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Perform flash test and insulation resistance test - AR54.10-P-0018-01LF

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TRANSMISSION 724.2 

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
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 205.0/2 with code ME04 (Mild hybrid drive) Model 205 with code ME06 (Hybrid drive 50-KW variant (incl. plugin))
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 222
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.

Fig 1: View Of Cordoned Off Test Area
G10241462Courtesy of MERCEDES-BENZ USA

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 bolt of wiring harness (5) on high-voltage connection (4) to torque. Transmission 724.2 in model 212 with engine 276

    Transmission 724.2 in model 212 with engine 651

    IMPORTANT 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 50-KW variant (incl. plugin)) Transmission 724.2 in model 222TORQUE SPECIFICATION

    Fig 2: Connecting Voltage Proof Tester To Highvoltage Connection
    G10241463Courtesy of MERCEDES-BENZ USA
  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 information on display and confirm with "Escape".

    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 information on display and confirm with "Escape".

  7. Adjust test voltage on voltage proof tester (7) using control.

    IMPORTANT Press "Preset" button, set test voltage after replacing electrical machine or stator to 1500 V using control, and confirm with "Escape".

    Fig 3: Connecting Wiring Harness To Low-Voltage Plug Connection
    G10241464Courtesy of MERCEDES-BENZ USA

    IMPORTANT Press "Preset" button, set test voltage after repair to transmission to 1200 V using control and confirm with "Escape".

  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.

    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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