BODYWORK FITTING GUIDE 1/398 English edition 06/2007 Recommendation "free space to the rear of the cab for positioning the crane feet" © RENAULT TRUCKS – 2007 1/37 14/10/2008 TABLE OF CONTENTS 1. Change in position of SCR "Selective Catalytic Reduction" silencer - 1.1. Introduction 3/37 - 1.2. Reminder (refer to « Vehicle Servicing Handbook ») 4/37 - 1.3. Types of SCR silencer outlets 7/37 - 1.4. Replacement of SCR silencer 10/37 - 1.5. Change in position of SCR silencer 11/37 - 1.6. Modifications to tube before the SCR silencer 13/37 - 1.7. Heat shielding 20/37 - 1.8. Modifications to tube after the SCR silencer 22/37 - 1.9. Table of wiring harnesses 29/37 2. Change in position of air filter - 2.1. Introduction 31/37 - 2.2. Generalities 31/37 - 2.3. Change in position of vertical air filter on wheelarch 33/37 - 2.4. Replacement of water drainage valve 37/37 © RENAULT TRUCKS – 2007 2/37 14/10/2008 1. Change in position of SCR "Selective Catalytic Reduction" silencer 1.1. Introduction Vehicles concerned: - RENAULT PREMIUM (Distribution, Long Distance and Lander) Euro 4 DXi 11 - RENAULT KERAX Euro 4 DXi 11 - RENAULT MAGNUM Euro 4 DXi 13 Renault Trucks vehicles are marketed after the completion of confirmed technical designwork and validation trials, bearing in mind the different laws, regulations, standards… The bodybuilder must comply with: - Different European and/or destination countries' laws and regulations governing the driving and building of vehicles. - Stipulations of the Highway Code and its various amendments and appendices. - Different regulations and standards governing toad traffic in force in the destination countries. Any modification not described in the present document or change in position of parts or elements making up the vehicle must be covered by a technical agreement issued by the Renault Trucks Products Application Department. Note: For any further information, consult the Renault Trucks Product Applications Department. Note: Parts to be used are available from the Renault Trucks Spare Parts Warehouse. WARNING For the crane pre-arrangement and/or vehicles fitted with landing legs in conjunction with air suspension systems, it is recommended to use the suspension inhibition feature (refer to Bodywork Fitting Guide, "Electrics" chapter, "Supplementary features" section) in order to avoid the feedback of faults from the suspension management electronic control box (ECS). Important: In this document, all dimensions are given in millimetres. © RENAULT TRUCKS – 2007 3/37 14/10/2008 1.2. Reminder (refer to « Vehicle Servicing Handbook ») G - “INFORMATION” warning light: indicating that a new message has appeared on the multi-function information display (L) I - "SERVICE" warning light: Make your way to the nearest RENAULT TRUCKS service station N - Pollution control system fault warning pictogram Note: For a description of the warning lights, see the «instrument panel» section below. If the level is correct, warning pictogram (2) is displayed and bargraph (1) shows the AdBlue level. If the level is too low, warning light (AA) comes on. (refer to "Vehicle Servicing Handbook") Note: If there is any AdBlue level sensor fault, bargraph (1) disappears. © RENAULT TRUCKS – 2007 4/37 14/10/2008 If the vehicle is used with the AdBlue reservoir empty: – Warning pictogram (N) flashes. – Warning light (G) comes on. – Warning pictogram (G79) - (1) and a related text (2) appear on the multi-function information display (L). Engine pollution control is no longer assured, so an engine torque reduction phase will be applied the next time the vehicle is stationary. Note: When warning pictogram (N) flashes, it means that the next time the engine is started, the fault will be memorized and cannot be erased for 400 days. It can be consulted at any moment by the police. In the event of detection of insufficient pollution control by the system (NOx level above 7g/kWh): – Warning pictogram (N) flashes. – Warning light (I) comes on. – Warning pictogram (G12) - (1) and a related text (2) appear on multi-function information display (L). Make your way to a RENAULT TRUCKS service station. Note: If engine pollution control is no longer assured, a 40% reduction in engine torque (25% for certain vehicles) will be applied the next time the vehicle is stationary. Make your way to a RENAULT TRUCKS service station. Note: When warning pictogram (N) flashes, it means that the next time the engine is started, the fault will be memorized and cannot be erased for 400 days. It can be consulted at any moment by the police. © RENAULT TRUCKS – 2007 5/37 14/10/2008 In the event of failure of the exhaust gases analysis sensor: – Warning light (I) comes on and warning pictogram (N) is displayed. – Warning pictogram (G12) - (1), a related text (2) and a countdown (3) starting at 50 hours, appear on the multi-function information display (L). Note: The countdown (3) indicates the time remaining before application of engine torque reduction. Make your way to a RENAULT TRUCKS service station. Warning: The use of AdBlue is vital both for correct running of the vehicle and for compliance with the regulations in force. If you do not use AdBlue, it may be considered as an offence. © RENAULT TRUCKS – 2007 6/37 14/10/2008 1.3. Types of SCR silencer outlets WARNING Non-compliance with the recommendations given in this document, or starting the engine with an AdBlue reservoir empty, may lead to the recording of unerasable fault codes. Instructions for achieving other exhaust line directions of orientation are dealt with in this document. There are three possible exhaust outlets for Renault Trucks vehicles: A - in the track B - vertical © RENAULT TRUCKS – 2007 7/37 14/10/2008 WARNING The position of an SCR silencer with exhaust outlet on the left cannot be changed. If your vehicle is equipped with this configuration, it is essential to install an outlet in the track. C – on the left © RENAULT TRUCKS – 2007 8/37 14/10/2008 Vehicles equipped with DXi 11 engine (1) - horizontal outlet (RENAULT PREMIUM, RENAULT KERAX) (2) - vertical outlets: (2a) - oblique outlet with day cab and global cab, except for 8x4 (2b) – straight outlet with sleeper cab, except for 8x4, day cab and global cab for 8x4 Vehicles equipped with DXi 13 engine (1) - horizontal outlet (RENAULT MAGNUM) Silencer weights: - 71 kg for Euro 4 - 77 kg for Euro 5 incentive WARNING The heavy weight of catalytic converters requires the use of lifting tackle. Depending on vehicle configuration and workshop tools, use appropriate lifting tackle (handling trolley, strap(s)…). © RENAULT TRUCKS – 2007 9/37 14/10/2008 1.4. Replacement of SCR silencer If the SCR silencer is replaced, the new SCR silencer must be compatible with the vehicle’s engine and feature the same exhaust emissions level as the original SCR silencer (Euro 4 and Euro 5 incentive SCR "Selective Catalytic Reduction"). Heat shields and other parts must be fitted to the SCR silencer as on the original installation. The SCR silencer must always be supported by its original brackets: A - SCR silencer bracket, front wing bracket and securing straps B - anchorage, bracket and securing straps © RENAULT TRUCKS – 2007 10/37 14/10/2008 1.5. Change in position of SCR silencer Reminder: x – change in position towards the rear y – change in position towards the interior z – change in position of towards the bottom WARNING Any person carrying out work is responsible for his own services in terms of warranty and liability, including damage caused by the work and/or equipment installed on the vehicle or on the basic product. WARNING Any failure to observe these recommendations shall be considered as breach of the same rules and will relieve RENAULT TRUCKS from its responsibility in the event of any damage connected directly or indirectly with such non-observation. The requirements below must be obeyed in sequence in order to comply with Euro 4 and Euro 5 incentive pollution control standards, for meeting the correct operating temperatures and not exceeding the maximum authorized exhaust line head loss. Note: -The installations recommended in this manual are covered by engine type approvals. - The maximum temperature is 450°C at the exhaust outlet. - Ensure that the exhaust outlet does not damage or adversely affect other on-vehicle components. - Do not modify existing wiring harnesses – replace if necessary (refer to "Wiring harnesses table"). For any further information on wiring and cabling, please contact the Renault Trucks Product Applications Department. Euro 4 vehicles The position of the SCR silencer can be moved to the rear of the sidemembers by a maximum of 2000 mm, measured from its initial position (outlet in the track (1) and vertical outlet (2)). © RENAULT TRUCKS – 2007 11/37 14/10/2008 Euro 5 incentive vehicles The position of the SCR silencer can be moved to the rear of the sidemembers by a maximum of 2000 mm for the outlet in the track (1) and 1200 mm for the vertical outlet (2), measured from its initial position. WARNING If the change in position of the SCR silencer is recommended along axis (x) only, do not modify the vertical orientation of the silencer, i.e. keep the same lines of drillings. If possible, keep the original SCR silencer brackets supplied with the vehicle. WARNING If the change in position of the SCR silencer is recommended along the three axes (x, y, z), the modifications made to the SCR silencer bracket and its fastenings, together with the reliability of assembly, are the equipment manufacturer’s responsibility. This is also applicable if the change in position takes place along axis (x) involving modification to the SCR silencer brackets. © RENAULT TRUCKS – 2007 12/37 14/10/2008 1.6.