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Perform Flash Test And Insulation Resistance Test - AR54.10-P-0018-01LF

TRANSMISSION 724.2 

  Risk of death  when touching components on vehicles with high-voltage on-board electrical system Do not touch damaged or defective components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers) must not carry out any work on high-voltage on-board electrical systems. AS54.00-Z-0001-01A 
  Note on high-voltage on-board electrical system   AH54.00-P-0010-01A
  Evaluation of high-voltage components   AH54.00-P-6500-01SXH
REFER TO SPECIAL TOOLS 000 588 15 21 00 Measuring instrument   WS54.00-P-0048B
REFER TO SPECIAL TOOLS 000 588 16 98 00 Support   WS54.00-P-0047B
MODIFICATION NOTES

27.03.2015 Bolt, 3-phase high-voltage line coupling connector to electrical machine housing Model 205.0/2 with CODE ME04 (Mild-Hybrid Drive) BA08.10-P-1001-01F
ELECTRIC MOTOR

Number Designation Engine 276, 651 in model 212
BA08.10-P-1001-01E Bolt, connector for 3-phase high-voltage line to electric machine housing Nm 10
ELECTRIC MOTOR

Number Designation Model 166 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) Model 205.0/2 with code ME04 (Mild hybrid drive)
BA08.10-P-1001-01F Bolt, 3-phase high-voltage line coupling connector to electrical machine housing Nm 10 10
ELECTRIC MOTOR

Number Designation Model 205 with code ME06 (Hybrid drive 60 kW variant (incl. plugin)) Model 222
BA08.10-P-1001-01F Bolt, 3-phase high-voltage line coupling connector to electrical machine housing Nm 10 10
ELECTRIC MOTOR

Number Designation Model 253 (except 253.992/993) with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN))
BA08.10-P-1001-01F Bolt, 3-phase high-voltage line coupling connector to electrical machine housing Nm 10

IMPORTANT No-one may be present in the cordoned-off test area during the test.

IMPORTANT An insulation mat is used as a floor mat.

IMPORTANT A voltage proof tester (7) is used as test equipment.

Set up test station using barrier tape, insulation mat, information label, warning label and operating instructions 

IMPORTANT View of cordoned off test area.

G12079397

Check "interlock circuit open circuit" 

  1. Visually inspect HV components including electrical connections and electrical lines for damage.

    IMPORTANT If one of the components is damaged, the responsible market support must be notified and the remainder of the test sequence stopped.

  2. Connect wiring harness (5) of voltage proof tester (7) to high-voltage connection (4) first and then to connector (6) on voltage proof tester (7).

    Tighten screw/bolt of wiring harness (5) on high-voltage connection (4) with Transmission 724.2 in model 166 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN))

    Transmission 724.2 in model 205.0/2 with code ME04 (Mild hybrid drive)

    Transmission 724.2 in model 205 with code ME06 (Hybrid drive 60 kW variant (incl. plugin))

    Transmission 724.2 in model 222

    Transmission 724.2 in model 253 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN))

    TORQUE SPECIFICATION Transmission 724.2 in model 212 with engine 276, Transmission 724.2 in model 212 with engine 651 TORQUE SPECIFICATION tightening torque.

    G12079398
  3. Switch on voltage proof tester (7) and observe display.

    IMPORTANT The EMERGENCY OFF switch must not have been pressed (green ring visible).

    IMPORTANT Observe notes in display.

    IMPORTANT Interlock circuit is checked.

    IMPORTANT "Interlock open circuit" must be shown on the display.

    IMPORTANT If the test result does not return "Interlock open circuit", then the voltage proof tester (7) has to be switched off and the low-voltage plug connection (1) checked for a short circuit.

  4. Switch off voltage proof tester (7) and store key in a safe location.

    Run voltage proof test and check insulation resistance 

  5. Connect wiring harness (9) to low-voltage plug connection (1).

    IMPORTANT The connector for the wiring harness (9) must audibly latch into place on the low-voltage plug connection (1).

  6. Switch on voltage proof tester (7) and observe display.

    IMPORTANT Observe notes in display.

  7. Adjust stress under proof load via the "Test plan" point in the menu.

    IMPORTANT Test plan 0001 with 1500-V stress under proof load must be selected after replacing the electric machine or the stator.

    G12079399

    IMPORTANT Test plan 0002 with 1200-V stress under proof load must be selected after repairs on the transmission.

  8. Start test.

    IMPORTANT Green indicator lamp on voltage proof tester (7) lights up.

    IMPORTANT Throughout the test procedure both buttons (8) on the two-hand control unit must be pressed and held at the same time, until the complete test (total of 3 test steps) has run its course.

    IMPORTANT The test procedure is complete when all the test results are shown on the display.

  9. Read off check values on display and enter into test log.

    IMPORTANT After releasing both buttons (8) all windings are electrically discharged.

  10. Switch off voltage proof tester (7) and store key in a safe location.
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