SMART Fortwo 451 Series Introduction Into Service Manual Download Page 90

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Index

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451

Annex

Additional instruments

. . . . . . . . . . . . . . 76

Air conditioning

. . . . . . . . . . . . . . . . . . 78

Bodyshell structure

. . . . . . . . . . . . . . . . 81

Charging duration

. . . . . . . . . . . . . . . . . 33

Coolant circuit

. . . . . . . . . . . . . . . . . . . 70

Cooling system

. . . . . . . . . . . . . . . . . . 72

DC/DC converter

. . . . . . . . . . . . . . . . . 43

Deenergization

Deenergization matrix

. . . . . . . . . . . . . . 52

Desiccant cartridge

. . . . . . . . . . . . . . . . 24

Diagnosis assistance system

. . . . . . . . . . . 57

Dimensions

. . . . . . . . . . . . . . . . . . . . . 11

Dimensions and weights

. . . . . . . . . . . . . . 12

Front axle

. . . . . . . . . . . . . . . . . . . . . 67

Fuse assignment

. . . . . . . . . . . . . . . . . . 59

Fuses

. . . . . . . . . . . . . . . . . . . . . . . . 58

Heating

. . . . . . . . . . . . . . . . . . . . . . . 78

High-voltage battery

Transport

. . . . . . . . . . . . . . . . . . . . 26

High-voltage battery supporting strut

. . . . . 67

High-voltage components

Check after an accident

. . . . . . . . . . . . . 23

Overview

. . . . . . . . . . . . . . . . . . . . 20

Safety function after an accident

. . . . . . . . 23

Wiring harness check

. . . . . . . . . . . . . . 23

High-voltage fuses

. . . . . . . . . . . . . . . . 45

Initial startup

Form

. . . . . . . . . . . . . . . . . . . . . . . 51

Innovations

. . . . . . . . . . . . . . . . . . . . . 9

Limp-home mode

. . . . . . . . . . . . . . . . . . 75

Maintenance concept

. . . . . . . . . . . . . . . 14

Maintenance interval

. . . . . . . . . . . . . . . 14

Maintenance interval display

. . . . . . . . . . . 14

Maintenance points

. . . . . . . . . . . . . . . . 15

Multifunction display

. . . . . . . . . . . . . . . 75

Output reduction

. . . . . . . . . . . . . . . . . 75

Park pawl

. . . . . . . . . . . . . . . . . . . . . . 66

Performance

. . . . . . . . . . . . . . . . . . . . 11

Plug&Charge

. . . . . . . . . . . . . . . . . . . . 35

Power disable event log

. . . . . . . . . . . . . . 51

Powerline Gateway

. . . . . . . . . . . . . . . . . 34

Pre-conditioning

. . . . . . . . . . . . . . . . . 80

Refrigerant circuit

. . . . . . . . . . . . . . . . 70

Refrigerant compressor

. . . . . . . . . . . . . 46

Relays

. . . . . . . . . . . . . . . . . . . . . . . 62

Reverse gear

. . . . . . . . . . . . . . . . . . . . 66

Selector lever

. . . . . . . . . . . . . . . . . . . 66

Service Disconnect

. . . . . . . . . . . . . . . . 50

Smart Charging

. . . . . . . . . . . . . . . . . . 34

Storage of high-voltage batteries

. . . . . . . . 27

Summary of Contents for Fortwo 451 Series

Page 1: ...Introduction of the smart fortwo electric drive 3rd generation Model series 451 Introduction into Service Manual Introduction of the smart fortwo electric drive 3rd generation Model series 451 ...

Page 2: ...Daimler AG Technical Information and Workshop Equipment GSP OI D 70546 Stuttgart Introduction of the smart fortwo electric drive 3rd generation Model series 451 ...

Page 3: ...mler AG GSP OIS HPC R822 W002 D 70546 Stuttgart 2012 by Daimler AG This document including all its parts is protected by copyright Any further processing or use requires the previous written consent of Daimler AG Department GSP OIS HPC R822 W002 D 70546 Stuttgart This applies in particular to reproduction distribution alteration translation microfilming and storage and or processing in electronic ...

Page 4: ...ical system On board electrical system power supply 17 High voltage battery 24 Charging infrastructure 31 On board charger 32 Vehicle Homepage 36 Charger feed in socket 37 Charging cable 40 Regenerative braking 42 Power electronics control unit 43 High voltage adapter plate fuse box 44 Electric refrigerant compressor 46 High voltage PTC heater 47 High voltage interlock 48 ...

Page 5: ...5 Diagnosis 57 SAM control unit 58 Brake system 63 Sound generator 64 Electric drive system Motor description 65 Transmission Transmission description 66 Chassis Axles and suspension 67 Wheels tires and brakes 68 Cooling systems Cooling system overview 69 Cooling system components 72 High voltage battery cooling system 73 ...

Page 6: ...on Model Series 451 Design Instrument cluster 74 Additional instruments 76 Climate control 78 Body 81 Notes on damage analysis 83 Notes on supplemental restraint system 84 Notes on repair operations 85 Special tools Electrical system 86 Annex Abbreviations 87 Index 89 ...

Page 7: ...Notes 6 Introduction of smart fortwo electric drive 3rd Generation Model Series 451 ...

Page 8: ...for the diagnosis of technical problems For such needs more extensive information is available in the Workshop Information System WIS and in the Diagnosis Assistance System DAS The content in WIS is updated Therefore the infor mation available there reflects the latest technical status of our vehicles This Introduction into Service Manual presents initial information relating to the 3rd generation...

Page 9: ...new high voltage battery the 3rd genera tion of the smart fortwo electric drive makes a significant contribution to conserving fossil fuels and reducing emissions during driving operation With a range of roughly 150 km the smart fortwo electric drive thus represents an ideal alterna tive for mobility requirements in urban areas and is a further step towards the electromobility of the future Thanks...

Page 10: ...ating cooling of interior compartment pre conditioning With a maximum torque of 130 Nm and acceleration boost the powerful electric motor provides good driving performance and responsiveness Due to the output characteristics of the electric motor the smart fortwo electric drive only requires a single fixed transmission ratio This makes gearshifting unnecessary The motor changes its direction of ro...

Page 11: ...oupé 1 Electric motor 2 Power electronics control unit 3 High voltage battery 4 Battery management system control unit 5 On board charger 6 Transmission 7 Cooling module 8 Brake booster vacuum pump 9 Charger feed in socket 10 Drivetrain control unit 11 High voltage battery heat exchanger chiller 12 High voltage battery heater 13 Interior high voltage PTC heater 14 High voltage adapter plate fuse b...

Page 12: ...ed km h 125 100 145 1553 Acceleration 0 100 km h s 11 5 26 7 13 7 Range as per NEDC km 145 135 7601 7502 Range as per UDDS miles 100 91 CO2 emissions g km 0 0 981 1002 Consumption as per NEDC kWh 100 km 13 3 18 2 Consumption as per NEDC l 100 km 4 31 4 42 Consumption as per UDDS mpg 333 Dimensions Vehicle length mm 2695 Vehicle width mm 1559 Vehicle height mm 1565 Wheelbase mm 1867 Front track wid...

Page 13: ...ortwo 52 kW gasoline engine mhd passion Dimensions and weights Curb weight as per DIN EPA kg 9001 9202 9001 9202 7501 7902 Curb weight as per US Curb Weight kg 9501 9702 9451 9652 8351 8552 Permissible gross vehicle weight kg 1150 1120 1020 10703 Maximum payload ECE kg 2501 2302 2201 2002 2701 2302 Maximum payload USA kg 1901 1802 2051 1852 2351 2152 Trunk capacity l 220 1 coupé 2 cabrio 3 USA 52 ...

Page 14: ... 5 Rated voltage max voltage V 339 391 Rated capacity Ah 52 Weight kg approx 175 approx 150 Electric motor Motor model designation 780 993 780 009 Design Permanently energized 3 phase AC motor Max output continuous output kW 55 35 30 20 Peak torque Nm 130 120 Max rpm 11 800 12 000 Power transmission Drive Rear wheel drive Transmission New single stage transmis sion with integrated bevel gear diffe...

Page 15: ... located in the multifunction display of the instrument cluster The maintenance interval is displayed here in the form of two wrench symbols The remaining time is shown in days roughly one month before a service date The remaining distance is displayed as of 1000 km Service indicator Service in XXX km Service in XX days Maintenance interval The maintenance interval for the smart fortwo electric dr...

Page 16: ... 1 Brake fluid reservoir 2 Windshield washer fluid reservoir 3 Coolant expansion reservoir 4 Lamp unit for bulb replacement P00 20 2678 00 High voltage battery desiccant cartridge The desiccant cartridge is located on the under side of the high voltage battery under the connection for the high voltage lines on the right in the direction of travel 1 Desiccant cartridge G5 High voltage battery P54 1...

Page 17: ...nts occurs One or more red warning lamps e g high voltage battery drive diagnosis 12 V battery lights up on the instrument cluster Increased or pulsating braking effect If a fault in the high voltage system is detected the message Do not tow is also shown on the multifunction display a Warning If the vehicle is towed at a speed greater than 50 km h there is a risk that the electric drive or high v...

Page 18: ...nics control unit The DC DC converter transforms the high direct voltage from the high voltage on board electrical system into 12 V direct voltage The power electronics control unit thus performs the task of the alternator on a vehicle with combustion engine Information on the high voltage system General The high voltage system consists of several components The individual components are connected...

Page 19: ...you Remove covers from components which are identified with a warning sticker Tamper with components of the high voltage on board electrical system Open housings Disconnect connectors Touch components or orange coloured lines of the high voltage on board electrical system on a vehicle involved in an accident Touch damaged orange coloured lines or their damaged connectors Touch damaged components o...

Page 20: ...ontrol line is then physically disconnected The high voltage output remains irreversibly deacti vated Shutoff by high voltage crash sensor control unit The high voltage crash sensor control unit is located under the left hand seat on the vehicle floor It shuts off the high voltage on board elec trical system in the following conditions During charging in the event of a stationary crash During driv...

Page 21: ...ric drive motor Power electronics control unit High voltage battery Electric refrigerant compressor High voltage PTC heater High voltage adapter plate fuse box On board charger P54 00 2890 00 A9 6 Electric refrigerant compressor F34 6 High voltage adapter plate fuse box G5 High voltage battery M5 Electric drive motor N33 5 High voltage PTC heater N83 On board charger 3kW N83 10 On board charger 22...

Page 22: ...ystems P00 19 5200 00 A9 6 Electric refrigerant compressor F34 6 High voltage adapter plate fuse box F90 12 V charge line prefuse G1 Battery 12 V G5 High voltage battery M5 Electric drive motor N33 5 High voltage PTC heater N83 On board charger 3kW N83 10 On board charger 22 kW with code 908 22 kW on board charger N129 1 Power electronics control unit HV High voltage LV Low voltage 12 V ...

Page 23: ...on course Successful completion of the smart electric drive product training course Working requirements When work is performed on a high voltage system the system must be deenergized and the voltage free state of the high voltage system must be secured This has to happen in accordance with 5 safety rules as per DIN VDE 0105 Deenergize Secure against reactivation Check deenergisation at all termin...

Page 24: ...ation or external damage is found on the high voltage components or lines they must be replaced Repair of the high voltage components or lines is not permissible Safety function after an accident High voltage system shut off Automatic shutoff of the high voltage battery and discharge of the high voltage components takes place via the high voltage crash sensor control unit During charging in the ev...

Page 25: ...e connection When fully charged the high voltage battery supplies an output voltage of approx 391 V The high voltage output can be disconnected from the high voltage on board electrical system by contactors actuated by the battery management system control unit The high voltage battery also supplies 12 V on board electrical system with power via the DC DC converter in the power elec tronics contro...

Page 26: ...ult at temperatures below 0 C the high voltage battery is heated during charging by a 12 V PTC heater high voltage battery heater in the coolant circuit of the high voltage battery The temperature of the high voltage battery is recorded by the battery management system control unit via temperature sensors and cooling heating mode is initiated as necessary In order to comply with the maximum permis...

Page 27: ...oods regulations High voltage batteries may only be transported in accordance with the applicable international and national hazardous goods regulations for the respective mode of transport Every high voltage battery must be checked for transport safety in the workshop Defective or damaged high voltage batteries must be classed as NOT safe for trans port if following points apply to the transport ...

Page 28: ...e case of high voltage batteries which are safe for transport undamaged the following distinction is made based on fire protection requirements Storage with sprinkler protection and Storage without sprinkler protection Storage of high voltage batteries which are safe for transport in storage facilities with sprinkler protection When storing high voltage batteries in storage areas with sprinkler pr...

Page 29: ...ecting pan Protection from access by unauthorised persons Handling and storage of high voltage batteries which are not safe for transport High voltage batteries which are damaged during operation or an accident may represent a hazard to their surroundings depending on the level of damage In the event of fire or smoke formation the fire department must be informed immediately and a safe distance mu...

Page 30: ...the special container the high voltage battery must be stored in a marked storage location outside of the building until special transport approval is received In this case the following points must always be observed Presence of weather protection to protect against wet weather or direct sunlight Liquid resistant ground surface or collecting pan Protection from access by unauthorised persons Stor...

Page 31: ...ing as per the relevant dangerous goods regulations as well as addi tional requirements with regard to transport must be observed High voltage batteries which are not safe for transport A high voltage battery is not safe for transport in the following circumstances High voltage battery is not diagnosis capable Insulation fault Status of contactors is closed high voltage output energised Visual ins...

Page 32: ...ed In the case of intelli gent charging stations digital communication also takes place via Powerline PLC Powerline Communication on lines L1 and N For this purpose data are transferred as per the protocol specified in ISO IEC 15118 When charging at a household power outlet the charging current may have to be limited in order to avoid overloading the local power grid The maximum permissible chargi...

Page 33: ...ng process In the case of intelligent charging stations addi tional communication takes place via the Power line Gateway on phase L1 and the neutral wire N Connections High voltage output direct voltage High voltage input AC voltage 12 V on board electrical system Control system CAN Coolant lines Since the maximum possible charging current depends on the charging cable or is determined by the char...

Page 34: ...d charger with 3 kW max at 230 V standard Input 100 to 240 VAC Output Approx 380 VDC Charging duration at 13 A e g household power outlet 7h 0 100 SOC at 25 C Charging duration at 16 A e g charging station or wall box 6 h 0 100 SOC at 25 C On board charger 22 kW with 3 x 400 V 32 A with code 908 22 kW on board charger Input 3 x 400 VAC Output Approx 380 VDC Charging duration 1h 0 100 SOC at 25 C ...

Page 35: ...ternet connection of the customer e g by connection to their DSL router Configuration of the PLGW is initiated by entering the appropriate information on the instrument cluster and completed by pressing the encryption button on the Powerline socket adapter If the customer already has a Powerline networked installed the vehicle can also be inte grated into this network i Note Powerline Communicatio...

Page 36: ...p on a USB stick After the customer enters the password the file is decrypted with the certificate The certificate is then installed via Star Diagnosis by a service employee Two other electronic certificates are installed in the vehicle ex factory Root certificate Provisioning certificate The certificates can be updated in the workshop using Star Diagnosis if they become invalid or require an upda...

Page 37: ...nt charge level of the high voltage battery the estimated range or the charging time The Plug Charge function see on board charger can also be configured via the Vehicle Homepage e g the Plug Charge certificate from a power supplier can be installed on the on board charger via the Vehicle Homepage The customer requires a Vehicle Verification Code to use the Vehicle Homepage This is required to cre...

Page 38: ...d for data exchange with the charging station and the PP contact allows the vehicle to detect when the charging cable is plugged in On vehicles with the 3 kW on board charger only high voltage contacts L1 N and PE are used There are 2 indi cator lamps above the socket which indicate locking of the charging connector and the status of the charging process P54 10 3678 00 1 Tank cap 2 Protective cap ...

Page 39: ...rging cable connector X58 23 Charger feed in socket Indicator lamp Lights up When no charging cable is connected it can be connected When a charging cable is connected it can be removed Flashes Charging cable connector not plugged incorrectly or deformed Lock or position sensor in charge socket defective Indicator lamp Flashes orange The connection between the vehicle and power supply is being est...

Page 40: ...ntact is used for data exchange with the charging station and the PP contact allows the vehicle to detect when the charging cable is plugged in P54 10 3722 00 Block diagram 1 Locking status 2 Lock 3 Release CP Control Pilot L1 Phase L1 N Neutral wire PE Protective Earth PP Proximity S Charging cable connector X58 23 Charger feed in socket P54 10 3720 00 CP Control Pilot L1 Phase L1 N Neutral wire ...

Page 41: ...he available charging current to the on board charger via the CP contact In order to avoid overload situations the charging current can be adjusted to the circumstances of the local power grid using a button on the control box of the charging cable The charging connector is locked at the vehicle end during the charging process P54 10 3715 00 Charging cable stowage compartment in liftgate 1 Mains p...

Page 42: ...nction display 1 Connector symbol 2 Charging progress 3 Charging duration i Note The vehicle cannot be started during the charging process Charging cable for charging at public charging stations A 7 pin charge coupling as per IEC62196 2 is installed at the vehicle end and a 7 pin charge connector as per IEC62196 2 is installed at the power outlet end The operating parameters are exchanged between ...

Page 43: ...ith combustion engine The level of regenerative braking in deceleration mode can be adjusted using the steering wheel shift paddles as a special equipment option Stage 0 No regenerative braking the vehicle retains the maximum possible amount of kinetic energy Stage 1 Normal driving default setting stan dard Stage 2 For sporty driving The brake pedal has to be used less because the level of decel e...

Page 44: ...ontrol unit records the rpm rotor position and temperature of the electric motor If the electric motor is operated as a generator in deceleration mode the power electronics control unit converts the induced alternating voltage into direct voltage and uses it to supply the high voltage on board electrical system DC DC converter The DC DC converter in the power electronics control unit generates the...

Page 45: ...oss sections to the on board charger the high voltage PTC heater and the electric refrigerant compressor with high voltage fuses There are three fuses in the high voltage adapter plate fuse box to protect the high voltage on board electrical system The high voltage fuses are not accessible and thus not exchangeable P54 10 3684 00 1 Electric refrigerant compressor connector 2 On board charger conne...

Page 46: ...fuse 40 A 2 3 kW on board charger fuse 40 A or 22 kW on board charger fuse 100 A 3 Electric refrigerant compressor fuse 40 A A9 6 Electric refrigerant compressor F34 6 High voltage adapter plate fuse box G5 High voltage battery M5 Electric drive motor N33 5 High voltage PTC heater N83 On board charger 3kW N83 10 On board charger 22 kW with code 908 22 kW on board charger N129 1 Power electronics c...

Page 47: ...is a high voltage component and contains an inverter for powering a spiral compressor which is driven by an electric motor as well as an integrated control unit The control unit of the electric refrigerant compressor regulates the speed of the electric motor to the value set by the heater AC operating unit The control unit communicates with the driv etrain control unit via LIN This only acts as a ...

Page 48: ...s and transfer the heat to the air For better control the surface area of the high voltage PTC heater is divided into 4 independently controllable sections The control unit of the high voltage PTC heater receives the output request for the individual PTC sections from the drivetrain control unit and actuates the individual output stages of the power electronics via PWM signals In order to maintain...

Page 49: ...r If the signal loop is interrupted e g by discon necting a high voltage or 12 V connector this causes the contactors in the high voltage battery module to open and the high voltage on board electrical system to shut down Since capacitors are also present in the high voltage components the high voltage on board electrical system is not immediately rendered voltage free once the contactor is opened...

Page 50: ... voltage adapter plate fuse box F19 Pyrofuse G5 High voltage battery M5 Electric drive motor N33 5 High voltage PTC heater N82 2 Battery management system control unit N83 On board charger 3kW N83 10 On board charger 22 kW with code 908 22 kW on board charger N129 1 Power electronics control unit S7 Service Disconnect X26 Interior engine connector HV High voltage LV Low voltage 12 V HVIL High volt...

Page 51: ...AS Pulling out the Service Disconnect plug underneath the instrument panel in the left footwell physically interrupts the actuation of the contactors of the high voltage battery The empty slot is protected against reinsertion by a lock i Note When a high voltage on board electrical system has been deenergised only the repair and main tenance operations which made the deenergisa tion necessary shou...

Page 52: ...Deenergisation Electrical system 51 Introduction of smart fortwo electric drive 3rd Generation Model Series 451 DAS form power disable event log extract DAS form initial startup log extract ...

Page 53: ...smission X Remove install integral support X Remove install axle tube X Remove install drive system coolant pump X Remove install high voltage battery coolant pumps X Remove install A C condenser X Remove install pedals X Remove install ESP control unit X Remove install ESP hydraulic unit X Remove install electric steering X Remove install high voltage battery X Remove install vacuum pump X Remove...

Page 54: ...l front axle X Remove install front suspension X Outside of vehicle Remove install CBS parts X Remove install soft top roof X Remove install windshield X Remove install rear end door upper section coupé X Remove install rear end door lower section X Remove install front exterior lights X Remove install rear exterior lights X Remove install wiper blades X Remove install charger feed in socket charg...

Page 55: ... front service brake X Remove install rear service brake X Vehicle interior 12 V battery X Remove install restraint systems X Remove install floor covering X Remove install instrument cluster X Remove install instrument panel X Multifunction control lever X Remove install driver passenger seat X Remove install interior high voltage lines X Remove install air distribution box X ...

Page 56: ... sensor control unit N2 7 Restraint systems control unit N10 10 SAM control unit N15 5 Electronic selector lever module N23 Heater AC operating unit N33 5 High voltage PTC heater N47 5 ESP control unit N49 Steering angle sensor N68 Power steering control unit N82 2 Battery management system control unit N83 On board charger 3kW N83n1 Powerline Gateway control unit N83 10 On board charger 22 kW wit...

Page 57: ...e sound generator M46 Electric drive and on board charger coolant pump N2 1 High voltage crash sensor control unit N2 7 Restraint systems control unit N10 10 SAM control unit N15 5 Electronic selector lever module N23 Heater AC operating unit N33 5 High voltage PTC heater N47 5 ESP control unit N49 Steering angle sensor N68 Power steering control unit N82 2 Battery management system control unit N...

Page 58: ...ector X11 4 is located in the vehicle interior on the underside of the instru ment panel on the driver side Diagnosis capable control units Instrument cluster A1 High voltage crash sensor control unit N2 1 Restraint systems control unit N2 7 SAM control unit N10 10 Electronic selector lever module N15 5 Heater AC operating unit N23 ESP control unit N47 5 Power steering control unit N68 Battery man...

Page 59: ...of the SAM control unit fuses 32 35 are on the back The SAM control unit is linked with the engine compartment CAN CAN C in order to exchange data It communicates with the following compo nents Instrument cluster ESP control unit Restraint systems control unit Heater AC operating unit Power steering control unit Yaw rate and lateral acceleration sensor Drivetrain control unit Steering angle sensor...

Page 60: ... conditioner 25 A White 9 Engine components brake system ESM 7 5 A Brown 10 Engine components electric expansion valve battery Coolant pump 1 and 2 15 A Blue 11 ESP control unit 25 A White 12 Left multifunction control lever functions switch panel functions data link connector mirror heater ATA rain sensor light sensor LHD only additional instruments central locking instrument cluster TPM USA only...

Page 61: ...ght multifunction control lever functions cabrio soft top operation 10 A Red 21 12 V socket cigarette lighter 15 A Blue 22 Left low beam 7 5 A Brown 23 Right low beam 7 5 A Brown 24 Brake lights except USA backup lamps USA only rear fog lamp except USA 15 A Blue 25 Right high beam 7 5 A Brown 26 Left high beam 7 5 A Brown 27 Engine components 7 5 A Brown 28 Rear window heater coupé 40 A Orange 29 ...

Page 62: ... A Brown R2 Brake lights USA only 7 5 A Brown R4 TPM USA only 7 5 A Brown R5 Engine components on board charger electric refrigerant compressor coolant pump power electronics electric drive motor on board charger high voltage PTC heater 10 A Red R6 Radio systems subwoofer standard sound soft top 15 A Blue R7 Interior lights 5 A Light brown beige R8 Premium sound amplifier 20 A Yellow R9 Heated sea...

Page 63: ...changeover relay K9 7 cooling fan stage 1 2 Circuit 15 30 stationary air conditioner relay K16 1 2 micro relays on one holder 12 V PTC heater booster relay K16 5 Relay for brake vacuum pump K109 Relay for brake vacuum pump K109 1 P54 15 3498 00 Relay arrangement K9 7 Fan stage switching changeover relay K16 1 Circuit 15 30 stationary air conditioner relay K16 5 12 V PTC heater booster relay K109 R...

Page 64: ...tmo spheric pressure Depending on the vehicle speed the drivetrain control unit actuates the brake booster vacuum pump directly via the relays A check valve integrated in the vacuum pump prevents the vacuum from being released when the pump is switched off i Note The number of operating hours of the vacuum pump must be determined using DAS at the following intervals Up to 4 years 125 000 km every ...

Page 65: ...y late by other road users particularly pedestrians For this reason a sound generator is offered as special equipment for the smart fortwo electric drive The sound generator is located at the front under the service flap and generates a speed depen dent noise at up to approx 30 km h The sound generator consists of a control unit an audio output stage and a speaker The sound generator is actuated b...

Page 66: ...as rotor position rpm and motor temperature are trans mitted to the power electronics control unit over another connector The direction of rotation of the electric drive motor is reversed for reverse travel In deceleration mode the electric drive motor operates as a generator regenerative braking In this case the voltage generated by the motor is fed to the high voltage on board electrical system ...

Page 67: ...he use of standard drive shafts Reverse gear The direction of rotation of the electric drive motor is reversed for reverse travel Selector lever The system is operated via the electronic selector lever module The mechanical park pawl is engaged in the trans mission in position P via a cable The drivetrain control unit reads in the status of the park pawl via the park pawl switch P26 60 2482 00 1 T...

Page 68: ...e to the greater vehicle weight modified springs are used at the front and rear axle On the front axle the crossmember for holding the supporting strut for the high voltage battery was modified P33 00 2122 00 1 Front axle crossmember 2 High voltage battery supporting strut P00 00 4820 00 Suspension and steering ...

Page 69: ... Rear tire Light alloy wheels cast aluminum Standard 4 5 Jx 15 H2 ET23 5 155 60 R15 74 T 5 5 Jx 15 H2 ET22 175 55 R15 77 T Spare wheel TIREFIT tire sealant Brake system Front axle Rear axle Brake type Disk brake 1 piston floating caliper Drum brake 2 piston simplex Disk diameter 280 mm Drum diameter 203 mm Disk thickness 9 7 mm Drum width 30 mm ...

Page 70: ...e can also be shut off electrically There is an additional electrical expansion valve battery on the chiller Drivetrain component cooling system Cooling of the drivetrain components is performed by a coolant circuit The following components are cooled Electric drive motor Power electronics control unit High voltage battery On board charger The cooling module consisting of a cooler coolant expansio...

Page 71: ...5 Electric drive motor M43 1 Coolant pump 1 feed M43 3 Coolant pump 2 return M46 Electric drive and on board charger coolant pump N83 On board charger 3kW N83 10 On board charger 22 kW with code 908 22 kW on board charger N129 1 Power electronics control unit R101 High voltage battery heater Y133 1 Drive system coolant pump switchover valve Y133 2 High voltage battery coolant pump switchover valve...

Page 72: ...pump 1 feed M43 3 Coolant pump 2 return M46 Electric drive and on board charger coolant pump N83 On board charger 3kW N83 10 On board charger 22 kW with code 908 22 kW on board charger N129 1 Power electronics control unit R101 High voltage battery heater Y19 1 Electric expansion valve interior Y19 3 Electric expansion valve battery Y133 1 Drive system coolant pump switchover valve Y133 2 High vol...

Page 73: ...oolant pump 2 return M46 Electric drive and on board charger coolant pump N83 On board charger 3kW N83 10 On board charger 22 kW with code 908 22 kW on board charger N129 1 Power electronics control unit R15 2 Fan control series resistor 2 stage R101 High voltage battery heater Y19 1 Electric expansion valve interior Y19 3 Electric expansion valve battery Y133 1 Drive system coolant pump switchove...

Page 74: ...a refrig erant coolant heat exchanger which is connected to the refrigerant circuit of the air conditioning and the cooling circuit of the high voltage battery The electric expansion valves of the chiller and of the evaporator for interior cooling can be actuated by the battery management system control unit The high voltage battery can thus be cooled independently of the interior climate control ...

Page 75: ...nt illumination set clock A1 Instrument cluster A1e1 Left turn signal indicator lamp A1e2 Right turn signal indicator lamp A1e3 High beam indicator lamp A1e7 Brake fluid and parking brake warning lamp A1e9 Seat belt warning lamp A1e15 Airbag indicator and warning lamp A1e17 ABS indicator lamp A1e18 Electric steering indicator lamp A1e41 ESP warning lamp A1e52 Rear fog light indicator lamp A1e54 Co...

Page 76: ... ECO indicator Time P54 33 2053 00 Multifunction display 1 Trip odometer pre conditioning ON 2 Total distance pre conditioning departure time 3 Gear indicator trip computer messages 4 Time 5 Outside temperature with black ice warning 6 Cruise control 7 Available power 8 ECO indicator 9 Remaining range Limp home mode The limp home function with power reduction is activated if one of the following e...

Page 77: ...etrain control unit via LIN EV The right additional instrument Powermeter shows the power flow of the high voltage battery and has the following functions Rest condition OFF Level of regenerative braking Charge Power use 0 100 P54 33 2051 00 Right additional instrument A15p6 High voltage battery energy flow The left additional instrument shows the high voltage battery state of charge SOC P54 33 20...

Page 78: ...58 00 2 HV battery reserve indicator A1p13 Multifunction display The remaining range is displayed on the multi function display down to a battery charge level of 10 P54 33 2157 00 1 Remaining range indicator A1p13 Multifunction display When the remaining charge level of the battery is 10 the text message HV battery reserve appears again After this Low Battery is displayed permanently on the multif...

Page 79: ...pplied with power by the high voltage adapter plate fuse box Air conditioning As on a smart with conventional drive system it is controlled via the heater AC operating unit The design of the system differs in the following aspects Electrically driven refrigerant compressor Thermostatic expansion valve on interior evaporator with electromagnetic shutoff function only with code V03 Battery cooling s...

Page 80: ...The control unit in the high voltage PTC heater activates the output stages in accordance with the requested heat output Cooling The drivetrain control unit communicates with the control unit in the electrically driven high voltage refrigerant compressor via LIN The control unit of the electric refrigerant compressor regulates the speed to the value set by the heater AC operating unit On vehicles ...

Page 81: ...high voltage PTC heater is switched on at interior temperatures below 18 C The heat output is adjusted so that an interior temperature of 18 C is reached 5 minutes before the programmed departure time The electric refrigerant compressor is switched on at interior temperatures above 24 C The cooling output is adjusted so that an interior temperature of 24 C is reached 5 minutes before the programme...

Page 82: ...d A High strength steels These areas consist of high strength micro alloyed steels Resistance spot welding can easily be carried out in these areas However metal active gas MAG welding can only be performed in approved areas B Soft deep drawing steels In these areas all the usual welding methods can be used P60 00 2875 00 Bodyshell material overview A High strength steels B Soft deep drawing steel...

Page 83: ... the area of the underfloor Underfloor paneling A continuous underfloor panel made of plastic is installed in the front area from the bumper up to the high voltage battery This has the effect for example of significantly reducing the ingress of dirt and corrosive materials P60 00 2945 00 1 High voltage battery supporting strut 2 Reinforcement for protection against side crashes ...

Page 84: ... frame damage electronic body measurement systems can be used for diag nostic purposes e g Contact CAR BENCH NAJA Celette Shark Blackhawk High voltage system If the vehicle suffers significant damage due to external force the high voltage system must be checked to determine whether it is deenergised Work on the vehicle may only be carried out by an Electrical specialist for HV systems in motor veh...

Page 85: ...ised by an Elec trical specialist for HV systems in motor vehicles series production vehicles i Note Airbag or emergency tensioning retractor units which have been dropped from a height of over 0 5 m must be replaced Do not allow airbag or emergency tensioning retractor units to come into contact with grease oil or cleaning agents To allow emergency tensioning retractor units to be installed witho...

Page 86: ...e fault memory must be read out and any faults present must be documented After repairs to the body or body connections e g suspension the steering angle sensor ESP must be reparameterized Welding Welding may only be performed on the vehicle after the high voltage battery has been deener gised The high voltage battery should be protected from the influence of thermal energy Before welding a voltag...

Page 87: ... of smart fortwo electric drive 3rd Generation Model Series 451 68 pin adapter cable P58 20 2388 00 Use For checking lines on drivetrain control unit MB number W 451 589 07 63 00 FG 54 Set B Note Only in combination with test box W 000 589 00 21 00 ...

Page 88: ...Controller Area Network CBS Customized Bodypanel System CP Control Pilot DAS Diagnosis Assistance System DC Direct Current DSL Digital Subscriber Line EPS Electronic Power Steering ESM Electronic selector lever module ESP Electronic Stability Program HV High Voltage HVIL High Voltage Interlock Loop LED Light Emitting Diode LIN Local Interconnect Network LHD Left Hand Drive LV Low Voltage MAG Metal...

Page 89: ...l Identification Number PLC Powerline Communication PLGW Powerline Gateway PP Proximity PTC Positive Temperature Coefficient PWM Pulse Width Modulation RFID Radio Frequency IDentification SAM Signal acquisition and actuation module SRS Supplemental Restraint System SOC State of Charge TPM Tire Pressure Monitor WIS Workshop Information System ...

Page 90: ...oltage battery supporting strut 67 High voltage components Check after an accident 23 Overview 20 Safety function after an accident 23 Wiring harness check 23 High voltage fuses 45 I Initial startup Form 51 Innovations 9 L Limp home mode 75 M Maintenance concept 14 Maintenance interval 14 Maintenance interval display 14 Maintenance points 15 Multifunction display 75 O Output reduction 75 P Park pa...

Page 91: ...ion of smart fortwo electric drive 3rd Generation Model Series 451 Annex T Topology of on board electrical system 21 Towing 16 Transport Notes on transport of high voltage batteries 26 U Underfloor 82 V Vehicle concept 8 ...

Page 92: ...Introduction of the smart fortwo electric drive 3rd generation Model series 451 smart A Daimler Brand www smart com ...

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SMART Fortwo 451 Series, Introduction Into Service Manual

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