power take off - renault...

POWER TAKE OFF

POWER TAKE OFF

24/02/2004 1

GENERAL FEATURES ZF power take-offs NH1 and NH4, which were proposed on all top of the range and construction site vehicles (on ZF G/B 9S109, 16s151/181/221 and Astronic Optidriver), have been replaced by Hydrocar PTO 81 and PTO 84. ZF power take-offs N109/10 and N221/10 are retained. On vehicles equipped with gearboxes with power take-offs and flanged hydraulic pumps, we remind you of the assembly recommendations and choice criteria for these equipment items. APPLICATION

In production: MAGNUM New PTO fitted as from 05/05/2003 CAM 05E3 PREMIUM New PTO fitted as from 05/05/2003 CAM 05E3 KERAX New PTO fitted as from 02/06/2003 CAM 02F3

In aftermarket: These PTOs are available from the RENAULT TRUCKS Spare Parts Department.

For any assembly of a PTO in the aftermarket, use the kit (studs + gaskets) related to each PTO part number . PARTS

REFERENCE N° DESIGNATION QTY

50 10 545 295 Power take-off Hydrocar 81 B 1 50 10 545 322 Power take-off Hydrocar 81 C 1 50 10 545 346 Power take-off Hydrocar 84 B Z1 torque 430 Nm 1 50 10 545 383 Power take-off Hydrocar 84 B Z3 torque 500 Nm (Kerax) 1 50 10 545 347 Power take-off Hydrocar 84 C Z1 torque 430 Nm 1 50 10 545 384 Power take-off Hydrocar 84 C Z3 torque 500 Nm (Kerax) 1

The RENAULT TRUCKS Product Applications Department is at your disposal for any further information. Note: The letter "B" or "C" added after the PTO type indicates the type of coupling mounted on the PTO output: B – Flange (in this case, the maximum prop shaft angle is 7.5°). C – Splined shaft. PARAMETER DEFINITION On RENAULT TRUCKS equipped with a power take off, the engine speed is pre-set at the factory, but it can be modified by the dealer network or by a bodybuilder by using the "Bodybuilder Software". The latter permits amongst other things, to limit the torque delivered by the engine for certain applications in order to protect the hydraulic equipment.

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HYDROCAR PTO 84 B or C

Max. torque : G/B Ecomid, Ecosplit DD and Astronic DD: 430 Nm G/B Ecosplit OD and Astronic OD: 500 Nm

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HYDROCAR PTO 81 B or C

Max. torque: Version B or C: 1000

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PRESENTATION

POWER TAKE-OFF HYDROCAR 84

The seal between the gearbox and the power take-off is provided by an O-ring (1). The seal between the pump and the power take-off is provided by a gasket inside the power take-off (2).

WARNING

THESE GASKETS DO NOT PREVENT LEAKAGE IN THE EVENT OF INCORRECT TIGHTENING OR WORKING LOOSE OF THE GEARBOX/PTO/HYDRAULIC

PUMP UNIT.

POWER TAKE-OFF HYDROCAR 81

WHENEVER WORKING ON THE PTO, WATCH THAT O-RING (A) IS PLACED CORRECTLY IN THE GROOVE IN THE PTO.

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The seal between the gearbox and the power take-off is provided by an O-ring (1). The seal between the pump and the power take-off is provided by a metal gasket (2).

WARNING

THESE GASKETS DO NOT PREVENT LEAKAGE IN THE EVENT OF INCORRECT TIGHTENING OR WORKING LOOSE OF THE GEARBOX/PTO/HYDRAULIC

PUMP UNIT. WHENEVER WORKING ON THE PTO, WATCH THAT O-RING (A) IS PLACED CORRECTLY

IN THE GROOVE IN THE PTO.

CHOICE OF POWER TAKE-OFF

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Choice criteria

In all circumstances, the choice of power take-off must be made in relation with the equipment manufacturer. It must take operating characteristics and installation of the hydraulic system into account:

- Hydraulic pump output (Q in dm3/mn). - Operating pressure (p in bar). - Operating time (mn). - Operating speed (n in rpm). - Load exerted by the pump on the power take-off (in Nm).

Refer to the table of features of power take-offs proposed for the vehicle ranges..

Power take-off calculations

PTO output speed: r : coefficient régime ou rapport d'entraînement (see table APPENDIX 8) nPTO : PTO output speed (rpm) nmot : engine speed (rpm)

Maximum power transmissible by the power take-off:: P : power (KW) C : PTO maximum output torque (Nm) n pmt : PTO output speed (rpm) Q : flow (L/mn.) p : pressure (bar)

Maximum torque permissible for a flanged power take-off:: C : torque (Nm) Q : flow (L/min) p : pressure (bar) n pmt : PTO output speed (rpm) V : pump cylinder capacity (cm3/rev.)

nPTO= nmot x r

C x npmt Pmax. =

9550 ou

Q x p Pmax. =

600

15,92 x Q x p C max. =

npmt ou

V x p C max. =

50

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INSTALLATION / ATTACHMENT You will find in the APPENDIX the different possible positions for power take-offs on the gearbox, together with the maximum acceptable cantilever couple (Cp in Nm) of the hydraulic pump. Calculation of cantilever couple

NON-OBSERVANCE OF THESE RECOMMENDATIONS MAY LEAD TO SEIZING OR JAMMING OF THE GEARBOX:

either because of lack of oil suction of oil from gearbox by hydraulic pump (seizing)

or because of too much oil delivery of oil from hydraulic system into gearbox (jamming). You will find hereafter choice criteria and basic calculations serving to define the features of the power take-off necessary for correct functioning of your installation. Warning The securing studs for Hydrocar power take-offs 81 and 84 have a reduced section on the non-threaded portion (it is ESSENTIAL to use the studs supplied in the kits).

For information: Tightening torque PTO ZF on G/B : 65 ± 5 Nm

IT IS ESSENTIAL TO USE ORIGINAL NUTS AND WASHERS. (Supplied in a kit or delivered with the vehicle.)

Cp Nm = p(N) x d (m)

"d" distance from centre of gravity to pump support face

"p" weight in N of pump (mass x 9.81)

g: Centre of gravity of pump.

g

d

p

(other) Hydrocar PTO Tightening torque:

STUDS ON G/B : 40 ± 2 Nm Tightening torque:

PTO ON G/B : 70 ± 5 Nm

Hydrocar PTO 81 et 84 Tightening torque:

STUDS ON G/B : 20 ± 3 Nm Tightening torque:

PTO ON G/B : 35 ± 5 Nm

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Recommendations Bearing in mind the weight and the significant overhang of some PTOs with flanged pumps, the rear end of the PTO must be supported by a suitable bracket to be secured to the rear face of the gearbox. Note: Comply with standard NF ISO 7653 In the case of exceptional situations requiring the removal of the PTO, refer to the manufacturer’s assembly instructions. Stud tightening torque: 20 N.m 3 with application of Loctite 242 or 542. IMPORTANT It is compulsory, whenever fitting a PTO, to ensure a shimming clearance to allow optimum backlash (namely 0.15 to 0.20 mm), then insert a gasket or apply sealing compound so as to give a tight seal, then top up with oil (see vehicle servicing handbook). Refer to our product information sheet and to the bodybuilder’s 1/20th scale «PTO» drawing, available from the Product Applications Department IMPORTANT For the assembly of HYDROCAR 84 PTOs, it is absolutely essential to grease the splines with Molykote grease.

IMPORTANT - When fitting a hydraulic pump to a HYDROCAR 84 PTO, do not insert any metallic gasket or paper gasket, or apply Loctite between two contact faces IMPORTANT - The assembly of equipment to the PTO remains the installer’s responsibility

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PRIOR TO DELIVERY OF THE VEHICLE Check for oil leaks when preparing the vehicle for the road. In the event of leakage, replace O-ring (1) part N° 50 01 864 042.

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TABLE OF POWER TAKE-OFF RECOMMENDATIONS ACCORDING TO USE The functional selection criteria for the right power take-off for the task in hand are as follows:

- use while moving or at a standstill; - torque to be transmitted; - ratio (speed factor in relation to engine); - max. working time connected with usage; direction of rotation

SEE APPENDICES:

Appendix 1:

Recommendation for TIPPER uses: central ram, front end ram, ram under body, tipper and crane. Recommendation for SWAP BODY uses: tipper, compactor. Appendix 2:

Recommendation for CONCRETE DISTRIBUTION uses: mixer, outfeed belt, pump, arm. Recommendation for CONCRETE PUMP uses: concrete pump alone. Appendix 3:

Recommendation for TANKER uses: hydraulic motor, dairy vacuum pump, U/J. Recommendation for BULK POWDER uses: hydraulic pump, compressor, tilt tanker. Appendix 4:

Recommendation for CRANE uses: handling, logger, scrap metal. Appendix 5:

Recommendation for SEWER CLEANER uses: water pump, vacuum pump, hydraulic pump. Recommendation for REFUSE COLLECTOR uses: automatic G/B, manual G/B. Appendix 6:

Recommendation for SNOW PLOUGH uses: tipper, plough + salter. Recommendation for SNOW PLOUGH, SPREADER/SALTER uses: Recommendation for DUAL SPREADER uses: Appendix 7:

Recommendation for FIRE ENGINE uses: light fire pumper / tanker, fire pumper tanker, 4 x 4. Appendix 8:

Heavy-duty range and construction site global offer.

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Appendix 1

TIPPER SWAP BODY Lifting arm PTO Type Central ram

Front end ram Ram under body

Tipper +

Crane Tipper Compactor

PTO independent of clutch X PTO on G/B X X X Extra PTO Direction of rotation Clockwise (engine) X X X X Direction of rotation Opposite (engine) X X X X Torque (Nm) 50 100 150 X 200 X 250 X 300 X X X 350 X X X X 400 X X X X 430 X X X X 450 X X X X 470 X X X X 500 X X X X 560 X 600 X 700 730 800 870 900 1000 > 1000 2000 Operating time < 1h X X X > 1h and < 4h X X > 4h Coupling type Type B (flange) Type C (hollow splined shaft) X X X Flange dimension DIN90 DIN100 DIN120

PTO choice for PREMIUM-KERAX-MAGNUM

PTO 84 (<1h) PTO 81 65L

PTO 84/81 PTO GP

PTO 84(<1h) PTO 81 65L PAM

PTO choice for MIDLUM-PREMIUM (6l)

PTO 2264 PTO 2266

PTO 2264 PTO 2266

PTO 2264 PTO 2266 PAM

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Appendix 2 CONCRETE DISTRIBUTION CONCRETE PUMP

Pump + Arm PTO Type Mixer Outfeed

belt Pump Arm Concrete pump alone

PTO independent of clutch X X PTO on G/B X X Extra PTO X Direction of rotation Clockwise (engine) X X X X X Direction of rotation Opposite (engine) Torque (Nm) 50 100 150 200 X X X 250 X X X 300 X X X 350 X 400 X 430 450 X 470 500 X X 560 600 X X 700 X X 730 X 800 X X 870 900 X 1000 X > 1000 X 2000 Operating time < 1h X X > 1h and < 4h X X X > 4h Coupling type Type B (flange) X X X Type C (hollow splined shaft) X X Flange dimension DIN90 X X DIN100 X X DIN120 X

PTO choice for PREMIUM-KERAX-MAGNUM PAM

PTO 84 (<1h)

PTO 81 65L

PTO GP Extra PTO 84

PTO GP + Extra PTO

or NMV + 81/84


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Appendix 3 TANKER BULK POWDER

PTO Type Hydraulic motor

Dairy Vacuum

pump U/J Hydraulic

pump Compress. Tilt tanker

PTO independent of clutch PTO on G/B X X X X Extra PTO X Direction of rotation Clockwise (engine) X X X X X Direction of rotation Opposite (engine) X X Torque (Nm) 50 100 X 150 X 200 X X 250 X X 300 X X 350 X 400 X 430 X 450 X 470 X 500 X 560 600 700 730 800 870 900 1000 > 1000 2000 Operating time < 1h X > 1h and < 4h X X X X > 4h X Coupling type Type B (flange) X X X Type C (hollow splined shaft) X X X X Flange dimension DIN90 X DIN100 X DIN120 X X


PTO 81 65L

PTO GP PAM PTO 81

PTO GP PTO 85 N221/10

PTO 85 N221/10

Extra PTO 84


PTO 2264 PTO 2266 PAM PTO 2264

PTO 2266

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Appendix 4 CRANE

PTO Type Handling < 12 t.m

Handling > 12 t.m Logger Scrap metal

PTO independent of clutch PTO on G/B X X X X Extra PTO X X Direction of rotation Clockwise (engine) X X X X Direction of rotation Opposite (engine) X X X X Torque (Nm) 50 100 150 200 250 X 300 X 350 X 400 X X 430 X X 450 X X 470 X 500 X X X 560 X X X 600 X X X 700 X X X 730 X X 800 X X 870 900 1000 > 1000 2000 Operating time < 1h X X > 1h and < 4h X X > 4h X X X X Coupling type Type B (flange) X X Type C (hollow splined shaft) X X X X Flange dimension DIN90 X X DIN100 DIN120


PAM 84/81 PTO GP

PTO 81 PTO GP

PTO GP + Extra PTO

PTO GP + Extra PTO


PTO 2264 PTO 2266

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Appendix 5 SEWER CLEANER REFUSE COLLECTOR

PTO Type Water pump Vacuum

pump Hydraulic

pump Automatic

G/B Manual

G/B PTO independent of clutch X X X PTO on G/B X X X X Extra PTO Direction of rotation Clockwise (engine) X X Direction of rotation Opposite (engine) Torque (Nm) 50 X X 100 X 150 X 200 250 300 350 400 X X 430 X X 450 X X 470 X X 500 X X 560 X X 600 X X X 700 X 730 X 800 X 870 X 900 X 1000 X > 1000 X 2000 X Operating time < 1h > 1h and < 4h X X X > 4h X X Coupling type Type B (flange) X X Type C (hollow splined shaft) X X Flange dimension DIN90 X X DIN100 X DIN120 X


MNV/PAM PTO 81

MNV/PAM PTO 81/GP PTO 81 PTO 17 PAM

PTO choice for MIDLUM-PREMIUM (6l) MNV MNV MNV PTO 17 PAM

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Appendix 6 SNOW PLOUGH

PTO Type Tipper Plough

+ Salter

SPREADER OR

DUAL SPREADER PTO independent of clutch X X PTO on G/B X Extra PTO Direction of rotation Clockwise (engine) X X X Direction of rotation Opposite (engine) Torque (Nm) 50 100 150 200 250 X 300 X 350 X 400 X X 430 X X 450 X X 470 X X 500 X X 560 600 700 730 800 870 900 1000 > 1000 2000 Operating time < 1h X > 1h and < 4h X X > 4h X Coupling type Type B (flange) X Type C (hollow splined shaft) X X X Flange dimension DIN90 X DIN100 DIN120


PTO 84 (<1h) PTO 81 65L PAM PAM


PTO 2264 PTO 2266 PAM PAM

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Appendix 7

FIRE ENGINE PTO Type Light fire

Pumper / tanker (MIDLUM 220 hp)

Fire pumper tanker

(MIDLUM 270 hp) 4 x 4

(MIDLUM 220 hp) PTO independent of clutch PTO on G/B X X X Extra PTO X Direction of rotation Clockwise (engine) X X X Direction of rotation Opposite (engine) Torque (Nm) 50 100 150 200 250 300 X X X 350 X X X 400 X X X 430 450 470 500 560 600 700 730 800 870 900 1000 > 1000 2000 Operating time < 1h > 1h and < 4h > 4h X X X Coupling type Type B (flange) X X X Type C (hollow splined shaft) Flange dimension DIN90 X X X DIN100 DIN120



PTO 2903 PTO 2904

PTO 2907 PTO 2908

PTO 2903/2904 + PTO 2250

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Appendix 8 Torque S5-42 5206 and 4106 A

PTO 81 B/C PTO 84 B/C (<1h) PTO NS42 PTO 2264 PTO 2266

1000N.m 430/500**N.m

300N.m 300N.m 400N.m

ratio 0.87

ratio 0.84

PTO GP (High Power) PTO 2903 B PTO 2904 B PTO 2907 B PTO 2908 B PTO N109/10 PTO N221/10 PTO 85 (2 outputs) PTO AS/10 PTO PTRD-D (2 outputs)

300N.m 245N.m 410N.m 400N.m

flange 530N.m 730/870**N.m

pump 800N.m flange 500N.m

flange 430N.m


PTO on G/B

**: on Kerax

Extra PTO - on N221/10 PTO 81Z2 C PTO 84Z2 C (<1h) - on 2903/04/07/08 PTO 2250 C

600N.m 430N.m

600N.m

- on G/BA Allison MD PTO 17

flange torque 400N.m

ratio 0.93 other ratio and

pump version as adaptation

- on dCi 6 and dCi11 PAM

ratio 1.1 pump 600N.m

flange 1000N.m

PTO independent

of clutch

NMV

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Appendix 8 Torque FSO 4106A

(OD) 6406 6309/8309 A

PTO 81 B/C PTO 84 B/C (<1h) PTO NS42 PTO 2264 PTO 2266

1000N.m 430/500**N.m

300N.m 300N.m 400N.m

ratio 1.245

ratio 0.84

ratio 1.04


300N.m 245N.m 410N.m 400N.m

flange 530N.m 730/870**N.m


flange 430N.m


ratio 1.9 ratio 2.215


PTO

on

G/B **: on Kerax


600N.m 430N.m

600N.m

ratio 0.59







flange 1000N.m

PTO independent

of clutch

NMV

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Appendix 8 Torque Ecomid

9S109 OD Ecomid

16S109 OD PTO 81 B/C PTO 84 B/C (<1h) PTO NS42 PTO 2264 PTO 2266

1000N.m 430/500**N.m

300N.m 300N.m 400N.m

0.77 (800N.m) ratio 0.99

0.79-0.93 (800N.m) ratio 1.02-1.2


300N.m 245N.m 410N.m 400N.m

flange 530N.m 730/870**N.m


flange 430N.m


ratio 1.16

Adaptation PTO on

G/B **: on Kerax


600N.m 430N.m

600N.m

Adaptation with N109/10

Adaptation with N109/10







flange 1000N.m

PTO independent

of clutch

NMV NMV 130

as adaptation NMV 130

as adaptation

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Appendix 8 Torque Ecosplit OD

16S151/181/221/251 Ecosplit DD

16S151/181/221 PTO 81 B/C PTO 84 B/C (<1h) PTO NS42 PTO 2264 PTO 2266

1000N.m 430/500**N.m

300N.m 300N.m 400N.m

ratio 0.92-1.09 0.82-0.98 (500N.m)

ratio 0.77-0.92 ratio 0.99-1.19


300N.m 245N.m 410N.m 400N.m

flange 530N.m 730/870**N.m


flange 430N.m


ratio 1.35-1.62/1.13-1.35**

ratio 1.11-1.32 ratio 1.57-1.87

ratio 1.14-1.35

ratio 0.93-1.11 ratio 1.31-1.57

PTO on

G/B **: on Kerax


600N.m 430N.m

600N.m

ratio 0.92-1.09 ratio 0.82-0.98

ratio 0.77-0.92 ratio 0.99-1.19







flange 1000N.m

PTO independent

of clutch

NMV

NMV 221 flange150 ratio 0.98 2000 N.m

NMV 221 as adaptation

http://1.35-1.62/1.13

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Appendix 8 Torque Astronic

12AS2301 DD Astronic

12AS2301 OD PTO 81 B/C PTO 84 B/C (<1h) PTO NS42 PTO 2264 PTO 2266

1000N.m 430/500**N.m

300N.m 300N.m 400N.m


ratio 1.35 1.21 (500N.m)


300N.m 245N.m 410N.m 400N.m

flange 530N.m 730/870**N.m


flange 430N.m


ratio 1.51

Adaptation

PTO on

G/B **: on Kerax


600N.m 430N.m

600N.m







flange 1000N.m

PTO independent

of clutch

NMV

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Appendix 8 Torque Astronic

16AS2601 DD Astronic

16AS2601 OD PTO 81 B/C PTO 84 B/C (<1h) PTO NS42 PTO 2264 PTO 2266

1000N.m 430/500**N.m

300N.m 300N.m 400N.m


ratio 1.11 ratio 1 (500N.m)


300N.m 245N.m 410N.m 400N.m

flange 530N.m 730/870**N.m


flange 430N.m


Adaptation

Adaptation

PTO

on

G/B **: on Kerax


600N.m 430N.m

600N.m







flange 1000N.m

PTO independent

of clutch

NMV

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