Fiat Professional E-DUCATO User manual

Fiat professional
Quick guide to Repairs

E-Ducato
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 vehicle
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 Securing a vehicle safe after a breakdown
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 vehicle
4.9 Intervention in case of fire of the vehicle
5. Emergency procedures
5.1 Charging cable emergency unlock
5.2 Safety switch
5.3 Jump starting
6. Towing the vehicle
6.1 Tow ring
6.2 Rear tow ring
6.3 Towing the vehicle after a breakdown
7. Vehicle storage
7.1 Delimitation of the storage area
7.2 Safety information

E-DUCATO
Vehicle identification
1
ó
External recognition elements
1. Vehicle identification

E-DUCATO
Technical description
2
2.1 Electrical system functional diagram
A. Charging port
B. High-voltage batteries
C. High-voltage electric compressor
D. Electric heater
E. Voltage converter
F. Traction electric motor
2. Technical description

E-DUCATO
Technical description
3
The propulsion system of the E-Ducato is completely powered by
the energy contained in the high-voltage lithium-ion rechargeable
batteries of the vehicle. Unlike conventional or hybrid cars, there is
no internal combustion engine on this vehicle.
The E-Ducato uses the electrical energy stored in the high-voltage
battery and not fuel. These batteries provide the energy needed to
start moving and therefore needs to be recharged before use. If the
high-voltage batteries are completely flat the vehicle will not start.
This vehicle 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 vehicle 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 batteries supply power to the electric motor and
supply the high-voltage auxiliary devices (heaters, electric climate
control compressor, etc.). The electronic converter that powers the
12V system for general operation of the vehicle is also powered by
the high-voltage batteries and also recharges the 12V battery.
The batteries are charged by connecting the charging port of the
vehicle 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 batteries are also partially recharged while driving
during deceleration or braking. During this steps, a battery is
recharged by regeneration via the electric motor. This is an efficient
way of recharging as the kinetic energy of the vehicle 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 vehicle respects the environment because it does not emit
exhaust gases and therefore has zero CO2 emissions.

E-DUCATO
Technical description
4
HIGH-VOLTAGE BATTERIES
The high-voltage batteries are located at the central and rear area
of the vehicle.
The high-voltage batteries are located at the central and rear area
of the vehicle.
A. High-voltage wires
B. High-voltage battery
C. High/voltage distribution unit
The high-voltage batteries are 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.

E-DUCATO
Technical description
5
• 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 vehicle.
Two possible battery configurations are provided:
- LOW RANGE configuration, 3 packs in parallel, 47.4 kWh (2)
- HIGH RANGE configuration, 5 packs in parallel, 79 kWh (1)

E-DUCATO
Technical description
6
IMPORTANT
1. Do not resell, give away or modify the high-voltage battery. The
high-voltage battery must only be used on the vehicle on which
it is supplied. If used outside the vehicle or modified, accidents
such as electric shock, heat or smoke generation, explosion or
electrolyte leakage may occur. If the vehicle 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.
WARNING
1. If, as a result of a violent impact or accident, the vehicle 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

E-DUCATO
Technical description
7
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.
WARNING
1. Live parts of the vehicle 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.

E-DUCATO
Technical description
8
TECHNICAL SPECIFICATIONS
High-voltage batteries
Powertrain
The electrical machine is a 6-pole permanent magnet synchronous
motor.
It is equipped with a resolver sensor to read the rotor position.
Description Data
Nominal capacity 2900 mAh
Rated voltage 3,6 V
Charging voltage 4,2 V
Internal impedance < 35 mOhm (AC, 1000 Hz)
Height 65,1 mm
Width 18,5 mm
Weight 48 g
Motor Resolver sensor
Description Data Description Data
Peak power 90 kW Type magnetoresistive
Rated power 55 kW Number of poles 3
Peak current 410 A Excitation voltage 7 VAC
Rated current 187 A Input resistance 100 ± 15 Ohm
Peak torque 288 Nm Maximum rotation speed 20.000 rpm
Nominal torque 136 Nm Operating temperature -40 ~ 150°C
Peak speed 12000 rpm
Nominal speed 3500 rpm
Weight 55 kg
Cooling Liquid cooling
Efficiency >95 %
Environmental IP67

E-DUCATO
Technical description
9
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.).
IMPORTANT
• If necessary, the 12V battery must be replaced by an equivalent
battery.
• The battery is located in the passenger compartment under the
driver's feet. 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 HV
high-voltage electrical circuit of an electric vehicle.
2.3 Precautions relating to the HV electrical system
Works on HV electrical system
IMPORTANT
- The propulsion system of the electric vehicle is connected by
the high-voltage batteries and when the system is active the
components are then powered at high-voltage. Observe the
warning messages on the labels on the vehicle when ac-
cessing the zones where HV wires are present. Any interven-
tion or modification on the high-voltage electrical system of the
vehicle (components, cables, connectors, high-voltage bat-
teries) 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 consequences.
- Do not resell, give away or modify the high-voltage batteries.
The high-voltage batteries must only be used on the vehicle on
which they were supplied. If a battery is used outside the ve-
hicle or modified, accidents such as electric shock, heat or
smoke generation, explosion or electrolyte leakage may occur.
- If the vehicle is scrapped without removing the high-voltage
batteries, contact with high-voltage components, cables and
connectors could cause very dangerous electric shock.

E-DUCATO
Technical description
10
- If a 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 vehicle, always set the
speed selector switch to P and engage the electric parking
brake and stop the motor. DANGER OF SERIOUS INJURY.
WARNING
The high-voltage batteries may only be disconnected by qualified
personnel at a Fiat Dealership.
WARNING
- Do not dispose of the batteries yourself. If the vehicle is
scrapped, it must be taken to a Fiat Dealership to have a 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 vehicle are marked with safety warning labels.
The high-voltage components have a label indicating this
danger.
WARNINGS
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 batteries, 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 vehicle or high-voltage batteries 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.
WARNING
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.
WARNING
Do not touch, disassemble or remove the electric climate control
compressor or the electrical heater.

E-DUCATO
Technical description
11
IMPORTANT
• 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.
WARNING
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.

E-DUCATO
Safety regulations for working with high
voltages
12
3.1 High-Voltage System
WARNING:
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 vehicle, 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.
WARNING
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

E-DUCATO
Safety regulations for working with high
voltages
13
WARNING
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
WARNING
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.

E-DUCATO
Safety regulations for working with high
voltages
14
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, complying with 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 vehicle.
This instrument must comply with the following standards:
European: EN 61 243-3
International: CEI 61 243-3

E-DUCATO
Securing the vehicle
15
4.1 Accessing the passenger compartment
(with 12V battery charged)
Press the "unlock" button (B) on the remote control or insert and
turn the metal insert (A) in the driver's door lock clockwise to unlock
all the doors
4.2 Accessing the passenger compartment
(with 12V battery flat)
- With the 12V battery flat or disconnected, access to the vehicle
will only be possible by unlocking the driver's door using the
mechanical lock.
•
4. Securing the vehicle
AB

E-DUCATO
Securing the vehicle
16
4.3 Immobilisation
- With the vehicle stationary, press the brake pedal;
- Set the gear selector to position "N".
- Engage the parking brake.

E-DUCATO
Securing the vehicle
17
4.4 Stabilisation
To stabilise the vehicle, support it at all four points (A) under the
front and centre pillars, using wooden blocks or equivalent objects.
When using a hoist, use points (B).
A: support points
B: support points with lift
4.5 Securing a vehicle safe after a breakdown
IMPORTANT
IMPORTANT INFORMATION FOR DEACTIVATING THE HIGH-
VOLTAGE SYSTEM
• Use personal protective equipment (see Chap. 3)
• DO NOT CUT OR TAMPER WITH ORANGE CABLES AND
CONNECTORS
The orange cables and components connected to these cables
are part of the high-voltage system and may 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

E-DUCATO
Securing the vehicle
18
• THE HIGH VOLTAGE COULD REACTIVATE IN THE KEY-
OFF CONDITION WITH THE 12V SERVICE BATTERY
CONNECTED
- Turn the key-off
- Remove cover (A)
- Access the black-green connector (HVIL port)
- Open the HVIL port as follows:
1. Press the red release tab downwards
2. Slide the internal body to the end of its travel while holding
down the red release tab.
3. At the end of its travel, the device is locked in the open
position (HVIL open).