SMART Fortwo 451 Series Referenzhandbuch

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

smart - A Daimler Brandwww.smart.com

Daimler AG · Technical Information and Workshop Equipment (GSP/OI) · D-70546 Stuttgart

Introduction of the smart fortwo electric drive

(3rd generation)

Model series 451

Information and Copyright

Product Portfolio

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portfolio in our Internet portal:

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write to us.

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D-70546 Stuttgart

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Daimler AG, Department GSP/OIS, HPC R822, W002, D-70546 Stuttgart.

This applies in particular to reproduction, distribution, alteration,

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Image no. of title image: P00.01-4254-00

Image no. of poster P00.00-4839-00

Order no. of this publication 6519 3005 02 - HLI 000 000 07 65

03/12

Contents

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

Preface 7

Overall vehicle

Overview 8

Technical data 11

Maintenance 14

Towing 16

Electrical 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

Contents

4Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451

Deenergisation 50

Overall network 55

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

Contents

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

Notes

6Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451

Preface

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

Dear Reader,

This Introduction into Service Manual presents the

3rd generation of the smart fortwo electric drive of

model series 451.

The purpose of this brochure is to acquaint you with

the technical highlights of this new vehicle in

advance of its market launch. This brochure is

intended to provide information for people

employed in service or maintenance/repair as well

as for aftersales staff. It is assumed that the reader

is already familiar with the Mercedes-Benz and

smart model series currently on the market.

In terms of the contents, the emphasis in this Intro-

duction into Service Manual is on presenting new and

modified components and systems.

This Introduction into Service Manual is not

intended as an aid for repairs or 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 of

the smart fortwo electric drive in model series 451

and, as such, is not stored in WIS. The contents are

not maintained and there is no provision for

updates.

We will publicize modifications and new features in

the relevant WIS documents. The information

presented in this Introduction into Service Manual

may therefore differ from the more up-to-date

information found in WIS.

All information relating to technical data, equipment

and options is valid as of the copy deadline in

February 2012 and may therefore differ from the

current production configuration.

Daimler AG

Technical Information

and Workshop Equipment (GSP/OI)

Overview

Overall vehicle

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

Vehicle concept

The 3rd generation smart fortwo electric drive is

a series produced passenger car which is solely

of the smart fortwo electric drive is available in

right-hand and left-hand drive versions in the

coupé and cabrio models.

With a 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 to standardised charging components, the

smart fortwo electric drive can be charged at any

household power outlet or on public charging

infrastructure.

P00.00-4810-00

P00.00-4811-00

P00.00-4812-00

Overview

Overall vehicle

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

Innovations

• Water-cooled 3-phase AC motor with 35 kW

continuous output and 55 kW peak output

• Single stage transmission with integrated

bevel gear differential

• Water-cooled high-voltage battery (lithium-

ion battery) of the latest generation with high

energy density

• Charging of high-voltage battery through

regenerative braking

• Electrically powered refrigerant compressor

for interior and battery cooling

(only with code (V03) Battery cooling system)

• High-voltage PTC heater for interior heating

• Pre-heating/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 rotation for reverse

travel.

The high-voltage battery is installed between the

axles in the underfloor instead of a fuel tank. The

electric drive does not result in any space-

related limitations for the smart fortwo electric

drive; the interior compartment and trunk are

exactly the same size as on a smart fortwo with

combustion engine.

P08.00-2027-00

Electric drive system of smart fortwo electric drive

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