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BULLETIN

RENAULT TRUCKS IRAN Technical Assistance Group 01211

Premium DXi 11 Kerax DXi 11

Date 08-2009

Number 1-3

Document reserved exclusively to the ARYA network. It must not be communicated to third parties without written authorization from RENAULT TRUCKS IRAN.

REMINDER OF ESSENTIAL

MAINTENANCE INSTRUCTIONS

The technical changes made over the past years increase in power, more restrictive emissions, drop of diesel consumption aiming to make engines quieter and cleaner, but raising their working temperature, etc…render these engines less tolerant as regards divergences in maintenance. Consequently maintenance operations must form the subject of total strictness. This bulletin shows all maintenance details, these details cannot be subject to compromise or negotiation, they are connected with the technical definition of engines. The performance levels of the lubricants required and the lubrication intervals for the correct operation of the vehicles must be strictly followed. Make sure that the maintenance level carried out is properly observed: Service is to be carried out every 10 000 Km or 200 hours. For more details: See Driver's handbook manual. See Repair Manuals. See Parts catalogue. The manufacturer cannot be held responsible for damage caused by driving errors, or failure to comply with the recommendations made in this handbook, particularly regarding the use of lubricants or filters that are not in conformity with the performance specifications given.

1 – SERVICE SCHEDULE: ARYA DIESEL - PREMIUM & KERAX DXi - FIXED SERVICE SCHEDULE

M0: FIRST MAINTENANCE AT 10,000Km or 200 hours M1: EVERY 10,000 Km (AS FROM SECOND ENGINE OIL CHANGE) M2 EVERY 20,000 Km or 400 hours MP: SPECIAL MAINTENANCE A: EVERY 40,000 Km OR 800 hours B: EVERY 80,000 Km OR 1,600 hours C: EVERY YEAR OR 100,000 Km OR 2,000 hours D: EVERY 2 YEARS OR 200,000 Km OR 4,000 hours

ENGINE OIL: MAXIMA 15W40 RLD2 - ACEA E7 MANUAL,OPTIDRIVE GEARBOX OIL: PREXIMA 40 - API CF4/SF Premium DXi : DRIVE AXLE P13170: HD 85W140 - GL5

Kerax DXi : D. AXLE P1395/2695/3395 LONGEVIA P80W90 - GL5 HT COOLING LIQUID: ULTRACOOLING PLUS - "D" Organic STEERING/CAB TILT FLUID: STARMATIC III - ATF DEXRON III CLUTCH FLUID: FLUID FE4 - SAE J 1703 F / DOT4

GREASE: NLGI 2 lithium soap grease lead-free calcium EP add.

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ARYA DIESEL - PREMIUM & KERAX DXi - FIXED SERVICE SCHEDULE

Km Hours M0 M1 M2 MP/A MP/B MP/C MP/D 10000 200 X 20000 400 X X 30000 600 X 40000 800 X X X 50000 1000 X 60000 1200 X X 70000 1400 X 80000 1600 X X X X 90000 1800 X

100000 2000 X X X° 110000 2200 X 120000 2400 X X X 130000 2600 X 140000 2800 X X 150000 3000 X 160000 3200 X X X X 170000 3400 X 180000 3600 X X 190000 3800 X 200000 4000 X X X X° X°° 210000 4200 X 220000 4400 X X 230000 4600 X 240000 4800 X X X X 250000 5000 X 260000 5200 X X 270000 5400 X 280000 5600 X X X 290000 5800 X 300000 6000 X X X° 310000 6200 X 320000 6400 X X X X 330000 6600 X 340000 6800 X X 350000 7000 X 360000 7200 X X X 370000 7400 X 380000 7600 X X 390000 7800 X 400000 8000 X X X X X° X°°

X° :MAXIMUM 1 YEAR X°° : MAXIMUM 2 YEARS

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ARYA DIESEL - PREMIUM & KERAX DXi - FIXED SERVICE SCHEDULE

page

SERVICE M

0

M1

M2

MP/

A

MP/

B

MP/

C

MP/

D

1 5 Engine Drain & Refill X X 2 5 Oil filters Replace 2 engine oil filter cartridge

Replace turbo oil filter cartridge X

3 6 Air filtration Check operation of clogging indicator Clean air filter inlet grille if necessary

X

4 6 Outer air filter Replace X 5 6 Inner air filter Replace X 6 8 pressure-vacuum cap Replace X 7 8 Cooling system Drain & Refill X 8 Cooling system Check Degree of protection X 9 Heater Check Operation

Check for leak X

10 Radiators Check External cleanliness of cores X 11 9 Radiators Clean radiators

Clean intercooler Clean air conditioning condenser Clean mosquito net

X

12 9 fuel filters Replace fuel filter element X 13 10 fuel pre-filters Replace pre-filter element X 14 11 Fuel tank Drain, clean & Refill without water X 15 Fuel tank Check Atmospheric venting X 16 11 Rocker arm Adjust valve clearances X 17 11 Hydraulic clutch system Drain & Refill X 18 11 Clutch wear indicator Check X 19 12 Gearbox(Manaul

,Optidrive) / PTO Drain & Refill. Clean the breather

X

20 14 Rear drive axle Drain & Refill Clean the breather

X

21 15 Suspension Check condition of suspension springs Check condition of pads Check condition of anti-roll bar

X

22 15 power steering filter Replace X 23 Steering Check attachment of pipes

Check ball joints X

24 Steering Check Operation Check Condition of steering components (hub and king pin play )

X

25 16 Air circuit systems Check for leak Drain water from air tanks

X X

26 16 APM cartridge Replace X 27 16 brakes Check visually brake pads/linings wear and

discs Check brake wear sensors Check brake lines and flexible pipes Check braking reaction. Directional stability

X

28 17 Fan coil heater filter Clean replace if necessary

X X

29 17 Air conditioning Renew chilling fluid Replace dehydrator filter

X

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30 17 Wipers Check condition and operation of wipers Refill washer reservoir

X X

31 18 Tyres Check inflation pressures Check State of tyres

X X

32 18 Wheels Check Wheel nut tightness Check attachment of spare wheel

X

33 19 fifth wheel Check Operation of locking Check attachment of fifth wheel Check Clearance between fifth wheel coupling and semi-trailer

X

34 20 Grease King pins Fifth wheel Door hinges Door locks Cab lock etc…

X X

35 Drive belts Check Condition and tension of drive belts X 36 Drive belts Replace X 37 Propeller shaft Check play

Check Secure tightening of bolts X

38 air suspension Check operation of air suspension X 39 shock absorbers Check attachment and condition X 40 Cab Check Security of Cab mountings

Check stability and air suspension Check Operation of cab locking mechanism

X

41 Electricity Check attachment of batteries Operation of master switch

X

42 Signalization Check Operation of warning lights Check pressure gauges Check Lighting Check Turning lights Check stop lights Check reverse lights Check horn

X X

43 Lubricants Check All levels Check Units for leaks (oil, coolant, fuel, steering, cab tilting and clutch fluid)

X X

44 Belt tensioner Replace alternator belt tensioner roller. Replace fan belt tensioner roller.

X

45 Mountings Check condition and tightening of engine, gearbox and radiator mountings

X

46 soundproofing Check Presence and positioning of soundproofing screens and heat shields

X

47 Harnesses and pipes Check Condition of wiring harnesses, supports, pipes

X

48 Preventive maintenance Deactivate preventive maintenance

X

49 Power cable Make Sure Power cable has been removed

X

50 Towing hook Check towing hook is operating properly X

Prior to carry out any work on the vehicle, pay particular attention that inflammable products like oil and grease when spread on some parts such as soundproofing screens could be fire hazard.

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2 – DETAILS OF SERVICE SCHEDULE: For more details, see Vehicle's Handbook and Repair Manuals.

2.1 – ENGINE: 2.1.1 – LUBRICATION:

Use only 'RENAULT TRUCKS OILS MAXIMA RLD2 E7' and Drain every 10 000 KM. Oil grade 15W40, quality ACEA E7. Quantity: 30.5 litres without filter change. 35 litres with filter change 36 litres if the engine is dry.

The use of additives in the oil is strictly forbidden. They do not provide any complementary performance. Additives risk altering the composition of the lubricant and consequently impairing engine reliability. Change turbo oil filter and engine oil filters every 20 000km or 400hours. Use only genuine filters where the filtration level has been designed to guarantee maximum reliability for the service life of units to be lubricated. Remove all soundproofing screens before to drain, oil soiled soundproofing are fire hazard. Consequence of a poor oil use or non respect of service intervals: oil would not stand high temperature, would become thicker, destruction of the turbocharger, destruction of bearings, damage to the crankshaft and camshaft and other parts, block oil galleries, engine seizure, etc…

OIL LEVEL: Filler plug (5). Check the oil level with dipstick (4). Run the engine for few minutes. Check for leaks. Check again the oil level with dipstick (4).

CHANGING FILTERS(n°2): It is essential to fill the oil filters (2&3) prior to refitting. Oil the seals. Turbo oil filter (2): ref: 7420541379 engine oil filters (3): ref: 7420709459 x2 Tighten the cartridge by hand until contact is made with the filter head. Tighten to 25±5Nm using tool 5000262684 or 5000262655.

DRAINING (n°1): Drain plug (1). Replace the seal ref 7420579690*. Tightening torque 60Nm* *Plastic or metal sump.

25Nm 60Nm

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2.1.2 – AIR FILTRATION: Outer cartridge (8) (n°4): Premium DXi: Ref: 5001865723

Kerax DXi: 5001865725

Outer cartridge is cleanable, it must be cleaned regularly depending on the use. To clean outer cartridge use air pressure from the inside of the filter to the outside, make sure the

air pressure is below 2 bars. A pressure too high damages the paper of the filter and hence makes it useless and hazardous for the engine. Inner cartridge (7) (n°5): Premium DXi: Ref: 5010317187

Kerax DXi: 5010269584

Inner cartridge is not cleanable and is not supposed to be dirty A dirty inner cartridge is the sign of a worn out outer cartridge, then replace it. Replace inner cartridge every 2 outer cartridge changes.

Use only genuine filters where the filtration level has been designed to guarantee maximum reliability for the service life of units to be protected. When the clogging indicator (1) comes ON, it means that the air filter cartridges is

clogged, then replace the cartridges. (1) It is recommended not to wait for the clogging indicator to come ON and to replace the outer air

filter(8) every 40000 km and the inner air filter(7) every 80000km. CHECKING OPERATION OF THE CLOGGING SENSOR (n°3): At the schedule intervals check operation of the clogging indicator (1): By blanking off the filter Running the engine at 1500rpm.

The consequences of blocked air filter will be: over-fuelling and overheating of the engine, lack of air in combustion chambers and excess of diesel, normally leads to black smoke, quick destruction of the injectors, exhaust manifold etc…). Engine could seriously be damaged with blocked air filters then always keep air filters clean. REMOVING AIR FILTER CARTRIDGES (n°4&5): Undo clips (2), Withdraw cover (3) Remove both cartridges in same time.

FITTING AIR FILTER CARTRIDGES (7&8): Prior to installing the cartridges, clean and carefully inspect: the bowl (4) the sealing zone (5&9) these zones should not be damaged.

The new cartridges (7&8) should be free from signs of knocks and distortion.

Do not clean with flammable product such as diesel or petrol. Risk of over-revving of the engine.

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Insert inner cartridge (7) inside outer cartridge (8) as shown on picture (6).

(6) Ensure correct positioning of the cartridges (7&8). Exert firm pressure on the inner cartridge end (11). Exert firm pressure on the outer cartridge end (10). Do not apply any pressure in the middle of the outer cartridge;

the cartridge rubber could be damage and causes serious damages to the engine.

Before closing the cover (3), check it is clean. Position the cover according to pointer (13).

2.1.3 – COOLING SYSTEM: Use only 'ULTRACOOLING PLUS' ready mixed coolant (protection down to -25°C) or 'MAXIGEL' concentrated coolant and Drain every 2 YEARS or 200 000 KM. Organic additives 'D type' coolant is only to be used. Quantity = 33,5 litres If you use concentrate product, mix it only with still water, 40% Maxi-gel and 60% still water. Never mix it with mineral 'C type' coolant even if it is written mixable with all coolant on the container. Mineral additives coolant contains nitrite, phosphate and amine to protect against cavitations and corrosion. Organic coolants have a very high capability to clean the cooling system, if you mix or even put organic coolant after mineral coolant there is a risk for the new coolant to wash out the phosphate from the previous coolant and this would block the radiator). The use of any additives (including anti-freeze) to the coolant is strictly forbidden. They do not provide any complementary performance. Additives risk altering the composition of the coolant and consequently impair engine reliability. Role of coolant: Stabilize engine temperature Protect engine from corrosion Avoid cavitations. Avoid fur deposit.

The consequences of Lack of coolant, pressure vacuum cap not working, blocked cooling system, dirty radiator, dirty intercooler or fan not working will be: overheating of the engine; engine could seriously be damaged.

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2.1.3.1 – PRESSURE-VACUUM CAP ( N°6) Pressure-vacuum cap (1) (ref: 5010213367 <05F6 /

7420783957 <05F6), according to Service Schedule, change it or check the pressure (0.7 bar).

Filler cap (2). Always keep coolant to level (3), bottom of filler cap. Do not leave caps open. Never remove cap (2) when the engine is hot, you may

seriously burn yourself. If it is needed to open the cap, first of all, carefully release the pressure vacuum cap (1) by ¼ of a turn to decompress the system.

2.1.3.2 – DRAINING THE ENGINE COOLING SYSTEM ( N°7): set temperature control to 'maximum heat' (4). master switch ON.

Remove filler cap (2). Remove radiator drain plug (5).

Loosen the engine block drain plug (6) or use tool 7409996049.

2.1.3.3 – FILLING THE COOLING SYSTEM: Retighten draining plugs (5&6): Radiator drain plug (5): 2Nm. Engine block drain plug (6): 40Nm.

Pour the coolant slowly through the filler (2) so as to enable all the air to escape from the system. Top up with coolant until flush with the filler (2). Refit the filler cap (2). Run the engine for 3 minutes at a speed of 1200 rpm, then stop it. Carefully open pressure vacuum cap (1). Check the coolant level and top up if necessary. Refit the filler cap (2). Run the engine until it reaches its operating temperature (thermostat open), then stop it. Let the engine to cool down, check the coolant level again and top up, if necessary. 2.1.3.4 – Cleaning The Exterior of The Radiator/intercooler/ mosquito net ( n°11):

2Nm

40Nm

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The quality of the engine environment and more especially the cleanliness of the radiators and intercoolers are DECISIVE factors in engine reliability. RADIATOR AND INTERCOOLER: Clean the radiator / intercooler by blowing compressed air or a high pressure hot water through

the radiator core from the engine side. Never use greasy products such as paraffin, diesel fuel, …

RADIATOR MOSQUITO NET: Disassembly: Remove clip (1). Disengage mosquito net (2). Unhook springs (3). Remove the mosquito net (2).

Cleaning: Clean the mosquito net by blowing through with low

pressure compressed air or hot water. Do not use high pressure jets, they would damage the

mosquito net. Assembly: Hook springs (3). Fit clip (1).

2.1.4 – FUEL SYSTEM: Prior to disassembly, carefully clean the surrounding area then take all necessary precautions to

prevent the ingress of foreign matter.

Fuel on hot engine may cause fire, it is recommended to change fuel cartridges when the engine is cold

2.1.4.1 –DIESEL: Only PROPER DIESEL is to be used, do not mix it with alcohol. The vehicle is equipped with a fuel pre-heater, the incorporation of additives or alcohol is strictly forbidden, they are Fire a hazard. 2.1.4.2 – DIESEL FILTERS ( N°12 & 13): Every 2 engine oil changes: Change diesel filter Ref: 7420541381 (1). Change fuel pre-filter element Ref: 7420754418 (2).

Your vehicle is equipped with a high-performance fuel-injection system: Pressure up to 2000 bars. This injection system is very sensitive to pollution due to the very high pressure it operates,

therefore to avoid risks of damage to expensive parts: It is essential to use only genuine filters where the filtration level has been designed to guarantee

maximum reliability for the service life of units to be protected. REPLACING THE MAIN DIESEL FILTER CARTRIDGE: Unscrew the filter cartridges (1). Clean the filter housing joint face. Upon assembly, watch out for cleanliness of the gasket, smear it with diesel fuel and tighten the element by hand.

Do not fill new cartridge filters with diesel. When the work is finished, refit the sound-proofing screens correctly in place.

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DRAINING THE DIESEL PRE-FILTER: Push and unscrew the feed pump plunger (9). Unscrew the draining screw (3). When water and dust has been drained from the bowl (4), tight up bleeding screw (2) and the draining screw (3). REPLACING THE DIESEL PRE-FILTER CARTRIDGE: Unscrew the bowl (4). Unscrew the cartridge (7) from the pre-filter.

Clean the assembly exclusively with diesel fuel and compressed air. Check that the draining hole (3) is not obstructed. Lubricate seals with diesel fuel. Screw up the cartridge (7) by hand and tighten through ½ to 2/3 of a turn. Screw up the sediment bowl (4) by hand and tighten through 1/3 of a turn. Screw up the feed pump plunger (9).

Do not fill new cartridge filters with diesel. BLEEDING THE FUEL SYSTEM: Unscrew the bleeding screw (2). Push and unscrew the feed pump plunger (9). Operate the feed pump plunger (9) until diesel fuel flows out of (2) without air. Screw the bleeding screw (2). Screw up the feed pump plunger (9). Run the engine for 1 min at idle speed.

Water in the injection system leads to immediate destruction of injector-pumps.

2.1.5.3 – DIESEL TANK ( N°14) Fuel tank: At the scheduled intervals, it is recommended that any impurities that may have been deposited in the tank are cleaned out. This is achieved by removing the drain plug in the bottom of the tank, allowing the contaminated fuel to drain off.

2.1.5 – ROCKER ARMS ( N°16): Rocker arm must be adjusted regularly, over time valves open less and less, when a valve does not open enough it may brakes. Valves are to be adjusted when engine is cold. Inlet = 0.20 mm, torque 38±4Nm. Exhaust without Optibrake = 0.50 mm, torque 38±4Nm. Exhaust with Optibrake = 1.60 mm, torque 38±4Nm.

38Nm

4.5Nm

2.8Nm

1/2 to 2/3

1/3

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ADJUSTMENT OF EXHAUST ROCKER ARMS WITH OPTIBRAKE: Press rocker arm (1). Compress valve spring (2) to free the oil in the rocker arm Use a piece of rigid iron wire to make a hook (A).

With dial gauge 9661, measure the clearance Y while moving the rocker arm up and down, note down the value. If clearance Y is < or > than 1.6 mm, remove bolt (3) and adjusting shim (4). Note down the thickness X engraved on adjusting shim (4). Calculate the new thickness for adjusting shim (4): Y mm - 1.6 mm = Z mm, X mm + Z mm = X' mm You can superimpose a maximum of 2 adjusting shims, provided that they have the same

thickness. Shims are available from 2.00 mm to 3.95mm, with thickness of 0.05 mm by 0.05 mm.

Install a new adjusting shim (4) with a thickness of X' mm. Tighten bolt (3) to torque 38±4Nm, Do not over tight the adjusting nut; screw may brake after few kilometres.

CYLINDER HEAD COVER: Cylinder head cover: 24±4Nm. The item numbers indicate the tightening sequence.

2.2 – CLUTCH: Use only Fluid DOT4 ( n°17): The fluid level should always be between the ‘MINI’ and the ‘MAXI’ marks. Level too low: the clutch would not work properly. Level too high: overflow of the excessive corrosive fluid

would make severe damages to the vehicle. Quantity = 0.5 litre.

LINING WEAR INDICATOR (1) ( n°18): Engine stopped and pedal up, check the driven plate wear:

A: new plate. B: worn plate.

When the value "X" is equal to 25±1 mm, the clutch plate is to be replaced. Note: this is correct only if the indicator has never been moved

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2.3 – GEARBOX ( n°19): Use only 'RENAULT TRUCKS OILS PREXIMA 40' and Drain every YEAR or100 000 KM Oil quality: API CF4/SF Quantity / 10 liters, 13 liters if the gearbox is dry +1 liter if PTO.

DRAINING OF THE GEARBOX: Remove plugs (1), (2) & (3).

DRAINING

FILLING OF THE GEARBOX: Refit plugs (1), (2) & (3) and torque to 60Nm. Fill with oil through port (4). As soon as the oil overflows, screw up the plug but do not tighten. With the vehicle at a standstill, run the engine for 5 min. Stop the engine and let it rest for 5 min. Remove the plug (4) and top up the oil level. Refit the plug.(4) and tight to the torque to 60Nm.

FILLING

CLEANING THE BREATHER: Wash the breather in diesel fuel and dry it with compressed air OPTIDRIVE+ Oil quality: API CF4/SF Quantity / 14.5 liters, 16 liters if the gearbox is dry +1 liter if PTO.

DRAINING OF THE GEARBOX: Remove plugs (1) Refit plug (1), plug tightening torque (1):35±5 Nm.

FILLING OF THE GEARBOX: Remove plug (2). Fill with oil through port. Check oil level through sight (3).

The oil level should be between marks(4) and (5) Screw up the plug but do not tighten. With the vehicle at a standstill, run the engine For 5 minutes. Stop the engine and let it rest for 5 minutes. Check the oil level through sight (3) And top up, if necessary. Plug tightening torque (2): 35±5 Nm.

60Nm

60Nm

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Replacement of filter:

Remove cap (1). Unscrew the filter element bracket (2) using a

36 mm wrench. At the time of each gearbox oil change replace gearbox oil filter:7420779040

Remove the filter element bracket (2). Unscrew the filter element (3) from the

Bracket (2).

Replace the gasket (4).

Fit a new filter element (3) to the bracket (2).

Fit and screw up the filter element bracket (2). Tighten to a torque of 50±5Nm. Refit plug (1). Tighten to a torque of 25±5Nm. When the work is finished, refit the soundproofing Screw correctly in place.

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2.4 – FRONT AXLE:

2.5 – REAR DRIVE AXLE ( n°20): Premium DXi only: Use only 'RENAULT TRUCKS OILS, HD 85W140 GL5 and Drain every YEAR or100 000km or 2000 hours. Oil quality GL5. Quantity: pan = 17 Lit. First draining is carried out at 100 000 km or 2000 hours. Kerax DXi only: Use only 'RENAULT TRUCKS OILS, LONGEVIA P80W90 GL5 HT and Drain every YEAR or100 000km or 2000 hours. Oil quality GL5. Quantity: middle pan = 20 Litres, rear pan = 17.5 litres, hub reduction 4 x 0.5liters. First draining is carried out at 100 000 km or 2000 hours. Kerax DXi only: DRAINING OF WHEEL REDUCTION UNITS: Remove plugs (4) placed in the downwards position. FILLING OF WHEEL REDUCTION UNITS: Plug port placed in the upwards position. Poor 1 litre of oil into each hub reduction unit. Refit plug (4) and torque to 30Nm. CHECKING LEVEL OF WHEEL REDUCTION UNITS: With the arrow pointing downwards, the oil should be flush.

DRAINING OF THE AXLE: Remove plugs (3). FILLING OF THE AXLE: Refit plugs (3) and torque to 80Nm. Fill with oil through port (2). CLEANING THE BREATHER: Remove the breather (1) and blow through with compressed air. Rear U-bolt tightening torques: Premium DXi: 860 Nm. Kerax DXi: 660 Nm.

When adjusting wheel alignment you must systematically replace the track rod clamp. To avoid any risk of damage to the steering system, it is essential that the stub axle lock stops are adjusted after any changes to the stub axle assembly. Front U-bolt tightening torques = 440 Nm

80Nm Premium Kerax

30Nm

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2.6 – SUSPENSION ( n°21):

Premium DXi only: ANTI-ROLL BAR PLAY: Check the play between the bushes and the anti-roll bars. The play 'J' should not exceed 2mm. If worn out replace them: ref 5010130022

2.7 – STEERING: Use only 'STARMATIC III' or 'ATF DEXRON III' Fluid quantity = 4 Litres No fluid change is schedule for steering; however change the fluid if it gets dirty or if any work takes place within the steering system. A hydraulic circuit can only operate if it is perfectly dean. The utmost care must therefore be taken to ensure that no dirt enters the system. REPLACING THE FILTER ELEMENT ( n°22): Remove filler cap (1). Press handle (2) and turn by 1/4 of a turn. Withdraw the filter element assembly. Fit a new filter element Ref: 5000820895. Press and turn handle (2). Make sure the handle is engaged under the catches. Check the oil level (3). FILLING THE SYSTEM AND BLEEDING: Raise the front wheels of the vehicle. Fill the reservoir with fluid via filler (1). When the reservoir level stabilizes, operate the starter a few times to turn the pump. Top Up accordingly. When the level is stabilized once again, run the engine at idling speed. Turn the steering wheel fairly quickly from one lock to the other several times so as to bleed air from the system. Watch the fluid 1evel during this operation, top up if necessary. Repeat this until the fluid level remains constant. Stop the engine and top up the level. Lower the wheels onto the ground. Continue the steering wheel until no fluid flow noise is heard and until the fluid in the reservoir has become clear and is no longer emulsified.

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2.8 – AIR SYSTEM (n°25): Front brake air system pipes are marked with Orange Rings Rear brake air system pipes are marked with Blue Rings. Parking brake air system pipes are marked with Green Rings Auxiliary air system pipes are marked with Brown Rings. It is forbidden to modify the brake circuit. Any extra air supply should be taken from air auxiliary equipment circuit. Air leaks must be fixed immediately Lives of the air compressor and of the APM are severely reduced with accumulation of air leaks. DRAINING OF AIR TANK: Check air tanks regularly for presence of water by actuating the plunger (1). If any water change the APM cartridge even if the schedule

is not reach. Saturation of the APM cartridge will lead the chemical from the cartridge to go all over the air system and block all the air valve.

CHANGING THE APM CARTDRIDGE ( n°26): Clean the APM and its surrounds. Fully drain all air the tanks. Remove the cartridge (1). Tighten the new cartridge (1) Ref: 5001865404 by hand.

Pay attention: Cartridge with left-hand thread Start the engine and run it to check that the APM cuts out the pressure at 12.5bars.

When changing the APM cartridge, check for presence of oil. Oil in small quantity is fine. Oil in big quantity is often the sign of tired compressor rings. Presence of carbon is often the sign of overheating or over fuelling of the engine.

2.9 – BRAKE DISCS & PADS: CHECKING FOR WEAR (n°27): Premium DXi: See repair manual 51634. At each Service or if warning light comes on, check brake pad wear. Brake pads: To check wear, the wheels have to be removed. If the pad is < 11mm, then replace the 4 pads on the axle.

Disks: If the thickness of a disk is < 41 mm then replace both discs on the axle. If a disk on one axle is cracked then replace both discs on the axle. NOTE: Replacement of a brake pad requires replacement of all the pads on the same axle. Replacement of brake disk requires replacement of all the disks on the same axle.

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Kerax DXi: See repair manual 51639. At the scheduled intervals check the degree of wear of the brake linings. Move blanking caps (1) aside to gain access to the inspection holes.

2.10 – FAN COIL HEATER FILTER (N°28):

FILTER REMOVAL: Withdraw the screws (1), tilt the grille and remove the filter (2). CLEANING WITH COMPRESSED AIR: At the scheduled intervals, clean the filter (2). Apply a maximum pressure of 7 bars. Direct the jet of air in the direction opposite to that of filtration. Keep the nozzle a minimum of 5 cm away from the filter. CLEANING WITH WATER: Immerse the filter in a mixture of detergent and water for approximately 15 minutes. Rinse the filter until the rinsing water remains clear. Leave to dry in the open air or use compressed air. If the filter presents irregularities, replace it. FITTING: Position the filter (2). Make sure the front grille is properly in position and tighten the screws (1). Ref: 5001867491

2.11 – AIR CONDITIONING ( n°29): REPLACING THE DEHYDRATOR FILTER AND FLUID:

See repair manual 63616. Every 200 000 km or 4 000 hours or 2 years, get the chilling fluid and the dehydrator filter replaced. Ref: 5010563591

2.12 – WINDSCREEN WASHER RESERVOIR ( n°30):

Quantity = 9 litres. Top-up when servicing the vehicle

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2.13 – TYRE AND SPARE WHEEL INFLATION PRESSURES (N°31): Tyre pressure must be checked regularly. Tyre pressure must always be checked when tyres are cold. Never deflate hot tyres, risk of explosion.

315/80 R22.5 load bar

Front (kg) Single Wheel

Rear (kg) Dual Wheel

6 270 11 090 6.5 6 700 11 860 7.0 7 100 12 640 7.5

13 000 7.7

1200 R 24 load bar

Front (kg) Single Wheel

Rear (kg) Dual Wheel

6 200 11 300 5.5 7 300 13 300 6.75 8 000 14 600 7.5

2.14 – WHEEL NUT TIGHTNESS (N°32): Before tightening check cleanliness of the rims and hubs. Lightly lubricate the studs and nuts with engine oil. Respect tightening sequence (1) whether you tight or check tightening. Tightness of the wheels: When fitting a wheel:

-Steel wheel: 200Nm + 90degrees. -Trilex wheel: 360Nm.

When checking tightness: at least 670Nm (steel wheel). Re-tighten after 20 to 30km, and again after 150 to 250km, and every 6 months When checking, if one wheel nut is <670Nm (steel wheel): Loosen all the wheels nuts. Retighten to torque.

Failure to carry out these elementary precautions may result in loosening of the wheel nuts and lead to serious consequences.

Over tightening may cause damage. Never paint rim or hub contact areas

1

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2.15 – FIFTH WHEEL (N°33): WEAR TEST: Fifth wheel couplings and king pins are subject to more or less wear depending on the conditions in which they are used. Excessive play causes shocks and may lead to instability on the road and damage to the fifth wheel coupling, mounting plate and vehicle chassis. When the wear limit on the king pins has been reached, it must be replaced. Do not try to adjust the locking mechanism if the king pin is worn out. After replacing the king pin, the locking mechanism must be adjusted again.

ADJUSTING THE LOCKING MECHANISM: The locking mechanism must be adjusted using: A semi-trailer without forced steering. With an new king pin as described below.

Park the vehicle on flat firm ground. Uncouple the trailer. Unscrew the lock nut (2) Unscrew the adjusting screw (3) by approx. 15 turns.

Connect the trailer. Swing the handle (5) towards the front of the vehicle and get an assistant to hold it. Tighten the adjusting screw (3) again until the handle (5) starts to move (have your assistant check this). To adjust the recommended basic play of 0.3 mm, tighten the adjusting screw (3) by a further 1½ turns and secure it with the lock nut (2). If the play is still excessive, replace the wearing ring and the lock jaw as described in the repair manual. LOCKING MECHANISM WEAR LIMIT: The lock wear limit is reached when there is no longer any gap between the lever (7) and the coupling plate. No further adjustment of the lock jaw is possible after this. In this case, replace the wearing ring and the lock jaw.

The lock wear limit is reached when there is no longer any gap between the lever (8) and the coupling plate. No further adjustment of the lock jaw is possible after this. In this case, replace the wearing ring and the lock jaw.

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2.16– GREASING ( N°34): Use NLGI2 lithium soap grease with lead-free calcium EP additive. To be done at each Service.

with grease nipple

without grease nipple

Premium DXi Kerax DXi

3x left 3x right

1x left 1x right

1x left 1x right

GREASING OF THE FIFTH WHEEL To ensure a long service life of the fifth wheel, especially before using for the first time and after cleaning, make sure that: the top of the fifth wheel coupling plate the lock jaw the king pin

are properly lubricated At short intervals, at the latest every 5 000 km: Disconnect the semi-trailer. Clean the fifth wheel coupling. Clean the skid plate. Grease the fifth wheel coupling plate, locking parts and king pins.

Every 10,000 km: Grease the locking mechanism with a trailer attached using the grease nipple on the edge of the

coupling plate. The pivot bearings on the fifth wheel coupling require no servicing. To prevent corrosion on the skid plate, we recommend that the skid plate base is greased lightly.