Recommendations/precautions : MCP piloted manual gearbox

B2CK0107P0 Recommendations/precautions : MCP piloted manual gearbox

MC MANUAL GEARBOX

1. Foreword
The operations must be carried out by qualified personnel, informed about the control system
and the safety recommendations and precautions to be taken.
The features of the MCP piloted manual gearbox make it essential to observe the safety
instructions given below.

2. Safety recommendations
ESSENTIAL : Before carrying out any work on the piloting actuator, depressurise the piloted
manual gearbox hydraulic circuit.
ESSENTIAL : After sales checks performed with the engine running should be carried out with
gear "N" engaged and the handbrake applied (except where explicitly mentioned otherwise in the
repair procedures).
ESSENTIAL : During the piloted manual gearbox programming operations, do not allow anyone
to walk or stand in front of the vehicle.
ESSENTIAL : Work on the piloting actuator with the engine running is prohibited (no tool, no
hand).

3. Working conditions
Recommendations for cleanliness :
 The working area should be clean and tidy
 Parts being repaired should be protected from dust
 The operator must wear clean clothing
 Following removal, immediately close all of the openings using plugs to prevent the entry
of impurities into the pipes and parts of the piloting actuator
Quality of work :
 Observe the tightening torques using a torque wrench which is checked regularly
 Observe the operations described in the repair methods

4. Repairs to the electrical components

Do not disconnect :
 The battery with the engine running
  The ECUs : Ignition on
During electrical checks :
 The battery must be fully charged
 Never use a voltage source greater than 16 V
 Never use a test lamp
Before re-connecting a connector, check :
 The condition of the various contacts (distortion, corrosion ...)
 The presence and condition of the mechanical unlocking

5. Driving
Never push the vehicle in an attempt to start it (impossible with a piloted manual gearbox).

6. Towing
In the presence of a piloted manual gearbox fault or malfunction, the vehicle may remain
immobilised with a gear engaged.
If the vehicle remains immobilised with a gear engaged, it is imperative that the front of the
vehicle is lifted when towing.
CAUTION : The vehicle can only be pushed or pulled if the gearbox is in neutral.
If a gear is engaged and "jammed", try to engage gear "N" ; Using the diagnostic equipment.
There is no mechanical unlocking device.

7. Preliminary operations
List of operations to be carried out before replacement or removal-refitting of the mechanical
components.

7.1. Protection of the piloting actuator

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Put the handle G.0346 in place when removing-refitting the piloting actuator or the piloted
manual gearbox.
ESSENTIAL : The handle [1] is essential to avoid damaging the hydraulic reservoir (1) and the
pressure accumulator (2) when the piloted manual gearbox rests on the ground. The handle [1]
also permits a better grip on the piloted manual gearbox when it is removed-refitted.

7.2. Depressurizing the system

The operating pressure is 37 bars ; The pressure accumulator permits the storing of a pressure
which may pose a risk to the technician if he opens the hydraulic circuit.
Before removal, it is imperative that the piloting actuator is depressurised using the diagnostic
tool.

7.3. Reading of the counters

This operation permits reading of the gear engagement counter and number of clutch cycles
counter written in the piloted manual gearbox ECU.
Read the counters if the following components are to be replaced ; Using the diagnostic
equipment :
 Piloted manual gearbox ECU
 Actuator electro-hydraulics
 PILOTING actuator
N.B. : Make a note of or print the values in order to write them to the new piloted manual
gearbox ECU.

8. Additional operations
List of operations to be carried out following replacement or removal-refitting of the mechanical
components.

8.1. Writing of the counters

Write the values read previously in the counters if the following components are replaced ; Using
the diagnostic equipment :
 Piloted manual gearbox ECU
 Actuator electro-hydraulics
 PILOTING actuator

8.2. Pressurising
To obtain an operational pressure in the hydraulic circuit, activate the electric motor to fill the
pressure accumulator ; Using the diagnostic equipment.

8.3. Bleeding of the air in the hydraulic circuit

Pressurise the hydraulic circuit.
Using the diagnostic tool, this function activates engagement of the gears and releasing of the
clutch to bleed the air as far as the piloted manual gearbox hydraulic reservoir.

8.4. Initialisation of the bite point

Using the diagnostic tool, this function activates the hydraulic clutch stop to define the actual
position of the stop in relation to the clutch wear.

8.5. Programming of the piloted manual gearbox grille

Using the diagnostic tool, this function activates the engagement of all of the gears to enable the
piloting actuator to define the position of the gearbox grille.
8.6. Learning : Value of the engine torque transmitted to the clutch
By means of a dynamic test, this function makes it possible to define the position of the clutch in
relation to the engine torque transmitted. The gearbox grille and the point of load bearing must
be programmed first.

9. Summary table of the preliminary and additional operations

Operations to be carried out ; Using the diagnostic equipment.
N.B. : 1, 2, 3, 4, 5, 6, 7, 8 : Order number of the operations to be carried out.

9.1. Clutch
Replacement :
Removing - Replacement of the
Operations to be performed clutch release
refitting : Clutch clutch
bearing
Reading of the counters No OK No OK No OK
7 (Reset the clutch
Writing of the counters No OK No OK
cycles counter to zero)
Depressurisation of the piloting 1 (Before 1 (Before
1 (Before replacement)
actuator replacement) replacement)
Pressurisation of the piloting 2 (After 2 (After
2 (After replacement)
actuator replacement) replacement)
Bleeding of the air in the hydraulic
3 3 3
circuit
Initialisation of the bite point 4 4 5
Programming of the piloted
No OK No OK 6
manual gearbox grille
Reinitialisation of the programmed
No OK No OK 4
values
Learning : Value of the engine
No OK No OK 8
torque transmitted to the clutch

9.2. Controlled manual gearbox

Operations to be performed Removing - Refitting Replacement
Reading of the counters No OK No OK

Writing of the counters
Depressurisation of the piloting No OK (Yes for clutch stop
actuator
Pressurisation of the piloting
actuator
Bleeding of the air in the
hydraulic circuit
Initialisation of the bite point
Programming of the piloted
manual gearbox grille
No OK
removal-refitting)
No OK (Yes for clutch stop
removal-refitting)
No OK (Yes for clutch stop
removal-refitting)
No OK
1 (After refitting)
2 (Writing of the gear
engagement counters)
No OK (Yes for clutch stop
removal-refitting)
No OK (Yes for clutch stop
removal-refitting)
No OK (Yes for clutch stop
removal-refitting)
No OK
1 (After replacement)

9.3. PILOTING actuator

Removing -
Operations to be performed Replacement
Refitting
1 (Reading of all of the counters
Reading of the counters No OK
before replacement)
Writing of the counters No OK 7 (Writing of all of the counters)
1 (Before
Depressurisation of the piloting actuator 2 (Before replacement)
removal)
2 (After
Pressurisation of the piloting actuator 3 (After replacement)
refitting)
3 (After
Bleeding of the air in the hydraulic circuit 4
refitting)
5 (After
Initialisation of the bite point 6
refitting)
Programming of the piloted manual gearbox 4 (After
5
grille refitting)
Learning : Value of the engine torque
No OK 8
transmitted to the clutch

9.4. Electro-hydraulic unit

Operations to be performed Removing - Replacement
 Refitting
1 (Reading of all of the counters before
Reading of the counters No OK
replacement)
Writing of the counters No OK 7 (Writing of all of the counters)
Depressurisation of the piloting 1 (Before
2 (Before replacement)
actuator removal)
2 (After
Pressurisation of the piloting actuator 3 (After replacement)
refitting)
Bleeding of the air in the hydraulic 3 (After
4
circuit refitting)
Initialisation of the bite point No OK 6
Programming of the piloted manual
No OK 5
gearbox grille

9.5. Actuator electro-pump

Removing -
Operations to be performed Replacement
Refitting
Reading of the counters No OK No OK
4 (Reset the electric motor counter to
Writing of the counters No OK
zero)
1 (Before
Depressurisation of the piloting actuator 1 (Before replacement)
removal)
Pressurisation of the piloting actuator 2 (After refitting) 2 (After replacement)
Bleeding of the air in the hydraulic
3 (After refitting) 3
circuit
Initialisation of the bite point No OK No OK
Programming of the piloted manual
No OK No OK
gearbox grille

9.6. Piloted manual gearbox ECU

Removing -
Operations to be performed Replacement
Refitting
 1 (Reading of all of the counters
Reading of the counters No OK
before replacement)
Writing of the counters No OK 7 (Writing of all of the counters)
1 (Before
Depressurisation of the piloting actuator 2 (Before replacement)
removal)
2 (After
Pressurisation of the piloting actuator 3 (After replacement)
refitting)
3 (After
Bleeding of the air in the hydraulic circuit 4 (After replacement)
refitting)
Initialisation of the bite point No OK 6 (After replacement)
Programming of the piloted manual gearbox
No OK 5 (After replacement)
grille
Learning : Value of the engine torque
No OK 8
transmitted to the clutch

9.7. Piloting electrovalves - Pressure sensor

Operations to be performed Removing - Refitting Replacement
Reading of the counters No OK No OK
Writing of the counters No OK No OK
Depressurisation of the piloting actuator 1 (Before removal) 1 (Before replacement)
Pressurisation of the piloting actuator 2 (After refitting) 2 (After replacement)
Bleeding of the air in the hydraulic circuit 3 (After refitting) 3 (After replacement)
Initialisation of the bite point No OK No OK
Programming of the piloted manual gearbox grille No OK No OK

9.8. Position sensors

Operations to be performed Removing - Refitting Replacement
Reading of the counters No OK No OK
Writing of the counters No OK No OK
Depressurisation of the piloting actuator No OK No OK
Pressurisation of the piloting actuator No OK No OK
Bleeding of the air in the hydraulic circuit No OK No OK
Initialisation of the bite point No OK No OK
Programming of the piloted manual gearbox grille 1 (After refitting) 1 (After replacement)

9.9. Actuator electro-pump unit electric motor

Removing -
Operations to be performed Replacement
Refitting
Reading of the counters No OK No OK
4 (Reset the electric motor counter to
Writing of the counters No OK
zero)
1 (Before
Depressurisation of the piloting actuator 1 (Before replacement)
removal)
Pressurisation of the piloting actuator 2 (After refitting) 2 (After replacement)
Bleeding of the air in the hydraulic
3 3
circuit
Initialisation of the bite point No OK No OK
Programming of the piloted manual
No OK No OK
gearbox grille

9.10. Pressure accumulator

Operations to be performed Removing - Refitting Replacement
Reading of the counters No OK No OK
Writing of the counters No OK No OK
Depressurisation of the piloting actuator 1 (Before removal) 1 (Before replacement)
Pressurisation of the piloting actuator 2 (After refitting) 2 (After replacement)
Bleeding of the air in the hydraulic circuit 3 (After refitting) 3 (After replacement)
Initialisation of the bite point No OK No OK
Programming of the piloted manual gearbox grille No OK No OK
9.11. Hydraulics reservoir
Removing - Check the oil level - Changing the
Operations to be performed Replacement
Refitting Topping up the oil level oil
Reading of the counters No OK No OK No OK No OK
Writing of the counters No OK No OK No OK No OK
Depressurisation of the 1 (Before 1 (Before 1 (Before
1 (Before check)
piloting actuator removal) replacement) fluid change)
Pressurisation of the piloting 2 (After 2 (After 2 (After fluid
2 (After check)
actuator refitting) replacement) change)
Bleeding of the air in the 3 (After 3 (After 3 (After fluid
No OK
hydraulic circuit refitting) replacement) change)
Initialisation of the bite
No OK No OK No OK No OK
point
Programming of the piloted
No OK No OK No OK No OK
manual gearbox grille