Ngug Transmission Repairs Transmissions G210 - 260: Service Training

Service Training
NGUG
Transmission Repairs
Transmissions G210 - 260
As at 02/00
Reordering or subsequent delivery of this document is not possible.
The present training document can be downloaded from the following Intranet address for a limited period only.
http://intra-mbma.daimlerchrysler.com/ ”Produkte und Dienst-Leistungen / Trainingskonzepte” (Products and services / training
concepts)
This document is intended solely for use in training and is not subject to regular updating.
Printed in Germany
 2000 Copyright DaimlerChrysler AG
This document with all its sections is protected under the laws of copyright. Its use for any purpose whatsoever
requires the prior written consent of DaimlerChrysler AG. This applies in particular to its reproduction, distribution,
modification, translation, recording on microfilm or storage and/or processing in electronic systems, including
databases and on-line services.
1510 3189 02 - 1st edition 02.00 116

Contents 15.02.2000
Page Title
1 Preface
2 Welcome, initial test and fundamentals of transmissions
9 Starting off with gearbox repairs, procedure and objectives
12 Peripheral components and lines
17 Removing transverse shift and range group: exercise and work sheets
20 Station 1 / Oil circuit: exercise and work sheets
31 Group work transmission repairs: survey and work sheets
36 Station 1 / Disassembling main transmission and determining findings: exercise and work sheets
43 Station 1 / Assembling and setting main transmission
50 Station 2 / Disassembling main shaft and determining findings: exercise and work sheets
59 Station 2 / Assembling and setting main shaft
66 Station 2 / Disassembling range group and determining findings: exercise and work sheets
71 Station 2 / Assembling and setting range group
76 Station 3 / Disassembling transverse shift and peripheral components and determining findings: exercise and work sheets
91 Station 3 / Assembling and setting transverse shift
96 Assembling transmission
103 Operational check of transmission
108 Concluding discussion on transmission repairs
02/00 NGUG <> Transmission Repairs G210 - 260

Contents I 1
Contents I 2
Preface 15.02.2000
The transmission repairs training has been matched to the

transmissions fitted to the ACTROS. At the same time, we have set
ourselves the aim of structuring the training course in such a way as
to more actively involve the participants. If in the past, the extent of
the practical work at the transmission was more or rather less, we
have now placed emphasis on ensuring that all the setting and
repair operations are carried out in small groups.
In this training course, you will have the possibility of intensifying
your skills and knowledge in respect of repairing MB range-change
transmissions in small groups. In addition, you will acquire greater
confidence in diagnosis, determining the findings and carrying out
repairs on range-change transmissions, and you will work with the
workshop literature. A further important aspect is that you will have
the possibility of communicating with your group colleagues and
thus bringing your own experience into the training.
What we understand by a small group is that 3 participants (and not
more than 4) work together at a point. The training course does
take a little longer than was the case in the past, but we are
confident that this will provide greatly improved training results N26.60-2068-76
than before.

Preface 1
Welcome, initial test and fundamentals of transmissions 15.02.2000
Transmission design
Work through the following 6 exercises in groups. Use the info sheet on transmission ratios and gear steps as an aid for
k
answering the questions.
Exercise 1: What gear step ( gear step = 1L : 8S. In the case of G 211, 17.03 : 1.0 = 17.03 ) do the following types of transmissions have?
G 211 = 17.03 G 210 = G 240 = G 260 =
Exercise 2: Which gear is the direct gear in the case of the transmissions listed below?
G 211 = 8S G 210 = G 240 = G 260 =
Exercise 3: How many gears in the following types of transmission are in the high range
G 211 = no gear G 210 = G 240 = G 260 =
"Hi folks, I'm Theo and I'll be coaching you

through the transmission training.
I'll be providing you with tips and useful
information or will simply say something to
liven up the atmosphere. And now you can
show me what has been left over from your
apprenticeship time."

Welcome, initial test and fundamentals of transmissions 2
Gear ratios and gear steps
Gear step / ratio G 211 Gear step / ratio G 210 Gear step / ratio G 240 Gear step / ratio G 260
1L 17,03 1L 14,19 1L 11,72 1L 9,75

1,21 1,21 1,2 1,21
1S 14,19 1S 11,72 1S 9,75 1S 8,07
1,23 1,22 1,23 1,23
2L 11,50 1,48 2L 9,58 1,48 2L 7,92 1,48 2L 6,58 1,48
1,2 1,21 1,2 1,21
2S 9,58 2S 7,92 2S 6,58 2S 5,45
1,23 1,22 1,24 1,24
3L 7,80 1,48 3L 6,50 1,48 3L 5,29 1,50 3L 4,40 1,50
1,2 1,21 1,2 1,21
3S 6,50 3S 5,37 3S 4,40 3S 3,64
1,23 1,22 1,21 1,2
4L 5,28 1,48 4L 4,40 1,48 4L 3,64 1,46 4L 3,02 1,46
1,2 1,21 1,2 1,21
4S 4,40 4S 3,64 4S 3,02 4S 2,50
1,14 1,13 1,13 1,13
5L 3,87 1,36 5L 3,22 1,36 5L 2,66 1,37 5L 2,22 1,37
1,2 1,21 1,2 1,21
5S 3,22 5S 2,66 5S 2,22 5S 1,83
1,23 1,22 1,23 1,23
6L 2,61 1,48 6L 2,18 1,48 6L 1,80 1,48 6L 1,50 1,48
1,2 1,21 1,2 1,21
6S 2,18 6S 1,80 6S 1,50 6S 1,24
1,23 1,22 1,24 1,24
7L 1,77 1,48 7L 1,48 1,48 7L 1,20 1,50 7L 1,00 1,50
1,2 1,21 1,2 1,21
7S 1,48 7S 1,22 7S 1,00 7S 0,83
1,23 1,22 1,21 1,2
8L 1,20 1,48 8L 1,00 1,48 8L 0,83 1,46 8L 0,69 1,46
1,2 1,21 1,2 1,21
8S 1,00 8S 0,83 8S 0,69 8S 0,57
RL 15,48 RL 12,90 RL 10,66 RL 8,86
RS 12,90 RS 10,66 RS 8,86 RS 7,33

You should be familiar with the shift possibilities and power flow in 8S of G 210 from the preliminary training.
When it comes to the other types of transmissions, please complete the boxes and draw in the power flow in 8S.
SH SL 4 3 2 1 R RL RH
Shift possibilities: ï ð ï ð ï ð ï ï ð
Splitter low: SL
Splitter high: SH
Gear: 1
2
3
4
R
Range low: RL
Range high: RH
N26.10-2045-79
G 210 GS

Exercise 4: Enter the remaining shift possibilities and draw in the power flow in 8S!
2 1 R RL RH
Splitter low: SL
Splitter high: SH
Gear: 1
2
3
4
R
Range low: RL
Range high: RH
N26.50-2089-79
G 211 GS

2 1 R RL RH
Splitter low: SL
Splitter high: SH
Gear: 1
2
3
4
R
Range low: RL
Range high: RH
N26.10-2044-79
G 240 GS

2 1 R RL RH
Splitter low: SL
Splitter high: SH
Gear: 1
2
3
4
R
Range low: RL
Range high: RH
N26.10-2002-09
G 260 GS

Starting off with gearbox repairs, procedure and objectives 15.02.2000
N26.00-2023-06

Starting off with gearbox repairs, procedure and objectives 9
Objectives of NGUG training course
As the training course progresses, you will ...
intensify your skills and knowledge in connection with repairing MB range-change transmissions
in small groups.
acquire greater confidence in diagnosis, determining findings and carrying out repairs to range-
change transmissions.
make specific use of the workshop literature.
exchange experience on repairing transmissions with your colleagues.
"On your marks, get ready, go !"

Stations of the NGUG training course
Œ Welcome, getting to know the course participants

ð Theory: transmission design G 211, G 210, G 240 and G 260
ð Removing transverse shift and range group
• Disassembling main transmission, determining findings, assembling and setting
Ž Disassembling range group and main shaft, determining findings, assembling and setting
• Elaborating on operation of shift mechanism and removing
º Stating peripheral parts and components and removing
‘ Fitting parts to transmission and carrying out operational check
¼ Concluding discussion

Peripheral components and lines 15.02.2000
Info Where is each component located?
Certain information and illustration regarding peripheral components and the installation points are provided in the WIS and
i
Diagnosis Manual. To simplify the task of locating these, we have made the effort of listing in this brochure the EPS and HPS
transmission with their peripheral components.
The Diagnosis Manual has no longer been updated for some time now.
i
I've already seen a picture with all the sensors in the

WIS at some time and there's also something about
this under EPS in Diagnosis Manual Volume 3!

Peripheral components and lines 12
Mechanical emergency shift Gear sensor (B60) Range solenoid valves Speedo sensor
G 210 EPS
N26.10-2038-08
Gear shift Gear cylinder air admission Gear cylinder air ATF temperature Transmission input Rpm sensor
cylinder solenoid valves release solenoid valves sensor (B47) speed sensor (B3) (only with EAS)

Range sensor (B63) Transmission mount Splitter sensor (B62) Gate sensor (B61) Gate shift cylinder
G 210 EPS
N26.10-2039-08
Gate solenoid valves Splitter solenoid valves Transmission central connector

Range-change valve HPS gate cylinder connection
G 210 HPS
N26.10-2040-08
Clutch sensor (B2) cable ATF temperature Transmission input speed Retarder cable PTO 2 indicator
connection sensor (B47) sensor (B3) connections switch

Reverse gear switch S7 Neutral position switch S9 Splitter solenoid valves Retarder central connector
MS1/MS2
G 210 HPS
N26.10-2041-08
PTO 1 solenoid valve PTO 1 indicator switch HPS gear cylinder connection PTO central connector Transmission central connector

Removing transverse shift and range group: exercise and work sheets 15.02.2000
Exercise : Remove the transverse shift and range group
Work through the exercise again in groups.

e
Group 2 removes the transverse shift. Note the most important points on the following work sheets. Enter your own personal
comments!
Group 1 has the good luck to be able to observe the procedure of the two other groups and to note the most important points.
If you have any questions, ask your colleagues in the group performing the work if there is any step in the operation you don't
understand, and make your own notes.
Use the info from WIS and the microfiche for the exercise wherever you consider this necessary!
i
"Off we go!"

Removing transverse shift and range group: exercise and work sheets 17
e Work sheet removing transverse shift
Important points of disassembly:

"The gearshift
1. cylinder can
normally remain
2. attached for
removing the
3. transverse
shift"
4.
5.
6.
7.
8.
W26.60-0015-06
Personal notes

e Work sheet removing power take-off and range group
Important points for removal:
1.
2.
3.
4.
5.
6.
W26.31-0002-09
Personal notes

Station 1 / Oil circuit: exercise and work sheets 15.02.2000
Station 1
Main transmission
Station 2
Main shaft and
range group
Station 3
Transverse shift and
peripheral components

Station 1 / Oil circuit: exercise and work sheets 20
Exercise: Develop your knowledge of the oil circuit
The oil circuit refers to the entire transmission. At the individual stations, pay attention to the components of the oil circuit and
j
answer the questions on the pages which follow.
Remember that the drillings - for example in the main shaft or in the sun wheel - also form part of the oil circuit!
i
Make a note of the most important points on the work sheet "Oil circuit".
Enter your own personal comments!
"Now things are getting oily!"

j Work sheet oil circuit: survey of oil circuit
N26.55-2009-79

Exercise: Develop your knowledge of the oil circuit
Exercise 1: Mark the places in the illustrations at which the oil circuit is sealed with O-rings. Work through this exercise very carefully
and examine the transmission closely so that you do not forget any point!
Exercise 2: In the work sheet "Survey of oil circuit" mark the approximate positions of the oil spray nozzles of the gears at the oil pipe.
Which gear in the splitter box and in the main transmission is not sprayed?
Exercise 3: Follow the path of the basic oil circuit and number the components
in the illustrations in line with the designations:
1.) Oil inlet pipe

2.) Oil filter with bypass valve
3.) Oil pump
4.) Oil pressure relieve valve and cooler bypass valve (only on models fitted with oil cooler)
5.) Oil pipe
6.) Input shaft and front bearing of countershaft
7.) Main shaft with bearing points
8.) Planetary gear set
"The oil circuit is a single-stream

design."

j Work sheet oil circuit: range group
"There's a history to question 5.

Who of you still remembers our
SK with its screaming range
group in 1st to 4th gear?"
N26.40-2026-82

Exercise : Develop your knowledge of the oil circuit - continued
Exercise 4: The sliding blocks of the range groups are specifically lubricated. How does the lube oil get to the sliding blocks of the range group?
______________________________________________________________________________________________________
Exercise 5: The sun wheel has a lot of small lube oil drillings. This ensures that all the teeth flanks of the sun wheel are directly supplied with
oil. Discuss in the group why the sun wheel has so many oil drillings and note your answer.
Exercise 6: Follow the path of the oil circuit in the range group. The oil flows into and onto the planet gears. There is one component which
must be correctly installed to ensure that the planet gears are supplied with oil. Reference is made to this component in the repair
instructions. Mark the component in the illustration. Note the information which is indicated in respect of this component in the
repair instructions.

j Work sheet oil circuit: input shaft and front bearing cap
N26.40-2024-81 N26.40-2025-11

Exercise: Develop your knowledge of the oil circuit - continued
Exercise 7: A critical component when it comes to the oil supply is the pilot bearing in the transmission. The designers had to ensure that
sufficient oil still remains at the pilot bearing when the vehicle is stationary, in other words when the engine is not running, to allow
the vehicle, for example, to be tow-started or towed. Note the name of this component and mark the position in the illustration
where this part is installed.
"Don't forget to pay attention to the

towing instructions, in particular also
because of the transmission!"

Exercises: Work sheet on oil pump and valves
Exercise 8: For which transmission version is the valve combination illustrated, the version with or without oil cooler?
Exercise 9: How many valve combinations are there on the ACTROS?
Exercise 10: Different springs (spring length) are fitted to the valve combination shown in the illustration. Mark the springs in the illustration
(page 35) with "long spring" and "short spring".
"That's enough questions on oil circuit!

I'm sure you were able to answer all of them."

j Work sheet oil circuit: oil pump and valves
"There are two versions of the

top valve insert, depending on
whether an oil cooler is fitted, or
not!"
W26.55-0004-12

Work sheets: Setting operations on range-change transmissions
Exercise: Complete the work sheets
Quite a number of things have been achieved in the course of the develop in history of the range-change transmissions. The one
o
thing or the other has been modified when it comes to the various setting operations. We have included these info sheets in order
to provide you with an overview of which setting has to be performed on which range-change transmission. Study the info sheets in
order to obtain a picture of which settings have to be carried out at which transmission.
Do not work on the sheets until your group has nothing to carry out at the transmission. In other words, once you have finished at
i
your station and cannot yet move on to the next one.
"The new transmissions no longer

have so many setting positions, or?"

Group work transmission repairs: survey and work sheets 15.02.2000
Survey of group work with group rotation
In the training which follows, you will work through the different transmission repair stations illustrated in the diagram below -
split up into groups of three.
For this exercise, process the work sheets which relate to the particular station, to the extent that they exist. Make your own
notes and prepare your own individual training document.
Read through the exercise sheets carefully before beginning with the processing of the work sheets.
You can use the work sheet "Special Tools" to mark the special tools which are important for you, or to verify whether the
l
tools which are required for repairs, are available back in your workshop. Or simply only to look at which special tool is used
at what point.
"For G 240 and G 260 certain

other special tools are required
than for G 210 and G 211!"

Group work transmission repairs: survey and work sheets 31
i Group work with group rotation
Station 1
ð Main transmission,
rotation after about 3 hours
Station 2
ð Range group and main shaft,
Station 3
ð Transverse shift and peripheral components
N26.00-2038-06

Survey of special tools
N26.00-2037-00

Special tools
Tool Order No. is required for Remarks
Dial gage 001 589 53 21 00 Setting K2, main shaft bearing ... important, check whether available in your
workshop

Station 1 / Disassembling main transmission and determining findings: exercise and work 15.02.2000
sheets
Exercise: Disassemble the main transmission STATION 1
Work out a procedure for disassembling the main transmission. Use the info from WIS and microfiche for this exercise. Disassemble
c
also the splitter group cylinder; the input shaft is not disassembled.
Note the most important points on the work sheet "Disassembling main transmission".
Create your own personal notes for the use of special tools. Take the work sheet "Special tools" as an aid for this exercise.
l
Pay attention to the oil circuit and its components. Process the work sheet "Oil circuit" for this purpose.
j
Only remove main shaft and countershaft, do not disassemble!
i
We have enclosed examples of damage diagnosis for you. Discuss in the group the experience you have with the findings. You can
i
note additional examples from your practical experience in the documents.
"Let's get on with it!

Lots of fun in disassembling the parts."

Station 1 / Disassembling main transmission and determining findings: exercise and work sheets 36
c Work sheet - Disassembling main transmission
Important points regarding disassembly:
1.
2.
"Oh, oh, I don't
know if that's
really so
3. easy!?"
4.
5.
6.
7.
W26.40-0024-09
Personal notes

i Info sheet - Removing and installing front part of transmission housing
When is the transmission disassembled from

the front side?
You can refer to WIS for the exact procedure as

well as the tightening torques, inspection and
setting data.
"You don't have to do anything here"
W26.40-0025-09
Personal notes

i Info sheet - Disassembling and assembling countershaft
free of oil and cool down if possible heat to100° C fit on and press home!
grease
It is only possible to press the fixed gears off the
countershaft if a press with a force of at least 100
tonnes is available.
"Wow, that's a stress!

Have any of you ever taken apart this thing
before?"
W26.50-0039-05
heat to 100° C Circlip between bearing and first fixed gear. Only free of oil and heat to max.
one thickness of circlips grease 180° C
Personal notes
Tools required: puller 001 589 41 33 00, 100 t press,
grip 714 589 01 34 00 and 000 589 58 34 00

g Examples of damage diagnosis of main transmission
Component possible damage to main transmission, input shaft and countershaft as well as splitter cylinder
Input shaft wear to bearing journal of pilot bearing (engine). Spline: wear to flank, fit corrosion
Bearing tracks: wear, pitting and/or spalling, rolling defects (foreign bodies rolled in or on), furrows, traces of initial seizure
Oil pipe, small damaged, blocked
Baffle plate damaged, hard
Shift rods bent, damaged, wear to holes and grooves
Shift forks bent, wear to holes and journals
Sliding blocks stiff, wear to pins, wear to contact surfaces
Sealing surfaces of housing damaged, porous
Oil pipe, large bent, blocked, oil spray drillings blocked
Countershaft fit of fixed gears: initial seizure scores in longitudinal and circumferential direction
Inner fixed gears initial seizure scores in longitudinal and circumferential direction
Outer fixed gears flank of teeth: wear, edge wear, scratches, scores, rubbing, pitting, impressions, tooth fracture, rust damage
Splitter cylinder O-rings: damaged or hard; cylinder wear
Splitter piston seal, wear, tight

g Damage diagnosis main transmission - continued
Component possible damage to main transmission, drive shaft and countershaft as well as splitter cylinder
Splitter piston rod wear, worn in

Station 1 / Assembling and setting main transmission 15.02.2000
Exercise: Professionally assemble the main transmission STATION 1
Before beginning the work, think about the procedure you wish to adopt. Make a note of your "work schedule":
ð ..................................................................................................................................................................................................
ð ..................................................................................................................................................................................................
ð ..................................................................................................................................................................................................
Professionally assemble the main transmission and carry out all the necessary settings.
bo
Use the info from WIS and microfiche for this exercise.
Make a note of the most important points on the following work sheets. Enter your own personal comments!
Before carrying out the measurements, please remove the existing shims and mix them with the replacement shims. Carry
i
out all the settings thoroughly. Use the prepared measurement sheets as an aid.
"The new transmissions are

definitely easier to set!
You can record the differences
to the older transmissions
on the work sheet of
settings of transmission
types"

Station 1 / Assembling and setting main transmission 43
N26.00-2026-06

b Work sheet - Assembling main transmission
Important points for assembly:
1.
2. "Put all the

parts together
3. in the reverse
order, or?"
4.
5.
6.
7.
W26.40-0024-09
Personal notes

o Work sheet - Setting bearings of input shaft and countershaft
Important points for setting

1. "I'd first make a
rough measurement
2.
with the depth
3. gage"
4.
Do you have any problems with the

measurement?
What is the procedure for measuring? Note
your answer.
W26.30-0002-01 W26.30-0003-01
Personal notes

o Measurement sheet for setting bearings of input shaft and countershaft
Measurement of input shaft Measurement of countershaft
Dimension B mm Dimension B mm
which shim thickness which shim thickness
did you fit mm did you fit mm
which which
play (+), or which mm play (+), or which mm
preload (-), mm preload (-), mm
did you determine did you determine
Personal notes

o Work sheet on determining shim for shift cylinder of splitter group
1.
"How am I
supposed to
2. understand this
description?!"
3.
4.
5.
6.
7.
W26.35-0010-11
Personal notes

o Measurement sheet for setting shift cylinder and shift piston of splitter group
Measurement of shim for shift piston Measurement of shim for shift cylinder
Dimension A mm Dimension A mm
Dimension B mm Dimension...... mm
Dimension A - B = X mm mm
Dimension..... mm
thickness of shim determined mm mm
setting determined mm thickness of shim determined mm
setting determined mm
Why must the thickness of the shim be thinner by the size of the The setting is not so clearly described in the WIS, or did you
setting? understand it? Work out a "suitable" measurement procedure!
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________

Station 2 / Disassembling main shaft and determining findings: exercise and work sheets 15.02.2000
Station 1
Main transmission
Station 2
Main shaft and
range group
Station 3

Station 2 / Disassembling main shaft and determining findings: exercise and work sheets 50
Exercise: Disassemble the main shaft STATION 2
Disassemble the main shaft complete. This also includes disassembling the sliding gears, in other words separating the sliding gear
c
from the needle bearing, synchronizer body, synchronizer ring and synchronizer cone. Arrange the parts to match the components.
We know that in the workshop the parts remain together. The parts are only arranged in the training course in order to
better see the differences between the individual parts.
Measure the wear of the synchronizer cones. Refer to the work sheet "Inspecting wear limit" as an aid.
g
Use the info from WIS and microfiche for your exercise.
i
Note the most important points on the work sheet "Disassembling main shaft".
Create your own personal notes for the use of special tools. Refer to the work sheet "Special tools" as an aid for this exercise.
l
Pay attention to the oil circuit and its components.

j "Depending on the type of
Process the work sheet "Oil circuit" for this purpose
and answer the questions which are asked! transmission, a different grip is
required for removing the bearing of
i We have enclosed examples of damage diagnosis for
you. Discuss in the group the experience which you K2!"
have with the findings. You can make a note of
additional examples from your practical experience in
the documentation.

c Work sheet - Disassembling main shaft
"Take care when disassembling the main shaft.

1.
What do you have to pay attention to?"
2.
"Mark in the illustration the components which
require a puller, with "d" for difficult to remove"
3.
4.
5.
"Hey, guys, these

bearings are really on
tight!"
W26.50-0028-05

c Disassembling main shaft - continued
6.
7.
8.
9.
10.
11.
12. W26.50-0028-05
Personal notes

g Examples of damage diagnosis main shaft
Component Possible damage to main shaft
Outer sliding gears Tooth flank: wear, edge wear, scratches, scores, initial seizure, pitting, impressions, rust damage (not fit corrosion), tooth fracture
Inner sliding gears, Rolling defects and roughening, traces of initial seizure, welding and material application, grooves, initial seizure scores in
bearing running surface longitudinal direction, initial seizure scores in circumferential direction
Sliding gears, contact Traces of grinding, circumferential scores, initial seizure, welding
surfaces
Synchronizer bodies Wear to teeth in circumferential direction; traces of grinding, circumferential scores, initial seizure and welding on contact surface
Sliding sleeve Wear in groove of sliding block; running surface

Synchronizer cone: worn (scores from synchronizer core), traces of scorching
Teeth: wear in circumferential direction, snatching, wear to flank
Synchronizer cones Spalling, wear, synchromesh reserve, traces of scorching
Synchronizer rings Wear to teeth in circumferential direction, snatching, wear to flank
Annular spring of Wear

synchromesh
Main shaft Shoulder: initial fretting of contact surfaces at face end
Bearing running surfaces Wear, pitting and/or spalling, rolling defects (foreign bodies rolled in or on), grooves, traces of initial seizure
Oil drillings No residues in drillings
Circlips Wear, pretension

Component Possible damage to main shaft
Angular-contact roller bearings Corrosions scars, pitting, poor running characteristics, sticks, traces of wear, cross scores, grooves (wear to bearing inner
(see info sheet) and outer race, no traces of wear at face end of rollers)
Needle bearings Cage not damaged, no traces of wear at face end and in inner area of roller. No traces of oil scorching, no corrosion and
(see info sheet) pitting.

o Work sheet: Inspecting wear limit between sliding sleeve and synchronizer cone
"The feeler gage is inserted between the

synchronizer cone and sliding sleeve!"
Where is the wear limit then?
_____________
W26.50-0047-02
Personal notes

i Re-using anti-friction bearings
Assessment criteria for needle bearings ð slight discoloration is o.k. "Too often, bearings are thrown out
ð cage must be o.k., no traces of wear at face end and in inner too soon.
area of roller
Bearings are in fact designed for
ð no presence of oil scorching
one million kilometers. Always
ð no corrosion and pitting
inspect the bearings before
ð no damage from extreme force (e.g. main shaft fractured)
ð no damage to hardness on running surface throwing them into the scrap box!"
Assessment criteria for roller, cylinder and ð no damage from force, e.g. tooth fracture
taper roller bearings ð no traces of overheating because of oil deficiency
1. Disassembling ð no removal damage, e.g. twisted cage
ð bearing complete (do not mix up shell and cage)
2. Determining condition
ð avoid corrosion from water residues when cleaning
ð no corrosion scars, pitting, no catching, etc.
ð no traces of wear at face end of rollers
ð after inspecting, oil bearing and store as a pair (shell and cage)

Station 2 / Assembling and setting main shaft 15.02.2000
Exercise: Professionally assemble the main shaft STATION 2
Professionally assemble the main shaft and carry out all the necessary settings.
bo
Note the most important points on the following work sheets. Enter your own personal comments!
Before starting the measurement, please remove the existing shims and mix them with the replacement shims. Carry out all
i
settings thoroughly!
"Don't forget the work sheet with the

differences to other types of
transmissions!"

Station 2 / Assembling and setting main shaft 59
b Work sheet - Assembling main shaft

1.
2.
"The bearings
slip on by
themselves if
3. they are warm
4. enough"
5.
6.
7.
8.
W26.50-0028-
Personal notes

o Work sheet - Determining shim for main shaft (K2)
1. _______________________________________ "The bearing is free

of play if it is still
_______________________________________ just possible to
move the rollers
2. _______________________________________ back and forward
with a
_______________________________________
screwdriver!?"
3. _______________________________________
_______________________________________
_______________________________________
W26.50-0030- W26.50-0031-01
4. _______________________________________
____________________________________
Personal notes

o Determining shim for main shaft (K2) - continued
Measurement of main shaft (bearing play K2)
Dimension B mm
thickness of shim determined
with spacer ring mm
which
play (+), or which mm
preload (-), did you mm
determine
Personal notes

o Determining shim for main shaft (K2) - continued
"Pulling off and fitting on bearing again is necessary so

that shim abuts flush with shoulder of main shaft. Only
then does K2 have the correct play, which you then
check in the following steps"
W26.50-0034-01
W26.50-0036-02
Personal notes

o Determining shim for main shaft (pilot bearing) - continued
"In conclusion, the setting now for the pilot

bearing ... and we're finish?
Wait a moment! That's no longer necessary on
the ACTROS, in contrast to the SK!"

Station 2 / Disassembling range group and determining findings: exercise and work sheets 15.02.2000
Exercise: Disassemble the range group STATION 2
Disassemble the range group. This also includes disassembling the planetary gear set. Arrange the parts according to components.
c
Use the info from WIS and microfiche for your exercise
Note the most important points on the work sheets "Removing planetary gear set with shift device" and "Disassembling planetary
gear set with shift device". Enter your own personal comments!
Create your own personal note sheets for the use of special tools. Refer to the work sheet on special tools as an aid for this
l
exercise
Pay attention to the oil circuit and its components. Process the work sheets on the oil circuit for this purpose!
j
We have enclosed examples for damage diagnosis for you. Discuss in the group the experience you have with the findings. You can
i
note in the document additional examples from your practical experience.
"Removing the
planetary gear set
from the housing is a
bit difficult!"

Station 2 / Disassembling range group and determining findings: exercise and work sheets 66
ec Work sheet - Removing and disassembling planetary gear set with shift device
Important points for disassembly:
1.
2. "The hollow
gears are
available in two
versions"
3.
4.
5.
6.
W26.50-0046-09
Personal notes

g Examples for damage diagnosis of range group
Component Possible damage to range group which is not dealt with in the main transmission and the main shaft
Hollow gear Tooth flank: wear, edge wear, scratches, scores, initial seizure, pitting, impressions, rust damage (not fit corrosion), tooth fracture
Output shaft Wear to flank and fit corrosion of teeth
Locking plate Guide holes worn, cracks
Flange Damaged, twisted, wear to flank at teeth, worn at seal
Oil spray nozzle Fitted, drilling clear, damage (installation)
Oil pump Axial wear, scores, damage to running surface

cb Additional exercise only if trainer points this out! Work sheet: Removing and installing planetary gears
Important points:
1. "It's best to drill on a

column drill. And, take
care that the chips do not
drop into the planetary
gear carrier!"
2.
3.
4.
5.
6. W26.50-0041-01
W26.50-0040-01
Personal notes

Station 2 / Assembling and setting range group 15.02.2000
Exercise: Professionally assemble the range group
Professionally assemble the range group and carry out all the necessary settings
bo
Install the oil pump and determine the thickness of shim
Before starting the measurements, please remove the existing shims and mix them with the replacement shims. Carry out all
i
the settings thoroughly!
"Remember the work sheet on

settings of different
transmission types!"

Station 2 / Assembling and setting range group 71
b Work sheet - Assembling planetary gear set with shift device
1.
"At last, I've

2. seen it all
disassembled"
3.
4.
W26.50-0046-09
Personal notes

o Work sheet - Determining shim for housing cover of output shaft
1.
"Measurement is
2. made from spacer
ring on the retarder
3. version"
4.
5. W26.30-0006-01
6.
7.
Personal notes

o Work sheet - Determining shim for oil pump

"The oil pump
1. must not
2. project"
3.
4.
W26.55-0001-01 W26.55-0002-01
5.
Personal notes

o Determining shim for housing cover of output shaft and of oil pump
Measurement of housing cover of output Measurement of oil pump
Dimension B mm Dimension mm
what thickness of shim what thickness of shim
did you fit mm did you fit mm
what what
play (+) or what mm play (+) or what mm
preload (-), mm preload (-), mm
did you determine did you determine
Personal notes

Station 3 / Disassembling transverse shift and peripheral components and determining findings: 15.02.2000
exercise and work sheets
Station 1
Main transmission
Station 2
Main shaft and
range group
Station 3

Station 3 / Disassembling transverse shift and peripheral components and determining findings: exercise and work sheets 76
Exercise: Disassemble the transverse shift STATION 3
Disassemble the transverse shift complete

c
Use the info from WIS and microfiche for your exercise
i
Note the most important points on the particular work sheets "Disassembling transverse shift of EPS / HPS / MPS".
Create your own personal note sheets for the use of the special tools. Refer to the exercise sheet "Special tools" for this purpose
l
We have enclosed examples of damage diagnosis for you. Discuss in the group the experience you have with the findings. You can
i
note in the documents additional examples from your practical experience.
"The transverse shift of

the EPS transmission is
the simplest design!"

c Work sheet - Disassembling transverse shift (EPS)
Important points for disassembly: "Take care when

knocking out the
1. ________________________ roll pin. It easily
wedges at the
2. ________________________ locking pawl"
3. ________________________
4. ________________________
5. ________________________
6. ________________________
7. ________________________
8. ________________________
9. ________________________
W26.60-1034-05
Personal notes

c Work sheet - Disassembling transverse shift (HPS)
1. ________________________ "Damn it! Now I

have to run after
2. ________________________ all these balls"
3. ________________________
4. ________________________
5. ________________________
6. ________________________
7. ________________________
8. ________________________
9. ________________________
W26.60-1035-05
Personal notes

c Work sheet - Disassembling transverse shift (MPS)
1. ________________________
"This time, I've
2. ________________________ managed to
catch them all"
3. ________________________
4. ________________________
5. ________________________
6. ________________________
7. ________________________
8. ________________________
9. ________________________
W26.60-1036-05
Personal notes

g Examples of damage diagnosis of transverse shift
Component Possible damage to transverse shift
Needle bearings worn, damaged, rollers tight, wear
Detent pin wear
Shift finger wear, tensioning sleeve loose
Circlips wear, damage, preload
Springs damage, wear
Shift hub wear
Detent segment worn
Locking pawl wear
Shift shaft worn
Balls wear
Bush of gate detent wear

i Exercises on the transverse shift
Are you familiar with this? Just a few questions to rack

your brains on the transverse shift:
1. What is the type of shift shown in the illustration

opposite? (viewed in direction of travel)
Make a cross!
a MPS
b EPS (GS)
c HPS
2. What is the reason we need two shift fingers on the

MPS and HPS?
3. What is the task of the locking pawl?
N26.60-2068-76

4. State the gates (shift rods) of the main

transmission with:
ðR
ð 3-4
ð 1-2
5. In which gate of the EPS (GS) is the shift

finger in the neutral position?
6. Mark the following components:

ð Neutral position spring with NF
ð Gear detent with RG
ð Locking pawl (locking arm) with SR
N26.60-2068-76

R
7. Mark the shift fingers with:
ð S1 for low range
ð S2 for high range
8. Assign the gears to the shift fingers:

ð S1 shifts gears
ð S2 shifts gears
9. Mark the following parts:

ð Neutral position spring NF
ð Gear detent RG
ð Interlock pin IB
ð Thrust piece (shift gate)
of range group valve DR
ð Range group valve RV
ð Gate detent pin with RB1 / RB2
10. Mark the gate stops; we have already

assigned reverse gear:
ð Gear 1-2 with 1-2
N26.60-2069-76

Exercise: What are the checks which you can carry out at the components listed below?
Answer the three following work sheets - split up into three groups:
Work sheet 1, sensors: Take a look at the removed sensors. Think about how the sensors can be inspected, and note this. Refer to the
table as an aid for this exercise.
Disassemble the range group cylinder without taking off the piston. Use the work sheet "Range group solenoid
valves" for this exercise, and complete it. Look through the repair instructions for notes.
Important: Range group cylinder and solenoid valves are not available as individual replacement parts!
Work sheet 2, gate cylinder: Disassemble the gate cylinder and think about which checks are sensibly performed on the individual components.
Which electrical measurements can be carried out at the solenoid valves in order to check their operation. Look
through the repair instructions for notes.
Important: Gate cylinder and solenoid valves are not available as individual replacement parts!
Work sheet 3, gear cylinder: Disassemble the gear cylinder and think about which checks are sensibly performed on the individual
components. Which electrical measurements can be carried out at the solenoid valves in order to check their
operation. Look through the repair instructions for notes.
Important: Gear cylinder and solenoid valves are not available as individual replacement parts!
Use the info from the WIS and microfiche for answering the exercises
"But I'm not an electrician!"

Important: Repair kits are available as replacement parts for
− gaskets
− valve inserts

o Work sheet - Sensors
Inspection
Designation Connections mechanical electrical visual
Gear sensor 1ð2

(B60)
50 - 110 Ω
Gate sensor
(B61)
Range sensor
(B63)
Splitter sensor
(B62)

o Work sheet - Sensors
Inspection
Designation Connection mechanical electrical visual
Transmission input
speed sensor (B3)
Speedo sensor
EAS rpm sensor
Temperature sensor

cob Work sheet - Range group solenoid valves
Mechanical inspection Visual inspection
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
Personal notes Electrical inspection
____________________________________
____________________________________
____________________________________

cob Work sheet - Gate cylinder with gate and splitter solenoid valves
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
_____________________________________ ____________________________________
N26.21-2004-12
____________________________________
____________________________________
____________________________________

cob Work sheet - Gear cylinder with solenoid valves
____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________
N26.21-2002-11 ____________________________________ ____________________________________
____________________________________
____________________________________
____________________________________
____________________________________

Station 3 / Assembling and setting transverse shift 15.02.2000
Exercise: Professionally assemble the transverse shift STATION 3
Professionally assemble the transverse shift and carry out all the necessary settings.
bo
"Don't forget the work sheet

on settings of transmission
types!"

Station 3 / Assembling and setting transverse shift 91
b Work sheet- Assembling transverse shift (EPS)
1. ________________________
"Take care again
2. ________________________ with the roll pin
here too!"
3. ________________________
4. ________________________
5. ________________________
6. ________________________
7. ________________________
8. ________________________
9. ________________________
W26.60-1034--05
Personal notes

b Work sheet - Assembling transverse shift (HPS)
1. ________________________
2. ________________________ "Is there also a

roll pin here?"
3. ________________________
4. ________________________
5. ________________________
6. ________________________
7. ________________________
8. ________________________
9. ________________________
W26.60-1035-05
Personal notes

b Work sheet - Assembling transverse shift (MPS)
Important points on assembly:
1. ________________________
2. ________________________
"Do you know
3. ________________________ what we have to
pay attention
4. ________________________ to?"
5. ________________________
6. ________________________
7. ________________________
8. ________________________
9. ________________________
W26.60-1036-05
Personal notes

o Work sheet - Setting shift fingers (EPS, HPS and MPS)
Important points for setting:

"The grub screws must
1. ____________________________________________ be secured with Loctite!
2. ____________________________________________ With which Loctite, 242

or 270 ... ?"
3. ____________________________________________
4. ____________________________________________
5. ____________________________________________
6. ____________________________________________
7. ____________________________________________
8. ____________________________________________
9. ____________________________________________
W26.60-1037-11
Personal notes

Assembling transmission 15.02.2000
Exercise: Professionally assemble the transmission
Answer this exercise in groups.

o
One group installs the transverse shift with shift cylinders. Note the most important points on the following work sheets. Enter
your own personal comments!
One group installs the range group. Note the most important points on the following work sheets. Enter your own personal
comments!
One group installs the sensors and switches and connects the wiring harness as well as the compressed air supply. Note the
most important points on the following work sheets. Enter your own personal comments!
Process the work sheets "Interlock" and "Setting interlock" at the end of this section.
i
Don't forget the work sheet on special tools.

l
"Okay folks, we've soon

managed it all. Let's hope
there's no part left over at the
end!"

Assembling transmission 96
d Work sheet - Installing transverse shift and shift cylinders
1. _______________________________________
2. _______________________________________ "It's really quite

easy"
3. _______________________________________
4. _______________________________________
5. _______________________________________
6. _______________________________________
7. _______________________________________
8. _______________________________________
9. _______________________________________
W26.60-0015-06
Personal notes

d Work sheet - Installing range group
Important points for

installation:
1. _______________________
2. _______________________
3. _______________________
4. _______________________
5. _______________________
6. _______________________
7. _______________________
8. _______________________
9. _______________________
W26.31-0002-09
Personal notes

d Work sheet - Connecting wiring harness and compressed air supply
mechanical emergency shift Gear sensor (B60) Range solenoid valves Speedo sensor
G 210 EPS
N26.10-2038-08
Gear shift Gear cylinder air Gear cylinder air Transmission oil Transmission input rpm sensor
cylinder admission solenoid valves release solenoid valves temperature sensor (B47) speed sensor (B3) (only with EAS)

d Connecting wiring harness and compressed air supply - continued
Range sensor (B63) Transmission mounts Splitter sensor (B62) Gate sensor (B61) Gate shift cylinder
G 210 EPS N26.10-2039-08
Gate solenoid valves Splitter solenoid valves Transmission central connector

i Work sheet - Interlock
1. Describe the task of the interlock in a few

short sentences
2. State the components which are operated
N26.60-2082-81

i Work sheet - Setting interlock
Which statement regarding the setting of the interlock is correct:
a The distance between the interlock pin of the shift lock and the
interlock pin of the lock rod is the setting.
b The interlock pin of the lock rod must project into the hole of the
interlock pin of the shift lock by the stated setting.
c The setting indicates the travel of the lock rod as a result of the
movement of the interlock pin of the shift lock.
W26.60-0019-11

Operational check of transmission 15.02.2000
Each time you carry out repairs to a transmission, you ask yourself the question: "Have I done everything properly?"
The external transmission actuation is provided for checking individual components when carrying out troubleshooting or after repairs.
The requirements as well as the inspection instructions and special tools required for external actuation are described in the Workshop Information System -
WIS.
Exercise 1 m Carry out a transmission external actuation as specified in the inspection instructions!
Shift the following gears and mark the solenoid valves which must be energized in order to be able to
shift the gear.
At the same time, think out in the group what verification can be provided to show that you have
shifted the corresponding gear.
If there are any communication problems, refer to the section on "Gear control".
Neutral: a MG1 b MG2 c MGB d MGE e MUB
f MUE g MR1 h MR2 i MS1 j MS2
Verification:

Operational check of transmission 103
Gear 2S: a MG1 b MG2 c MGB d MGE e MUB
Verification:
Gear 5L: a MG1 b MG2 c MGB d MGE e MUB
Verification:
Gear R L: a MG1 b MG2 c MGB d MGE e MUB
Verification:

Gear 8L: a MG1 b MG2 c MGB d MGE e MUB
Verification:
Notes:

G 211 GS
N26.50-2089-79

i Info sheet transmission ratios and gear steps
Gear step / Ratio G 210 Gear step / Ratio G 211 Gear step / Ratio G 240 Gear step / Ratio G 260
1L 14,19 1L 17,03 1L 11,72 1L 9,75
1,21 1,21 1,2 1,21
1S 11,72 1S 14,19 1S 9,75 1S 8,07
1,22 1,23 1,23 1,23
2L 9,58 1,48 2L 11,50 1,48 2L 7,92 1,48 2L 6,58 1,48
1,21 1,2 1,2 1,21
2S 7,92 2S 9,58 2S 6,58 2S 5,45
1,22 1,23 1,24 1,24
3L 6,50 1,48 3L 7,80 1,48 3L 5,29 1,50 3L 4,40 1,50
1,21 1,2 1,2 1,21
3S 5,37 3S 6,50 3S 4,40 3S 3,64
1,22 1,23 1,21 1,2
4L 4,40 1,48 4L 5,28 1,48 4L 3,64 1,46 4L 3,02 1,46
1,21 1,2 1,2 1,21
4S 3,64 4S 4,40 4S 3,02 4S 2,50
1,13 1,14 1,13 1,13
5L 3,22 1,36 5L 3,87 1,36 5L 2,66 1,37 5L 2,22 1,37
1,21 1,2 1,2 1,21
5S 2,66 5S 3,22 5S 2,22 5S 1,83
1,22 1,23 1,23 1,23
6L 2,18 1,48 6L 2,61 1,48 6L 1,80 1,48 6L 1,50 1,48
1,21 1,2 1,2 1,21
6S 1,80 6S 2,18 6S 1,50 6S 1,24
1,22 1,23 1,24 1,24
7L 1,48 1,48 7L 1,77 1,48 7L 1,20 1,50 7L 1,00 1,50
1,21 1,2 1,2 1,21
7S 1,22 7S 1,48 7S 1,00 7S 0,83
1,22 1,23 1,21 1,2
8L 1,00 1,48 8L 1,20 1,48 8L 0,83 1,46 8L 0,69 1,46
1,21 1,2 1,2 1,21
8S 0,83 8S 1,00 8S 0,69 8S 0,57
RL 12,90 RL 15,48 RL 10,66 RL 8,86
RS 10,66 RS 12,90 RS 8,86 RS 7,33

Concluding discussion on transmission repairs 15.02.2000
Exercise: Concluding discussion
To round of, discuss in the group the results and knowledge you have acquired.
Don't hesitate to once again mention the experience which you have already obtained in repairing transmissions.
What aspects of the training course did you like?
What aspects of the training course did you not like?
What, in your opinion, should be improved, intensified or even shortened?
Which subjects were completely missing?
Was the training course sufficiently practical in terms of his contents, or did it, in your opinion, contain too much theory?
What did you like about the preliminary training for this course?
"That's it folks. Bye then. I hope

you learned something from
this course and are able to go
back home all the better for it!"

Concluding discussion on transmission repairs 108
1510 3189 02 - 1st edition 02.00 116

Ngug Transmission Repairs Transmissions G210 - 260: Service Training

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ngug Transmission Repairs Transmissions G210 - 260: Service Training

Uploaded by

Copyright:

Available Formats

Service Training

1510 3189 02 - 1st edition 02.00 116

02/00 NGUG <> Transmission Repairs G210 - 260

The transmission repairs training has been matched to the

02/00 NGUG <> Transmission Repairs G210 - 260

G 211 = 17.03 G 210 = G 240 = G 260 =

G 211 = 8S G 210 = G 240 = G 260 =

G 211 = no gear G 210 = G 240 = G 260 =

"Hi folks, I'm Theo and I'll be coaching you

02/00 NGUG <> Transmission Repairs G210 - 260

1L 17,03 1L 14,19 1L 11,72 1L 9,75

RL 15,48 RL 12,90 RL 10,66 RL 8,86

RS 12,90 RS 10,66 RS 8,86 RS 7,33

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

make specific use of the workshop literature.

exchange experience on repairing transmissions with your colleagues.

"On your marks, get ready, go !"

02/00 NGUG <> Transmission Repairs G210 - 260

Œ Welcome, getting to know the course participants

• Disassembling main transmission, determining findings, assembling and setting

• Elaborating on operation of shift mechanism and removing

º Stating peripheral parts and components and removing

‘ Fitting parts to transmission and carrying out operational check

02/00 NGUG <> Transmission Repairs G210 - 260

Info Where is each component located?

I've already seen a picture with all the sensors in the

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

Gate solenoid valves Splitter solenoid valves Transmission central connector

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

Exercise : Remove the transverse shift and range group

Work through the exercise again in groups.

02/00 NGUG <> Transmission Repairs G210 - 260

Important points of disassembly:

02/00 NGUG <> Transmission Repairs G210 - 260

Important points for removal:

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

"Now things are getting oily!"

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

1.) Oil inlet pipe

"The oil circuit is a single-stream

02/00 NGUG <> Transmission Repairs G210 - 260

"There's a history to question 5.

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

02/00 NGUG <> Transmission Repairs G210 - 260

"Don't forget to pay attention to the

02/00 NGUG <> Transmission Repairs G210 - 260

Exercise 9: How many valve combinations are there on the ACTROS?

"That's enough questions on oil circuit!

02/00 NGUG <> Transmission Repairs G210 - 260

"There are two versions of the

02/00 NGUG <> Transmission Repairs G210 - 260

Exercise: Complete the work sheets