Remove/install electric motor with transmission - AR08.10-P-0005MEX
ENGINE 780.993 in MODEL 451.390/392/490/492
Shown without code 908 (Onboard charger 22KW)
Fig 1: Identifying Electric Motor With Transmission Remove/Install Components - Shown Without Code 908
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of death when touching components on vehicles with high-voltage on-board electrical system | Do not touch 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 | |
| Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. | Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. |
AS20.00-Z-0001-01A | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Notes on coolant | AH20.00-N-2080-01A | ||
| Note on high-voltage on-board electrical system | AH54.00-P-0010-01A | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| Remove/install | |||
| 1 | Remove transmitter key and battery charger power supply plug | ||
| 2 | Connect Star Diagnosis and enable high voltage on-board electrical system | ||
| AD00.00-P-2000-04MCC | |||
| 3 | Disconnect battery ground line | AR54.10-P-0003MCC | |
| 4 | Remove interior flap above engine | AR88.40-P-1100-03MCC | |
| 5 | Raise vehicle using the vehicle lift and secure in place | When work is continued on the vehicle such as, for example when supporting major assemblies using a jack (e.g. transmission jack) which exert an uneven load distribution, and when removing the following components: front axle, front axle carrier, axle tube, rear axle integral carrier, engine or transmission. | AR00.60-P-0100MCC |
| 6 | Remove bar link | AR35.15-P-0200MCC | |
| 7 | Remove rear axle shafts | Engine 780.993 in model 451.390/392/490/492 except code 494 (US version) |
AR35.30-P-0620MCC |
| Engine 780.993 in model 451.390/392/490/492 with code 494 (US version) |
AR35.30-P-0620MCU | ||
| 8 | Remove fender liners in right and left fenders | Engine 780.993 in model 451.390/392/490/492 except code 494 (US version) |
AR88.10-P-1400MCC |
| Engine 780.993 in model 451.390/392/490/492 with code 494 (US version) |
AR88.10-P-1400MCU | ||
| 9 | Lower vehicle with vehicle lift | ||
| 10 | Remove screw/bolt (1) at ground line (2) | Ensure that the contact surfaces are absolutely clean. Contact problems can occur otherwise. |
*BA54.10-P-1009-01H |
| 11 | Remove screw/bolt (3) at bracket (4) | ||
| 12 | Remove screws/bolts (6) on power electronics control unit (N129/1) | Do not bend refrigerant lines (5). Damage to the refrigerant lines (5) can occur otherwise. |
*BA54.10-P-1005-01H |
| 13 | Attach support fixture for high-voltage components in engine compartment | AR08.10-P-0010-06MEX | |
| Fig 9 | |||
| Fig 6 | |||
| 14 | Raise vehicle with vehicle lift | ||
| 15 | Clamp off coolant hoses on electric motor drive (M5) using clamping devices (15) | Fig 5 | |
| 16 | Unfasten clamps (16) using hose clamp pliers and push top the rear onto the coolant hose | Fig 11 | |
| 17 | Disconnect coolant hoses from connection fittings on electric motor drive (M5) | ||
| 18 | Disconnect electrical connection from park pawl switch (S16/2) | ||
| 19 | Remove screw/bolt (10) and remove parking lock cable cover panel (9) | Only if installed. | |
| 20 | Pry off ball head (11) for the parking lock cable from relay lever on transmission (12) | ||
| 21 | Unhook counter bearing (8) on parking lock cable from bracket | ||
| 22 | Remove screw/bolts (13) from switchover valve bracket (14) | ||
| 23 | Disconnect drive electric motor high voltage connector (18) from electric motor drive (M5) | ||
| 24 | Attach protective cover on the line side and component side to the high voltage plug connector for the electric motor drive (18) | Protect electric motor drive high voltage connector (18) against dirt and moisture. Otherwise, consequential damage may occur on the high voltage on-board electrical system. |
Fig 7 |
| 25 | Disconnect electrical connections (17) | ||
| 26 | Remove screw/bolt (19) and screw/bolt (21) from engine support (20) over the brake booster vacuum pump (M57) | *BA22.10-P-1014-01M | |
| 27 | Position major assembly lifting platform (23) under the electric motor drive (M5) and transmission (12) and support with suitable substratum (22) | ||
| 000 588 03 62 00 Lifting platform | WS01.00-P-0091A | ||
| 28 | Remove screw/bolts (25) on engine support (20) | *BA22.10-P-1014-01M | |
| 29 | Loosen screw/bolt (28) | *BA22.10-P-1010-01M | |
| 30 | Remove screw/bolt (27) on torque support (26) | *BA22.10-P-1011-01M | |
| 31 | Turn torque support (26) downwards and allow to hang on integral carrier (29) | ||
| 32 | Remove screw/bolts (32, 33 and 34) on transmission carrier (30) | *BA26.00-P-1005-01E | |
| 33 | Remove screw/bolts (31) on onboard charger bracket (24) | *BA54.10-P-1007-01H | |
| 34 | Carefully lift out electric motor drive (M5) with transmission (12) | During lowering ensure that no electrical lines and hoses get pinched. Damage can occur to lines and hose otherwise. |
|
| 35 | Disconnect electric motor drive (M5) from transmission (12) and modify detachable parts | When replacing the electric motor drive (M5) or the transmission (12). Remove/install electric motor drive (M5) |
AR08.10-P-0010MEX |
| Remove/install transmission (12) | AR26.10-P-0020MEX | ||
| 36 | Install in the reverse order | ||
| 37 | Bleed engine cooling system using Star Diagnosis | ||
| AD00.00-P-2000-04MCC | |||
| AR20.00-P-1142-06MEX | |||
| Fig 8 | |||
| Fig 10 | |||
| 38 | Check engine cooling system for leaktightness | AR20.00-P-1010MCC |
ENGINE MOUNTS, ENGINE SUPPORTS
| Number | Designation | ENGINE 780.993 | |
|---|---|---|---|
| BA22.10-P-1010-01M | Screw/bolt, torque support to integral carrier | Nm | 115 |
ENGINE MOUNTS, ENGINE SUPPORTS
| Number | Designation | ENGINE 780.993 | |
|---|---|---|---|
| BA22.10-P-1011-01M | Screw/bolt, torque support to front engine mount carrier | Nm | 115 |
ENGINE MOUNTS, ENGINE SUPPORTS
| Number | Designation | ENGINE 780.993 | |
|---|---|---|---|
| BA22.10-P-1014-01M | Screw/bolt, right engine support to engine | Nm | 58 |
MANUAL TRANSMISSION COMPLETE
| Number | Designation | Engine 780.993 | |
|---|---|---|---|
| BA26.00-P-1005-01E | Bolt, left transmission carrier to transmission | Nm | 58 |
BATTERY
| Number | Designation | Model 451.390/392/490/492 except code 908 (Wheel loader 22kW) | Model 451.390/392/490/49 2 with code 908 (Wheel loader 22kW) | |
|---|---|---|---|---|
| BA54.10-P-1005-01H | Bolt, line electronics control unit to bracket | Nm | 23 | 23 |
BATTERY
| Number | Designation | Model 451.390/392/490/492 except code 908 (Wheel loader 22kW) | Model 451.390/392/490/49 2 with code 908 (Wheel loader 22kW) | |
|---|---|---|---|---|
| BA54.10-P-1007-01H | Bolt, on-board charger to bracket | Nm | 20 | 20 |
BATTERY
| Number | Designation | Model 451.390/392/490/492 except code 908 (Wheel loader 22kW) | Model 451.390/392/490/49 2 with code 908 (Wheel loader 22kW) | |
|---|---|---|---|---|
| BA54.10-P-1009-01H | Bolt, ground line to line electronics control unit | Nm | 18 | 18 |