Remove/install, disassemble/assemble electric machine - AR08.10-P-0012EH

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TRANSMISSION 724.2

MODIFICATION NOTES

9.1.14	Assembly device special tool, 724 589 03 40 00 replaced by 724 589 04 40 00.
9.1.14	Special tool Removal and installation tool, 724 589 01 63 00 replaced by 724 589 03 63 00.

Fig 1: Electric Machine Remove/Install Components (1 Of 6)

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Fig 2: Electric Machine Remove/Install Components (2 Of 6)

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Fig 3: Electric Machine Remove/Install Components (3 Of 6)

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Fig 4: Electric Machine Remove/Install Components (4 Of 6)

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Fig 5: Electric Machine Remove/Install Components (5 Of 6)

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Fig 6: Electric Machine Remove/Install Components (6 Of 6)

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	Note on the 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 8
6	Place removal and installation tool (8) with cross bridge (8.13) on assembly device (9)	Helper required.
		Removal and installation tool	Fig 8
		Assembly device	Fig 9
7	Fully tighten screw/bolts (8.8)	Removal and installation tool	Fig 8
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 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).
8		Removal and installation tool	Fig 8
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 8
12	Remove screw/bolt (8.8)	Removal and installation tool	Fig 8
13	Remove removal and installation tool (8) with cross bridge (8.13) on assembly device (9)	Helper required.
		Assembly device	Fig 9
		Removal and installation tool	Fig 8
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); replace ring package (10) if necessary. Assembly: Note installation sequence of the rings (10.4, 10.3, 10.2. 10.1). Check axial play at stator (11); adjust if necessary.
		Check/adjust axial play at stator of electric machine	AR08.10-P-1012-01EH
		Preload force at ring assembly	*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 8
16	Attach thrust ring (8.4) to carrier (8.2)	Removal and installation tool	Fig 8
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 9
		Removal and installation tool	Fig 8
18	Fully tighten screw/bolts (8.8)	Removal and installation tool	Fig 8
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 8
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. 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 a impact wrench/driver or similar tool. The 3-phase connector (6) and the associated electrical lines can get damaged otherwise.
20		Removal and installation tool	Fig 8
21	Ensure that the lock (8.7) is opened	Removal and installation tool	Fig 8
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 8
23	Close lock (8.7)	Removal and installation tool	Fig 8
24	Tighten all 4 clamp screws (8.5)	Removal and installation tool	Fig 8
25	Turn the thrust ring (8.4) completely on the spindle (8.1) using a reversible ratchet	Removal and installation tool	Fig 8
26	Remove screw/bolt (8.8)	Removal and installation tool	Fig 8
27	Remove removal and installation tool (8) together with attached stator (11) from assembly device (9) and lay to one side	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. 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. Assembly: Generally replace O-rings (15) on stator (11) and coat with Vaseline. TRANSMISSION 724.2 with CODE ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) with CODE ME06 (Hybrid drive 50-KW variant (incl. plugin)) Assembly: Introduce inner guide (8.10) at the rotor (12) and mount retaining ring (28). TRANSMISSION 724.2 with CODE ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) with CODE ME06 (Hybrid drive 50-KW variant (incl. plugin)) Assembly: Mount pilot bushing (8.11) on inner guide (8.10). Assembly: Mount removal and installation tool (8) with cross bridge (8.13) together with the attached stator (11) on assembly device (9) and tighten screw/bolts (8.8). TRANSMISSION 724.2 with CODE ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) with CODE ME06 (Hybrid drive 50-KW variant (incl. plugin)) Assembly: The inner guide (8.10) must be mounted through the openings on the removal and installation tool (8). Assembly: Lower the removal and installation tool (8) until the stator (11) touches below and then raise the removal and installation tool (8) somewhat so that the thrust ring (8.4) is unstressed. Assembly: Unfasten clamp screws (8.5), unlock locking pin (8.9), lift up and lock thrust ring (8.4) counterclockwise. Assembly: Extend removal and installation tool (8) from stator (11) and detach. TRANSMISSION 724.2 with CODE ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) with CODE ME06 (Hybrid drive 50-KW variant (incl. plugin))
		Assembly: Screw in pressure screw (8.12) and remove pilot bushing (8.11). TRANSMISSION 724.2 with CODE ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN)) with CODE ME06 (Hybrid drive 50-KW variant (incl. plugin)) Assembly: Remove retaining ring on rotor (12) and remove inner guide (8.10). TRANSMISSION 724.2 For rotor (12) with a plugged in cover Assembly: Replace retaining ring on rotor (12).
		VASELINE/DBL 6850.00	*BR00.45-Z-1098-06A
		Assembly device	Fig 9
		Removal and installation tool	Fig 8
28	Loosen all 4 clamp screws (8.5)	When replacing the stator (11).
28	Loosen all 4 clamp screws (8.5)	Removal and installation tool	Fig 8
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).
29		Removal and installation tool	Fig 8
30	Remove removal and installation tool (8) from stator (11)	When replacing the stator (11).
		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 8
31	Turn the rotor (12) until the screw/bolts (13) are accessible
32	Remove screw/bolt (13)	Assembly: First lay on the screw/bolts (13) and then tighten down evenly crosswise using the prescribed tightening torque.
32	Remove screw/bolt (13)	Bolt, rotor to transmission housing	*BA27.10-P-1021-04G
33	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.
33		Assembly tool	Fig 11
34	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.
35	Remove assembly tool (14) from rotor (12)	Assembly tool	Fig 11
36	Remove screw/bolts (26) and take off wing disk (16) from rotor (12)	If necessary
36		Bolt, impeller to rotor	*BA27.10-P-1020-04G
37	Remove Torlon rings (17)	Assembly: Generally replace the Torlon rings (17).
38	Remove retaining ring (18)	Only for replacement of the bearing
39	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.
39		Sleeve	Fig 12
40	Remove Torlon rings (21) on the drive shaft (27)	Assembly: Generally replace the Torlon rings (21).
41	Check oil groove (23); replace if necessary	Bolt, oil catch channel to transmission housing	*BA27.10-P-1023-04G
42	Assemble and install in the reverse order
	Check
43	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.
44	Print out test log
		TRANSMISSION 724.2 Before starting testing work, the test log has to be printed out, and filled out during the test.	-
45	Check resistance values of sensors on electrical machine
		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. Digital multimeter (DMM)	AD08.30-P-0001-01LF
		Test box	Fig 7
		Test adapter	Fig 10
46	Perform flash test and insulation resistance test		AR54.10-P-0018-01LF
		Model 222, screw/bolt, connector for 3-phase high-voltage line to electrical machine housing	*BA08.10-P-1001-01F
		Model 212, screw/bolt, connector for 3-phase high-voltage line to electrical machine housing Specific tools	*BA08.10-P-1001-01E
47	Connect diagnostic system and perform encoder adaptation	When replacing the electrical machine.
		MODEL 222	AD00.00-P-2000-04B
		MODEL 212 Menu guidance: Power electronics control unit Adaptations Teach-in 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 at ring assembly	-	N	10000
BE08.10-P-1002-01A	Preload force at ring assembly	corresponds 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 222
BA08.10-P-1001-01F	Bolt, connector for 3-phase high-voltage line to electric machine housing	Nm	10

COMPLETE AUTOMATIC TRANSMISSION

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

COMPLETE AUTOMATIC TRANSMISSION

Number	Designation		TRANSMISSION 724.2
BA27.10-P-1021-04G	Bolt, rotor to transmission housing	Nm	9

COMPLETE AUTOMATIC TRANSMISSION

Number	Designation		TRANSMISSION 724.2
BA27.10-P-1023-04G	Bolt, oil catch channel to transmission housing	Nm	9

Fig 7: Identifying Test Box (000 589 00 21 00)

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Fig 8: Identifying Removal And Installation Tool (724 589 03 63 00)

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Fig 9: Identifying Assembly Device (724 589 04 40 00)

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Fig 10: Identifying Test Adapter (724 589 04 63 00)

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Fig 11: Identifying Assembly Tool (724 589 03 31 00)

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Fig 12: 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