Renault lum Service Manual

DT 4/366 AN

english edition

GUIDE FOR THE FITTING
OF BODYWORK FOR THE

RENAULT MIDLUM

Series

50 21 008 236 - 04/02

édition anglaise

RENAULT V.I.

S.A. au capital de 50 000 000 €.
Siège social : 99, route de Lyon - 69802 Saint-Priest

IMPORTANT
Reading the “Guide for the Fitting of Bodywork for the MIDLUM series”

The “Guide for the Fitting of Bodywork for the RENAULT MIDLUM series” ushers in a new type
of presentation for bodywork fitting guides.

This new presentation sets out in one single document all those details which are necessary
for the bodybuilder and equipment manufacturer to have available.

The present document consists of three sections:
A - “General features”: This describes the relevant general principles and basic rules applicable

for the conversion and fitting of equipment to vehicles in most cases for the majority of
applications.

B -“RENAULT MIDLUM special bodybuilding features”: This deals in greater detail with presen-

tation of the vehicle, attachment of the body, electrical pre-arrangements, trade vehicles
and trade packs.

C -“Supplementary information on the RENAULT MIDLUM Euro 3 vehicle”: This deals in

greater detail with power take-offs, air-operated and specific equipment, assembly of
equipment to chassis and cab.

If a topic is dealt with in the three sections, the relative information may be:

- complementary: in this case the “Special bodybuilding features” section provides details or
values relating to the topic dealt with in “General features”.

- partially or fully contradictory: when the RENAULT MIDLUM vehicle is endowed with a
special feature whose characteristics go against general principles. In such case, the ele­ments regarding this specificity in the “Special bodybuilding features” section supersede
those dealing with the same topic in the “General features” section.

You may need, when looking for information on a specific point, to consult the three “General
features”, “Special bodybuilding features” and “Supplementary information on the RENAULT
MIDLUM vehicle” sections, so as to ensure that you have obtained all the relevant details.

The information given by the Manufacturer in this document is compiled in relation to
the technical specifications in force on the date of drafting of the document.
It is subject to modification in the event of changes made by the OEM during the manu­facture of the different units and accessories for vehicles of its make.



RENAULT V.I. - 04/02 - Imprimé en France

CONTACTS

Belgique België

RENAULT TRUCKS Belgique SA

Avenue du port 138,
1000 Bruxelles

Télèphone fax

Correspondant carrossier

00.32/02.421.76.31 00.32./02.425.56.06

Ceská Republika

RENAULT TRUCKS CR s.r.o.

Saldova 425/12,
18621 Praha 8,
Ceská Republika

Télèphone fax

Technicky inspektor

00.42/24.23.20.80 00.42/24.23.20. 84

Deutschland

RENAULT LKW Deutschland Gmbh

Renault StraBe 12,
50321 Brühl

Télèphone fax

Verkaufstechn. und Aufbauberatung

00.49/0.222.32.7077.142 00.49/0.222.32.7077.181

España

RENAULT TRUCKS España, s.a.

C/Eduardo Barreiros, 104
28080 Madrid

Teléfono fax

Tecnico comercial

00.34/91.3.47.13.84 00.34/91.3.47.13.53

France

RENAULT TRUCKS

99, route de lyon,
69800 Saint–Priest

Télèphone fax

Technico comercial

04.72.96.96. 70 04.72.96.81.93

DT 4/366 RENAULT V.I. 04/02

RENAULT V.I. 04/02 DT 4/366

Great–Britain

RENAULT TRUCKS UK Ltd,

Boscombe Road,
Dunstable,
Bedfordshire LU5 4LX

Télèphone fax

Applications Engineering Manager

00.44/1582.479150 00.44/1582.479328

Italia

RENAULT TRUCKS Italia S.P.A.

Via Castiglioni 20,
20010 Arluno (MI)

Telefonico fax

Marketing

00.39/02.902.52.267 00.39/290.376.800

Magyarország

RENAULT TRUCKS Hungária Kft.

2046 Törökbálint, Tó Park
Magyarország

Telefon fax

Müszaki–kereskedelmi munkatárs

00 .36/23.51.35.13 00 .36/23.51.35.14

Nederland

RENAULT TRUCKS Nederland B.V.

Edisonweg 8
4132 PC Vianen

Télèphone fax

Begeleiding carrosseriebow

00.31/31.347.323624 00.31/31.347.323650

Österreich

RENAULT LKW Österreich

Industriestrasse 5
A–2353 Guntramsdorf

Télèphone fax

Dispo

00.43/22.36.41.171.48 02236/860166

Polska

RENAULT TRUCKS Polska Sp.Z.o.o.

ul. Polczynska 10
01–378 Warszawa

Telefon fax

Dyrektor Techniczny

00.48/22.66.45.199 00.48/22.66.45.040

Portugal

RENAULT TRUCKS Polska Sp.Z.o.o.

ul. Polczynska 10
01–378 Warszawa

Teléfono fax

Técnico–comercial

00.351/263.28.0864 00.351/263.28.0850

Schweiz Suisse Svizzera

RENAULT NUTZFAHRZEUGE (Schweiz) AG

Rütiweg 5
4133 Pratteln

Télèphone fax

Responsabile tecnico

00.41/61.82.10.811 00.41/61.82.10.817

Slovenská Republika

RENAULT TRUCKS CR s.r.o.
organizacná zlozka RENAULT TRUCKS SR

Teslova 30, P.O. BOX 168, 820 05
Bratislava 25,
Slovenská Republika

Télèphone fax

Obchodno–Technicky inspektor

421/2/43 41 27 96–7 421/2/43 63 36 01

Türkiye

RENAULT TRUCK Ticaret A.

Hülagûl Cad. Tepeüstü Sok. No: 30
81610 / Kavac k / Beykoz / Stanbul

Télèphone fax

Bayi Geli im Planlama Müdürü

00.90/216.413.69.16 00.90/216.331.21.98

DT 4/366 RENAULT V.I. 04/02

RENAULT V.I. 04/02 DT 4/366

DT 4/366 1 RENAULT V.I. 04/02

Page

1. GENERAL FEATURES

1.1 Scope of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2

- Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2

1.2 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2

1.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3

1.4 Quality assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4

1.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4

1.6 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5

1.7 Safety on tilt cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6

1.8 Chassis markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6

1.9 Adjustments to the vehicle settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7

1.10 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7

1.10.1 Bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7

1.10.2 Chassis/Underbodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7

1.10.3 Cleaning of the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7

1.10.4 Cleaning of the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7

1.11 Safety and protection of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7

1.12 Summary of definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8

1.13 Certificate of approval of the conversion of a vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9

1.13.1 Application for approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9

1.13.2 Body fitting certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9

1.13.3 Responsibility for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9

1.14 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A10

1.14.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A10

1.14.2 Major units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A10

- Retouch method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A10

1.14.3 Chassis frame and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A11

- Retouch method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A11

1.14.4 Recommended products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A12

- Manual cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A12

- High pressure cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A12

- Filling and sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A12

1.14.5 Marking of polymer components (recycling of plastics) . . . . . . . . . . . . . . . . . . . . . . . . .A13

- Table of the principal polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A14

1.15 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A15

1.15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A15

1.15.2 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A15

1.15.3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A16

1.15.4 Available power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A16

1.15.5 Flasher units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A16

1.15.6 List of standard power sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A17

1.15.7 Additional direction indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A19

CONTENTS

GENERAL RULES FOR CONVERSIONS

CHAPTER -A-

GENERAL FEATURES

RENAULT V.I. 04/02 2 DT 4/366

1.16 Air-operated equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A20

1.16.1 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A20

1.16.2 Polyamide pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A20

- Identification marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A20

- Coding (RENAULT TRUCKS Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A20

- Brakes code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A20

- Coding used on pneumatic appliances (DIN Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A21

- Replacement of a brake line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A21

- Modification to the length of the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A21

- Connections for firtree type pneumatic brake pipes type “RILAX 2000” . . . . . . . . . . . . . . . . .A21

2. GENERAL RULES TO BE OBSERVED WHEN FITTING BODYWORK

2.1 General principles of welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A22

2.1.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A22

- Protection of the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A22

- Soundproofing screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A22

- Protection of electrical and mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A22

2.1.2 Preparation of parts for welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A22

- Preparation of specific edges on chassis frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A23

- Method of welding to be specifically used on chassis frames . . . . . . . . . . . . . . . . . . . . . . . . .A23

- Slave butts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A23

2.1.3 Welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A24

- Static or rotary arc welding set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A24

- Relevant standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A24

- MIG or MAG semi-automatic welding set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A24

2.1.4 Equivalent steel grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A25

2.2 Reinforcement, extension, reduction of sidemembers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A26

2.2.1 Bans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A26

2.2.2 Reinforcement of sidemembers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A26

- Examples of reinforcements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A26

- Method of joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A27

- Extension, shortening of sidemembers in the wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . .A28

2.2.3 Modification of the rear overhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A29

- Attachment of cross-members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A29

- Towing cross-members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A29

- Intermediate cross-members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A29

2.3 Attachment of bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A30

2.3.1 Bans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A30

2.3.2 Protection against exhaust heat radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A30

2.4 Sub-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A31

2.4.1 Finishing of sub-frames behind the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A31

2.5 Nuts and bolts, tightening torque for parts in steel and cast iron . . . . . . . . . . . . . . . . . . . . . .A31

2.6 Addition of equipment to the bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A34

2.7 Rear run-under guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A35

3. SPECIFIC EQUIPMENT FEATURES

3.1 Running the engine when vehicle stationary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A35

3.2 Mounting of power take-offs and flanged pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A35

3.3 Front power take-offs (crankshaft nose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A36

3.4 Front and rear power take-offs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A36

3.4.1 Propeller shaft alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A36

- Angularity criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A36

- Angular acceleration criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A37

- Transversal stress criteria for prop shaft tubes and bearings . . . . . . . . . . . . . . . . . . . . . . . . .A37

DT 4/366 3 RENAULT V.I. 04/02

3.4.2 Propeller shaft balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A38

3.4.3 Maximum permissible length of a prop shaft as a function of the rotating speed . . . . . .A38

3.5 Vehicle driveline (powertrain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A38

3.6 Mounting of handling cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A39

3.6.1 Mounting on the sub-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A39

3.6.2 Graph of the moment of inertia of the sub-frame as a function of the lifting torque . . . .A40

3.6.3 Crane in the rear overhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A41

3.7 Tail lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A42

3.7.1 Sub-frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A42

3.7.2 Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A42

3.7.3 Electrical connections for a tail lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A42

3.7.4 Special recommendations for tail lifts from 1500 to 2000 kg without landing legs . . . . .A42

3.7.5 Graph of the moment of inertia of the sub-frame as a function of the lifting torque . . . .A43

3.8 Sub-frame box sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A44

3.9 Fitting of specific equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A44

3.9.1 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A44

3.9.2 Installation of receivers or generators with a voltage of more than 24 V . . . . . . . . . . . . .A44

3.10 Tapping on the diesel fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A44

3.11 Fifth wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A45

3.11.1 Mounting standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A45

- Kingpin 50 mm (2”) dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A45

- Kingpin 90 mm (3.5”) dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A45

CHAPTER -B-

RENAULT MIDLUM SPECIAL BODYBUILDING FEATURES

1. PRESENTING THE “RENAULT MIDLUM” SERIES

1.1 Make-up of the range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3

1.2 Changes to “RENAULT MIDLUM” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4

1.3 Electronic management of “RENAULT MIDLUM” vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5

1.3.1 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5

1.3.2 Bodybuilders’ electrical pre-arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6

1.4 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6

1.5 Trade vehicle models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B7

- “Normal use” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B7

- “Tanker vehicle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B7

- “Refuse collector vehicle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B8

- “Road sweeper vehicle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B8

- “Light fire tender vehicle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B8

- “Buildings and public works vehicle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B9

1.6 Make-up of “Trade packs” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B9

- “Crane” installation pre-arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B9

- “Tail lift” installation pre-arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B9

2. GENERAL REMARKS ON “RENAULT MIDLUM Euro 3” SERIES

2.1 Identification of the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B10

2.2 General drilling principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B11

2.2.1 Drilling cab panels for fitting accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B11

2.2.2 Drilling in sidemembers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B12

- Anti-corrosion protection and paint retouches to the chassis . . . . . . . . . . . . . . . . . . . . . . . . .B12

2.3 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B13

RENAULT V.I. 04/02 4 DT 4/366

2.3.1 Protection of wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B13

2.3.2 Protection of electrical installation prior to welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B13

2.4 Minimum load on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B15

2.5 Soundproofing screens and heat shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B15

2.5.1 Instructions for soundproofing screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B15

2.5.2 Instructions for heat shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B15

2.6 Side impact beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B15

3. INSTALLATION OF BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B16

3.1 Use of 1/20th scale drawings and calculation sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B16

3.2 Example of a search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B16

3.3 Body start dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B19

3.3.1 Day cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B19

3.3.2 Behind-cab surrounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B20

3.3.3 Sleeper cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B21

3.3.4 4-door cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B21

3.3.5 Presentation of the different air intakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B22

3.4 Sub-frame sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B23

3.4.1 Minimum height according to range of suspension movement . . . . . . . . . . . . . . . . . . . .B23

3.4.2 Sub-frame minimum inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B24

3.5 Finishing of sub-frame entrance dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B24

- RENAULT MIDLUM B/C’/C/HD/Construction/D/4x4 day cab and under-floor air intake . . . . . .B25

- RENAULT MIDLUM B/C’/C/HD/Construction/D/4x4 sleeper cab whatever the air intake . . . . .B25

- RENAULT MIDLUM B/C’/C/HD/Construction/D/4x4 day cab and roof level air intake . . . . . . .B26

3.6 Lateral guiding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B27

- Inertia stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B27

3.7 Attachment of bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B28

3.8 Attachment of sub-frames to brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B29

3.8.1 Fastening types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B29

- Guiding and fastening zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B29

3.8.2 Vertical positioning of brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B30

3.8.3 Types of bodywork attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B31

- Flexible attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B31

- Semi-flexible attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B33

- Rigid attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B34

3.8.4 Special features of vehicles with 4-door cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B35

3.8.5 Special features of vehicles with sleeper cab and vertical exhaust . . . . . . . . . . . . . . . . .B36

3.9 Longitudinal positioning of brackets on chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B37

3.9.1 RENAULT MIDLUM B 2-door day & sleeper cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B37

3.9.2 RENAULT MIDLUM B 4-door cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B37

3.9.3 RENAULT MIDLUM C’/C 2-door day & sleeper cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B38

3.9.4 RENAULT MIDLUM C’/C 4-door cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B39

3.9.5 RENAULT MIDLUM HD / Construction 2-door day & sleeper cabs . . . . . . . . . . . . . . . . . .B40

3.9.6 RENAULT MIDLUM HD / Construction 4-door cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B40

3.9.7 RENAULT MIDLUM D 2-door day & sleeper cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B41

3.9.8 RENAULT MIDLUM 4x4 2-door cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B42

3.9.9 RENAULT MIDLUM 4x4 4-door cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B42

3.10 Changing the position of lateral flashing direction indicators . . . . . . . . . . . . . . . . . . . . . . . .B43

- Assembly on body front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B43

- Assembly on body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B44

DT 4/366 5 RENAULT V.I. 04/02

4. LEVEL 1 ELECTRICAL PRE-ARRANGEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B46

4.1 Available power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B46

4.2 Level 1 electrical pre-arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B46

- In the cab on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B46

- Available power supplies in the cab under the connection unit . . . . . . . . . . . . . . . . . . . . . . . .B48

- In the battery compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B49

4.3 Assembly of lateral signalling installation kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B50

4.4 Electrical diagram for level 1 available power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B51

- Assignment of fuses concerning electrical pre-arrangements . . . . . . . . . . . . . . . . . . . . . . . . .B52

4.5 Bodywork attachment kit (located in cab and supplied with this pre-arrangement) . . . . . . . .B52

5. LEVEL 2 ELECTRICAL PRE-ARRANGEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B54

5.1 Available power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B54

5.2 Level 2 electrical pre-arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B54

- In the cab on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B54

- Available power supplies in the cab under the connection unit . . . . . . . . . . . . . . . . . . . . . . . .B56

- In the battery compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B57

- In the RH sidemember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B57

5.3 Management of engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B56

5.4Power take-off wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B58

5.4.1 Vehicle fitted with one PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B58

- A) Determining the rotating speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B58

- B) Using the chassis-mounted fast idling variable speed control . . . . . . . . . . . . . . . . . . . . . .B58

- C) Controlling speed regulation without cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B59

5.4.2 Vehicle fitted with two PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B59

- A) Determining the rotating speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B59

- B) Using the chassis-mounted fast idling variable speed control . . . . . . . . . . . . . . . . . . . . . .B59

- C) Controlling speed regulation without cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B59

5.4.3 Vehicle fitted with three PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B60

- A) Determining the rotating speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B60

- B) Using the chassis-mounted fast idling variable speed control . . . . . . . . . . . . . . . . . . . . . .B60

- C) Controlling speed regulation without cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B60

5.4.4 Vehicle fitted with one engine rear PTO or no PTO at all . . . . . . . . . . . . . . . . . . . . . . . . . .B60

- A) Determining the rotating speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B60

5.5 Use of the steering wheel fast idling fingertip control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B61

5.5.1 Vehicle fitted with one power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B61

5.6Engine speed information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B62

5.7Chassis-mounted starting and stop controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B63

Chassis-mounted stop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B64

5.8Parking brake information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B64

5.9Vehicle speed limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B64

5.10 Assembly of lateral signalling installation kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B64

5.11 Electrical diagram for level 2 available power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B65

- Assignment of fuses concerning electrical pre-arrangements . . . . . . . . . . . . . . . . . . . . . . . . .B67

5.12 Bodywork attachment kit (located in cab and supplied with this pre-arrangement) . . . . . . .B67

5.13 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B68

6. VEHICLE EQUIPPED WITH A TAIL LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B70

- “Tail lift” installation pre-arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B70

6.1 Fuse-holder 200 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B70

6.2 Tail lift earth in rear overhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B70

RENAULT V.I. 04/02 6 DT 4/366

7. TANKER VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B72

- Tanker special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B72

- ADR equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B72

- Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B72

7.1 ADR plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B73

7.2 Remote controlled clutch release operating ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B73

7.3 Assembly of chassis accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B73

7.4 Longitudinal positioning of brackets on chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B75

7.4.1 RENAULT MIDLUM C tanker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B75

7.4.2 RENAULT MIDLUM D 18 tonnes tanker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B75

7.5 Passage of wiring harnesses and compressed air pipes through cab . . . . . . . . . . . . . . . . . . .B76

8. “REFUSE COLLECTOR” VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B80

- Refuse collector vehicle special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B80

- Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B80

8.1 Longitudinal positioning of brackets on chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B81

8.1.1 RENAULT MIDLUM C refuse collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B81

8.2 Passage of wiring harnesses and compressed air pipes through cab . . . . . . . . . . . . . . . . . . .B81

8.3 Electrical pre-arrangements for refuse collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B83

- Available power supplies in cab under the connection unit . . . . . . . . . . . . . . . . . . . . . . . . . . .B83

- In the battery compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B84

8.4 Reversing safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B85

8.5 Assembly of lateral signalling installation kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B86

8.6 Electrical diagram for “refuse collectors” optional available power supplies . . . . . . . . . . . . .B87

- Assignment of fuses concerning electrical pre-arrangements . . . . . . . . . . . . . . . . . . . . . . . . .B89

8.7 Bodywork attachment kit (located in cab and supplied with this pre-arrangement) . . . . . . . .B89

9. ROAD SWEEPER VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B92

- Road sweeper special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B92

9.1 Longitudinal positioning of brackets on chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B93

9.1.1 RENAULT MIDLUM C’/C road sweeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B93

9.2 Passage of wiring harnesses and compressed air pipes through cab . . . . . . . . . . . . . . . . . . .B93

10. LIGHT FIRE TENDER VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B96

- Light fire tender special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B96

- Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B96

10.1 Longitudinal positioning of brackets on chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B97

10.1.1 RENAULT RENAULT MIDLUM B 10 tonnes 4-door light fire tender . . . . . . . . . . . . . . . . .B97

10.2 Light fire tender electrical pre-arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B98

- Available power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B98

- Electrical diagrams for available power supplies on light fire tender . . . . . . . . . . . . . . . . . . .B102

11.BUILDINGS & PUBLIC WORKS VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B108

- Buildings and public works vehicle special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B108

- Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B108

11.1 Fastening of tipper control in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B109

11.1.1 Location on engine tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B109

11.1.2 Location on cab rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B109

11.1.3 Location on side pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B110

11.2 Passage of wiring harnesses and compressed air pipes through cab . . . . . . . . . . . . . . . . .B111

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11.3 Assembly of rear lamps to lighting bar - tractor version

(on RENAULT MIDLUM C/C’/D/HD/Construction only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B112

11.4 Fitting a tool-holder to the front of a vehicle with sheet metal bumper . . . . . . . . . . . . . . . .B113

12.BEHIND-CAB HANDLING CRANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B116

12.1 Maximum lifting moment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B116

12.2 Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B116

12.2.1 Attachment of crane brackets to the sub-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B117

12.2.2 Attachment of crane brackets to the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B117

- Crane support plates assignment table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B117

- RENAULT MIDLUM C’/C/D/HD Construction day cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B118

- RENAULT MIDLUM C’/C/D/HD Construction sleeper cab . . . . . . . . . . . . . . . . . . . . . . . . . .B118

- RENAULT MIDLUM B day cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B119

- RENAULT MIDLUM B sleeper cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B119

12.3 Position of vertical centre-line of crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B120

12.3.1 Day cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B120

12.3.2 Sleeper cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B121

13.INDEPENDENT REFRIGERATOR UNIT LOCATED ABOVE THE CAB . . . . . . . . . . . . . . . . . . . .B124

- Maximum permissible load on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B124

13.1 Mechanical receiver on crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B125

- Position of receiver on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B125

13.2 Additional fuel tapping on fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B126

14.SNOW CLEARING VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B128

14.1 Sheet metal bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B128

14.2 Signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B128

14.3 Hydraulic pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B128

CHAPTER -C-

SUPPLEMENTARY INFORMATION

ON THE “RENAULT MIDLUM” VEHICLE

1. MOUNTING OF POWER TAKE-OFFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3

1.1 Mechanical receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3

1.1.1 Gearbox-mounted PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3

- Table of possible gearbox-mounted PTO assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3

- HYDROCAR 2903 & 2904 PTOs with two independent outputs . . . . . . . . . . . . . . . . . . . . . . .C3

- PTO characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4

- Flywheel-mounted PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5

- Maximum torque transmissible by the PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5

- Frequency of use of PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5

1.2 Instructions for the assembly of auxiliary hydraulic pumps to type “C” PTOs

(ZF or Hydrocar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6

1.2.1 Supplementary instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6

- Fluidtight seal between pump and PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6

- Calculation of the weight torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6

- Calculation method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6

RENAULT V.I. 04/02 8 DT 4/366

2. AIR-OPERATED EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C7

2.1 Connection of extra auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C7

2.1.1 Coupling for extra auxiliary equipment to chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C7

- Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C8

2.1.2 Coupling for extra auxiliary equipment in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C8

- Cab not equipped with air-operated appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C8

- Cab equipped with air-operated appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C9

2.2 Table of compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C9

3. ELECTRICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

3.1 Earths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

3.1.1 Cab earths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

- Door earths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

- Front end earths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

- Cab floor earths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

- Fastening of earth lug or braid to cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C10

3.1.2 Chassis earths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C11

- Assembly to electrical earth points diameter 11 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C11

3.2 Hook-up of lateral lamps to the rear lamp

(vehicle with rear lighting bar, without variant 155 02 & 155 03) . . . . . . . . . . . . . . . . . . . . . . . .C12

3.3 Hook-up in front end connection zone

(vehicles without “bodybuilder pack” and refuse collectors) . . . . . . . . . . . . . . . . . . . . . . . . . .C12

3.4 Changing the position of vehicle rear lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C12

3.5 Doubling up the rear lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C13

- Assignment of connector terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C13

3.6 Extension of the wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C15

3.7 Assembly of the immersion heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C15

4. CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C16

4.1 Steel classes for sidemembers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C16

4.2 Sections of sidemembers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C16

- RENAULT MIDLUM B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C16

- RENAULTMIDLUM C’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C16

- RENAULTMIDLUM C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C17

- RENAULTMIDLUM D & D Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C17

- RENAULTMIDLUM HD/Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C18

- RENAULTMIDLUM 4x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C18

- Trade vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C18

4.3 Reinforcement, extension, shortening of sidemembers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C19

4.3.1 Modification to the rear overhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C19

4.3.2 Modification to the wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C19

- RENAULTMIDLUM B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C19

- RENAULTMIDLUM C’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C20

- RENAULTMIDLUM C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C20

- RENAULTMIDLUM D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C21

- RENAULTMIDLUM D Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C21

- RENAULTMIDLUM HD/Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C21

- Trade vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C22

4.4 Intermediate cross-member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C22

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5. CHANGING THE POSITION OF EQUIPMENT ON CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . .C23

5.1 Rear run-under guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C23

5.2 Changing the position of the rear run-under guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C24

- Table of possible vertical positionings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C24

5.3 Changing the position of rear lighting bar lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C24

5.4 Changing the position of the towing cross-member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C24

- Table of possible horizontal positionings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C24

- RENAULT MIDLUM B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C25

- Table of possible horizontal positionings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C26

- RENAULT MIDLUM C’/C/HD/Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C27

5.5 Assembly of rear lamps to lighting bar - tractor version

(on RENAULT MIDLUM C/C’/HD/Construction only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C28

5.6 Changing the position of the cab tilting manual pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C29

- RENAULT MIDLUM C/C’/HD/Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C29

- RENAULT MIDLUM B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C29

5.7 Trailer hitch coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C30

5.7.1 Maximum permissible range of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C30

5.7.2 Towing cross-member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C30

5.7.3 Hitch coupling for drawbar rigid trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C32

- Installation of an extra cross-member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C32

- Minimum thickness (E) of stiffener plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C32

6. CAB FOOTPRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C33

6.1 Day cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C33

6.2 Sleeper cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C35

6.3 6/7 place cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C37

7. ASSEMBLY OF EQUIPMENT TO CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C39

7.1 Roof catwalk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C39

7.1.1 Attachment of catwalk to day cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C39

7.1.2 Attachment of catwalk to sleeper cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C40

7.2 Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C41

7.2.1 Attachment of ladder to day cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C41

7.2.2 Attachment of ladder to sleeper cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C42

7.3 Assembly of accessories on roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C43

- Table of roof assembly possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C43

7.3.1 Installation of antennae . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C44

7.3.2 Installation of revolving beacons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C45

7.3.3 Installation of air horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C45

7.3.4 Installation of roof deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C46

7.3.5 Installation of frontview mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C47

7.3.6 Installation of sunshade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C48

7.3.7 Installation of gantry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C49

- Assembly of a gantry equipped with a frontview mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C49

7.4 Assembly of accessories in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C50

7.4.1 Location in dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C50

7.4.2 Location on engine tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C50

8. AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C51

8.1 Identification of a vehicle equipped with an airbag system . . . . . . . . . . . . . . . . . . . . . . . . . . .C51

8.2 Work on the vehicle (excluding the airbag) requiring precautions

to be taken to avoid inadvertent deployment of the airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . .C51

RENAULT V.I. 04/02 10 DT 4/366

DT 4/366 A1 RENAULT V.I. 04/02

CHAPTER -A-

GENERAL FEA TURES

IMPORTANT

General principles and basic rules applicable for the conversion and fitting of equipment to vehicles
in most cases for the majority of applications are detailed in this “General features” chapter.

RENAULT V.I. 04/02 A2 DT 4/366

1. GENERAL FEATURES

1.1 Scope of liability

RENAULT TRUCKS vehicles are merchandized at the end of corroborated technical designwork and enduran­ce testing, taking the various laws, regulations, standards... involved into consideration.
Modifications to a RENAULT TRUCKS vehicle for the fitting of bodywork and equipment should be carried out
in accordance with the rules and recommendations set out in this bodywork fitting guide and require an
“Agreement in Principle”, issued by the Product Applications Department.

Guarantee and responsibility

Any intervening party is responsible for his services in terms of guarantee and responsibility, including any dam­age caused by his work and/or the equipment installed on-vehicle or the basic product.

In the event of RENAULT TRUCKS (or its network) being prime contractor for its own equipment (in relation to
the end customer), the guarantee is considered as being at least that of the warranty offered by RENAULT
TRUCKS to its customer.

Unless clearly specified otherwise in the order, the equipment warranty shall be negotiated directly between the
end customer and the equipment manufacturer.

The meeting of recommendations contained in the present document can in no way be considered as relieving
the equipment manufacturer’s responsibility, but simply as complying with the basic rules for professional trade
practice.

Any breach of these recommendations must be considered as shortcoming in respect of the rules and shall relieve
RENAUL TTRUCKS of its liability in the event of damage connected directly or indirectly to such non-compliance.

All the equipment is considered to comply with these recommendations and shall not require any acceptance test­ing upon delivery to check the conformity.

RENAULT TRUCKS guarantees non-modified original parts and components.
Interventions, conversions, adaptations of fittings carried out by the intervening party involves his responsibility,

even if they are authorized administratively (Conversion appendix II).
Such conversions must not under any circumstance lead to any impairment of the quality or of the primary func-

tions of the component elements of the vehicle (whether these elements are affected directly or not by the inter­vention).

Any modification, changing of position of constituent vehicle parts or elements must be covered by an “Agreement
in Principle”, issued by the RENAULT TRUCKS Product Applications Department.

For further information or assembly agreement, contact:
TO OBTAIN ANY INFORMATION OR APPROVAL OF MOUNTING, PLEASE CONTACT:

For France:
SERVICE TECHNICO-COMMERCIAL
RENAUL TTRUCKS
API. COM 00A 238
69806 ST PRIEST CEDEX
Tel.: [phone]
Telex: 300 265 UDCF +
Fax: [phone]

1.2 Regulations

The bodybuilder must meet:

- the different European and/or destination country laws, regulations and standards governing driving and

vehicle building,

- the stipulations of the Highway Code and its various amendments and appendices,

- the different laws, regulations and standards governing road traffic in force in the country of destination.

For the United Kingdom:
Product Applications Department
RENAULT TRUCKS UNITED KINGDOM
Boscombe Road,
Dunstable
Bedfordshire LU5 4LX
Tel. (Switchboard): (+44) (0)1582 471 122
Fax (Marketing) (+44) (0)1582 479 146

DT 4/366 A3 RENAULT V.I. 04/02

The scope of this compliance must cover:

- Lighting and signalling,

- Weight and dimensions,

- The field of vision and rear view,

- The regulation protection devices (e.g. side guards, anti-spray, run-under guard),

- The hitch coupling and towing systems, (compliance with standards and regulations),

- Specific clauses concerning the transport of dangerous goods (ADR, COSHH etc.),

- Sun-roofs,

- Pollution control standards,

- Electromagnetic compatibility standards for electronic equipment.

1.3 Safety

All components having an influence on:

- The control of the driver of the trajectory and the ability to stop the vehicle and its trailer,

- The load distribution on the front or the rear, the left or the right,

- The risk of fire,

- and any other risk for the vehicle and its surrounding environment.

Among the components, we would mention, among others:

- The cab tilt mechanism,

- The wheels (tightening of the nuts),

- Seats and seat belts (anchorage points),

- The attachment of bodywork or equipment to be in conformity with the technical instruction document in force,

(i.e. the Guide for the Fitting of Bodywork),

- The hitch coupling and towing systems, (i.e. anchorages),

- Electrical systems (protection of circuitry, the electrical rating, attachment, conformity of the connections with

the technical instruction document, (i.e. the Guide for the Fitting of Bodywork),

- Warning systems and driver information systems, (i.e. no interference with the information given by the instru-

ment panel on the dashboard),

- Information for use affixed by the manufacturer to the vehicle (i.e. decals for tilting of the cab, drilling points,

welding points, batteries, etc.)

- Extension and reduction of the length of the wheelbase and the rear overhang.

- Re-location or replacement of the cross-members.

- Circuits for ancillary equipment.

In order to guarantee the safety and the satisfactory operation of the vehicle, modification of the follo­wing components is strictly forbidden:

- Brakes: circuits, controls and anchorages,

- Steering: circuits, controls, anchorages and geometry,

- Axle and axle housing assemblies,

- The air-bag system and pretensioning systems on the seat belts,

- The electronics.

RENAULT V.I. 04/02 A4 DT 4/366

1.4 Quality assurance

Our permanent objective is to give satisfaction to our customers and we must achieve this in full on the final
product consisting of a chassis, bodywork and/or an item of equipment.

In order to achieve this objective, RENAULT TRUCKS expects from all those co-operating with it in the field
of mounting bodywork and equipment supply to implement a Quality Assurance System.

RENAULT TRUCKS can demand proof for the execution of all bodywork, the fitting of equipment or modifi­cation of a basic truck, in accordance with Standard ISO 9000, of:

- The conformity with all legislation, EC Directives and national regulations,

- The compliance with the manufacturers’ directions,

- The control of quality of the execution of the work.

This is done with the knowledge that, on the face of it, the vehicle is considered as complying with the
whole of the regulations.

1.5 Documentation

In all cases involving equipment, the installer is obliged to supply a manual covering the use, service, main­tenance and safety of his installation.

Tension aux bornes de l’accumulateur

’

batterie 6 Volts batterie 12 Volts

ens

e

e charge

6,3 Volts 12,7 Volts 1,27 100 %
6,2 Volts 12,5 Volts 1,24 80 %

DT 4/366 A5 RENAULT V.I. 04/02

1.6 General instructions

When building and fitting a body (including such equipment as rear run-under guards), a certain number of
requirements and a certain number of vital requirements specific to each type of vehicle must be taken into
consideration. These various points relate to maintenance, accessibility and the circulation of fluids.

Examples:

- Ease of access to the various maintenance and lubrication points, to the fuel tank and fuel gauge, to the

batteries and the various electrical terminal boxes.

- The ability to easily dismantle the various component parts of the transmission and the suspension.

- Access to the circuits for air-intake, exhaust, and fuel supply.

- Taking into account the wheel movement detailed on the bodywork drawing (i.e. take care to allow for snow
chains; extra clearance must be provided).

- Ventilation of the brake drums and discs and the battery compartment.

- The radiator inlet and outlet areas, which must not be modified.

- Full compliance with the dimensions and weights specified in our technical documents. Under all circum­stances, the bodybuilder must ensure free movement and safe operation of all the moving component parts
of the chassis (i.e. springs, prop shaft, etc.)

- The addition of a body must not affect the vehicle running and driving safety. Take care to ensure that a
balanced distribution of the loads on the right and the left hand sides of the vehicle is obtained.

- For any bodywork installation, a calculation of load distribution must be made for each axle, in order to check
that the weight imbalance between the right and the left hand side is below 4%.

- The flow of the coolant must be maintained at all times. It is, therefore, not allowed to blank off, even par­tially, the air intakes provided (on the radiator grille or the front end). Orange ADR or similar “Hazardous
Substances” plates should be affixed to solid surfaces (i.e. without vent holes).

On the arrival of a vehicle in your workshop for body fitting, we recommend that you should check one hour
after the arrival of the vehicle, the state of charge of the batteries.

During the period for the fitting of the bodywork, you should particularly check that:

- The vehicle is not run without a battery.

- Do not move the vehicle on the starter motor.

- Do not use a booster starter.

- Ensure that the tyre pressure is checked and tyres inflated to the correct value where necessary.

- Protect body components or items of trim against all damage.

- Refit the original batteries, where these have been taken off.

IMPORTANT

- Whatever work you are doing on the vehicle, you must switch off the electrical circuit at the master switch or
by disconnecting the batteries in order to avoid any risk of electric shock during work.

- When a vehicle is laid up (i.e. at a standstill for longer than 10 days), disconnect the electrical circuit by remo­ving the fuse or by the circuit-breaker so as to avoid discharge of the batteries through the tachograph.

Voltage at the battery terminals

Specific gravity

of the electrolyte

State of charge

6 Volt battery 12 Volt battery

6.3

6.2

12.5

12.7

1.24

1.27

D

ité de l’électrolyt

Etat d

RENAULT V.I. 04/02 A6 DT 4/366

The information contained in this manual is only applicable to bodywork in steel. For aluminium bodies, refer
to the Product Applications Department of RENAULT TRUCKS.

It is forbidden to weld, grind, cut up, drill or heat the sidemembers or cross-members unless the contrary is
clearly stated. These operations may only be carried out in conformity with the recommendations laid down
in the present document.
Any special case, any bodywork fasteners and fittings not described in this manual must be submitted for our
approval prior to use.

Before commencing the fitting of any bodywork, you must consult:

- The Vehicle Technical Data Sheet,

- The bodybuilders drawing and the relevant calculation sheets which relate to the body to be fitted,

- The vehicle driving and maintenance handbook.
If you do not have these items available, you should obtain them from RENAULT TRUCKS Dealers or the

Product Applications Department.
In the technical manual and on the bodywork drawing is stated the permitted maximum and minimum length

of body; we would strongly advise you to stay within these limits.
Furthermore, it should be noted that the changing of position of a component such as spare wheel, tank, etc.,

the modification of a chassis without uniform weight distribution or the fitting of an over-cab extension, causes
a modification of the load distribution of a fully equipped chassis in every single case.

Modification to load distribution must be compensated for by an alteration in the permitted length for body­work. It then becomes necessary to calculate the new position of the centre of gravity of the bodywork.

The weights specified in our technical data sheets refer to standard vehicles, ready for the road, without optio­nal extras.
Furthermore, the weight of chassis cab is given with a tolerance of plus or minus 4%.

Optional equipment such as reinforced springs, power take-offs, different tyre fitments, will cause an increa­se in weight for the basic chassis.

For these reasons, when weighing the chassis cab, bodybuilders should weigh:

- The front axle(s),

- The rear axle(s),

- The complete vehicle,
without driver, without passenger, but with full fuel tanks and with vehicle on-board tool kit.

For the preparation and attachment of the various types of bodywork, it is preferable not to take off the wheels,
unless absolutely necessary.

Nevertheless, you must take the precautions set out below:

- It is forbidden to paint the bearing surfaces of the wheel rim hubs and the seating for wheel nuts.

- During fitting, make certain that the parts are perfectly clean prior to fitting.

- Tighten the wheel nuts to the torque recommended (cf. vehicle driving and maintenance handbook)
Installation fitted with key-operated locks: the section of such keys must be very different to that used for the

vehicle keys. Indeed, these keys should not be able to be put into the vehicle locks by mistake, thus avoiding
any risk of damage to the barrels of the locks.

1.7 Safety on tilt cabs

After the conversion of standard cabs by the bodybuilders, (i.e. extension, bunk adaptation, over-cab exten­sion, etc.) because the weight distribution has changed, the tilt system may no longer meet the requirements
of the safety standards.
Under these circumstances, and without prior agreement from the manufacturer, the full and entire responsi­bility rests with the bodybuilder.

1.8 Chassis markings

The identification number of the vehicle is on the sidemember (refer to the vehicle driving handbook).
The identity markings of the vehicle must remain visible and accessible without having to remove any part of

the body.

DT 4/366 A7 RENAULT V.I. 04/02

1.9 Adjustments to the vehicle settings

Under no circumstance may bodybuilder or converters make any alteration to the original settings of
RENAULT TRUCKS vehicles.

1.10 Cleaning

1.10.1 Bodywork

So as not to cause any damage to the condition of the paintwork and the seals:

- Avoid using a high temperature jet of steam.

- Restrict the use of brushes. They must be in good condition and well maintained.

- We advise against the use of brushes, during the first month of vehicle use.

- If you are using a high pressure jet wash unit, limit the pressure to 80 bars maximum.

- Keep the lance well away from the bodywork; do not spray fluidtight joints.

- Use neutral soap based products.

- In order to remove grease spots, use cleaning fluid (not petrol).

- Parts in aluminium must be cleaned with water to which a non-alkaline washing product has been added,
and rinsed with clean water.

- Spread a coat of Vaseline or talcum powder over the seals.

1.10.2 Chassis/Underbodies

Use a high pressure unit. Limit the pressure of the jet to 80 bars maximum and the time of use to the strict
minimum necessary.
In order to prevent any risk of a problem, do not spray:

- electronic or electrical boxes,

- the seals of link rods,

- hinge pins,

- air inlets for the heater, the engine air intake and air filter,

- pneumatic and electrical apparatus,

- absorbent materials and soundproofing screens,

- the fuel gauge.

1.10.3 Cleaning of the cab

Spray lightly or use a cloth dipped in a cleaning agent (i.e. soapy water, methylated spirits, etc.). Products
with a petroleum and trichlorethylene base are not to be used.
Spread talcum powder lightly onto the door seals and the windows, as well as any link rods.

1.10.4 Cleaning of the instrument panel

Only use soapy water. Any other product is not allowed.

1.11 Safety and protection of components

Before any operation of grinding, drilling, or welding, ensure that the following are effectively protected or
taken off:

- Plastic pipework and tubes,

- Electrical wiring harnesses,

- Suspension springs (particularly for the protection against corrosion),

- The bags for the air suspension,

- The soundproofing screens,

- Any other component sensitive to heat, to the discharge of incandescent matter, to ultraviolet rays (i.e. elec­tronic control units, electronic components, items in plastic material, flexible anti-vibration mountings, pain­ted items, etc.)

- For welding work, comply with the other recommendations described in the chapter entitled “Protection of
electrical and mechanical components”.

RENAULT V.I. 04/02 A8 DT 4/366

1.12 Summary of definitions

Maximum body length (Dimension W on technical data sheets and bodywork drawings).

This is the bracket of lengths for bodies (not including fittings and accessories) worked out in relation to the
extreme positions of a given centre of gravity for a load which is taken to be evenly distributed and taking into
account the space which must be left to the rear of the cab, laid down by the manufacturer, and the maximum
permitted loads per axle on a chassis cab without options.

Body start (Dimension B on technical data sheets)
Minimum distance between the front axle centre-line and the front end plane of the body.

Load distribution calculations

Comply with the regulatory constraints for each country and the load limits given per axle for each model by
RENAULT TRUCKS.
We remind you that these values are given for uniformly distributed loads.
The lateral imbalance of the loads should not exceed a maximum of 4% between the LH and RH roadwheel
of each axle.

Chassis rear overhang (Dimension N on technical data sheets)
Horizontal distance between the centre-line of the rear roadwheels and the rear extremity of the body (exclu­ding fittings and accessories).
In the case of vehicles with 3 or 4 axles: distance between the centre-line of the rearmost axle and the extre­mity of the chassis.

Body rear overhang (Dimension X on technical data sheets)
Horizontal distance between the centre-line of the rear roadwheels and the rear extremity of the body (exclu­ding fittings and accessories).
In the case of vehicles with 3 or 4 axles: distance between the technical centre-line of the tandem and the
rear extremity of the body.

Wheelbase (Dimension F or F’ on technical data sheets).
Distance between the centre-lines of the front and rear roadwheels (vehicle laden).
In the case of vehicles with 3 or 4 axles: distance between the centre-line of the front roadwheels and the
centre-line of the foremost rear axle - for calculations take dimension F’ (technical wheelbase).

Tandem

Solely in the case of vehicles with 3 or 4 axles: the 2 rear axles taken together, regardless of whether they
are driving axles or trailing axles.

Maximum axle weight

Carrying weights are stipulated on each axle for each type of vehicle. These values are indicated on the tech­nical data sheets and on the VIN plate and must be complied with on all vehicles fitted with bodies when laden
and when empty.

Driver and cab passengers weight

The weight of the driver and passenger (passengers) in the cab is applied to the front axle in the case of a
forward control cab.
For cabs of the semi-forward control type, 2/3 of the weight should be applied to the front axle and 1/3 to the
rear axle.
Weight of driver or each passenger: 75 kg (calculated on the basis of the cab seating capacity), unless sti­pulated otherwise: i.e. Export, Army, Fire Brigade, etc.
For cabs with a seating capacity of more than 3 persons, calculate the weight distribution of the persons on
the basis of the seats layout.
For equipment intended for the Army or for Civil Administrations, take the specific specifications into account.

DT 4/366 A9 RENAULT V.I. 04/02

1.13 Certificate of approval of the conversion of a vehicle

1.13.1 Application for approval

1 If the body or the equipment fitted do not modify the weight and dimensional characteristics of the chas-

sis entered in the descriptive sheet, the vehicle can be submitted to the T ype Approval Department without
any action by RENAULT TRUCKS being necessary (within the permitted limits in force).

2 The maximum rear overhang is equal to 60% of the wheelbase. However, for special cases, we can grant

higher percentages - for this, consult us.

3 If the layout requires modification to the wheelbase, it is essential to consult the Product Applications

Department. Each case has to be covered by a specific design.

4 The certificate will be issued in accordance to the legislation in force regarding modifications made by and

under the responsibility of the bodybuilder, within the limits stipulated by the Manufacturer and relative to:

- the wheelbase

- the distribution of loads

- the cab characteristics.

5 For more accuracy in your calculations, we recommend you to introduce into the data the weighed weight

of the chassis cab to be equipped (capable of varying according to manufacturing tolerances and the
various options available). The same applies to equipment for which the manufacturers can accurately
define the weight and the position of the centre of gravity.

1.13.2 Body fitting certificate

This defines the installation of the equipment on the chassis cab and the unladen weight imposed on the axles
and then the weight when fully laden.
It must be attached to all applications relating to the equipment which do not comply with any of the dimen­sions set out in the descriptive sheet.

1.13.3 Responsibility for installation

The building and fitting of a body on a vehicle is the sole responsibility of the bodybuilder, who must comply
with the recommendations in the present document.

He must ensure that the installation of the body does not affect the functions or the reliability of the compo­nents or the road behaviour of the vehicle.

RENAULT V.I. 04/02 A10 DT 4/366

1.14 Painting

1.14.1 Precautions

- Protect the RENAULT TRUCKS equipment (i.e. by using screens, self-adhesive tape, cab cover etc.)

- Never put vehicles into drying ovens at a temperature of more than 80° C.

- The chassis of the vehicle must be electrically earthed to allow static electricity to run away to earth (protec­tion of electronic boxes).

- The vehicle must be protected against corrosion by paints compatible with those used by our Company and
conforming to RENAULT TRUCKS Specification No 4702 441 (protection of bodywork and equipment adap­ted to RENAULT TRUCKS vehicles) available from the Product Applications Department.

- Thinner solvents must never be used on cables and electrical sheaths.

- Protect the identification marking of electrical wires and compressed air pipes.

Never paint bearing surfaces of brake drums and disc wheels, or with twin tyre fitment, the assembly surfaces
between the disc wheels. As a general rule, do not repaint the support surfaces of original fitment nut and bolt
hardware and comply with the specification.

NOTE

Our Product Applications Department holds the reference numbers for paint colour shades for chassis and cabs
at your disposal. These paint colours can be procured as “spare parts” and can be ordered from our dealers.
The cab colour shade is indicated on the front end of the cab.
Since 1994, chassis and accessories are no longer sprayed with the customer’s shade of paint at the time of
original fitment.
To preserve the aspect and original quality, it is essential to observe the following methods after fitting equip­ment, body, sub-frames and various adaptations to major units or chassis frame:

1.14.2 Major units (gearboxes, drive axles, engines, axles, etc.)

Works paint: GLYCEROPHTHALIC
Retouch (after fitting PTO, charge indicator, etc.)

Retouch method

- Clean with a universal cleaner or using a high-pressure cleaner.

- Wipe down, then apply a primer.

- Let the product cure until mat (about 15 minutes at 20° C), then apply the corresponding polyurethane lacquer.

DT 4/366 A11 RENAULT V.I. 04/02

1.14.3 Chassis frame and accessories (sidemembers, cross-members, fittings, lockers,

etc.)

Works paint: POLYURETHANE or POLYESTER powder.

Retouch method:
Superficial scratches (the metal is not affected).

- Clean with a universal cleaning product.

- Wipe down, then apply the corresponding undiluted but catalyzed polyurethane lacquer, using a small brush.

Deep and fine scratches (down to the bare metal).

- Clean with a universal cleaning product.

- Wipe down, then apply the primer, using a small brush.

- Let the product cure (about 15 minutes at 20° C), then apply the corresponding undiluted but catalyzed poly­urethane lacquer.

Deep and wide scratches (down to the bare metal, drilling of sidemembers for attaching tail lifts and acces­sories) due to drilling.

- Rub down.

- Clean with a universal cleaning product.

- Let the product cure until mat (about 15 minutes at 20° C), then apply the corresponding polyurethane lac­quer.

Making good after conversion (after converting wheelbase and overhang).

- Grind, rub down; prepare the area in question (burnt paint, welding scale, etc.).

- Clean with a universal cleaning product or using a high-pressure cleaner.

- Mask with tape (electrical wiring harnesses, air and fuel pipes, labels, etc.)

- Wipe down, then apply the primer.

- Let the product cure until mat (about 15 minutes at 20° C), then apply the corresponding polyurethane lac­quer.

- After drying, put back the electrical wiring harnesses, air and fuel pipes and accessories.

Spraying chassis and accessories (with customers colour shade).

- The bodybuilder undertakes to preserve the aspect and quality of the original fitment vehicle (except for nut

and bolt hardware).

- Clean with a universal cleaning product or using a high-pressure cleaner.

- Mask with tape (electrical wiring harnesses, air and fuel pipes, labels, etc.)

- Wipe down, then apply the primer.

- Let the product cure until mat (about 15 minutes at 20° C), then apply the corresponding polyurethane lac-

quer.

- After drying, put back the electrical wiring harnesses, air and fuel pipes and accessories.

NOTE

All spray gun operations are to be carried out in a painting booth.
Since August 1999, the chassis are painted grey as replacement for Enduro red. For paint retouches on grey
chassis, use a grey paint aerosol ref. N° 50 01 848 147.

1.14.4 Ingredients

Nettoyage manuel

Nettoyant universel, nettoyant équivalent, solvant.
Produits homologués RENAULT V.I.

Fournisseur Appellation commerciale Réf. RENAULT V.I. Réf. fournisseur

BASF PK 900 50 01 821 758 SV 20023F
ICI AUTOCOLOR Slow Spirit Wipe 50 01 854 983 P850–1402
STANDOX Agent ENTFERNER 50 01 825 985 FA 931 2002

Nettoyage haute pression

Dégraissant, dégraissant phosphatant

Apprêtage

Produits homologués RENAULT V.I.

Fournisseur Appellation commerciale Réf. RENAULT V.I. Réf. fournisseur

STANDOX apprêt “EPOXY”

durcisseur “EPOXY”
diluant “EPOXY”
diluant lent “EPOXY”
diluant 2KS

50 01 826 019
50 01 825 990
50 01 826 005
50 01 829 256
50 01 825 992

FA 931 5203
FA 931 5204
FA 931 5205
FA 931 5213
FA 020 7810

ICI AUTOCOLOR apprêt “EPOXY”

durcisseur “EPOXY”
diluant

50 01 829 477
50 01 829 480
50 01 829 481

P580–2100
P210––833
P850–3091

RENAULT V.I. 04/02 A12 DT 4/366

1.14.4 Recommended products

Manual cleaning

Universal cleaning product or equivalent solvent
Products approved by RENAULT TRUCKS

High-pressure cleaning

Degreaser, phosphater degreaser

Filing and sealing

Products approved by RENAULT TRUCKS

“EPOXY” filler-sealer
“EPOXY” hardener
“EPOXY” thinner
“EPOXY” slow thinner

thinner 2KS

“EPOXY” filler-sealer
“EPOXY” hardener

thinner

Supplier Commercial name

RENAULT TRUCKS Ref.

Supplier Ref.

Supplier Commercial name

RENAULT TRUCKS Ref.

Supplier Ref.

ENTFERNER Agent

§Finish paint

Two-component polyurethane paint and corresponding thinner.

> A B – C D <

Variante du polymère de base

Séparateur
Désignation des charges et renforts
Pourcentage de charges

Terme abrégé du ou des polymères

DT 4/366 A13 RENAULT V.I. 04/02

1.14.5 Marking of polymer components (recycling of plastics)

Plastic parts are marked so as to simplify their sorting during recycling at the time when the vehicle is scrap­ped at the end of its life.

Marking of the plastic parts is done by placing abbreviated terms for the polymer components between the
symbols “>“ and “<“. The parts are marked on a face which the customers cannot see and when it is possible
the marking is indelible. Marking is done in the following manner:

Marking of single component products

The abbreviated term for the material is enclosed in symbols “>“ and “<“.
For example: “>PP<“ or “PP” indicates polypropylene.

Marking of copolymers

The abbreviated terms for the polymers are separated by a “/”.
For example: “>P/E<” indicates the copolymer propylene ethylene.

Marking of mixtures or blends of polymers

The abbreviated terms are separated by a “+” (heterogeneous structure).
For example: “>PP + EPDM<“ stands for a blend of polypropylene and EPDM.

Marking of polymers with fillers (additives)

The abbreviated term for the polymer is separated from that for the filler by a dash “-”.
The number following the abbreviated term for the filler relates to its percentage in the mixture.
For example: “>PA66 - (GF25 + MD15)<“ indicates polyamide 66 with 25% filler and 15% reinforcement with
mineral fillers (in decreasing order of percentage).

Marking of multi-component products

The abbreviated terms for the components are separated by commas, in order of appearance (firstly the
surface material).
For example: “>PVC, PUR, ABS<“ indicates skin surface PVC on PUR foam with an ABS insert.

Marking of special features

Abbreviated terms for the polymers can be added up to 4 symbols, in order to indicate a modification.
The symbols are put in after the abbreviated terms.
For example: “>PE - C<“ indicates chlorinated polyethylene, “>PE - LLD” stands for linear low density
polyethylene.

Abbreviation for the polymer(s)

Variant of the base polymer

Separator

Designation of the fillers and additives

Percentage of fillers

Tableau des principaux polymères

Terme abrégé

Variante Matériaux

A.B.S Acrylonitrile/butadiène/styrène
A.S.A Acrylonitrile/styrène/acrylate
E/P Ethylène/propylène
E.P.D.M copolymère éthylène/propylène/diène
P.A Polyamide
P.A 6 Polyamide 6
P.A 66 Polyamide 66
P.C Polycarbonate
P/E Propylène/éthylène
P.E Polyéthylène
P.E – HD Polyéthylène haute densité
P.E – LD Polyéthylène basse densité
P.E – LLD Polyéthylène linéaire basse densité
P.E – X Polyéthylène réticulé
P.M.M.A Poly(méthacrylate de méthyle)
P.O.M Polyoxométhylène
P.P Polypropylène
P.P.E Poly(phénylène éther)
P.P.O.X Poly(oxyde de propylène)
P.S Polystyrène
P.S – HI Polystyrène choc
P.T.F.E Poly(tétrafluorométhylène)
P.U.R Polyuréthanne
P.V.C Polychlorure de vinyle
P.V.C – C Polychlorure de vinyle chloré
P.V.C – P Polychlorure de vinyle plastifié

RENAULT V.I. 04/02 A14 DT 4/366

Abbreviated term Variant Materials

Acrylonitrile/butadiene/styrene
Acrylonitrile/styrene/acrylate
Ethylene/propylene
Copolymer ethylene/propylene/diene
Polyamide
Polyamide 6
Polyamide 66
Polycarbonate
Propylene/ethylene
Polyethylene
High density polyethylene
Low density polyethylene
Linear low density polyethylene
Cross-linked polyethylene
Poly(methacrylate of methyl)
Polyoxomethylene
Polypropylene
Poly(phenylene ether)
Poly(oxide of propylene)
Polystyrene
Impact polystyrene
Poly(tetrafluoroethylene)
Polyurethane
Polyvinyl chloride
Chlorinated polyvinyl chloride
Plasticized polyvinyl chloride

Table of the principal polymers

DT 4/366 A15 RENAULT V.I. 04/02

1.15 Electrical equipment

1.15.1 General

- Any mounting of a specific item of equipment on a commercial vehicle must be in conformity with the recom­mendations of RENAUL TTRUCKS and the legislation in force. Its execution remains the entire responsibility of
the bodybuilder, both with regard to the suitability for the vehicle being equipped and any possible electroma­gnetic interference.

- For reference to wiring diagrams, consult the electrical equipment workshop manual for the vehicle (available
from the Spare Parts Department of RENAULT TRUCKS).

- Check that the electrical consumption of this equipment is appropriate for the capacity of the batteries and also
the charging current rate of the alternator (if not, refer to the recommendations of the manufacturer CIC 1081).
For the fitting of any particular equipment, consult the Product Applications Department of RENAULT TRUCKS

- A schematic diagram should be submitted for the approval of RENAULT TRUCKS, when raising any specific
question.

- A wiring diagram for the bodybuilder’s or equipment manufacturer’s installation must be incorporated into the
vehicle driving and maintenance handbook. The electrical connection points for the equipment being supplied
should be clearly and precisely indicated on this wiring diagram (even after the agreement of RENAULT
TRUCKS has been obtained).

- Follow the electrical protection recommendations of RENAULT TRUCKS; it is forbidden to change the rating of
fuses.

- In order to harmonize vehicle equipment, you should use in preference such items as are identical to those fit­ted in the basic vehicle (i.e. indicator lamps, controls, relays, etc.).

- Assembly of a protective shield on the electric retarder is compulsory for ADR (Transport of Hazardous
Substances) vehicles (refer to regulations in force).

- It is compulsory for the supply voltage for the equipment installed to be equal to the rated voltage of the vehicle.
The installation of equipment with a 12 volt power rating on our vehicles (24 volt rated voltage) is not permitted
unless a voltage dropper is added.

- Under the circumstances that additional lamps are fitted, the installation must not damage the fluidtight sealing
of the junction boxes.

- Operating without a battery is forbidden.

1.15.2 Wiring harnesses

- Use to the full the wiring runs already set up by the manufacturer (i.e. conduits, tubes, sleeves, etc.) and com­ply with the limit of their capacity.

- Any wiring harness added by the bodybuilder must be protected by a sealed sheath (smooth and thick or rin­ged) and can be routed along with the original wiring runs for the vehicle provided that it does not adversely
affect the mechanical mountings for the original harnesses. For vehicles for the transport of hazardous goods,
use the protective equipment authorized by the regulations covering the transport of hazardous goods.

- If you are obliged to route wires close to a source of heat (i.e. engine, exhaust system, etc.), the minimum clea­rance to be complied with is 200 mm.

- Never route a wiring harness over projecting angles.

- Never attach a wiring harness to moving parts (even slight movement).

- The section of the cables being used must be suitable for the use in question. Their cross-section should be
selected in accordance with the maximum current on-line (5 amperes per mm

2

).

- The length of the wiring harnesses should be long enough to allow the electrical appliance which is connected
to be taken off (i.e. principal display unit, tachograph, etc.).

- The numbering of the wires must be in accordance with the manufacturer’s standard.

- The link between the sheath and the connector must be fluidtight.

RENAULT V.I. 04/02 A16 DT 4/366

1.15.3 Electrical connections

- Any additional connection requires protection that is suitable for the use for which it is intended (even if the

power supply provided for the customer by RENAULT TRUCKS is already protected by a fuse).

- Any electrical connection must be properly wired on the power lines supplied by the manufacturer to the

bodybuilder’s equipment (refer to the servicing and maintenance handbook for the vehicle in question).

- Tapping into the various wiring harnesses supplied by RENAULT TRUCKS is completely FORBIDDEN (for

example vehicle rear lamps, external marker lamps, contactors, pressure switches, relays, electronic box
inputs and outputs, etc.)

Reminder: a 12 V tapping at the middle point between the two batteries is strictly FORBIDDEN.

- The electrical connections of the various wiring harnesses of the bodybuilder must be made using a fluid-

tight junction box or otherwise using sealed connectors. If connections have to be made on circuits hooked
up to electronic equipment:

- Ensure that you comply with the polarity recommended.

- No inductance current must pass through the circuits which have been added.

- All the earths must be connected up to the available “EARTH” points provided and not to the bodywork of

the vehicle.

- After work on junction boxes, the seal must always be as integrally effective as the original seal.

- Any power supply requiring a direct connection to the batteries must be capable of being isolated by a bat-

tery cut-out (for example: tail lifts) and protected by a fuse sited as near as possible to the batteries. Suitable
connection terminals should be used.

- The + power supply is taken from the master switch, or failing this, from the battery terminal for vehicles

without a master switch, but in no case from the alternator or starter motor terminal.

- Power supplies to auxiliary equipment: i.e. telephone, fax, etc. The quality of the installation is the respon-

sibility of the installer (i.e. reception, static, interference, etc.)

- Preferably, you should use connectors approved and distributed by RENAULT TRUCKS (i.e. type, sealing

properties, rating, number of channels, etc.)

- Connectors for equipment should be positioned near the bottom, whilst avoiding areas subject to splashing

(i.e. wheelarches, etc.).

1.15.4 Available power supplies

All our vehicles are equipped with the available power supply protected by fuses and these are at the dispo­sal of bodybuilders and equipment manufacturers.

These power supplies are described in the vehicle driving and maintenance handbook (supplied with every
vehicle), in the Workshop Repair Electrical Manual, and in this document (all these documents are available
from the RENAULT TRUCKS dealer network).

1.15.5 Flasher units

Should the flasher unit become inoperative due to failure to comply with the instructions contained in this
document, the coverage granted by the warranty will be lost.

The flasher units are designed for a maximum rating which is marked on the unit.
Do not exceed this power rating.

Connection

In order to make the connections correctly, consult either the identification marks which are located close to
the terminals, or the wiring diagram on the label which is affixed to the flasher unit cover.

1.15.6 Tableaux récapitulatifs des prises de courants normalisees

12 Volts Socle type 12 N

(Norme – BNA.R.43.407 d’A vril 1982

– ISO 1724)
1 – Feux indicateurs de direction gauche
2 – Feu arrière de brouillard
3 – Masse
4 – Feux indicateurs de direction droit
5 – Feux de position arrière et encombrement droit

et éclairage plaque d’immatriculation
6 – Feux de stop
7 – Feux de position arrière et encombrement gauche et

éclairage plaque d’immatriculation

TENSION DESIGNATION ET NORME SCHEMA DU SOCLE

(vue de face)

12 Volts Socle type 12 S

(Norme – BNA.R.43.410 d’Août 1984

– ISO 3732)
C’est un socle supplémentaire qui se monte en plus du
socle 12 N.
1 – Feux de recul
2 – Sans affectation
3 – Masse
4 – Alimentation “+” supplémentaire
5 – Contrôle par mise à la masse
6 – Alimentation “+”
7 – Sans affectation

24 Volts Socle 12 broches

(Norme – BNA.R.43.405 de Mars 1961

– DEFA 1457 b

– DCEA 5.556.

– NATO)

A –Feu de position gauche black–out
B –Feux indicateurs de direction gauche

C –Feu de position droit black–out
D –Masse
E –Feux de position arrière, encombrement et éclairage

plaque d’immatriculattion
F – Feux de stop black–out
H –Sans affectation
J – Feux indicateurs de direction droit
K –Alimentation “+” batterie
L – Masse
M –Feux de stop
N –Sans affectation

DT 4/366 A17 RENAULT V.I. 04/02

1.15.6 List of standard power sockets

SUPPLY

VOLTAGE

DESCRIPTION AND STANDARDS

12 N type socket
(Standard: - BNA.R.43.407 dated April 1982

- ISO 1724).
1 - LH direction indicator lamp.
2 - Rear fog lamp.
3 - Earth.
4 - RH direction indicator lamp.
5 - RH rear side and marker lamp and number plate

illumination lamp.
6 - Stop lamp.
7 - LH rear side and marker lamp and number plate

illumination lamp.

12 S type socket
(Standard: - BNA.R.43.410 dated August 1982

- ISO 3732).
This is a supplementary socket which is assembled in
addition to the 12 N socket.
1 - Reversing lamp.
2 - Not allocated.
3 - Earth.
4 - Supplementary + power supply.
5 - Earthing monitor.
6 - Positive (+) power supply.
7 - Not allocated.

12-pin socket
(Standard: - BNA.R.43.405 dated March 1961

- DEFA1457 b

- DCEA 5.556

- NATO).
A - LH black-out side lamp.
B - LH direction indicator lamps.
C - RH black-out side lamp.
D - Earth
E - Rear side and marker lamps and number plate illumina-

tion lamp.
F - Black-out stop lamp.
H - Not allocated.
J - RH direction indicator lamps.
K - Battery + power supply.
L - Earth.
M- Stop lamps.
N - Not allocated

SOCKET DIAGRAM

(front view)

TENSION DESIGNATION ET NORME SCHEMA DU SOCLE

(vue de face)

24 Volts Socle type 24 S

(Norme – BNA.R.43.409 d’A vril 1982

– ISO 3731)
C’est un socle supplémentaire qui se monte en plus du
socle 24 N.
1 – Masse
2 – Sans affectation
3 – Feux de recul
4 – Alimentation “+”
5 – Contrôle par mise à la masse
6 – Alimentation “+” supplémentaire
7 – Feu arrière de brouillard

24 Volts Socle 24 P (Pétrolier)

(Norme – BNA.R.10.120 de Juin 1977)
Socle pour véhicules TMD–ADR se monte en
plus du socle 24N.
1 – Masse
2 – Eclairage des vannes
3 – Feux de recul
4 – Alimentation “+”
5 – Masse isolée
6 – Sans affectation
7 – Feu arrière de brouillard

24 Volts Prise ABS spécifique

(Norme ISO 7638)
1 – Alimentation puissance (30A)
2 – Alimentation commande (2A)
3 – Masse commande (2A)
4 – Masse puissance (30A)
5 – Information (2A)
6 – Libre
7 – Libre

24 Volts Socle type 24 N

(Norme – BNA R 43 406 de janvier 1976

– ISO 1185)
1 – Masse
2 – Feux de position arrière et encombrement gauche

et éclairage plaque d’immatriculation
3 – Feux indicateurs de direction gauche
4 – Feux de stop remorque
5 – Feux indicateurs de direction droit
6 – Feux de position arrière et encombrement droit

et éclairage plaque d’immatriculation
7 – Disponible

La broche 7 est prévue dans certains pays pour le contrôle
frein de remorque.

RENAULT V.I. 04/02 A18 DT 4/366

24 N type socket
(Standard: - BNA.R43.406 dated January 1976

- ISO 1185).
1 - Earth.
2 - LH rear side and marker lamp and number plate illumi-

nation lamp.
3 - LH direction indicator lamps.
4 - Stop lamps.
5 - RH direction indicator lamps.
6 - rear side and marker lamps and number plate illumina-

tion lamp.
7 - Trailer braking lamp.
Terminal 7 is scheduled in certain countries for supplying
power to regulation trailer brakes. Under no circumstances
must it be used as an earth terminal.

24 S type socket
(Standard: - BNA.R43.409 dated April 1982

- ISO 3731).
This is a supplementary socket which is assembled in
addition to the 24 N socket.
1 - Earth.
2 - Not allocated.
3 - Reversing lamp.
4 - Power supply.
5 - Earthing monitor.
6 - Supplementary power supply.
7 - Rear fog lamp.

24 P (oil tanker) type socket
(Standard: - BNA.R.10.120 dated June 1977)
This is the socket for ADR (Transport of Hazardous
Substances) vehicles which is assembled in addition to the
24 N socket.
1 - Earth.
2 - Valve lighting.
3 - Reversing lamp.
4 - Positive (+) power supply.
5 - Insulated earth.
6 - Not allocated.
7 - Rear fog lamp.

ABS specific type socket
(Standard: - ISO 7638)
1 - Power (30A).
2 - Control power supply (2A).
3 - Control earth (2A).
4 - Power earth (30A).
5 - Information (2A).
6 - Free.
7 - Free.

SUPPLY

VOLTAGE

DESCRIPTION AND STANDARDS SOCKET DIAGRAM

(front view)

La prise 15 voies peut être montée sur un véhicule équipé de prises 24N et 24P en utilisant un adaptateur
24N/24P – 15 voies réf. : 50 01 851 060 disponible au département pièces de rechange Renault V.I.

1.15.7 Feux indicateurs de direction supplémentaires

– Sur tracteurs ou camions

Dans le cas où les feux prévus ne remplissent pas entièrement les conditions de la réglementation, le carrossier
doit rajouter des feux supplémentaires alimentés par le même circuit que le feu avant ou par un circuit spécial
si la centrale en est munie. Respecter la puissance admissible.

Le montage de tout autre feu non exigé par les impératifs de la réglementation est interdit.

– Sur remorque et semi-remorque

Les normes actuelles concernant les prises de remorque ne prévoient que deux circuits pour les clignotants,
un pour le côté droit et un pour le côté gauche. Le montage de feux supplémentaires sur remorque ou semi–re-
morque est interdit à partir des feux contrôlés remorque.

L’addition de feux supplémentaires nécessite la mise en place de nouvelles lignes tirées des feux non-
contrôlés de la centrale.

Surcharge

Le montage de feux supplémentaires au-delà de la puissance indiquée sur la centrale est formellement

interdit ; cette surcharge a pour conséquence notamment (suivant les cas) :
– de réduire notablement la durée de vie de la centrale, même si le fonctionnement paraît normal,
– de perturber le fonctionnement de la centrale clignotante (les feux restent allumés sans clignoter),
– de mettre l’appareil hors circuit tant que dure la surcharge.

Protection de la centrale clignotante (selon équipement du véhicule)
En cas de surintensité, la centrale ne fonctionne plus. Pour la remise en service :

– ramenez la commande des feux clignotants à la position 0,
– recherchez et supprimez la cause de surintensité (lignes ou feux).
Vous pourrez alors réutiliser les feux clignotants normalement.

TENSION DESIGNATION ET NORME SCHEMA DU SOCLE

(vue de face)

24 Volts Socle type 24 N

(Norme – ADR 1999 IP54 et anti–décrochement

– ISO 12098)
1 – Feux indicateurs de direction gauche
2 – Feux indicateurs de direction droit
3 – Feu arrière de brouillard
4 – Masse
5 – Feux de position arrière et encombrement gauche et

éclairage plaque de police
6 – Feux de position arrière et encombrement droit

et éclairage plaque d’immatriculation
7 – Feux de stop
8 – Feux de recul
9 – Alimentation “+” 24 V

La prise 15 voies remplace depuis juillet 1999 les prises
24N et 24P.
Les voies 10, 11, 12, 13, 14, 15 ne sont pas affectées.

DT 4/366 A19 RENAULT V.I. 04/02

15-pin trailer socket
(Standard: - ADR 1999 IP54 and anti-unhooking

- ISO 12098).
1 - LH direction indicator lamps
2 - RH direction indicator lamps
3 - Rear fog lamp
4 - Earth
5 - RH rear side/parking and marker and registration plate

lamps

6 - LH rear side/parking and marker and registration plate

lamps
7 - Stop lamps
8 - Reversing lamps
9 - 24V positive (+) power supply
Since July 1999, the 15-way socket replaces 24N and 24P
sockets.
Channels 10, 11, 12, 13, 14, 15 are unaffected.

The 15-way socket can be mounted on vehicles equipped with 24N and 24P sockets with the use of a 15-way
24N/24P adapter ref. N° 50 01 851 060 available from the RENAULT TRUCKS Spare Parts department.

1.15.7 Additional direction indicator lamps

- On tractors and rigids

Should the lamps provided not meet all the requirements of the legislation in force, the bodybuilder may add
extra lamps supplied with power by the same circuit as the front lamp or by a special circuit should one be
available from the flasher unit. In all cases, comply with the power rating.
We strongly advise you to refrain from fitting any other lamp not required by the regulations.

- On trailers and semi-trailers

The standards in force concerning trailers require only two circuits for the flasher units: one circuit for the RH
side and the other for the LH side. No additional lamps must be fitted on the trailer or semi-trailer which run
from the monitored trailer lamps.

The addition of extra lamps entails the fitting of new wire runs which have to be drawn from the non­monitored lamp terminals in the flasher unit.

Overloading

Under no circumstances must extra lamps be fitted that exceed the power rating on the flasher unit. The main
consequences of such overloading are as follows:

- The service life of the flasher unit is shortened, even when it would appear to be operating normally in spite
of the overload.

- Operation is adversely affected by intermittent or permanent sticking of the contacts (the lamps remain lit
without flashing)

- The appliance may be off-circuit for the duration of the overload.

Protection of the flasher unit (depending on the vehicle equipment)
In the event of excess current, the flasher unit will cease to operate. To return it to service:

- Move the flashing lights control switch to the 0 “off” position.

- Find the cause of the overcurrent (lines or lamps) and remedy it.

You will then be able to use the flashing lights again normally.

SUPPLY

VOLTAGE

DESCRIPTION AND STANDARDS SOCKET DIAGRAM

(front view)

1.16 Equipement pneumatique

L’adjonction d’une servitude supplémentaire non prévue par le constructeur doit se raccorder impérativement
au circuit spécifique servitudes.

La consommation en air comprimé de cette servitude ne doit en aucun cas compromettre le temps de remplis-
sage des circuits de freinage imposé par la législation en vigueur.

Les services technico-commerciaux RENAUL T V.I. sont à votre disposition pour tous renseignements complé-
mentaires.

1.16.1 Réglementation

Il est interdit de modifier le circuit de freinage qui est homologué et conforme aux normes prescrites par le code
de la route.

Toute modification sans accord préalable de RENAULT V.I. engage la seule responsabilité du réalisateur.

1.16.2 Tubes polyamide

Repérage

Avant toute intervention de dépose d’appareils ou de débranchement de canalisations polyamide, repérer le tube
par rapport à l’orifice de raccordement sur l’appareil.

Codification utilisée sur les tubes polyamide (norme RENAULT V.I.).

Les tubes polyamide sont repérés par un code couleur matérialisé par du ruban adhésif ou par des anneaux
élastiques.

Code freinage :

Sous-fonctions

ББББББББ

Á

Fonctions principales

БББББ

Á

Pression

constante

ББББББ

Á

Pression délivrée

ББББББ

Á

Pression pilote

Frein de service avant

Orange

Orange - blanc

Orange - jaune

Frein de service arrière

Bleu

Bleu - blanc

Bleu - jaune

Frein de stationnement

Vert

Vert - blanc

Vert - jaune

ББББББББ

Á

Frein de remorque

БББББ

Á

Rouge

ББББББ

Á

Rouge - blanc

ББББББ

Á

Rouge - jaune

Frein supplémentaire

Jaune

Jaune - blanc

Jaune - jaune

RENAULT V.I. 04/02 A20 DT 4/366

1.16 Air-operated equipment

Should it be necessary to add auxiliary equipment not provided by the manufacturer, it must compulsorily be
connected to the circuit specifically provided for auxiliary equipment on the vehicle.

The compressed air consumption of such auxiliary equipment should under no circumstances compromise
the filling times of the brake circuits laid down by the legislation in force.

The RENAULT TRUCKS Product Applications Department is at your disposal for any further information you
may require.

1.16.1 Regulations

It is forbidden to modify officially approved braking circuits which conform with the standards set out by the
Highway Code.

Any modification, without prior agreement from RENAULT TRUCKS, is done under the sole responsibility of
the author of such a modification.

1.16.2 Polyamide pipes

Identification marking

Before removing any equipment or disconnecting polyamide pipes, mark the pipe in relation to the connec­tion port on the equipment.

Coding system used on polyamide pipes (RENAULT TRUCKS standard):

Polyamide pipes are identified with a colour code marked with adhesive tape or by elastic rings.

Brakes code:

Constant
pressure

Delivered pressure

Sub-functions

Signalling pressure

Main functions

Front service brake Orange Orange - White Orange - Yellow
Rear service brake Blue Blue - White Blue - Yellow
Parking brake Green Green - White Green - Yellow
Trailer brake Red Red - White Red - Yellow
Extra brake Yellow Yellow - White Yellow - Yellow

ББББББББ

Á

Dimension

ÁÁÁÁ

Á

4 x 6

ÁÁÁÁ

Á

6 x 8

ÁÁÁ

Á

9 x 12

ÁÁÁ

Á

12 x 16

ББББББББ

Á

Rayon courbure

ÁÁÁÁ

Á

30 mm

ÁÁÁÁ

Á

50 mm

ÁÁÁ

Á

70 mm

ÁÁÁ

Á

130 mm

DT 4/366 A21 RENAULT V.I. 04/02

Coding used on pneumatic appliances (DIN standard)

0 - Air intake 5 - Free
1 - Pressurized supply 6 - Free
2 - Delivered pressure 7 - Antifreeze
3 - Air vent 8 - LubricatIon. 81 - Inlet. 82 - Outlet
4 - Signalling pressure 9 - Water cooling. 91 - Inlet. 92 - Outlet

When the figure is followed by a second figure, the latter figure indicates the sequence number.
Example: 41, 42, 43: The figure 4 indicates the signalling function, the figures 1, 2, 3 indicate a sequence

number in that function.

Replacement of a brake line

The entire length of a damaged polyamide pipe should be replaced by a pipe with identical characteristics
(length and diameter), and corresponding with the standard in force. (See technical memo 8655 group 53000,
part N° 50 20 034 156 available with spare parts). It must also be provided with coloured rings which are iden­tical to those of the tube replaced.

Use an original manufacturer’s pipe available from the RENAULT TRUCKS Spare Parts warehouse.
The routing of a polyamide pipe must be carefully executed. Ensure there is no interference with sharp-edged

metal parts and there is no routing close to high temperature units. The pipes must be held at regular inter­vals by plasticized clamps or run in existing ducting. Non-plasticized attachment clamps are absolutely for­bidden. Take care to ensure the minimum radius of curvature of polyamide pipes is observed.

Modification to the length of the chassis

Modification to brake pipe lengths requires braking response times to be checked out, in accordance with the
legislation in force, and with agreement from the Type Approvals Department.

Connections for firtree type pneumatic brake pipes type “RILAX 2000”

For the fitting of this type of connector, refer to and comply absolutely with the technical instruction sheet NT
8852 (method and tooling) available from the RENAULT TRUCKS Spare Parts Department.

Dimension

Radius of curvature

RENAULT V.I. 04/02 A22 DT 4/366

2. GENERAL RULES TO BE OBSERVED WHEN FITTING BODYWORK

Before carrying out any work, protect the cab with a cover.
Our vehicles are equipped with plates, pedestals or brackets. Preparation work may involve extra drilling or

welding.
The principles described below must be adhered to.

2.1 General welding principles

2.1.1 Precautions

Protection of the batteries

A battery at the end of its charge produces a mixture of oxygen and hydrogen gas. The ignition of this gas
presents dangers of battery explosion in the case of the presence of a source of heat nearby. As a result,
during a welding operation near the batteries (i.e. engine compartment, front end of the vehicle), take out the
batteries and store them in a well-aired location away from the place where welding is being done. This
recommendation applies equally for grinding operations.

Soundproofing screens

In the case of welding or use of a sanding disk, either provide effective protection or remove the soundproo­fing screens, if necessary.

Protection of electrical and mechanical components

The vehicle is equipped with numerous electronic circuits: alternator, regulator, flasher units, speed limiter,
ABS, etc.

Before any operation involving electric arc welding, make an earth connection by disconnecting the two nega­tive (-) and positive (+) cables from the battery (starting with the earth cable) and connecting them to the
frame earth. If the vehicle is equipped with a master switch, this should kept engaged (circuit closed). Place
the earthing clamp as near as possible to the point of welding, but never on rotating parts (prop shaft, fan
hub, etc.) or on a subassembly having moving parts (i.e. air compressor, turbocharger, etc.)

Nearby plastic pipes and electrical cables, springs and air-suspension bags are to be protected or removed.
This also applies when grinding or drilling.

When reconnecting the battery, observe the polarities, commencing with the positive (+) terminal. Reversal
of polarity may cause irreparable damage to electronic components.

2.1.2 Preparation of parts for welding

Clean the parts, primarily at the location of the weld and at the connection of the earthing wire. This allows:

- free and regular electrical current flow (regularity of weld bead),

- avoidance of inclusion of impurities in the molten metal (weld quality),

- avoidance of spatter and emission of smoke (safety for the welder).
For conversions (extensions, reductions and reinforcement gussets), we recommend arc welding with elec-

trode type B. When semi-automatic welding is use, the bodybuilder must be able to guarantee weld quality.

Préparation des bords spécifiques aux cadres–châssis

A – Avec soudure à arc électrique
B – Avec soudure sous protection gazeuse (MIG – MAG)
J – 1 mini, 2 maxi

Méthode de soudage spécifique aux cadres–châssis

– préparation des bords à 45°
– pointage
– mise en place des abouts

– soudure d’un seul côté

– soudure du deuxième côté

– meulage des deux côtés

Abouts de cratère terminal

Les abouts ont pour but d’éviter une amorce de rupture aux extrémités du joint de soudure.
Positionner impérativement avant soudure des abouts (1) de même épaisseur que les tôles à assembler mainte-
nus par des dispositifs de serrage rapide.
Ils ne doivent être en aucun cas maintenus par des points de soudure sur les éléments à assembler.

DT 4/366 A23 RENAULT V.I. 04/02

Preparation of specific edges on chassis frames

A - With electric arc welding
B - With weld under gas shield (MAG or MIG)
J - 1 min., 2 max.

– Preparation of the edges at 45°
– Tack
– Position slave butts

– Weld on one single side

– Weld on second side

– Welds ground flush on both sides

Slave butts

The object of slave butts is to avoid the starting of cracks at the outside edges of the weld joint. Before final
welding align butts with plates of the same thickness as the plates to be joined, holding them in position using
quick action clamping devices.

They must not under any circumstances be held in position by weld tacks on the plates to be joined.

Method of welding to be specifically used on chassis frames

RENAULT V.I. 04/02 A24 DT 4/366

2.1.3 Welding process

Static or rotary arc welding set

- dc welding set recommended

- coated welding rods
Welding rod usage table

(*) Most frequently used diameters
Coated welding rods recommended: standard NF EN 499 (January 1995)
EN 499 E 38 2 1 NI B for class: A- B - C
EN 499 E 46 2 1 NI B for class: D - E
EN 499 E 50 2 1 NI B for class: F
E 515/5 B 26 BH for steels class F

If steels are mixed, take the best performing steel electrode category.
Standard NF EN 499 replaces standard NF A 81-309.

MIG or MAG semi-automatic welding set

MIG : - Metal Inert Gas

- for welding with electrode wire under inert gas shield (Argon, Helium...)

MAG : - Metal Active Gas

- for welding with electrode wire under active gas shield (CO

2

Argon + CO2Argon + CO2+ O2).

- used for welding mild steels.

Electrode diameter (in mm)
Average current (in amperes)

Wire diameter (in mm)

Thickness to be welded (in mm)

2.5

3.15

75 to 90

95 to 110

120 to 140

150 to 175

0.8

up to 2 mm

from to 8 mm

1.0

Diamètre des électrodes (en mm)
Intensité (en ampères) 75 à 90 95 à 110 120 à 140 150 à 175

(*) Diamètres les plus fréquemment utilisés.
Electrodes enrobées conseillées : Norme NF EN 499 (Janvier 1995)
EN 499 E 38 2 1 NI B pour classe A – B – C

EN 499 E 46 2 1 NI B pour classe D – E
EN 499 E 50 2 1 NI B pour classe F

E 515/5 B 26 BH pour aciers classe F

Si mixage des aciers, prendre la catégorie d’électrode de l’acier le plus performant.
La norme NF EN 499 remplace la norme NF A 81–309.

Poste semi–auto MIG ou MAG

MIG : – Métal Inerte Gaz

– soudage avec fil électrode sous protection de gaz inerte (argon, hélium...)
– utilisé pour le soudage des aciers inoxydables et métaux non ferreux.

MAG : – Métal Active Gaz

– soudage avec fil électrode sous protection de gaz actif (CO

– utilisé pour le soudage des aciers doux.

2,5 3,15 (*) 4 (*) 5

argon + CO2 argon + CO2 + O

2

)

2

Diamètre du fil (en mm) Epaisseur à souder (en mm)

0, 8 Jusqu’à 2 mm
1, 0 de 2 à 8 mm

2.1.4 Correspondance des aciers

Les quatre classes concernent les produits plats laminés à chaud en acier à haute limite d’élasticité pour formage
à froid, définis aujourd’hui dans la norme française et européenne NF EN 10149–2 qui a remplacé la norme NF

A 36.231.

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ББББББББББББББББББББББ

Á

ББББББББББББББББББББ

Á

Cahier des charges RENAULT V.I. 31.09–402

БББББББББ

ББББББ

Á

ÁÁÁÁ

Á

Classe C

ÁÁÁÁ

Á

Classe D

БББББ

Á

Classe E

ÁÁÁÁ

Á

Classe F

Rm en N/mm2 mini

ББББББ

450

500

540

610

БББББББББ

БББББББББ

Re à 0,2 %
en N/mm2 mini

ББББББ

Á

ÁÁÁÁ

Á

Á

ÁÁÁÁ

Á

355

ÁÁÁÁ

Á

ÁÁÁÁ

Á

445

БББББ

Á

БББББ

Á

490

ÁÁÁÁ

Á

ÁÁÁÁ

Á

560

A % mini

ББББББ

23

20

18

15

БББББББББ

KCV à - 20°C
J/cm

2

sens long mini

ББББББ

Á

ÁÁÁÁ

Á

35

ÁÁÁÁ

Á

35

БББББ

Á

35

ÁÁÁÁ

Á

37,5

Pliage sens travers

ББББББ

1 e

1 e

1,5 e

1,5 e

Grosseur du grain

ББББББ

n° 5

–

–

–

БББББББББ

БББББББББ

= correspondance

européenne NFEN 10149–2

Normes françaises

ББББББ

Á

ÁÁÁÁ

Á

Á

ÁÁÁÁ

Á

S 355 MC

NF

EN 10149.2

ÁÁÁÁ

Á

ÁÁÁÁ

Á

S 420 MC

NF

EN 10149.2

БББББ

Á

БББББ

Á

S 500 MC

NF

EN 10149.2

ÁÁÁÁ

Á

ÁÁÁÁ

Á

S 550 MC

NF

EN 10149.2

БББББББББ

БББББББББ

= correspondance

DIN

Normes allemandes

ББББББ

Á

ÁÁÁÁ

Á

Á

ÁÁÁÁ

Á

QStE 380TM

SEW

092

ÁÁÁÁ

Á

ÁÁÁÁ

Á

QStE 420TM

SEW

092

БББББ

Á

БББББ

Á

QStE 500TM

SEW

092

ÁÁÁÁ

Á

ÁÁÁÁ

Á

QStE 550TM

SEW

092

БББББББББ

БББББББББ

= correspondance

BS

Normes britanniques

ББББББ

Á

ÁÁÁÁ

Á

Á

ÁÁÁÁ

Á

43 F 35

BS 1449

ÁÁÁÁ

Á

ÁÁÁÁ

Á

46 F 40

BS 1449

БББББ

Á

БББББ

Á

ÁÁÁÁ

Á

ÁÁÁÁ

Á

БББББББББ

БББББББББ

= correspondance

ASTM

Normes américaines

ББББББ

Á

ÁÁÁÁ

Á

Á

ÁÁÁÁ

Á

Gr. 50

050 YKL

ASTM 607–50

ÁÁÁÁ

Á

ÁÁÁÁ

Á

Gr. 60

060 YKL

ASTM 607–55

БББББ

Á

БББББ

Á

Gr. 70

ÁÁÁÁ

Á

ÁÁÁÁ

Á

Gr. 80

БББББББББ

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= correspondance

Normes EURONORM

149-80

ББББББ

Á

ÁÁÁÁ

Á

Á

ÁÁÁÁ

Á

FeE355 TM

ÁÁÁÁ

Á

ÁÁÁÁ

Á

FeE420 TM

БББББ

Á

БББББ

Á

FeE490 TM

ÁÁÁÁ

Á

ÁÁÁÁ

Á

F e E560 TM

ББББББББББББББББББББББ

DT 4/366 A25 RENAULT V.I. 04/02

UTS in N/mm2min.
YP at 0.2% in

N/mm2 min.
E % min.
KCV at - 20 °C

J/cm2min., longitudinal
Bending, transversal

Grain size

= European

equivalent

French standards

= German standards

equivalent

DIN

= British standards

equivalent

BS

= American standards

equivalent

ASTM

= EURONORM

standards equivalent

149-80

2.1.4 Equivalent steel grades

The four classes relate to hot rolled steel plate with a high yield strength for cold forming, as currently set out
in the French and European Standard NF EN 10149-2, which has replaced French Standard NF A36.231.
High yield strength sheet steel (dispersed carbon)

RENAULT TRUCKS Specification 31.09-402

Class C

Class D Class E Class F

1.5

1.5

RENAULT V.I. 04/02 A26 DT 4/366

2.2 Reinforcement, extension, reduction of sidemembers

2.2.1 Bans

It is absolutely forbidden to weld onto sidemembers, except for reinforcement, extension, reduction, and the
following instructions must be observed:

- Do not weld on the edges of flanges.

- Do not weld in sidemember bending radii.

- In the case of flat irons: no directly opposing welds on the two faces of the same web - only “alternate” or
“plug” welds are authorized.

- No welds which are less than 15 mm from the edge of a hole.

Insofar as possible, we advise you to have modifications of the lengths of sidemembers carried out by spe­cialists.

- The general rules for welding in the paragraph entitled “General Principles of Welding” must be strictly followed.

Only conversions (extensions or reductions) rendering the modified vehicle completely in conformity with a
type approved chassis are permitted without additional testing, with certification from the vehicle manufactu­rer.

2.2.2 Reinforcement of sidemembers

- For inner reinforcements and chassis flange stiffeners, the thickness should be the same as the thickness
of the sidemember.

NOTE

The steel grade must be identical to that used for the sidemember.

Examples of reinforcements

Sidemember upper and lower stiffeners

A : Offset of the stiffener in relation to the external face of the sidemember
B : Offset of the stiffener in relation to the edge of the sidemember
e : Thickness of the sidemember
1 : Welds through round or slotted holes, staggered

Thickness of the sidemember

Upper and lower stiffeners using angle-irons

A : Déport du renfort par rapport à la face extérieure du longeron
B : Déport du renfort par rapport au bord du longeron
e : Epaisseur du longeron
1 : Soudures par trous ou boutonnières à souder en quinconce

Epaisseur du longeron

e t 6 mm 10 mm 15 mm

A B

e w 6 mm 15 mm 15 mm

Renforts supérieurs et inférieurs par cornière :

Modes de liaison

Dans le cas de renforts constitués de plats (sur l’aile supérieure ou sous l’aile inférieure des longerons) nous
préconisons la fixation par :

Cordons intermittents de soudure électrique : à titre indicatif, cordons de 80 mm espacés de 120 mm et dispo-
sés en quinconce.

Soudures “BOUCHON’’ : à titre Indicatif, trous de diamètre 14 à 18 mm ou boutonnières (1) diamètre 14 x 50
mm à 18 x 5 0 mm “au pas’’ de 200 mm mini à 300 mm maxi, disposées en quinconce, avec soudure de bonne
qualité.

ATTENTION

Pas de soudure verticale sur l’âme des longerons, pas de soudure transversale sur les ailes des longerons.

DT 4/366 A27 RENAULT V.I. 04/02

Methods of joining

In the case of stiffeners made from flats (on the upper flange or under the lower flange of sidemembers), we
recommend attachment by:

Intermittent beads by electric welding: as guidance, 80 mm beads spaced 120 mm apart and staggered.

“PLUG” welds: as guidance, round holes dia. 14 to 18 mm or slotted (1) holes dia. 14 x 50 mm to 18 x 50

mm at a “pitch” of 200 mm min. to 300 mm. max., staggered, with good quality weld.

WARNING

No vertical welds on sidemember webs. No transversal welds on sidemember flanges.

Allongement, raccourcissement des longerons dans l’empattement

Légende

A – morceau de longeron ajouté (longueur maximum 500 mm),
B – longeron,
C – renfort reconstitué,
D – soudure débordante en bordure d’aile avec about puis meulage en long (suppression des arêtes

vives),
e – épaisseur du longeron,
F – cornière d’épaisseur (E) maxi : Ev (e–1mm),
G – soudures,
J – jeu de pénétration de la soudure (environ 2 mm),
L – longueur de rallongement maxi,
X – longueur minimale de dépassement du renfort mesurée en bordure d’aile (rallongement),
Y – longueur d’appui minimale du renfort mesurée en bordure d’aile du longeron (rallongement),
Z – longueur d’appui minimale du renfort mesurée en bordure d’aile (renforcement sans rallongement).

Allongement des longerons dans l’empattement

Longeron sans plat de renfort sur l’aile

Longeron avec plat de renfort sur l’aile

RENAULT V.I. 04/02 A28 DT 4/366

Extension, shortening of sidemembers in the wheelbase

Key

A – piece of sidemember added,
B – sidemember,
C – reconstituted stiffener,
D – welds projecting beyond flanged edge with butt-ends then longitudinal grinding (elimination of sharp

edges),
e – thickness of the sidemember,
F – angle-iron of thickness (E) max. : E ≤ (e - 1 mm),
h – height of the sidemember,
J – weld penetration clearance (about 2 mm),
L – max. length of extension,
X – max. length of projection of the stiffener measured on the edge of the flange (extension),
Y – min. length of support of the stiffener measured on the edge of the flange of the sidemember (extension).
Z – min. length of support of the stiffener measured on the edge of the flange (stiffener without extension).

Extension of the sidemembers in the wheelbase

Sidemember without stiffener flat on the flange

Sidemember with stiffener flat on the flange

DT 4/366 A29 RENAULT V.I. 04/02

2.2.3 Modification of the rear overhang

If the bodywork or the equipment fitted do not alter the weight and dimensional characteristics of the chassis
entered on the description sheet, the vehicle can be submitted to the Type Approval Department without any
action being necessary on the part of RENAULT TRUCKS (within the permitted limits in force).

- Welding stiffeners are required for drawbar rigids or if the extension is longer than 400 mm for a solo vehicle.
Examples : Drawbar rigid; tail lift; crane at the rear of the chassis; tipper; etc.

- Extension of the rear overhang will also be required when the rear extremities of the bodywork project
beyond the maximum authorized value which is indicated on the bodybuilder’s drawing and calculation
sheets relating to the vehicle.

Attachment of cross-members

Cross-members should be attached with nut and bolt hardware of the 10.9 SSS protected class as per stan­dard 01714002 and distributed by RENAULT TRUCKS.

Towing cross-members

Please refer to the chapter on “Drawbar cross-members” in the section entitled “SPECIFIC FEATURES OF
THE MIDLUM VEHICLE”.

Intermediate cross-members

In the case of extension of the wheelbase or the rear overhang, it is essential to add cross-members, so as
not to weaken the rigidity of the frame.

Observe the following instructions:

- Between two cross-members, the spacing must be no greater than the original spacing.

- If the extension to the overhang is longer than 500 mm, the rear cross-member must be moved and an inter-

mediate cross-member fitted which is identical to the others.

Sidemember with stiffener flat on the flange

RENAULT V.I. 04/02 A30 DT 4/366

2.3 Attachment of bodywork

The bodywork must be correctly attached so that both the static and dynamic stresses are freely transmitted
without causing excessive local strain, which could prejudice the reliability of the chassis frame or affect the
road behaviour of the vehicle.

The following rules apply to the fastening of various standard bodies fitted to our chassis cabs, such as plat­forms, vans, tippers, and tankers. For special cases, contact the RENAULT TRUCKS Applications
Department.

For body design (i.e. length, load distribution, location of accessories on sidemembers, etc.) refer to the CD­ROM “Information for Bodybuilders” or the 1:20 scale bodywork drawing which we supply upon simple
request.

Fastenings should always be tightened progressively and alternately.
The shape of sub-frames or underbodies should always be tapered towards the front (i.e. at the back of the

cab), so as to avoid sudden variations in inertia (refer to chapter entitled “Finishing of sub-frame behind the
cab”.

2.3.1 Bans

- The use, drilling or welding of spring hangers.

- Any modification of: the chassis, the driveline, or the suspension.

- Fastening of sub-frames to our sidemembers by welding.

- The drilling of stiffener gussets.

- The notching of sidemembers, gussets or cross-members.

- With the exception of special cases described in this document, the use or modification of our nut and bolt
hardware and our riveting for the attachment of a body or sub-frame.

- The attachment of sub-frames by U-bolts.

All bodies attached by clamps and brackets must mandatorily have 1 inertia stop to the aft of each side­member to stop the body from moving in the event of fierce braking, as well as 4 body guides 2 at the front,
2 at the rear).

For bolted fastenings, comply with the following instructions:

- By preference use brackets attached to the chassis.

- Use the fixing bolt holes dia. 11, 13 or 15 mm depending on the particular vehicle, spread out along the leng­th of the sidemembers of the chassis frame.

- Take good note of the attachment principles, set out in the chapter on the “Attachment of sub-frames”.

2.3.2 Protection against exhaust heat radiation

Depending on the features of your bodywork or equipment, the fitting of a heat shield on the original protec­tion is recommended.

DT 4/366 A31 RENAULT V.I. 04/02

2.4 Sub-frame

In order to attach bodywork to the frame of the chassis, you should allow for the fitting of a sub-frame whose
module of inertia (I/V) is determined in accordance with the vehicle series in question (refer to the section
entitled “RENAULT MIDLUM special bodybuilding features”.
In order to ensure better distribution of the stresses along the sidemembers, you must allow for a cut-out as
far forward as possible under the cab.

2.4.1 Finishing of sub-frames behind the cab

Nous proposons également, lorsque le faux-châssis est constitué par du tube carré ou rectangulaire, la coupe
ci-dessous.

A – plaque d’obturation d’épaisseur 1,5 mm

RENAULT V.I. 04/02 A32 DT 4/366

When the sub-frame is constructed of square or rectangular tube section, we also suggest the cut-out shown
below.

A: Blank off with 1.5 mm thick sheet metal

DT 4/366 A33 RENAULT V.I. 04/02

2. 5 Visserie et couples de serrage pour pièces en acier et en fo nt e

Les couples indiqués dans le tableau sont des couples nominaux (valeur moyenne calculée à partir du couple
minimal et du couple maximal).

La classe III est la classe de précision de serrage (± 20 % du couple nominal) suivant la norme 01504002
(coefficient de frottement 0,15 ± 0,03).
Les couples de serrage sont donnés pour une visserie sèche et traitée dacromet.

Désignation Caractéristique Classe acier Réf. P.R. Couple de serrage

Vis

Vis à embase

H 10 x 125 L 30
H 10 x 125 L 50
H 12 x 125 L 40
H 12 x 125 L 45
H 12 x 125 L 50
H 12 x 125 L 60
H 14 x 150 x 40
H 14 x 150 x 50
H 14 x 150 x 60

H 14 x 150 x 90
H 14 x 150 x 100
H 14 x 150 x 110

H14 x 150 x 120
H14 x 150 x 130
H14 x 150 x 140

H 16 x 150 x 50

H 10 x 125 L 30

H 12 x 125 L 40

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

10.9

50 03 101 460
50 03 101 148
50 03 101 151
50 03 101 749
77 03 101 679
50 03 101 153
50 03 101 161
50 03 101 162
50 03 101 163
50 03 101 169
50 03 101 660
50 03 101 171
50 03 101 172
50 03 101 887
50 03 101 173
50 03 101 103

50 03 002 048
50 03 002 049

60 N.m

60 N.m
110 N.m
110 N.m
110 N.m
110 N.m
170 N.m
170 N.m
170 N.m
170 N.m
170 N.m
170 N.m
170 N.m
170 N.m
170 N.m
220 N.m

60 N.m
110 N.m

Désignation Caractéristique Réf.P.R.

Rondelle conique

Rondelle plate

Rondelle conique BELLEVILLE

10 x 20 x 2,2
10 x 24 x 2,8
10 x 27 x 2,8
12 x 30 x 3, 2
14 x 28 x 3
16 x 32 x 3,4
16 x 39 x 3,6

10 x 22 x 3
10 x 27 x 3
10 x 24 x 2,5
12 x 28 x 5
12 x 32 x 2,5
14 x 30 x 5

14,5 x 35 x 1,8

50 03 058 081
50 03 058 071
50 03 058 076
50 03 058 075
50 03 058 069
50 03 058 034
50 03 058 070

50 03 053 453
50 03 053 455
50 03 053 026
50 10 054 526
50 03 053 441
50 03 053 014

00 21 721 040

Désignation Caractéristique Classe acier Réf. P.R. Couples de serrage

Ecrou

Ecrou frein DRH
(à embase)

10 x 125
12 x 125
14 x 150
16 x 150

10 x 125
12 x 125
14 x 150

10
10
10
10

10
10
10

50 03 032 156
50 03 032 157
50 03 032 159
50 03 032 236

50 03 034 246
50 03 034 248
50 03 034 250

60 N.m
110 N.m
170 N.m
220 N.m

60 N.m
110 N.m
170 N.m

2.5 Nuts and bolts, tightening torques for parts in steel and cast iron

The torques indicated in the table are the nominal torques (i.e. average value calculated on the basis of the
minimum and maximum torque).

Class III is the class covering precision tightening (

± 20 % of nominal torque) in accordance with Standard

01504002 (coefficient of friction 0.15 ± 003).
The tightening torques are given for nut and bolt hardware that is dry and coated with Dacromet.

Description Characteristics Class of Steel Part Nos.

Part Nos.

Tightening torque

Description

Description

Characteristics

Characteristics

Class of Steel

Part Nos.

Tightening torque

Cone washer

Flat washer

Cone washer “Belleville” type

Nut

Locknut DRH
(flanged)

Screw

Collar screw

2.2

2.8

2.8

3.2

3

3.4

3.6

3
3

2.5
5

2.5
5

1.8

14.5

50 10 377 934

50 03 053 511

Ecrou à sertir M6 – fût hexagonal

Réf. : 50 03 043 050

Méthode :

– Percer au Ø 9,2 (voir chapitre “Perçage éléments de carrosserie pour montage d’accessoires”).
– Utiliser l’outillage OPEX de OTALU SA (N° Agrément RENAULT TRUCKS 8162).
– Réaliser le poinçonnage hexagonal.
– Poser l’écrou à sertir.

Indications :

– Couple de serrage maxi 10 Nm
– Longueur du fût dépassant sous support après sertissage : 17 mm.

Ecrou à sertir M8 – fût hexagonal

Réf. : 50 03 043 052

RENAULT V.I. 04/02 A34 DT 4/366

2.6 Addition of equipment to the bodywork

The attachment of equipment to the bodywork must be done with fluidtight crimping nuts.

Tooling and crimping nuts

M6 crimp nut - hexagonal barrel

Part N°: 50 03 043 050

Method:

- Drill a dia. 9.2 mm hole (refer to chapter entitled “Drilling of bodywork members for the fitting of accessories”).

- Use the OPEX tooling from OTALU S.A. (RENAULT TRUCKS approval N° 8162).

- Punch out the hexagonal.

- Insert the nut for crimping.

Information:

- Tightening torque max. 10 Nm.

- Length of barrel projecting under bracket after crimping: 17 mm.

Method:

- Drill a dia. 11.2 mm hole (refer to chapter entitled “Drilling of bodywork members for the fitting of accessories”).

- Use the OPEX tooling from OTALU S.A.

- Punch out the hexagonal.

- Insert the nut for crimping.

Information:

- Tightening torque max. 24 Nm.

- Length of barrel projecting under bracket after crimping: 21 mm.

M8 crimp nut - hexagonal barrel

Part N°: 50 03 043 052

DT 4/366 A35 RENAULT V.I. 04/02

2.7 Rear run-under guard

RENAULT TRUCKS obtains approval for its equipment to cover the requirements of its range. Their attach­ment being by means of bolts, this allows them to be moved down along the sidemembers to suit such modi­fications that the chassis may undergo. This must be observed, along with the maintenance of the attachment
method detailed on the 1:20 scale bodywork drawing and compliance with the dimensional requirements
under the regulations.
Avehicle which is not equipped at the time of delivery can be fitted afterwards, following a conversion making
the fitting compulsory, using items which can be supplied from the Parts Stores of our dealers.

Changing of position of items of equipment

Modifications of a RENAULT TRUCKS vehicle for the fitting of bodywork and equipment requires technical
approval to be obtained from the Product Applications Department of RENAULT TRUCKS.

3. SPECIFIC EQUIPMENT FEATURES

3.1 Running the engine when vehicle stationary

Under the conditions of running an engine for a long period under load, it is vital to fit an additional cooler unit
in order to keep the temperature of the engine at a normal level (water temperature approx. 80° C).
The prolonged use of the engine under these conditions can cause malfunctions which could adversely affect
the life of the engine.

3.2 Mounting of power take-offs and flanged pumps

RENAULT TRUCKS power take-offs (PTOs) and their adapter kits should be ordered from the RENAULT
TRUCKS Spare Parts Department. In order to carry out the fitting, refer to the specific information circulars
that are available from the Product Applications Department.
Bearing in mind the weight and the large overhang required for certain PTOs having flanged pumps, the rear
of these units should be supported by a suitable bracket attached to the rear of the gearbox.

Comply with the standard NF ISO 7653

IMPORTANT

It is compulsory at the time of fitting a power take-off to ensure that there is a certain amount of play in the
setting adjustment, so as to allow an ideal backlash of 0.15 to 0.25 mm then to fit a gasket or apply paste in
order to achieve a good seal and also to top-up the oil level. (Refer to the vehicle maintenance handbook).
Refer to our Product Information Sheet and 1:20 scale bodywork drawing on “power take-offs”, which can be
requested from our Product Applications Department.

RENAULT V.I. 04/02 A36 DT 4/366

Règle pour le signe b
On considère que la fourche 1 est la fourche de référence.

b > 0 lorsque les fourches menantes sont parallèles à la première fourche menante (Ma).
Exemple 1 :

b

E

+|b

a

2

) b

b

2

) b

c

2

– b

d

2

|

Ǹ

M – Fourches menantes
N – Fourches menées

b < 0 lorsque les fourches menantes sont perpendiculaires à la première fourche menante (Ma).
Exemple 2 :

bE+|b

a

2

) b

b

2

– b

c

2

) b

d

2

|

Ǹ

b

E+

|

b

a

2

" b

b

2

" b

c

2

"

Ǹ

...

|

b

E

v 3°

3.3 Front power take-offs (crankshaft nose)

RENAULT TRUCKS pre-arrangement

For belt drive units, pulleys with extra grooves fitted to the engine may be available.
Consult the Product Applications Department to obtain the relevant information and technical approval for the

assembly.

3.4 Front and rear power take-offs

3.4.1 Propeller shaft alignment

In order to achieve satisfactory propeller shaft alignment, several minimum basic criteria have to be obser­ved.

Angularity criteria (or: equivalent angle of inclination βEpermissible for all articulations).
This angle βEmust comply with the following condition:

Rule for sign β:
Yoke N° 1 is to be considered as the reference yoke.

ββ

> 0 when the leading yokes are parallel to the first leading yoke (Ma).

Example 1:

M - Leading yokes
N - Trailing yokes

ββ

< 0 when the leading yokes are perpendicular to the first leading yoke (Ma).

Example 2:

DT 4/366 A37 RENAULT V.I. 04/02

Angular acceleration criteria ΘΘ1

Calculated criterion for a theoretical maximum speed of rotation (N).

NOTE

This value is calculated without dynamic amplification of the prop shaft tubes and bearings.

Measured criteria ΘΘ2:

The angular acceleration or torsional vibrations criteria value Θ2 must not exceed 1500 rd/s2at the PTO out­put or at any point whatsoever of the driveline for a downstream inertia of I such that I ≤ 0.2 kg/m2.

NOTE

This limit value Θ2 takes into account possible dynamic amplification of the driveline.

Transversal stress criteria for prop shaft tubes and bearings.

Example β1 and β2 maximum not to be exceeded.

- ββa < 2° for a prop shaft with bearing.

- ββb < 7° for a prop shaft with sliding yoke.

NOTE

If this 7° value has to be exceeded for space or clearance reasons, the vehicle manufacturer must be consulted.

Θ1 : criterion of acceleration in rd/s

2

N : max. speed of rotation in rpm

O

O

O

O

O

2

2

p

180

:

q1+ǒbE

q

v 270

1

NOTA

Cette valeur est calculée sans amplification dynamique des tubes de transmission et des paliers.

Critère mesuré q

La valeur Critère q2 d’accélération angulaire ou de vibrations de torsion ne doit pas excéder 1500 rd/s2 en so
prise de mouvement et en un quelconque point de la chaîne cinématique pour une inertie avale “I” telle que

p N

Ǔ

ǒ

30

2

Ǔ

q

: critère d’accélération angulaire en rd/s

1

N : vitesse de rotation maximale en tr/min

2

< 0,2 m2 kg.

q

v 1500

2

NOTA

Cette valeur limite q

rd
s

2

tient compte d’une amplification dynamique éventuelle de la chaîne cinématique.

2

Critères des sollicitations transversales des tubes de transmission et des paliers

Exemple ba et bb maximum à ne pas dépasser.
– bat2° pour une transmission à palier

– bbt7° pour une transmission coulissante

NOTA

Si cette valeur de 7° doit être dépassée pour des raisons d’encombrement, le constructeur du véhicule doit ê
consulté.

RENAULT V.I. 04/02 A38 DT 4/366

3.4.2 Propeller shaft balancing

Permissible imbalance value (B):

1 - 1/2 prop shaft
2 - prop shaft

per balancing plane

NOTE

g = m = 10 m/s

2

3.4.3 Maximum permissible length of a prop shaft as a function of the rotating speed
(L, L1 or L2)

L : Distance between centres of articulation of a prop shaft.
L2 : Distance between centres of articulation welds of a half prop shaft.
L1 : Distance between centres of articulations of a half prop shaft.
L1 = L2

Nt = prop shaft maximum operating speed

1.2 = safety coefficient
D = prop shaft large diameter
d = prop shaft small diameter

3.5 Vehicle driveline (powertrain)

Any modification to the driveline is forbidden. For special cases, agreement must be obtained from the
RENAULT TRUCKS Product Applications Department.

Any propeller shaft modifications must only be carried out in conformity with the requirements of paragraphs

3.4.2 and 3.4.3.

with

1.22

B v 3

1 – demi–transmission
2 – transmission

NOTA

g = 10m/s

3.4.3 Calcul de la longueur maximale admissible d’une transmission en fonction de

L : entraxe entre centres d’articulation d’une transmission
L1 : entraxe entre soudures d’articulation d’une demi–transmission
L2 : entraxe entre centres d’articulation d’une demi–transmission
L1 = L2

g cm

2

son régime de rotation (L, L1 ou L2).

par plan dȀéquilibrage

kg

Ǹ

Nt 1,2

K

avec

K + 0, 75 1, 22 105 D2) d

L +

2Ǹ

DT 4/366 A39 RENAULT V.I. 04/02

3.6 Mounting of handling cranes

The installer of the crane is responsible with regard to compliance with the regulations, and also for the stabi­lity of the vehicle. The recommendations of RENAULT TRUCKS are only concerned with the attachment of the
equipment.

3.6.1 Mounting on the sub-frame

The mounting of a crane on the chassis behind the cab or in the rear overhang requires the fitting of a speci­fic sub-frame.

The sub-frame module is defined in the graph of inertia in accordance with the lifting torque only for a crane
mounted behind the cab and on rigid or drawbar rigid vehicles (refer to the next page).

For all mountings of cranes in the rear overhang, off-limits and on tractors, consult the RENAULT TRUCKS
Product Applications Department.

The sub-frame must be in one single piece, starting from the rear of the cab, and extending as far back as the
rear tip of the overhang. The front end must be finished in a single or double bevel (refer to the chapter 2.4.1
entitled “Finishing of the sub-frame behind the cab”).

Should the crane be mounted in conjunction with another item of mobile equipment, one single sub-frame shall
be designed in accordance with the item of equipment that places the most strain on the sidemembers.

RENAULT V.I. 04/02 A40 DT 4/366

3.6.2 Graph of the moment of inertia of the sub-frame as a function of the lifting
torque

Example:

Achassis with sidemembers 252 mm long, fitted with a crane having a lifting capacity of 10 tonnes per metre.
The chassis requires a sub-frame built of size 160 U-section beams (—- direction of reading).
The U-section can be replaced by any other steel section offering equivalent total inertia.

The U-section beams (UPN) can be replaced by any other steel section offering equivalent total inertia (I/V).

WARNING

Before undertaking the mounting of a crane on a vehicle, it is essential to make calculations to check the load
distribution, and to determine the new maximum body length of the vehicle, whilst complying with:

- The plated gross vehicle weight (GVW).

- The maximum plated axle loads.

- The maximum rear overhang indicated in the Type Approval Department’s descriptive sheet and the body­work diagram.

Should such limits be exceeded and in all cases where the work does not comply with the type approval
department descriptive sheet, special authorization must be requested from the RENAULT TRUCKS Product
Applications Department.

In addition to this, the bodybuilder will be responsible for commissioning the equipment.

RIGIDS - DRAWBAR RIGIDS WITHOUT SUB-FRAME

Height of sidemember

Crane LIFTING TORQUE in tonnes/metre

OFF-LIMITS

3.6.2 Abaque de l’inertie du faux–châssis en fonction du couple de levage

Exemple :

Un châssis avec longerons de 252 mm, équipé d’une grue d’une capacité de levage de 10 tonnes /mètre.
Il nécessite donc un faux-châssis construit en UPN de 160 (--- sens de lecture).
L’UPN peut être remplacé par tout autre profilé donnant une inertie totale équivalente.

Hauteur longeron

PORTEUR – PORTEURS-REMORQUEURS SANS FAUX-CHÂSSIS

HORS LIMITES

Le profilé UPN peut être remplacé par tout autre profilé donnant une inertie équivalente (I/V).

UPN 100 : I/V = 41200 mm
UPN 120 : I/V = 60700 mm
UPN 140 : I/V = 86400 mm

3
3
3

UPN 160 : I/V = 116000 mm
UPN 180 : I/V = 150000 mm
UPN 200 : I/V = 191000 mm

COUPLE LEV AGE de la grue en Tonnes /Mètre

3

3
3

UPN 220 : I/V = 245000 mm
UPN 240 : I/V = 300000 mm
UPN 260 : I/V = 371000 mm

3
3
3

DT 4/366 A41 RENAULT V.I. 04/02

3.6.3 Crane in the rear overhang

The installer of the crane is responsible with regard to compliance with the regulations, and also for the sta­bility of the vehicle. The recommendations of RENAULT TRUCKS are only concerned with the attachment of
the equipment.

The sub-frame required for such assemblies must be diagonally braced in accordance with the diagram
below, using U-section beams with a module that is immediately lower than that recommended for the sub­frames.

Example: A sub-frame made of size 140 U-section beams shall be diagonally braced with size 120 U-sec­tion beams.

For a crane mounted in the rear overhang, in addition to the recommendations contained in the “WARNING”
paragraph above, the following must also be observed:

- The minimum front axle load, for a vehicle fitted with a body and equipped with crane.

- The maximum plated front axle load shedding: 5% of the value of the weight of the chassis cab on the front
axle.

1 - Sub-frame
2 - Vehicle chassis

RENAULT V.I. 04/02 A42 DT 4/366

3.7 Tail lifts

3.7.1 Sub-frames

In the majority of cases, the mounting of a tail lift involves the fitting of a sub-frame to the vehicle. Such a sub­frame must reinforce the entire length of the chassis, with the bevelled front end being located as far forward
as possible under the cab.

The module to be used for the sub-frame must be determined for tail lifts:

- without landing legs, for a capacity of 400 to 2,000 kg

- with landing legs, for a capacity of 1,000 to 2,000 kg

- by referring to the graph of inertia of the sub-frame depending on the load to be lifted, plus the information
contained in the paragraph entitled “Special Recommendations”, which also deals with tail lifts with a capa­city of 1,500 kg without landing legs and tail lifts with a capacity of 2,000 kg with or without landing legs.

3.7.2 Attachment

The tail lift is to be fastened in position with bolted plates. In all cases, the design of the attachment should
involve that of the body sub-frame as well. Nut and bolt hardware is to be of class 10.9 fine pitch with a dia­meter of 12 mm. The plates are to be fastened in position with at least 6 nuts and bolts on each side of the
chassis and by 3 bolts and nuts or only by welding to the sub-frame.
If necessary, it may be necessary to wedge the tail lift beam or plate on the lower flange chassis sidemem­ber, so as to avoid flexing of the sidemember.

NOTE

Do not weld the bolted plate to the chassis.

WARNING

In all cases of conversions for tail lifts, it is absolutely essential to calculate the new length of body, to ensu-

re compliance with:

- The maximum plated gross vehicle weight (GVW).

- The maximum load on the front axle, with the vehicle fitted with its body and equipped with tail lift.

- The maximum plated loads on the front and rear axles.

- The maximum rear overhang indicated in the Type Approval Department’s descriptive sheet and the body­work diagram.

If any loads are exceeded, you should consult the Product Applications Department.

3.7.3 Electrical connections for a tail lift

Electrical connections should comply with the recommendations set out in the chapters entitled “Fitting of spe­cific equipment” and “Electrical equipment”.

3.7.4 Special recommendations for tail lifts from 1500 to 2000 kg without landing legs

1,500 kg tail lift

- This is only possible using our chassis with a GVW equal to or greater than 16 tonnes.

2,000 kg tail lift

- This is only possible using our chassis with a GVW equal to or greater than 19 tonnes.

- For off-limits and for vehicles with a lower capability, consult the Product Applications Department.

Should the run-under guard have to be modified, care should be taken to ensure compliance with regulations
in force.

DT 4/366 A43 RENAULT V.I. 04/02

HAUTEUR DE FAUX-CHÂSSIS

Capacité hayon avec béquilles

Capacité hayon sans béquille

Hauteur de longeron

HORS
LIMITE

OTA

e profilé UPN peut être remplacé par tout autre profilé donnant une inertie equivalente (I/V).

PN 80 : I/V = 26500 mm

3

UPN 120 : I/V = 60700 mm

3

PN 100 : I/V = 41200 mm

3

UPN 140 : I/V = 86400 mm

3

3.7.5 Graph of the moment of inertia of the sub-frame as a function of the lifting
torque

How to use the graph

- Draw a straight line joining the type of tail lift in question (lower part of the graph) to the mark corresponding

with the height of the sidemember in mm.

- Draw a straight line from the value of the sidemember height.

- Read the value for the sub-frame at the intersection of these two lines.

NOTE

For the mounting of tail lifts on 6x2 vehicles, it is essential to consult the RENAULT TRUCKS Product
Applications Department.

Example:

Take a chassis with 234 mm high sidemembers, equipped with a 750 kg tail lift.
It requires a sub-frame made of size 80 U-section beams.

NOTE

The size 80 U-section beams can be replaced by any other section which gives an equivalent inertia (I/V).

Height of sidemember

HEIGHT OF SUB-FRAME

OFF-LIMIT

Capacity of the tail lift with landing legs

Capacity of the tail lift without landing legs

:

:

:
:

RENAULT V.I. 04/02 A44 DT 4/366

3.8 Sub-frame box sections

The recommended box sections should:

- be constructed in sheet metal which is as thick or thicker than that used for the sub-frame.

- stretch over the entire rear of the sub-frame, starting gradually at least one metre in front of the foremost

spring hanger of the rear spring.

WARNING

If the sub-frame is to be constructed in a material other than commercially available U-section beams, we
approve all other sections on condition that the modulus of inertia of the “truck sidemember + sub-frame” sec­tion, measured at the centre-line of the rear axle, be at least equal to the modulus which we recommend
(refer to the previous page).

It is forbidden to make any butt welds on the sub-frame in the area defined as follows:

- from the centre-line of the rear axle up to 500 mm to the aft of the rearmost spring hanger of the rear spring,

in the case of 4x2 and 4x4 vehicles.

- from the centre-line of the middle axle up to 500 mm to the aft of the centre-line of the rear axle, in the case

of all other vehicles.

3.9 Fitting of specific equipment (for example: refrigerator unit, tail lift)

3.9.1 Electrical connections

Refer to the recommendations for use (chapter on “Electrical equipment” in the General Section).
The power supply cable should be in one single piece, with a cross-section calculated for a max. rating of 5

Amps per mm

2

. The power supply must be protected by a fuse and controlled by a specific master switch
during fitting. It is compulsory for the cables to be connected to the battery terminals. The fuse and the mas­ter switch must be located as close to the battery connection as possible (in order to keep to a minimum the
length of unprotected line).

The electric power and auxiliary wiring must compulsorily be independent from that of the vehicle network.
For this, you should contact the Product Applications Department in order to obtain its permission.
In the case of conversion of an independent self-contained unit on the front end of the body, an access lad-

der and platform for maintenance purposes should be provided.

3.9.2 Installation of receivers or generators with a voltage of more than 24 V

Comply with the standards in force and with the safety regulations covering installations and safety of the
person (decree dated 14/11/1988). The protective earth is to be made on the equipment, and never on the
vehicle structure.

3.10 Tapping on the diesel fuel tank

It is forbidden to drill the tank for the installation of a tapping point.

DT 4/366 A45 RENAULT V.I. 04/02

3.11 Fifth wheels (baseplates and couplings)

Tractor chassis are normally supplied as original equipment with bolted angle-irons. In this case they allow
for the longitudinal positioning of the baseplate for the fifth wheel on the chassis, in order to ensure good load
distribution on the tractor axles.

The fifth wheel is located on these angle-irons by the use of a cross-member and/or a baseplate (in certain
cases the baseplate is sufficient).

The fitting of the fifth wheel must allow for the manoeuvring of a swan-necked semi-trailer in accordance with
the ISO Standard in force : ISO 015/1726: Road vehicles – mechanical links between tractors and semi-trai­lers - interchangeability.

The bedplate and the baseplate must be independently mounted, with a minimum strength equal to that of
the attachment for the fifth wheel.

Baseplates for each type of vehicle are available in several heights from the Spare Parts Department.
Refer to the Product Applications Department.

3.11.1 Mounting standards

Comply with the standard in force.

Kingpin 50 mm (2”) dia.

The attachment of the fifth wheel to the chassis must be done using 12 nuts and bolts size M16, quality class

10.9.

Kingpin 90 mm (3.5”) dia.

For details of the attachment of the fifth wheel, refer to the Product Applications Department or comply with
the recommendations of the supplier.

These values apply equally for the attachment of the baseplate.
As far as swan-necked semi-trailers are concerned, which are not constructed in accordance with the ISO

Standard in force, the attachment of the fifth wheel must take into account the instructions given above, whil­st conforming with the capability of the tractor to manoeuvre, i.e. it must not come into contact with parts of
the chassis, such as mudguards, rear lamps, registration plates, the back end of the chassis, the tyres, etc.

If the changing of position of the fifth wheel towards the front causes any interference of the mounts of the
baseplate with those of a cross-member, you are obliged to refer to the Product Applications Department.

RENAULT V.I. 04/02 A46 DT 4/366

Drawing for drilling the baseplate for the attachment of the fifth wheel using 12 nuts and bolts
dia. 16 mm (DIN Standard 74081)

Drawing for drilling the baseplate for the attachment of the fifth wheel by 12 nuts and bolts
dia. 16 mm with slotted holes (Standard NF R 41-171 dated October 1986)

A - Direction of movement of vehicle
1 - Lateral axis
2 - Longitudinal axis of the tractor engine
3 - Kingpin axis

Plan de perçage sur sommier de la fixation de la sellette par 12 boulons ∅ 16 mm avec trous oblongs
(Norme NF R 41-171 d’octobre 1986).

A – Sens d’avancement du véhicule
1 – Axe transversal
2 – Axe longitudinal tracteur moteur
3 – Axe pivot d’attelage

DT 4/366 B1 RENAULT V.I. 04/02

CHAPTER -B-

“RENAULT MIDLUM” SPECIAL BODYBUILDING

FEATURES

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DT 4/366 B3 RENAULT V.I. 04/02

1. PRESENTING THE “RENAULT MIDLUM” SERIES

This RENAULT MIDLUM range, the new RENAULT TRUCKS offer for 7.5 to 18 tonne vehicles specifically
designed for distribution, replaces and completes the old range.

This modern series hinges around three types of chassis, with greatly optimized models in the major
European market segments:

- 7.5 tonnes with a wide choice of power ratings,

- 12 tonnes with a multiple offer allowing maximum adaptation to different trades,

- 18 tonnes.
Two new engines cover the power units for the range:

- 4-cylinder 4200 cc (dCi 4) developing 150 or 180 hp,

- 6-cylinder 6200 cc (dCi 6) developing 220 or 270 hp.

1.1 Make-up of the range

RENAULT MIDLUM B 7.5 to 10 tonnes:

- 3 power levels (150, 180, 220 hp)

- 6 wheelbases (2700*, 2950, 3250, 3850, 4450, 5050 mm)
RENAULT MIDLUM B 12 tonnes:

- 2 power levels (150, 180 hp)

- 6 wheelbases (2700*, 2950, 3250, 3850, 4450, 5050 mm)
The RENAULT MIDLUM B 12 tonnes is the “typical” vehicle for urban and suburban distribution.
The main features of RENAULT MIDLUM B are:

- 200 x 70 mm sidemembers module,

- 17.5” tyre fitment,

- one single access step to the cab.
* for dCi 4 only.

RENAULT MIDLUM C’ 12 tonnes:

- 2 power levels (180, 220 hp)

- 8 wheelbases (3070, 3350, 3650, 3950, 4550, 5150, 5750, 6480 mm)
The main features of RENAULT MIDLUM C’ are:

- 220 x 70 mm sidemembers module,

- 17.5” tyre fitment,

- two access steps to the cab.
The RENAULT MIDLUM C’ consists of a RENAULT MIDLUM C chassis and cab with RENAULT MIDLUM B
powertrain and rolling gear.

RENAULT MIDLUM C 12, 14 and 16 tonnes

- 3 power levels (180, 220, 270 hp)

- 8 wheelbases (3070, 3350, 3650, 3950, 4550, 5150, 5750, 6480 mm)
The main features of RENAULT MIDLUM C are:

- 220 x 70 mm sidemembers module,

- 19.5” tyre fitment,

- two access steps to the cab.
RENAULT MIDLUM HD and Construction 12, 14 and 16 tonnes

- 2 power levels (220, 270 hp)

- 5 wheelbases (3070, 3350, 3950, 4550 mm)
The main features of RENAULT MIDLUM HD and Construction are:

- 220 x 70 mm sidemembers module,

- 20” or 22.5” tyre fitment,

- two access steps to the cab,

- sheet metal bumper.
The RENAULT MIDLUM HD is proposed for export and the RENAULT MIDLUM Construction is officially
approved for EEC.
These vehicles consist of a RENAULT MIDLUM C chassis and cab with sheet metal bumper and 22.5” tyres
for better ground clearance.

RENAULT MIDLUM 18 tonnes:

- 2 power levels (220, 270 hp)

- 11 wheelbases (3650, 3950, 4250, 4550, 4850, 5150, 5450, 5750, 6050, 6480, 6780 mm)

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The main features of RENAULT MIDLUM D are:

- 244 x 70 mm sidemembers module,

- 22.5” tyre fitment,

- two access steps to the cab,

- sheet metal bumper for Buildings & Public Works version (wheelbases 3650 to 4550 mm).
RENAULT MIDLUM 4x4 TA(all-wheel grip) and TC (unkept tracks):

- 11, 13, 15 tonnes for export, in TC version only,

- 12, 13, 14, 15, 16 tonnes for EEC,

- 1 power level (220 hp),

- 4 wheelbases (3070, 3350, 3650, 3950 mm).
The main features of RENAULT MIDLUM 4x4 are:

- 220 x 70 mm sidemembers module,

- 19.5” tyre fitment (twin fitment for TA only), 20” or 22.5” (single tyre fitment at rear possible for TC),,

- two access steps to the cab,

- sheet metal bumper.
The RENAULT MIDLUM range, the perfect adaptation to all trades:

- a comprehensive offer for all collection and distribution activities,

- an optimized offer for express delivery and building trades with specific models,

- a specific offer for long-distance haulage,

- a vehicles offer dedicated to bodybuilders (tankers, refuse collectors, road sweepers...).
This search for perfect adequation between the activity and the vehicle is expressed through the attributes of

the new RENAULT MIDLUM range:

- Compactness connected with overall cab width and overhang, and reduced front overhang.

- Loading capacity with tare weight among the best on the market (RENAULT MIDLUM B 12 tonnes “payload
champion” with a tare weight below 3300 kg).

- Accessibility to loading with an unladen height among the best on the market.

- Safety by the adoption of “all-disc” brakes.

- Adaptation to all trades through the “Trade” vehicles offer and development of pre-arrangements for the fit­ting of bodies.

- The determination to fully respond to the different trades of the intermediate series is fully expressed in the
range of cab appointments that constitute an innovation in the world of distribution, both as regards the diver­sity and the equipment comfort level.

- The result of the work conducted in common with bodybuilders and the pre-arrangements for the fitting of
bodies ensure bodybuilders and users time savings and product quality.

These pre-arrangements concern the assembly of tail lifts, behind-cab cranes and other equipment items.
They are completed by an “Electrical pre-arrangements” pack intended to facilitate the fitting of electrical fea­tures (for a full description, see “Trade packs and vehicles” chapter).

1.2 Changes to “RENAULT MIDLUM”

- engines equipped with common rail fuel-injection and electronic management offering new power ratings:

. dCi 4 & dCi 6 available on RENAULT MIDLUM B, C’, C
. dCi 6 available on RENAULT MIDLUM HD & Construction.

- new oil sumps,

- fuel filters in LH front wing,

- fuel prefilter (option),

- new gearbox cross-member,

- new closing cross-member fastened to sidemembers web,

- battery compartment and air tanks superimposed on the entire series,
(configuration identical to RENAULT MIDLUM B),

- air-operated auxiliary equipment identical on all the vehicles,

- new gearboxes,

- discontinuation of soundproofing screens behind cab and on gearbox,

- front run-under guard (option),

- 4-spring cab suspension on RENAULT MIDLUM D 18 tonnes,

- new instrument panel and new display (with new functions).

Liaison par Bus de communication numérique (Bus CAN)

Afficheur

AFFI 2000

Calculateur

moteur

EECU

Calculateur

véhicule

VECU

Contrôlo-

graphe

Témoins :

– charge batteries
– suspension pneumatique

Capteurs :

– niveau pression d’huile
– température d’eau
– pression et température d’air
– vitesse volant moteur
– pression d’injection

Injecteurs électriques Informations véhicule :

– pédale d’accélérateur
– commande cruise control

et FOWA
– capteurs PMT enclenchée,
pédales freins et embrayage,
frein de parc...
– commandes essuie–glaces,
lave–vitres...

Capteur boîte
de vitesses

Feux et indicateurs de
changement de direction

Commande d’arrêt sur châssis Electrovannes de la

pompe haute pression

Défauts / usure :
– ABS, transpondeur,
suspension
pneumatique,
usure plaquettes...

Electrovanne EGR

Electrovanne FOWA

Il est interdit de couper le faisceau calculateur moteur situé dans le coffre à batteries (pour le rallonger
ou le raccourcir).
Tout déplacement doit s’effectuer dans la zone autorisée par le débattement du faisceau, veillez à
protèger le calculateur des projections.

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1.3 Electronic management of “RENAULT MIDLUM” vehicles

1.3.1 Operating principle

Engine electronic management is used to improve engine performance while optimizing fuel consumption and
pollutant emissions (in order to meet Euro 3 standard).

The electronic system consists of two principal electronic control units:

- the EECU (Engine Electronic Control Unit):
This is located in the battery compartment and manages, among other things, the fuel pump solenoid valves,
the exhaust brake... on the basis of information it receives from the different engine, speed, air temperature,
fuel pressure... sensors.

- the VECU (Vehicle Electronic Control Unit):
This is located at the side of the dashboard electrical distribution panel and manages operation of the diffe­rent vehicle equipment items (windscreen wash/wipe...), controls (accelerator, parking brake, electric retar­der...), together with “bodybuilder” functions (PTO, related engine speeds...).

An instrument panel display (AFFI 2000) makes the interface between vehicle and driver. Not only classic
information such as distance travelled, average or instant fuel consumption... is displayed, but also informa­tion on the state of the vehicle or its body (tailgate incorrectly closed, interior lighting in service...) coupled in
case of danger with the STOP warning light or a buzzer.

All these modules are interlinked by a digital communication bus (CAN bus) that allows them to exchange the
necessary orders and information.

It is forbidden to cut the engine ECU wiring harness located in the battery compartment (for extension or
shortening purposes).
Any changing in position must be done in an area permitted by range of movement of the wiring harness

- take care to protect the ECU against splash and spray.

Link by digital communication bus (CAN bus)

Display

AFFI 2000

Engine ecu

EECU

Vehicle ecu

VECU

VECU

T achograph

control
Gearbox sen­sor

Vehicle information

- accelerator pedal

- cruise control and exhaust
brake control

- PTO engaged, brake and
clutch pedals, parking
brake... sensor

- windscreen wash/wipe...control

Electric injectors Sensors

- oil level / pressure

- coolant temperature

- air pressure / temperature

- flywheel speed

- injection pressure

Warning lights:

- battery charge

- air suspension

Direction change lights
and indicators

Defects / wear:

- ABS, transponder, air
suspension, brake pad
wear...

Chassis-mounted stop control HP pump solenoid

valves
EGR solenoid valve

Exhaust brake solenoid valve

Toute intervention sur le circuit gas–oil est interdite.
Sur les moteurs équipés de la rampe d’injection fonctionnant à très haute pression, la présence d’air
peut entraîner la casse de la pompe.
Respecter les règles de purge et de propreté du système rampe commune, à effectuer après chaque
intervention.
Pour tout renseignement, consulter le service technico–commercial RENAULT V.I.

Sur le circuit basse pression, déplacer un réservoir, ajouter des raccords ou composants, risque de créer des
pertes de charges supplémentaires :
– la spécification risque de ne pas être respectée aussi bien en entrée de pompe d’alimentation qu’en retour de

pompe,

– la régulation de pression risque de mal fonctionner(le système est sensible aux pertes de charge),
– vérifier les prises d’air, s’assurer du niveau gas–oil même en position inclinée du véhicule et pendant les phases

de freinage (difficulté de démarrage ou calage du moteur),
– les filtres doivent demeurer la dernière pièce avant l’entrée de la pompe haute pression,
– la position du préfiltre doit rester la même sur le circuit hydraulique (entre le retour injecteur et l’entrée de la

pompe d’alimentation).

Du fait de l’utilisation de boîtiers électroniques, l’installation d’équipements pouvant créer des pertuba-
tions électromagnétiques oblige les carrossiers à procéder à une nouvelle homologation du véhicule
à la norme Compatibilité Electromagnétique.

La gestion des régimes moteur en mode prise de mouvement est gérée par l’électronique.
Tout véhicule non équipé de la prédisposition électrique N°2 ne pourra pas être équipé d’une prise
de mouvement.
Pour les véhicules métiers, l’installation ultérieure de prédispositions électriques nécessite des inter-
ventions importantes et complexes (mise en place de faisceaux cabine et châssis, reparamétrage des
calculateurs véhicule et moteur...).

Il est interdit de marcher ou de déposer des éléments lourds sur le moteur au risque de détériorer les
tubes d’injection haute pression et les couvre–culbuteurs en plastique.

Garantir l’accès aux circuits d’admission d’air, d’échappement et d’alimentation combustible.
Les surfaces d’entrée et de sortie radiateur ne doivent pas être modifiées.
Le flux de refroidissement doit être préservé.

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1.3.2 Bodybuilders’ electrical pre-arrangements

For a detailed description of the electrical pre-arrangements, wee the Trade Packs chapters. The vehicle elec­trics is managed by the Vehicle ECU and there are two electrical pre-arrangements levels:

- electrical pre-arrangement N° 1 dedicated to vans with tail lifts for control of lighting, switching on machines,
wiring of side lights...

- electrical pre-arrangement N° 2 dedicated to trades for management of PTOs and related engine speeds...

1.4 Warning

On the low pressure circuit, changing of position of a fuel tank, adding unions or components, risks creating
extra head losses:

- The specification risks not being met both at supply pump inlet and at pump return.

- The pressure regulation device risks malfunctioning (the system is sensitive to head losses).

- Check the air take-offs, make sure the fuel level is correct even when the vehicle is on an incline and during
the brake application phases (difficulty in starting or stalling of the engine).

- The fuel filters must still be the last part before the HP pump inlet.

- The position of the prefilter must still be the same on the hydraulic circuit (between the injector return and
the feed pump inlet).

Any work on the fuel system is forbidden.
On engines equipped with common rail fuel-injection operating at very high pressure, the presence of
air may lead to damage to the pump.
Observe the rules governing common rail system cleanliness and bleeding, that is to be performed
whenever any work is carried out on the system
For further information, consult the RENAULT TRUCKS Product Applications Department.

On account of the use of electronic boxes, the installation of equipment may cause electromagnetic
disturbance and oblige bodybuilders to proceed with new approval of the vehicle in respect of
Electromagnetic Compatibility.

The management of engine speeds in PTO mode is managed by the electronics.
Any vehicle not equipped with electrical pre-arrangement N° 2 cannot be equipped with a PTO.
For trade vehicles, the subsequent installation of electrical pre-arrangements requires significant and
complex intervention work (installation of cab and chassis wiring harnesses, re-definition of vehicle
and engine ECUs...).

It is forbidden to walk on or place heavy articles on the engine for risk of damaging the HP injector
pipes and the plastic rocker covers.

Guarantee access to the air intake, exhaust and fuel supply circuits.
The radiator inlet and outlet surfaces must not be modified.
The cooling flow must be conserved.

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1.5 Trade vehicle models

In order to optimize the facility of adaptation and bodybuilding and to best meet customers’ expectations,
RENAULT MIDLUM vehicles can cascade down into models or be equipped as standard with a “Trade pre­arrangement” based on the “Normal use” model. These pre-arrangements are a combination of options allo­wing, when installing the equipment, to have a basic vehicle on hand adapted to the constraints of its use,
equipped with various pre-arrangements thus reducing conversion work and making for easier installation
work.

“Normal use”

Basic vehicle with “general use” vocation, specialized by the fitting as standard of a “Trade pre-arrangement”.

“Tanker vehicle”

Tanker special features

- level 2 bodybuilder electrical pre-arrangement (see chapter B-5),

- RH sidemember cleared for the installation of specific accessories,

- punchings on chassis for fastening accessories and wing brackets,

- gearbox-mounted PTO with flange output,

- fast idling set at 1200 rpm with regulated fast idling control, (2 programmed engine speeds available, plus
chassis-mounted variable speed control),

- pneumatic coupling for engagement of PTO,

- remote controlled clutch release operating ram,

- 80 litre and 130 litre main fuel tank on the left,

- reinforced front and rear parabolic leaf spring suspensions,

- tanker lateral signalling installation kit,

- ABS,

- exhaust on left side.

ADR equipment

- rear run-under guard for tanker overall width 2350 mm,

- chassis-mounted “palm switch” stop control,

- 2 kg fire extinguisher in cab,

- portable orange wander lamps in cab,

- wheel chock,

- tachograph with current limiter,

- exhaust silencer shield,

- behind-cab shield,

- pre-arrangement for fixing ADR plate,

- battery isolation switch with pneumatic control,

- ADR chassis wiring harnesses.

Options

- loose spare wheel,

- gearbox-mounted PTO with splined shaft output,

- without “ADR” (“transport of dangerous materials”) equipment,

- engine hourmeter in cab,

- towing cross-member capacity > 3.5 tonnes.

For all the vehicles (other than tankers), it is possible to choose the ADR variant.

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“Refuse collector vehicle”

- refuse collector bodybuilder electrical pre-arrangement (see chapter B-8),

- automatic transmission,

- gearbox-mounted continuous high-power PTO with regulated fast idling control, (2 programmed engine
speeds available, plus chassis-mounted variable speed control),

- reinforced front parabolic leaf spring suspension,

- reinforced dissymmetrical rear suspension,

- vertical exhaust,

- 80 litre fuel tank,

- without rear run-under guard,

- RH door with peep window,

- reversing buzzer,

- ripper presence 30 km/h speed limiter,

- without spare wheel,

- mileometer without tachograph,

- frontview mirror,

- passenger bench seat,

- fuel tank to right,

- adapted grab handles,

- central passenger holding bar.

Options

- roof level engine air intake,

- single rear tyre fitment,

- fixed passenger seat,

- engine hourmeter in cab.

“Road sweeper vehicle”

- level 2 bodybuilder electrical pre-arrangement (see chapter B-5),

- dissymmetrical rear suspension,

- right-hand drive,

- LH door with peep window,

- lateral exhaust,

- plastic 80 litre main fuel tank,

- with run-under guard,

- mileometer without tachograph,

- with battery isolation switch,

- reversing buzzer,

- roof level engine air intake,

- without spare wheel,

- frontview mirror.

“Light fire tender vehicle”

- fire brigade bodybuilder electrical pre-arrangements,

- EATON 4106 OD gearbox + power take-off 2903P,

- 4-door cab (6/7 places),

- reinforced front parabolic leaf spring suspension,

- reinforced rear parabolic leaf spring suspension,

- lateral exhaust with internal outlet,

- plastic 130 litre main fuel tank,

- adjustable fast idling,

- lamps mounted on lighting bar,

- pneumatic battery isolation switch,

- loose spare wheel,

- 9.5 R 17.5 XYZ tyres,

- white bumper,

- cab pre-arrangements (working spotlamp with remote control, radio antenna, earth braid on doors, foot-ope­rated horn control, special steering column trim, self-adhesive reflectors on doors...).

Options

- blue revolving beacons.

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“Buildings and public works vehicle”

- level 2 bodybuilder electrical pre-arrangement (see chapter B-5),

- glazed cab rear wall,

- gearbox-mounted PTO, engine speed limitation 1400 rpm, PTO engaged,

- rear drive axle differential lock,

- without run-under guard (depending on country),

- towing cross-member and hook capacity 3.5 tonnes,

- front and rear parabolic leaf spring suspensions,

- 2-place bench seat,

- changing of position of air braking appliances for installation of cab tilting ram.

Options

- vertical exhaust,

- roof level engine air intake,

- engine hourmeter in cab,

- pre-arrangement for installation of a crane.

1.6 Make-up of “Trade packs”

“Crane” installation pre-arrangement

- level 2 bodybuilder electrical pre-arrangement (see chapter B-5),

- reinforced front and rear suspensions,

- crane fastening plates,

- gearbox-mounted PTO with regulated fast idling control, (2 programmed engine speeds available, plus
chassis-mounted variable speed control).

Options

- vertical exhaust,

- pre-arrangement for engine hourmeter in cab,

- with rear run-under guard for platform body.

For a tipper vehicle, provide only additional crane support plates.

“Tail lift” installation pre-arrangement

- level 1 bodybuilder electrical pre-arrangement for installation of a tail lift (see chapter B-4),

- reinforced rear suspension,

- without rear run-under guard (option for column type tail lifts),

- 80 Amp alternator,

- 170 Amp-hour batteries,

- 200 Amp fuse-holder located in battery compartment,

- tail lift earth available in the rear overhang,

- earth screw in rear overhang.

Options

- level 2 bodybuilder electrical pre-arrangement (see chapter B-5).

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2. GENERAL REMARKS ON “RENAULT MIDLUM” SERIES

2.1 Identification of the vehicle

LH drive vehicles RH drive vehicles

Position of on-vehicle identification plates

1 - chassis
2 - rear drive axle
3 - gearbox
4 - manufacturer’s plate
4 - pollution index
5 - manufacturing plate
6 - tachograph plate (if fitted)
7 - CAM reference
7 - paint reference
8 - engine
9 - front axle

10 - load sensing valve plate

View from above

IMPORTANT

The identification markings must remain visible and accessible without need for removing any bodywork
component.

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2.2 General drilling principles

2.2.1 Drilling cab panels for fitting accessories

Drilling the cab allows the fastening of sealed crimping nuts for the assembly of accessories.
The recommendations below will help avoid damage to the roof headlining at the time of drilling.

A - Roof stiffener
B - Weld nut on stiffener
C - Bodywork panel
D - Positions of impressions for drilling and access to weld nut
E - Centring drill with stop:

- dia. 11 mm for crimping nut dia. 8 mm
F - Positions of impressions for drilling and access to crimping nut
G - Centring drill with stop:

- dia. 9 mm for crimping nut dia. 6 mm

Method

Use a centring drill with stop positioned on the bit to drill the roof.
Drilling depth: 5 mm max. for fastening crimping nut.

Anti-corrosion protection:

Deburr the holes after drilling.
Protect the metal with a zinc aerosol spray available from the Spare Parts department, ref. N° 77.01.406.425.

INTERDICTION

– De perçer les ailes de longerons,
– De perçer plus de trois trous sur la même verticale.

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2.2.2 Drilling in sidemembers

BAN

- No drilling in the flanges of sidemembers.

- No drilling more than 3 holes on the same vertical.

B - Chassis zero plane (RENAULT TRUCKS reference centre-line)
e - Thickness of sidemember
P - Between-centres distance between two drillings

All the drillings must be at a minimum distance from the sidemember flanges: A> R+3 mm + F

R - sidemember internal radius of curvature
F - diameter of washer or diameter of rivet head divided by two

For maximum safety, take for dimension A a minimum value of 28 mm.
C - Recommended drilling diameter:

13 mm for assembling elements (tool box...)

17 mm for assembling built-on units (tail lifts...)
D - Alignment of 3 holes maximum on the same vertical axis
l - Minimum width corresponding to 3 times the thickness of the sidemember must be observed between

2 drillings

Anti-corrosion protection and paint retouches to the chassis

Protect the metal with a zinc aerosol spray, ref. N° 77.01.406.425.
Retouch paintwork with a grey chassis aerosol paint spray, ref. N° 50.01.848.147.
These consumables are available from the RENAULT TRUCKS Spare Parts department.

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When welding or using a sanding disk, take care to protect electrical wiring harnesses and air pipe
bundles against any spatter that might damage them.

2.3 Precautions

2.3.1 Protection of wiring harnesses

Important operations to be carried out without fail, prior to welding.

2.3.2 Protection of electrical installation prior to welding

The vehicle is equipped with numerous electrical circuits. Before any operation involving electric arc welding,
disconnect the positive (+) cable from the battery and connect it to earth.
Place the earthing clamp as near as possible to the point of welding, but never on rotating parts (prop shaft,
fan hub, fan, etc.) nor on a sub-assembly having moving parts (i.e. air compressor, turbocharger, etc.).
Nearby plastic pipes and electrical cables, springs and air-suspension bags are to be protected or removed.
This also applies when grinding or drilling.
The master switch must be closed.

Diagram : Vehicle with electrical, mechanical or pneumatic master switch

Disconnect the 2 cables and join them together.

a - batteries
b - electromagnetic master switch

After welding, reconnect all the cables finishing with the earth cable.
Other precautions before welding: refer to chapter “Precautions befo-

re welding” in the “General Features” section.

When welding in the RENAULT MIDLUM cab, place the earthing
clamp as close as possible to the point of welding.

Lors de soudure, d’utilisation de disqueuse... veillez à protéger les faisceaux électriques et pneumati-
ques des éventuelles projections qui pourraient les endommager.

2.3.2 Protection électricité véhicule avant soudure

Précautions importantes à réaliser impérativement avant soudure.

Le véhicule est équipé de nombreux circuits électriques. Avant toute opération de soudure électrique, déconnec-
ter le câble (+) de la batterie d’accumulateurs et reliez–le à la masse.
Placer la pince de masse le plus près possible du point de soudure, mais jamais sur un ensemble tournant (trans-
mission, moyeu, ventilateur ect...), ni sur un sous ensemble ayant des pièces en mouvement (compresseur d’air,
turbo–compresseur ect...).
Les tuyauteries en matière plastique et les câbles électriques à proximité seront protégés ou déposés.
Ceci est valable aussi pour un meulage ou un perçage.
L’interrupteur général doit être fermé.

Schéma : véhicule avec interrupteur général électrique, mécanique ou pneumatique

a – batteries d’accumulateurs
b – interrupteur général électromagnétique

Après soudure, remonter tous les câbles électriques en terminant
l’opération par le câble de masse.

Autres précautions avant soudure : se reporter au chapitre
“Précautions avant soudure” dans la section “Généralités”.

Débrancher les 2 câbles et reliez–les entre eux.

Lors de la réalisation de soudure en cabine
RENAULT MIDLUM,
placer la pince de masse le plus près possible du point de soudure.

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Pay attention to cab movements at articulation level for wiring harnesses that connect the chassis
and the cab.

Welding must be an exceptional operation on our vehicles (cab extension, welding of crane frames...).

When installing the wiring harnesses, pay attention to hot areas (exhaust, turbocharger, electric retar­der).

Bodybuilder wiring harnesses can be routed parallel to the vehicle harnesses with independent fas­tenings (do not make use of the vehicle wiring harnesses to connect them to bodybuilder harnesses).

IMPORTANT
Preservation of the batteries during bodybuilding :

- On vehicles with a master switch, open the circuit with the battery isolation switch.

- If the lay-up time is > 2 days, disconnect the battery negative (-) terminal.

- Reconnect the (-) terminal after finishing body fitting.
Tighten the terminal screw to a torque of 4.5 Nm.

Reminder :

- When welding to the chassis or to bodywork fitted to the chassis, it is essential to connect the circuit posi-

tive (+) terminal (master switch closed) to the negative (-) terminal (earth) connected to the chassis via a
well-tightened nut and bolt.

- If the truck is fitted with an alarm, refer to the “alarm” procedure before touching the batteries (see vehicle

operating handbook).

Equipement du véhicule

Charge minimale sur l’essieu avant

Véhicule seul 25% du poids total du véhicule
Véhicule équipé d’un hayon élévateur,

ou d’une grue de chargement à l’arrière du véhicule

30% du poids total du véhicule

IMPORTANT

– Ne pas dépasser la charge maximale admissible sur l’essieu avant,
– L’application de la charge dans le porte–à–faux arrière du véhicule nuit au comportement routier de véhicule.

Une grande prudence est recommandée lors de la conduite dans ce cas,

– Veiller à ce que le centre de gravité de la charge soit positionné latéralement le plus au centre possible du

véhicule.

2.5 Ecrans insonorisants et thermiques

2.5.1 Instructions pour écrans insonorisants

Les écrans insonorisants ne doivent être ni enlevés, ni modifiés ou déplacés pour ne pas dégrader le niveau
sonore du véhicule qui fait l’objet d’une homologation.

Ils doivent être impérativement remis en place après toute intervention nécessitant leur dépose.
Après dépose, seuls des écrans parfaitement propres doivent être remontés.
Leur nettoyage s’effectue avec un chiffon et de l’eau savonneuse si nécessaire. Tout autre produit est interdit.

Les applications de tous solvants et de peintures sont à proscrire sur les faces internes et externes
des écrans insonorisants.

DT 4/366 B15 RENAULT V.I. 04/02

2.4 Minimum load on front axle

In order to guarantee suitable vehicle ride behaviour, stability and handling under maximum safety conditions,
the minimum recommended load on the front axle must be applied whatever the vehicle load and equipment
conditions.
For special cases, consult the RENAULT TRUCKS Product Applications Department.

2.5 Soundproofing screens and heat shields

2.5.1 Instructions for soundproofing screens

Soundproofing screens should neither be removed, modified nor displaced so as not to downgrade the
vehicle sound level, which is covered by official homologation.

If it is unavoidable for them to have to be removed, they must without fail be put back into place when the
work is completed.

After removal, only perfectly clean screens should be refitted.
The screens are to be cleaned using a cloth. If necessary , use soapy water (all other products are to be forbidden).

Vehicle equipment Minimum load on front axle

25% of the vehicle gross weight
30% of the vehicle gross weight

Vehicle alone
Vehicle equipped with tail lift, or loading crane to rear of

vehicle

IMPORTANT

- Never exceed the maximum permissible load on the front axle.

- Application of the load in the rear overhang of the vehicle is detrimental to vehicle ride behaviour, stability
and handling. Great prudence is recommended when driving under such conditions.

- Watch that the centre of gravity of the load is positioned laterally as close as possible to the centre of the
vehicle.

No solvents or paints are to be applied at all on either the inner or the outer faces of soundproofing
screens.

Any damage to the internal protective film of the screen requires the screen to be replaced.
In the event of on-vehicle welding or the use of a sanding disk, provide efficient protection to the screens.
If the screens have been removed, provide efficient protection to the wiring harnesses.
Pay particular attention that there are no inflammable products present on the screen protective films.
Overtightening of screen attaching nuts and bolts may lead to damage.
Observe the recommended tightening torques without fail.

- screen bracket / chassis fastenings: 20 Nm

- screen / chassis bracket fastenings: 8 Nm

2.5.2 Instructions for heat shields

It is forbidden to remove or modify these shields. They play a part in the safety of your vehicle.

During chassis painting operations, take care to efficiently protect the hot face of heat shields against spla­shing paint and especially the shields surrounding the electric retarder. In effect, these shields are only effec­tive if the surfaces are free from any foreign matter.

2.6 Side impact guards

Side impact beams must comply with the laws in force and should not impede access to chassis components
(spare wheel, air and fuel tanks, air dryer...).

Normal

Benne Citernier B.O.M. Balayeuse Pompier Construction

ou

Tracteur

5 – Choisir le modèle de véhicule en fonction de la cabine, du P.T.A.C. et des jantes (cliquer sur “Midlum B”)

Porteur Midlum normal

P.T.A.C.–

jantes

Cabine courte et

profonde

Cabine double

4 portes

7,5 à 12T–17,5”

Midlum B

Midlum B

12T–17,5” Midlum C’ Midlum C’

12 à 16T–19,5” Midlum C Midlum C

11,9 à 18T–22,5” Midlum D

6 – Choisir le n° du plan en fonction de l’empattement et de la puissance du moteur (cliquer sur “5010528253”)

Midlum Porteur B (cabine courte et profonde)

Empattement 150 à 220 ch

2700 5010528680
2950 5010528251
3250

5010528252

3850 5010528253
4450 5010528254
5050 5010528255

RENAULT V.I. 04/02 B16 DT 4/366

3. INSTALLATION OF BODYWORK

3.1 Use of 1/20th scale drawings and calculation sheets

Technical data sheets are tools used by sales engineers to present the range or series. They cannot be repre­sentative of particular vehicles.
To obtain precise information, refer to the 1/20th scale drawings, calculation sheets or type approval depart­ment reports to be found in the RENAULT MIDLUM CD-ROM.
Only these documents will give you accurate and reliable information on vehicles according to tonnage, air
intake, cab type, weights...

3.2 Example of a search (according to Euro 2 scenario)

1 - Click on the chosen language.
2 - Click on “1/20th scale bodybuilder ’s drawings”.
3 - Click on “Chassis cab drawings”.
4 - Choose the vehicle use (click on “Normal”).

Rigid

5 - Choose the vehicle model according to cab, GVW and wheel rims (click on “RENAULT MIDLUM B”).

6 - Choose the drawing N° according to wheelbase and engine power rating (click on “5010528253”).

GVW

Rims

Day &

Sleeper cab

4-door cab

Normal rigid LH drive

RENAULT MIDLUM B Rigid (day & sleeper cab)

Wheelbase

150 - 220 hp

Tractor

or

7.5 to 12 T-17.5”
12T-17.5”

12T to 16T-19.5”

11.9 to 18T-22.5”

Normal

Tipper Tanker

RCV

Road sweeper

Fire tender

Construction

9 – Revenir à l’écran précèdent

10 – Cliquer sur “Acces aux grilles”

11 – Choisir le modèle de véhicule et la puissance du moteur(cliquer sur “Midlum B” 150 à 180 ch)

Porteur

MidlumBMidlumC’MidlumCMidlumDCiternier B.O.M. Balayeuse Pompier

150 à

180 ch

180 ch 180 ch 220 ch 220 ch 220 ch 180 à

220 ch

220 ch

220 ch 220 ch 220 ch 270 ch 270 ch

270 ch
Jantes

22,5”

Tracteur

220 ch

DT 4/366 B17 RENAULT V.I. 04/02

7 - Click on “Visualize PDF format”.

8 - Visualize the drawing and print out.

Drawing N° 5010528253

Visualization of PDF format

Recording of DXF format

Access to grids

9 - Go back to the last screen.

10 - Click on “Access to grids”.

11 - Choose the vehicle model and the engine power rating” (click on “RENAULT MIDLUM B” 150 to 180 hp).

Rigid

Tractor
220 hp

150 to

180 hp

180 hp 180 hp 220 hp 220 hp 220 hp 180 to

200 hp

220 hp

Tanker RCV Sweeper Sweeper

tander

220 hp 220 hp 220 hp 270 hp 270 hp

270 hp

Wheel rims

22.5”

RENAULT V.I. 04/02 B18 DT 4/366

Midlum B 150 à 180 ch

PTAC MAX AV/AR SUSPENSION CABINE GRILLE N°

6T 3,2/4,8–3,2/5,2 Parabolique Courte

5010554392

6T 3,2/4,8–3,2/5,2 Parabolique Profonde 5010554453
6T 3,2/4,8–3,2/5,2 Pneumatique Courte 5010554393
6T 3,2/4,8–3,2/5,2 Pneumatique Profonde 5010554454

13 – Cliquer sur “Visualisation du format PDF”

Grille N° 5010554392

Visualisation du format PDF

14 – Visualiser et imprimer la grille de calcul

A – numéro de la grille de calcul
B – identification véhicule
C – constitution véhicule
D – numéro des plans 1/20 ème
E – empattement
F – cote entrée de caisse
G – altitude

Voir impérativement :

– les plans d’accompagnement cabine (encombrement, rayon de basculement, ...),
– les plans d’accompagnement chassis (position des appareils, ...).

Choose grid N° “5010554392” according to GVW, suspension and cab.

14 - Visualize the grid and print out.

A - calculation grid Number
B - vehicle identification
C - vehicle make-up
D - 1/20th scale drawings number
E - wheelbase
F - body start dimension
G - height

See without fail;

- cab accompanying drawings (overall dimensions, tilting radius...)

- chassis accompanying drawings (position of appliances...).

Grid N° 5010554392

Visualization of PDF format

Midlum B 150 to 180 hp

GVW MAX. FRONT/REAR SUSPENSION CAB GRID N°

13 - Click on “Visualize PDF format”

DT 4/366 B19 RENAULT V.I. 04/02

Véhicule Cote d’entrée de caisse minimale

Type Côté du poste de conduite B1 B2 B3 B4

MIDLUM B

gauche 448

MIDLUM B

4 cylindres

droite

MIDLUM B

gauche 423

423

MIDLUM B

6 cylindres

droite 492

MIDLUM C’/C

gauche 398

MIDLUM C/C

4 cylindres

droite

MIDLUM C’/C

gauche 373 373

MIDLUM C/C

6 cylindres

droite

442

MIDLUM HD/construction

gauche 401 503 401

MIDLUM HD/construction

6 cylindres

droite 490

442

MIDLUM D

gauche 373 490 373

MIDLUM D

6 cylindres

droite 490

442

MIDLUM 4x4 TA

gauche 401 503 401

MIDLUM 4x4 TA

6 cylindres

droite 490

442

MIDLUM 4x4 TC

gauche 401 503 401

MIDLUM 4x4 TC

6 cylindres

droite 490

442
MIDLUM BOM gauche 490
MIDLUM Balayeuse droite 490

3.3 Body start dimension

3.3.1 Day cab (1.6 m)

B1 - minimum body start dimension for version with under-floor engine air intake
B2 - minimum body start dimension for version with roof level engine air intake
B3 - minimum body start dimension for version with vertical exhaust
B4 - minimum body start dimension for version with air intake to aft of cab

NOTE

The values (B1 - B2 - B3 - B4) are calculated for a body positioned at a height more than 130 mm from the
upper face of the sidemembers.
To move the position of the side direction indicator lights (see chapter B-3.10).

Vehicle Minimum body start dimension

Driving position side

left

right

left

right

left

left

right

right

left

right

left

right

left

right

left

right

left

right

Type

4 cylinders

6 cylinders

4 cylinders

6 cylinders

6 cylinders

6 cylinders

Road sweeper

RENAULT MIDLUM RCV

6 cylinders

6 cylinders

448

540 600

490 490 398

490 490

505

490

505

505

RENAULT V.I. 04/02 B20 DT 4/366

MIDLUM B MIDLUM C’/C MIDLUM HD/construction MIDLUM D

C 470 420 400
F 50 63 50

I 130 260

3.3.2 Behind-cab surrounds

To prevent the components forming the rear surrounds of the cab from entering into contact with the bodywork,
a minimum body start dimension, depending on the height of the sub-frame employed, is to be observed.

The components forming the rear surrounds of the cab are:

- direction change indicator lamps,

- cab rear fireproof screen for ADR vehicles,

- front wings and wing brackets.

Key to diagram on next page

A - front axle centre-line
C - between-centres distance between front axle and rear extremity of direction indicator lamps

(see chapter B-3.10).
B - body start dimension
F - height of front wing bracket in relation to the chassis
I - protrusion of side direction indicator lamps in relation to top of sidemembers
1 - front wing
2 - side direction change indicator lamp

Table of overall dimensions of components to the rear of the cab

Construction

DT 4/366 B21 RENAULT V.I. 04/02

Véhicule Cote d’entrée de caisse minimale

Type Côté du poste de conduite B1 B2 B3 B4

MIDLUM B

gauche 770

770

MIDLUM B

4 et 6 cylindres

droite

MIDLUM C’/C

gauche 720

MIDLUM C/C

4 et 6 cylindres

droite

gauche 720

construction

droite

MIDLUM D

gauche 720

MIDLUM D

6 cylindres

droite

B1 – cote d’entrée de carrosserie minimale pour version avec prise d’air d’admission moteur sous plancher
B2 – cote d’entrée de carrosserie minimale pour version avec prise d’air au niveau du pavillon
B3 – cote d’entrée de carrosserie minimale pour version avec échappement vertical
B4 – cote d’entrée de carrosserie minimale pour version avec prise d’air sur arrière cabine

3.3.4 Cabine 4 portes

Véhicule Cote d’entrée de caisse minimale

MIDLUM B
4 et 6 cylindres

1752

MIDLUM C’/C
4 et 6 cylindres

MIDLUM HD/construction
6 cylindres

MIDLUM 4x4 TA
6 cylindres

MIDLUM 4x4 TC
6 cylindres

3.3.3 Sleeper cab (2 m)

B1 - minimum body start dimension for version with under-floor engine air intake
B2 - minimum body start dimension for version with roof level engine air intake
B3 - minimum body start dimension for version with vertical exhaust
B4 - minimum body start dimension for version with air intake to aft of cab

3.3.4 4-door cab

left

right

left

right

left

right

left

right

Vehicle Minimum body start dimension

Minimum body start dimension

Driving position side

Type

4 cylinders

Vehicle

4 cylinders

4 cylinders

6 cylinders

6 cylinders

6 cylinders

4 & 6 cylinders

6 cylinders

Construction

Construction

MIDLUM HD/

876 950

826 870

720

826 910

826 870 720

1702

RENAULT V.I. 04/02 B22 DT 4/366

3.3.5 Presentation of the different air intakes

1 - under-floor engine air intake
2 - roof level engine air intake
3 - air intake to aft of cab

Capability of adjusting the behind-cab air intake nozzle according to bodybuilder requirements.

When fitting the vehicle body, take care to maintain access to the air filter box so as to be able to replace the
filter.

When changing the position of equipment or for trade applications (refuse collectors, road swee­pers...), take care to not take up the place of the original filtration system or change its position.
In fact, its size and position are defined to get optimum yield from the engine by avoiding the ingress
of foreign matter (water, gravel, dust...).

Lors d’un déplacement d’équipements ou d’applications métiers (benne à ordures ménagères,
balayeuse...), veillez à ne pas remplacer le système de filtration d’origine ainsi que sa position.
En effet, sa taille et sa position sont définies pour assurer un rendement optimum au moteur en évitant
l’introduction de corps étrangers (eau, graviers, poussières...).

Lors du carrossage du véhicule veillez à conserver l’acces au boîtier filtre à air pour remplacer le filtre.

DT 4/366 B23 RENAULT V.I. 04/02

Hauteur minimale du faux–châssis en fonction du type de suspension

Types de suspensions

es

Mécaniques Pneumatiques

MIDLUM B 4 cylindres 7,5 tonnes 90 mm 55 mm
MIDLUM B 6 cylindres 7,5 tonnes

60 mm

MIDLUM B 4 et 6 cylindres 10 tonnes

mm

55 mm

MIDLUM B 4 cylindres 12 tonnes

110 mm
MIDLUM C’ 12 tonnes 80 mm 55 mm
MIDLUM C 180 et 220 12 tonnes

60 mm

MIDLUM C 270 12 tonnes

mm

MIDLUM C 180 et 220 14 tonnes

mm

MIDLUM C 270 14 tonnes
MIDLUM C 180 et 220 16 tonnes

mm

mm

MIDLUM C 270 16 tonnes

105 mm

MIDLUM HD 14 tonnes

145 mm
MIDLUM construction 14 tonnes

125 mm
MIDLUM HD 16 tonnes

160 mm
MIDLUM construction 16 tonnes

135 mm
MIDLUM D 18 tonnes 170 mm 150 mm
MIDLUM 4x4 TA 14 et 16 tonnes 10 mm
MIDLUM 4x4 TC 11 tonnes 30 mm
MIDLUM 4x4 TC 12 tonnes monte simple 100 mm
MIDLUM 4x4 TC 13 et 14 tonnes 65 mm
MIDLUM 4x4 TC 15 et 16 tonnes 85 mm

3.4 Sub-frame sections

3.4.1 Minimum height according to range of suspension movement

A minimum sub-frame height is imposed by the range of movement of the rear suspension. The use of a
subframe with insufficient height would result in possible damage to the underbody or equipment due to fric­tion by the rear wheel tyres.

Minimum sub-frame height according to suspension type

Vehicles

MIDLUM B 4 cylinders 7.5 tonnes
MIDLUM B 6 cylinders 7.5 tonnes

MIDLUM B 4 & 6 cylinders 10 tonnes
MIDLUM B 4 cylinders 12 tonnes
MIDLUM C’ 12 tonnes
MIDLUM C 180 & 220 12 tonnes
MIDLUM C 270 12 tonnes
MIDLUM C 180 & 220 14 tonnes

MIDLUM C 270 14 tonnes
MIDLUM C 180 & 220 16 tonnes
MIDLUM C 270 16 tonnes

MIDLUM HD 14 tonnes

MIDLUM construction 14 tonnes

MIDLUM HD 16 tonnes
MIDLUM construction 16 tonnes
MIDLUM D 18 tonnes

MIDLUM 4x4 TA 14 & 16 tonnes

MIDLUM 4x4 TC 11 tonnes

MIDLUM 4x4 TC 12 tonnes single fitment
MIDLUM 4x4 TC 13 & 14 tonnes

RENAULT MIDLUM 4x4 TC 15 & 16 tonnes

Suspension type

Mechanical Air

Véhicul

100

110

120

75

90

RENAULT V.I. 04/02 B24 DT 4/366

3.4.2 Inertie minimale du faux–châssis

Inertie minimale du faux–châssis (mm4)

e

Suivant l’axe (X) Suivant l’axe (Y)

MIDLUM B
MIDLUM C’
MIDLUM C
MIDLUM HD

construction

850 000 3 500 000

MIDLUM D
18 tonnes

1 000 000 5 505 500

Rappel de la formule de calcul de la contrainte normale maximale dans la surface

s : contrainte maximale en bord de surface (N / mm

2)

Mf : moment fléchissant (N.m.)
I : moment quadratique de la surface (mm4)
v : distance entre l’extrémité et la fibre neutre de la section (mm)

3.5 Terminaison et cotes d’entrée des faux–châssis

s +

Mf

ǒ

I

v

Ǔ

3.4.2 Sub-frame start dimensions

Sub-frame minimum inertia (mm4)

Vehicle

Along axis (X)

Along axis (Y)

Reminder of formula for calculating maximum normal surface stress

σ : maximum stress at surface edge (N/mm2)
Mf: bending moment (Nm)
I : surface quadratic moment (mm4)
v : distance between section extremity and neutral fibre (mm)

3.5 Finishing of sub-frame start dimensions

Depending on:

- cab length (day cab, sleeper cab, 6/7 place crew cab),

- position of engine air intake (roof level air intake or under-floor air intake),

- width of section making up the sub-frame,
the finishing of the sub-frame must be:

- symmetrical or asymmetrical (LH side start dimension different from that of the RH side),

- provided or not with horizontal cut-outs (reduction in width), allowing passage of the cab rear soundproofing
screen and the roof level air intake.

Key to drawings, following pages.
A - Front axle centre-line,
e - Width of sub-frame section,
L - Distance from centre-line of the first bracket in relation to the centre-line of the front axle,
F - Sub-frame start dimension (symmetrical sub-frame),
Fg - Sub-frame LH start dimension (asymmetrical sub-frame),
Fd - Sub-frame RH startdimension (asymmetrical sub-frame),
Xg - Distance between LH end of sub-frame and first bracket centre-line (asymmetrical sub-frame),
Xd - Distance between RH end of sub-frame and first bracket centre-line (asymmetrical sub-frame),
1 - Air intake pipe,
2 - Cab rear soundproofing screen,
3 - Sub-frame,
4 - First bracket,
5 - Chassis sidemember,
6 - Cab rear attachment.

IMPORTANT

ADR vehicles (transport of dangerous materials) are equipped with a screen behind the cab and a screen
on the gearbox. To limit cut-outs at the extremities of the sub-frame, the recommended width of the sections
is 50 mm. If this width is greater, provide horizontal cut-outs (reduction in width) allowing passage of the
rear screen.

Construction

Véhicul

700 000 1 250 000

DT 4/366 B25 RENAULT V.I. 04/02

MIDLUM cabine courte et prise d’air sous plancher

Terminaison du faux–châssis symétrique

Véhicule

F L X

MIDLUM B 273 735,5 462,5
MIDLUM C’/C
MIDLUM HD/construction
MIDLUM D

612,5

MIDLUM 4x4

MIDLUM cabine profonde quelque soit la prise d’air

Terminaison du faux–châssis symétrique

Véhicule

F L X

MIDLUM B 620 735,5 115,5
MIDLUM C’/C
MIDLUM HD/construction
MIDLUM D

265,5

MIDLUM 4x4

RENAULT MIDLUM day cab and under-floor air intake

Symmetrical sub-frame finishing

RENAULT MIDLUM sleeper cab whatever the air intake

Symmetrical sub-frame finishing

Vehicle

Vehicle

Construction

735.5

462.5

612.5

835.5

735.5

835.5

265.5

115.5

Construction

223 835,5

570 835,5

RENAULT V.I. 04/02 B26 DT 4/366

MIDLUM cabine courte et prise d’air niveau pavillon

Terminaison du faux–châssis symétrique

– faux–châssis asymétrique,
– découpe du côté droit quelque soit la largeur (e) du profilé,
– découpe du côté gauche si la largeur (e) du profilé est supérieure à 50 mm.

Véhicule

Fg Fd L Xg Xd

MIDLUM B 273 425 735,5 462,5 310,5
MIDLUM C’/C
MIDLUM HD/construction
MIDLUM D
MIDLUM 4x4

RENAULT MIDLUM day cab and roof level air intake

Symmetrical sub-frame finishing:

- asymmetrical sub-frame,

- cut-out on the RH side whatever the width (e) of the section.

- cut-out on the LH side if the width (e) of the section is greater than 50 mm.

Vehicle

Construction

735.5

835.5

612.5

460.5

462.5 310.5

223 375 835,5 612,5 460,5

DT 4/366 B27 RENAULT V.I. 04/02

3.6 Lateral guiding

All bodies must be fitted with lateral guides to the fore and aft of the sub-frame.

At the front:

For vehicles fitted with flush first brackets, lateral guiding must be assured by two guide plates that are:

- welded to the sub-frame,

- bolted to the sub-frame or the chassis, but never both at the same time.

At the rear:

Lateral guiding must be assured by two guide plates. These are drilled and screwed to the sidemembers if
they also fulfil the function of inertia stop.

For positioning the drillings to the guides, observe the sidemember drilling recommendations described in the
chapter “Drilling of sidemembers”.

A: minimum support height, 3/4 of height (h) of the sidemember
B: minimum support height, 1/4 of height (h) of the sidemember

Inertia stop

All bodies or equipment must be fitted with an inertia stop to the aft of each sidemember to retain the body
against motion.

IMPORTANT

For vehicles fitted with raised first brackets, the latter play the part of front guides.
The fitting of guide plates is therefore unnecessary.

IMPORTANT

– Pour les véhicules équipés de corbeaux réhaussés, ces derniers remplissent la fonction de guidage ava

Le montage de plaques de guidage n’est alors pas nécessaire.

A l’arrière :

Le guidage latéral doit être assuré par deux guides. Ils sont percés et vissés aux longerons s’ils remplissent a
la fonction de butée d’inertie.

Pour le positionnement des perçages sur les guides, respecter les préconisations de perçage des longe
décrites chapitre “Perçage des longerons”.

A : hauteur minimale de l’appui, 3/4 de la hauteur (h) du longeron
B : hauteur minimale de l’appui, 1/4 de la hauteur (h) du longeron

X (mm)

Y (mm) Z (mm)

30 50 45

RENAULT V.I. 04/02 B28 DT 4/366

3.7 Attachment of bodywork

It is essential to comply with the stipulations hereafter for attaching bodywork of equipment to our vehicles.
For special cases, contact the RENAULT TRUCKS Product Application Department.
The bodywork must be correctly attached so that both the static and dynamic stresses are freely transmitted

without causing excessive local strain, which could prejudice the reliability of the chassis frame or affect the
road behaviour of the vehicle.

The use of brackets mounted in production to the chassis is compulsory.
The fastening of body sub-frames or undercarriages must be carried out according to the recommendations

defined in this document (consult the “Bodywork fastening type” chapter).
Sub-frames or undercarriages must be continuous and fit perfectly over the entire length of the chassis. They

may however be intermittent for a few specific applications (e.g. tankers). In such case, their attachment
remains entirely under the bodybuilder’s responsibility.

Sub-frames or undercarriages should always be tapered towards the front (i.e. under the cab), so as to avoid
sudden variations in inertia.

Behind-cab overall dimensions are given in the “Cab footprint” and “Behind-cab surrounds” chapters.

Protection against exhaust heat radiation: the closeness of the bodywork to the exhaust pipe and the fitting
of certain accessories (electric retarder, etc...) may require the installation of a suitable eat shield by the body­builder.

WE FORBID:

- Attachment of sub-frames by U-bolts, clamps or equivalent systems (hooks).

- Use, drilling or welding of spring hangers.

- Any modification to: chassis, driveline, suspension (except if contained in the Guide for Fitting Bodywork).

- Attachment of sub-frames by welding to sidemembers.

- Drilling of stiffener gussets.

- Welding, notching of sidemembers, gussets or cross-members.

- Use or modification of our nut and bolt hardware for the attachment of a body or a sub-frame (except for
special cases specified in this document).

- Dismantling of brackets attached to the chassis (unless specified otherwise in this document).

- Insertion of wooden blocks between sub-frames and the chassis.

BANS

INTERDIC

DT 4/366 B29 RENAULT V.I. 04/02

3.8 Fixation du faux–châssis sur corbeaux

3.8.1 Types de fixations

A – fixation souple (premier corbeau)
B – fixation mi–souple (second corbeau)
C – fixation rigide (tous les autres corbeaux)

Zone de guidage et de fixation

Véhicules

E F

MIDLUM B 735,5 1302,5
MIDLUM C’/C
MIDLUM HD/construction
MIDLUM D
MIDLUM 4x4

D – axe de l’essieu avant
E – position fixation souple (A) (premier corbeau) par rapport à l’axe d’essieu avant
F – position fixation mi–souple (B) (second corbeau) par rapport à l’axe d’essieu avant
G – zone de guidage latéral et de fixation élastique
H – zone de guidage et de fixation rigide

(Voir pages suivantes)

3.8 Attachment of sub-frames to brackets

3.8.1 Fastening types

A - Flexible attachment (first bracket)
B - Semi-flexible attachment (second bracket)
C - Rigid attachment (all other brackets)

Guiding and fastening zone

D- Front axle centre-line
E - Flexible fastening position (A) (first bracket) in relation to front axle centre-line
F - Semi-flexible fastening position (B) (second bracket) in relation to front axle centre-line
G- Lateral guiding and elastic fastening zone
H- Guiding and rigid fastening zone
(See following pages).

Vehicles

Construstion

835,5 1585,5

RENAULT V.I. 04/02 B30 DT 4/366

Conditions de montage

1 – corbeau réhaussé (premier corbeau)
2 – corbeaux affleurants (autres corbeaux)

3.8.2 Positionnement vertical des corbeaux

Deux montages de corbeaux sont réalisés sur le châssis MIDLUM.
– le premier corbeau, réhaussé par rapport aux autres (1),
– tous les autres corbeaux sont affleurants à la face supérieure des longerons (2).

La taille et la position de la boutonnière (3) sont les mêmes sur tous les corbeaux.

En cas de nécessité, le premier corbeau (1) peut être monté en position affleurante (3). Dans ce cas, l’installation
d’un guidage latéral avant est nécessaire. Réduire la hauteur du corbeau par tronçonnage si nécessaire.
(Voir chapitre–B–3.6)

Assembly conditions

Raised bracket (first bracket)
Flush brackets (other brackets)

3.8.2 Vertical positioning of brackets

Two bracket assemblies are fitted on the RENAULT MIDLUM chassis :

- The first bracket (1) is raised in relation to the other brackets.

- All the other brackets (2) are flush with the top face of the sidemembers.

The size and position of the slotted hole (3) is the same for all the brackets.

If need be, the first bracket (1) can be assembled in a flush position (3). In this case, the installation of a front
lateral guide is necessary. Reduce the height of the bracket by sawing off, if necessary (see chapter B-3.6).

DT 4/366 B31 RENAULT V.I. 04/02

3.8.3 Types of bodywork attachment

A - Flexible attachment
Kit 50 01 839 172

1 - Hexagon bolt M 14 x 150 x 90, class 10.9
2 - 3 plain washers 14 x 30 x 5
3 - 6 spring washers:

i/d 14.5 mm
o/d 35 mm
thickness 1.8 mm
unit preload 400 kg

4 - Flanged nut DRH M 14 class 10, or other

locknut except nut with nylon ring (e.g. Nyloc)
a - Clearance: 10 to 15 mm max.
b - Clearance: 2 mm max.

Tightening :
Place nut (4) in contact with
spring washers (3) by hand,
then tighten mechanically as far as crushing of
the spring washers by 3 to 4 mm.

de l’écrou (4) sur

3),
nt jusqu’à écrasement

de 3 à 4 mm.

RENAULT V.I. 04/02 B32 DT 4/366

First raised bracket (works assembly)

First flush bracket (assembly reworked by bodybuilder)

Bodywork attachment kit

The bodywork attachment kit is supplied with level 1 and level 2 electrical pre-arrangements
(see chapters B-4 and B-5).

Note

An equivalent fastening technique solution is permitted (e.g. rubber sandwich mounting), if it keeps the same
preload.

orbeau affleurant (montage reprise carrossier)

Fixation mi–souple (second corbeau)

DT 4/366 B33 RENAULT V.I. 04/02

B - Semi-flexible attachment
Kit 50 01 839 172

1 - Hexagon bolt M 14 x 150 x 110, class 10.9
2 - 2 plain washers 14 x 30 x 5
3 - Steel spacer 15x38-65 (min.)

(after cutting, true both faces)

4 - Flanged nut DRH M 14 class 10, or

other locknut except nut
with nylon ring (e.g. Nyloc)

a - Slight clearance before tightening

Contact under torque 20 to 30 Nm

b - Clearance 2 mm max.

Tightening torque : 170 Nm
Note : Give priority to assembling with spacer positio-

ned at top of bracket.

Bodywork attachment kit

The bodywork attachment kit is supplied with level 1 and level 2 electrical pre-arrangements
(see chapters B-4 and B-5).

001839172

Vis HM 14 x 150 x 110, classe 10.9
2 rondelles plates 14 x 30 x 5
Entretoise en acier 15x38–65 (mini)
Après découpe dresser
les deux faces
Ecrou DRH M14, classe 10. ou
autre écrou frein, sauf écrou
à bague Nylon (ex : Nylstop)
léger jeu avant serrage
contactsous couple 20 à 30 N.m
Jeu 2 mm maxi

age au couple : 170 N.m

: réaliser en priorité le montage avec l’entretoise

positionnée au dessus du corbeau

RENAULT V.I. 04/02 B34 DT 4/366

C - Rigid attachment (all other brackets)

1 - Hexagon bolt M 14 x 150 x 50, class 10.9
2 - 2 plain washers 14 x 30 x 5
3 - Nut Flanged nut DRH M 14 class 10,

or other locknut
except nut with nylon ring
(e.g. Nyloc)

a - Contact mandatory

Tightening torque : 170 Nm

Bodywork attachment kit

The bodywork attachment kit is supplied with level 1 and level 2 electrical pre-arrangements
(see chapters B-4 and B-5).

s les autres corbeaux)

50, classe 10.9

4 x 30 x 5

asse 10.

n,

e

)

0 N.m

DT 4/366 B35 RENAULT V.I. 04/02

3.8.4 Special features of vehicles with 4-door cab

Vehicles equipped with the 4-door cab are fitted with a reinforcement (1) bolted to the chassis (2) under the
cab. This reinforcement must be screwed to the front end of the sub-frame (4) using drillings (3) or plug wel­ded using slotted hole (5).

Use M12 class 10.9 bolts with locknuts.

IMPORTANT

Reinforcements (1) can in no way substitute for sub-frame lateral guide stops. The assembly of guides is
still vital for vehicles with 4-door cabs.

RENAULT V.I. 04/02 B36 DT 4/366

3.8.5 Special features of vehicles with sleeper cab and vertical exhaust

The vertical exhaust support brackets prevent passage of the sub-frame if the sub-frame brackets are welded
on top. It is therefore important to:

- fasten the first bracket to the sub-frame by bolting.

- ban any welding on the sub-frame subsequent to its assembly on-vehicle.
Watch out to leave sufficient clearance (E) between the cab suspension and the first sub-frame bracket.

If necessary, notch it.
The width of this bracket should not exceed 90 mm.

1 - chassis
2 - cab rear support bracket
3 - wheelarch support
4 - first sub-frame bracket
5 - vertical exhaust support bracket
6 - sub-frame

IMPORTANT

To prevent exhaust gases from dirtying the cab, the vertical exhaust pipe nozzle is adjustable over a height
of 250 mm.

DT 4/366 B37 RENAULT V.I. 04/02

Véhicule E C3 C4 C5 C6 C7 C8

2700 1020 640
2950 1270

725

p

3250 930 640 850

uspension mécanique

3850 1000 1170

1100
4450 800 900 1070 805 840
5050 1100 1170

970 980

3850 1000 780 1280 1010

Suspension pneumatique 4450 800 900 680 715 840

5050 1100 780

880 980

3.9.2 MIDLUM B cabine 4 portes

E – empattements
X – axe essieu
Y – axe du premier corbeau

Véhicule E C1 C2 C3 C4 C5 C6

3250 2157 715 850

p

3850 2402 1070

1100

uspension mécanique

4450 2152 850 1070 805 840
5050 2502 1000 1170

970 980

3.9 Longitudinal positioning of brackets on chassis

3.9.1 RENAULT MIDLUM B 2-door day & sleeper cabs

E - wheelbases
X - axle centre-line
Y - first bracket centre-line

3.9.2 RENAULT MIDLUM B 4-door cab

E - wheelbases
X - axle centre-line
Y - first bracket centre-line

Vehicle

Mechanical suspension

Air suspension

Vehicle

Mechanical suspension

800

S

800

800

1280

800

S

800

RENAULT V.I. 04/02 B38 DT 4/366

Véhicule E C3 C4 C5 C6 C7 C8 C9 C10 C11

3070 1012 950 692
3350 650 917
3650

950 950

Suspension

3950 910 980

Sus ension

mécanique

4550 830 1020 950 782 810
5150 630 830 990 1000 997
5750

900 1100 1050

1100 1100
6480 780 1000 950 900 872 900
3650 640 670
3950 910 700

Suspension

4550 830 740 1250 762 810

Sus ension

pneumatique

5150 630 830 710 980 997
5750

900 1100 770

1080 1077
6480 780 1000 720 1250 880 872 900

3.9.3 RENAULT MIDLUM C’/C 2-door day & sleeper cabs

E - wheelbases
X - axle centre-line
Y - first bracket centre-line

Vehicle

Mechanical
suspension

Air suspension

640

640

1250 942

640

962

950

1250