RENAULT Truck Gearbox OPTIDRIVE 2 Workshop Manual

32 661 - GB - 10/2004 32 661 32.6 . . . . 32.6 . . . . 50 21 014 334 32.6 RENAULT TRUCKS GEARBOX OPTIDRIVER 2 The above information may change in the course of time. Only the "Consult" section of the workshop manuals repertory in standard N° 10320 serves as reference. RANGE FAMILY VARIANT RENAULT MAGNUM DXi 12 440 - 480 17RD 150FX 17SD 17TD

1 32 661 50 21 014 334 © RENAULT TRUCKS SA 10/2004 - Imprimé en France - le 11/2004 CONTENTS Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 → 15 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 → 3 — General features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-5 → 6 — Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1 → 5 — Dimensions and tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1 → 1 Tools / Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 → 14 Stripping and mounting on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 → 3 — Clutch slave cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1-3 → 4 — Mounting on stand N° 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1 → 2 — Stripping the gearbox on stand N° 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1 → 8 Primary shaft and output shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 → 7 Dismantling of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 → 15 Transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 → 13 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1 → 5 Range change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 → 16 Primary shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1 → 6 Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1 → 11 Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1 → 4 Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1 → 7 Assembly of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-1 → 19

A-1 32 661 RENAULT TRUCKS 10/2004 GENERALITIES

A-2 32 661 RENAULT TRUCKS 10/2004 APPLICABILITY Range Family Title Variant Applicability date Updating Page N° Start End RENAULT MAGNUM DXi 12 440 - 480 17RD Warnings 150FX 31/03/2003 A-3 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD Conventional symbols 150FX 23/05/2002 A-4 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD General instructions 150FX 07/10/2002 A-6 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD Presentation of the gearbox 150FX 28/08/2003 A-7 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD Transmission control unit 150FX 28/08/2003 A-8 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD Countershaft disc brake 150FX 29/08/2003 A-10 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD Power flow diagram 150FX 27/08/2003 A-11 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD Lubrication system 150FX 24/06/2003 A-13 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD Sensors and electrical connections 150FX 24/06/2003 A-14 17SD 17TD RENAULT MAGNUM DXi 12 440 - 480 17RD Sensors and ompressed air system unions 150FX 24/06/2003 A-15 17SD 17TD

A-3 32 661 RENAULT TRUCKS 10/2004 Warnings In this document, safety instructions are symbolized as follows: DANGER! NON-OBSERVANCE OF THE PROCEDURE DESCRIBED OR LACK OF CARE OR ATTENTION, RISK CAUSING SERIOUS INJURY OR EVEN DEATH. WARNING! Any different or inappropriate working method risks causing damage to the product. NOTE! Draws attention to particular or important points of the method. Comply without fail with the regulations in force relative to the recovery and treatment of used parts and waste.

A-4 32 661 RENAULT TRUCKS 10/2004 Conventional symbols Fitting Dimensioning Repair Tighten to torque (Nm) (left-hand thread) Tighten by indicated value Tighten to torque (Nm) (right-hand thread) Loosen by indicated value Tightening torque with lubricated threaded hardware Tightening ... Greater than or equal to ... Equal to Wear limit ... Less than ... Machining limit or dimension ... Greater than ... Maximum out-of-true ... Less than or equal to ... Maximum parallelism error Force to be exerted in the direction shown (hammer - press) Smear or coat (see "Consumables" table) Heat or cool: Temperature in degrees Celsius (e.g. + 80 °C) Fill to level (see "Technical Data" and "Consumables" table) Weld bead Grease or oil (see "Consumables" table) Repair time - Heating time Mark - Assemble according to marking

A-5 32 661 RENAULT TRUCKS 10/2004 Adjustment Various information Rotating friction torque Turn anti-clockwise Turn in alternate directions Turn anti-clockwise (the figure shows the number of turns) Turn clockwise Turn clockwise (the figure shows the number of turns) Place in contact Move in the direction shown Dimension to be assured (mm) Exhaust - Outlet Operation with a sequence Intake - Inlet Involves Weight in kg (example: 275 kg) Return to numbered operation - Connected with numbered operation Depending on versions or options Withdraw - Delete Wrong Direction of disassembly (the arrow shows the direction) Correct Direction of assembly (the arrow shows the direction) Injection ... to ... Repair dimension Inspect - Check condition of part Part to be replaced Danger for persons, vehicle or equipment

A-6 32 661 RENAULT TRUCKS 10/2004 General instructions Practical advice Prior to any work: – Clean the major unit and its surrounds (See Driving Servicing Handbook, "Vehicle washing"). – Ensure the batteries are disconnected. – Mark the pipes and wiring harnesses, if necessary. – Protect all ports to prevent the ingress of foreign matter. – Before disconnecting an air pipe, drop the circuit pressure. – If liquid is splashed onto the bodywork, clean quickly with a cleaning product recommended by RENAULT TRUCKS. Preparation prior to assembly: Carefully clean and check all the parts. Do not unpack a new bearing until you are ready to install it. Do not clean off the protective grease on new bearings. Old seals and lock-plates must be discarded and new ones fitted. Never force fit parts with copper or brass punches or drifts. Always use a specially adapted driver to prevent ingress of metal particles into the casings and bearings. Always oil parts prior to force fitting. Always apply grease on the inside of seal ring lips. Shrink fitted parts are to be heated with a hot air blower or in an oven. etc. Flame heating is strictly forbidden. When using a torque multiplier, calibrate the torque wrench/multiplier unit at the required torque loading. Fastening, locking, sealing and adhesive products: Prior to assembly, carefully clean the product application surfaces of the parts. Old product residue is to be removed. Threaded portions are to be brushed, tapped and, if necessary, cleaned with a suitable product. Using the product: Always adapt the recommended product while observing the utilization conditions appearing on the pack: – Surface finish, – Working temperature, – Reaction, drying, etc. time, – Shelf life. Observe the assembly method so as to guarantee the quality of the repair.

A-7 32 661 RENAULT TRUCKS 10/2004 Presentation of the gearbox The gearbox consists of 3 main parts. – The clutch casing (7), which also serves as front wall for the gearbox. – The basic gearbox casing (13), which contains the primary shaft, the secondary shaft, the countershaft, the reverse shaft, the selector mechanism integrated in the transmission control unit, together with the range change and the splitter. – The range change casing (3), which contains the epicyclic gear train for the range change and the output shaft (10). The principal gearbox parts are: – Primary shaft (8), – Secondary shaft (9), – Range change (10), with selector mechanism (4), – Intermediate shaft (11), with disc brake (6), – Reverse shaft (12), with oil pump drive shaft (5), – Transmission control unit (1), with gear change mechanism. The countershaft and reverse shaft gears and all the basic gears are on the secondary shaft, with the range change sun gear on the secondary shaft. The countershaft gears are fixed. The range change, which consists of an epicyclic gear train forms integral part of the output shaft. The oil pump drive shaft forms integral part of the reverse shaft.

A-8 32 661 RENAULT TRUCKS 10/2004 Transmission control unit The transmission control unit is located above the gearbox. The gears are selected by means of the gear selector. When a gear is selected, the system first of all reduces the engine torque to an ac- ceptable level and the gearbox is put into neutral. When the gearbox is in neutral, the engine speed is adjusted so as to choose the correct engine speed for the gear selected and the gear is then engaged. The control unit casing cover serves to house the following compo- nents: – 3 electrical connections, – 1 transmission control unit (TECU), – 9 solenoid valves, – 1 pressure sensor. The control unit casing cover includes 3 electrical connections: – I: vehicle communication , – II: retarder, – III: clutch. The control unit casing cover serves to house 9 solenoid valves: – 1: solenoid valve 1 st gear, – 2: solenoid valve 2 nd gear, – 3: solenoid valve 3 rd gear, – R: reverse solenoid valve – B: disc brake solenoid valve, – LR: low range solenoid valve, – HR: high range solenoid valve, – HS: high split solenoid valve, – LS: low split solenoid valve.

RENAULT Truck Gearbox OPTIDRIVE 2 Workshop Manual

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