Remove/Install, Disassemble/Assemble Electric Machine - AR08.10-P-0012EH

Transmission 724.2

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Note on high-voltage on-board electrical system		AH54.00-P-0010-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on automatic transmission		AH27.19-P-0001-01NKB
	Evaluation of high-voltage components		AH54.00-P-6500-01SXH
	Remove/install, disassemble/assemble
1	Remove wet clutch (1)	Cleanliness is essential for all work on the transmission. Otherwise, even the smallest foreign particle in the hydraulic components of the transmission can lead to malfunctions or a total failure of the transmission. For cleaning, do not use lint-free cleaning cloth. Chamois leathers are the most suitable.	AR27.51-P-0300EH
2	Unclip connector for interlocking lines (2, 3) together from the contact carrier (4)	The connector for interlocking lines (2, 3) cannot be unclipped individually from the contact carrier (4). All electrical components of the electrical machine must generally be checked by means of visual inspection for damage and replaced if necessary.
3	Remove interlocking lines (2) from housing for electrical machine (5)	Assembly: Replace cable tie.
4	Unclip 3-phase connector (6) from housing for electrical machine (5)	Assembly: Introduce the 3-phase connector (6) parallel and do not tilt. The seals on the 3-phase connector (6) will be damaged otherwise. Assembly: Generally replace the insulating caps (7).
5	Attach thrust ring (8.3) to the carrier (8.2)	Removal and installation tool	Fig 1
6	Place removal and installation tool (8) with cross bridge (8.13) on assembly device (9)	Helper required. Removal and installation tool	Fig 1
		Assembly device	Fig 2
7	Fully tighten screws (8.8)	Removal and installation tool	Fig 1
8	Screw thrust ring (8.3) onto the spindle (8.1) with a reversible ratchet until the thrust ring (8.3) lies on the weld ring (10.2) of the ring package (10) (arrow A)	Lay the 3-phase connector (6) and interlock line (3) inwards to the rotor. The 3-phase connector (6) and the associated electrical line (3) can get damaged otherwise. Carefully screw down thrust ring (8.3) and not by using a impact wrench/driver or similar tool. The 3-phase connector (6) and the associated electrical line (3) can get damaged otherwise. The ring package (10) consists of a retaining ring (10.1), weld ring (10.2), wave washer (10.3) and cone ring (10.4). Removal and installation tool	Fig 1
9	Screw down thrust ring (8.3) further onto the spindle (8.1) using a reversible ratchet and press down the weld ring (10.2) in the process until the retaining ring (10.1) is removed
10	Remove retaining ring (10.1) from the radial groove on housing for electrical machine (5)
11	Turn the thrust ring (8.3) completely on the spindle (8.1) using a reversible ratchet	Removal and installation tool	Fig 1
12	Remove screws (8.8)	Removal and installation tool	Fig 1
13	Remove removal and installation tool (8) with cross bridge (8.13) on assembly device (9)	Helper required. Assembly device	Fig 2
		Removal and installation tool	Fig 1
14	Remove ring package (10)	Assembly: Observe correct installation position of weld ring (10.2). The weld ring (10.2) must not lie in the radial groove of the retaining ring (10.1). The weld ring (10.2) will get damaged otherwise. : Check ring package (10) for damage; replace ring package (10) if necessary. Assembly: Note installation sequence of the rings (10.4, 10.3, 10.2. 10.1). Check axial play on stator (11). ↓ Adjust axial play on stator, of the electric machine if necessary	AR08.10-P-1012-01EH
		Preload force on ring package	*BE08.10-P-1002-01A
		Axial play on electrical machine stator	*BE08.10-P-1001-01A
15	Remove thrust ring (8.3) from carrier (8.2)	Removal and installation tool	Fig 1
16	Attach thrust ring (8.4) to carrier (8.2)	Removal and installation tool	Fig 1
17	Place removal and installation tool (8) with cross bridge (8.13) on assembly device (9)	Place cross bridge (8.13) in the correct position so that the locking pin (8.9) can lock in the cutout (arrow C). Helper required. Assembly device	Fig 2
		Removal and installation tool	Fig 1
18	Fully tighten screws (8.8)	Removal and installation tool	Fig 1
19	Loosen all 4 clamp screws (8.5) and turn thrust ring (8.4) counterclockwise up to the end stop	Removal and installation tool	Fig 1
20	Turn down thrust ring (8.4) on the spindle (8.1) using a reversible ratchet until the thrust ring (8.4) lightly touches the stator (11)	Lay the 3-phase connector (6) and interlock line (3) inwards to the rotor (12). The 3-phase connector (6) and the associated electrical line (3) can get damaged otherwise. Carefully screw down thrust ring (8.4) and not by using an impact wrench/driver or similar tool. The 3-phase connector (6) and the associated electrical lines can get damaged otherwise. Removal and installation tool	Fig 1
21	Ensure that the lock (8.7) is opened	Removal and installation tool	Fig 1
22	Turn thrust ring (8.4) clockwise until the hook (8.6) of the thrust ring (8.4) engages completely in the cutouts (arrow B) on stator (11) and the locking pin (8.9) must lock	Removal and installation tool	Fig 1
23	Close lock (8.7)	Removal and installation tool	Fig 1
24	Tighten all 4 clamp screws (8.5)	Removal and installation tool	Fig 1
25	Turn the thrust ring (8.4) completely on the spindle (8.1) using a reversible ratchet	Removal and installation tool	Fig 1
26	Remove screws (8.8)	Removal and installation tool	Fig 1
27	Prepare shelf for the removal and installation tool (8) with attached stator (11), remove removal and installation tool (8) with attached stator (11) from the electric machine housing (5)	There must be no fluff, chips or other contaminants in the place it is laid down in. For example iron containing chips can otherwise gather on the stator (11) which cannot be removed or only removed with great difficulty. A new, clean foil is particularly suitable for covering the place the stator is laid down in or the stator (11) itself. An assistant is needed to disassemble and lay to one side	AR08.10-P-0014-01EH
		VASELINE/DBL 6850.00	*BR00.45-Z-1098-06A
		Assembly device	Fig 2
		Removal and installation tool	Fig 1
28	Loosen all 4 clamp screws (8.5)	When replacing the stator (11). Removal and installation tool	Fig 1
29	Open lock (8.7), pull upwards, unlock locking pin (8.9), hold up and turn thrust ring (8.4) counterclockwise to the end stop	When replacing the stator (11).
		Removal and installation tool	Fig 1
30	Remove removal and installation tool (8) from stator (11)	When replacing the stator (11). The thrust ring (8.4) may only be placed on a planned plastic pad. The hooks (8.6) must not lie on the plastic pad. The hooks (8.6) will be bent otherwise. Assembly: Generally replace O-rings (15) on stator (11) and coat with Vaseline. VASELINE/DBL 6850.00	*BR00.45-Z-1098-06A
		Removal and installation tool	Fig 1
31	Remove Torlon ring (17)	Assembly : Replace Torlon rings (17).
32	Turn the rotor (12) until the screw/bolts (13) are accessible
33	Remove screws/bolts (13)	Assembly: First lay on the screw/bolts (13) and then tighten down evenly crosswise using the prescribed tightening torque. Screw/bolt, rotor to transmission housing	*BA27.10-P-1021-04G
34	Place assembly tool (14) on the rotor (12) and turn until the locking pin (14.1) is locked in the rotor (12)	For a rotor with a screwed on cover. Do not lock locking pin (14.1) in the threaded hole. Otherwise the thread can be damaged. Assembly tool	Fig 4
35	Remove rotor (12) from the housing for the electrical machine (5) using the assembly tool (14) and lay to one side	There must be no fluff, chips or other contaminants in the place it is laid down in. For example iron containing chips can otherwise gather on the rotor (12) which cannot be removed or only removed with great difficulty. A new, clean foil is particularly suitable for covering the place the stator is laid down in or the stator (12) itself. Assembly tool	Fig 4
36	Remove assembly tool (14) from rotor (12)	Assembly tool	Fig 4
37	Remove screw/bolts (26) and take off wing disk (16) from rotor (12)	If necessary. Bolt, impeller to rotor	*BA27.10-P-1020-04G
38	Remove Torlon rings (32)	Assembly : Replace Torlon rings (32).
39	Remove retaining ring (18)	Only for replacement of the bearing.
40	Turn rotor (12) and knock the bearing retainer plate (19) down using a suitable punch (24) with the bearing (20) from the rotor lug	In order to avoid tilting of the bearing (20) and the bearing retainer plate (19), knock through the bores in the rotor base alternately and evenly. Assembly : Press bearing (20) and bearing retainer plate (19) with sleeve (25) onto the rotor lug. Sleeve	Fig 6
41	Remove Torlon rings (21) on the drive shaft (27)	Assembly : Generally replace the Torlon rings (21).
42	Check oil groove (23); replace if necessary	Bolt, return channel to transmission housing	*BA27.10-P-1023-04G
43	Assemble and install in the reverse order
	Check
44	Visually inspect HV components including electrical connections and electrical lines for damage.	If one of the components is damaged, the responsible market support must be notified and the remainder of the test sequence stopped.
45	Print out test log	Transmission 724.2 in model 166, 205, 212, 222, 253 Transmission 724.2 in model 205, 212, 222 Before starting testing work, the test log has to be printed out, and filled out during the test.	OF54.10-P-3000-14A
46	Check resistance values of sensors on electric machine		AD08.30-P-0001-01LF
	000 588 06 19 00 Measuring instrument	Attach test box and test adapter to the low voltage plug connection. The connector for the test adapter must audibly engage on the low voltage plug connection. The test equipment must be checked for proper operation before starting the test work in accordance with the manufacturer's specifications.	WS54.00-P-0043B
		Test box	Fig 3
		Test adapter	Fig 5
47	Perform flash test and insulation resistance test		AR54.10-P-0018-01LF
	000 588 15 21 00 Measuring instrument		WS54.00-P-0048B
	000 588 16 98 00 Support		WS54.00-P-0047B
	000 588 00 19 00 Insulation measuring unit		WS54.00-P-0046B
		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 253.954 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) Bolt, 3-phase high-voltage line coupling connector to electrical machine housing	*BA08.10-P-1001-01F
		Transmission 724.2 in model 212 with engine 276 Transmission 724.2 in model 212 with engine 651 Bolt, connector for 3-phase high-voltage line to electric machine housing	BA08.10-P-1001-01E
		Transmission 724.2 in model 166, 253 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) Bolt, 3-phase high-voltage line coupling connector to electrical machine housing	BA08.10-P-1001-01F
48	Connect diagnostic system and perform encoder adaptation	When replacing the electrical machine. Transmission 724.2 in model 166	AD00.00-P-2000-04A
		Transmission 724.2 in model 205 Transmission 724.2 in model 222 Transmission 724.2 in model 253	AD00.00-P-2000-04B
		Transmission 724.2 in model 212 Menu guidance: Power electronics control unit→ Adaptations → Learning processes	AD00.00-P-2000-04A

ELECTRIC MACHINE

Number	Designation		Transmission 724.2
BE08.10-P-1001-01A	Axial play on electrical machine stator	mm	0, 3...0, 6

ELECTRIC MACHINE

Number	Designation			Transmission 724.2
BE08.10-P-1002-01A	Preload force on ring package	-	N	10000
BE08.10-P-1002-01A	Preload force on ring package	equivalent to	Nm	40

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

AUTOMATIC TRANSMISSION COMPLETE

Number	Designation		Transmission 724.2
BA27.10-P-1020-04G	Bolt, impeller to rotor	Nm	5

AUTOMATIC TRANSMISSION COMPLETE

Number	Designation		Transmission 724.2
BA27.10-P-1021-04G	Screw/bolt, rotor to transmission housing	Nm	9

AUTOMATIC TRANSMISSION COMPLETE

Number	Designation		Transmission 724.2
BA27.10-P-1023-04G	Bolt, return channel to transmission housing	Nm	9

Fig 1: Identifying Removal And Installation Tool (724 589 03 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Assembly Device (724 589 04 40 00)

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Fig 3: Identifying Test Box (000 589 00 21 00)

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Fig 4: Identifying Assembly Tool (724 589 03 31 00)

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Fig 5: Identifying Test Adapter (724 589 04 63 00)

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Fig 6: Identifying Sleeve (711 589 00 14 00)

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REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1098-06A	VASELINE/DBL 6850.00	A 000 989 15 51