1990-2012 Renault Trucks (Kerax/Magnum/Mascott/Midlum/Premium) OEM Service & Repair Manual

Supplement DT 354 MODIFICATION NOTE EVOLUTIONS ON THE KERAX RANGE Some modifications have been carried out on the vehicles. According to configuration, the application dates are as follows : ˜ 4x2 / 4x4 14/06/99 ˜ 6x4 / 6x6 06/09/99 ˜ 8x4 29/11/99 The "Guide to Body Mounting" is being re-written, so meanwhile you will find the main changes in the following pages. .../...

ELECTRICITY ˜ Deletion of the separate isolator switch box - relocation of the isolator switch to the battery box. Prepared insulated wires for « auxiliaries » in the battery box. ˜ Deletion of the junction box on the rearmost cross member. Prepared insulated wires for « auxiliaries ». ˜ Harness for side marker lights available, coiled up in the right side member. CAB ˜ Fixings for a tipper control becomes possible by 2 M8 nutserts (behind trim) - on the step behind the left door - on the back wall AIR CIRCUIT ˜ Relocation of « auxiliary » air tappings behind the left side lateral tanks on the 4x2, 4x4, 6x4, 6x6. REAR CROSS MEMBER ˜ Possibility to move the rear cross member in 55 mm steps using existing holes. ˜ The drilling pattern for towing hook fixings on 40, 44 and 60T cross members permits fitment of an « MG » brand towing hook. ˜ The electrical sockets can be positioned on top of the cross member by turning the brackets. POSITION OF UNDERRUN BAR ˜ The rear protection must not be located more than 316 mm from the rear face of the bodywork.

BODY FIXINGS ON THE EXTREME REAR OF CHASSIS ˜ Recommendations for 4x2 - 4x4 - 5 bolts per side, 14 mm diameter - minimum fixing plate thickness = 8 mm ˜ Recommendations for 6x4 - 6x6 - 8x4 - 2 lines of 4 bolts per side, 14 mm diameter - minimum fixing plate thickness = 12 mm NEW WHEELBASES ˜ 6x4 vehicles 3500 rear overhang 1 605 and 1 850mm 4200 rear overhang 2 560mm 4600 rear overhang 2 560mm End of production of 4 300 wheelbase ˜ 8x4 vehicles 4550 rear overhang 1 605mm 5365 rear overhang 1 515mm 6163 rear overhang 2 202mm (Transformation between tandem axles of 6076) MAXIMUM TRAVEL OF TANDEM BRAKE CHAMBERS ˜ During maximum suspension travel, the brake chambers of the middle axle can rise above the upper level of the side members. This displacement can reach: 33mm maxi on 6x4 and 8x4 75mm maxi on 6x4 Heavy Export with optional GCW 120 T (no registrated)

RECOMMENDATIONS FOR FITTING CLOSE COUPLED HYDRAULIC PUMPS TO TYPE C POWER TAKE OFFS ON ZF GEARBOXES Refer to auxiliary Drawings N° 5430127762-3 CAUTION: Hydraulic pumps each have an upper speed limit which must not be exceeded. On gearboxes such as the ZF 16S..., for any given engine speed, two power take off output speeds are possible according to the position of the gearbox splitter switch. Example: on PTO type N71/2 1000 engine revs --> 1210 or 1440 PTO output revs

Hydraulic pump connection must comply with ISO 7653 Standard Type D. a) Additional specification: (for all PTO versions) Sealing between pump and PTO Sealing between pump and PTO must be effected by means of two sealing rings (D1 + D2) and a vent (E1) between the sealing rings. The vent is to make sure that no transmission oil is sucked out and no hydraulic oil can penetrate into the transmission. The sealing rings must resist temperatures of up to120°C. The sealing ring on the PTO side (D1) must seal off the transmission with the oil released by the vehicle manufacturer / ZF. The sealing ring on the pump side (D2) must seal off the pump with the hydraulic oil. Vent bore function must be guaranteed at all times (not blocked by paint, plug, or dirt). In the event of oil leakage of (E1), a prompt check of the entire system is required. b) Additional specification: (for PTO N ../2c) Radial force of PTO output gear Pump bearing design must be such that the resulting radial force (9700 Nm) can be transmitted by the PTO gear (P1). The specified value corresponds to the max. permitted output torque of 300 Nm (calculated lifetime: 500 h). Positioning of the gear must be effected according to ISO 7653. The torgues on the PTO can be ascertained by means of the following formulas. Example: 15.92 x Q x p Torque T = = [Nm] n x η 15.92 x 50 x 350 Torque T = = 300 Nm 1000 x 0.95 Q = Flow rate (l/min) p = Pressure (bar) n = Speed (min -1 ) η = Efficiency D2 D1 P1 E1

c) Load: Gravity torque “M” With version “c” of the PTOs, static load caused by the pump on the mounting face (gravity moment “M”) may amount to 30 Nm. EXCEPTION Elevated static loads of max. 50 Nm are only permitted for transmissions with PTO N..1 and PTO N..4 flanged directly to the housing. M = Gravity torque G = Pump weight (incl. fittings) s = Distance between the centre of gravity of the pump and the flange mounting face X = Centre of gravity X M perm = s x G [Nm]

1990-2012 Renault Trucks (Kerax/Magnum/Mascott/Midlum/Premium) OEM Service & Repair Manual

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