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TKR Group 83 30 5 A87 F94 Translation Of The Original Manual

Disassembly and assembly tool
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83 30 5 A87 F94
Disassembly and assembly tool
Translation of the original owner's manual
R1-23.12-V7

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Summary of Contents for TKR Group 83 30 5 A87 F94

  • Page 1 83 30 5 A87 F94 Disassembly and assembly tool Translation of the original owner's manual R1-23.12-V7...

  • Page 3: Table Of Contents

    Safety Maintenance General instructions Troubleshooting Explanation of symbols Regular inspection and maintenance Scope of supply Safety instructions Service Disposal Technical data Warranty and service Technical data Declaration of conformity Device components EC Declaration of conformity Startup Intended use Working with the tool - basic principles Commissioning and safe handling Preparatory work Removing the stator winding from a mild hybrid...

  • Page 4: General Instructions

    1.1 General instructions State-of-the-art Declaration of Conformity This tool is state-of-the-art technology. To ensure that the The tool has been manufactured and inspected in equipment operates safely, it must be operated in a proper and compliance with European directives. The Declaration safety-conscious manner.

  • Page 5: Explanation Of Symbols

    1.2 Explanation of symbols Some sections in this instruction manual use internationally recognised warning symbols, warning notes and general in- struction symbols. The individual symbols are explained below. Follow all the instructions and safety rules. Warning! Follow the manual Torx, size Hands could become trapped Warning! Danger from Follow the general instruc-...

  • Page 6: Scope Of Supply

    1.3 Scope of supply 83 30 5 A87 F94 83 30 5 A87 FB1 Item Designation Disassembly and assembly tool with lifting eye (83 30 5 A87 F94_A), lifting plate (83 30 5 A87 F94_C), and spacer (83 30 5 A87 F94_D) Hexagon screws with centering sleeves Owner’s manual German/ English...

  • Page 7: Safety Instructions

    1.4 Safety instructions The tool is strictly approved solely for the purpos- CAUTION es for which the manufacturer has designed it. Danger of crushing and serious injuries The tool must only be used for the activities described in this own- Position hands and feet away from where there is a risk of er's manual.
  • Page 8 When lifting and lowering the load, avoid bump- CAUTION ing into obstacles. Risk of material damage and bodily injury Make sure that there is sufficient light. Using the device to carry people or climbing on the raised load is not permitted. Make sure that there is sufficient space for working.

  • Page 9: Technical Data

    -20°C to +60°C/ -4°F to 140°F front left Disassembly and assembly tool 83 30 5 A87 F94 (with lifting eye 83 30 5 A87 F94_A, lifting plate 1 83 30 5 A87 F94_B, and spacer 1 83 30 5 A87 F94_C)
  • Page 10 Accessory kit: Lifting plate 2 front 83 30 5 A87 FB1_A Width: 450 mm Min. height: 675 mm Max. height: 725 mm...

  • Page 11: Device Components

    2.2 Device components 2.2.1 2.2.1 Disassembly and assembly tool Spindle with square 8 AF Hexagon screws with centering sleeves Adjustment nut Lifting plate 2 Lifting plate 1 Spacer 2 (long) Baseplate Centering pins Spacer 1 (short) Centering ring...

  • Page 12: Intended Use

    3.1 Intended use Use as described in The disassembly and assembly device 83 30 5 A87 F94 is designed exclusively for install- instruction manual ing and removing the transmission cover and stator winding from a BMW AG mild hybrid transmission for which it has been approved. The accessory kit 83 30 5 A87 FB1 can be used to convert the device for installing and removing the stator winding from BMW AG plug-in hybrid transmissions for which it has been approved.

  • Page 13: Working With The Tool - Basic Principles

    3.2 Working with the tool - basic principles Risk of injury Warranty The tool must be positioned so there is no risk of The manufacturer accepts no liability for damage crushing. caused by repairs which have been carried out incorrectly. Stable positioning The tool may only be used on a level, horizontal floor.

  • Page 14: Commissioning And Safe Handling

    3.3 Commissioning and safe handling 3.3.1 3.3.2 3.3.1 Engine and transmission mount 00 2 300 3.3.2 Workshop crane WW-DHZ-1000 CAUTION Lifting and lowering the transmission components Risk of injury is only permissible using the workshop crane Do not exceed the permissible lifting weight of the WW-DHZ-1000 with the rope hoist attachment engine and transmission mount.
  • Page 15 3.3.3 3.3.4 3.3.3 Support 83 30 5 A82 CC8 3.3.4 Two persons are required to operate the crane and to adjust CAUTION and attach the tool. Risk of damage to aterial and personal injury Take into account the permissible nominal load of Two persons are required to remove the tool from the packaging.

  • Page 16: Preparatory Work

    4.1 Preparatory work 4.1.1 4.1.1 4.1.2 4.1.2 4.1.1 4.1.2 Carry out the following activities before removing the transmis- [short, D] Move the spacer 1 to the top positon by turning the sion cover and the stator winding from either the mild hybrid adjustment nut [A2] counterclockwise in order to avoid damag-...

  • Page 17: Removing The Stator Winding From A Mild Hybrid Transmission

    4.2 Removing the stator winding from a mild hybrid transmission 4.2.1 4.2.1 4.2.2 4.2.2 4.2.1 4.2.2 Remove the radial shaft seal (RWDR) using a suitable tool Remove the cover screws for the three pole contacts of the stator (83 30 5 A85 A86). Remove the snap ring with a suitable tool winding (12 mm Allen key).
  • Page 18 15 Nm 4.2.5 4.2.6 Lower the tool 83 30 5 A87 F94 onto the case flange. When cen- Screw the baseplate of the tool to the transmission flange tering, one of the centering pins P1, P2 or P3 aligns with one of with three of the hex screws [E].
  • Page 19 4.2.9 4.2.9 4.2.10 4.2.10 4.2.9 4.2.10 Before lowering the lifting plate 1 [B], check that the two clamp- Lower the lifting plate 1 onto the transmission cover by turn- [B2] ing lugs [B1] are in position and all the positioning lugs ing the hexagon on the spindle [A1] (8 mm AF).
  • Page 20 4.2.13 4.2.13 4.2.14 4.2.14 max. 10 max. 10 Nm 4.2.13 4.2.14 Lift the transmission cover by turning the spindle hexagon [A1] by turning the adjustment nut [A2]. The Lift the spacer 1 clockwise until the fixed winding can be seen approximately above spacer 1 must hang freely above the shaft end.
  • Page 21 4.2.17 4.2.17 4.2.18 4.2.18 4.2.17 4.2.18 You can now move the stator winding and transmission cover Lower the lifting plate 1 onto the cone by turning the spindle freely and place them on the cone designed for this purpose hexagon [A1]. After lowering, undo the connection between the (according to the specifications of the BMW workshop manual).

  • Page 22: Installing A Stator Winding In A Mild Hybrid Transmission

    4.3 Installing a stator winding in a mild hybrid transmission 4.3.1 4.3.1 4.3.2 4.3.2 4.3.1 4.3.2 Carry out the following activities before assembling the stator On the cone, lower the lifting plate 1 onto the transmission winding: cover by turning the spindle hexagon [A1]. Make sure that the •...
  • Page 23 4.3.3 4.3.3 4.3.4 4.3.4 15 Nm 4.3.3 4.3.4 Position the tool in the center on the transmission flange. Make Lower the spacer onto the shaft end by turning the adjust- sure that the slot in the baseplate is aligned with the center ment nut [A2] until you feel resistance.
  • Page 24 4.3.5 4.3.5 4.3.6 4.3.6 4.3.5 4.3.6 Lower the transmission cover with the stator winding into the After lowering, release the position lugs [B2] with the green transmission case by turning the spindle hexagon [A1]. Use a wing nuts and push them inward. Make sure that the pole con- suitable tool (8 AF).
  • Page 25 4.3.9 4.3.9 4.3.10 4.3.10 4.3.9 4.3.10 Screw in the cover screws of the pole contacts of the stator wind- Fit the snap ring with a suitable tool (83 30 5 A82 CE3). Fit the ing (12 mm Allen key). radial shaft seal (RWDR) using a suitable tool (83 30 5 A85 A86). See BMW workshop manual for further work steps.

  • Page 26: Removing The Stator Winding From A Plug-In Hybrid Transmission

    4.4 Removing the stator winding from a plug-in hybrid transmission 4.4.1 4.4.1 4.4.2 4.4.2 4.4.1 4.4.2 Prepare the transmission (see Step 4.1.1 and 4.1.2). Undo the cover screws of the pole contacts between the inverter and the transmission case (12 mm Allen key). 4.4.3 4.4.3 4.4.4...
  • Page 27 4.4.5 4.4.5 4.4.6 4.4.6 15 Nm 4.4.5 4.4.6 Screw the baseplate of the tool to the transmission flange with Undo the pole screw connections between the inverter and three of the hex screws provided [E]. Make sure that the diameter transmission case and unscrew the inverter from the transmis- of the red or blue sleeves is suitable for the holes in the transmis- sion case (see BMW AG workshop manual).
  • Page 28 4.4.9 4.4.9 4.4.10 4.4.10 4.4.9 4.4.10 Lower the lifting plate 1 onto the transmission cover by turn- After lowering the lifting plate 1 [B], push the clamping lugs ing the spindle hexagon [A1]. Use a suitable tool (8 AF). Make into the position and fix them by screwing tight the red screw [B2]...
  • Page 29 4.4.13 4.4.13 4.4.14 4.4.14 4.4.13 4.4.14 Undo the screw connection between the baseplate and the Using a suitable tool (83 30 5 A82 D11, see owner’s manual), lift transmission flange. You can now lift the tool off the transmis- the absorber unit from the transmission and place it on a suita- sion.
  • Page 30 4.4.17 4.4.17 4.4.18 4.4.18 4.4.17 4.4.18 You must refit the tool to disassemble the stator winding. Use Dismantle the spacer 1 [short, D]. Use a 4 mm Allen key to undo the accessory kit 83 30 5 A87 FB1 for this purpose. the countersunk screw.
  • Page 31 4.4.21 4.4.21 4.4.22 4.4.22 15 Nm 4.4.21 4.4.22 Install the spacer 2 [long, G]. Use a 4 mm Allen key for this. Align the tool, put it on and screw it to the transmission (see Steps 4.4.3, 4.4.4 and 4.4.5). CAUTION Risk of damage to material Before putting on the tool, ensure that the lifting...
  • Page 32 4.4.25 4.4.25 4.4.26 4.4.26 4.4.25 4.4.26 Lower the spacer onto the shaft end 2 by turning the adjust- Lower the lifting plate 2 onto the stator winding by turning ment nut [A2]. the spindle hexagon [A1]. CAUTION Risk of personal injury Do not place your hands on the baseplate the device.
  • Page 33 4.4.29 4.4.29 4.4.30 4.4.30 max. 10 max. 10 Nm 4.4.29 4.4.30 Undo the screw connections between the stator and the trans- Lift the stator from the transmission case by turning the spindle [A1] mission case (multi-tooth profile). hexagon clockwise. Check the clamping screws (No.2) are firmly seated by lifting slightly.
  • Page 34 4.4.33 4.4.33 4.4.34 4.4.34 4.4.33 4.4.34 By turning the spindle hexagon [A1], lower the stator onto a suit- The rotor can now be lifted from the transmission using a suit- able cone (according to the specifications of the BMW workshop able tool (83 30 5 A82 D11, see owner’s manual) and placed in a manual).

  • Page 35: Installing A Stator Winding In A Plug-In Hybrid Transmission

    4.5 Installing a stator winding in a plug-in hybrid transmission 4.5.1 4.5.1 4.5.2 4.5.2 4.5.1 4.5.2 After inserting the rotor, screw the three centering pins [H, 7 AF] When removed: Insert the rotor using a suitable tool (83 30 5 A82 D11, see owner’s manual).
  • Page 36 4.5.5 4.5.5 4.5.6 4.5.6 4.5.5 4.5.6 Swivel the hooks of the lifting plate 2 into the recess of the Screw in the positioning screws (No. 1) and the three clamping stator laminations by pulling the latch bolt, (lifting plate 2 from screws (No.
  • Page 37 4.5.9 4.5.9 4.5.10 4.5.10 4.5.9 4.5.10 Remove the three centering pins [H, 7 AF] and screw the stator Screw the two positioning screws and three clamping screws to the transmission case (multi-tooth profile, see BMW workshop (No. 1, No. 2) upward. manual for torque setting).
  • Page 38 4.5.13 4.5.13 4.5.14 4.5.14 4.5.13 4.5.14 Remove the centering ring [K]. If necessary, you can screw screws Install the clutch (see BMW AG Workshop manual). (M6, not contained in the scope of supply) into the four tapped holes to make removal easier. CAUTION Risk of damage to material The centering ring MUST be removed.
  • Page 39 4.5.17 4.5.17 4.5.18 4.5.18 4.5.17 4.5.18 Refit the tool to install the transmission cover. In order to do this, Release the lifting plate 2 from the flange (three countersunk first release the long spacer from the spindle by the counter- screws, use 4 mm Allen key).
  • Page 40 4.5.21 4.5.21 4.5.22 4.5.22 15 Nm 4.5.21 4.5.22 Insert the transmission cover into the tool. After insertion, push Align the tool, put it on and screw it to the transmission (see the clamping lugs [B1] to the position. Place the pins of the Steps 4.4.3, 4.4.4 and 4.4.5).
  • Page 41 4.5.25 4.5.25 4.5.26 4.5.26 4.5.25 4.5.26 Lift the spacer 1 off the shaft end by turning the adjustment Insert the screws of the pole contacts between the transmission nut [A2]. Move the lifting plate 1 to the top by turning the case and stator winding and tighten them (left-hand threads, see spindle hexagon [A1].

  • Page 42: Transmission Assignments For Centering And

    Store the tool lying down. Always store the tool dry and safe. Avoid contamination. Clean the tool before storing it. We recommend storing the tool 83 30 5 A87 F94 together with the accessory kit 83 30 5 A87 FB1.

  • Page 43: Troubleshooting

    5.1 Troubleshooting Fault Problem Remedy Chapter Stator cannot be lifted Pole screw connections Undo pole screw connections 4.2.2/ out of the transmission between transmission 4.2.3 case (mild-hybrid, plug- case and stator winding (MH) in hybrid) not undone 4.4.2, 4.4.6, 4.4.7 (PH) Mild-hybrid (MH): Trans- Snap ring not pulled off Remove snap ring...

  • Page 44: Regular Inspection And Maintenance

    5.2 Regular checking and maintenance Checks may only be carried out by qualified personnel. The tool must be inspected at least once a year. If you are using the tool frequently, carry out the inspection at shorter intervals. Essentially, the inspections are visual and functional ones, required to evaluate the condition of parts in terms of damage, wear, corrosion or other changes and to determine the completeness and effectiveness of the safety devices.

  • Page 45: Service

    6.1 Disposal Devices and machinery and components of devices and machinery must be disposed of in compliance with the laws, regulations and other stipulations of the country in which they are located. We recommend using specialist licensed companies for disposal. The modules and units have been developed to be environmentally compatible and suitable for recycling.

  • Page 46: Declaration Of Conformity

    Am Waldesrand 9–11 D-58285 Gevelsberg (Germany) Phone +49 2332 66607-0 Other languages, accessories and replacement parts: +49 2332 66607-941 E-mail info@tkrgroup.com www.tkr-service.com Internet www.tkrgroup.com...

This manual is also suitable for:

83 30 5 a87 fb1

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