Perform flash test and insulation resistance test

AR54.10-P-0018-01LF

Perform flash test and insulation resistance test

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Notes on battery

AH54.10-P-0001-01A



000 588 15 21 00 Measuring instrument

WS54.00-P-0048B



000 588 16 98 00 Support

WS54.00-P-0047B

Transmission

724.2

 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 85 kW-94 kW variant (incl. plug-in))

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 85 kW-94 kW variant (incl. plug-in))

BA08.10-P-1001-01F

Bolt, 3-phase high-voltage line coupling connector to electrical machine housing

Nm

10

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

Check "interlock circuit open circuit"

1

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.

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 85 kW-94 kW variant (incl. plug-in))
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 85 kW-94 kW variant (incl. plug-in))
  Transmission 724.2 in model 212 with engine 276
Transmission 724.2 in model 212 with engine 651  tightening torque.

3

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

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

 Observe notes in display.

 Interlock circuit is checked.

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

 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).

 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.

 Observe notes in display.

7

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

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

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

8

Start test.

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

 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.

 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.