RENAULT TRUCKS

41 050 - GB - 09/2007
STEERING BOXES AND STEERING PUMPS TESTING / DIAGNOSTICS

RANGE
RENAULT KERAX
RENAULT KERAX DXi 11
RENAULT MAGNUM
RENAULT MAGNUM DXi
RENAULT MASCOTT DXi PHASE II
RENAULT MASCOTT DXi PHASE III
RENAULT MASCOTT dCi
RENAULT MIDLUM 12-16 t Euro 2
RENAULT MIDLUM 12-16 t Euro 3
RENAULT MIDLUM 16-18 t
RENAULT MIDLUM 4x4
RENAULT MIDLUM 7-12 t
RENAULT MIDLUM DXi
RENAULT PREMIUM
RENAULT PREMIUM DXi 11 EURO 3
RENAULT PREMIUM DXi 11 EURO 4
RENAULT PREMIUM DXi 7
RENAULT PREMIUM DXi 11 EURO 3 (DOI)
RENAULT PREMIUM SAPEUR POMPIER

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.

(1)
Check the corresponding vehicle families on the next page

41 050

41.0
41.0 . . . .

41.0 . . . .

50 21 029 159
-2 41 050
RANGE FAMILY VARIANT
33G P 6X4, 33GG P 6X4, 33H P 6X4
33HH P 6X4, 33I P 6X4, 33II P 6X4
33J P 6X4, 33JJ P 6X4, 33K T 6X4
33KK T 6X4, 33L T 6X4, 33LL T 6X4
RENAULT KERAX
33M P 6X6, 33MM P 6X6, 33N T 6X6
33NN T 6X6, 33P P 4X2, 33PP P 4X2
33Q T 4X2, 33QQ T 4X2, 33R P 4X4
33RR P 4X4, 33S T 4X4, 33SS T 4X4
34FC T 6X4 EURO 3, 34FF T 6X4 EURO 4
34MC P 6X6 EURO 3, 34MF P 6X6 EURO 4
34NC P 6X4 EURO 3, 34NF P 6X4 EURO 4
34SC P 4X2 EURO 3, 34SF P 4X2 EURO 4
RENAULT KERAX DXi 11
34TC T 4X2 EURO 3, 34TF T 4X2 EURO 4
34XC P 4X4 EURO 3, 34XF P 4X4 EURO 4
34YF T 4X4 EURO 4, 34ZC T 6X6 EURO 3
34ZF T 6X6 EURO 4
RENAULT MAGNUM 11E T 4X2/6X2, 11F P 4X2/6X2, 11H T 6X4
17JE - TR 6x2 PUSHER, 17RD, 17RE,
RENAULT MAGNUM DXi
17SD, 17SE, 17TD, 17TE
RENAULT MASCOTT DXi
PHASE II
RENAULT MASCOTT DXi
PHASE III
RENAULT MASCOTT dCi
RENAULT MIDLUM 12-16 t -
Euro 2
RENAULT MIDLUM 12-16 t
44C1, 44C2, 44T, 44V
Euro 3
RENAULT MIDLUM 16-18 t 45D2, 45D3, 45E2
RENAULT MIDLUM 4x4
RENAULT MIDLUM 7-12 t 42B1, 42B2, 42B3, 42B4
RENAULT MIDLUM DXi
22A P 4X2, 22AA P 4X2, 22AB P 4X2
22C T 4X2, 22CC T 4X2, 22E P 6X2/4
22EE P 6X2/4, 22H P 6X2/4, 22HA P 6X2/4
RENAULT PREMIUM
22HB P 6X2/4, 22J T 6x2 PUSHER
22JJ T 6X2 PUSHER, 22Q P 6X2
22QQ P 6X2, 22R T 6X2, 22RR T 6X2
RENAULT PREMIUM 27JC - TR 6X2 PUSHER, 27RC - PR 6x2
DXi 11 EURO 3 27SC - PR 4x2, 27TC - TR 4x2
RENAULT PREMIUM
DXi 11 EURO 4
RENAULT PREMIUM
DXi 7
RENAULT PREMIUM
DXi 11 EURO 3 (DOI)
RENAULT PREMIUM
23P SP 4X2
SAPEUR POMPIER

RENAULT TRUCKS 09/2007

 41 050 1

CONTENTS

Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 → 5

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 → 3

— Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-2 → 6
— Table of appliance assembly correlations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-1 → 8
— Standard tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1 → 2

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 → 4

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 → 5
— Tester 9432 + 9908 (old generation apparatus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1-2 → 4
— Tester 8149 (new generation apparatus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2-1 → 3
— Testing the steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3-1 → 3
— Testing the steering hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4-1 → 4
— Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5-1 → 1

© RENAULT TRUCKS SAS 09/2007 - Imprimé en France - le 09/2007 50 21 029 159

 41 050 A-1

GENERALITIES

RENAULT TRUCKS 09/2007

A-2 41 050
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.

Draws attention to special important points of procedures or regulations in force that must be obeyed without
fail, especially those relative to the recovery and treatment of used parts and waste.

RENAULT TRUCKS 09/2007

 41 050 A-3

Conventional symbols

Fitting

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

Dimensioning

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

Repair

Force to be exerted in the direction shown

Smear or coat (see "Consumables" table)
(hammer - press)

Heat or cool: Temperature in degrees Fill to level (see "Technical Data" and
Celsius (e.g. + 80°C) "Consumables" table)

Weld bead Grease or oil (see "Consumables" table)

Repair time - Heating time Mark - Assemble according to marking

RENAULT TRUCKS 09/2007

A-4 41 050
Adjustment

Rotating friction torque Turn anti-clockwise

Turn anti-clockwise
Turn in alternate directions
(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)

Various information

Exhaust - Outlet Operation with a sequence

Intake - Inlet Involves

Return to numbered operation -

Weight in kg (example: 275 kg)
Connected with numbered operation

Depending on versions or options Withdraw - Delete

Direction of disassembly
Wrong
(the arrow shows the direction)

Direction of assembly
Correct
(the arrow shows the direction)

Injection ... to ...

Repair dimension Inspect - Check condition of part

Part to be replaced Danger for persons, vehicle or equipment

RENAULT TRUCKS 09/2007

 41 050 A-5

General instructions

Practical advice
Prior to any work:
– Clean the major unit and its surrounds (See Driving Servicing Handbook, "Vehicle washing").
– Disconnect the batteries, always starting with the negative (-) terminal.
– 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.

Raising a vehicle on lifts or elevators

– For tyres with size less than or equal to 16 inches, place fork reducers on each lift column.
– Position and centre the lift columns.
– Release the parking brake.
– Raise the vehicle and put safety trestles into place.

Preparation prior to assembly:

Carefully clean and inspect 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, circlips 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.
Stick to the assembly method so as to guarantee the quality of the repair.

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A-6 41 050

RENAULT TRUCKS 09/2007

 41 050 B1-1

TECHNICAL DATA

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B1-2 41 050
Identification
Steering box

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 41 050 B1-3

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B1-4 41 050
Steering pump

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 41 050 B1-5

RENAULT TRUCKS 09/2007

B1-6 41 050

RENAULT TRUCKS 09/2007

 41 050 B2-1

Table of appliance assembly correlations

MASCOTT

Engine
Vehicle family Vehicle type Hydraulic pump type Steering box type
type
90 TRW TAS 30 613
110 TRW TAS 30 614
52A 8140 ZF 7683.955.126
130 TRW TAS 30 615
150 TRW TAS 30 616

MASCOTT DXi

Hydraulic pump
Vehicle family Vehicle type Engine type Steering box type
type
54A 120 TRW TAS 30 620
ZD30 KAYABA 07 KYB
54B 160 TRW TAS 30 621
130 TRW TAS 30 620
56A ZD30 KAYABA 07 KYB
150 TRW TAS 30 621

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B2-2 41 050
MIDLUM

Engine
Vehicle family Vehicle type Hydraulic pump type Steering box type
type
135
42B1 04.02.26 Enerflux 5228 Sheppard M 83
150
42B 180
42B2/43C1/
43C2 210 Sheppard M 83
43E1/43E2 06.02.26 Enerflux 5227
ZF 8095
43V 210 BOM
43C2/43T 250
HPI 5405
dCi 150 HPI XA 5091053
42B3 dCi 4
dCi 180 HPI XA 5093804
ZF 7684.955.175 Sheppard M 83
HPI 5405 ZF 8090
HPI XA 5090908
42B4 dCi 220 dCi 6
HPI XA 5093802
ZF 7684.955.200
44V dCi 180 dCi 4 HPI 5404
44C1 dCi 220 dCi 6 HPI XA 5089633
HPI XA 5089634
dCi 180 dCi 4
HPI XA 5090907
44C2 dCi 220 HPI XA 5093801
dCi 6
dCi 270 HPI XA 5091052
44T dCi 270 dCi 6 HPI XA 5093805
45D2 HPI 5404
dCi 220 HPI XA 5089634
dCi 6 ZF 8095
45D3 dCi 270 HPI XA 5090907
HPI XA 5093801 ZF 8098
dCi 220 HPI XA 5089634
45E2 dCi 250 dCi 6 HPI XA 5090907
dCi 270 HPI XA 5093801
HPI 5404
47XA dCi 220 dCi 6 HPI XA 5090907
HPI XA 5093801
47XC HPI XA 5090907
dCi 220 dCi 6
47XF HPI XA 5093801

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 41 050 B2-3

MIDLUM DXi

Engine
Vehicle family Vehicle type Hydraulic pump type Steering box type
type
44AE
190 ZF 8095.955.228
44MA/44ML ZF 7685.955.289
215 ZF 8095.955.230
44LA DXi 5
160
ZF 8090.955.181
44EL 190 ZF 7684.955.204
ZF 8090 955.184
215
44XL ZF 8095.955.228
ZF 8098.955.322
44HB
ZF 8098.955.324
44BE ZF 8095.955.228
44LB/44MB ZF 8095.955.230
240
DXi 7 ZF 7685.955.289
280 ZF 8095.955.228
ZF 8095.955.229
44XE
ZF 8095.955.230
ZF 8095.955.231
ZF 8095.955.228
44XM
ZF 8095.955.229

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B2-4 41 050
PREMIUM

Engine
Vehicle family Vehicle type Hydraulic pump type Steering box type
type
260 (4x2)
22A 260
(4x2 BOM)
23SP 260 SP
300 (4x2)
300 06.20.45
22A/22C
(4x2 BOM)
340 (4x2)
22Q 300 (6x2) Enerflux 2900
22Q/22R 340 (6x2)
22J 340 (6x2)
22Q/22R
385 (6x2) 06.23.56
22J
22C 400 (4x2)
06.23.56
22Q/22R
400 (6x2) B41
22J
ZF 8098
300
22A/22H (6x2 BOM)
340 (6x2/4)
06.20.45
300 (6x2/4) Enerflux 2901
22E 340
(6x2 BOM)
22E 380 (6x2/4) 06.23.56
210
22A 06.02.26
250
300 (4x2) Enerflux 2902
22A/22C 300 06.20.45
(4x2 BOM)
300 (4x2)
22A/22C 300 06.20.45
(4x2 BOM) Enerflux 8609.003
22C 400 (4x2) 06.23.56
22J 400 (4x2) B43
HPI 5404
HPI XA 5089634
dCi 220
22AB/22HB dCi 6 HPI XA 5089635
dCi 270
HPI XA 5090904
HPI XA 5090907
dCi 320 ZF 8098
22JJ/22RR
dCi 370 dCi 11 HPI 5271
22AA/22CC dCi 420
dCi 320
22EE/22HA dCi 11 HPI XA 5090300
dCi 370

RENAULT TRUCKS 09/2007

 41 050 B2-5

PREMIUM DXi

Engine
Vehicle family Vehicle type Hydraulic pump type Steering box type
type
ZF 8098.965.193
27SC
ZF 8098.965.194
25SC/25AC/
ZF 8098.965.195
25NC
ZF 8098.988.705
330
27JC/27TC 380 ZF 8098.965.193
25TC/25BC/ 440 ZF 8098.988.705
25JC/25DC
27RC ZF 8098.965.194
25RC/25CC DXi 11 ZF 8694.974.513 ZF 8098.965.195
24TF/24BF/ ZF 8098.965.193
24JF/24DF ZF 8098.988.705
ZF 8098.965.193
370
24SF/24AF/ ZF 8098.965.194
410
24NF ZF 8098.965.195
450
ZF 8098.988.705
ZF 8098.965.194
24CF/24RF
ZF 8098.965.195
29TG/29BG/ 280 ZF 8098.965.193
29TB/29BB 320 ZF 8098.988.705
ZF 8098.965.193
240
29SG/29AG/ ZF 8098.965.194
280
29SB/29AB DXi 7 ZF 7685.955.289 ZF 8098.965.195
320
ZF 8098.988.705
29CG/29NG/
280 ZF 8098.965.194
29CB/29NB/
320 ZF 8098.965.195
29RG/29RB

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B2-6 41 050
KERAX

Vehicle
Vehicle family Engine type Hydraulic pump type Steering box type
type
260 (4x2)
300 (4x2)
340 (4x2) 06.20.45 Enerflux 2900 ZF 8098.955.324
33P/33Q
350 (4x2) 06.23.56 Enerflux 2901 TRW TAS 85
385 (4x2)
400 (4x2)
300 (6X4)
340 (6X4)
350 (6X4) 06.20.45 Enerflux 2900 ZF 8098.955.323
33G/33H/33I
350 (6X4) 06.23.56 Enerflux 2901 ZF 8098.955.324
385 (6X4)
400 (6X4)
260 (4X4)
300 (4X4)
340 (4X4)
33R/33S
350 (4X4)
385 (4X4) 06.20.45
400 (4X4) Enerflux 2901 ZF 8098.955.323
06.23.56
340 (6X6)
350 (6X6)
33M/33N
385 (6X6)
400 (6X6)
ZF 8098.955.323
33PP/33RR dCi 270
ZF 8098.955.424
33HH/33II/33JJ dCi 320
33GG/33HH/
33ii
33KK/33LL/
33MM dCi 370
33PP/33QQ/ HPI 5271
33RR dCi 11
HPI XA 5093806 ZF 8098.955.323
33SS
ZF 8098.955.424
33GG/33HH/
33ii
33KK/33LL/
33MM dCi 420
33NN/33PP/
33QQ
33RR/33SS

KERAX DXi

Engine
Vehicle family Vehicle type Hydraulic pump type Steering box type
type
34FC/34MC/
330
34NC/34SC/
380
34TC/34XC/
440
34ZC ZF 8098.955.720
DXi 11 ZF 8694.974.513
34FF/34MF/ ZF 8098.955.722
370
34NF/34SF/
410
34TF/34XF/
450
34YF/34ZF

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 41 050 B2-7

MAGNUM

Engine
Vehicle family Vehicle type Hydraulic pump type Steering box type
type
AE 380
11A/11B/11C/11D
AE 385
Enerflux 1594
11A/11B/11C/11D
11E/11F AE 420TI
11A/11B/11C/11D AE 385
11A/11B/11C/11D 06.35.40 Enerflux 2900
11E/11F AE 420TI
AE 380
11A/11B/11C/11D
AE 385
Enerflux 35296.030
11A/11B/11C/11D
11E/11F AE 420TI
11E/11F Magnum 390
Magnum 430 Enerflux 3684
11E/11F/11G/11H ZF 8098
Magnum 470 06.24.65
11E/11F Magnum 390
Enerflux 5329
11E/11F/11G/11H Magnum 470
AE 500
11A/11B/11C/11D
AE 520 EE9 VICKERS V 20NF
11E/11F/11H AE 560
11E/11F Magnum 400
06.24.65
Magnum 440 HPI 5090909
11E/11F/11H E-TECH
Magnum 480
11E/11F Magnum 400
06.24.65 HPI 5328
Magnum 440 EUP ZF 7686.955.174
11E/11F/11H
Magnum 480
AE 380
11A/11B/11C/11D
AE 385
Enerflux 1594
11A/11B/11C/11D
11E/11F AE 420TI
11A/11B/11C/11D AE 385
11A/11B/11C/11D 06.35.40 Enerflux 2900
11E/11F AE 420TI
AE 380
11A/11B/11C/11D
AE 385
Enerflux 35296.030
11A/11B/11C/11D
11E/11F AE 420TI
11E/11F Magnum 390
Magnum 430 Enerflux 3684
11E/11F/11G/11H ZF 8098
Magnum 470 06.24.65
11E/11F Magnum 390
Enerflux 5329
11E/11F/11G/11H Magnum 470
AE 500
11A/11B/11C/11D
AE 520 EE9 VICKERS V 20NF
11E/11F/11H AE 560
11E/11F Magnum 400
06.24.65
Magnum 440 HPI 5090909
11E/11F/11H E-TECH
Magnum 480
11E/11F Magnum 400
06.24.65
Magnum 440 HPI 5328
11E/11F/11H EUP
Magnum 480

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B2-8 41 050

MAGNUM DXi

Engine
Vehicle family Vehicle type Hydraulic pump type Steering box type
type
ZF 8098.955.720
17TD
ZF 8098.955.722
440 ZF 8098.955.719
17RD DXi 12 ZF 7684.974.710
480 ZF 8098.955.721
ZF 8098.955.720
17SD
ZF 8098.955.722
ZF 8098.955.719
17JE/17TE
ZF 8098.955.721
ZF 8098.955.719
460
17RE DXi 13 ZF 8694.974.514 ZF 8098.955.720
500
ZF 8098.955.722
ZF 8098.955.720
17 SE
ZF 8098.955.722

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 41 050 B3-1

Standard tightening torques

Definitions
There are several types of tightening:
– Tightening to torque (in Nm)
– Tightening to angle (in °)
– Tightening to torque-angle (in Nm + °)

Torques given in Nm are nominal torques (average value calculated on the basis of the minimum torque and the
maximum torque).
The tightening precision class defines the tolerance of this torque in percent as a function of the nominal torque
applied.

Tightening precision classes:

– Class I: Special threaded hardware (tolerances ± 10% of the final torque).
– Class II: Reserved for precise tightening (tolerance ± 10% of the nominal torque).
– Class III: Reserved for normal standard tightening (tolerance ± 20% of the nominal torque)

For standard threaded hardware indicated in the table below, use tightening class III.
For other torques, see the following page(s).

"FIH" type (Nylstop) locknuts must be replaced whenever removed. "DRH" type (oval) locknuts can be re-
used. If locknuts (DRH, FIH or other) are re-used, make absolutely certain that the screw-thread of the bolt
protrudes least two threads above the top edge of the nut.

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B3-2 41 050
Standard nut and bolt tightening torques table

The tightening torque values given in the table are based on standard 01.50.4002 and apply to new nuts and bolts
fitted dry and re-used nuts and bolts with oil applied to the screw-threads. If any nuts and bolts are replaced, it is
absolutely essential to use nuts and bolts recommended by the RENAULT TRUCKS Spare Parts Department
(coefficient of friction in compliance with standard 01.50.4002).

Tightening torque values in Nm for conventional "metric system" threaded hardware

based on standard 01.50.4002 (H: normal and HE: with flange)

Diameter and pitch Quality class III

of nuts and bolts Quality class 8.8 Quality class 10.9

6 x 1.00 7.5 ± 1.5 11 ± 2.2

7 x 1.00 15 ± 3 20 ± 4
8 x 1.00 20 ± 4 30 ± 6
8 x 1.25 20 ± 4 27 ± 5.4
10 x 1.00 40 ± 8 60 ± 12
10 x 1.25 40 ± 8 60 ± 12
10 x 1.50 40 ± 8 50 ± 10
12 x 1.25 70 ± 14 100 ± 20
12 x 1.50 65 ± 13 95 ± 19
12 x 1.75 60 ± 12 90 ± 18
14 x 1.50 105 ± 21 155 ± 31
14 x 2.00 100 ± 20 145 ± 29
16 x 1.50 160 ± 32 220 ± 44
16 x 2.00 150 ± 30 220 ± 44
18 x 1.50 240 ± 48 340 ± 68
18 x 2.50 210 ± 42 310 ± 62
20 x 1.50 330 ± 66 480 ± 96
20 x 2.50 300 ± 60 435 ± 87
22 x 1.50 450 ± 90 650 ± 130
22 x 2.50 410 ± 82 595 ± 119
24 x 2.00 560 ± 112 820 ± 164
24 x 3.00 510 ± 102 750 ± 150

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 41 050 C-1

TOOLS

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C-2 41 050
Generalities
RENAULT TRUCKS divides tools into three categories:

– General-purpose tools: proprietary tools

• 50 00 26 .... reference number (possibility of purchasing through the RENAULT TRUCKS Spare Parts
department).
• 4-figure reference number (tools classified by RENAULT TRUCKS but available from the supplier).

– Special tools: specifically created tools distributed by the RENAULT TRUCKS Spare Parts Department
• To be ordered according to the reference numbers appearing in the list of tools on the following pages.

– Locally manufactured tools:

• 4-figure reference number (represented by a drawing): tools that are simple to make without need for
special qualification.

Three levels (or echelons) determine their assignment:

– Level 1: tools for servicing, maintenance and minor tasks
– Level 2: tools for major repairs
– Level 3: tools for refurbishment

Proprietary tools mentioned in this manual do not appear in the tools list.
These tools are identified in the standard tools manual (MO) by a 4-figure number.

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LIST OF TOOLS
General-purpose tools

RENAULT Manufacturer Manufacturer

Illustration Designation Level Qty
TRUCKS Ref. reference code

5000265013 Ram 1 1

5000269432 9432 tester 1 1

9432 tester
5000269908 pressure 1 1
reducer

5000268149 8149 tester 1 1

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Special Tools

RENAULT Manufacturer Manufacturer

Illustration Designation Level Qty
TRUCKS Ref. reference Code

5000261767 Union 1 1

Flexible test
5000262985 1 1
pipe

5000261500 Union 1 1

5000262898 Union 1 1

5000261515 Union 1 1

5000262947 Union 1 1

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TESTING

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Tester 9432 + 9908 (old generation apparatus)

Technical data

This serves to monitor the output, pressure and temperature of hydraulic systems.
Pressure reducing valve (1): Serves to control the steering box pressure limiter pressure and guarantees
safety of the apparatus for the other checks.
Switch (2): Flowmeter and temperature gauge on/off (to be used only at the moment of read-out).
Pressure gauge (3): Pressure from 0 to 210 bar.
Flowmeter (4): Scale A corresponds to values from 0 to 60 l/min or scale B corresponds to values from 0 to
30 l/min.
Temperature gauge (4): Temperature display from 0 to 150°C or 0 to 300°C.
Calibrating button (5): For setting the galvanometer (4) to zero.
‘V ADJ’ calibrating knob (6): Adjustment is connected with battery voltage. This varies according to circuit
temperature.
Selector knob (7): Five positions
– OFF = Stop.
– V ADJ = Calibration of galvanometer connected to calibrating knob (6).
– TEMP = Temperature.
– A = d Flowrate from 0 to 60 l/min.
– B = Flowrate from 0 to 30 l/min.
Valve (8): Alters hydraulic circuit flow.

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How to connect up and use the apparatus

The item numbers indicated in the text refer to the figure on page D-1-2.
Connect up the apparatus, matching the direction of connection and use the set of unions corresponding to the
vehicle (see table hereafter).
Raise the front end of the vehicle.
Fill the hydraulic steering reservoir with fluid.
Open valve (8).
Run the engine at idling speed and top up with fluid to the correct level.
Turn the steering wheel from one lock to the other several times to bleed the system (fluid level stable without
air bubbles).
Close valve (8) slightly to heat the fluid to its operating temperature (about 50°C).
Open valve (8) as soon as normal operating temperature is reached.
To check the temperature:
– Move selector knob (7) to the “TEMP” position.
– Actuate switch (2).
To calibrate the apparatus:
– Move selector knob (7) to the “V ADJ” position.
– Actuate switch (2).
– Use calibrating button (5) to move the pointer onto the “V ADJ” mark.

The battery voltage may be affected by changes in temperature. If it proves impossible to calibrate, replace the
batteries.

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Vehicle Union (**)
RENAULT MASCOTT 1767
RENAULT MASCOTT DXi 1767 / 2985
RENAULT MIDLUM 1500
RENAULT MIDLUM DXi 2898
RENAULT PREMIUM 1515
RENAULT PREMIUM DXi 2898
RENAULT KERAX 1515
RENAULT KERAX DXi 2898
RENAULT MAGNUM 1515
RENAULT MAGNUM DXi 12 2898
RENAULT MAGNUM DXi 13 2947

Adjusting the pressure reducing valve:

– Run the engine at idling speed.
– Fully open pressure reducing valve (1).
– Close valve (8).
– Adjust pressure reducing valve (1) until the required pressure is obtained.
– Open valve (8).

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Tester 8149 (new generation apparatus)

Technical data

This serves to monitor the output, pressure and temperature of hydraulic systems.
Pressure reducing valve (1): Serves to test the steering box pressure limiter and guarantees safety of the
apparatus for other checks.
Selector switch (2): Flowmeter or Temperature gauge ON/OFF (Start/Stop)
(to be used only at the moment of read-out).
Pressure gauge (3): Pressure from 0 to 400 bar.
Flowmeter (4): 4 to 60 l/min.
Temperature gauge (4): Temperature display from 0 to 150°C or 0 to 300°C.
Valve (8): Alters hydraulic circuit flow.
Cover screw (9).

The apparatus is equipped with an overpressure safety device.

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How to connect up and use the apparatus

The item numbers indicated in the text refer to the figure on page D-2-1.
Connect up the apparatus, matching the direction of connection and use the set of unions corresponding to the
vehicle (see table hereafter).
Raise the front end of the vehicle.
Fill the hydraulic steering reservoir.
Open valve (8).
Run the engine at idling speed and top up with fluid to the correct level.
Turn the steering wheel from one lock to the other several times to bleed the system
(fluid level stable without air bubbles).
Close valve (8) slightly to heat the fluid to its operating temperature (about 50°C).
Open valve (8) as soon as normal operating temperature is reached.
To check the temperature:
– Move selector knob (2) to the "TEMP" position.

The voltage of the batteries may be affected by changes in temperature. A light signal (:) flashes meaning that it is
necessary to replace the batteries. To gain access to the batteries, remove screws (9) and take off the cover.

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Vehicle Union (**)

RENAULT MASCOTT 1767
RENAULT MASCOTT DXi 1767 / 2985
RENAULT MIDLUM 1500
RENAULT MIDLUM DXi 2898
RENAULT PREMIUM 1515
RENAULT PREMIUM DXi 2898
RENAULT KERAX 1515
RENAULT KERAX DXi 2898
RENAULT MAGNUM 1515
RENAULT MAGNUM DXi 12 2898
RENAULT MAGNUM DXi 13 2947

Adjusting the pressure reducing valve:

– Run the engine at idling speed.
– Fully open pressure reducing valve (1).
– Close valve (8).
– Adjust pressure reducing valve (1) until the required pressure is obtained.
– Open valve (8).

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Testing the steering box

Testing the steering box hydraulic pressure limiter

All pressure checks must be carried out while the engine is idling

The item numbers indicated in the text refer to the figure on page D-1-2 / D-2-1
The test time is about 5 seconds, without exceeding a temperature of 50°C.
– Set pressure reducing valve (1) to a pressure 5 bars higher than the maximum operating pressure
(see table below).
– Immobilize the steering in the mid-point position using tool 5013.
– With the engine idling, valve (8) open, exert a torque of 50 Nm in one direction on the steering wheel.
– The maximum operating pressure should be within the tolerances.
– Repeat the test in the other direction
– Check the operating temperature.
– Replace the pressure limiter, if necessary:
• For a ZF 8095/8098 steering box, see Steering Box 8095 - 8098 Workshop Manual.
• For a TRW TAS30/TAS75/TAS85/TAS87 steering box, see Steering Box TAS 30 / 75 / 85 / 87
Workshop Manual.
• For a SHEPPARD M83 steering box, replace the steering box.

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TRW STEERING BOX
LH drive RH drive Pressure (in bars)
TAS 30 611 TAS 30 612
97 -> 103
TAS 30 615 TAS 30 616
TAS 30 613 TAS 30 614
TAS 75 633 130 -> 140
TAS 75 634
TAS 85 629 150 -> 160
TAS 30 620 TAS 30 621 125 -> 135

SHEPPARD STEERING BOX

LH drive RH drive Pressure (in bars)
M83.PAA2 M83.PAB2 120 -> 130
M83.PAK21 M83.PAL21
160 -> 170
M83.PAK23 M83.PAL23

ZF STEERING BOX
LH drive RH drive Pressure (in bars)
ZF 8095 974 101 ZF 8095 974 102
ZF 8095 988 304 ZF 8095 988 314
ZF 8095 988 305 ZF 8095 988 313
ZF 8095 955 202 ZF 8095 955 203 170 -> 180
ZF 8095 955 228 ZF 8095 955 230
ZF 8095 955 229 ZF 8095 955 231
ZF 8090 955 181 ZF 8090 955 184
ZF 8098 955 322 ZF 8098 955 324
ZF 8098 955 323 ZF 8098 955 424
ZF 8098 955 454 ZF 8098 955 455 150 -> 165
ZF 8098 965 135 ZF 8098 965 136
ZF 8098 965 134 ZF 8098 965 137
ZF 8098 955 719 ZF 8098 955 721
ZF 8098 955 720 ZF 8098 955 722
ZF 8098 988 705 ZF 8098 988 706
170 -> 180
ZF 8098 988 707 ZF 8098 988 708
ZF 8098 988 718 ZF 8098 965 193
ZF 8098 965 194 ZF 8098 965 195

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Checking the hydraulic lockover limitation pressure

All pressure checks must be carried out while the engine is idling

The item numbers indicated in the text refer to the figure on page D-1-2 / D-2-1
The test time is about 5 seconds, without exceeding a temperature of 50°C.
– Set pressure reducing valve (1) to the maximum operating pressure.
– Roadwheels placed on rotary plates.
– Engine idling, valve (8) open.
– Lock the steering wheel over on one side as far as mechanical abutment of the axle.
– Exert a torque of 75 Nm on the steering wheel.
– The pressure should not exceed:
• 30 to 35 bars for road vehicles.
• 50 to 55 bars for off-road vehicles.
– Repeat the test in the other direction.
– Check the operating temperature.
– Adjust the hydraulic pressure limitation stops:
• For a SHEPPARD M83 type steering box, see Steering Box M83 Workshop Manual.
• For a TRW TAS 30/TAS 75/TAS 85/TAS 87 type steering box, see Steering Box TAS 30 / 75 / 85 / 87
Workshop Manual.
– Replace the hydraulic pressure limitation stops:
• For a ZF 8095/8098 type steering box, see Steering Box 8095 - 8098 Workshop Manual.

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Testing the steering hydraulic pump

Checking the output

The test time is about 5 seconds, without exceeding a temperature of 50°C.
The item numbers indicated in the text refer to the figure on page D-1-2 / D-2-1
– Set pressure reducing valve (1) to a pressure of more than 50 bars.
– Raise the fluid temperature to 50°C.
– Move the steering to the mid-point position.
– For apparatus 9432 + 9908, move selector (7) B to the "flow" position B.
– For apparatus 8149, move switch (2) to the "flow" position.
– With the engine running at the recommended speed:
– Adjust the circuit pressure to 50 bars by turning valve (8).
– Read out the flowrate.

For the values, see the table hereafter.

ENERFLUX HYDRAULIC PUMP
Part N° Check at 50°C at 50 bars
Supplier RENAULT TRUCKS Engine speed in rpm Flowrate in l/min +3/-1
650 13
1594 50 10 224 771
1800 16
650 16
2900 50 10 239 652
1800 18
650 10
2901 50 10 239 654
1800 20
650 12
2902 50 10 239 659
1800 16
750 14
3684 50 10 294 213
1800 18
750 10
5227 50 10 383 229
1800 20
750 10
5228 50 10 383 364
1800 20
600 12
5329 50 10 383 956
2000 16
750 12
8609.003 50 10 383 854
1800 16
650 16
35296.030 50 00 792 830
1800 18

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HPI HYDRAULIC PUMP
Part N° Check at 50°C at 50 bars
Supplier RENAULT TRUCKS Engine speed in rpm. Flowrate in l/min +3/-1
750 16
5271 50 10 383 854
1800 16
700 15
5328 50 10 383 957
1800 16
680 11
5404 50 10 488 110
1800 16
680 11
5405 50 10 488 168
1800 12
680 13
XA 5089633 50 10 488 350
1800 16
680 13
XA 5089634 50 10 488 349
1800 16
680 14
XA 5089635 50 10 488 125
1800 20
750 17
XA 5090300 50 10 488 130
1800 20
680 14
XA 5090904 50 10 557 050
1800 20
680 11
XA 5090907 50 10 557 048
1800 16
680 11
XA 5090908 50 10 557 049
1800 12
700 15
XA 5090909 50 10 488 925
1800 16
680 11
XA 5091052 50 10 557 090
1800 16
680 10
XA 5091053 50 10 557 092
1800 12
680 10
XA 5093801 50 10 600 045
1800 16
680 10
XA 5093802 50 10 600 053
1800 12
750 15
XA 5093803 50 10 600 044
1800 20
750 10
XA 5093804 50 10 600 051
1800 12
750 12
XA 5093805 50 10 600 052
1800 16
680 10
XA 5093806 50 10 600 046
1800 16

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KAYABA HYDRAULIC PUMP

Part N° Check at 50°C at 50 bars
Supplier Renault Trucks Engine speed in rpm Flowrate in l/min +3/-1
50 10 557 120 / 750 7
07 KYB
74 21 049 376 1800 9

VICKERS HYDRAULIC PUMP

Part N° Check at 50°C at 50 bars
Supplier Renault Trucks Engine speed in rpm Flowrate in l/min +3/-1
750 14
V 20 NF 50 00 823 037
1800 19

ZF HYDRAULIC PUMP
Part N° Check at 50°C at 50 bars
Supplier Renault Trucks Engine speed in rpm Flowrate in l/min +3/-1
750 7
7683.955.126 50 10 851 055
1800 7
680 8
7684.955.175 50 10 557 602
1800 8
680 8
7684.955.200 50 10 557 435
1800 8
700 16
7686.955.174 50 10 557 813
1800 16
600 16
7684.974.710 74 20 567 060
1800 16
700 8
7684.955.204 50 10 600 534
1800 8
600 12
7685.955.289 50 10 600 495
1800 16
600 16
8694.974.513 74 20 701 199
1800 16
600 16
8694.974.514 74 20 824 535
1800 16

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Checking the pressure
The item numbers indicated in the text refer to the figure on page D-1-2 / D-2-1
The test time is about 5 seconds, without exceeding a temperature of 50°C.
Steering pump without integrated pressure limiter
– Set pressure reducing valve (1) to a pressure 5 bars higher than the pressure of the pressure limiter
integrated in the steering box (see page D-3-1).
– With the engine idling, progressively close valve (8) so that the pressure stabilizes at the value of the
pressure limiter integrated in the steering box.
– After making this check, open valve (8).

– To find the correlation of the steering pump to the steering box, refer to the "Technical data" chapter.

Steering pump with integrated pressure limiter

– Set pressure reducing valve (1) to a pressure 5 bars higher than the pressure setting of the pressure limiter
integrated in the steering pump (see table hereafter).
– With the engine idling, progressively close valve (8) so that the pressure stabilizes at the value of the
pressure limiter integrated in the steering pump.
– After making this check, open valve (8).

VICKERS HYDRAULIC PUMP

Pressure limiter setting
Supplier's Part N° Renault Trucks Part N°
(in bars)
V 20 NF 50 00 823 037 155 → 165

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Diagnostics

Troubleshooting

Incident Probable cause Remedy

Pump noisy Fluid too cold Let fluid heat up
Maximum lockover Release steering wheel
(limit max. lockover)
Air in circuit Bleed
Insufficient fluid Top up with fluid
Steering heavy on Insufficient fluid Top up with fluid
both sides Oil filter clogged Replace filter
Air in circuit Bleed circuit
Distributor jammed Replace steering box
Pump damaged Repair - replace pump
Internal leaks Replace steering box
Steering heavy on Distributor jammed Replace steering box
one side only Hydraulic pressure limitation valves
defective Adjust - repair - replace
Internal leaks Replace steering box
Air in steering box Bleed
Steering does not Stub axle or axle Grease stub axle. Check out axle and
return properly caster angle
Pump output Check - repair - replace
Vehicle pulls to one Distributor worn or maladjusted Replace steering box
side Distributor internal leaks Replace steering box
Wheel alignment defect Check - adjust
Abnormally long Pump output Check - repair
response time upon Air in circuit Bleed- replace
lockover
Momentary Air in circuit Bleed
steering heaviness Valve seized Repair
Fluid emulsified Poor seal / Ingress of air Retighten pipes or replace pump inlet
gasket
Steering locks itself Incorrectly centred distributor Replace steering box
over
Vehicle wanders Steering system / roadwheels mid-point Check - repair
incorrect
Joints - axle worn Check - repair
Distributor worn Replace steering box

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RENAULT TRUCKS 09/2007