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Bulletin1-3 Reminder of Essential Maintenance Optidriveinstructions Premium Dxi Tractor - Kerax Dxi1
Bulletin1-3 Reminder of Essential Maintenance Optidriveinstructions Premium Dxi Tractor - Kerax Dxi1
Date 08-2009
Premium DXi 11
Number 1-3
Kerax DXi 11
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.
1
ARYA DIESEL - PREMIUM & KERAX DXi - FIXED SERVICE SCHEDULE
2
ARYA DIESEL - PREMIUM & KERAX DXi - FIXED SERVICE SCHEDULE
MP/A
MP/D
MP/B
MP/C
M0
M1
M2
SERVICE
page
1 5 Engine Drain & Refill X X
2 5 Oil filters Replace 2 engine oil filter cartridge X
Replace turbo oil filter cartridge
3 6 Air filtration Check operation of clogging indicator X
Clean air filter inlet grille if necessary
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 X
Check for leak
10 Radiators Check External cleanliness of cores X
11 9 Radiators Clean radiators X
Clean intercooler
Clean air conditioning condenser
Clean mosquito net
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 Drain & Refill. X
,Optidrive) / PTO Clean the breather
20 14 Rear drive axle Drain & Refill X
Clean the breather
21 15 Suspension Check condition of suspension springs X
Check condition of pads
Check condition of anti-roll bar
22 15 power steering filter Replace X
23 Steering Check attachment of pipes X
Check ball joints
24 Steering Check Operation X
Check Condition of steering components (hub
and king pin play )
25 16 Air circuit systems Check for leak X X
Drain water from air tanks
26 16 APM cartridge Replace X
27 16 brakes Check visually brake pads/linings wear and X
discs
Check brake wear sensors
Check brake lines and flexible pipes
Check braking reaction. Directional stability
28 17 Fan coil heater filter Clean X X
replace if necessary
29 17 Air conditioning Renew chilling fluid X
Replace dehydrator filter
3
30 17 Wipers Check condition and operation of wipers X X
Refill washer reservoir
31 18 Tyres Check inflation pressures X X
Check State of tyres
32 18 Wheels Check Wheel nut tightness X
Check attachment of spare wheel
33 19 fifth wheel Check Operation of locking X
Check attachment of fifth wheel
Check Clearance between fifth wheel
coupling and semi-trailer
34 20 Grease King pins X X
Fifth wheel
Door hinges
Door locks
Cab lock
etc…
35 Drive belts Check Condition and tension of drive belts X
36 Drive belts Replace X
37 Propeller shaft Check play X
Check Secure tightening of bolts
38 air suspension Check operation of air suspension X
39 shock absorbers Check attachment and condition X
40 Cab Check Security of Cab mountings X
Check stability and air suspension
Check Operation of cab locking mechanism
41 Electricity Check attachment of batteries X
Operation of master switch
42 Signalization Check Operation of warning lights X X
Check pressure gauges
Check Lighting
Check Turning lights
Check stop lights
Check reverse lights
Check horn
43 Lubricants Check All levels X X
Check Units for leaks (oil, coolant, fuel,
steering, cab tilting and clutch fluid)
44 Belt tensioner Replace alternator belt tensioner roller. X
Replace fan belt tensioner roller.
45 Mountings Check condition and tightening of engine, X
gearbox and radiator mountings
46 soundproofing Check Presence and positioning of X
soundproofing screens and heat shields
47 Harnesses and pipes Check Condition of wiring X
harnesses, supports, pipes
48 Preventive maintenance Deactivate preventive X
maintenance
49 Power cable Make Sure Power cable has been X
removed
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.
4
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…
25Nm 60Nm
5
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.
6
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.
7
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.
2Nm
Loosen the engine block drain plug (6) or use tool 7409996049.
40Nm
8
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.
9
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).
Clean the assembly exclusively with diesel fuel and compressed air. 1/3 4.5Nm
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.
2.8Nm
Water in the injection system leads to immediate destruction of injector-pumps.
38Nm
10
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.
11
2.3 – GEARBOX ( n°19):
Use only 'RENAULT TRUCKS OILS PREXIMA 40' and Drain every YEAR or100 000 KM
Oil quality: API CF4/SF DRAINING
Quantity / 60Nm
10 liters,
13 liters if the gearbox is dry
+1 liter if PTO.
DRAINING OF THE GEARBOX:
Remove plugs (1), (2) & (3).
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.
12
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
13
2.4 – FRONT AXLE:
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
14
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).
15
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.
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.
16
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.
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
17
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) Rear (kg)
Single Wheel 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) Rear (kg)
Single Wheel Dual Wheel
6 200 11 300 5.5
7 300 13 300 6.75
8 000 14 600 7.5
18
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.
1
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.
19
2.16– GREASING ( N°34):
Use NLGI2 lithium soap grease with lead-free calcium EP additive.
To be done at each Service.
3x left
3x right
1x left
1x right
1x left
1x right
20