service m30

Modification Bulletin Terberg Trucks

Document : Service.m30.doc SF362.02

Date Group Nr. Pages 01-09-08 30 02/GB 1/14

Service and Maintenance Improvements on WG211 installation

Terberg YT / TT /RT **2 tractors

Scope of this instruction: ZF introduced alterations in the ZF 6-WG211 transmission installation requirements. The changes are: > A. The use of 3 instead of 2 flexplates. > B. A hardened centre plate in the flywheel. These changes have become standard for tractors produced from October 2007 of. Practice shows that the 2 flexplate installation has a restricted lifetime. Since failures can cause further damage to the installation Terberg and ZF decided for a full campaign. In line with this campaign the following changes will also be implemented:

> C. Re-programming of transmission ECU > D. Check of converter condition, replacement were required > E. Check of oil pump condition, replacement were required

The procedure for this consist out 6 steps:

> 1. Removal of the transmission > 2. Inspection > 3. Rename type shield > 4. Installation in the tractor > 5. Re-Program of ECU > 6. Return into service

As a guideline, this campaign repair takes 10 to 12 hours, depending if the oil pump needs to be replaced. In some stages a help from a second man can be useful.




Converter recognition In this bulletin it is necessary to recognize the differences in converters used in the WG211 transmission. Below chart shows the dimensional differences as well as the numbers which are stamped in the converter.

Transmission

‘long’ Converter

‘short’ Converter

‘parts list No.’ Stamped no. ZF part number

Stamped no. ZF part number

4657 066 003

For 205kW engine:

Mercedes OM906LA

21 0700 284 201 4168 034 077 21 0700 001 704 4168 034 124

4657 066 004

For 170kW engine:

Mercedes OM906LA

Volvo TAD750VE

21 0700 284 203 4168 034 078 21 0700 001 706 4168 034 126

4mm 2mm




1. Removal of the transmission Before the transmission can be removed from the tractor following steps are required. Remove the cover plates over the transmission. Remove noise panels from underneath the transmission if they are installed. For the ease of removal it is required to remove the dipstick from the transmission. To drain the transmission oil quicker, you can partly loosen the dipstick tube. The transmission contains approx. 21L of oil, so use an adequate sized, clean collecting device. Depending on the condition of the oil, there can be decided to re-use it after installation. Remove the dipstick completely. Disconnect the oil lines to the oil cooler from the transmission. Disconnect electrical wiring from the transmission. Make sure that you know were to connect them to during installation, by marking the connectors were required. Disconnect the prop shaft from the transmission. If required remove it completely by also disconnecting it from the transfer case / rear axle. On the back of the transmission a hydraulic pump is installed. Disconnect the pump, by unscrewing it and tie it back as far away from the transmission as possible, leaving the hoses connected. Next the flexplates can be disconnected from the engine flywheel / adapter plate. The 4 bolts can be taken out through the access cover plate, located in the flywheel housing bottom side close to the engine sump. Now the transmission is ready to be removed from the tractor, for which lifting is required. Use, preferably, a suitable crane for this job. A forklift truck can be used as alternative, but make sure that it has sufficient capacity and that slings / belts / chains can not slide from the forks. The transmission weight is approx. 500Kg, the converter has to stay with it, during removal. Use proper lifting tackle and connect this to the lifting lugs on the transmission top. Apply some tension with the lifting device. On the RT type tractor it is required to remove the rear support from the transmission by unscrewing it from the transmission. Be aware for the spring tension, doing this. To completely remove the rear support, it is required to disconnecting the spring leafs from the bracket. Now the transmission mounting bolts, connecting the transmission to the engine flywheel housing, can be removed. When removed, the transmission can be lifted out. To do so, the transmission needs to be moved to the rear over approx. 80mm, so that converter and converter spigot can clear the flywheel house.




2. Inspection > Converter re-use: To determine if the ‘long ‘ converter can be re-used, 2 checks are required: Check 1: The horizontal distance from flexplate mounting pads to converter spigot support front face, which is nominal 4mm on the existing converter, should not exceed 4,5mm. If it does exceed, the converter needs replacement.

Check 2: Secondly the bearing behind the converter, which is part of the transmission oil pump, needs to be inspected. To do so, the converter needs to be removed from the transmission. We advise to tilt the transmission slightly over the front, while removing the converter. There is chance that the needle bearing cage is already damaged and that it drops out the needles as soon as the converter is removed. Tilting of the transmission can avoid that the needles fall in the transmission. The bearing contains 56 needles. Make sure that : > the transmission can not fall over. > the converter doesn’t slide out the transmission by this manoeuvre. If this bearing is damaged, the contact surface of the converter shaft inside the bearing can also show wear. If this converter shaft is visually damaged, this is also a reason to replace the converter. To reinstall a converter, the transmission needs to be tilted, so that it rests on its back ( output shaft side down ). In this position all shafts are centred, so that the converter shaft slides nicely over this.




> Oil pump replacement required? Since the bearing is an integral part of the oil pump, the oil pump needs to be replaced, when the bearing needs replacement. For installing the oil pump, see the ZF instructions: 6WG211 - Conversion Instructions – Exchange transmissions Terberg.

> Transmission overhaul required? If the transmission has been running for a longer period with a severe damaged bearing, needles and metal debris will have entered the transmission. In this case the transmission has to be revised by ZF. There are swing units available to replace the transmission. Please contact Terberg Aftersales department to arrange for this replacement. In case debris is found in the transmission oil cooler and oil lines, this needs to be cleaned. Please consult Terberg Aftersales department for further instruction.




3. Rename type shield To be able to recognize the different transmission installations after installation, the ‘parts list No.’ on the type shield needs to be renamed as follows: Original ‘parts list No.’ 3 flexplates + ‘long’ converter 3 flexplates + ‘short’ converter 4657.066.003 4657.066.020 4657.066.023 4657.066.004 4657.066.021 4657.066.024

Please stamp XX over the last numbers and stamp the last 2 digits of the new number besides it in the type shield. 4. Installation in the tractor On the engine side, the flywheel or flywheel adapter plate needs to be replaced. The new installation gets an extra centre plate, which is hardened. > Mercedes OM906LA Remove the adapter plate t15012533. Install the adapter plate t15012761 with centre plate t15012756, using screws t29020729. See figure 1 & 2.

> Volvo Penta TAD750VE Remove the flywheel v20532339. Install the flywheel t15012762 with centre plate v21112999. The old flywheel can be disposed. See figure 3 & 4.




On the transmission WG211 side, 3 flexplates needs to be provided. > Existing ‘long’ converter can be used: Remove the 2 flexplates from the transmission. Install the new 3 flexplates pack to the converter, using the supplied new bolts and the existing 2 washers. One washer located under the bolt head and a washer between flexplates and converter. Remove the transport bolts out of the clips, don’t loose the clips.

> When an overhauled transmission is installed: In an overhauled transmission is a new converter used. Check if a 3 flexplates pack with clips is installed. If not, then follow the instructions for a new converter. Rename the type shield of the overhauled transmission according chapter 3.

> With a new or existing ‘short’ converter: Install a new 3 flexplates pack to the transmission with the supplied bolts. Use in total 4x 1mm washers per screw. One washer located under the bolt head and 3 washers between flexplates and converter. Remove the transport bolts out of the clips, don’t loose the clips.

When required adjustments on transmission and engine side are fulfilled, the transmission can be re-installed to the tractor again. Lift the transmission with the same precautions. Slide the converter spigot into the flywheel / adapter plate centre ( provide some grease for this ). Pre-mount the bolts in the engine – transmission connection. Install the bolts in the clips around the flexplates from underneath engine. Install the transmission rear support, if this was removed. Install the Hydraulic pump back in place. Connect the prop shafts. Connect oil lines from the cooler, install the dipstick tube and reconnect electrics. Torque all bolts to the required settings, see fig 5. Fill the transmission again with the correct oil, as specified in the ZF recommendations or re-use the oil which came out of the transmission. Make sure that the oil is clean.




5. Re-Program of ECU In line with this campaign, the transmission ECU needs to get a new program loaded. For instructions read the modification bulletin 30-03/GB

6. Return into operation If the transmission is installed, filled up with oil and the ECU is reprogrammed, the tractor can be started and tested. It is recommended to run an AEB calibration before the tractor is returned into operation. For AEB-Calibration see procedure by the AEB-starter. Check the oil level with running engine. Make a test run, to check the operational performance of the transmission. Finally check for any external oil leaks. The tractor can be returned in operation. Inform Terberg Aftersales department ( via involved service manager ) that a tractor has been finalised. At least include following information:

> Tractor chassis number > Running hours > Repair date > Status of old flexplates ( broken, cracked etc. ) > Is the converter and / or oil pump replaced? > What number is stamped on the name shield




Engine: Mercedes OM906LA Transmission: ‘long’ converter

t15012761

t15012756

t29060266

t29020729

Fig. 1




t15012761

t15012756

t29060266

t29020729

Install additional

2 washers

Engine: Mercedes OM906LA Transmission: ‘short’ converter

Fig. 2




Engine: Volvo Penta TAD750VE Transmission: ‘long’ converter

t15012762

V21112999

t29060894

V20405654

Fig. 3




Engine: Volvo Penta TAD750VE Transmission: ‘short’ converter

t15012762

V21112999

t29060894

V20405654

Install additional

2 washers

Fig. 4




OM 906 LA

ZF -WG 211

44 Nm + Loctite 243

55-61 Nm

83 Nm + Loctite 243

44 Nm

Section A-A

RT only

A

A

46 Nm

34 Nm

Engine side

Only by 'short' converter

TAD 750 VE

ZF -WG 211

44 Nm + Loctite 243

Step 1: 20 - 30 NmStep 2: turn 60°Step 3: turn 60°

RT only

46 Nm

34 Nm

Only by 'short' converter

55 - 61 Nm

115 Nm + Loctite 262

115 Nm + Loctite 262

Fig. 5

Non specified tightening torques according general chart on next page




Coarse metric threads

For assembly without grease For assembly with grease

Hexagon Flange Hexagon Flange

Size Quality Tightening torque

(Nm)

Tightening torque

(Nm)

Tightening torque

(Nm)

Tightening torque

(Nm)

8.8 2,8 3,4 2,5 3,0

10.9 4,1 4,7 3,7 4,3 M 4

x 0.7 12.9 4,8 5,5 4,3 4,9

8.8 5,5 6,6 4,9 5,9

10.9 8,1 9,3 7,3 8,4 M 5

x 0.8 12.9 9,5 10,9 8,5 9,8

8.8 9,5 11,4 8,5 10,2

10.9 14,0 16,1 12,5 14,4 M 6

x 1 12.9 16,5 19,0 14,5 16,7

8.8 15,5 18,6 14 17

10.9 23 26 21 24 M 7

x 1 12.9 27 31 24 28

8.8 23 28 21 25

10.9 34 39 30 35 M 8

x 1.25 12.9 40 46 35 40

8.8 46 55 41 49

10.9 68 78 60 69 M 10

x 1.5 12.9 79 91 71 82

8.8 79 95 71 85

10.9 117 135 104 120 M 12

x 1.75 12.9 135 155 121 139

8.8 125 150 113 136

10.9 185 213 165 190 M 14

x 2 12.9 215 247 195 224

8.8 195 234 170 204

10.9 280 322 250 288 M 16

x 2 12.9 330 380 300 345

8.8 280 336 245 294

10.9 390 449 350 403 M 18

x 2.5 12.9 460 529 410 472

8.8 390 468 350 420

10.9 560 644 490 564 M 20

x 2.5 12.9 650 748 580 667

8.8 530 636 470 564

10.9 750 863 670 771 M 22

x 2.5 12.9 880 1012 780 897

8.8 670 804 600 720

10.9 960 1104 850 978 M 24

x 3 12.9 1120 1288 1000 1150

8.8 1000 1200 880 1056

10.9 1400 1610 1250 1438 M 27

x 3 12.9 1650 1898 1450 1668

8.8 1350 1620 1190 1428

10.9 1900 2185 1700 1955 M 30

x 3.5 12.9 2250 2588 2000 2300

8.8 1850 2220 1600 1920

10.9 2600 2990 2300 2645 M 33

x 3.5 12.9 3000 3450 2700 3105

8.8 2350 2820 2100 2520

10.9 3300 3795 3000 3450 M 36

x 4 12.9 3900 4485 3500 4025

8.8 3000 3600 2700 3240

10.9 4300 4945 3800 4370 M 39

x 4 12.9 5100 5865 4500 5175

Source: VDI 2230, DIN 13 section 13, DIN 931, DIN 912

service m30

Business

transmission oil quicker

flexplate installation

check of oil pump condition

oil cooler

oil lines

check of converter condition

converter recognition

date group nr