2009 11 001 001 en

,
Introduction of the smart fortwo electric drive

Model Series 451
www.smart.com
smart A Daimler Brand
Introduction of the smart fortwo electric drive Model Series 451
Introduction into Service Manual
This printout will not be recorded by the update service. Status: 09 / 2009

Introduction into Service Manual for Model
Series 451
Daimler AG Technical Information and Workshop Equipment (GSP/OI) D-70546 Stuttgart
Information and Copyright

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Link:
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Fax:
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+49(0)18 05/0 1079 79
+49(0)18 05/0 1079 78
Outside Germany
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If you have any questions or suggestions concerning this product, please
write to us.
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Daimler AG
GSP/OIS
HPC R822, W002
D70546 Stuttgart
2009 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, D70546 Stuttgart.
This applies in particular to reproduction, distribution, alteration,
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systems, including databases and online services.
Image no. of title image:

P00.10483200
Note: This publication is only available online
09/09
Contents
Preface
Overall vehicle
Overview
Technical data
11
Maintenance
13
Towing
15
Electrical system
Onboard electrical system/power supply
16
Highvoltage battery
20
Highvoltage charger control unit
24
External power outlet communications control unit
25
Charger feedin socket
26
Charging cable
27
Charge detection
28
Interlock
29
Highvoltage distributor control unit (PDU)
31
Brake system
32
Power disconnect
34
Overall network
39
Diagnosis
42
SAM
44
Introduction of the smart fortwo electric drive, Model series 451

Contents
Electric drive system
Motor description
47
Transmission
Transmission description
48
Chassis
Axles and suspension
49
Rear module
50
Cooling systems
Electric drive cooling system
51
Highvoltage battery and interior cooling system
53
Design
Instrument cluster
57
Climate control
60
Body
63
Notes on damage analysis
65
Notes on supplemental restraint systems
66
Notes on repair operations
67

Contents
Special tools
Electrical system
68
Annex
Abbreviations
71
Index
73

Contents

Preface
Dear Reader,
This Introduction into Service Manual presents the
new smart fortwo electric drive in model series 451.
The purpose of this brochure is to acquaint you with
the technical highlights of this new vehicle in
advance of its market launch. This brochure is
intended to provide information for people
employed in service or maintenance/repair as well
as for aftersales staff. It is assumed that the reader
is already familiar with the MercedesBenz and
smart model series currently on the market.
In terms of the contents, the emphasis in this Intro
duction into Service Manual is on presenting new and
modified components and systems.
This Introduction into Service Manual is not
intended as an aid for repairs or for the diagnosis of
technical problems. For such needs, more extensive
information is available in the Workshop Information
System (WIS), via vehicle diagnosis (DAS) and drive
system diagnosis.
WIS is updated continuously. Therefore, the infor

mation available there reflects the latest technical
status of our vehicles.
This Introduction into Service Manual presents
initial information relating to the new smart fortwo
electric drive in model series 451 and, as such, is
not stored in WIS. The contents are not maintained
and there is no provision for updates.
We will publicize modifications and new features in
the relevant WIS documents. The information
presented in this Introduction into Service Manual
may therefore differ from the more uptodate
information found in WIS.
All information relating to specifications, equipment
and options is valid as of the copy deadline in
October 2009 and may therefore differ from the
series production configuration.
Daimler AG
Technical Information
and Workshop Equipment (GSP/OI)

Overall vehicle
Overview
Vehicle concept
The smart fortwo in model series 451 with electric
drive system is being introduced in December
2009.
The new smart fortwo electric drive is available in
the coup and cabrio variants.
With its electric drive system, the smart fortwo
electric drive embodies the concept of an emis
sionfree motor vehicle. Its introduction is
another step forward in the use of innovative
drive technologies which are suitable for
everyday use and efficient.
P00.00-4517-00
With the smart fortwo electric drive, the brand is

pursuing an ambitious goal the production of a
technically mature, attractive city car which
releases zero emissions locally.
The smart fortwo electric drive can be charged at
a conventional household power socket. A full
battery charge is sufficient for a range of around
135 kilometers in urban traffic.
The green design elements, except the light alloy
wheels, cannot be ordered and invoiced via the
usual replacement part/warranty process.
These elements must be obtained from BRABUS via
the "tailormade" process.
P00.00-4518-00
P00.00-4519-00

Innovations
30 kW permanent magnet motor
Transmission with fixed gear ratio (1speed
forward/reverse) and differential
Watercooled lithiumion batteries of the
latest generation
Temperaturecontrolled air conditioning with
battery cooling system
Charging of battery via regenerative braking
Preheating/precooling of interior
(preconditioning) with Telestart remote
control
The 30 kW electric motor provides fast accelera

tion and high responsiveness with 120 Nm of
torque available right from startoff.
Overall vehicle
Overview
Due to the output characteristics of the electric

motor, the smart fortwo electric drive only
requires a single fixed transmission ratio. This
means that gearshifting is no longer required a
major advantage is heavy urban traffic. The motor
changes its direction of rotation for reverse
travel.
The highlyefficient lithiumion battery is housed
between the axles in a spacesaving manner. The
electric drive does not result in any space
related limitations for the smart fortwo electric
drive; the interior compartment and trunk are
exactly the same size as on a smart fortwo with
combustion engine.
P08.00-2009-00
Electric drive system of smart fortwo electric drive

Overall vehicle
Overview
Model 451
Model
Motor
smart fortwo electric drive coup
451.39
780.009
smart fortwo electric drive cabrio
451.49
780.009
P00.00-4493-00
smart fortwo electric drive coup

1
2
3
4
5
6
7
8
10
Electric motor
Electric motor control unit EDCM
(Electric Drive Control Module)
Lithiumion battery incl. BMS
(BatteryManagementSystem)
Highvoltage charger
Transmission
Cooler for electric drive system and
highvoltage charger
Brake booster vacuum pump
Vacuum pump control unit
9 Charger feedin socket

10 Communications control unit
Smart Charge Communication Unit
11 Highvoltage battery heat exchanger (chiller)
12 Highvoltage battery heater booster
13 Highvoltage interior PTC heater
(Positive Temperature Coefficient
14 Interior air conditioning expansion valve
15 Battery air conditioning expansion valve
16 Electric vehicle control unit EVCM
(Electric Vehicle Control Module)
17 PDU highvoltage distributor
(Power Distribution Unit)
18 Electric refrigerant compressor

Unit
smart fortwo
electric drive coup
smart fortwo
electric drive cabrio
Performance
Maximum speed
km/h
100
Acceleration
050 km/h
5.8
Range as per NEDC
km
miles
135
84
CO2 emissions
g/km
Overall vehicle
Technical data
Dimensions
Vehicle length
mm
2695
Vehicle width
mm
1559
Vehicle height
mm
1542
Wheelbase
mm
1867
Front track width
mm
1283
Rear track width
mm
1385
Dimensions and weights
Curb weight (as per DIN/EPA)
kg
890
910
Permissible gross vehicle weight
kg
1120
1120
Maximum payload
kg
230
210
Max. seating capacity
Trunk capacity
220

11
Overall vehicle
Technical data
Unit
smart fortwo
electric drive
Highvoltage battery
Configuration
Lithiumion battery
Rated voltage
< 400 V
Capacity
kW/h
Weight
kg
approx. 148
Motor model designation
780.009
Configuration
Permanent magnet motor
Rated voltage
360
Maximum output
kW
30
Maximum torque
Nm
120
16.5
Electric motor
Power transmission
12
Drive
Rear wheel drive
Transmission
1speed
forward/reverse
Transmission ratio
9.77:1

Maintenance concept
Maintenance interval display
The maintenance concept mainly differs in terms

of the maintenance performed on the drive
system. In contrast to a vehicle driven by a
combustion engine, the electric drive is largely
maintenance free.
The maintenance interval display is located in the

multifunction display of the instrument cluster.
The maintenance interval is displayed here in the
form of one or two wrench symbols.
In addition to a visual inspection for damage and

leaks as well as checking, refilling or replacing
operating fluids, only the desiccant cartridge of
the highvoltage battery has to be replaced if
indicated accordingly by the drive diagnosis
system.
Overall vehicle
Maintenance
The same maintenance must be performed for

both indicators.
The remaining time is shown in days roughly one
month before a service date.
The remaining distance is displayed as of
1000 km.
Maintenance interval
The maintenance interval for the smart fortwo
electric drive is specified as follows:
1 year or 15,000 km
P54.32-8103-00

(example of remaining distance)
i Note
A special feature of the maintenance process is
that the number of operating hours of the brake
booster vacuum pump has to be determined via
the vehicle diagnosis system (DAS) and the condi
tion of the desiccant cartridge has to be checked
via the drive diagnosis system.

13
Overall vehicle
Maintenance
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 for cooling and
heating of highvoltage battery
4 Lamp unit for bulb replacement
P00.20-2670-00
Maintenance items at front
Rear maintenance item

The following maintenance item must be reached
via the cover in the luggage compartment cover:
5 Coolant expansion reservoir on cooler for electric
drive system and highvoltage charger
P00.20-2671-00
Rear maintenance item
14

Notes on towing
a Warning
The vehicle can be towed at a maximum speed of

50 km/h for a distance of up to 40 km.
If the vehicle is towed at a speed greater than

50 km/h, there is a risk that the electric drive or
highvoltage battery may overheat.
Prerequisite:
Overall vehicle
Towing
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
(e.g. highvoltage battery, drive diagnosis,
12 V battery) lights up on the instrument
cluster
Increased or pulsating braking effect

15
Electrical system

The onboard electrical system ensures that the
power supply to the electric drive system and all
electrical consumers and components in the
vehicle is appropriate for the requirements and
the situation.
The power supply in the smart fortwo electric
drive consists of two onboard electrical systems:
12 V onboard electrical system with 12 V
battery
In order to ensure a continuous supply of elec
trical energy to the 12 V onboard electrical
system, the DC/DC converter in the electric motor
control unit transforms high direct voltage into
12 V direct voltage. All 12 V consumers are
supplied with power by the 12 V onboard elec
trical system.
Information on the highvoltage system

General
The highvoltage system consists of several
components. The individual components are
connected by highvoltagecarrying electrical
lines.
Identification of HV components and HV lines
Every component of the highvoltage onboard
electrical system installed in the vehicle is iden
tified by a yellow warning sticker. All electrical
lines carrying high voltage are identified by a
warning color (orange).
Highvoltage onboard electrical system with

highvoltage battery
The highvoltage battery is charged in decelera
tion mode by the regenerative braking system or
by connecting it to an external power supply via
the highvoltage charger control unit.
P08.00-2008-00
Warning sticker
P08.10-2035-00
1
DC/DC converter
M5
Electric motor
N145 Electric motor control unit EDCM
16
i Note
The connectors of the HV lines on the electric
drive system and on the highvoltage battery
may only be disconnected using the special tools
intended for this purpose (see chapter "Special
tools").

Overview of highvoltage components
Electrical system
P54.00-2782-00
G5
M5
N24/3
N116/1
N116/5
N145
R23
X58/23
Highvoltage battery
Electric motor
Refrigerant compressor control unit (EAC)
Electric motor control unit (EDCM)
Highvoltage PTC heater

17
Electrical system

General activities
Working requirements
Repair, maintenance and diagnosis activities on

vehicles with a highvoltage system may only be
performed by qualified employees. (The high
voltage awareness course is the minimum qualifi
cation required for this).
When work is performed on a highvoltage system,

the system must be deenergized and the voltage
free state of the highvoltage system must be
secured.
Deenergization (power disconnect) of the high

voltage system before operations are carried out
on the vehicle and subsequent initial startup after
the operations have been performed may only be
carried out by an electrical specialist for HV
systems in motor vehicles (series production
vehicles). The following preconditions must be
met:
Successful completion of the highvoltage
awareness course
Successful completion of the highvoltage
qualification course
Successful completion of the smart electric
drive product training course
18
This has to happen in accordance with 3 safety

rules:
Power disconnect (voltagefree)
Secure against reactivation
Check and secure the deenergized state
The following information must be observed and
complied with for operations on highvoltage
systems:
Measuring instruments and aids must be
checked for proper condition before use
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

Evaluation of highvoltage components
Safety Inertia Switch
Wiring harness check:
There is a Safety Inertia Switch located on the

inside of the right Apillar above the instrument
panel crossmember.
If the chafe protection or the lines are damaged

by external influences (e.g. animal bites), the
lines must be replaced immediately. Repair is not
permissible.
Check after an accident:
Electrical system
Pressing the switch can reset the open circuit and

restore the availability of the highvoltage
network.
The highvoltage system must be checked for

external damage and defects. If defects or
damage is found on the highvoltage components
or lines, they must be replaced. Repair of the
highvoltage components or lines is not permis
sible.
Safety function after an accident:
Highvoltage system shut off
1 Automatic shutoff of the highvoltage battery
and discharge of the highvoltage components
takes place via a Safety Inertia Switch after a
rollover.
a Warning
The Safety Inertia Switch may not be actuated if
the emergency tensioning retractors or airbags
have been triggered after a rollover.
2) Automatic shutoff takes place via the airbag

control unit after triggering of the emergency
tensioning retractors (stage 1) or front
airbags (stage 2).

19
Electrical system
Highvoltage battery
Highvoltage battery module
The highvoltage battery module is located under
the vehicle floor. The highvoltage battery
module incorporates the following components
Highvoltage battery
Battery management system (BMS) control unit
Service Disconnect with cover
Contactors (positive and negative)
Desiccant cartridge
HV onboard electrical system connection
12 V onboard electrical system connection
Coolant line connections
Overpressure twoway valve
The HV battery is a lithiumion battery, which

stores energy for the electric motor. The HV
battery is connected to the 12 V onboard elec
trical system via the DC/DC converter (integrated
in the electric motor control unit) so that it can
provide support to the 12 V onboard electrical
system. The contactors are actuated by the
battery management system (BMS) control unit
and internally isolate the highvoltage battery
positive and negative terminals from the high
voltage onboard electrical system.
P54.10-3329-00
Highvoltage battery module

1
2
3
4
20
HV onboard electrical system connection

12 V onboard electrical system connection
Desiccant cartridge
Service Disconnect cover
5
6
Coolant line connections

Overpressure twoway valve
G5
Highvoltage battery
N82/2 Battery management system control unit

The HV battery is cooled or heated by a coolant

circuit. The temperature is recorded by a
temperature sensor in the highvoltage battery
module. The electric vehicle control unit (EVCM)
evaluates the signal and initiates cooling or
heating mode for the HV battery. The connections
for the coolant lines are located at the right front
of the vehicle when viewed in the direction of
travel.
A desiccant cartridge is installed at the lower left

of the highvoltage battery module to ensure the
required air moisture content. The electric
vehicle control unit (EVCM) issues a corre
sponding code via the drive diagnosis system if
the desiccant cartridge needs to be replaced.
Electrical system
Highvoltage battery
Low outside temperatures

The efficiency of the highvoltage battery is
temperaturedependent and decreases rapidly
as temperatures drop. In addition, the electro
lytes can "gel" at very low temperatures.
It must be ensured that the inside temperature of
the highvoltage battery does not drop below
15 C.
i Note
The condition of the desiccant cartridge must be
checked at every maintenance interval using the
drive diagnosis tester.
Discharged highvoltage battery
i Note
If the highvoltage battery is fully discharged,

the drive system shuts off. This protects the high
voltage battery against deep discharging.
The drive system can be temporarily reactivated

once in order to park the vehicle in a safe place
by switching the ignition off and back on.

21
Electrical system
Highvoltage battery
Information on highvoltage battery
General information on transport
If used according to specifications, the high

voltage battery presents no danger.
Highvoltage batteries are hazardous goods and

are classified as "UN 3480 Lithiumion battery,
class 9, packaging group II" in accordance with
international hazardous goods regulations. High
voltage batteries may only be transported in
accordance with the applicable international and
national hazardous goods regulations for the
respective mode of transport. Before any high
voltage battery is transported, it must be checked
to determine whether it is safe for transport.
A highvoltage battery which has been damaged
must be classed as not safe for transport if
following points apply to the transport:
Information on safe handling

Risk of short circuit Avoid physical damage
(pressure)
Risk of explosion Thermal load (avoid the
effect of heat/welding; painting work/force
drying up to max. 60 C)
Risk of injury due to the formation of
poisonous and corrosive gases
Use personal protective equipment (with high
voltage batteries that are damaged and not
safe for transport: Safety glasses
Electrical gloves
gotis:// O_01.0_04.0
There is a possibility of dangerous exposure

to heat
The highvoltage battery can cause fires or
short circuits
Danger can occur in another way e.g. due to
the release of fluid electrolyte or combustible,
corrosive or poisonous vapors.
i Note
Further information on handling procedures and
safety requirements can be found in the safety
data sheet for highvoltage batteries in the
Daimler hazardous goods management system.
Link: http://gms.aftersales.daimler.com
Requirements for storage areas and

containers
Highvoltage batteries may not be stored in
bulk containers because this can result in
leakage, short circuits or explosion
Protect highvoltage batteries from moisture
Protect contacts with suitable terminal caps
Store highvoltage batteries in a cool and
wellventilated location
Prevent fluids from the highvoltage battery
from entering the sewage system, water drains
or the ground
22
i Note
Shipment must be performed/arranged by a
qualified logistics employee.

Highvoltage batteries which are safe for

transport
Highvoltage batteries which are not safe for

transport
Highvoltage batteries which are safe for trans

port may only be transported in original pack
aging and the highvoltage battery must be
packed in the same way as it was delivered. The
following minimum requirements must be
observed:
A highvoltage battery is not safe for transport in

the following circumstances:
The highvoltage battery must be protected

against external short circuit by the use of
insulating caps and by activating the Service
Disconnect
All of the openings on the highvoltage
battery, particularly the coolant connections,
must be sealed
The highvoltage battery housing must be free
from dangerous soiling on the outside
It is important to observe the requirement for
proper packaging with adhesive tape and dual
strapping, labeling of the package in accordance
with the respective applicable hazardous goods
regulations and any other requirements associ
ated with the transport.
Electrical system
Highvoltage battery
Highvoltage battery is not diagnosiscapable

Insulation fault
Contactor status "closed" (energized with high
voltage)
Visual inspection:
Crack in housing
Housing deformed
Housing tarnished
Electrolyte leakage
Highvoltage contacts damaged
Highvoltage batteries which are not safe for

transport may only be transported via road or sea
with an exemption from the relevant national
authority and where the conditions described in
the exemption are complied with in full.
i Note
Shipment must be performed/arranged by a
qualified logistics employee.
The transport of highvoltage batteries which are

not safe for transport via air is forbidden under
any circumstances!

23
Electrical system

The battery is charged by connecting the
charging cable to the charger feedin socket and
an external power supply. The highvoltage
charger control unit is located above the drive
unit.
Connections:
HV line to highvoltage distributor

HV line to charger feedin socket
12 V line
Coolant lines
For cooling purposes, the highvoltage charger

control unit is connected to the electric motor
cooling circuit via two connections.
Performance data:
Input:
100 to 240 V (AC voltage)
Output:
270 to 380 V (DC voltage)
Output:
3 kW max. at 115230 V
Charging duration: 8 h (0100% SOC) at +25 C

4 h (2080% SOC) at +25 C
The highvoltage charger control unit converts

the alternating current from the charger feedin
socket into direct current and forwards it to the
highvoltage distributor.
The charging procedure is controlled and moni
tored by the battery management system control
unit.
P54.10-3330-00
6
7
8
9
24
Connection, HV line to highvoltage distributor

Connection, HV line to charger feedin socket
12 V line connection
Coolant line connection
N24/3 Highvoltage charger control unit

The optional external power outlet communica

tions control unit (SCCU = Smart Charge Commu
nication Unit) allows the vehicle to be charged
using public infrastructure.
A communication connection (power line) is
established between the vehicle and public
charging station for data exchange. The following
information can be accessed:
Electrical system
External power outlet communications control unit
Payment information
Tariff information
Maximum available charging current
In addition, the customer can query status infor
mation over the Internet during the charging
process e.g.
Current SOC
Range
Estimated charging duration until 100% SOC
Error conditions detected by the external power
outlet communications control unit are output via
the drive diagnosis system.
P54.10-3355-00
1
2
3
The control unit is attached to the frametype

integral support by a bracket above the electric
refrigerant compressor at right rear.
HV connection
12 V connection
Frametype integral support

N24/4 External power outlet communications
control unit
N116/1 Electric refrigerant compressor (EAC)
Connections:
HV connection:
HV line from charger feedin socket to external
power outlet communications control unit
12 V connection:
Circuit 30
Circuit 15
ESSCAN
Drive train CAN

25
Electrical system

The charger feedin socket is located on the right
rear Bpillar under a flap. The socket is fitted
with a removable protective cap.
There is a ring of indicator LEDs positioned
around the socket which light up during the
charging process when the charge socket is
correctly connected to an external power supply
and when the preconditioning function is active.
When the connector is connected to the socket,
this is indicated on the instrument cluster by the
charging cable indicator lamp and gear indicator
"0" on the multifunction display. Driving operation
is not possible as long as the connector is
connected to the socket.
P54.10-3348-00
P54.10-3343-00
10
Protective cap
E34
Charger feedin socket indicator LED
X58/23 Charger feedin socket
The 12 V battery is fused via the prefuse in the

charge line from the electric motor control unit to
the 12 V battery.
The prefuse is located in the battery box for the
12 V battery.
P54.10-3344-00
F90 12 V charge line prefuse

G1 Battery
26

Charging cable
The charging cable for connection to an external
power supply is included as standard.
The charging cable is equipped with a RCD
(Residual Current Protection Device).
Electrical system
Charging cable
The RCD protects against impermissibly high

contact currents. If a certain differential current
level (fault current) is exceeded, the monitored
electric circuit is disconnected at the positive
and negative terminals.
ON button
The triggered RCD is switched back on using the
ON button.
TEST button (OFF button)
Pressing the TEST button simulates a fault for the
purpose of a function test. If the RCD is triggered
after the TEST button is pressed, the RCD is oper
ating properly.
RCD indicator lamp
The indicator lamp (LED) indicates the current
status of the RCD.
Before the mains plug is disconnected, the RCD
must be switched off by pressing the TEST button
(OFF button).
P54.10-3347-00
1
2
3
Charging cable
Connector to charger feedin socket
Mains plug
S203
S203e1
S203s1
S203s2
Residual current protection device (RCD)

RCD indicator lamp
ON button
TEST button
i Note
i Note
If the mains plug is disconnected from the socket

and then plugged back in, the RCD is triggered
and must be switched back on by pressing the ON
button.
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).

27
Electrical system
Charge detection
When the connector of the charging cable is
plugged into the charger feedin socket, the
battery management system control unit wakes
the CAN buses with the associated control units.
The charging process is monitored and controlled

by the highvoltage charger control unit and
battery management system control unit.
P00.19-4754-00
A1
A1e70
E34
F90
G1
G5
N3
N10/10
N24/3
N82/2
28
Instrument cluster
Charging current indicator lamp
Charger feedin socket indicator lamp
12 V battery prefuse
Battery
Highvoltage battery
Electric vehicle control unit EVCM
SAM control unit
Battery management system control unit
N116/5 Highvoltage distributor control unit (PDU)

N145
X58/23 Charger feedin socket
CAN C Drive train CAN
EDCAN Electric Drive CAN
ESSCAN Electric Storage System CAN
HV
LV
Highvoltage line
12 V line

Interlock
The interlock circuit serves to protect people who
deal with the highvoltage onboard electrical
system. The interlock circuit detects an open
connector circuit in the highvoltage onboard
electrical system.
Since capacitors are present in the highvoltage
components, the highvoltage onboard elec
trical system is not immediately rendered
voltagefree once the protection switch is
opened. For this reason, an active rapid
discharge function is incorporated in the high
voltage components. This discharges the high
voltage onboard electrical system to voltages
below 60 V within 2 to 5 s.
If the interlock circuit is interrupted, this causes
the protection switch in the highvoltage battery
module to open and the highvoltage onboard
electrical system to shut down. In addition, acci
dents trigger a 2stage crash shutdown proce
dure. This shuts down the highvoltage battery
and discharges the highvoltage onboard elec
trical system:
The interlock signal is generated in the battery

management system (BMS) control unit and trans
mitted to the following components over a series
connection:
Electrical system
Interlock

Refrigerant compressor control unit
If the interlock signal is interrupted during

driving operation, the highvoltage onboard
electrical system is only shut off the next time the
vehicle is stopped when the selector lever is
moved to position "N" with the vehicle at a stand
still or the vehicle key is turned to position "Off".
Stage 1: Reversible (without airbag triggering)

Stage 2: Irreversible (with airbag triggering)
The crash signal is transmitted by the restraint
systems control unit to the electric vehicle
control unit (EVCM) via the drive train CAN.

29
Electrical system
Interlock
Interlock layout
P00.19-4728-00
F90
G1
G5
M5
N3
N24/3
N82/2
N116/1
N116/5
N145
R23
30
12 V battery prefuse
Battery
Highvoltage battery
Electric motor
Battery management control unit
A
B
Red
Yellow
Orange
Circuit 30
Circuit 30c
12 V line
Interlock signal line
Highvoltage line

The highvoltage distributor control unit PDU

(Power Distribution Unit) is installed above the
drive unit.
All HV components are supplied with power via the
highvoltage distributor control unit (PDU). There
are three fuses in the highvoltage distributor
control unit (PDU) to protect the highvoltage on
board electrical system.
The connectors from the HV line to the HV battery

and to the electric motor control unit (EDCM) must
be disconnected with the corresponding special
tools.
Electrical system
P54.10-3331-00
1
2
3
4
5
6

Highvoltage battery
Refrigerant compressor
Electric motor control unit
12 V line
N116/5
Highvoltage distributor control unit

(PDU)

31
Electrical system
Brake system
General
The brake system is largely the same as the brake

system of the smart fortwo with combustion
engine in terms of its design and operation.
The vacuum is measured and monitored by the

brake booster vacuum pump control unit. The
vacuum is recorded via a measurement line which
branches off the vacuum line from the vacuum
pump to the brake booster via a Tpiece.
The regenerative braking function and the elec

tric vacuum pump, which is controlled by the
brake booster vacuum pump control unit, are new
features.
If the required vacuum drops, e.g. due to frequent

operation of the brake, the vacuum pump is actu
ated to generate the required vacuum.
Regenerative braking
The electric motor operates in generator mode
during braking. During driving operation, the
electric motor generates mechanical rotational
energy from electrical energy in order to drive
the vehicle. In regenerative braking mode, elec
trical energy to supply the highvoltage
consumers and to charge the highvoltage
battery is generated from mechanical energy. If
the energy generated is greater than the current
requirements of the highvoltage consumers, it is
stored in the highvoltage battery.
The status, charging and discharging of the high
voltage battery are monitored by the battery
management system control unit.
Control of charging, discharging and the charge
level is performed by the electric vehicle control
unit (EVCM).
P42.22-2043-00
1
2
M57
N65/3
32
Measurement line
Tpiece
Brake booster vacuum pump control unit

Electrical system
Brake system
P42.22-2044-00
Vacuum pump control (schematic)

1
2
3
4
5
Measurement line
Tpiece
Vacuum line
Check valve
Brake booster
M57 Brake booster vacuum pump

N65/3 Brake booster vacuum pump control unit
i Note
A Plug connection A
A1 Circuit 15 (ignition ON)
A2 Data link connector
A5 Brake light switch signal
B Plug connection B
B1 Circuit 31 (ground)
B2 Circuit 30 (permanent current)
C Plug connection C
C1 Pump power supply +
C2 Pump power supply
The brake booster vacuum pump must be replaced

after 300 operating hours.
The number of operating hours of the brake

booster vacuum pump must be determined at
every maintenance interval via the vehicle diag
nosis system (DAS).

33
Electrical system
Power disconnect
To allow service operations to be performed
without any risk of electric shock, the high
voltage onboard electrical system must be deen
ergized and protected against reactivation.
The power disconnect and restart must be docu
mented in a vehicle power disconnect and vehicle
initial startup log. The logs must be enclosed with
the vehicle repair documents.
The power is disconnected by switching the igni

tion "Off". Finally, a check is performed using the
diagnostic unit for drive system diagnosis. The
Service Disconnect cover underneath the HV
battery is then removed and the Service Discon
nect is pulled out of the highvoltage battery An
activation lock is installed in place of the Service
Disconnect to protect against reactivation.
P54.10-3332-00
G5 Highvoltage battery
34
1 Cover
2 Service Disconnect
3 Activation lock

Electrical system
Power disconnect
P00.01-3964-00
SF54.10P300007A
F54.10P300008A
Form for power disconnect log

Form for initial startup log

35
Electrical system
Power disconnect
Power disconnect matrix for operations where power disconnect is required
Yes
Underside of vehicle
Rear module lowering
Remove/install electric motor with power electronics
Remove/install transmission
Remove/install frametype integral support
Remove/install axle tube
Remove/install battering cooling system coolant pump
Remove/install electric motor cooling system

coolant pump
Remove/install A/C condenser
Remove/install pedals
Remove/install ESP control unit
Remove/install ESP hydraulic unit
Remove/install electric steering
Remove/install highvoltage battery
Remove/install vacuum pump
36
No
Remove/install refrigerant compressor
Remove/install highvoltage distributor

Yes
No
Underside of vehicle
Remove/install highvoltage AC/DC battery
charger control unit
HV lines
Remove/install front axle
Remove/install front suspension
Electrical system
Power disconnect
Outside of vehicle
Remove/install CBS parts
Remove/install soft top/roof
Remove/install windshield
Remove/install rearend door upper section (coup)
Remove/install rearend door lower section
Remove/install front exterior lights
Remove/install rear exterior lights
Remove/install wiper blades
Remove/install charger feedin socket

(charge socket)

37
Electrical system
Power disconnect
Yes
No
Wheels, brakes
Remove/install wheels/tires
Remove/install front service brake
Remove/install rear service brake
Vehicle interior
38
12 V battery
Remove/install restraint systems
Remove/install floor covering
Remove/install instrument cluster
Remove/install instrument panel
Steering gear pitman arm
Remove/install driver/passenger seat
Remove/install interior HV lines
Remove/install air distribution box

P00.19-4729-00
Overall network Location of components

Electrical system
Overall network
39
Electrical system
Overall network
Overall network
A1
A15p6
A15p7
B24/15
B37
B38
M4/8
Instrument cluster
HV battery energy flow
HV battery charge level indicator
Yaw rate and lateral acceleration sensor
Accelerator pedal
Rain sensor/light sensor
Electric drive and highvoltage charger fan
motor
M4/9
Highvoltage battery and interior fan motor
M43/2 Battery cooling system coolant pump
M46
Electric motor cooling system coolant pump
M57
N2/7
Restraint systems control unit
N3
N10/10 SAM control unit
N15/5 Electronic selector lever module
N23
Heater/AC operating unit
N475 ESP control unit
N49
Steering angle sensor
The electric vehicle control unit (EVCM) serves as

a gateway between
Drive train CAN
EDCAN
ESSCAN
Diagnosis of the electric vehicle (EVCM) and elec
tric motor (EDCM) control units is only possible
via the separate diagnostic tool for drive system
diagnosis.
40
N65/3
N68
N82/2
N116/1
N116/5
N145
R23
R101
S16/2
X11/4
X58/23
X200
X201
Y19/1
Y19/3

Steering assist control unit
Highvoltage battery heater booster
Park pawl switch
Data link connector
EVCM data link connector (6pin)
EDCM data link connector (9pin)
Interior air conditioning expansion valve
Battery air conditioning expansion valve
CAN C
EDCAN
ESSCAN
LIN
Drive train CAN

Electric Drive CAN
Energy Storage System CAN
Local Interconnect Network
In the event of a crash, the connection to the drive

train CAN is used to transfer the crash signal from
the restraint systems control unit. If the airbags
are triggered, the contactors switch and the
vehicle is deenergized.
The highvoltage distributor control unit distrib
utes power to the highvoltage consumers and is
not a CAN subscriber.

P00.19-4730-00
Overall network, CAN bus/LIN bus (for picture legend, see page 40)

Electrical system
Overall network
41
Electrical system
Diagnosis
General
The network architecture allows external access
to the individual control units of the CAN bus
systems.
By connecting a diagnostic tester, the vehicle with
all its equipment characteristics can be identi
fied. This enables accurate fault evaluation and
rectification and the analysis of vehiclespecific
values and parameters.
On the smart fortwo electric drive, diagnosis is
separated into two areas:
Vehicle diagnosis via DAS (data link connector
X11/4)
Drive diagnosis via separate diagnostic tester
(data link connector X200)
Diagnosis Assistance System (DAS)

All control units of the drive train CAN (CAN C) can
be diagnosed with DAS. The data link connector
(X11/4) is located in the vehicle interior on the
underside of the instrument panel on the driver
side.
The following control units have diagnosis capa
bility:
42
Instrument cluster
SAM control unit
ESP control unit
Refrigerant compressor control unit
Electronic selector lever module (ESM)
P54.22-2062-00
DAS
X11/4 Data link connector

Drive system diagnosis

The electric drive system with its components is
checked separately via drive system diagnosis.
For this purpose, the electric vehicle control unit
(EVCM) is equipped with a data link connector
(6pin) which is connected to the external drive
system diagnosis tester.
Electrical system
Diagnosis
The following control units have diagnosis capa

bility:
Electric vehicle control unit

Electric motor control unit
Highvoltage charger control unit.
The electric motor control unit (EDCM) is

equipped with a data link connector (9pin) for
connecting to the diagnostic tester, which is used
to update the software of the electric motor
control unit (EDCM).
P54.22-2063-00
Drive system diagnosis

N3
X200 EVCM data link connector (6pin)
X201 EDCM data link connector (9pin)

43
Electrical system
SAM
All fuses, except the highvoltage fuses in the
highvoltage distributor control unit and the 12 V
charge line prefuse, are housed on the SAM
control unit. Fuses 131 are located on the front
of the SAM control unit; fuses 3235 are located
on the rear.
The SAM control unit is installed in the vehicle
interior on the left side near the Apillar under
the instrument panel.
Modified fuse assignments:

F1 25A
F8 25A
F9 7.5A
F10 15A
F12 10A
F16 15A
F30 40A
F32
Ignition Brake booster vacuum pump

Main relay Highvoltage battery heater
booster
Main relay Electric drive and high
voltage charger cooling system fan
motor
Main relay Electric drive and high
voltage charger cooling system coolant
pump and battery cooling system coolant
pump
Additional Telestart preheating/
precooling
Electric vehicle control unit Blower
stage 2
Highvoltage battery and interior
cooling fan motor
Omitted
P54.21-3106-00
SAM control unit (front)
44

Modified fuse assignments:

R5 7.5A Battery Highvoltage charger control
R6 15A
R7 15A
R8 5A
R9 25A
unit
Battery Electric vehicle control unit
Battery Electric motor control unit
Battery Electric vehicle control unit
Battery Brake booster vacuum pump
The SAM control unit is linked with the drive train

CAN in order to exchange data. It communicates
with the following components:
Instrument cluster
ESP control unit
Yaw rate and lateral acceleration sensor
Steering angle sensor
Vehicle diagnosis/DAS data link connector
Electrical system
SAM
P54.21-3107-00
SAM control unit (rear)

45
Electrical system
SAM
The SAM control unit communicates with the rain
sensor/light sensor via LIN.
The relay and fuse box with all relays and fuses is
integrated in the SAM control unit, with the
exception of the following relays:
Relay 1 and 2 for air conditioning blower motor
Relay for electric drive and highvoltage
charger cooling system fan motor
Relay for highvoltage battery heater booster
P54.15-3318-00
K61 Relay 1 for blower motor

K62 Relay 2 for blower motor
P54.15-3317-00
K57 Relay for highvoltage battery heater booster

K59 Relay for cooler fan motor
46

The smart fortwo electric drive is driven by a

permanent magnet motor with an output of 30 kW.
The electric motor is connected to the electric
motor control unit. The motor is supplied with
power and controlled via the electric motor
control unit (EDCM).
The efficiency of the electric motor depends on

the operating temperature. The output of the
electric motor is reduced at temperatures over
95 C. This is displayed on the performance indi
cator of the instrument cluster.
Motor description
Both components are cooled via the electric drive

and highvoltage charger coolant circuit.
The DC/DC converter is integrated in the electric
motor control unit (EDCM).
P54.32-000-00
Output reduction indication
P08.10-2035-00
P20.00-2380-00
Electric motor coolant circuit
1
DC/DC converter
M5
Electric motor
M5
Electric motor

47
Transmission
Transmission description
A transmission with park pawl, which has been
modified for the electric drive system, is used in
the smart fortwo electric drive.
All components for gearshifting have been
removed and the resulting openings have been
fitted with covers. The drive system has a perma
nent gear ratio of 9.77:1. The differential has
been taken over from previous models and allows
the use of standard drive shafts.
Selector lever
Operation takes place via the selector lever/PRND
shifter with park pawl.
The mechanical park pawl is engaged in the trans
mission in position "P" via a cable.
The electric vehicle control unit (EVCM) reads in
the status of the park pawl via the park pawl
switch.
The reverse gear is implemented by changing the

rotating field of the electric motor.
P27.00-2332-00
1
2
3
4
5
48
Transmission
Right drive shaft
Left drive shaft
Park pawl
Selector lever/PRND shifter
M5
Electric motor
S16/2 Park pawl switch

Due to the greater vehicle weight, modified

springs are used at the front and rear axle.
Chassis
Axles and suspension
On the front axle, the crossmember for holding

the supporting strut for the highvoltage battery
was modified.
P33.00-2107-00
1
2
Front axle crossmember

Highvoltage battery supporting strut
P00.00-4499-00
Suspension and steering

49
Chassis
Rear module
The rear drive module can also be lowered on the
smart fortwo electric drive.
This allows access to various components such
as the refrigerant compressor, electric motor,
drive shafts etc. without removing CBS parts
(CBS = Customized Bodypanel System).
P35.00-2093-00
Lowered rear module

1 Spacer sleeve
2 Bolt
3 Frame-type integral support
i Note
a Warning
Before the rear module is lowered, the vehicle

power must be disconnected as per the deacti
vation log!
Spacer sleeves must be used at the front bolts to

lower the rear module, otherwise the HV connec
tion on the HV battery will be damaged and the
entire HV battery will have to be replaced!
Observe the corresponding notes in WIS:
f01.00P3050MEV
50

The smart fortwo electric drive is equipped with

two cooling systems:
Electric drive and highvoltage charger
cooling system
Highvoltage battery and interior cooling
system
Cooling systems

The electric drive cooling system is located at the
rear of the engine compartment and consists of
the following parts:
Cooler with coolant expansion reservoir
Fan
Coolant pump
The electric drive cooling system cools the HV
components
Electric motor
The electric vehicle control unit records the

values from the temperature sensors in the
components involved and controls the fan motor
and coolant pump according to requirements.
M4/8 Electric drive and highvoltage charger

fan motor
M46 Electric drive and highvoltage charger coolant
pump
P20.00-2381-00
Cooler with coolant expansion reservoir
The coolant (glycol/water mixture) is pumped

from the cooler to the electric motor control unit
by the coolant pump. From there, it passes into
the electric motor and flows through the coolant
ducts integrated in the outer wall of the electric
motor on to the highvoltage charger control unit.
From there, it returns to the coolant expansion
reservoir.

51
Cooling systems
P20.00-2375-00
Coolant circuit
M4/8 Electric drive and highvoltage charger fan
motor
M5
Electric motor
M46 Electric drive and highvoltage charger
coolant pump
52

The highvoltage battery and interior cooling

system consists of the refrigerant circuit and the
highvoltage battery coolant circuit. It includes
the following individual components:
The interior evaporator and HV battery heat

exchanger use thermostatic expansion valves with
electromagnetic shutoff capability.
Cooling systems
Highvoltage refrigerant compressor

Condenser
Evaporator (interior)
HV battery heat exchanger (chiller)
Coolant expansion reservoir
Battery cooling system coolant pump
P20.00-2378-00
G5
Highvoltage battery
M4/9 Highvoltage battery and interior fan motor
M43/2 Battery cooling system coolant pump
R101 Highvoltage battery heater booster
Y19/1 Interior air conditioning expansion valve
Y19/3 Battery air conditioning expansion valve
1
2
3
4
5
A
B

Condenser
Evaporator
Heat exchanger (chiller)
Refrigerant
Coolant

53
Cooling systems

Highvoltage battery cooling system
Interior cooling system
In order to cool the highvoltage battery, the

coolant pump pumps coolant from the expansion
reservoir through the highvoltage battery heat
exchanger and the highvoltage battery heater
booster to the highvoltage battery. From there,
it returns to the expansion reservoir.
As on vehicles with a combustion engine, the inte

rior is cooled via the refrigerant circuit with the
following components:
If the temperature in the highvoltage battery

exceeds certain specified values, refrigerant is
directed through the highvoltage battery heat
exchanger (chiller) via the battery air condi
tioning expansion valve so that heat is removed
from the coolant circulating in the highvoltage
battery coolant circuit.
Condenser
Expansion valve
Evaporator
If the coolant temperature is below the optimal

highvoltage battery operating temperature, the
battery management system activates the high
voltage battery heater booster integrated in the
highvoltage battery coolant circuit and the
coolant is heated.
The output of the electric motor is reduced at a

highvoltage battery operating temperature of
above +55 C or below +5 C. This is displayed on
the performance indicator of the instrument
cluster.
P54.32-000-00
Output reduction indication
54

Highvoltage battery cooling mode

In cooling mode, the battery management control
unit actuates the battery cooling system coolant
pump with a PWM signal according to require
ments and coolant is pumped through the heat
exchanger via the coolant circuit. If the cooling
requirement is high enough, the electric vehicle
control unit (EVCM) opens the battery cooling air
conditioning expansion valve and actuates the
refrigerant compressor.
The refrigerant is directed through the heat

exchanger and removes thermal energy from the
coolant in the highvoltage battery coolant
circuit.
Cooling systems
P00.00-2376-00
Cooling mode (schematic)

G5
M43/2
N3
N82/2
R101
Y19/1
Y19/3
Highvoltage battery
1
2
3
4
5
a
b
c
d

Condenser
Evaporator
Refrigerant feed
Refrigerant return
Coolant feed
Coolant return

55
Cooling systems

Highvoltage battery heating mode
If the temperature is low enough, the highvoltage
battery is heated via the coolant circuit until the
optimal operating temperature is reached. The
12 V highvoltage battery heater booster is
located between the heat exchanger and battery
cooling system coolant pump.
The battery air conditioning expansion valve is

closed by the electric vehicle control unit (EVCM)
so that no refrigerant flows through the heat
exchanger. The coolant passes through the heat
exchanger without temperature change, is heated
by the highvoltage battery heater booster
installed behind it and is pumped to the high
voltage battery. From there, it returns to the
coolant expansion reservoir.
P00.00-2377-00
Heating mode (schematic)

G5
M43/2
N3
N82/2
R101
Y19/1
Y19/3
56
Highvoltage battery
1
2
3
4
5
a
b
c
d

Condenser
Evaporator
Refrigerant feed
Refrigerant return
Coolant feed
Coolant return

Instrument cluster
Additional instruments
The instrument cluster has been adapted to the

requirements of the electric drive system with
new indicator and warning lamps and a power
indicator instead of a fuel level indicator.
The function of the two additional instruments on

the center of the instrument panel has been modi
fied:
The new indicator and warning lamps display the

following information:
Charging cable connected

Regenerative braking inactive
Drive diagnosis indicator lamp
Drive diagnosis warning lamp
Electric drive system, highvoltage charger
and highvoltage battery coolant temperature
warning lamp
Highvoltage battery warning lamp
12 V battery warning lamp
Design
Instrument cluster
Right: Highvoltage battery energy flow (kW)

Left: Charge level indicator of battery
(SOC in %)
Multifunction display
The multifunction display provides information
about variable changes in the vehicle, its
surroundings and the route. These include:
Outside temperature
Main odometer
Trip odometer
Display of available power from electric motor
Coolant temperature gauge
Frost warning symbol
Clock
P54.32-8104-00
Additional instruments
A15p6 HV battery energy flow
A15p7 HV battery charge level indicator

57
Design
Instrument cluster
P54.32-8087-00
Instrument cluster
1
2
A1
A1e1
A1e2
A1e3
A1e7
A1e9
58
Left button, select multiple display/set clock

Right button, instrument illumination/set clock
Instrument cluster
Left turn signal indicator lamp
Right turn signal indicator lamp
High beam indicator lamp
Brake fluid and parking brake warning lamp
Seat belt warning lamp
A1e15
A1e17
A1e18
A1e41
A1e52
A1e54
A1e66
A1e67
A1e70
A1e72
A1e73
A1e74
A1e75
A1p8
A1p13
Airbag indicator and warning lamp

ABS indicator lamp
Electric steering indicator lamp
ESP warning lamp
Rear fog light indicator lamp
Coolant temperature warning lamp
Tire pressure monitor warning lamp
Low beam indicator lamp
Charging cable indicator lamp
Drive system diagnosis indicator lamp
Drive system diagnosis warning lamp
Highvoltage system warning lamp
12 V battery warning lamp
Electronic speedometer
Multifunction display

Design
Instrument cluster
Limphome mode
The limphome function with output and torque
reduction is activated if one of the following
events occurs:
Faults in the 12 V onboard electrical system
Accelerator pedal malfunction
Faults in battery management system
and malfunction of HV battery coolant pump
The drive diagnosis indicator lamp comes on in
the instrument cluster.
P54.32-8211-00
1
Performance indicator
A1
Instrument cluster
A1e72 Drive system diagnosis indicator lamp
HV battery charge level SOC (State Of Charge)

As of 5% SOC, an acoustic warning sounds and the
performance indicator on the instrument cluster
starts to flash.
Between 5% and 2% SOC, the output is continuously
limited down to 10 kW.
P54.32-8257-00
A15p7 HV battery charge level indicator

59
Design
Climate control
Heating
Air conditioning
A highvoltage PTC heater booster with 4 kW

output is used instead of a heating system heat
exchanger through which coolant flows as is the
case on vehicles with a combustion engine.
Operation takes place via the AAC operating unit

as on conventional vehicles of model series 451.
Heating is controlled via the drive train CAN by

the electric vehicle control unit depending on the
charge level of the highvoltage battery. The heat
output can be reduced if the charge level of the
highvoltage battery becomes too low because
the electric vehicle control unit gives priority to
supplying power to the electric motor and high
voltage battery cooling system.
The PTC heater is supplied with power by the
highvoltage distributor control unit.
However, the system design is different from that

of conventional vehicles of model series 451 in
some significant aspects.
The differences in the design of the air condi
tioning are:
Nonbeltdriven highvoltage refrigerant
compressor
Thermostatic expansion valve on interior
evaporator with electromagnetic shutoff
capability
Additional refrigerant circuit branch to high
voltage battery heat exchanger (chiller) with
expansion valve on highvoltage battery heat
exchanger with electromagnetic shutoff
capability.
P83.00-2323-00
1 Condenser
2 Evaporator
3 Refrigerant compressor
60
M4/9 Highvoltage battery and interior fan motor

R23 Highvoltage PTC heater
Y19/1 Interior air conditioning expansion valve

Air conditioning operating unit
The drive system for the refrigerant compressor

has to be kept separate from the drive motor so
that sufficient cooling output can be provided
when the vehicle and the electric motor are
stationary. This ensures that the highvoltage
battery can be cooled independently and climate
control for the vehicle interior can operate inde
pendently. This is achieved by means of an elec
trically driven highvoltage refrigerant
compressor.
The air conditioning operating unit is located at

the top of the center console. The interior
temperature sensor is located at the bottom of the
air conditioning operating unit.
The highvoltage refrigerant compressor draws

in and compresses the refrigerant (R134a) and
pumps the refrigerant through the system.
Depending on the evaporator temperature, the
highvoltage refrigerant compressor is step
lessly regulated from 800 to 9000 rpm.
The electric refrigerant compressor consists of
the following three main groups:
Control unit with integrated power electronics
Electric motor
Spiral compressor
The control unit of the highvoltage refrigerant
compressor regulates the speed of the electric
motor and the quantity of refrigerant. The elec
tric motor drives the spiral compressor. This
consists of two spiral coils nested inside each
other, whereby the first coil is permanently
attached to the housing and the second moves in a
circular pattern inside the first. The spiral coils
thus touch each other at several points and form
a number of chambers of ever decreasing size
within the coils. The refrigerant is thus
compressed and moves towards the center of
these chambers, where it then exits the spiral in
compressed form.
Design
Climate control
When the desired temperature is set, the request

for heating or cooling is transmitted to the elec
tric vehicle control unit (EVCM) via the drive train
CAN. There, the values for outside temperature
and interior temperature provided by the instru
ment cluster are compared to the desired value
and the corresponding function is activated.
Heating:
The electric vehicle control unit (EVCM) regulates
the power supply to the highvoltage PTC heater
in the air conditioner housing from the high
voltage distributor control unit (PDU) via a PWM
signal.
Cooling:
The electric vehicle control unit (EVCM) opens the
interior air conditioning expansion valve and the
interior cooling refrigerant circuit is closed. The
electric vehicle control unit (EVCM) gives priority
to cooling the highvoltage battery. If the battery
management system control unit reports that the
temperature of the highvoltage battery is above
the specified value, cooling of the interior is
reduced for the duration of the battery cooling
period.

61
Design
Climate control
Preconditioning
As a special comfort feature, the vehicle interior
of the smart fortwo electric drive can be pre
heated or precooled. The Telestart T 91 system
is installed for this purpose. Telestart consists of
the following components
Antenna
Receiver
Transmitter
Operation takes place via the Telestart trans
mitter.
P83.70-5300-00
Prerequisites
A6/2 Telestart receiver
Driver door and liftgate closed

Soft top closed (cabrio)
Vehicle is supplied with mains power via an
external charging cable
SOC over 75%
The Telestart antenna is located on the windshield
above the inside rearview mirror. The Telestart
receiver is installed on the right cockpit cross
member next to the steering column.
When a "Heating/cooling" request is received
from the receiver, the electric vehicle control
unit (EVCM) checks the required parameters and
actuates the corresponding components.
Replacement parts for the Telestart components
are supplied by Webasto.
P83.70-5301-00
A8/7 Telestart transmitter
P83.70-5303-00
A2/24 Telestart antenna
62

Design
Body
Bodyshell structure
The bodyshell structure has been taken over from
the series production vehicles unchanged.
A Soft deepdrawing steels:
In these areas, all the usual welding methods can
be used.
B Highstrength steels:
These areas consist of highstrength, 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.
P60.00-2875-00
Bodyshell material overview

A
B
Soft deepdrawing steels

Highstrength steels

63
Design
Body
Underfloor
The holding devices for the highvoltage battery
are located in the area of the underfloor.
P60.00-2876-00
Highvoltage battery holding devices (red)
64

Chassis
Highvoltage system
If damage to the chassis has occurred or is

suspected, a wheel alignment check is recom
mended for quick diagnosis of the damage. The
wheel alignment data for the series production
vehicle with combustion engine apply.
After the vehicle has been subjected to a signifi

cant impact, the highvoltage system must be
checked to determine whether it is deenergized.
Work on the vehicle may only be carried out by an
"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
before the wheel alignment check. In particular,
the four bolting points (front axle carrier/frame
type integral support) to the body must be
checked for displacement.
If there is any type of deformation on the front or
rear axle, it must be replaced. For this reason,
these components must be visually inspected with
care for cracks and deformation.
In order to check for frame damage, electronic
body measurement systems can be used for diag
nostic purposes e.g.
"Contact" (CAR BENCH)
"NAJA" (Celette)
"Shark" (Blackhawk)
Design
Notes on damage analysis
If it is not possible to definitively determine that

the highvoltage system is deenergized, e.g. due
to mechanical damage, no further work may be
performed on the highvoltage system.
Once the power has been disconnected, the high
voltage system must be checked for external
damage and defects. Damaged or defective high
voltage components, cooling systems or lines
must be replaced.
Repairing the highvoltage components is not
permissible.
When inspecting highvoltage components,
personal protective equipment must always be
worn (safety glasses, electrical gloves etc.).

65
Design
Notes on supplemental restraint systems

Airbag or emergency tensioning retractor
units
Before performing work on the airbag or emer
gency tensioning retractor units, which requires
intervention in their electric circuits (e.g. disas
sembly), the highvoltage system must always be
deenergized.
The vehicle's power may only be disconnected by
an "Electrical specialist for HV systems in motor
vehicles (series production vehicles)".
66
i Note
Airbag or emergency tensioning retractor units
which have been dropped from a height of over
0.5 m must be replaced.
Do not allow airbag or emergency tensioning
retractor units to come into contact with grease,
oil or cleaning agents.
To allow emergency tensioning retractor units to
be installed without damage or soiling, they are
fitted with a PVC protective hose. After installa
tion, these protective components can be
removed. No sharpedged tools may be used for
removal to prevent damaging the belt strap.

Body
Welding
Depending on the extent of the damage, sheet

metal damage can be repaired in various ways:
Welding may only be performed on the vehicle

after its power has been disconnected.
Remove dents from sheet metal part(s)

Partially replace sheet metal part(s)
Completely replace sheet metal part(s)
The highvoltage battery should be protected

from the influence of thermal energy.
Only the cutting areas are specified for sectional

repairs (also "replacement part repairs"). This
gives the service operation some leeway when
adjusting the section to the respective damage
profile. Cuts should always be made at the
narrowest point and along the shortest distance.
Sectional repairs on the front longitudinal
member are only permissible in front of the axle
mount. The dull repair weld seams on the front
longitudinal member repair section may not be
ground smooth for strengthrelated reasons.
Before and after body repairs, the fault memory
must be read out and any faults present must be
documented.
After repairs to the body or body connections
(e.g. suspension), the steering angle sensor (ESP)
must be reparameterized.
Design
Notes on repair operations
Before welding, a voltage monitor can be attached

to the 12 V battery. This protects electronic
systems and components from brief voltage peaks
(overvoltage) caused by the welding equipment.
The 12 V battery does not then have to be discon
nected.
The decision as to whether a voltage monitor is
used or the 12 V battery is disconnected depends
on the extent of the damage.
Postrepair refinishing
The following measures must be observed before
and during painting work:
The preparation of paints produces vapors
which combust in an explosion if ignited.
Good ventilation must be provided before and
during painting work.
A dry temperature (or object temperature) of
60 C may not be exceeded.

67
Special tools
Electrical system
Release tool
Use Release tool for HV connectors. For

releasing HV connectors on the high
voltage lines to the highvoltage battery
and electric drive.
MB number W 245 589 00 63 00
P58.20-2278-00
FG 06
Set B
Activation lock
Use Reactivation lock.
MB number A 451 545 01 08
68

P58.20-2279-00
Guide pins
Special tools
Electrical system
Use Guide pins for installing the highvoltage

battery.
MB number W 156 589 00 31 00
P58.20-2280-00
FG 54
Set B
Spacer sleeves
Use Spacer sleeves for bolts for lowering rear

module.
Note Tool is shopmade
P58.50-2066-01
y58.50P035001MEV
Lifting platform
Use Lifting platform for removing/installing

highvoltage battery and for lowering rear
module.
MB number gotis://A_01_07.1
P58.20-2110-00

69
Special tools
Electrical system
Highvoltage battery locks
Use Set of locks for electrical connections on

highvoltage battery.
MB number A 451 546 05 35

P58.20-2282-00
70

ABS
EAC
Antilock Brake System
Electric Air Compressor
AKSE
EBD
Automatic Child Seat Recognition (ACSR)
Electronic brake force distribution
BAS
ECO
Brake Assist System
Electronically Controlled Orifice
BMS
EDCM
Battery Management System
Electric Drive Control Module

(electric motor control unit)
Annex
Abbreviations
CAN
ESP
Controller Area Network
Electronic Stability Program
CBS
ESS
Customized Bodypanel System
Energy Storage System
COMAND
EVCM
Cockpit Management and Data System
Electric Vehicle Control Module
DAS
VIN
Diagnosis Assistance System
Vehicle Identification Number
DVD
GF
Digital Versatile Disc
Basic knowledge/functions (WIS)

71
Annex
Abbreviations
HV
RBS
High Voltage
Regenerative Braking System
HVIL
RCD
High Voltage Interlock Loop
Residual Current Protection Device
LED
SAM
Light Emitting Diode
Signal acquisition and actuation module
LIN
SCCU
Local Interconnect Network
Smart Charge Communication Unit

(external power outlet communications control unit)
LV
SIS
Low Voltage
Safety Inertia Switch
MAG
SOC
Metal Active Gas
State of Charge
NCT
UDDS
Negative Temperature Coefficient
Urban Dynamometer Driving Schedule
NEFZ
WIS
New European Driving Cycle (NEDC)
Workshop Information System
OBD
OnBoard Diagnostics
PDU
Power Distribution Unit
(highvoltage distributor)
PTC
Positive Temperature Coefficient
PWM
Pulse Width Modulation
72

Activation lock . . . . . . . . . . . . . . . . . . . . 34
Additional instruments . . . . . . . . . . . . . . . . 57
Air conditioning . . . . . . . . . . . . . . . . . . . . 60
Heating . . . . . . . . . . . . . . . . . . . . . . . . 60
Highvoltage battery
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
55
56
22
22
. . . . . . . . . . . . . . . . . . 24
.
.
.
.
Highvoltage refrigerant compressor .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
19
17
19
19
61
. . . . . . . . . . . . . . . . . . 52
HV line connectors . . . . . . . . . . . . . . . . . 16
Operating unit . . . . . . . . . . . . . . . . . . . 61
B
Bodyshell structure . . . . . . . . . . . . . . . . . 63
C
CAN bus . . . . . .
Charging duration
Coolant circuit . .
Cooling system . .
. . . . . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . . . . 51
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Check after an accident . . . . .

Overview . . . . . . . . . . . . .
Safety function after an accident
Wiring harness check . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
Cooling mode
Heating mode
Storage . . .
Transport .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Annex
Index
Highvoltage components
I
Initial startup
D
Desiccant cartridge . . . . .
Diagnosis assistance system
Dimensions . . . . . . . . . .
Dimensions and weights . . .
Drive system diagnosis . . .
Drive train CAN . . . . . . . .
. . . . . . . . . . . . 20
. . . . . . . . . . . . 42
. . . . . . . . . . . . 11
. . . . . . . . . . . . 11
. . . . . . . . . . . . 43
. . . . . . . . . . . . 40
Form . . . . . . . . . . . . . . . . . . . . . . . . 35
Innovations . . . . . . . . . . . . . . . . . . . . . . . 9
Instrument cluster . . . . . . . . . . . . . . . . . 57
L
Limphome mode . . . . . . . . . . . . . . . . . . . 59
LIN bus . . . . . . . . . . . . . . . . . . . . . . . . 41
Electric Drive CAN . . . . . . . . . . . . . . . . . . 40

Energy Storage System CAN . . . . . . . . . . . . 40
Maintenance concept . . . . .
Maintenance interval . . . . .
Maintenance points . . . . . .
Multifunction display . . . . .
F
Front axle . . . . . . . . . . . . . . . . . . . . . . . 49
Fuse assignments . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . 13
. . . . . . . . . . . 13
. . . . . . . . . . . 13
. . . . . . . . . . . 14
. . . . . . . . . . . 57

73
Annex
Index
Output reduction . . . . . . . . . . . . . . 47, 54, 59
Safety Inertia Switch . . . . . . . . . . . . . . . . . 19

Selector lever . . . . . . . . . . . . . . . . . . . . . 48
Service Disconnect . . . . . . . . . . . . . . . . . . 34
P
Park pawl . . . . . . . . . . . . . . . . . . . . . . . .48
Performance indicator . . . . . . . . . . . 47, 54, 59
Power disconnect
Power disconnect matrix . . . . . . . . . . . . . .36
Preconditioning . . . . . . . . . . . . . . . . . . .62
Prefuse
12 V battery . . . . . . . . . . . . . . . . . . . . .26
U
Underfloor . . . . . . . . . . . . . . . . . . . . . . 64
V
Vacuum pump . . . . . . . . . . . . . . . . . . . . . 32
Vehicle concept . . . . . . . . . . . . . . . . . . . . 8
R
Regenerative braking . . . . . . . . . . . . . . . .32
Residual current protection device . . . . . . . .27
Reverse gear . . . . . . . . . . . . . . . . . . . . .48
74


Model Series 451
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Introduction of the smart fortwo electric drive Model Series 451
Introduction into Service Manual

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Introduction of the smart fortwo electric drive

smart A Daimler Brand

Introduction of the smart fortwo electric drive Model Series 451

Introduction into Service Manual

Introduction of the smart fortwo electric drive

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

Information and Copyright

Questions and Suggestions

Image no. of title image:

Highvoltage charger control unit

External power outlet communications control unit

Charger feedin socket

Highvoltage distributor control unit (PDU)

Introduction of the smart fortwo electric drive, Model series 451

Highvoltage battery and interior cooling system

Notes on damage analysis

Notes on supplemental restraint systems

Notes on repair operations

Introduction of the smart fortwo electric drive, Model series 451

Introduction of the smart fortwo electric drive, Model series 451

Introduction of the smart fortwo electric drive, Model series 451

WIS is updated continuously. Therefore, the infor

Introduction of the smart fortwo electric drive, Model series 451

With the smart fortwo electric drive, the brand is

Introduction of the smart fortwo electric drive, Model series 451

The 30 kW electric motor provides fast accelera

Due to the output characteristics of the electric

Electric drive system of smart fortwo electric drive

Introduction of the smart fortwo electric drive, Model series 451

smart fortwo electric drive coup

smart fortwo electric drive cabrio

smart fortwo electric drive coup

9 Charger feedin socket

Introduction of the smart fortwo electric drive, Model series 451

Range as per NEDC

Front track width

Rear track width

Dimensions and weights

Curb weight (as per DIN/EPA)

Permissible gross vehicle weight

Max. seating capacity

Introduction of the smart fortwo electric drive, Model series 451

Motor model designation

Permanent magnet motor

Rear wheel drive

Introduction of the smart fortwo electric drive, Model series 451

Maintenance interval display

The maintenance concept mainly differs in terms

The maintenance interval display is located in the

In addition to a visual inspection for damage and

The same maintenance must be performed for

Maintenance interval display

Introduction of the smart fortwo electric drive, Model series 451

Maintenance items at front

Rear maintenance item

Rear maintenance item

Introduction of the smart fortwo electric drive, Model series 451

The vehicle can be towed at a maximum speed of

If the vehicle is towed at a speed greater than

Introduction of the smart fortwo electric drive, Model series 451

Onboard electrical system/power supply

Information on the highvoltage system