Remove/install electric motor with transmission

AR08.10-W-0005A

Remove/install electric motor with transmission

26.11.2019

Engine

924.9 in model 970

with code MY5 (BlueTec Hybrid)

1

High-voltage line

2

Clamps

3

Electrical connectors

4

Shield

5

Bolts

6

Battery lines

7

Electrical connectors

8

Propeller shaft

9

Supporting arm

10

Hydraulic line

11

Supporting arm

A92a1

Automatic gear control (AGS) control unit

1

High-voltage line

2

Clamps

5

Bolts

9

Supporting arm

11

Supporting arm

12

Ground lines

13

Bolts

14

Electrical connectors

15

High-voltage connector

M32

Hybrid system electric motor

 

Remove/install

 Warning

Risk of injury to hands or eyes when working on hydraulic pressure reservoir systems caused by hydraulic fluid to specification 345.0 spraying out under pressure

Depressurize hydraulic pressure reservoir system before commencing work on system. Wear protective gloves and safety glasses.

AS00.00-Z-0028-01A

 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

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

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

1

Disable the high-voltage system

AR54.10-W-1160A

2

Depressurize automatic gear control (AGS) pressure reservoir

AR26.10-W-0020-06A

Notes on hydraulic fluid as per specification Sheet 345.0

AH00.40-N-0002-01A


Depressurization should ideally be carried out with Star Diagnosis,
as the system may be filled with up to 90 bar of pressure and manual depressurization presents an increased risk.

 712.6, 715.060/068 transmissionBolt on pressure limiting valve

*BA26.60-N-1004-02A

3

Disconnect ground line from battery

AR54.10-W-0003A

4

Drain coolant at hybrid system electric motor (M32)



AP08.30-W-0880A

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

5

Tilt cab

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

6

Disconnect high-voltage connector (15)

 Seal plug of high-voltage line (1) with protective cover and seal open high voltage connection of hybrid system electric motor (M32) with protective plug.

 Set of protective covers

*001589019100

 Set of safety plugs

*970589036300

7

Disconnect electrical connectors (14) from hybrid system electric motor (M32)

8

Remove bolts (13) and remove ground line (12) from hybrid system electric motor (M32)

 Bolt, ground line to electric motor

*BA08.10-N-1003-01B

9

Remove high-voltage line (1) from clamps (2)

 Secure high-voltage line (1) to the side of the frame.

10

Remove shield (4) from automatic gear control (AGS) control unit (A92a1)

11

Disconnect all electrical connectors (3) from automatic gear control (AGS) control unit (A92a1)

12

Remove battery lines (6)

13

Remove hydraulic lines (10) of cab tilt release from crossmember

14

Take off propeller shaft (8) at transmission

 Set aside propeller shaft (8) and secure against falling down.

 Installation: Replace nuts.

 Bolt/nut, propeller shaft to flange connection

*BA41.10-N-1002-01F

15

Remove propeller shaft center support bearing from bracket

 Installation: Tighten bolts of propeller shaft center support bearing only if propeller shaft (8) is attached to transmission.

 Screw/bolt, intermediate bearing to side angle bracket

*BA41.40-N-1005-01C

16

Raise engine to lifting lugs or support on timing case

 Use a suitable lifting tool.

17

Place commercial vehicle transmission plate on the garage-pit lifter

18

Fasten transmission with tensioning strap to commercial vehicle transmission plate

19

Remove support arm (11) from transmission suspension

 712.63, 715.060/068 transmissionSupporting arm to frame

*BA26.10-N-1003-01C

20

Remove support arm (9)

 712.63, 715.060/068 transmissionSupporting arm to transmission

*BA26.10-N-1002-01C

 712.63, 715.060/068 transmissionSupporting arm to frame

*BA26.10-N-1003-01C

21

Remove bolts (5) around circumference of hybrid system electric motor (M32)

 Bolt, electric motor to timing case

*BA08.10-N-1001-01B

22

Remove hybrid system electric motor (M32) with transmission from timing case

 Pliers

*715589003700

23

Install in the reverse order

24

Check/correct hydraulic fluid level

AR26.60-W-0009A



Hydraulic fluids (Specification 345.0)

BB00.40-P-0345-00A


Only hydraulic oil as per Sheet 345.0 may be used,
as, otherwise, the hydraulic system may fail.

25

Teach in clutch position in automatic gear control (AGS) control unit (A92a1)

 Only when transmission has been replaced.
The teaching-in of the clutch position is menu-assisted in Xentry Diagnostics and listed in the automatic gear control (AGS) control unit (A92a1) under "Control unit adaptations", "Teach-in processes" .

26

Teach in automatic gear control (AGS) (A92a1) control unit

AR54.21-W-0017A

27

After the test drive, check transmission oil level, correct if necessary



Transmission oils (specification 235.1)

BB00.40-P-0235-01A

 Refill with transmission oil up to the bottom edge of oil filler opening.

 712.63, 715.060/068 transmissionOil filler and oil drain screw in transmission housing

*BA26.40-N-1004-01B

 Electric motor

Number

Designation

Engine 924.9

BA08.10-N-1001-01B

Bolt, electric motor to timing case

M10

Nm

45

 Electric motor

Number

Designation

Engine 924.9

BA08.10-N-1003-01B

Bolt, ground line to electric motor

M6

Nm

7

 Manual transmission complete

Number

Designation

Transmission 712.63, 715.060/068

BA26.10-N-1002-01C

Supporting arm to transmission

Nm

190

 Manual transmission complete

Number

Designation

Transmission 712.63, 715.060/068

BA26.10-N-1003-01C

Supporting arm to frame

Nm

330

 Transmission housing

Number

Designation

Transmission 712.63 in model 950, 952, 954
Transmission 712.63, 715.060/068

BA26.40-N-1004-01B

Oil filler and oil drain screw in transmission housing

Nm

60

 Automatic gear control (AGS)

Number

Designation

TRANSMISSION 712.611/62/63, 715.050/060/068 with CODE GE1

BA26.60-N-1004-02A

Bolt on pressure limiting valve

Nm

8

 Propeller shaft

Number

Designation

Model 375.1, 958.0, 970, 972, 974, 975, 976

BA41.10-N-1002-01F

Bolt/nut, propeller shaft to flange connection

M10

Nm

60

M12

Nm

100

M14

Nm

160

M16

Nm

200

 Propeller shaft intermediate bearing

Number

Designation

Model 970, 972, 974, 975, 976

BA41.40-N-1005-01C

Screw/bolt, intermediate bearing to side angle bracket

M10

Nm

55