SMART Fortwo 451 Series Introduction Into Service Manual
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SMART Fortwo 451 Series Introduction Into Service Manual

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Introduction of the smart fortwo electric drive (3rd generation)
Model series 451
Introduction into Service Manual

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Summary of Contents for SMART Fortwo 451 Series

  • Page 1 Introduction of the smart fortwo electric drive (3rd generation) Model series 451 Introduction into Service Manual...
  • Page 2 Introduction of the smart fortwo electric drive (3rd generation) Model series 451 Daimler AG · Technical Information and Workshop Equipment (GSP/OI) · D-70546 Stuttgart...
  • Page 3 Information and Copyright Product Portfolio You can also find comprehensive information on our complete product portfolio in our Internet portal: Link: http://aftersales.mercedes-benz.com Questions and Suggestions If you have any questions or suggestions concerning this product, please write to us. E-mail: customer.support@daimler.com Fax: +49-(0)18 05/0 10-79 78...

  • Page 4: Table Of Contents

    On-board charger Vehicle Homepage Charger feed-in socket Charging cable Regenerative braking Power electronics control unit High-voltage adapter plate fuse box Electric refrigerant compressor High-voltage PTC heater High-voltage interlock Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 5 Electric drive system Motor description Transmission Transmission description Chassis Axles and suspension Wheels, tires and brakes Cooling systems Cooling system overview Cooling system components High-voltage battery cooling system Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 6 Design Instrument cluster Additional instruments Climate control Body Notes on damage analysis Notes on supplemental restraint system Notes on repair operations Special tools Electrical system Annex Abbreviations Index Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 7 Notes Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 8: Preface

    February 2012 and may therefore differ from the information is available in the Workshop Information current production configuration. System (WIS) and in the Diagnosis Assistance System (DAS). Daimler AG Technical Information and Workshop Equipment (GSP/OI) Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 9: Overview

    Thanks to standardised charging components, the smart fortwo electric drive can be charged at any household power outlet or on public charging infrastructure. P00.00-4811-00 P00.00-4812-00 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 10 (pre-conditioning) exactly the same size as on a smart fortwo with combustion engine. P08.00-2027-00 Electric drive system of smart fortwo electric drive Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 11 14 High-voltage adapter plate fuse box 6 Transmission 15 Electric refrigerant compressor 7 Cooling module 16 Electric vehicle sound generator 8 Brake booster vacuum pump 9 Charger feed-in socket Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 12: Technical Data

    — — Dimensions Vehicle length 2695 Vehicle width 1559 Vehicle height 1565 Wheelbase 1867 Front track width 1283 Rear track width 1385 coupé cabrio USA 52 kW passion Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 13 (as per US Curb-Weight) Permissible gross vehicle 1150 1120 1020/1070 weight Maximum payload ECE /230 /200 /230 Maximum payload USA /180 /185 /215 Trunk capacity coupé cabrio USA 52 kW passion Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 14 Transmission – New single stage transmis- Modified single stage sion with integrated bevel transmission from smart gear differential fortwo with conventional drive system Transmission ratio – 9.922:1 9.77:1 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 15: Maintenance

    40,000 km. servicing at the following intervals: • Up to 4 years/125,000 km: every 2 years • After 4 years/125,000 km: annually Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 16 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: Desiccant cartridge High-voltage battery P54.10-3719-00 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 17: Towing

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

  • Page 18: Electrical System

    All electrical thus performs the task of the alternator on a lines conducting high voltages are marked by a vehicle with combustion engine. warning color (orange). P08.00-2008-00 Warning sticker Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 19 • Touch damaged orange-coloured lines or their damaged connectors • Touch damaged components of the high- voltage on-board electrical system. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 20 CAN bus. This shutoff of the high- output remains permanently deactivated and can voltage on-board electrical system is reversible. no longer be switched on by the battery manage- ment system control unit. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 21 N83/10 On-board charger 22 kW High-voltage battery (with code (908) 22 kW on-board charger) Electric drive motor N129/1 Power electronics control unit N33/5 High-voltage PTC heater X58/23 Charger feed-in socket Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 22 High-voltage battery Electric drive motor N33/5 High-voltage PTC heater 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 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 23 • Screw contacts must be tightened to the specified tightening torque and (if applicable) rotation angle Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 24 Repair of the high-voltage emergency tensioning retractors (stage 1) or components or lines is not permissible. the front airbags (stage 2) through simultaneous triggering of the pyrofuse. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 25: High-Voltage Battery

    High-voltage battery 2 12 V on-board electrical system connection N82/2 Battery management system control unit 3 Desiccant cartridge 4 Vent hose connection 5 High-voltage on-board electrical system connec- tion Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 26 If the high-voltage battery is fully discharged, by switching the ignition off and on in order to the drive system shuts off. move the vehicle a few metres outside of a possible hazard area. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 27 HV systems hazardous materials, hazardous substances and in motor vehicles (series production vehicles). packaging. Damaged high-voltage batteries may not be installed in a vehicle. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 28 (e.g. VdS CEA 4001), packaging must be distinction is made based on fire protection taken into account requirements: • Storage with sprinkler protection and • Storage without sprinkler protection Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 29 • Protection from access by unauthorised High-voltage batteries which are not safe for persons transport are stored in a leakproof metal container which is half-filled with vermiculite (non-combustible, absorbs escaping electrolyte). Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 30 The relevant MPC/general distributor will clarify the further procedure after consultation with the relevant product support team at GSP. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 31 Note The transport of high-voltage batteries which are not safe for transport via air is forbidden under any circumstances! Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 32: Charging Infrastructure

    The last selected value is retained on the multi- function display until the next change is made. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 33: On-Board Charger

    Onboard charger 3 kW Coolant circuit connections Charge socket high-voltage connection High-voltage on-board electrical system high-voltage connection 12 V on-board electrical syst./CAN connector On-board charger 3kW N83n1 Powerline Gateway Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 34 On-board charger Two different on-board chargers are used in the smart fortwo electric drive: On-board charger with 3 kW max. at 230 V On-board charger 22 kW with 3 x 400 V/32 A (standard) (with code (908) 22 kW on-board charger)
  • Page 35 If the customer already has a Powerline but at the lowest cost. networked installed, the vehicle can also be inte- Another functionality of Smart Charging is grated into this network. Plug&Charge. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 36 Star Diagnosis by a service employee. i Note Before installing the Plug&Charge certificate, it is necessary to ensure that the Plug&Charge certificate file has been decrypted by the customer with their password. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 37: Vehicle Homepage

    However, connection to the vehicle is only possible when the vehicle is connected to the Internet via an intelligent charging post or a Powerline socket adapter. P82.87-8524-00 Smartphone Application ("App") Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 38: Charger Feed-In Socket

    P54.10-3679-00 Control Pilot Phase L1 Phase L2 (22 kW on-board charger only) Phase L3 (22 kW on-board charger only) Neutral wire Protective Earth Proximity X58/23 Charger feed-in socket Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 39 Flashes green The high-voltage battery is X58/23 Charger feed-in socket being charged. Lights up green The high-voltage battery is fully charged. Flashes red A fault occurred during rapidly charging. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 40 Phase L1 Neutral wire Protective Earth Proximity Charging cable connector X58/23 Charger feed-in socket P54.10-3720-00 Control Pilot Phase L1 Neutral wire Protective Earth Proximity X58/23 Charger feed-in socket Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 41: Charging Cable

    In the stowage compartment of the liftgate i Note The mains plug of the charging cable must be plugged directly into a suitable power outlet. No extension cords may be used (increased line resistance). Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 42 (Control Pilot, CP). The charge connectors are locked at the vehicle end and the charging station end during the charging process. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 43: Regenerative Braking

    1. The level of regenerative braking is indicated on the right additional instrument Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 44: Power Electronics Control Unit

    P08.10-2052-00 Electric drive system Transmission F34/6 High-voltage adapter plate fuse box Electric drive motor N129/1 Power electronics control unit Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 45: High-Voltage Adapter Plate Fuse Box

    Electric drive motor power supply feed con- 3 Electric drive motor connector nector 4 High-voltage battery connector 5 High-voltage PTC heater connector F34/6 High-voltage adapter plate fuse box 6 Power electronics control unit connector Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 46 Electric refrigerant compressor fuse (40 A) Electric drive motor N33/5 High-voltage PTC heater 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 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 47: Electric Refrigerant Compressor

    P83.55-2216-00 High-voltage connection Pressure line Intake line 12 V on-board electrical system/LIN connector A9/6 Electric refrigerant compressor Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 48: High-Voltage Ptc Heater

    For better control, the surface area of the high- voltage PTC heater is divided into 4 independently controllable sections. P83.70-5432-00 Air conditioner housing High-voltage connection On-board electrical system/CAN connector N33/5 High-voltage PTC heater Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 49: High-Voltage Interlock

    • Interior/engine connector moved to position "P" with the vehicle at a stand- still or the vehicle key is turned to position "Off". Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 50 Battery management system control unit 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 Service Disconnect Interior/engine connector Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 51: Deenergisation

    P54.25-8975-00 Service Disconnect N10/10 SAM control unit Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 52 Deenergisation DAS form, power disable event log (extract) DAS form, initial startup log (extract) Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 53 Remove/install pedals Remove/install ESP control unit Remove/install ESP hydraulic unit Remove/install electric steering Remove/install high-voltage battery Remove/install vacuum pump Remove/install refrigerant compressor Remove/install high-voltage adapter plate fuse box Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 54 Remove/install rear-end door upper section (coupé) Remove/install rear-end door lower section Remove/install front exterior lights Remove/install rear exterior lights Remove/install wiper blades Remove/install charger feed-in socket (charge socket) Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 55 12 V battery Remove/install restraint systems Remove/install floor covering Remove/install instrument cluster Remove/install instrument panel Multifunction control lever Remove/install driver/passenger seat Remove/install interior high-voltage lines Remove/install air distribution box Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 56: Overall Network

    N83/10 On-board charger 22 kW Heater/AC operating unit (with code (908) 22 kW on-board charger) N127 Drivetrain control unit N129/1 Power electronics control unit X11/4 Data link connector Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 57 (V62) Rain sensor (car2go)) N10/10 SAM control unit LIN C Interior LIN 2 N15/5 Electronic selector lever module (with Code (V01) Anti-theft alarm system) Heater/AC operating unit Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 58: Diagnosis

    • Powerline Gateway control unit (N83n1) • On-board charger 22 kW (N83/10) (with code (908) 22 kW on-board charger) • Drivetrain control unit (N127) • Power electronics control unit (N129/1) Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 59: Sam Control Unit

    The SAM control unit communicates via LIN with • Microwave sensor (interior/ATA) • Rain sensor/light sensor • Alarm siren with inclination sensor P54.21-3283-00 P54.21-3284-00 Front of SAM control unit Back of SAM control unit Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 60 Rear windshield wiper (coupé only) 15 A Blue ESP control unit, EPS control unit, restraint system, Airbag 10 A On/Off indicator lamp, turn rate sensor, steering angle sensor Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 61 Electric power soft top (cabrio) 30 A Green Front radiator fan motor 40 A Orange Horn, central locking 20 A Yellow Ignition/starter switch 50 A ESP control unit 40 A Orange Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 62 Radio systems, subwoofer (standard sound), soft top 15 A Blue Interior lights Light brown/ beige Premium sound amplifier 20 A Yellow Heated seats control unit 25 A White Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 63 Fan stage switching changeover relay K109/1 Relay for brake vacuum pump (-) K16/1 Circuit 15/30 stationary air conditioner N10/10 SAM control unit relay K16/5 12 V PTC heater booster relay Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 64: Brake System

    P42.10-2902-00 B64/2 Brake vacuum sensor 1 K109 Relay for brake vacuum pump (+) B64/3 Brake vacuum sensor 2 Brake booster vacuum pump Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 65: Sound Generator

    The sound generator consists of a control unit, an audio output stage and a speaker. The sound P82.62-3826-00 generator is actuated by the drivetrain control H4/16 Electric vehicle sound generator unit via the CAN bus. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 66: Electric Drive System

    P08.10-2052-00 Electric drive system Transmission Electric drive motor F34/6 High-voltage adapter plate fuse box N129/1 Power electronics control unit Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 67: Transmission Description

    P26.60-2482-00 1 Transmission Electric drive motor 2 Park pawl N15/5 Electronic selector lever module 3 Park pawl cable S16/2 Park pawl switch Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 68: Axles And Suspension

    On the front axle, the crossmember for holding the supporting strut for the high-voltage battery was modified. P33.00-2122-00 Front axle crossmember High-voltage battery supporting strut P00.00-4820-00 Suspension and steering Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 69: Wheels, Tires And Brakes

    Disk brake Drum brake 1-piston floating caliper 2-piston simplex Disk diameter 280 mm — Drum diameter — 203 mm Disk thickness 9.7 mm — Drum width — 30 mm Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 70: Cooling System Overview

    The coolant fan motor can be operated in two stages. It is switched via the fan stage switching relay and fan control series resistor by the driv- etrain control unit. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 71 (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 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 72 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-voltage battery coolant pump switchover valve Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 73: Cooling System Components

    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-voltage battery coolant pump switchover valve Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 74: High-Voltage Battery Cooling System

    The high-voltage battery can thus be cooled independently of the interior climate control. P54.10-3703-00 High-voltage battery R101 High-voltage battery heater Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 75: Instrument Cluster

    A1e72 Drive system diagnosis indicator lamp A1e73 Drive system diagnosis warning lamp A1e74 High-voltage system warning lamp A1e75 12 V battery warning lamp A1p8 Electronic speedometer A1p13 Multifunction display Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 76 • The drive system diagnosis indicator lamp comes on in the instrument cluster. P54.33-2055-00 Instrument cluster A1e72 Drive system diagnosis indicator lamp Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 77: Additional Instruments

    A15p6 High-voltage battery energy flow The left additional instrument shows the high- voltage battery state of charge (SOC) P54.33-2052-00 Left additional instrument A15p7 High-voltage battery state of charge (SOC) indicator Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 78 As of 5% SOC, an warning tone sounds and the power display on the multifunction display starts to flash. P54.33-2159-00 "Low Battery" indicator A1p13 Multifunction display Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 79: Climate Control

    • Additional branch to chiller in refrigerant circuit (only with code (V03) Battery cooling system) P83.30-4835-00 1 Condenser A9/6 Electric refrigerant compressor 2 Expansion valve Heater/AC operating unit 3 Evaporator N33/5 High-voltage PTC heater Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 80 Cooling of the high-voltage battery is controlled by the battery management system control unit. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 81 The customer must set the air tion using a smartphone with corresponding distribution to the desired direction when the application ("App") or a PC. vehicle is parked. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 82: Body

    (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 High-strength steels Soft deep-drawing steels Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 83 This has the effect, for example, of significantly reducing the ingress of dirt and corrosive materials. P60.00-2945-00 High-voltage battery supporting strut Reinforcement for protection against side crashes Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 84: Notes On Damage Analysis

    When inspecting high-voltage components, personal protective equipment must always be • "Contact" (CAR BENCH) worn (safety glasses, electrical gloves etc.). • "NAJA" (Celette) • "Shark" (Blackhawk) Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 85: Notes On Supplemental Restraint System

    PVC protective hose. After installa- tion, these protective components can be removed. No sharp-edged tools may be used for removal to prevent damaging the belt strap. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 86: Notes On Repair Operations

    • Good ventilation must be provided before and must be reparameterized. during painting work. • A dry temperature (or object temperature) of 60 °C may not be exceeded. Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 87: Electrical System

    Use For checking lines on drivetrain control unit. P58.20-2388-00 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 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 88: Abbreviations

    High Voltage Interlock Loop Customized Bodypanel System Light Emitting Diode Control Pilot Local Interconnect Network Diagnosis Assistance System Left-Hand Drive Direct Current Low Voltage Digital Subscriber Line Metal Active Gas Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 89 Signal acquisition and actuation module Powerline Communication Supplemental Restraint System PLGW Powerline Gateway State of Charge Proximity Tire Pressure Monitor Positive Temperature Coefficient Workshop Information System Pulse Width Modulation Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...

  • Page 90: Index

    High-voltage fuses ....45 Smart Charging ....34 Storage of high-voltage batteries .
  • Page 91 Vehicle concept ....8 . . . 26 Notes on transport of high-voltage batteries Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451...
  • Page 92 - A Daimler Brand...

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