————————————————————————————————-— 35
8-1-2 Diagnosis function ————————————–—————————–—-————————— 35
8-2-1 Combination meter ——————————————————–—————————————- 36
8-2-2 Power meter ——–————–-—————-—————–—————————-——————— 36
8-2-3 DC 330V Battery meter —–——————-———–—-————————————————— 37
8-2-4 Calculation of remaining driving range ——————————————————————— 37
8-3 LED Head light ——————–———————————————————————————- 38
8-4 LED Rear combination lights ———–-————————————————————————- 39
8-5 Front windshield wiper ———–——————————————————————————— 39
8-6 Auto lighting control ———–————————————-———–—–————-—–——-——— 40
8-7 MMES [Mitsubishi Multi Entertainment System] ———–—————————-——————— 41
9. Heater & A/C System
9-1 Heater & A/C System: General ——————————————————————-———— 42
9-2 Heater & A/C System: HVAC unit —–————————————————-———————— 42
9-3 Heater & A/C System: A/C compressor ————————–——————————————— 43
9-4 Heater & A/C System: Heater —————————–——————————————–—— 44
9-5 Heater & A/C System: System control ————–——————-—————————————- 45
10. Interior
10-1 Instrument panel ——–——–————————————————————————————— 46
10-2 Tail gate trim ——————————————————————————————————— 46
11. Exterior
11-1 Door opening weather strip ——–———–——————————————-————————— 47
11-2 Special decal, marking ———–———————————————————————————— 47
12. Maintenance
12-1 Caution points when handle the Electric vehicle ———————————————————– 48
12-2-1 Shutoff procedure of DC 330V [How to remove the service plug] ——————–————– 49
12-2-2 Inspection points before removing the DC 330V battery and/or the related parts —————— 50
12-2-3 Procedures when the DC 330V could not shut off —————————-———————— 51
12-3 Maintenance for stock vehicle ————————–-—————————————————— 52
12-4 Non-use of the vehicle for long period [for both at customer hands / Dealership hands] —— 52
12-5 Pre-delivery Inspection —————————————————————————————— 53
12-6 Periodical Inspection ——————————————————————————————- 53
12-7-1 Periodical Inspection for i-MiEV —————————————————————————— 53
12-7-2a Periodical inspection item chart for i-MiEV [For EUR] —–—————–———–———-—— 54
12-7-2b Periodical inspection item chart for i-MiEV [For NAS] —–—————–———–———-—— 55
12-7-2c Periodical inspection item chart for i-MiEV [For EXP] —–—————–———–———-—— 56
12-7 DC 330V Battery capacity check and maintenance ————————————————— 57
12-8 Brake inspection / Sped meter check / DC dynamo —————–——————–————— 58
12-9 Power plant cooling system: Water (LLC) filling procedure ——————————————— 59
12-10 Cabin Heater system ————–—————————-————————————————- 60
12-10-1 Cabin Heater system: Water (LLC) draining procedure ———–———————————— 60
12-10-2 Cabin Heater system: Water (LLC) filling procedure ————————————————— 60
12-10-3 Cabin Heater system: Heater unit Removal —–———————————————-——— 61
12-11-1 A/C system ———————————————–-————————————————— 62
12-11-1 A/C system: Removal procedure ————–———————————————————— 62
12-11-2 A/C system: A/C refrigerant and lubricant —————————————————————- 62
12-12 DC 330V Battery ——–—————-———–————————————————————- 63
12-12-1 DC 330V Battery: Removal ——————–——–——————————————————— 63
12-12-2 DC 330V Battery: Installation —–—————————————–——————————— 67
12-12-3 DC 330V Battery: Convey battery ————————————————————————- 68
12-14 MCU Removal ————————————————————————————————— 69
12-15 OBC Removal ————————————————————–———-————————— 70
12-16 Electrical motor removal ——————————–———————————————————- 71
12-17 Data writing to the MCU by MUT-3 [Initial phase angle of motor] ———————-———— 72
12-18 Transmission removal —————————————————————————-—————- 73
12-19 Front positioning light bulb replacement —————–———-—–—-——————————— 74
12-20 Body repair / Paint ————-—————————————————————————— 75
12-20-1 Body repair / Paint General ————–——————————————————————— 75
12-20-2 Damage check of the batteries after the collision —————————————————— 76
13. Troubleshooting
13-1 Key points on trouble shooting ——————–—————————-—————————-— 79
13-1-1 P1A44 Electric leak is detected —————————————————————————— 79
13-1-2 P1B28 Impact signal to shutoff the high voltage line ————————————————— 80
13-2 Inspection of Charging cable ——————————————————————————- 81
13-3 DTC List
13-3-1 DTCs [EV-ECU related] ——–——–———————————————————————— 82
13-3-2 DTCs [MCU related] —————————————————————————————— 87
13-3-3 DTCs [BMU related] ——–——————————————————-————————— 89
14. Rescue
14-1 Rescue ———–——–——————-—————————————————————————— 93
15. New special tool
15-1 Special tool for the i-MiEV [Service on DC330V battery] ————————————–————– 94
Product features
0. General
0-1 Background of development
Mitsubishi Motors Corporation recently developed the i-MiEV: an EV (Electric Vehicle) utilizing the ultimate eco-friendly
zero-emission driving.
With the i-MiEV, MMC addressed the shortcomings of earlier electric vehicles using revolutionary technologies such as
high-performance lithium-ion batteries and compact high performance motors.
[Symbolic Technology]
MMC’s special and specific technologies which leads
the whole automotive industry.
[Technologies for future generation ]
Unique Key technologies as features of Clean Diesel Engine
Mitsubishi Motors. TC-SST
[Backbone technologies] Bi-fuel compatibility
Backbone technologies as a
automotive manufacture enrolling High efficiency engine
at the reading group . [multi valve, direct injection, etc]
High-efficiency transmissions
Three-top-shelf performances
Excellent Emission performance
Zero emission while driving. No exhaust gas, No CO2.
If you would count the CO2 to make the electrical power at thermal power station, it might be 70%
less than that of petrol powered “ i ”.
Excellent low running cost
Approx.1/3 cost[*] against petrol engine powered “i”.
If utilize midnight charge only, it become 1/8[*].
[*] Note: Japanese market prices are used for the cost calculation.
Excellent smooth driving
Free from vertical vibration associated with petrol engine.
Not only running quietly but also strong acceleration by high torque of motor.
１
Product features
Reduce CO2 source Reduce oil dependence
Interests for environment and fuel economy car from users
-Global warming
-Environmentally-friendly
-Oil price
-Economical crisis over the world
Each automakers are keen to develop
fuel-economy car
&
low emission vehicle
History of electric vehicle development at Mitsubishi Motors
MINICAB EV
MINICA EV
DELICA EV i-MiEV
FTO EV Eclipse EV
MINICA ECONO EV
LANCER Evolution MIEV
LIVERO[LANCER WAGON] EV
Lead-acid battery Lithium ion battery
２
Product features
0-2 Model code
Model Code
ZAA-HA 3 W L D D
1 2 3 4 5 6 7
№ Information category Information Details
１ Emission category ZAA Z: 0 Emission
A: Electrical Vehicle
A: Passenger Car
２ Model HA i
３ Power Train 3 Electrical Motor
４ Body type W Wagon
５ Body Category L ４door with tailgate
６ Transmission D Ｆ１Ｅ１Ａ
７ Trim level D “Ｍ” grade
Outline view ZAA-HA3W
[Cabin length]
[Cabin height [Overall height
[Ground clearance]
[Front track] [Wheelbase]
[Overall width] [Overall length]
[Rear track]
３
Product features
1. Product features
1-0 Product features general
i-MiEV uses same platform and other basic components for with petrol powered “ i “ and main battery and EV related
components are
newly designed.
・Vehicle size of i-MiEV is same as petrol powered “ i “ [Accommodate Japanese “Light Mini-car” category]
・Driving performance of i-MiEV caps petrol powered “ i “ even it has turbo charger
・Max. Motor power is tuned as 47kw to meet Japanese small car regulation.
・Max. driving speed is restricted up to 130km/h according to Japanese small car regulation.
・Driving distance ：160km(under Japanese 10/15 mode driving pattern)
・Required hours for battery charge
Quick Charge mode : 0.5 hours for 80% state of charge
Normal Charge mode under AC200V : 7.0 hours to charge 100% state of charge
Normal Charge mode under AC100V : 14.0 hours to charge 100% state of charge
・Basic driving manner is same as petrol powered “i”. No special technique is required.
1-1 Components layouts
Main components for EV are set at under floor of body.
It enables to accommodate 1 driver and 3 passengers as same as Petrol powered “ i “.
Combination meter LED rear combination light
LED Headlight Charging system
Selector lever panel Main battery [Lithium –ion ] Motor & transmission
On board
battery charger
Motor ＆
Control DC / DC converter
Unit [OBC]
[MCU]
Petrol Engine Electrical motor
Heater unit
Fuel tank Main Battery
[ Petrol powered “ i ” ] [i-MiEV]
４
Product features
1-2 Main components [View from vehicle top and bottom]
Vehicle Front
Electric vacuum pump
Charge connector For Brake
[For normal charge]
MCU
[Motor Control Unit]
OBC [On-Board Charger]
＆
DC / DC converter
：DC 330V
：DC 12V
Service plug EV-ECU
BMU Charge connector
[Battery Management Unit] [For quick charge]
Vehicle Front
Battery pack [Lithium ion]
Quick charge cable
Normal charge cable
A/C unit Heater unit Electrical motor
Harness for DC 330V
[Power Unit]
：Systems/Circuits with DC 330V
５
Product features
1-3 Driving performance
Under the comparison test with petrol powered “ i“, i-MiEV caps it in the acceleration at any range.
Acceleration
i MiEV 6%
Petrol powered “ i ”
i MiEV 2%
Petrol powered “ i ”
Time [sec.]
i MiEV 31%
Petrol powered “ i ”
i MiEV 35%
Petrol powered “ i ”
Time [sec.]
1-4 Driving distance
Driving distance of i-MiEV is 160km per charge under Japanese 10･15 test mode of driving.
However, the score will be vary by usage of A/C & Heater and/or ambient condition.
A/C OFF
With cooling
[Summer] 30％ Short
With Heating
[Winter] 50％ Short
Per charge range [km] [Driving under 10･15 mode]
A/C: OFF / Heater: OFF
A/C: ON / Heater: ON
A/C: Max / Heater: Max
６
EV System
2. EV System
2-1 Power unit
Major units Role
EV-ECU Perform the Integrated control for EV systems
Motor system MCU Convert DC 330V to AC 330 by integrated inverter for the motor.
Motor Control Unit It also controls the rotation speed/torque of motor.
Motor Forward the vehicle by receiving three phases AC 330V from MCU.
It also acts as alternator for regeneration when deceleration.
Battery System BMU Check battery condition based on data transmitted from CMU and shot-circuit
Contactor integrated. Battery Management Unit condition on high voltage line with data from short circuit sensor
CMU Monitoring Voltage between each cell and adjust the balance of each cell
Cell Monitor Unit voltage.
Lithium—ion battery High voltage battery for EV. It has 88 cells under series connection.
The rated voltage is 330V. ( = 3.75V x 88 cells)
OBC Battery charger to accommodate household electric power outlet
On board Battery Charger (Single phase AC100V/200V).
DC / DC converter Convert DC 330V to DC 14.4V to charge the battery for auxiliaries.
A/C system A/C Compressor Compressor is driven by the exclusive motor for it. DC 330V is provided to
the system and it is converted to AC330V by integrated inverter.
Heater PTC [Positive Temperature Coefficient] heater is adapted to provide
hot water to The heater unit. PTC heater uses DC 330V.
Electrical vacuum pump for brake master back To maintain the vacuum pressure in the brake master back.
Shut Down
BMU A/C & Heater
Lithum-ion ECU
Meter Battery
EV Switch 3.75V x 88 cells Electrical
Battery pack Heater compressor
BAT-CAN
On-board
CMU CMU CMU Battery charger
Shift position Switch DC / DC
Inhibitor Switch converter
EV ECU
Brake vacuum pressure
APS
MCU
Inverter
47kW/8000rpm
180Nm
Electrical Motor
vacuum pump
T/M
CHG-CAN
Quick
Radiator fan Connecter
Charger
Water pump Connecter
Household
Power supply
Reverse light Connecter
100V
or
200V
９
EV System
2-2-1 Electric Motor [for driving]
i MiEV uses a compact, high-performance, permanent magnet synchronous type electrical motor instead of an engine.
This motor can deliver the maximum torque even from 0 [r/min] .
This motor requires AC 330V therefore, DC 330V at battery pack is transform to AC 330V by inverter.
Unlike internal combustion engine vehicles, it can cover the entire range of driving speed without any
transmission system. It also helps to reduce the vehicle weight.
Permanent magnet synchronous motor for i-MiEV internal-combustion engine for petrol powered “ i “
Model type Y4F1 Model type 3B20 T/C
Power source AC 330V Fuel Petrol
Max. Output 47kW Max. Output 47kW
Max. Torque 180Nm[from ０r/min～] Max. Torque 94Nm[at 3000r/min]
Max. Speed 8,500r/min Max. Speed 7,500r/min
Running performance curve
Torque (Nm)
i-MiEV
Petrol powered “ｉ”
Engine Speed [r/min]
2-2-2 Electric Motor [for driving] : Structure
- DC 330V from the battery pack is transformed to three phase AC 330V by inverter, in order to rotate the motor.
The inverter also enables the reverse rotation of the motor by controlling the manner of the current wave pattern
applying to the motor. It means i-MiEV does not require any additional gears to make reverse drive.
- A rotor angle sensor which we call as “Resolver” is adopted on the motor.
- Motor equipped the water-jacket at its external wall and maintain the temperature of motor.
Electrical power line
[Three-phase]
Motor
Bearing
Motor shaft
Motor rotor
Permanent
magnet
Resolver
Electric Coil
Thermistor Water-jacket
Stator core
Resolver [Rotor angle sensor]
Since the initial phase angle signal from the resolver [Rotor angle sensor] may vary by install condition of the resolver,
MCU also uses it as ID.
It makes different ID for each motors therefore, the Initial phase angle of the rotor shall be set to MCU by using MUT-III,
every time when the electrical motor and/or MCU is/are replaced.
[Please refer to “Chapter.12. maintenance “-> “12-17 data writing to the MCU by MUT-3[Initial phase angle of motor]”]
１０
EV System
2-3-1 MCU [Motor Control Unit]
MCU has integrated inverter to convert DC 330 V at the battery pack to AC 330 V for the three-phase motor.
To:
-On Board charger
-DC / DC converter
Smoothing
capacitor
MCU Three -
phase
lines
Battery Current flow U phase
sensor
Pack Inverter V phase Motor coil
[DC 330V] Current flow W phase
sensor
Temperature Three Temperature sensors
Discharge sensor [ for U / V / W phases ]
circuit
Smoothing Control IC for Resolver
EV-ECU capacitor circuit Digital convert [Rev.sensor]
Item Specification
Basic Function Control the motor speed , power and regeneration.
[PWM:(Pulse Width Modulation) control]
Control element type IGBT: insulated gate bipolar transistor
Operating power range 230 - 400 V
Max. Alternating current 350 A rms *
Network system CAN-C(Main), K-Line(Back-up)
Cooling system Water cooled
Size W286 x D309 x H169(Excl. minor protrusions)
[rms :] root-mean-square= effective value
A rms=
: Maximum current value
: Effective current value
2-3-2 DC->AC Inverter :Principle
PWM [Pulse Width Modulation] control has been employed to output the Pseudo-exchange sine wave of the voltage.
I I [ V ] : Voltage wave pattern from
V Coil V the inverter to the motor
[ I ]: Current wave pattern from
V the inverter to the motor
I
Voltage and Current output under coil inductance
１２
EV System
2-3-3 DC->AC Inverter :Structure
Inverter transforms DC 330V at battery pack to AC 330V for the motor by PWM [Pulse Width Modulation] .
To carryout the pulse Width modulation, IGBT [Insulated Gate Bipolar Transistor ] is employed.
In order to rotate the motor, the inverter apply the power voltage to the stator coils at appropriate timing according to
the rotor position signal from the resolver.
The inverter could control the motor torque by changing the amount current flow, and could control the rev. speed by
changing Frequency of the pulse.
Motor
Inverter
Battery pack IGBT U Stator coil
Rotor
Battery
Pack N S
[Li-ion]
V
W
Control circuit
Smoothing condenser
IGBT
Insulated Gate Bipolar Transistor
Printed circuit board Heat sink
[Note]: ：IGBT: Insulated Gate Bipolar Transistor
IGBT could operate under ultra high-speed for the switching function
2-3-4 DC->AC Inverter :Control
Inverter controls the voltage and current, when the motor is under driving and/or regeneration.
[For Driving]
Inverter transform DC 330V at battery pack to AC 330V for the motor , and generates rotating magnetic flux by
stator coil.
Motor rotates by the rotating magnetic flux which is controlled by the inverter.
[For Regeneration]
By control the current phase, Inverter could make deceleration
torque. Battery pack
At this stage, motor could be act as alternator and generates
electrical current flow.
It is called as regeneration and the re-generated current is Drive Inverter Regeneration
introduced to the battery pack for charging.
Motor
１３
EV System
2-4-1 OBC [On-Board battery charger unit & DC / DC converter]
OBC has two function, On-Board Battery charger and DC/DC converter.
[On-Board Battery Charger Unit]
It converts AC [Alternating Current] either 200V or 100V to DC [Direct current] .
It boosts the voltage for the DC 330V battery charging.
Input pattern is categorized 3 ways as;
[200V or 100V or No power input]
No power input
Actual voltage at the household plug [V]
[DC / DC Converter]
DC / DC converter is equipped to convert from DC 330V at the battery pack to DC 14.4V, in order to charge the
DC 12V battery for auxiliaries.
On-Board
Battery pack battery
charger
DC / DC
Converter
Battery
For
auxiliaries
Noise Convert Convert Boost Convert Noise
Filter From AC to DC From DC to AC Voltage From AC to DC Filter
Power
Source
Battery
Pack
Relay for
EV control
Battery for
auxiliaries
Relay for
On-Board battery Charger
Circuit diagram of OBC
１４
EV System
2-4-2 Charging system [Normal charge]
The DC 330V Battery on i-MiEV can be charged by either AC100V or AC200V (Single phase) with using the special
cable supplied as a standard equipment.
The same type of cable will be used by other EV manufactures commonly.
i-MiEV required AC100V with grand cable or AC200V with Specified plug for the charging.
The electrical distribution board for the charging is required the safety circuit breaker [max.15A or more]
Charging plug gun
-Latching function is equipped on
the charging plug gun.
-The gun is Drip proof type
-Body of the gun is made by resin.
Safety circuit breaker Short circuit detecting
[15A or more] circuit breaker
Distribution
Sample of plug shape for AC200V/20A board
[ex. Type WK6520 by Panasonic]
AC100V/15A plug
[with Ground cable type]
5 m length of 200V charging cable is equipped as standard item. 1m long convert cable is also equipped as standard
and another 5m extension cable is available as an optional item. item to accommodate the plug for 100V.
Cable connection sequence Vehicle condition when charging
Follow the connection sequence shown bellow when the charging cable is used. To charge the vehicle,
vehicle power switch must be
STEP-1 STEP-2 ACC or LOCK position.
Connect cable to power supply plug Connect the gun to the vehicle
Caution
-Power supply plug must be
equipped with ground terminal.
-Do not use adopters.
-Do not use any extension cable
except the genuine one.
１５
EV System
2-4-3 Charging system [Quick charge]
i-MiEV can be charged 80% of battery within 30 minutes, if you charge with the special stational type charger called as
“Quick charger”.
The quick charger uses more large current by three-phase 200V[max.50kW] and this type of infrastructure will be
widely popularized in near future of Japan according to the guidance of JEVS:Japan Electric Vehicle Standard.
Generally, three phase 200V is for institutional
use in Japan.
Considering the versatility and popularization,
use of pint-size of electrical power supply which
is 50kW or less is supposed for i-MiEV.
In order to prevent excess heat of
the battery while charging,
A/C system will be automatically
started occasionally, and cool air
Power transmit system Quick Charger is introduced to the battery pack.
Charging cable with plug gun
[United with the quick charger]
[Caution]
In order to prevent excess heat of the battery while charging, A/C system will be automatically started occasionally,
and it sends the cooled air to the inside of battery pack.
Therefore, do not open the food while the charging, to prevent the injury by cooling fan which will be operated without
any notice.
１６
EV System
2-4-4 Charging Lid & Connector
Charging lids & Connectors are located on the rear quarter panel.
-Lid and connector for normal charge [Single-phase AC200V or 100V] is located at right side.
-Lid and connector for quick charge [Three-phase AC200V] is located at left side.
The Lid opener for normal charge is located at the lower area of the instrument panel [Driver’s knee area ],
and the Lid opener for quick charge is located under the drivers seat.
Lid & Connector for Normal charge [Right side]
Lid & connector for Quick charge [Left side]
１７
Lithium-ion battery
3. Battery
3-1-1 Lithium-ion battery
Battery pack for i-MiEV is consisted by 88 pieces of Lithium –ion battery cell.
Each battery cell has 3.75V 50Ah and they are connected serially.
Total output of battery pack is DC 330V 16kWh.
In order to provide an extra margin of safety against the collision, each batteries is set in the hard case.
Battery cell
Battery pack
Battery module
3-1-2 What is Lithium-ion battery
Lithium-ion battery uses Lithium manganate at anode and graphite at cathode.
It has better power vs weight ratio than lead-acid storage battery and it has higher electromotive force [per cell] than
Nickel-Mangan battery.
It uses carbonic acid ester as electrolyte, therefore, risk of burn injury is low .
Lithium-ion battery has no memory function, battery can be charged any time, any charging status of battery.
It will require the special handling when it is charged and discharged, i-MiEV manage them by EV-ECU, BMU, CMU.
Advantage ： -No memory function
: -High energy density
Disadvantage ：-Electrolyte of battery deteriorates easily under the battery is fully charged condition due to the
flocking of the Lithium-ion at Cathode.
-Cathode deteriorates easily under fully discharged condition.
Lithium-ion battery has disadvantage at fully charged condition and fully discharged condition.
１９
Lithium-ion battery
3-1-3 Battery unit: Structure
DC 330V battery unit is equipped with Service plug, Current sensor, Electric leak sensor as a unit.
CMU [Cell Monitor Unit] is set on the each battery module, and each of CMU has voltage sensor and
temperature sensor.
[Battery module]
i-MiEV has 10 pieces of 8 cells type and 2 pieces of 4 cell
type of battery module.
Each modules have CMU [Cell Monitor Unit] which inte-
grates voltage sensor temperature sensor. and etc.
Battery module[ 8 cells type] Battery module[ 4 cells type]
[Service Plug]
Service plug Magnet Service plug is located on the top of the battery pack unit and it can be accessed
from underneath of front passenger seat.
It reduces the battery voltage mechanically by removing it.
Service plug has a magnet at the lever area and it states the condition of service
plug to the EV-ECU.
ON : The service plug is fixed properly and the lock lever stays lock position.
To the battery pack OFF : The lock lever of service plug is released.
[Current sensor for DC 330V Battery]
Current sensor
For The current sensor for DC 330V battery is integrated in the battery pack and it
DC 330V Battery measures the electric current flow at high voltage circuit by using hole element.
There is two type of sensor ,High for wider range measurement and Low for
detailed measurement.
The measured value of flux is transferred into voltage and send to BMU.
Electric leak sensor
For [Electric leak sensor for DC 330V Battery ]
DC 330V Battery The electric leak sensor is integrated in the battery pack and it will send the
signals to BMU if there is leakage.
It also has a self check function by creating the ideal electrical leak.
3-1-4 Contactors
DC 330V battery has integrated contactors which control on/off of the battery output and they are located at the circuit
to the inverter.
There are three contactors, Main contactor P, Main contactor N and Contactor for Charging, and these are controlled
by EV-ECU.
MCU activate the discharging circuit when the power switch is OFF, and releasing the accumulated voltage at
Smoothing condenser.
MCU DC 330V Battery
Main contactor
Contactor for Charging
Inverter
Main contactor
Smoothing
Condenser Discharging
Circuit EV-ECU
２０
Lithium-ion battery
3-1-5 Balancing control among each cells
Each battery cell has area of over charging range and over discharging range, and it might be deteriorated quickly if the
battery cell voltage get into these area.
Therefore, BMU controls the battery cell voltage as neither over charge nor over discharge.
When charging DC 330V battery, BMU monitors the battery cell which has highest voltage, and control it as not to
enter over charge zone.
When discharging, BMU monitors the battery cell which has lowest voltage, and control it as not to enter to over
discharge zone.
However, differences among the each cell might be occurred as following graph , if the charging is repeated
many times.
BMU controls the charging and discharging according to the highest and lowest cells, used range of other cells become
narrowed.
This condition equals the battery capacity become lower.
To solve this condition, BMU send the signal to CMU in order to activates the balancing control if the following condi-
tions are met.
-Difference among each cells are exceeded while the normal charging.
-Difference among each cells are exceeded after Power switch “LOCK(OFF)”.
[Before activating the balancing control] [After activating the balancing control]
Over charge area
Area can be used Area can be used
Over discharge area
２１
Cooling system
4. Cooling system
4-1 Cooling system for Power unit
i-MiEV has cooling unit for the power unit, Motor, Inverter, OBC [On-Board Charging system] & DC/DC Converter
to achieve the high reliability of EV system.
[Features]
Electric motor driven water pump is adopted. The motor is brushless type which features long life and low noise,
and electrical power for the motor is supplied from DC 12V battery for auxiliaries.
Cooling system of i-MiEV is composed of a radiator, an cooling fan, a reservoir, and electric water pump and
connecting hoses that route LLC to maintain OBC, MCU under 60 degrees Celsius.
Basically, these cooling module is carried over from the petrol powered “i”.
When the coolant temperature is high, cooling fan is activated. The fan will activated also while the charging.
Fan speed at charging is regulated considering the noise at night. Noise level will not exceed the noise
from household use A/C.
MCU [Motor Control Unit]
OBC & DC/DC converter
Condenser
EV motor Water pump tank for
Radiator
Cooling module
Cooling fan register
Condenser Systems
tank for to be
Radiator Radiator cooled
A/C condenser
Cooling fan OBC & MCU
&
Motor DC/DC [Inverter] Water
converter Temperature
sensor
Air
WP EV motor
Water pump
２２
Cooling system
4-2-1 Cooling system for DC 330V Battery
In order to manage the battery temperature while the quick charging, cooled air blow system has been applied.
This system uses the A/C system and blower fan at HVAC [Heater Ventilation and Air Conditioning] , and send
the cooled air to the battery pack while quick charging.
Blower fan [battery pack Integrated] also adopted and evacuate the air inside of the battery pack.
DC 330V Battery cooling system
Cooling duct [Battery pack]
Blower fan [battery pack Integrated]
Damper
Battery pack
HVAC
Cooling duct [vehicle floor]
Part Name Role
HVAC Provide air for cooling to the inside of battery pack
Air outlet changing damper Open/Close the duct from HVAC to battery pack
Cooling duct [vehicle floor] Introduce the cool air from HVAC to battery pack
Cooling duct [Battery pack] Introduce the cool air from HVAC to battery pack
Blower fan [battery pack Integrated] Exhaust hot air from the inside of battery pack to outside
4-2-2 Cooling system for DC 330V Battery: Outline of function
Followings are outline of the cooling system for DC 330V battery.
[1] EV-ECU determines that the quick charger plug is connected.
[2] EV-ECU receives the battery temperature information from BMU [Battery Management Unit].
If the battery temperature is exceeding the certain value, EV-ECU send an order to Compressor / Heater control
ECU to activate the system.
[3] Heater control ECU activate the system. and BMU activates Blower fan [battery pack integrated] together.
Basic diagram of DC 330V Battery cooling system
-Compressor / inverter control
Compressor / Heater control ECU
-Cooling information -Quick Charge information
-Battery infomarion
Compressor
inverter A/C control Unit
-Fan sped control -Charging information
-Mode control BMU EV-ECU
Quick
Charger
Air outlet Blower fan
changing damper Battery pack [Battery pack integrated]
２３
Cooling system
4-2-3 Cooling system for Battery unit [A/C Blower fan control]
Cooling system for DC 330V battery is activated according to the following table.
Battery temp. Activation of cooling system Blower (HVAC and rear) A/C Compressor
20℃ or less OFF OFF OFF
20℃ or higher ON ON OFF
30℃ or higher ON ON ON
In order to prevent unnecessary frequent
activation of switch, Hysteresis characters
have been applied as shown in the right.
10 20 30
Temperature of Cell [℃]
Caution:
Blower at rear battery pack always operates 6 second after DC 330V charging is started.
[Either Quick charge or General charge]
２４
Total vehicle management
5. Total vehicle management and control system
5-1 Total vehicle management and control [MiEV OS: MiEV Operating System]
In order to bring out the best vehicle performance under varied conditions, i-MiEV adopts various ECUs and
they are communicated each other .
Operation by driver
- Accelerator pedal
- Brake pedal
- Shift lever position
Meter
Total vehicle management Motor
and Control
A/C & Control system Unit
Heater [MCU]
[EV-ECU]
On-board
Battery charger
Management unit &
[BMU] DC/DC converter
Current
Cell Flow
Monitor Sensor
Unit Electric
[CMU] leak
Sensor
5-2 MiEV OS: System configuration
In order to operate the vehicle smoothly, EV-ECU correct the many of information such as the operation by drivers,
battery condition, signals from each ECUs and control the actuators accurately.
Accelerator pedal
EV-ECU Brake pedal
Shift lever position
Charging connector
Power control Battery info. Charge control
MCU OBC A/C & Meter
Inverter BMU Heater
Motor
CMU CMU CMU Electric leak Current
sensor sensor
Li-ion battery Li-ion battery Li-ion battery
２５
Total vehicle management
5-3 MiEV OS: Fail safe system
In order to achieve the safety and reliability, fail safe system is applied. All malfunction and/or abnormal conditions are
reported to the EV-ECU and fail sale system is activated if it is necessary.
[4] Judgment of Fail safe[Store DTC]
EV-ECU
[5] Fail safe execution
[3] Report malfunction
MCU OBC A/C & Meter
Inverter BMU Heater
[2] Detect malfanction
Motor [1] Malfanction exist
Electric leak Current
sensor sensor
Li-ion battery Li-ion battery Li-ion battery
5-4 MiEV OS: DC 330V battery monitoring system
It is consisted by BMU, CMU, Electric leak sensor and Current sensor.
Each cell of the DC 330V battery is monitored by them.
Electric leak between the high voltage circuit line and the body is monitored also for the safety purpose.
Battery info.
BMU Current value
Electric leak sensor
Battery info.
-Voltage
-Temperature
Electric leak Current
sensor sensor
Li-ion battery Li-ion battery Li-ion battery
２６
Total vehicle management
5-5 MiEV OS: Over charging prevent system
In order to protect the battery from accidental overcharge, EV-ECU monitors DC 330V battery while it is charged,
and it stops the charging if the battery reached to the abnormal high voltage or temperature.
EV-ECU
Monitoring Monitoring
Charger Battery
Monitoring
Current value BMU
Emergent
OBC Shut off Current
sensor
CMU
Household DC 330V
100V/200V Battery
Battery pack
5-6 MiEV OS: High voltage circuit shut-off system
i-MiEV utilizes G-sensor of SRS Airbag as the collision sensor, and shut-off the DC 330V circuit to prevent the second
accident.
i-MiEV also has additional two G sensors for the impact from side and rear.
It shut off the current flow from the DC 330V battery when collision not only for the driver/passengers but also the
rescue personnel.
EV control relay
DC 330V Battery
SRS ECU EV ECU Main contactor (+)
Safing
G-Sensor
Analog CPU Main contactor (-)
G-Sensor
G-Sensor
[Side]
G-Sensor
[Rear]
MCU
Smoothing
condenser
Discharge
circuit
SRS ECU
G-Sensor [Rear]
G-Sensor [Side]
Front floor panel Rea floor panel
(Around the selector lever) (Under the rear seat)
２７
Total vehicle management
5-9 Traction Control System
Based on the wheel speed sensors, EV-ECU restricts the power of the motor if the excess slip is confirmed.
The system also acts while regeneration and keep the stability while regeneration.
With control Without control
With control
Vehicle Speed
Without control
Side skid is occurring
Yaw rate
[Side skid]
Time Time
5-10 Safety features while DC 330V battery charging
Charging of DC 330V battery is possible if the following conditions are met.
-Power switch : LOCK[OFF] position
-Driving selector lever position : P
The system never allow to become READY mode while charging.
If the charging cable is connected while READY mode, READY mode is aborted and vehicle could not be driven.
In case both of the quick charging cable and normal charging cable are connected at the same time, the quick charge
connection has priority.
Power Switch Driving selector Connect the Connect the
position lever position Normal charging cable Quick charging cable
LOCK(OFF)/ACC P Normal charge is run. Quick charge is run.
While charging===> Stop charging While charging===> Stop charging
ON Ｐ Charge indicator is blinked. Charge indicator is blinked.
While charging—-> Stop charging While charging—-> Stop charging
READY Ｐ Charge indicator is blinked. Charge indicator is blinked.
Prohibit to go into READY condition. Prohibit to go into READY condition.
Ｐ→ While charging—-> Stop charging While charging—-> Stop charging
LOCK(OFF)/ACC Charge indicator is blinked. Charge indicator is blinked.
R / N / D / Eco / B
Note: Since the detector is located at the vehicle plug side. it will not become READY while the normal charging
cable is connected to the vehicle.
The status is not changed even if the cable is disconnected at the household side of plug.
Charging indicator
２９
Transmission
6. Transmission
6-1 Transmission general
Due to the characteristic of the electrical motor , i-MiEV does not require the conventional transmission which
has many speed changing gears.
In order to use that characteristic of electrical motor effectively, small and light weight reduction gear box is newly
developed for i-MiEV.
As for the transmission oil, DiaQueen ATF SP-III is appointed as low-viscosity oil for long range drive by low
friction loss.
6-2 Shift position sensor
Shift position sensor has very important role on i-MiEV.
Rotate direction of motor is decided by the signal from the shift position sensor and no mechanical function is
supported.
Therefore, i-MiEV has two shift position sensors as the parallel circuits and apply the back-up function.
Shift position sensor [Sub] Shift position sensor [Main]
Link rod
３２
Brake system
7. Brakes
7-1 Brake system general
Since i-MiEV does not equipped the conventional petrol engine with generates negative pressure at intake manifold,
Electrical motor driven Vacuum pump for brake booster is adopted. and it enable to carry the same brake system for
petrol powered “i”.
i-MiEV has the larger side of brake system than that of the petrol powered “i” because increase of the vehicle weight.
Brake booster
Electrical motor driven
Vacuum pump
2010MY i-MiEV Petrol powered “i”
Front brake 14 inch Ventilated disc 13 inch Ventilated disc
Cylinder bore [mm] Φ51.1 Φ51.1
Rear brake 8 inch LT drum 8 inch LT drum
Cylinder bore [mm] Φ19.1 Φ17.5
Brake booster 8 inch single 8 inch single
Source of negative pressure Electrical motor driven Vacuum pump Intake manifold
Master cylinder Φ20.6 Φ20.6
7-2-1 Brake system: Electrical motor driven Vacuum pump
Since i-MiEV does not equipped the conventional petrol engine with generates negative pressure at intake manifold,
Electrical motor driven Vacuum pump for brake booster is adopted. and it enable to carry the same brake system for
petrol powered “i”.
Bracket
Vibration isolating rubber
３３
Chassis Electrical
8-2-3 DC 330V Battery meter
Based on the various information, vehicle computes the remaining battery energy at DC 330V battery and show it
on the battery meter at instrument panel.
Current from Compute electrical Remaining
Battery Consumption battery power
Voltage The computed result will be shown
at Cell Compute by the combination meter.
Expected
Temperature Remaining energy
at Cell of Compute
Remaining energy
DC 330V battery of
Driving DC 330V battery
condition
Battery Load
Compute
total battery
capacity
Re-charge history
8-2-4 Calculation of remaining driving range
Based on remaining energy at DC 330V battery and history of current consuming, vehicle computes the
remaining driving range and show it on the driving range meter at instrument panel.
Remaining
energy Remaining
of driving range
DC 330V battery
Average Computing
Electrical for
consumption remaining
driving range
A/C
switch
i-MiEV i [Petrol powered]
Features Computes the remaining battery power / driving Computes the remaining driving range by actual
range by actual consumption history of current. consumption history of fuel.
The computed result is subjective to the driving
habit, and usage of A/C. The computed result is
subjective to the driving habit.
Minimum unit 1 km 10km
Final digit to the end 1 km 50km
[After that “ “ will be appeared.] [After that “ “ will be papered.]
Update interval Real-time Every 10-20 sec.
Others Average electrical consumption history will be Average fuel consumption history will be stored to
stored to the memory and reflect it for the future the memory and reflect it for the future computing.
computing.
３７
Chassis Electrical
8-2-4 LED Head lights
Three pieces of High luminance LED are used for head lights unit [per side].
It has the twin projector lens for spot flux distribution, and the reflector for wide flux distribution.
These are combined to achieve the better visibility at night drive.
Primary projector lens
Secondary projector lens
Reflector
Primary
projector lens
Secondary
projector lens
Combination of three patterns
Reflector
[Features of LED headlights]
-Brightness-
LED headlights achieve more brightness than Halogen and Xenon.
-Lower Electricity consumption-
LED headlights achieve lower Electricity consumption than Halogen and Xenon [50%/less from halogen, 35% less from Xenon].
-Long life time
Lifetime of LED headlights are 2.5 times longer than that of Xenon.
-Natural color
Color of LED head lights is blended as the daytime sunlight.
-Indicator
The Indicator for LED head light is added and it will illuminated when the headlight has trouble.
LED
Headlight
50% less vs Halogen bulb
35% less vs Xenon bulb
Halogen HID Sunlight
[3300K] [4000K] [daytime]
Sunrise Cloud Fair
Sunset
1800K 4000K 5500K 8000K 12000K
110W 84W 55W Candle Fluorescent lamp
[1800K] -Beige- Fluorescent lamp Fluorescent lamp
Halogen bulb Xenon bulb LED [2800K] -White- -Ex. White-
[5000K] [6500K]
Incandescent lamp
[2800K]
Electricity consumption Luminosity
３８
Chassis Electrical
8-4 LED Rear combination lights
LEDs are adopted for tail & stop lamp.
Clear outer lens are equipped.
[Features]
-Less electricity consume, 85% lower than that of the incandescent lamp.
Total 2.8W LED x2 are used for stop lamps/0.5W LED x2 are used for tail lamps per vehicle.
-LED enables Long life
-LED might help to reduce the collisions due to the quick response of LED.
Tail & Stop lamp [LED] Tail & Stop lamp [Normal bulb]
Rear turn lamp Rear turn lamp
Reversing lamp Reversing lamp
i-MiEV Petrol powered “ i “
8-5 Front windshield wiper
AERO wiper blades are applied. i-MiEV is the first model of MMC which has the said blades.
[Features]
AERO wiper blade achieves to press the blade to the glass evenly and it helps to improve wiping performance
especially under high speed driving.
AERO wiper blade Non-AERO wiper blade
３９
Chassis Electrical
8-6 Auto lighting control
If Auto-mode is selected at rotary switch, headlights position, tail, license plate, instrument panel lamps are
automatically turn in accordance with outside light level.
The sensor is located on the top end of the instrument panel board.
Auto-light sensor
４０
Chassis Electrical
8-7 MMES [Mitsubishi Multi Entertainment System]
SSD type memory used Navigation system [Solid State Drive] is selected to reduce the cost of the vehicle.
- MMES is a optional equipment for i-MiEV
- Japanese language only
- Japanese Road map only
[Basic spec.]
-2 DIN size
-SSD Solid state drive] 8GB
-7 inch wide size QVGA monitor
-Touch panel
-1 seg. Digital TV tuner
-DVD drive [with illegal copy reject function]
-SD card slot
-Music catcher function
-USB/i-pod accommodation cable (Optional)
４１
Heater & A/C
9 Heater & A/C system
9-1 Heater & A/C system: General
Based on the A/C system for petrol powered “i”, Electric motor type of A/C compressor Electric water heater
are adopted.
A/C(HVAC) ECU
Condenser tank ass’y,
for EV heater
Condenser core
Compressor & Heater ECU
Liquid pipe
Dryer Heater ass’y
Water pump A/C Heater hose Heater [HVAC]
for Heater
9-2 Heater & A/C system: HVAC unit
Based on the HVAC unit for petrol powered “i”, additional duct and the additional damper motor are introduced to
maintain the temperature of the battery.
Defroster ( for windshield)
Defroster
( for side glass)
Side outlet
Defroster
( for side glass)
Side outlet Center outlet
Outlet for foot
Outlet for foot
Specially degigined for i-MiEV
Outlet for battery pack
４２
Heater & A/C
9-3 Heater & A/C system: A/C compressor
Electric motor driven type of A/C compressor has been introduced. Inverter is integrated and it is controlled by serial
communication with A/C control unit.
It receives DC 330V directly from the battery pack, transform it to AC 330V by integrated inverter, then drive the motor
for compressor.
The inverter is cooled by the refrigerant, it is unnecessary to introduce extra cooling device such as cooling water.
Since the compressor is driven by the electric motor, it helps to save energy because compressor revolution is
controlled as minimally as possible.
The A/C compressor requires the special new oil for the lubrication, named as (MA68EV) which has high insulation
performance.
Although the A/C compressor oil for petrol powered “ i “ could not be used for i-MiEV, same A/C gas as HFC134a can
be used for i-MiEV.
Low pressure hose
Expansion valve
High pressure hose
Evaporator
[Heater unit]
High pressure pipe
Liquid pipe Electric motor driven A/C compressor
[With Integrated inverter]
Condenser & Receiver
[Cooling module]
Low pressure pipe
DC 330V cable
Ground cable
Inverter
Compressor
DC 12V cable
DC 12V compressor bracket
Rubber vibration isolator
４３
Heater & A/C
9-4 Heater & A/C system: Heater
Electric type of heater is adopted to control the cabin temperature. It uses DC 330V to warm the coolant up to 80℃.
Although the drive motor requires water cooling system, Heater system could not share the system because
it uses different temperature ranges.
Electrical water pump used DC 12V and circulate the LLC among the system.
LLC is specified to use the genuine “Super Long life coolant” and the periodical replacement might be unnecessary
while the vehicle lifetime.
Condense tank
Brackets Heater core [in HVAC]
Heater pipes[5 pipes in total]
Electric water Heater
Heater pipe
[Electrical Water pump] [Electrical water heater]
Electrical harness
[DC 12V]
GND wire
Water outlet
Electrical harness
[DC 12V] Water inlet
Heater pipe
Rubber vibration isolator
Electrical harness
[DC 330V]
Air conditioning control dials / switches
Air selection switch MAX switch Temperature control dial
MAX switch is specially added for i-MiEV.
Since it would lead the maximum performance for cooling / hearting when it is pressed,
the MAX mode would consume large currents and affect to the driving distance.
Refer to i-MiEV owner’s manual for more details.
４４
Heater & A/C
9-5 Heater & A/C system: System control
“A/C ECU(HVAC ECU)” is adopted on i-MiEV as same as petrol powered “i” .
“Compressor & Heater control ECU” is additionally applied.
Both ECUs are connected by serial communication.
“Compressor & Heater control ECU” controls the following devices according to the signal from EV-ECU and A/C ECU
via CAN-C.
-A/C compressor
-Electric water heater
-Electric water pump
-Air selection damper (Outside air/Re circulated air) motor
Mode selection damper
A/C Thermistor motor
Air mix damper motor
Heater water temperature sen-
sor
Heater control transistor
Outside air temperature sensor A/C-ECU
HVAC-ECU
Mode selection damper Poten- Heater fan & Motor kit
tiometer
Air mix damper
Potentiometer
Local com.
Electrical water pump
A/C refrigerant pressure switch
Air selection damper Heater
(Outside air/Re circulated air)
Potentiometer Compressor
& Local com. A/C compressor
Heater control Inverter
ECU
Heater control transistor
Heater control transistor
Heater control transistor
CAN com.
４５
Interior
10. Interior
10-1 Instrument panel
Basically, instrument panel for i-MiEV is same as petrol powered “i”.
Followings are minor different points.
- Shape of floor console is little different to accommodate the cooling duct for DC 330V battery.
- Location of Rear window demister switch is shifted to the switch panel.
- TCL OFF switch is installed at the switch panel together with the Rear window demister switch.
Rear window demister switch
TCL OFF switch
TCL OFF switch
10-2 Tail gate trim
Bamboo fiber PBS [Poly-Butylene Succinate] is used as the material for the tail gate trim.
This is a kind of vegetable reign, and it will reduce 10% of CO2 emission in total life cycle.
Use of VOC (Volatile organic compound) is also reduced by 90%.
Bamboo fiber Tail gate trim
Bamboo Bamboo fiber Bamboo fiber PBS sheet
Succinic acid
1,4-Butanediol
PBS pellet PBS Fiber
Magnification
Tail gate trim
４６
Exterior
11. Exterior
11-1 Door opening weather strip
Because i-MiEV is ultra quietness, the outside noise can be easily heard.
In order to adjust this, extra weather strip is added to the rear door opening as the sound isolator.
Add extra weather strip
11-2 Special designed sticker
In order to appeal the EV, special designed sticker is prepared to the outer shell of the body.
[2-tone body color TYPE-A]
[2-tone body color TYPE-B]
[Mono tone body color]
４７
Maintenance
12. Maintenance
12-1 Caution points when handle the EV: Electric Vehicle
i-MiEV uses DC 330V and has a possibility to courses the serious accident as electrical shock to the human body
if it is handled wrongly.
Therefore, Technical staff who inspect / maintenance the i-MiEV as Electrical vehicle should be completed
the special training course for the electric power handling.
[Handling of the insulation grooves]
Entrepreneur should inspect the all of insulation goods for AC300V or more every 6 months and should confirm
the insulation performance on a voluntary basis.
Insulation goods which have not used for 6 months will be excluded from the inspection.
However, Entrepreneur should inspect insulation goods before use.
If the Entrepreneur found the abnormality in these insulation goods, Entrepreneur is required to repair or replace.
Entrepreneur should inspect for the following items and record every inspection history and store the records for
3 years.
-Inspection date
-Inspection method
-Inspection part
-Inspection result
-Inspector’s name
-Measure (if problem is found)
４８
Maintenance
12-2-1 Shutoff procedure of DC 330V [How to remove the Service plug]
Make sure to wear the insulation grooves while operation
Service Plug
Magnet for
Detection switch
1) Service plug must be removed every operation of cables/devices which is connected to DC 330V lines.
2) Put the signboard with the message of ” Danger! / KEEP OFF! / High voltage on the car.
3) Wear the insulation grooves while the operation.
[Removal of Service Plug]
Step Operation
Disconnect the cable from the (-) terminal of DC 12V battery.
[Note]:
It must be proceeded after 60 seconds from power switch OFF.
1
Peel off the floor carpet at the under front passenger seat , then remove
the 2 nuts and remove the service lid.
Forward Direction
Nut
2 Service lid Nut
It is more easy to reach the service lid, if the front passenger seat is removed.
Make sure 5 Minutes(300seconds) are already past from the disconnection
of the DC 12V battery cable(-) , then remove the service plug by releasing
the lock lever on it.
[Caution]]:
3
Operator must wear the insulation grooves when remove the service plug.
The removed service plug must hold by the operator always and operator should not leave it.
4
４９
Maintenance
12-2-2 Inspection points before removing the DC 330V battery and/or the related parts
After removing the service plug according to the procedure on page 49, check the followings before
remove/service the DC 330V battery and/or the parts which are connected to DC 330V.
Make sure to remove the service plug when make service on the parts using high voltage.
Wear the specifed protective clothing while the inspection
Inspection before removing the DC 330V battery
1. 2.
Lift up the vehicle. Remove the work hole lid.
3. 4.
Set the proves as shown
in the right, and read out
the voltage.
Standard Value: 0[V]
Vehicle front
Ins pec t i o n b efor e r e m o v i ng th e ot her
Before removing the DC 330V battery related parts which are connected to DC 330V battery
1. 2.
Open the tail gate. Open the access panel, and
[Note] The service lid of MCU.
Because i-MiEV has Electro-
Latch for the tail gate,
consider the opening timing
of the gate.
MCU
3.
Set the proves as shown
in the right, and read out
the voltage.
Standard Value: 0[V]
５０
Maintenance
12-2-3 Procedures when the DC 330V could not shut off
When the system failure happened or after the collision, voltage could not be shut off by the procedure
always. In those case, proceed the followings.
Make sure to wear the insulation grooves while operation
Use Make sure to use insulated socket wrench MB992337 or equivarants.
[1] Disconnect the P-cable and N-Cable
Vehicle front
[2] If the disconnection of the P-N cable from the
work hole lid is impossible. disconnect them at MCU.
[Caution]
Each end terminals of disconnected cables must be
covered separately as a isolation.
Electric insulation socket [MB992337]
５１
Maintenance OF23>;?9279:P S
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Maintenance
12-5 Pre-delivery Inspection
Inspection items and procedures are same as petrol powered “i”.
Pay attention for the following items especially.
[Note]
Since 2010MY i-MiEV does not have the storage connector at fuse box, pressing down of connector before delivery
is not required.
Item Work
1 EV-System start-up check Operation check of power switch
- Confirm if the power switch rotates smoothly (No stack at start position).
- Confirm the system is not start up except “P” position.
2 Other systems check Operation check for General charging and heater & A/C system
power switch
-Check the operation of A/C compressor by operating sounds.
-Check if the heater works normally.
-Check if the blower fan motor works smoothly, with out any abnormal noise.
-Check if the mode selection dial works normally and air direction changed accordingly
-Check if the temperature control dial works normally and air temp is changed accordingly.
3 Noise check Confirm the operation of following items by test driving.
-Speed meter -Brakes -Motor
-Transmission -Steering and related parts
12-6 Periodical inspection
12-6-1 Periodic inspection for i-MiEV
Although the following item to be inspected is newly added as i-MiEV special, total items to be inspected are
extremely reduced. For the items not mentioned in below, handle as same as petrol powered “i”.
Item Inspection timing Remarks
Check the leakage of Follow the inspection procedure which is separately
1 24months or 40,000km
motor coolant and heater water announced.
For the details, refer to;
First check at 12mo.
2 DC 330V Battery capacity check And Every 24 mo interval 12-7 DC 330V Battery capacity check and maintenance
Follows.
５３
Maintenance
12-6-2a Periodical inspection item chart for i-MiEV [For Europe]
Note: This table is tentative and only for 2010MY version of i-MiEV.
Check and exchange item Service Intervals
Check radiator hoses for damage and proper connection Inspection Every 40,000km or every 24 months
Check coolant level in reservoir Inspection Every 40,000km or every 24 months
Change coolant Replace Every 240 months
Check heater hoses for damage and proper connection Inspection Every 40,000km or every 24 months
Check heater liquid level in reservoir Inspection Every 40,000km or every 24 months
Change heater liquid Replace Every 240 months
Check fluid level in brake reservoir Inspection Every 20,000km or every 12 months
Change brake fluid Replace Every 40,000km or every 24 months
Check battery condition (Except Main battery) Inspection Every 20,000km or every 12 months
Check High-voltage harness for damage and looseness Inspection Every 40,000km or every 24 months
Check suspension system for damage and looseness Inspection Every 40,000km or every 24 months
Check suspension arm ball joints for play, and dust covers
Inspection Every 40,000km or every 24 months
for damage
Lubricate suspension arm and ball joints with grease fitting Lubrication Unnecessary
Normal Every 40,000km or every 24 months
Check driveshaft boots for damage Inspection
Severe Every 10,000km
Check steering linkage for damage and loose connections Inspection Every 20,000km or every 12 months
(including seals and boots)
Check transmission for oil leakage Inspection Every 20,000km or every 12 months
(In case of leakage, check the oil level)
Normal Every 100,000km
Change gear oil in transmission Replace
Severe Every 40,000km
Check brake pedal for play Inspection Every 20,000km or every 12 months
Check parking brake lever stroke and play Inspection Every 20,000km or every 12 months
Replace air purifier filter Replace Every 20,000km or every 12 months
Check wheel alignment Inspection Every 20,000km or every 12 months
Check front and rear wheel bearings for play Inspection Every 60,000km or every 36 months
Check brake hoses and pipes for leakage, damage and
Inspection Every 40,000km or every 24 months
installation.
Normal Every 20,000km or every 12 months
Check brake pads and discs for wear Inspection
Severe Every 10,000km or every 6 months
Normal Every 40,000km or every 24 months
Check brake shoe linings and drums (drum in disc) for wear Inspection
Severe Every 20,000km or every 12 months
Check body condition for damage Inspection Every 12 months
Road test Inspection Every 20,000km or every 12 months
First time is 12 months,
Check main battery condition Inspection
after every 24 months
５４
Maintenance
12-6-2b Periodical inspection item chart for i-MiEV [For G.EXP]
Note: This table is tentative and only for 2010MY version of i-MiEV.
At first
Check and exchange item Service Intervals
1,000km
Check radiator hoses for damage and proper connection Inspection Every 40,000km or every 24 months
Check coolant level in reservoir Inspection I Every 20,000km or every 12 months
Change coolant Replace Every 240 months
Check heater hoses for damage and proper connection Inspection Every 40,000km or every 24 months
Check heater liquid level in reservoir Inspection I Every 20,000km or every 12 months
Change heater liquid Replace Every 240 months
Check fluid level in brake reservoir Inspection I Every 10,000km or every 6 months
Change brake fluid Replace Every 40,000km or every 24 months
Check battery condition (Except Main battery) Inspection I Every 10,000km or every 6 months
Check High-voltage harness for damage and looseness Inspection Every 40,000km or every 24 months
Check suspension system for damage and looseness Inspection I Every 20,000km or every 12 months
Check suspension arm ball joints for play, and dust covers Inspection Every 20,000km or every 12 months
for damage
Lubricate suspension arm and ball joints with grease fitting Lubrication Unnecessary
Normal Every 20,000km or every 12 months
Check driveshaft boots for damage Inspection
Severe I Every 10,000km or every 6 months
Check steering linkage for damage and loose connections
Inspection Every 20,000km or every 12 months
(including seals and boots)
Check transmission for oil leakage Inspection Every 20,000km or every 12 months
(In case of leakage, check the oil level)
Normal Every 100,000km
Change gear oil in transmission Replace
Severe Every 40,000km
Check brake pedal for play Inspection Every 10,000km or every 6 months
Check parking brake lever stroke and play Inspection I Every 20,000km or every 12 months
Replace air purifier filter Replace Every 12,000km or every 12 months
Check wheel alignment Inspection Every 20,000km or every 12 months
Check front and rear wheel bearings for play Inspection Every 40,000km or every 24 months
Check brake hoses and pipes for leakage, damage and Inspection Every 20,000km or every 12 months
installation.
Normal Every 20,000km or every 12 months
Check brake pads and discs for wear Inspection
Severe Every 5,000km or every 6 months
Normal Every 40,000km or every 24 months
Check brake shoe linings and drums (drum in disc) for wear Inspection
Severe Every 10,000km or every 6 months
Check body condition for damage Inspection Every 12 months
Road test Inspection I Every 20,000km or every 12 months
First time is 12 months,
Check main battery condition Inspection
after every 24 months
５５
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