Introduction of the smart fortwo electric drive (3rd generation)

Model series 451

Introduction of the smart fortwo electric drive (3rd generation) - Model series 451

Introduction into Service Manual

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

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

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 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: [email protected]
Fax: +49-(0)18 05/0 10-79 78
or alternatively
Address: Daimler 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
systems, including databases and online services.

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

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 Contents

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

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

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

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

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

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 5
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 Notes

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

Dear Reader,
This Introduction into Service Manual presents the The content in WIS is updated. Therefore, the infor-
3rd generation of the smart fortwo electric drive of mation available there reflects the latest technical
model series 451. status of our vehicles.
The purpose of this brochure is to acquaint you with This Introduction into Service Manual presents
the technical highlights of this new vehicle in initial information relating to the 3rd generation of
advance of its market launch. This brochure is the smart fortwo electric drive in model series 451
intended to provide information for people and, as such, is not stored in WIS. The contents are
employed in service or maintenance/repair as well not maintained and there is no provision for
as for aftersales staff. It is assumed that the reader updates.
is already familiar with the Mercedes-Benz and
We will publicize modifications and new features in
smart model series currently on the market.
the relevant WIS documents. The information
In terms of the contents, the emphasis in this Intro- presented in this Introduction into Service Manual
duction into Service Manual is on presenting new and may therefore differ from the more up-to-date
modified components and systems. information found in WIS.
This Introduction into Service Manual is not All information relating to technical data, equipment
intended as an aid for repairs or for the diagnosis of and options is valid as of the copy deadline in
technical problems. For such needs, more extensive 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 7
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 Overall vehicle Overview

Vehicle concept

The 3rd generation smart fortwo electric drive is

a series produced passenger car which is solely
powered by electrical means. The 3rd generation
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 P00.00-4810-00

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.

P00.00-4811-00

P00.00-4812-00

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

Overall vehicle
Innovations

• Water-cooled 3-phase AC motor with 35 kW With a maximum torque of 130 Nm and acceleration
continuous output and 55 kW peak output boost, the powerful electric motor provides good
• Single stage transmission with integrated driving performance and responsiveness.
bevel gear differential
Due to the output characteristics of the electric
• Water-cooled high-voltage battery (lithium-
motor, the smart fortwo electric drive only
ion battery) of the latest generation with high
requires a single fixed transmission ratio. This
energy density
makes gearshifting unnecessary. The motor
• Charging of high-voltage battery through
changes its direction of rotation for reverse
regenerative braking
travel.
• Electrically powered refrigerant compressor
for interior and battery cooling The high-voltage battery is installed between the
(only with code (V03) Battery cooling system) axles in the underfloor instead of a fuel tank. The
• High-voltage PTC heater for interior heating electric drive does not result in any space-
• Pre-heating/cooling of interior compartment related limitations for the smart fortwo electric
(pre-conditioning) 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

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 9
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 Overall vehicle Overview

Model 451 Model Motor

smart fortwo electric drive coupé 451.390 780.993

smart fortwo electric drive cabrio 451.490 780.993

P00.00-4813-00
smart fortwo electric drive coupé

1 Electric motor 10 Drivetrain control unit

2 Power electronics control unit 11 High-voltage battery heat exchanger (chiller)
3 High-voltage battery 12 High-voltage battery heater
4 Battery management system control unit 13 Interior high-voltage PTC heater
5 On-board charger 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

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

Overall vehicle
Unit smart fortwo smart fortwo smart fortwo
electric drive electric drive 52 kW gasoline
engine
3rd generation 2nd generation mhd/passion
Performance

Maximum speed 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 width mm 1283

Rear track width mm 1385

1coupé 2cabrio 3
USA 52 kW passion

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 11
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 Overall vehicle Technical data

Unit smart fortwo smart fortwo smart fortwo

electric drive electric drive 52 kW gasoline
engine
3rd generation 2nd generation mhd/passion
Dimensions and weights

Curb weight kg 9001/9202 9001/9202 7501/7902

(as per DIN/EPA)

Curb weight kg 9501/9702 9451/9652 8351/8552

(as per US Curb-Weight)

Permissible gross vehicle kg 1150 1120 1020/10703

weight

Maximum payload ECE kg 2501/2302 2201/2002 2701/2302

Maximum payload USA kg 1901/1802 2051/1852 2351/2152

Trunk capacity l 220

1coupé 2cabrio 3
USA 52 kW passion

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

Overall vehicle
Unit smart fortwo smart fortwo
electric drive electric drive
3rd generation 2nd generation

High-voltage battery

Design – Lithium-ion battery

Max. output kW 63 30

Continuous output kW 42 20

Energy content kW/h 17.6 16.5

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- 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 13
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 Overall vehicle Maintenance

Maintenance concept Maintenance interval display

The maintenance concept mainly differs in terms The maintenance interval display is located in the
of the maintenance performed on the drive multifunction display of the instrument cluster.
system. In contrast to a vehicle driven by a The maintenance interval is displayed here in the
combustion engine, the electric drive is largely form of two wrench symbols.
maintenance free.
The remaining time is shown in days roughly one
In addition to a visual inspection for damage and month before a service date.
leaks as well as checking, refilling or replacing
The remaining distance is displayed as of
operating fluids and electronic battery testing,
1000 km.
only the desiccant cartridge of the high-voltage
battery has to be replaced. Service indicator:
° Service in XXX km
° Service in XX days

Maintenance interval

The maintenance interval for the smart fortwo

electric drive is specified as follows:

1 year or 20,000 km

i Note i Note
One special consideration is that the number of The desiccant cartridge in the high-voltage
operating hours of the brake booster vacuum battery module must be replaced every 2 years
pump must be checked using DAS as part of or every 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

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

Overall vehicle
Maintenance items at front

The following maintenance items are accessible

via the front service flap:
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

P54.10-3719-00

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 15
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 Overall vehicle Towing

Notes on towing a Warning

The vehicle can be towed at a maximum speed of If the vehicle is towed at a speed greater than
50 km/h for a distance of up to 50 km. 50 km/h, there is a risk that the electric drive or
high-voltage battery may overheat.
Prerequisite:
• Ignition "ON"
• Selector lever in position "N"
The vehicle must be loaded on to a suitable means
of transport if one of the following events occurs:
• One or more red warning lamps a Warning
(e.g. high-voltage battery, drive diagnosis,
12 V battery) lights up on the instrument If the instrument cluster display is not opera-
cluster tional (e.g. if 12 V battery is empty), the vehicle
• Increased or pulsating braking effect may not be towed!

If a fault in the high-voltage system is detected,

the message "Do not tow" is also shown on the
multifunction display.

16 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 On-board electrical system/power supply

Electrical system
The power supply in the smart fortwo electric Information on the high-voltage system
drive is provided via two separate on-board elec-
trical systems: General
• High-voltage on-board electrical system with The high-voltage system consists of several
high-voltage battery components. The individual components are
connected by high-voltage-carrying electrical
The high-voltage battery is charged via the on-
lines. The high-voltage on-board electrical
board charger when connected to an external
system is a fully insulated network. Neither the
power supply.
positive terminal nor the negative terminal are
In deceleration mode and when braking, the high- connected to the vehicle ground.
voltage battery is charged through regenerative
braking and the electric motor then operates as a
generator.
• 12 V on-board electrical system with 12 V
battery i Note
The 12 V on-board electrical system is supplied
Identification of high-voltage components
with power by a DC/DC converter in the power
and high-voltage lines
electronics control unit. The DC/DC converter
transforms the high direct voltage from the high- Every component of the high-voltage on-board
voltage on-board electrical system into 12 V electrical system installed in the vehicle is iden-
direct voltage. The power electronics control unit tified by a yellow warning sticker. 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 17
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 Electrical system On-board electrical system/power supply

a DANGER
Do not remove covers for components of the drive
Due to the high-voltage technology, electrical
system which are marked with a warning sticker.
lines and components which operate under high
Do not tamper with components or orange-
voltage are used in the vehicle. Accordingly,
coloured high-voltage cables of the drive system.
work on the vehicle may only be performed by
specially trained mechanics. When performing general work, e.g. changing
bulbs or checking the coolant level, ensure that
Special care must be taken at all areas of the
vehicle which are linked to the high-voltage • The ignition is switched off
system e.g. parts in the engine compartment. • The charging cable for charging the high-
Orange-coloured lines and their connectors voltage battery is not connected.
conduct high-voltage and may not be damaged.
You could be seriously or fatally injured if 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 of the high-
voltage on-board electrical system.

18 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 On-board electrical system/power supply

Electrical system
Shutting off the high-voltage on-board Accident
electrical system
In the event of an accident, the high-voltage on-
The high-voltage on-board electrical system must board electrical system can either be shut off by
be able to be shut off in an accident or for the high-voltage crash sensor control unit or the
servicing. For this purpose, the high voltage restraint system control unit.
output of the high-voltage battery can be discon-
nected from the high-voltage on-board electrical
Shutoff by restraint system control unit
system by contactors which are actuated by the
battery management system control unit. If the restraint system control unit triggers the
The pyrofuse and Service Disconnect plug are airbags in an accident, the pyrofuse in the control
connected in series in the control line of the line of the contactors is also triggered. The
contactors. control line is then physically disconnected. The
high-voltage output remains irreversibly deacti-
vated.

Shutoff by high-voltage crash sensor control

unit
i Note The high-voltage crash sensor control unit is
The procedure for deenergizing the system is located under the left-hand seat on the vehicle
described in the chapter "Deenergisation" as of floor. It shuts off the high-voltage on-board elec-
page 48. trical system in the following conditions:
• During charging: in the event of a stationary
crash
• During driving operation: in the event of a
rollover
The high-voltage on-board electrical system and
the high-voltage crash sensor control unit are
Service
also active during pre-conditioning on a parked
During servicing, the control line of the contac- vehicle. The high-voltage crash sensor control
tors is physically disconnected by disconnecting unit causes the battery management system
the Service Disconnect plug. The high-voltage control unit to shut off the contactors by means of
output remains permanently deactivated and can a signal on the CAN bus. This shutoff of the high-
no longer be switched on by the battery manage- voltage on-board electrical system is reversible.
ment system control unit.

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 19
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 Electrical system On-board electrical system/power supply

Overview of high-voltage components

The high-voltage on-board electrical system on

the smart fortwo electric drive consists of the
following high-voltage components:
• Electric 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 N83 On-board charger 3kW

F34/6 High-voltage adapter plate fuse box N83/10 On-board charger 22 kW
G5 High-voltage battery (with code (908) 22 kW on-board charger)
M5 Electric drive motor N129/1 Power electronics control unit
N33/5 High-voltage PTC heater X58/23 Charger feed-in socket

20 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 On-board electrical system/power supply

Electrical system
Topology of high-voltage/12 V on-board
electrical systems

P00.19-5200-00

A9/6 Electric refrigerant compressor HV High-voltage

F34/6 High-voltage adapter plate fuse box LV Low-voltage (12 V)
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

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 21
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 Electrical system On-board electrical system/power supply

General activities Working requirements

Repair, maintenance and diagnosis activities on When work is performed on a high-voltage system,
vehicles with high-voltage system may only be the system must be deenergized and the voltage-
performed by qualified staff (the minimum qualifi- free state of the high-voltage system must be
cation required is high-voltage awareness secured.
training).
This has to happen in accordance with 5 safety
Deenergization of the high-voltage system before rules as per DIN VDE 0105:
operations are carried out on the vehicle and
• Deenergize
subsequent initial startup after the operations
• Secure against reactivation
have been performed may only be carried out by
• Check deenergisation at all terminals
one and the same electrical specialist for high-
• Ground and short circuit
voltage systems in motor vehicles (series
• Cover or shield any adjacent current-
production vehicles). The following preconditions
conducting parts
must be met:
The following information must be observed and
• Successful completion of the high-voltage
complied with for operations on high-voltage
awareness course
systems:
• Successful completion of the high-voltage
qualification course • Testing equipment and aids must be checked
• Successful completion of the smart electric for proper condition before use
drive product training course • Cable lugs and contacts must be secured with
suitable protective bags and insulating caps
• Contacts, electrical lines and electrical
connectors must be checked for dirt and
damage before assembly and they must be
cleaned or replaced if necessary
• Screw contacts must be tightened to the
specified tightening torque and (if applicable)
rotation angle

22 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 On-board electrical system/power supply

Electrical system
Evaluation of high-voltage components Safety function after an accident:
High-voltage system shut off
Wiring harness check:
• Automatic shutoff of the high-voltage battery
If the chafe protection or the lines are damaged
and discharge of the high-voltage components
by external influences (e.g. animal bites), the
takes place via the high-voltage crash sensor
lines must be replaced immediately. Repair is not
control unit:
permissible.
- During charging: in the event of a stationary
Check after an accident: crash
The high-voltage system must be checked for - During driving operation: in the event of a
external damage and defects. If defects (e.g. loss rollover
of electrical insulation) or external damage is • Automatic shutoff takes place via the restraint
found on the high-voltage components or lines, system control unit after triggering of the
they must be replaced. 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 23
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 Electrical system High-voltage battery

The high-voltage battery is installed under the When fully charged, the high-voltage battery
passenger cell and consists of the following supplies an output voltage of approx. 391 V. The
components: high-voltage output can be disconnected from the
high-voltage on-board electrical system by
• 3 modules of lithium-ion cells of the latest
contactors actuated by the battery management
generation connected in series
system control unit. The high-voltage battery also
• Electronic modules for cell monitoring
supplies 12 V on-board electrical system with
• Battery management system control unit
power via the DC/DC converter in the power elec-
(N82/2)
tronics control unit.
• Contactors for disconnecting/connecting the
high voltage output
• High-voltage on-board electrical system
connection
• 12 V on-board electrical system connection
• Cooling system
• Coolant line connections i Note
• Desiccant cartridge
The high-voltage battery is locked in the
• Vent hose connection
delivery condition and has to be enabled through
initial startup in DAS.

P54.10-3680-00
High-voltage battery module

1 Coolant line connections G5 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

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 High-voltage battery

Electrical system
The permissible operating temperature of the In order to comply with the maximum permissible
high-voltage battery is -25 °C to +55 °C. air humidity level, a desiccant cartridge is
installed below the high-voltage connection at the
The service life of the high-voltage battery is
bottom right of the high-voltage battery.
reduced by high temperatures.
The high-voltage battery is thus cooled by a
coolant circuit under normal operating condi-
tions.
On vehicles with code (V03) Battery cooling
system there is also a heat exchanger with the
refrigerant of the air conditioning system
(chiller) in the coolant circuit of the high-voltage
battery.
The capacity of the high-voltage battery and thus
its power consumption characteristics drop off
heavily at low temperatures. As a result, 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.

i Note
The desiccant cartridge must be replaced every
2 years or every 40,000 km.

Discharged high-voltage battery i Note

If the high-voltage battery is fully discharged, The drive system can be briefly reactivated once
the drive system shuts off. by switching the ignition off and on in order to
move the vehicle a few metres outside of a
possible hazard area.

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 25
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 Electrical system High-voltage battery

Information on high-voltage battery General information on transport

If used according to specifications, the high- High-voltage batteries are hazardous goods and
voltage battery presents no danger. are classified as "UN 3480 Lithium-ion battery,
class 9, packaging group II" in accordance with
international hazardous goods regulations. High-
Information on safe handling voltage batteries may only be transported in
accordance with the applicable international and
• Risk of short circuit - Avoid physical damage national hazardous goods regulations for the
(pressure) respective mode of transport. Every high-voltage
• Risk of self-ignition battery must be checked for transport safety in
Thermal load (avoid the effect of heat/welding; the workshop. Defective or damaged high-voltage
painting work/force drying up to max. 60 °C) batteries must be classed as NOT safe for trans-
• Risk of injury due to the formation of port if following points apply to the transport:
poisonous and corrosive gases
• There is a possibility of dangerous exposure
• In addition to safety shoes, also wear personal
to heat
protective equipment as per the information in
• The high-voltage battery can cause fires or
the repair instructions.
short circuits
• Danger can occur in another way e.g. due to
the release of fluid electrolyte or dangerous
vapors.

i Note i Note
High-voltage batteries which are damaged Shipping must be carried out/arranged by a
during use or accident must be inspected and logistics employee who is trained to deal with
tested by an electrical specialist for 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.

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 High-voltage battery

Electrical system
Requirements for storage areas and Storage of high-voltage batteries which are
containers safe for transport in storage facilities with
sprinkler protection
Used or defective high-voltage batteries with
lithium-ion technology still contain a high level of When storing high-voltage batteries in storage
electrical and chemical energy in the form of areas with sprinkler protection1, the following
electrolytes. Since the condition of the battery is requirements must be taken into account:
no longer monitored by the internal battery
• They must be stored at a distance of 2.50 m
management system during storage, appropriate
from other stored materials. Alternatively a
precautionary measures must be taken.
partition wall made of non-combustible
The storage requirements depend on the condi- material can be installed. The partition wall
tion of the high-voltage battery as per the must be at least 1 m higher than the material
assessment protocol in WIS for evaluating trans- stored adjacent to it.
portability. • The maximum surface area of parts storage
areas is 75 m²
A distinction is made between:
• Maximum storage height 1.60 m, or
• Storage of high-voltage batteries which are • Storage in protected storage racks
safe for transport/undamaged (e.g. HHS 4 as per VdS CEA 4001)
• Storage of high-voltage batteries which are
not safe for transport/damaged
1 The ceiling sprinkler system must be designed as
and in the case of high-voltage batteries which
per the applicable sizing requirements for sprinkler
are safe for transport/undamaged, the following systems (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 27
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 Electrical system High-voltage battery

Storage of high-voltage batteries which are Handling and storage of high-voltage

safe for transport in storage facilities batteries which are not safe for transport
without sprinkler protection
High-voltage batteries which are damaged during
Due to fire protection requirements, if no sprin- operation or an accident may represent a hazard
kler protection system is installed, high-voltage to their surroundings depending on the level of
batteries should wherever possible always be damage. In the event of fire or smoke formation,
stored in specially partitioned fire-resistant the fire department must be informed immediately
rooms of category F90. Alternatively, individual and a safe distance must be maintained. If the risk
batteries can be stored in fire-resistant of acute danger can be ruled out, a high-voltage
hazardous goods cabinets of category F90 as long battery which has been diagnosed as not safe for
as no other materials are stored in them. If there transport may only be removed from a vehicle
is no appropriate facility in the building, the after consultation with the relevant MPC/general
batteries must be stored outside of the building at distributor and after provision of a special
a distance of more than 5 m from other buildings container.
or combustible materials. The following points
Until removal is carried out, the vehicle must,
must also be observed for storage outside the
where possible, be parked outside by a qualified
building:
employee of the technical field service (TAD) or a
• Presence of weather protection (roof) to qualified mechanic. It is important to ensure that
protect against wet weather or direct sunlight any electrolyte which escapes cannot enter the
• Liquid-resistant ground surface or collecting soil by parking the vehicle over an impermeable
pan floor/ground surface or a collecting pan.
• 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).

28 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 High-voltage battery

Electrical system
Various model-specific containers can be In this case, the following points must always be
ordered from the GLC for all high-voltage observed:
batteries. A container for storing the high-
• Presence of weather protection to protect
voltage battery from BR 451 can be ordered with
against wet weather or direct sunlight
part number Q451BOX207680 after consultation
• Liquid-resistant ground surface or collecting
with the MPC/general distributor.
pan
After removal and storage in the special • Protection from access by unauthorised
container, the high-voltage battery must be persons
stored in a marked storage location outside of the • Storage at a distance of > 5 m from buildings or
building until special transport approval is combustible materials
received.
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 29
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 Electrical system High-voltage battery

High-voltage batteries which are safe for High-voltage batteries which are not safe for
transport transport

High-voltage batteries which are safe for trans- A high-voltage battery is not safe for transport in
port may only be transported in original pack- the following circumstances:
aging and the high-voltage battery must be
• High-voltage battery is not diagnosis-capable
packed in the same way as it was delivered. The
• Insulation fault
following minimum requirements must be
• Status of contactors is "closed" (high-voltage
observed:
output energised)
• The high-voltage battery must be safeguarded
Visual inspection:
against external short circuits through the use
of insulating caps • Crack in housing
• All of the openings on the high-voltage • Housing deformed
battery, particularly the coolant connections, • Housing tarnished
must be sealed • Electrolyte leakage
• The high-voltage battery housing must be free • High-voltage contacts damaged
from soiling on the outside High-voltage batteries which are not safe for
All requirements with regard to flawless condition transport may only be transported via road or sea
of the packaging, sealing of the packaging, the with an exemption from the relevant national
identification of the packaging as per the relevant authority and where the conditions described in
dangerous goods regulations, as well as addi- the exemption are complied with in full.
tional requirements with regard to transport must
be observed.

i Note
Shipping must be carried out/arranged by a
logistics employee who is trained to deal with
hazardous materials, hazardous substances and
packaging.

i Note
The transport of high-voltage batteries which
are not safe for transport via air is forbidden
under any circumstances!

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

Electrical system
All components of the smart fortwo electric drive
which are involved in the charging process (on-
board charger, charge socket, charging cable)
have been standardised in line with future
requirements in accordance with international
standards (e.g. IEC62196-2). This allows for
simple charging on a wide range of power grids
and charging infrastructures.

Charging process:

The entire charging process is monitored. The The exact charging process and the various
on-board charger and the power source charging options are described in the current
(charging station) communicate via a data line in operating instructions.
the charging cable (Control Pilot, CP). In the
When the connector of the charging cable is
process, the signals "ready", "not ready" and
plugged into the charger feed-in socket, the on-
"charge" are transmitted. In the case of intelli-
board charger wakes the control units involved in
gent charging stations, digital communication
the charging process via CAN bus.
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 charging current can
therefore be set via the control box on the
charging cable or alternatively via the multifunc-
tion display in the vehicle.
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 31
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 Electrical system On-board charger

The on-board charger is located between the Connections:

drive unit and the rear end panel and converts the
• High-voltage output (direct voltage)
alternating current of an external power supply
• High-voltage input (AC voltage)
into direct current for charging the high voltage
• 12 V on-board electrical system
battery. Integrated in the on-board charger is
• Control system (CAN)
the Powerline Gateway, which is required for
• Coolant lines
"Smart Charging".
As soon as an external power supply is connected
with a charging cable, the on-board charger
communicates with the control box in the charging Since the maximum possible charging current
cable/charging station over a discrete control depends on the charging cable or is determined
line (Control Pilot). Here, the output data of the by the charging station, the smart fortwo electric
charging infrastructure is transmitted and the drive with both versions of the on-board charger
power consumption of the on-board charger is can be charged both at a household power outlet
adjusted accordingly. Only then does the on- or at a public charging station or wallbox (Smart
board charger initiate the charging process. In Charging).
the case of intelligent charging stations, addi-
tional communication takes place via the Power- The control unit of the on-board charger commu-
line Gateway on phase L1 and the neutral wire N. nicates with the battery management system
control unit and the drivetrain control unit over a
CAN connection.

P54.10-3681-00
Onboard charger 3 kW

1 Coolant circuit connections

2 Charge socket high-voltage connection
3 High-voltage on-board electrical system
high-voltage connection
4 12 V on-board electrical syst./CAN connector

N83 On-board charger 3kW

N83n1 Powerline Gateway

32 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 On-board charger

Electrical system
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)

Input: 100 to 240 VAC Input: 3 x 400 VAC

Output: Approx. 380 VDC Output: Approx. 380 VDC
Charging duration at 13 A Charging duration:
(e.g. household power outlet):
1h (0-100% SOC) at +25 °C
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

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 33
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 Electrical system On-board charger

Powerline Gateway (PLGW) i Note

The Powerline Gateway is integrated in the on- Powerline Communication (PLC) is a generic term
board charger for communication via the power for the transmission of data over power lines.
lines (PLC - Powerline Communication). This can Here, current-conducting lines are used simul-
connect the vehicle both to an intelligent taneously both for power supply purposes and
charging station and to the Daimler Vehicle for data transfer.
Backend (via Internet). PLC as per the Homeplug
AV-Standard is used here. Communicationtakes
place via phase L1 and the neutral wire N.
The Powerline Gateway can establish a connection
to the Daimler Vehicle Backend and provide
vehicle data for the Vehicle Homepage. To do so,
the vehicle must be connected to the Internet via
Powerline Communication.
The customer requires a commercially available Smart Charging
Powerline socket adapter based on the "Home-
Plug AV" standard for this purpose. This must be The PLGW is used to integrate the smart fortwo elec-
equipped with an encryption button in order to be tric drive into intelligent charging infrastructure.
able to configure it for communication with the This means that the charging process of the vehicle
vehicle. The adapter is connected to the power is adjusted to the power quantity available in the
grid and the Internet connection of the customer grid e.g. in order to make optimal use of power from
e.g. by connection to their DSL router. renewable sources.
Configuration of the PLGW is initiated by entering For this purpose, information about the power quan-
the appropriate information on the instrument tity available and its cost is transmitted to the
cluster and completed by pressing the encryption vehicle via the charging cable. A charging profile is
button on the Powerline socket adapter. created based on this data, which ensures that the
battery is fully charged by the set departure time
If the customer already has a Powerline
but at the lowest cost.
networked installed, the vehicle can also be inte-
grated into this network. Another functionality of Smart Charging is
Plug&Charge.

34 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 On-board charger

Electrical system
Plug&Charge Two other electronic certificates are installed in
the vehicle ex factory:
Plug&Charge refers to the automatic authentica-
• Root certificate
tion of a vehicle when the charging cable is
• Provisioning certificate
plugged into an intelligent charging station.
An electronic certificate is stored in the PLGW for The certificates can be updated in the workshop
this purpose. This means that the customer does using Star Diagnosis if they become invalid or
not require any additional authentication via PIN, require an update.
RFID card etc. The root certificate applies across different
When the vehicle is connected to an intelligent power suppliers and is required in order to check
charging station, the vehicle is recognised and a public charging station for "authenticity". This
invoicing by the power supplier takes place auto- prevents communication with unauthorised part-
matically. ners.
The owner of the vehicle receives the electronic The vehicle-specific provisioning certificate
certificate (Plug&Charge certificate) from their contains an individual identification number
power supply when the contract is signed. (PCID). The vehicle owner needs this PCID in
There are two ways of installing the certificate in order to be able to conclude a Plug&Charge power
the vehicle: supply contract. It is handed out to the customer
when the vehicle is handed over.
• Via the smart Vehicle Homepage
(connected services) If necessary, the workshop can print out this PCID
• Via diagnosis service in the workshop: the for the customer at any time (e.g. in the event of
vehicle owner brings the Plug&Charge loss or change of owner).
certificate + personal password to the
workshop 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.

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 35
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 Electrical system Vehicle Homepage

Data transfer via the Powerline Gateway makes the

"Vehicle Homepage" function possible. The
vehicle must be connected to the Internet via an
intelligent charging post or a Powerline socket
adapter for this purpose.
The Vehicle Homepage allows various functions of
the vehicle to be remotely controlled using a
modern smartphone or PC. For example, pre-
conditioning can be activated remotely or a new
departure time can be set.
It is also possible to query the current 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 create an account.

P82.87-8523-00
Vehicle Homepage

i Note
The Vehicle Homepage can be accessed at any
time using a smartphone or PC with the corre-
sponding access authorisation.
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")

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 Charger feed-in socket

Electrical system
The charger feed-in socket (charge socket) is
located on the right rear B-pillar under a flap.
The socket is fitted with a folding protective
cover. Different versions are installed depending
on the national version of the vehicle (ECE,
USA/Canada).

ECE version

The 7-pin socket has 5 high-voltage contacts (L1,

L2, L3, N and PE) for the alternating voltage feed
and 2 signal contacts for Control Pilot (CP) and
Proximity (PP). The CP contact is used for data P54.10-3678-00

exchange with the charging station and the PP

contact allows the vehicle to detect when the 1 Tank cap
charging cable is plugged in. On vehicles with the 2 Protective cap release
3 Charger feed-in socket protective cap
3 kW on-board charger, only high-voltage
4 Charging cable inserted indicator lamp
contacts L1, N and PE are used. There are 2 indi- 5 Charging status indicator lamp
cator lamps above the socket which indicate X58/23 Charger feed-in socket
locking of the charging connector and the status
of the charging process.

P54.10-3679-00

CP Control Pilot
L1 Phase L1
L2 Phase L2 (22 kW on-board charger only)
L3 Phase L3 (22 kW on-board charger only)
N Neutral wire
PE Protective Earth
PP Proximity
X58/23 Charger feed-in socket

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 37
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 Electrical system 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.

P54.10-3721-00
Block diagram Indicator lamp #
1 Locking status
2 Lock Flashes orange The connection between the
3 Release vehicle and power supply is
4 Temperature sensor being established before
5 Charging cable indicator lamp
6 Charging status indicator lamp
charging.
7 Ground

CP Control Pilot
L1 Phase L1
L2 Phase L2 (22 kW on-board charger only)
Lights up The vehicle is ready for
L3 Phase L3 (22 kW on-board charger only) orange charging.
N Neutral wire
PE Protective Earth
PP Proximity
S Charging cable connector 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.

38 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 Charger feed-in socket

Electrical system
USA/Canada

The 5-pin socket has 3 high-voltage contacts for

the alternating voltage feed and 2 signal contacts
for CP and Proximity.
The CP contact 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
PE Protective Earth
PP Proximity
X58/23 Charger feed-in socket

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 39
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 Electrical system Charging cable

Depending on the on-board charger installed,

different country-specific charging cable
versions are available:
Charging cable for charging at a household power
outlet (standard with on-board charger 3 kW)
A 7-pin charge coupling (ECE) as per IEC62196-2
is installed at the vehicle end and a country-
specific grounding contact plug is installed at the
power outlet end, e.g. Schuko, BS 1363. Monitoring
and communication with the on-board charger
takes place via a control box in the charging P54.10-3715-00

cable. When the mains plug is plugged in, the Charging cable, stowage compartment in liftgate
control box checks whether mains voltage and the
1 Mains plug
protective earth conductor are present and 2 Charge coupling, 7-pin
transmits the available charging current to the 3 Cable
on-board charger via the CP contact. 4 Control box
In order to avoid overload situations, the 5 Liftgate stowage compartment
charging current can be adjusted to the
circumstances of the local power grid using a
The charging cable can be stowed in the vehicle as
button on the control box of the charging cable.
follows:
The charging connector is locked at the vehicle
end during the charging process. • cabrio:
In a box, which is available as an accessory, or in
the stowage compartment in the liftgate if the
space is available. In this case, the side supports
of the soft top system cannot be stowed there.
• coupé:
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).

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

Electrical system
When the charging connector is connected to the
power outlet, this is shown on the multifunction
display with a connector symbol.
In addition, the charging progress (bar indicator)
and the expected charging duration are displayed
in the ignition key position "Circuit 15 On".

P54.33-2145-00
A1p13 Multifunction 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 the on-board charger and the
charging station via a data line in the charging
cable (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 41
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 Electrical system Regenerative braking

In deceleration mode and when braking, the high-

voltage battery is charged through regenerative
braking and the electric motor then operates as a
generator.

Regenerative braking in deceleration mode: Regenerative braking:

During regenerative braking in deceleration If the brake pedal is actuated, the regenerative
mode, the vehicle is braked in a similar way to a braking level is increased further.
vehicle with 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-
eration is higher than in stage 1.
The level of regenerative braking is indicated on
the right additional instrument

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 Power electronics control unit

Electrical system
The power electronics control unit is installed on DC/DC converter
the electric drive motor and is connected directly
to the high-voltage adapter plate fuse box and the The DC/DC converter in the power electronics
coolant circuit. It has the following tasks: control unit generates the 12 V direct voltage for
the 12 V on-board electrical system from the
Power supply and control of electric drive direct voltage of the high-voltage battery.
motor It charges the 12 V battery directly and thus
performs the function of the alternator on a
The inverter in the power electronics control unit vehicle with combustion engine.
generates the 3-phase alternating voltage for
operating the electric motor from the direct
voltage of the high-voltage battery. In the
process, the power electronics control 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.

P08.10-2052-00

Electric drive system

1 Transmission F34/6 High-voltage adapter plate fuse box
M5 Electric drive motor
N129/1 Power electronics control unit

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 Electrical system High-voltage adapter plate fuse box

The high-voltage adapter plate fuse box is There are three fuses in the high-voltage adapter
installed on the power electronics control unit plate fuse box to protect the high-voltage on-
above the electric motor. The adapter plate board electrical system. The high-voltage fuses
serves as a connecting element between the high- are not accessible and thus not exchangeable.
voltage lines and the power electronics control
unit.
It supplies high-voltage electrical consumers
from a central location and protects the corre-
sponding line cross-sections to the on-board
charger, the high-voltage PTC heater and the
electric refrigerant compressor with high-
voltage fuses.

P54.10-3684-00

1 Electric refrigerant compressor connector 7 High-voltage interlock connector

2 On-board charger connector 8 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

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 High-voltage adapter plate fuse box

Electrical system
P54.15-3497-00

Block diagram of high-voltage fuses

1 High-voltage PTC heater fuse (40 A) A9/6 Electric refrigerant compressor

2 3 kW on-board charger fuse (40 A) or F34/6 High-voltage adapter plate fuse box
22 kW on-board charger fuse (100 A) G5 High-voltage battery
3 Electric refrigerant compressor fuse (40 A) 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

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 45
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 Electrical system Electric refrigerant compressor

The drive system for the refrigerant compressor The electric refrigerant compressor is a high-
has to be kept separate from the drive motor so voltage component and contains an inverter for
that sufficient cooling output can be provided powering a spiral compressor, which is driven by
when the vehicle and the electric motor are an electric motor, as well as an integrated control
stationary. This ensures that the high-voltage unit. The control unit of the electric refrigerant
battery can be cooled independently and climate compressor regulates the speed of the electric
control for the vehicle interior can operate inde- motor to the value set by the heater/AC operating
pendently. This is achieved by means of an elec- unit. The control unit communicates with the driv-
trically driven refrigerant compressor. etrain control unit via LIN. This only acts as a
router for the CAN signals from the heater/AC
operating unit in this case.
On vehicles with code (V03) Battery cooling
system, the electric motor is also regulated
depending on the cooling output request of the
high-voltage battery.

P83.55-2216-00

1 High-voltage connection
2 Pressure line
3 Intake line
4 12 V on-board electrical system/LIN connector
A9/6 Electric refrigerant compressor

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 High-voltage PTC heater

Electrical system
The high-voltage PTC heater consists of a heating The control unit of the high-voltage PTC heater
element with PTC ceramic modules, corrugated receives the output request for the individual PTC
fins and a control unit with control electronics. In sections from the drivetrain control unit and
the PTC ceramic modules, the regulated current actuates the individual output stages of the power
from the control electronics is converted into electronics via PWM signals.
heat. Aluminium fins are in direct contact with the
In order to maintain a uniform load on the on-
PTC ceramic modules and transfer the heat to the
board electrical system, the stages are operated
air.
with a PWM offset.
For better control, the surface area of the high-
voltage PTC heater is divided into 4 independently
controllable sections.

P83.70-5432-00

1 Air conditioner housing

2 High-voltage connection
3 On-board electrical system/CAN connector
N33/5 High-voltage PTC heater

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 Electrical system High-voltage interlock

The interlock loop is used to protect people from If the signal loop is interrupted, e.g. by discon-
faults in the high-voltage on-board electrical necting a high-voltage or 12 V connector, this
system. The interlock loop detects an open causes the contactors in the high-voltage battery
connector circuit in the high-voltage on-board module to open and the high-voltage on-board
electrical system. electrical system to shut down. Since capacitors
are also present in the high-voltage components,
The interlock signal is generated in the battery
the high-voltage on-board electrical system is
management system control unit and passes in a
not immediately rendered voltage-free once the
loop via the following components:
contactor is opened. For this reason, an active
• High-voltage battery discharge function is incorporated in the high-
• On-board charger voltage components. This discharges the high-
• High-voltage PTC heater voltage on-board electrical system to voltages
• Electric refrigerant compressor below 60 V in less than 5 s.
• Power electronics control unit
If the interlock signal is interrupted during
• High-voltage adapter plate fuse box
driving operation, the high-voltage on-board
• Electric drive motor
electrical system is only shut off the next time the
• Service Disconnect
vehicle is stopped when the selector lever is
• Interior/engine connector
moved to position "P" with the vehicle at a stand-
still or the vehicle key is turned to position "Off".

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 High-voltage interlock

Electrical system
Topology of high-voltage interlock

P00.19-5199-00

A9/6 Electric refrigerant compressor HV High-voltage

F34/6 High-voltage adapter plate fuse box LV Low-voltage (12 V)
F19 Pyrofuse HVIL High-voltage interlock loop
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

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 49
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 Electrical system Deenergisation

To allow repair and service operations to be The high-voltage on-board electrical system is
performed without any risk of electric shock, the deenergised via vehicle diagnosis (DAS). Pulling
high-voltage on-board electrical system must be out the Service Disconnect plug underneath the
deenergized and protected against reactivation. instrument panel in the left footwell physically
interrupts the actuation of the contactors of the
The deenergization and restart must be docu-
high-voltage battery. The empty slot is protected
mented in a vehicle power disable event log and
against reinsertion by a lock.
vehicle initial startup log. The logs must be stored
with the vehicle repair documents.

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 should be performed.
All high-voltage relevant repairs and mainte-
nance operations should be designed as sepa-
rate procedures so that the vehicle is not put in
a condition which could affect restarting of the
high-voltage on-board electrical system
because multiple operations are in progress
simultaneously.
P54.25-8975-00

S7 Service Disconnect
N10/10 SAM control unit

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

Electrical system

DAS form, power disable event log (extract)

DAS form, initial startup log (extract)

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 51
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 Electrical system Deenergisation

Deenergisation matrix for operations where deenergisation is required

Yes No

Underside of vehicle

Remove/install electric motor with power electronics X

Remove/install transmission 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/install refrigerant compressor X

Remove/install high-voltage adapter plate fuse box X

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

Electrical system
Yes No

Underside of vehicle

Remove/install on-board charger X

High-voltage lines X

Remove/install 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 X

(charge socket)

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 53
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 Electrical system Deenergisation

Yes No

Wheels, brakes

Remove/install wheels/tires X

Remove/install 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

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

Electrical system
P00.19-5201-00

Overall network (ECE version)

A1 Instrument cluster N33/5 High-voltage PTC heater

A9/6 Electric refrigerant compressor N47-5 ESP control unit
B24/15 Yaw rate and lateral acceleration sensor N49 Steering angle sensor
H4/16 Electric vehicle sound generator N68 Power steering control unit
N2/1 High-voltage crash sensor control unit N82/2 Battery management system control unit
N2/7 Restraint systems control unit N83 On-board charger 3kW
N10/10 SAM control unit N83n1 Powerline Gateway control unit
N15/5 Electronic selector lever module N83/10 On-board charger 22 kW
N23 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 55
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 Electrical system Overall network

P00.19-5204-00

Block diagram of overall network (ECE version)

A1 Instrument cluster N33/5 High-voltage PTC heater
A15p6 High-voltage battery power flow N47-5 ESP control unit
A15p7 High-voltage battery state of charge (SOC) N49 Steering angle sensor
indicator N68 Power steering control unit
A9/6 Electric refrigerant compressor N82/2 Battery management system control unit
B24/15 Yaw rate and lateral acceleration sensor N83 On-board charger 3kW
B32 Microwave sensor N83n1 Powerline Gateway control unit
(with code (V01) Anti-theft alarm system) N83/10 On-board charger 22 kW
B38 Rain sensor/light sensor (with code (908) 22 kW on-board charger)
(with code (V54) Rain sensor/light sensor or N127 Drivetrain control unit
code (V62) Rain sensor (car2go)) N129/1 Power electronics control unit
B95 Battery sensor X11/4 Data link connector
H3/2 Alarm siren with inclination sensor
(with code (V01) Anti-theft alarm system) CAN C Engine compartment CAN
H4/16 Electric vehicle sound generator CAN V Electric vehicle CAN
M46 Electric drive and on-board charger LIN EV Electric vehicle LIN
coolant pump LIN B Interior LIN 1
N2/1 High-voltage crash sensor control unit (with code (V54) Rain sensor/light sensor or
N2/7 Restraint systems control unit code (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)
N23 Heater/AC operating unit

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

Electrical system
General

The network architecture allows external access

to the individual control units of the CAN bus
systems.
The vehicle and all of its equipment features can
be identified using Star Diagnosis. This enables
accurate fault evaluation and rectification and the
analysis of vehicle-specific values and parame-
ters.

Diagnosis Assistance System (DAS)

The data link connector (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)
P54.22-2062-00
• Power steering control unit (N68)
X11/4 Data link connector
• Battery management system control unit
(N82/2)
• On-board charger 3 kW (N83)
• 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 57
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 Electrical system SAM control unit

All fuses are housed on the SAM control unit. The SAM control unit is linked with the engine
compartment CAN (CAN C) in order to exchange
Exceptions:
data. It communicates with the following compo-
• In the high-voltage adapter plate fuse box: nents:
- High-voltage fuses
• Instrument cluster
• Fuse holder in battery recess (12 V battery):
• ESP control unit
- F 10/1 (40 A) Vacuum pump fuse
• Restraint systems control unit
- F 10/3 (60 A) High-voltage battery heater
• Heater/AC operating unit
fuse
• Power steering control unit
• In circuit 30 line to SAM:
• Yaw rate and lateral acceleration sensor
- F 91 (125 A) SAM prefuse
• Drivetrain control unit
Fuses 1-31 and reserve fuses R1-R9 are located • Steering angle sensor
on the front of the • Vehicle diagnosis/DAS datalink connector
SAM control unit, fuses 32-35 are on the back.
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

58 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 SAM control unit

Electrical system
Fuse assignment

Fuse Designation Amps Color

2 Front windshield wipers 25 A White

3 Power windows 20 A Yellow

4 Engine components, interior blower motor 25 A White

5 LED daytime running lights, front fog lamps 10 A Red

6 Right standing light/taillight, license plate illumination 7.5 A Brown

7 Left standing light/taillight 7.5 A Brown

8 Engine components, stationary air conditioner 25 A White

9 Engine components, brake system, ESM 7.5 A Brown

10 Engine components, electric expansion valve (battery) 15 A Blue

Coolant pump 1 and 2

11 ESP control unit 25 A White

12 Left multifunction control lever functions, switch panel 10 A Red

functions, data link connector, mirror heater, ATA, rain
sensor/light sensor (LHD only), additional instruments,
central locking, instrument cluster, TPM (USA only),
brake/turn signal light switching (USA only)

15 Electric drive safety circuit, pyrofuse 15 A Blue

17 Rear windshield wiper (coupé only) 15 A Blue

18 ESP control unit, EPS control unit, restraint system, Airbag 10 A Red
On/Off indicator lamp, turn rate sensor, steering angle
sensor

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 59
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 Electrical system SAM control unit

Fuse assignment

Fuse Designation Amps Color

19 Drivetrain control unit, TPM control unit (USA only), data link 7.5 A Brown
connector, drive components

20 Heater/AC operating unit, outside mirror adjustment, washer 10 A Red

fluid pump, radio systems, seat heaters, backup lamp (except
USA), right multifunction control lever functions, cabrio soft
top operation

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), 15 A Blue

rear fog lamp (except USA)

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 Electric power soft top (cabrio) 30 A Green

30 Front radiator fan motor 40 A Orange

31 Horn, central locking 20 A Yellow

33 Ignition/starter switch 50 A Red

34 ESP control unit 40 A Orange

60 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 SAM control unit

Electrical system
Fuse assignment

Fuse Designation Amps Color

35 EPS control unit (power steering) 30 A Green

R1 Mirror heater 7.5 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 10 A Red

compressor, coolant pump (power electronics/electric drive
motor/on-board charger), high-voltage PTC heater

R6 Radio systems, subwoofer (standard sound), soft top 15 A Blue

R7 Interior lights 5A Light

brown/
beige
R8 Premium sound amplifier 20 A Yellow

R9 Heated seats control unit 25 A White

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 61
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 Electrical system SAM control unit

Relays

The following relays for the smart fortwo electric

drive are located on the SAM and in relay holders
on branch-off lines of the wiring harness:
• Fan stage switching 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
K109 Relay for brake vacuum pump (+)
K9/7 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

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

Electrical system
General

The brake system is largely the same as the brake A check valve integrated in the vacuum pump,
system of the smart fortwo with combustion prevents the vacuum from being released when
engine in terms of its design and operation. the pump is switched off.
A new feature is the electric vacuum pump, which
is actuated by the drivetrain control unit.
Using two redundant differential pressure
sensors in the vacuum line, the drivetrain control i Note
unit measures the pressure differential between The number of operating hours of the vacuum
the vacuum in the vacuum line and the atmo- pump must be determined using DAS at the
spheric pressure. Depending on the vehicle following intervals:
speed, the drivetrain control unit actuates the
brake booster vacuum pump directly via the • Up to 4 years/125,000 km: every 2 years
relays. • After 4 years/125,000 km: annually
The brake booster vacuum pump must be
replaced after 1200 operating hours. If replace-
ment is required, this is indicated by the driv-
etrain control unit.

P42.10-2902-00

B64/2 Brake vacuum sensor 1 K109 Relay for brake vacuum pump (+)
B64/3 Brake vacuum sensor 2 M57 Brake booster vacuum pump

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 63
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 Electrical system Sound generator

Since the electric drive system of the smart

fortwo electric drive is very quiet, especially at
low speeds, there is a risk that the vehicle may not
be noticed or may only be noticed very 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 P82.62-3826-00

generator is actuated by the drivetrain control

unit via the CAN bus. H4/16 Electric vehicle sound generator

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

Electric drive system

The smart fortwo electric drive is driven by a The direction of rotation of the electric drive
permanently energized 3-phase AC motor with motor is reversed for reverse travel.
35 kW continuous output and 55 kW peak output.
In deceleration mode, the electric drive motor
An inverter in the power electronics control unit operates as a generator (regenerative braking).
converts the direct voltage of the high-voltage In this case, the voltage generated by the motor is
battery into 3-phase alternating voltage for fed to the high-voltage on-board electrical
operating the electric motor. The rpm of the system via the power electronics control unit.
motor is determined by the frequency and the
The efficiency of the power electronics and elec-
torque via the PWM duty cycle of the AC voltage.
tric motor depends on the operating temperature.
The power electronics control unit is connected
The power electronics control unit and electric
directly to the high-voltage adapter plate fuse
drive motor are cooled by a coolant circuit. At a
box. The electric motor is connected to the high-
coolant temperature between 80 °C and 90 °C,
voltage adapter plate fuse box via 3 high-voltage
measured by the power electronics control unit,
lines. The operating parameters such as rotor
the output is reduced by the power electronics
position, rpm and motor temperature are trans-
control unit down to 0 kW on a linear basis.
mitted to the power electronics control unit over
another connector.

P08.10-2052-00

Electric drive system

1 Transmission M5 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 65
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 Transmission Transmission description

The smart fortwo electric drive uses a newly Selector lever

developed single stage transmission with bevel
gear differential and park pawl. The system is operated via the electronic selector
lever module.
The drive system has a permanent gear ratio of
9.922:1. The new transmission allows the use of The mechanical park pawl is engaged in the trans-
standard drive shafts. mission in position "P" via a cable.
Reverse gear: The drivetrain control unit reads in the status of
the park pawl via the park pawl switch.
The direction of rotation of the electric drive
motor is reversed for reverse travel.

P26.60-2482-00

1 Transmission M5 Electric drive motor

2 Park pawl N15/5 Electronic selector lever module
3 Park pawl cable S16/2 Park pawl switch

66 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 Axles and suspension

Chassis
Due 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

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 67
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 Chassis Wheels, tires and brakes

Front wheel Front tire Rear wheel 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 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

68 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 Cooling system overview

Cooling systems
The smart fortwo electric drive has 2 cooling Drivetrain component cooling system
systems. Climate control of the interior compart-
ment is performed by a refrigerant circuit and Cooling of the drivetrain components is
cooling of the drivetrain components is performed by a coolant circuit. The following
performed by a coolant circuit. On vehicles with components are cooled:
code (V03) Battery cooling system, the coolant for • Electric drive motor
the high-voltage battery can additionally be • Power electronics control unit
cooled by the air conditioning system via a refrig- • High-voltage battery
erant/coolant heat exchanger (chiller). • On-board charger
The cooling module, consisting of a cooler,
Interior cooling system coolant expansion reservoir and condenser, is
the same as that of the smart with combustion
As on vehicles with a combustion engine, the inte- engine.
rior is cooled via the refrigerant circuit with the
following components: The drivetrain control unit records the values
from the temperature sensors in the components
• Electric refrigerant compressor involved and controls the coolant fan motor and
• Condenser electrical coolant pump according to require-
• Expansion valve ments.
• Evaporator
The coolant (glycol/water mixture) is pumped
On vehicles with code (V03) Battery cooling from the cooler to the drivetrain components by
system, the expansion valve can also be shut off the electric coolant pump. From there, it returns
electrically. There is an additional electrical to the coolant expansion reservoir.
expansion valve (battery) on the chiller.
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 69
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 Cooling systems Cooling system overview

Cooling system without code (V03) Battery cooling system

P20.00-2442-00

Coolant/refrigerant circuit (schematic)

A9/6 Electric refrigerant compressor 1 Expansion reservoir
G5 High-voltage battery 2 Condenser
M4/2 Coolant fan motor 3 Cooler
M5 Electric drive motor 4 Evaporator
M43/1 Coolant pump 1 (feed) 5 Expansion valve
M43/3 Coolant pump 2 (return)
M46 Electric drive and on-board charger coolant a Coolant circuit
pump b Refrigerant circuit
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

70 Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451
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 Cooling system overview

Cooling systems
Cooling system with code (V03) Battery cooling system

P20.00-2437-00

Coolant/refrigerant circuit (schematic)

A9/6 Electric refrigerant compressor 1 Expansion reservoir
G5 High-voltage battery 2 Condenser
M4/2 Coolant fan motor 3 Cooler
M5 Electric drive motor 4 Evaporator
M43/1 Coolant pump 1 (feed) 5 Chiller
M43/3 Coolant pump 2 (return)
M46 Electric drive and on-board charger coolant a Coolant circuit
pump b Refrigerant circuit
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-voltage battery coolant pump
switchover valve

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 71
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 Cooling systems Cooling system components

P20.00-2443-00

Cooling system with code (V03) Battery cooling

system
1 Expansion reservoir
A9/6 Electric refrigerant compressor 2 Condenser
G5 High-voltage battery 3 Cooler
M4/2 Coolant fan motor 4 Evaporator
M5 Electric drive motor 5 Chiller
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
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 switchover valve
Y133/2 High-voltage battery coolant pump
switchover valve

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 High-voltage battery cooling system

Cooling systems
High-voltage battery cooling system i Note
Since the optimal operating conditions of the In the smart fortwo electric drive, R134a is used
high-voltage battery are bound by tight temper- as refrigerant and ND8 is used as refrigerant
ature limits, the battery management system oil, including for service.
control unit can decouple the coolant circuit of
the high-voltage battery from the rest of the
cooling circuit via an electromotive water valve if
necessary.
The cooling circuit of the high-voltage battery
then consists of:
• 2 coolant pumps
• High-voltage battery heater
High-voltage battery heater
• Chiller (only with code (V03) Battery cooling
Since the capacity of the high-voltage battery drops
system)
at low temperatures, the high-voltage battery can
• Electric expansion valve (only with code (V03)
be heated by the high-voltage battery heater during
Battery cooling system)
the charging process at temperatures below 0°C.
• Electromotive water valve (coolant pump
switchover valve) The high-voltage battery heater is located in the
cooling circuit of the high-voltage battery, is
The chiller is only installed on vehicles with code
supplied with power by the 12 V on-board electrical
(V03) Battery cooling system. It is a refrig-
system and actuated by the drivetrain control unit.
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.

P54.10-3703-00
G5 High-voltage battery
R101 High-voltage battery heater

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 73
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 Design Instrument cluster

The instrument cluster is based on the High-Line It has been supplemented with the following elec-
instrument cluster of the facelifted smart fortwo. tric vehicle-specific indicators:
• Drive system diagnosis indicator lamp
• Drive system diagnosis warning lamp
• High-voltage system warning lamp
• Electric steering indicator lamp

P54.33-2054-00

1 Left button, select multiple display / set clock A1e15 Airbag indicator and warning lamp
2 Right button, instrument illumination / set A1e17 ABS indicator lamp
clock A1e18 Electric steering indicator lamp
A1 Instrument cluster A1e41 ESP warning lamp
A1e1 Left turn signal indicator lamp A1e52 Rear fog light indicator lamp
A1e2 Right turn signal indicator lamp A1e54 Coolant temperature warning lamp
A1e3 High beam indicator lamp A1e66 Tire pressure monitor warning lamp
A1e7 Brake fluid and parking brake warning lamp A1e67 Low beam indicator lamp
A1e9 Seat belt warning lamp 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

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

Design
Multifunction display

The multifunction display provides information

about variable changes in the vehicle, its
surroundings and the route. This includes:
• Outside temperature with black ice warning
• Main odometer
• Trip odometer
• Gear indicator P-R-N-D
• Maintenance interval display
The smart fortwo electric drive also includes the P54.33-2053-00

following new indicators: Multifunction display

• Available power of electric drive motor 1 Trip odometer/pre-conditioning ON
• Remaining charging time 2 Total distance/pre-conditioning departure time
3 Gear indicator/trip computer/messages
• Remaining range
4 Time
• ECO indicator 5 Outside temperature with black ice warning
• Time 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 events occurs:
• Faults in the 12 V on-board electrical system
• Accelerator pedal malfunction
• Faults in battery management system
and malfunction of high-voltage battery
coolant pump
• The drive system diagnosis indicator lamp
comes on in the instrument cluster.

P54.33-2055-00
A1 Instrument cluster
A1e72 Drive system diagnosis indicator lamp

Introduction of smart fortwo electric drive (3rd Generation) • Model Series 451 75
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 Design Additional instruments

Additional instruments

The function of the two additional instruments on

the center of the instrument panel has been modi-
fied: The additional instruments are actuated by
the drivetrain 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)

P54.33-2052-00

Left additional instrument

A15p7 High-voltage battery state of charge (SOC)
indicator

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

Design
Display of state of charge of high-voltage battery on multifunction display

When the remaining charge level of the battery is

20%, the text message "HV battery reserve"
appears.
When this is acknowledged by pressing the "OK"
button on the right multifunction control lever,
the remaining range is displayed again.

P54.33-2158-00

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 multifunction
display instead of the remaining range indicator.
As of 5% SOC, an warning tone sounds and the
power display on the multifunction display starts
to flash.
P54.33-2159-00

3 "Low Battery" indicator

A1p13 Multifunction display

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 Design Climate control

Heating Air conditioning

A high-voltage PTC heater with 4 kW output is As on a smart with conventional drive system, it is
used instead of a heater heat exchanger through controlled via the heater/AC operating unit.
which coolant flows as is the case on vehicles with
The design of the system differs in the following
a combustion engine.
aspects:
The heater is controlled using the heater/AC
• Electrically driven refrigerant compressor
operating unit via CAN based on the selected
• Thermostatic expansion valve on interior
interior target temperature and ambient temper-
evaporator with electromagnetic shutoff
ature.
function (only with code (V03) Battery cooling
The high-voltage PTC heater is supplied with system)
power by the high-voltage adapter plate fuse box. • 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 N23 Heater/AC operating unit
3 Evaporator N33/5 High-voltage PTC heater

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 Climate control

Design
Heater/AC operating unit

The heater/AC operating unit is located at the top Cooling:

of the center console. The interior temperature
The drivetrain control unit communicates with the
sensor is located under the temperature selector
control unit in the electrically driven high-
wheel.
voltage refrigerant compressor via LIN. The
When the desired temperature is set, the request control unit of the electric refrigerant
for heating or cooling is transmitted to the driv- compressor regulates the speed to the value set
etrain control unit via CAN C. This forwards the by the heater/AC operating unit.
output values requested by the heater/AC oper-
On vehicles with code (V03) Battery cooling
ating unit for the high-voltage PTC heater or the
system, the electric motor is also regulated
requested rpm for the electric refrigerant
depending on the cooling output request of the
compressor to the corresponding components.
high-voltage battery. These vehicles (for hot
Heating: countries) have an additional coolant/refrigerant
heat exchanger (chiller) in the refrigerant circuit
Climate control takes place via the heater/AC
for cooling the high-voltage battery.
operating unit. This communicates with the
These vehicles are equipped with electrically
control unit in the high-voltage PTC heater via
switchable expansion valves in order to allow the
CAN C. The control unit in the high-voltage PTC
interior and battery cooling systems to be acti-
heater activates the output stages in accordance
vated independently.
with the requested heat output.
Cooling of the high-voltage battery is controlled
by the battery management system control unit.

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 Design Climate control

Pre-conditioning

As a special comfort feature, the vehicle interior

of the smart fortwo electric drive can be pre-
heated or pre-cooled. The pre-conditioning
function can be set using the multifunction
display.
Requirements:
• Charging cable plugged in and connected to P54.33-2156-00

external power supply 1 Departure time

• Charge level of high-voltage battery (SOC) at 2 A/C On indicator
least 30%
• Temperature in interior below 18 °C or above A1p13 Multifunction display
24 °C
Pre-conditioning starts 35 minutes before
departure at the earliest and is maintained for a
maximum of 5 minutes after the programmed
departure time. The actual start of pre-condi-
tioning depends on the ambient temperature and
the temperature in the vehicle interior.
The 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 programmed departure time.
The blower is always operated at stage 2 in this
case. The temperature preselected on the
heater/AC operating unit has no influence on pre-
i Note
conditioning.
Pre-conditioning can also be activated and
The air distribution cannot be influenced by pre-
programmed via the "Vehicle Homepage" func-
conditioning. 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.

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 Body

Design
Bodyshell structure

The bodyshell structure has been taken over from

the series production vehicles unchanged.
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 steels

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 Design Body

Underfloor

Reinforcements
The reinforcements for the high-voltage battery
are located in 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

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 Notes on damage analysis

Design
Chassis High-voltage system

If damage to the chassis has occurred or is If the vehicle suffers significant damage due to
suspected, a wheel alignment check is recom- external force, the high-voltage system must be
mended for quick diagnosis of the damage. The checked to determine whether it is deenergised.
wheel alignment data for the series production Work on the vehicle may only be carried out by an
vehicle with combustion engine apply. "Electrical specialist for HV systems in motor
vehicles (series production vehicles)".
In order to prevent false measurement results,
undamaged wheels must be mounted on the vehicle If it is not possible to definitively determine that
before the wheel alignment check. In particular, the high-voltage system is deenergized, e.g. due
the four bolting points (front axle carrier/frame- to mechanical damage, no further work may be
type integral support) to the body must be performed on the high-voltage system.
checked for displacement.
Once the power has been disconnected, the high-
If there is any type of deformation on the front or voltage system must be checked for external
rear axle, it must be replaced. For this reason, damage and defects. Damaged or defective high-
these components must be visually inspected with voltage components, cooling systems or lines
care for cracks and deformation. must be replaced.
Repairing the high-voltage components is not
In order to check for frame damage, electronic
permissible.
body measurement systems can be used for diag-
nostic purposes e.g. When inspecting high-voltage components,
personal protective equipment must always be
• "Contact" (CAR BENCH)
worn (safety glasses, electrical gloves etc.).
• "NAJA" (Celette)
• "Shark" (Blackhawk)

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 Design Notes on supplemental restraint system

Airbag or emergency tensioning retractor i Note

units
Airbag or emergency tensioning retractor units
Before performing work on the airbag or emer- which have been dropped from a height of over
gency tensioning retractor units, which requires 0.5 m must be replaced.
intervention in their electric circuits (e.g. disas- Do not allow airbag or emergency tensioning
sembly), the high-voltage system must always be retractor units to come into contact with grease,
deenergized. oil or cleaning agents.
The vehicle may only be deenergised by an "Elec- To allow emergency tensioning retractor units to
trical specialist for HV systems in motor vehicles be installed without damage or soiling, they are
(series production vehicles)". fitted with a 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.

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 Notes on repair operations

Design
Body Welding

Depending on the extent of the damage, sheet Welding may only be performed on the vehicle
metal damage can be repaired in various ways: after the high-voltage battery has been deener-
gised.
• Remove dents from sheet metal part(s)
• Partially replace sheet metal part(s) The high-voltage battery should be protected
• Completely replace sheet metal part(s) from the influence of thermal energy.
Only the cutting areas are specified for sectional Before welding, a voltage monitor can be attached
repairs (also "replacement part repairs"). This to the 12 V battery. This protects electronic
gives the service operation some leeway when systems and components from brief voltage peaks
adjusting the section to the respective damage (overvoltage) caused by the welding equipment.
profile. Cuts should always be made at the The 12 V battery does not then have to be discon-
narrowest point and along the shortest distance. nected.
Sectional repairs on the front longitudinal The decision as to whether a voltage monitor is
member are only permissible in front of the axle used or the 12 V battery is disconnected depends
mount. The dull repair weld seams on the front on the extent of the damage.
longitudinal member repair section may not be
ground smooth for strength-related reasons.
Post-repair refinishing
Before and after body repairs, the fault memory
must be read out and any faults present must be The following measures must be observed before
documented. and during painting work:
After repairs to the body or body connections • The preparation of paints produces vapors
(e.g. suspension), the steering angle sensor (ESP) which combust in an explosion if ignited.
must be reparameterized. • Good ventilation must be provided before and
during painting work.
• A dry temperature (or object temperature) of
60 °C may not be exceeded.

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 Special tools Electrical system

68-pin adapter cable

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

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 Abbreviations

Annex
ABS EPS

Antilock Brake System Electronic Power Steering

AC ESM

Alternating Current Electronic selector lever module

ATA ESP

Antitheft alarm system Electronic Stability Program

BMS HV

Battery Management System High Voltage

CAN HVIL

Controller Area Network High Voltage Interlock Loop

CBS LED

Customized Bodypanel System Light Emitting Diode

CP LIN

Control Pilot Local Interconnect Network

DAS LHD

Diagnosis Assistance System Left-Hand Drive

DC LV

Direct Current Low Voltage

DSL MAG

Digital Subscriber Line Metal Active Gas

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 Annex Abbreviations

NEDC RFID

New European Driving Cycle Radio Frequency IDentification

PIN SAM

Personal Identification Number Signal acquisition and actuation module

PLC SRS

Powerline Communication Supplemental Restraint System

PLGW SOC

Powerline Gateway State of Charge

PP TPM

Proximity Tire Pressure Monitor

PTC WIS

Positive Temperature Coefficient Workshop Information System

PWM

Pulse Width Modulation

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 Index

Annex
A I
Additional instruments . . . . . . . . . . . . . . 76 Initial startup
Air conditioning . . . . . . . . . . . . . . . . . . 78 Form . . . . . . . . . . . . . . . . . . . . . . . 51
Innovations . . . . . . . . . . . . . . . . . . . . . 9
B
Bodyshell structure . . . . . . . . . . . . . . . . 81 L
Limp-home mode . . . . . . . . . . . . . . . . . . 75
C
Charging duration . . . . . . . . . . . . . . . . . 33 M
Coolant circuit . . . . . . . . . . . . . . . . . . . 70 Maintenance concept . . . . . . . . . . . . . . . 14
Cooling system . . . . . . . . . . . . . . . . . . 72 Maintenance interval . . . . . . . . . . . . . . . 14
Maintenance interval display . . . . . . . . . . . 14
D Maintenance points . . . . . . . . . . . . . . . . 15
DC/DC converter . . . . . . . . . . . . . . . . . 43 Multifunction display . . . . . . . . . . . . . . . 75
Deenergization
Deenergization matrix . . . . . . . . . . . . . . 52 O
Desiccant cartridge . . . . . . . . . . . . . . . . 24 Output reduction . . . . . . . . . . . . . . . . . 75
Diagnosis assistance system . . . . . . . . . . . 57
Dimensions . . . . . . . . . . . . . . . . . . . . . 11 P
Dimensions and weights . . . . . . . . . . . . . . 12 Park pawl . . . . . . . . . . . . . . . . . . . . . . 66
Performance . . . . . . . . . . . . . . . . . . . . 11
F Plug&Charge . . . . . . . . . . . . . . . . . . . . 35
Front axle . . . . . . . . . . . . . . . . . . . . . 67 Power disable event log . . . . . . . . . . . . . . 51
Fuse assignment . . . . . . . . . . . . . . . . . . 59 Powerline Gateway . . . . . . . . . . . . . . . . . 34
Fuses . . . . . . . . . . . . . . . . . . . . . . . . 58 Pre-conditioning . . . . . . . . . . . . . . . . . 80

H R
Heating . . . . . . . . . . . . . . . . . . . . . . . 78 Refrigerant circuit . . . . . . . . . . . . . . . . 70
High-voltage battery Refrigerant compressor . . . . . . . . . . . . . 46
Transport . . . . . . . . . . . . . . . . . . . . 26 Relays . . . . . . . . . . . . . . . . . . . . . . . 62
High-voltage battery supporting strut . . . . . 67 Reverse gear . . . . . . . . . . . . . . . . . . . . 66
High-voltage components
Check after an accident . . . . . . . . . . . . . 23 S
Overview . . . . . . . . . . . . . . . . . . . . 20
Safety function after an accident . . . . . . . . 23 Selector lever . . . . . . . . . . . . . . . . . . . 66
Wiring harness check . . . . . . . . . . . . . . 23 Service Disconnect . . . . . . . . . . . . . . . . 50
High-voltage fuses . . . . . . . . . . . . . . . . 45 Smart Charging . . . . . . . . . . . . . . . . . . 34
Storage of high-voltage batteries . . . . . . . . 27

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 Annex Index

T U
Topology of on-board electrical system . . . . . 21 Underfloor . . . . . . . . . . . . . . . . . . . . .82
Towing . . . . . . . . . . . . . . . . . . . . . . . 16
Transport V
Notes on transport of high-voltage batteries . . . 26 Vehicle concept . . . . . . . . . . . . . . . . . . 8

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 Introduction of the smart fortwo electric drive (3rd generation) - Model series 451

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