battery SMART FORTWO COUPE 2015 Repair Manual

ther gas is being discharged by the bat-
teries.
Only charge the battery in a well ventilated area.
There is a risk of acid burns during the
charging procedure due to the gases which
escape from the battery. Do not lean over
the battery when it is being charged. G
WARNING
Never charge a battery while still installed in the vehicle. Gases may escape during
charging and cause explosions that may
result in paint damage, corrosion or per-
sonal injury.
X Charge battery in accordance with the
instructions of the battery charger man-
ufacturer.
! Only use chargers of a correct and suit-
able voltage.
! Never attempt to recharge a frozen bat-
tery. Have the battery checked at a smart center. The battery housing could be
damaged.
Reinstalling the 12-volt battery X
Reinstall the charged battery. Follow the
previously described steps in reverse
order.
! The battery, its filler caps and the ven-
tilation hose must always be securely
installed when the vehicle is in opera-
tion.
Reconnecting the 12-volt battery !
Always connect the battery in the order
described below. Otherwise the vehi-
cle’s electronics can be damaged.
X Turn off all electrical accessories.
X Remove the key from the starter switch.
! Never invert the terminal connections! X
Connect the battery positive lead and
fasten cover ?(Ypage 199).
X Connect battery negative lead =
(Y page 199).
i After battery power (e.g. due to recon-
nection) was interrupted, you will have
to set the clock (Y page 94).
i Have the battery’s charge status and
acid level checked at the start of the cold
season at a an authorized electric drive
smart center. Jump starting
Notes
G
WARNING
Failure to follow these directions will
cause damage to the electronic components, and can lead to a battery explosion and
severe injury or death.
Never lean over batteries while connecting
or jump starting, you might get injured.
Battery fluid contains sulfuric acid. Do not
allow this fluid to come in contact with
eyes, skin or clothing. In case it does,
immediately flush affected area with
water, and seek medical help if necessary.
A battery will also produce hydrogen gas,
which is flammable and very explosive.
Keep flames or sparks away from battery,
avoid improper connection of jumper
cables, smoking, etc.
Attempting to jump start a frozen battery
can result in it exploding, causing per-
sonal injury.
Read all instructions before proceeding.
! Do not tow‑start vehicle. It is not pos-
sible to tow-start the vehicle. Attempt-
ing to do so may seriously damage the
drivetrain which would not be covered by the smart Limited Warranty.
If the 12-volt battery is discharged, the
drive system cannot be started, regardless 200
Jump starting>> Practical hints.

of whether the high-voltage battery is
charged or not. Jump starting will not help
to start the drive system if the high-volt-
age battery is drained. The high-voltage
battery must then be charged.
The drive system can be started with jumper cables and the fully charged battery of
another vehicle or an equivalent starter
pack.
Observe the following:
R Do not start the drive system if the bat-
tery is frozen. Let the battery thaw out
first.
R Only jump start from batteries with the
same voltage rating (12 V). Jump starting with a more powerful battery could dam-
age the vehicle’s electrical system. Such
damage will not be covered by the smart
Limited Warranty.
R Only use jumper cables with sufficient
cross-section and insulated terminal
clamps.
R Should the battery be drained com-
pletely, let the donating power source
charge the vehicle for several minutes
before reattempting the starting proc-
ess. G
WARNING
Keep flames or sparks away from battery. Do
not smoke.
Observe all safety instructions and pre-
cautions when handling automotive batter- ies. Jump starting
201>> Practical hints. Z

Jump start assistance
Your vehicle’s 12-volt battery is located in the passenger footwell below the footrest
(Y page 199).
For jump starting, use the terminals of the battery, keeping the leads connected.
X Make sure the two vehicles do not touch.
X Switch off all electrical consumers.
X Engage the parking brake.
X Move the gear selector lever to park position P.
X Switch off the drive system.
X Get access to the battery in the passenger footwell (Y page 199).
X Remove the positive terminal cover. Position
Arepresents the charged battery of another vehicle or an equivalent starter
pack.
! Never invert the terminal connections!
X Connect positive terminal :of charged battery Awith positive terminal ;of your
vehicle’s battery Bwith a jumper cable. Clamp the jumper cable to positive termi-
nal :of charged battery Afirst.
X Start the engine of the vehicle with charged battery A.
X Connect negative terminal =of charged battery Awith negative terminal ?of your
vehicle’s battery Bwith a jumper cable. Clamp the jumper cable to negative terminal
= of charged battery Afirst.
X Start the drive system of your vehicle. You can now switch on minimal consumers. Do not
switch on large consumers such as the rear window defroster or headlamps. 202
Jump starting>> Practical hints.

X
Remove the jumper cables from negative terminals =and ?first.
X Remove the jumper cables from positive terminals :and ;.
You can now switch on the headlamps.
X Remount the positive terminal cover.
X Have the 12-volt battery checked at the nearest authorized electric drive smart center.
i Please keep in mind that it will take quite some time to charge the 12-volt battery.
When you switch off the drive system after driving a short distance, you may not be able to start it again.
Charge the 12-volt battery completely as soon as possible. Towing
About towing
This section offers information on towing
methods for breakdown situations and
emergency towing. Recommended towing method - Break-
down situation
! To prevent damage during transport, do
not tie down the vehicle by its chassis or suspension parts — use only wheel straps to position and hold down the vehicle.
Improper tie down on a flatbed carrier
truck or trailer can damage suspension
parts and body panels.
smart recommends that the vehicle be
transported with all wheels off the ground
using a flatbed carrier truck or appropri- ate wheel lift/dolly equipment.
Always have your vehicle transported:
R when the Nwarning lamp for the high-
voltage system lights up in the instru-
ment cluster
R when the Do not tow (away)
Do not tow (away) message
appears in the instrument cluster
R when the multifunction display is inop-
erative R
when one or several of the following
warning lamps light up:
- þ Drive diagnostics (red)
- # 12‑Volt battery
D Power steering
R if the brake pedal already starts to pul-
sate just after towing begins
R if you have to transport the vehicle over
long distances
X Switch off the tow‑away protection* and
interior motion sensor* (Y page 50). Emergency towing
When circumstances do not permit the rec-
ommended towing method, the vehicle may
be towed with all wheels on the ground
using a strap or tow bar connected to
another vehicle. Only tow the vehicle as far as necessary to have the vehicle moved to a
safe location where the recommended tow-
ing method can be employed. G
WARNING
If circumstances require towing the vehi-
cle with all wheels on the ground, always tow
with a tow bar if:
R the drive system will not run
R there is a malfunction in the brake sys-
tem
R there is a malfunction in the power sup-
ply or in the vehicle’s electrical system Towing
203>> Practical hints.
* optional Z

A tow bar is necessary to adequately control
the towed vehicle.
Prior to towing the vehicle with all wheelson the ground, make sure the gear selector
lever is in neutral position Nand the igni-
tion is switched on. G
WARNING
With the drive system inactive, there is no power assistance for the brake and steering
systems. In this case, it is important to
keep in mind that a considerably higher
degree of effort is necessary to brake and
steer the vehicle. Adapt your driving
accordingly.
! The vehicle may be towed only for dis-
tances up to 30 miles (50 km) and at a
speed not to exceed 30 mph (50 km/h).
Otherwise, the electric drive or the
high-voltage system could be damaged.
! Do not tow other vehicles.
Otherwise, the drive system or compo-
nents of the high-voltage system could be damaged.
! Do not tow the vehicle with the front
axle raised. Doing so may cause serious
damage to the brake system which is not
covered by the smart Limited Warranty.
! Before towing the vehicle observe the
following instructions:
R Do not tow with sling-type equipment
attached to suspension parts. This may cause damage to the supports if towing on a bumpy road.
R Towing the vehicle should only be done
using the properly installed towing
eye bolt. Never attach a tow cable, tow
rope, or tow rod to the vehicle chassis, frame, or suspension parts.
! Make sure the gear selector lever is in
neutral position Nwhile towing the
vehicle. Doing otherwise may result in
significant drive train damage. !
Towing the vehicle with a luggage rack*
mounted is not permissible. The vehicle
must not be towed by the luggage rack*.
i If the 12-volt battery is disconnected
or discharged, the gear selector lever
will remain locked in park position P.
Contact an authorized electric drive
smart center for assistance or call Road-
side Assistance.
Towing eye bolt The towing eye bolt is located in the
passenger footwell under the carpet.
X Unscrew the carpet holder in the
passenger footwell (Y page 160).
X Lift the carpet. X
Take out towing eye bolt :.
Installing towing eye bolt
The towing eye bolt can be screwed into
threaded holes which are located behind
covers on the front and rear bumper. Front cover204
Towing>> Practical hints.
* optional

No. Accessory/Component Amperage Color
E
CPC, shifter, brake force booster vacuum
pump 7.5 A Brown
F
Coolant pumps 1 and 2, high-voltage battery 15 A Blue
G
ESP
®
control unit 25 A Neutral
H
Exterior lamp switch, turn signal lamp
switch, cockpit switch module, on-board
diagnostics socket, exterior rear view mir-
ror heating, anti-theft warning system,
rain-light sensor, charge level and power
gauges, central locking system, instrument
cluster, Tire Pressure Monitoring System
(TPMS), brake and turn signal lamps (left and right) 10 A Red
I
— — —
J
— — —
K
Safety circuit high-voltage battery 15 A Blue
L
— — —
M
Rear window wiper (coupé only) 15 A Blue
N
ESP
®
control unit, EPS control unit, restraint
systems 10 A Red
O
Electric drive components, engine control
unit, transmission control unit, on-board
diagnostics socket, sound generator 7.5 A Brown
P
Air conditioning system, exterior rear view
mirror adjustment, washer pump, audio, seat
heating, wiper switch, cruise control, soft
top switch (cabriolet only), backup lamp 10 A Red
Q
Auxiliary power outlet 15 A Blue
R
Left low‑beam headlamp 7.5 A Brown
S
Right low‑beam headlamp 7.5 A Brown
T
— — —
U
Right high‑beam headlamp 7.5 A Brown
V
Left high‑beam headlamp 7.5 A Brown
W
Electric drive components 7.5 A Brown Fuses
209>> Practical hints. Z

G
WARNING
Windshield washer concentrate is highly
flammable. Fire, naked flames and smoking
are prohibited when windshield washer
concentrate is being handled. Coolants
The battery and drive system coolant is a
mixture of water and anticorrosion/anti-
freeze, which provides: R Corrosion protection
R Freeze protection
R Boiling protection (by increasing the
boiling point)
The cooling system was filled at the factory with a coolant providing freeze protection
to approximately -35¦ (-37¥) and corro-
sion protection.
! Add premixed coolant solution only.
Adding water and MB 325.0 Anticorro-
sion/Antifreeze separately from each
other, could cause drive system damage
not covered by the smart Limited War-
ranty.
If the antifreeze mixture is effective to
-35¦ (-37¥), the boiling point of the
coolant in the pressurized cooling system
is reached at approximately 266¦ (130¥).
The coolant solution must be used year
round, even in countries which have high
temperatures to provide the necessary cor-
rosion protection and increase boil‑over
protection. Refer to Maintenance/ Service
Booklet for replacement interval.
Coolant system design and coolant used
determine the replacement interval. The
replacement interval published in the
Maintenance booklet is only applicable if
MB 325.0 Anticorrosion/Antifreeze solu-
tion or other smart approved products of
equal specification are used to renew the
coolant concentration or bring it back up
to the proper level. For information on other smart approved
products of equal specification, contact an
authorized electric drive smart center.
To provide important corrosion protec-
tion, the solution must be at least 50% anti-
corrosion/antifreeze (equivalent to freeze
protection to approximately -35¦
[-37¥]).
If you use a solution that is more than 55%
anticorrosion/antifreeze (freeze protec-
tion to approximately -49 ¦[(-45¥ ]), the
drive system and battery temperature will
increase due to the lower heat transfer
capability of the solution. Therefore, do
not use more than this amount of anticor-
rosion/antifreeze.
If the coolant level is low, water and
MB 325.0 Anticorrosion/Antifreeze should
be used to bring it up to the proper level
(have cooling system checked for signs of
leakage). Please make sure the mixture is
in accordance with label instructions.
Always use anticorrosion/antifreeze that
has been approved by smart. For informa-
tion contact an authorized electric drive
smart center.
The water in the cooling system must meet
minimum requirements, which are usually
satisfied by normal drinking water.
If you are not sure about the water quality, consult an authorized electric drive smart
center.
Capacities Cooling-system
capacity
All models approx. 6.9 US qt
(6.5 l)
Anticorrosion/antifreeze
Your vehicle contains a number of alumi-
num parts. The use of aluminum components
in motor vehicle drive systems necessi-
tates that anticorrosion/antifreeze cool- Service fluids and capacities
219>> Technical data. Z