Fiat 500 Abarth User manual

Fiat
Quick guide to Repairs

Nuova 500
Index
Index
1. Vehicle identification
2. Technical description
2.1 Electrical system functional diagram
2.2 12V battery
2.3 Precautions relating to the HV electrical system
3. Safety regulations for working with high
voltages
3.1 High-Voltage System
3.2 PPE characteristics
4. Securing the car
4.1 ACCESSING THE PASSENGER COMPARTMENT
(with 12V battery CHARGED)
4.2 ACCESSING THE PASSENGER COMPARTMENT
(with 12V battery FLAT)
4.3 Immobilisation
4.4 Stabilisation
4.5 Making a vehicle safe after an accident
4.6 Making the vehicle safe after an accident if the airbags were
NOT deployed
4.7 Making the vehicle safe after an accident if the airbags were
deployed
4.8 Intervention in case of submersion of the car
4.9 Intervention in case of fire of the car
5. Emergency procedures
5.1 Charging cable emergency unlock
5.2 Jump starting - Low-voltage battery (12V) flat
6. Flat battery operations
6.1 Electric sunroof emergency closing
6.2 Electric soft top emergency closure
6.3 Tailgate emergency opening
7. Towing the car
7.1 Tow ring
7.2 Towing a broken-down car
8. Car storage
8.1 Delimitation of the storage area
8.2 Safety information

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Vehicle identification
1
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External recognition elements
1. Vehicle identification

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Technical description
2
2.1 Electrical system functional diagram
A. Charging port
B. High-voltage battery
C. High-voltage electric compressor
D. Traction electric motor
E. Voltage converter
The propulsion system of the New 500 is completely powered by the
energy contained in the high-voltage lithium-ion rechargeable
battery of the car. Unlike conventional or hybrid cars, there is no
internal combustion engine in this car.
The New 500 uses the electrical energy stored in the high-voltage
battery and not fuel. This battery provides the energy needed to
start moving and therefore needs to be recharged before use. If the
high-voltage battery is completely flat the car will not start.
2. Technical description

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Technical description
3
This car also has a 12V battery of the same type as those used by
cars with internal combustion engines. If the 12V battery is
completely flat the car will not start.
The 12V battery supplies power to the conventional electrical
system: lights, windscreen wipers, restraint systems (airbags and
pretensioners), sound system, etc.
The high-voltage battery supplies power to the electric motor and
supplies the high-voltage auxiliary devices (heaters, electric climate
compressor, etc.). The electronic converter that powers the 12V
system for general car operation is also powered by the high-
voltage battery and also recharges the 12V battery.
The battery is charged by connecting the charging port of the car to
the mains power supply using the charging cable.
The charging procedure is specific according to the power source
which is used (domestic or public).
The high-voltage battery is also partially recharged while driving
during deceleration or braking. During this steps, the battery is
recharged by regeneration via the electric motor. This is an efficient
way of recharging as the kinetic energy of the car is used and
converted into electric charging energy.
Electric cars have specific characteristics of use, which is useful to
know, in order to achieve optimal performance.
This car respects the environment because it does not emit exhaust
gases and therefore has zero CO2.
HIGH-VOLTAGE BATTERY
The high-voltage battery is located at the bottom of the car in a
central area and is maintenance-free.
A. High-voltage wires
B. High-voltage battery

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Technical description
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The high-voltage battery is lithium-ion.
Lithium-ion batteries provide the following benefits:
• are much lighter than other types of chargeable batteries of the
same size;
• keep the charge longer;
• have no memory effect, i.e. it is not necessary to discharge
them completely before recharging, as is the case with other
types of batteries;
• can be recharged and discharged, charging times vary
depending on home or public charging mode and power.
The high-voltage battery of the New 500 in the larger version
(with more energy) has a nominal voltage of 350V, while in the
smaller version the voltage is 395V.
The high-voltage battery is equipped with conditioning systems
that ensure that it operates under the best temperature
conditions appropriate to its operation.
NOTE
If the battery pack needs to be cooled, the electric climate control
compressor is automatically activated even when the passenger
compartment cooling function is not operating. The high-voltage
battery is cooled by a specific liquid that is kept at low temperature
by the air conditioning system of the car.

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Technical description
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ATTENTION
1. Do not resell, give away or modify the high-voltage battery. The
high-voltage battery must only be used on the car on which it is
supplied. If used outside the car or modified, accidents such as
electric shock, heat or smoke generation, explosion or
electrolyte leakage may occur. If the car is scrapped without
removing the high-voltage battery, contact with high-voltage
components, cables and connectors could cause very
dangerous electric shock. If the high-voltage battery is not
disposed of properly, it may cause electric shock, resulting in
serious injury or death.
2. The mains power supply and the high-voltage battery are
potentially dangerous: they can cause injury, burns and risk of
electrocution. Always take great care.
3. Never touch or tamper with the cables and components of the
high-voltage battery in any way: do not allow the high-voltage
battery components to come into contact with bracelets,
necklaces or any metal objects worn.
4. Do not open, modify or remove the high-voltage battery cover:
any gases released may be harmful and flammable: avoid
inhaling the gases.
5. Damage to the vehicle or the high-voltage battery may cause
harmful gases to escape, which could cause a fire. In the event
of a fire, move away from the vehicle, wear a reflective vest (if
required by the regulations in force), position yourself in a safe
place, and immediately contact the rescuers, police or fire
brigade informing them that this is a vehicle with a high-voltage
system.
6. The electrolyte inside the battery is a polluting and flammable
material. If the high-voltage battery is not disposed of properly,
it may cause fire and pollute the environment.

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Technical description
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IMPORTANT
1. If, as a result of a violent impact or accident, the car has hit the
bottom (underbody), have the battery and the high-voltage
system checked by qualified technicians.
2. Behaviour in the event of electrolyte leakage from the traction
battery.
Leakage of electrolytes from the traction battery is not very
likely. However, specific PPE must be worn if this occurs.
Sprinkle the appropriate absorbing products, then, always
wearing the specific PPE, collect them to be treated with
organic solvents.
The electrolyte of a lithium-ion traction battery is a clear
flammable liquid.
- It has the characteristic smell of organic solvent. Do not
breathe the vapours. Ventilate the area in case of leakage,
if necessary.
- Contact with the electrolyte causes skin burns and serious
eye injury.
- If swallowed, inhaled or in contact with skin or eyes, wash
immediately with plenty of water. Promptly call a poison
control centre or seek medical attention.
IMPORTANT
1. Live parts of the car are marked with safety warning labels. The
high-voltage battery bears a label indicating this danger.
2. Do not dispose of the high-voltage battery yourself. For more
information contact a Fiat Dealership.
High-voltage battery and electric motor specifications
(*) The temperature of 60°C is to be understood as the temperature that the battery can reach, it is not to be understood as the operating
temperature of the car.
Specifications High Range
Battery type Lithium ions
Nominal voltage (Volt) 350
Maximum power (CEE) Kw (CV) 87 (117)
Maximum power (CEE) Nm (Kgm) 220 (22.43)
Battery operating temperature -30/60°C (*)

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Technical description
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2.2 12V battery
The 12V battery in the electric vehicle is a secondary 12V direct-
current battery. This battery provides the energy necessary for
operating the vehicle equipment (headlights, windscreen wipers,
sound system, etc.)
ATTENTION
• If necessary, the 12V battery must be replaced by an equivalent
battery.
• The battery is located in the motor compartment at the front of
the vehicle. Its negative terminal is connected to the metal
chassis for electrical earthing.
• The operations on the battery must be carried out by a qualified
towing operative/mechanic who is qualified to work on the high-
voltage electrical circuit of an electric vehicle.
2.3 Precautions relating to the HV electrical system
Works on HV electrical system
ATTENTION
- The propulsion system of the electric car is connected by the
high-voltage battery and when the system is active the compo-
nents are then powered at high-voltage. Observe the warning
messages on the labels on the car when accessing the motor
compartment. Any intervention or modification on the high-
voltage electrical system of the car (components, cables,
connectors, high-voltage battery) is strictly forbidden due to the
risks it may imply for your safety. In this case, contact a Fiat
Dealership. Tampering with the high-voltage system can lead
to serious burns or electrical discharges with even fatal conse-
quences.Do not resell, give away or modify the high-voltage
battery. The high-voltage battery must only be used on the car
on which it is supplied. If used outside the car or modified,
accidents such as electric shock, heat or smoke generation,
explosion or electrolyte leakage may occur.
- If the car is scrapped without removing the high-voltage battery,
contact with high-voltage components, cables and connectors
could cause very dangerous electric shock.

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Technical description
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- If the high-voltage battery is not disposed of properly, it may
cause electric shock, resulting in serious injury or death.
- Due to the quiet operation of the electric car, always set the
speed selector switch to P and engage the electric parking
brake and stop the motor. DANGER OF SERIOUS INJURY.
IMPORTANT
The high-voltage battery may only be disconnected by qualified
personnel at a Fiat Dealership.
IMPORTANT
- Do not dispose of the battery yourself. If the car is scrapped, it
must be taken to a Fiat Dealership to have the high-voltage
battery removed and disposed of properly by the Fiat
Dealership personnel who have the technical skills to operate
in complete safety.
- Live parts of the car are marked with safety warning labels. The
high-voltage battery bears a label indicating this danger.
IMPORTANT NOTES
In case of fault, damage or fire to the vehicle:
• the components of the electrical system can be live and the
high-voltage battery can be charged;
• the high-voltage battery, cables and electrical components may
be exposed and pose a potential risk of electrocution;
• vapours released during handling or disconnection of the high-
voltage battery from the system are potentially toxic and
flammable;
• damage to the car or high-voltage battery may cause
immediate or delayed release of toxic and/or flammable gases
or a fire; the electrical wires and the components connecting to
the high-voltage system are orange.
IMPORTANT
Non-insulated cables or wires may be visible inside or outside the
vehicle. Never touch cables and/or connectors: electric shock could
occur, resulting in injury or death by electrocution.
IMPORTANT
Do not touch, disassemble or remove the electric climate control
compressor.

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Technical description
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ATTENTION
• The orange high-voltage cables must not be cut under any
circumstances.
• The earth braids must not be cut under any circumstances.
• These connections are a safety device for the occupants of the
vehicle and for the Rescue Services to prevent any risk of
electric shock.
• RISK OF SERIOUS INJURY OR ELECTRIC SHOCK THAT
COULD CAUSE DEATH.
IMPORTANT
Apply the safety procedures and precautions (Chapters 3 and 4) in
the event of an accident that compromises the mechanical
components of the vehicle and does not allow the vehicle to move
independently or that caused the airbags to deploy.

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Safety regulations for working with high
voltages
10
3.1 High-Voltage System
IMPORTANT:
When performing repairs that directly involve or imply
possible contact with live high-voltage components/systems,
the technician must ensure that the power supply of the high-
voltage system is disconnected throughout the operation.
- Only specifically trained staff qualified to perform repairs on
vehicles with high-voltage systems under current national laws/
regulations are authorised to work on the vehicle.
- Before performing any repair/diagnosis on the car, carefully
read and comply with the general instructions for working in
safety on hybrid/electric vehicles and use suitable general
equipment and personal protective equipment (PPE).
Failure to follow all these warnings could result in personal injury,
such as burns, shock or fatal injury.
IMPORTANT
Before performing any diagnostic or service procedures, read and
follow all applicable safety procedures in the presence of high
voltage. Carry out the vehicle safety procedure by cutting off the
power supply of the high-voltage battery before carrying out any
repair directly involving components or wiring of the high-voltage
system or operating in close proximity to them which could imply
potential contact.
3. Safety regulations for working with
high voltages

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Safety regulations for working with high
voltages
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IMPORTANT
Be sure to use the appropriate personal protective equipment (PPE)
when working on high-voltage installations. Failure to do so may
result in serious injury or death.
• Protective eyewear/visor
• Clothes made of natural fibres
• Hand tools with HV certification and a dielectric barrier of not
less than 1000 Volts
• Certified and unexpired rubber gloves
• Insulating mat
• Safety hook
IMPORTANT
Do not use only leather gloves to protect yourself from electric
shock. Failure to do so may result in serious injury or death.
Always use rubber insulating gloves of the appropriate voltage
class.

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Safety regulations for working with high
voltages
12
3.2 PPE characteristics
Electrical safety gloves
Insulating gloves for working on electrical systems, class 00, test
voltage 2500V, operating voltage 500V.
Class III personal protective equipment that complies with the
following standards:
European: EN 60 903
International: CEI 60 903
Visor
To protect the face from splashes of liquid/solid material and electric
arcs in case of short circuit.
Class III personal protective equipment that complies with the
following European standards:
EN 166: Personal eye protection - Specifications.
EN 170: Personal eye protection - Ultraviolet filters.
The absence of voltage is detected using a tester.
The measurement must be carried out between the metal chassis
of the vehicle and all 400V (orange) cables that are damaged to
such an extent that direct electrical contact between the tester tip
and the conductive core is possible. If several cables or contacts are
exposed as a result of the damage, the absence of voltage must
also be checked between the concerned points and not only with
reference to the metal chassis of the car.
This instrument must comply with the following standards:
European: EN 61 243-3
International: CEI 61 243-3

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Securing the car
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4.1 ACCESSING THE PASSENGER COMPART-
MENT (with 12V battery CHARGED)
Unlocking doors and boot
Briefly press the button: unlocking of doors and boot, timed
switching-on of internal lights and double flashing of direction
indicators (where provided).
When the function is available, press and release the unlock button
on the remote control once only to unlock the driver's door or twice
within 1 second to unlock all doors and the tailgate.
4.2 ACCESSING THE PASSENGER COMPART-
MENT (with 12V battery FLAT)
- take the key from the lower side (A) (the one without buttons)
and, using the fingertips, move the cover in the direction of the
key chain hole until the teeth are released (motion 1);
- gently remove the lower cover by pulling it upwards (motion 2);
- pull up the edge of the metal key (B) until the release and pull it
out;
- The emergency key (B) can be housed in the charging
compartment.
4. Securing the car

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Securing the car
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•
- Open the charging compartment flap and remove the holder
(A).
Insert the key into the holder from the grip side and refit the
holder on the flap.

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Securing the car
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4.3 Immobilisation
- With the car stationary, press the brake pedal.
- Set the selector (A) to position "P".
- Release the brake pedal.
- Fully press the START-ENGINE-STOP (A) button and turn
off the motor.

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Securing the car
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- Engage the electric parking brake (B).
•
IMPORTANT
Remove the smart key or the wearable key from the inside of the car
and take it to a distance of about 1.5 m to avoid any unintentional
activation.
4.4 Stabilisation
To stabilise the vehicle, support it at all four points under the front
and centre pillars, using wooden blocks or equivalent objects.

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Securing the car
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4.5 Making a vehicle safe after an accident
ATTENTION
IMPORTANT INFORMATION FOR DEACTIVATING THE HIGH-
VOLTAGE SYSTEM
• Use personal protective equipment (see Chap. 3)
• DO NOT CUT OR DAMAGE THE ORANGE CABLES AND
CONNECTORS UNDER ANY CIRCUMSTANCES
• The orange cables and the components connected to them are
part of the high-voltage system and could be energised.
• The energy is still present in the high-voltage battery.
• THE HIGH VOLTAGE MAY REMAIN ACTIVE IN THE KEY-ON
CONDITION WITH THE POSITIVE AND NEGATIVE
TERMINALS OF THE 12V SERVICE BATTERY
DISCONNECTED
• THE HIGH VOLTAGE COULD REACTIVATE IN THE KEY-
OFF CONDITION WITH THE 12V SERVICE BATTERY
CONNECTED
- Open the tailgate using the opening control (A).