雷诺KARAX DXI 11-13改装手册

雷诺KARAXDXI11-13改装手册2010.07.07MediumHeavyKERAX更多的关注严格的专业需求ConstructionmarketRENAULTKERAX4x2,18/19/22tonnetractors.–2wheelbases(3700,3900mm)RENAULTKERAX4x4,18/19/22tonnetractors.–1wheelbases(3700mm)RENAULTKERAX6x4,26/35/38tonnetractors.–4wheelbases(3200,3500,3700,3900mm)RENAULTKERAX6x6,26/35/38tonnetractors.–1wheelbases(3900mm)RENAULTKERAX4x2,18/19/22tonnerigids.–7wheelbases(3500,3900,4100,4500,5000,5500,5800mm)RENAULTKERAX4x4,18/19/22tonnerigids.–6wheelbases(3550,3700,3900,4100,4300,4500mm)RENAULTKERAX6x4,26/35tonnerigids.–7wheelbases(3200,3500,3850,4200,4500,5000,5500mm)RENAULTKERAX6x6,26/35/38tonnerigids.–5wheelbases(3550,3850,4200,4500,5000mm)RENAULTKERAX8x4,32tonnerigids.–6wheelbases(4350,4495,5050,5300,5650,6000mm)NEWFEATURESNewCab

Newinteriorandexteriordesign3-sectionbumperwithamoreprotectivecentralsectionNewadditionalfirstcabaccessstepNewPowertrain

NewDXi11Dxi13Euro4engineNewDXi11Euro4powerratings=>(370,410and440hp)NewDxi13Euro4powerratings=>(460,500hp)AnewgenerationofZFgearboxes（新一代ZF变速箱）NewdoublereductionP1595,P2695,P3395driveaxles（新的双机减速驱动桥）NewChassis

NewBrakes

Anewchassiswithspecificreinforcements（特有加固的新底盘）Newfrontandrearsuspensions8tand9tfrontaxleReinforcedairfilter(cyclonicfilter)（加强的空滤（飓风型空滤））Newfrontcrossmemberwithincreasedtowingcapacity（新型前横梁、具备更强的牵引能力）MorewheelbaseoptionsDrumbrakeswithABSandEBS（带ABS和EBS的鼓式制动）NewOptibrakeenginebrake（新型发动机制动）OptionalIntarder（选装缓速器）NewVehicle

Architecture

新型车辆结构

TheNewKERAX简介-车辆标识车辆标识：1–Chassis2–Driveaxle3–Gearbox4–OEMplate5–ConformityplateADRplate6–Tachographplate7–PaintreferenceCAMreference8–Engine9–Axle必须保持在可见或容易获得的位置，不能移动作为上装的需要！常规建议ModificationstoaRENAULTvehicleforthefittingofbodyworkandequipmentshouldbecarriedoutinaccordancewiththerulesandrecommendationssetoutinthisbodyworkfittingguide。在雷诺卡车上进行的车体或装备的改装必须与改装手册的推荐一致。Inordertoguaranteethesafetyandthesatisfactoryoperationofthevehicle,modificationofthefollowingcomponentsisstrictlyforbidden:为了确保车辆的安全和符合要求的操作，以下部件的操作是严格禁止的。–Brakes–Steering–Axlesanddriveaxles–Electronics–Electricalwiring.Itisforbiddentoweld,grind,cutup,drillorheattheside-memberorcross-membersunlessthecontraryis

clearlystated.

禁止焊接、打磨、切割、钻孔、加热纵梁和横梁。Generalinstructions：考虑维修、润滑点；不要影响传动和悬架部分零件的拆卸；考虑进气、排气、燃油的供给；考虑车轮的运动，制动盘和电池组件的通风；散热器进出口不得改动；符合技术文件的尺寸、载荷分配，任何情况下，上装必须保证底盘上所有运动部件的自由运动和安全操作；附加的任何部分不得影响车辆的运行和驾驶安全，特别要确认载荷的平衡分布；任何上装的安装，车辆左侧和右侧的重量平衡必须低于4%。在着手改装前，你必须查阅：车辆的技术数据、符合改装的图纸和相关的计算、驾驶和维修手册。Beforeanyworkontheelectricalsystem,disconnectthebatteries,alwaysbeginningwiththenegative(-)terminal.Whenrefittingabattery,alwaysstartwiththepositive(+)terminal.Neveruseanakedflamenearthecellvents(riskofexplosion).在针对电器系统的任何工作之前，断开蓄电池链接，通常从搭接的负极开始。重新安装从正极开始。不要再通气孔附近使用明火（爆炸的危险）。Whateverworkyouaredoingonthevehicle,youmustswitchofftheelectricalcircuitatthemasterswitchordisconnectthebatteriesinordertoavoidanyriskofelectricshockduringwork.计算和几何结构车体起始尺寸：Lowhungexhaust&Verticalexhaust：考虑排放、进气道、前翼子板、发动机隔音等因素，确定最小的车体起始尺寸。AE-Axlecentre-lineB/B1-bodystart1-normalcabposition2-changedcabpositionSub-frameheight=200mm上装最大长度(W)毫米 7578上装最小长度（W）6620上装最大后悬X3018上装最小后悬X2060上装最小重心位置Y771上装最大中心位置Y1250整车最大长度Z9686整车最小长度Z8728上装最小起始位置B620--675计算和几何结构F'=F+E/2-2040/2F‘=4495+1370/2-1020=4160Vehiclewith4axlesP1=PxY/FP2=P-P1底盘纵梁的截面：概述：预防措施1、Beforecarryingoutanywork,protectthecabwithacover.2、InstructionsforsoundproofingscreensSoundproofingscreensshouldneitherberemoved,modifiednordisplacedsoasnottodowngradethevehiclesoundlevel,whichiscoveredbyofficialhomologation.隔音垫等，不能移动、修改、取代导致降低噪音水平；Ifitisunavoidableforthemtohavetoberemoved,theymustwithoutfailbeputbackintoplacewhentheworkiscompleted.Afterremoval,onlyperfectlycleanscreensshouldberefitted.Thescreensaretobecleanedusingacloth.Ifnecessary,usesoapywater.3、Instructionsforheatshields(隔热垫)Itisforbiddentoremoveormodifytheseshields.Theyplayapartinensuringyourpersonalsafety.Duringchassispaintingoperations,takecaretoefficientlyprotectthehotfaceofheatshieldsagainstsplashingpaintandespeciallytheshieldssurroundingtheelectricretarder.4、SideimpactbeamsSideimpactbeamsmustcomplywiththelawsinforceandshouldnotimpedeaccesstochassiscomponents(sparewheel,airandfueltanks,airdryer...).侧防护必须符合强制的法规，但不能阻碍接近底盘的一些部件；1、Safetyandprotectionofcomponents部件的安全和防护Beforecarryingoutanyofgrinding,drilling,orweldingwork,efficientlyprotectorremove,ifnecessary:–Plasticpipesandtubes.气路管路–Electricalwiringharnesses.电路线束–Suspensionsprings(particularlyforprotectionagainstcorrosion).特别注意对腐蚀的防护–Airsuspensionsprings(chassis).–Soundproofingscreens.–Anyothercomponentsensitivetoheat,tothedischargeofincandescentmatter,toultravioletrays保护热敏元件以防加热、白炽灯照射、紫外线等2、Protectionofbatteries蓄电池的保护Abatteryattheendofitschargeproducesamixtureofoxygenandhydrogengas.Theignitionofthisgaspresentsdangersofbatteryexplosioninthecaseofthepresenceofasourceofheatnearby.Asaresult,whenweldingnearthebatteries(i.e.enginecompartment,frontendofthevehicle),takeoutthebatteriesandstoretheminawell-airedlocationawayfromtheplacewhereweldingisbeingdone.Thisrecommendationappliesequallyforgrindingoperations.3、Protectionofsoundproofingscreens隔音罩的防护Whenweldingorifusingsandingdisks,eitherprovideeffectiveprotectionorremovethesoundproofingscreens,ifnecessary.4、Protectionofthecab驾驶室的防护底盘—焊接1、WeldingonvehiclesequippedwithamasterswitchThevehicleisequippedwithnumerouselectroniccircuitsandnumerouselectroniccontrolunits(ECU).Beforeanyoperationinvolvingelectricwelding,potentialsmustbeeliminatedbyconnectingtheECUstoearth.Thiscanbequicklydonebydisconnectingthepositive(+)cablefromthebattery,connectingittoearthandthenclosingthemasterswitch,iffitted.Placetheearthingclampasnearaspossibletothepointofwelding,butneveronrotatingparts(propshaft,fanhub,etc...)noronasub-assemblyhavingmovingparts(i.e.aircompressor,turbocharger,etc...).Nearbyplasticpipesandelectricalcables,mechanicalspringsandairsuspensionspringsaretobeprotectedorremoved.Thisalsoapplieswhengrindingordrilling.Whenreconnectingthebattery,matchthepolarities,startingwiththepositive(+)terminal.Reversalofpolaritymaycauseirreparabledamagetoelectroniccomponents.2、Vehiclewithelectricalmasterswitchdiagram底盘—焊接I-InitialstateII-StatebeforeweldingA-BatteriesB-Electromagneticmasterswitcha-Batteryearthb-Positive(+)aftermasterswitch1–Disconnectthepositive(+)cableandthenegative(-)cablefromthebatteries.2–Connectthepositive(+)cableandthenegative(-)cable(earthingofthepositive(+)cable).3–Connectthe2positive(+)cablesbeforeandafterthemasterswitch底盘-钻孔–Nodrillingofmorethan4holesonthesamevertical–Nodrillingintheflangesofsidemembers.Inthissection,alldimensionsaregiveninmillimetres.A-Maximumrecommendeddrillingdiameter:-13mmfora12mmbolt-15mmfora14mmbolt-17mmfora16mmbolte-SidememberthicknessP-Between-centresdistancebetweentwodrillingsR-sidememberinternalradiusofcurvature:12mm底盘-机械连接Verticalpositioningofbodybrackets8x4rigid1.6-2mcabA-bodybracketB-reinforcedbodybracketC-lateralplatetype1D-lateralplatetype21-chassis2-sub-frame底盘-机械连接底盘-后悬参数6x4,6x6,8x4rigidShorttipperLongtipper副车架ITISFORBIDDENTO:

FASTENSUB-FRAMESWITHU-BOLTS,CLAMPSOREQUIVALENTSYSTEMS(HOOKS),严禁用U型螺栓、夹具、吊钩等紧固副车架；–USE,DRILLORWELDSPRINGHANGERS,严禁使用、钻孔和焊接板簧支架；–MODIFYTHECHASSIS,THEDRIVELINE,ORTHESUSPENSION(UNLESSSPECIFIEDINTHEGUIDETOTHEFITTINGOFBODYWORK),严禁改动底盘、传动系统和悬架，除非改装手册有明确的说明；–WELDSUB-FRAMESTOSIDEMEMBERS,严禁主副车架焊接一起；–DRILLINPROXIMITYTOENDSOFSTIFFENERS,严禁加强筋附近或末端钻孔；–WELDORNOTCHSIDEMEMBERSORCROSS-MEMBERS,严禁纵梁和横梁的焊接和开V型槽；–USEORMODIFYOURNUTANDBOLTSHARDWARETOFASTENBODYWORKANDSUB-FRAMES(EXCEPTFORSPECIALCASESDESCRIBEDINTHISDOCUMENT),禁止使用或更改螺栓和螺母用于紧固副车架和上装，除非手册中有明确的说明；–DISMANTLEBODYBRACKETSATTACHEDTOTHECHASSIS(EXCEPTFORSPECIALCASESDESCRIBEDINTHISDOCUMENT),禁止拆卸连接车身和底盘的支架；–INSERTWOODENBLOCKSBETWEENTHESUB-FRAMEANDTHEVEHICLECHASSIS.禁止在副车架和底盘之间插入木块；副车架Aminimumsub-frameheightisimposedbytherangeofmovementoftherearsuspension.R-FreeradiusA-Normalheightwhenheight(Δ)ofairspring(2)isnominal(roadposition)B-Heightwhenairspring(2)isinmechanicalabutment(bumpstop)1-Chassis2-AirspringFinishingofsub-framesbehindthecabThesub-framemustbeplacedasfarforwardsaspossibleonthechassisofrigidstowardsthefrontofthevehicle.副车架必须是近可能的向前，朝向车辆的前端；A-assemblywithregularcabB-assemblywithlongcabC-chassisAE-axlecentre-lineRI-industrialreference:firstholeafterthenecking副车架前端的形状和尺寸上装的连接A-lateralguidingandflexiblefasteningzoneAE-axlecentre-lineB-lateralguidingandrigidfasteningzonea-flexibleattachmentposition(firstbodybracket)b-flexibleattachmentposition(secondbodybracket)c-flexibleattachmentposition(thirdbodybracket)d-rigidattachmente-rigidattachmentRI-industrialreference:firstholeaftertheneckingA-minimumsupportheight,ofthesidememberheightX:-60mmforsidememberheight300mmForvehiclesfittedwithbodybracketsthatdnotserveasfrontguides,lateralguidingmustbeprovidedby2guideplates,whichareweldedtothesub-frameonly（起重机）.上装连接的类型a-Semi-flexibleattachmentReinforcedbodybracketB1-hexagonboltHM14x150x110,class10.92-2plainwashers14x30x53-steelspacer15x38-65(minimum)–aftercut-out,truebothsides.4-nutDRHM14,class10oranyotherlocknutexceptnutwithnylonring(e.g.Nyloc)a-slightplaybeforetighteningtotorque20to30Nm,thecontactb–play:2mmmaximumTightentotorque:170NmBodybracketAandReinforcedbodybracketBPTO-S81CPTO81Z1B/CLayoutofgearbox-mountedPTOsAB=1414\B=520\C=832\DC=64\E=96\F=180\G=335\H=10\I=154\J=51\L=44\α=4°InstallationofhydraulicpumpsThesealbetweenthepumpandthePTOmustbeachievedbytwogaskets(J1andJ2)withanairdrain(E)betweenthegaskets(J1andJ2).CalculationoftheweighttorqueCp(Nm)=P(N)×d(m)g–pumpcentreofgravityP–pumpweight(N)(weight(kg)×9.81)d–distancebetweencentreofgravityandpumpsupportfacetheweighttorqueshouldnotexceed50Nm.OversteppingthisvaluemayleadtofastdamagetothePTOortothegearbox.Ifitisoverstepped,itisessentialtoaddapumpsupportbracket.Fasteningthehydraulicpump(A)-ItisvitaltousethenutsandwasherssuppliedwiththePTO(class10.9).-Applyatighteningtorque:–35Nm±15%(81,84PTOs,studswithreducedcross-section)Positionofconnectionunionforextraauxiliaryequipment1-multiplesnap-onunion(diameter6-8mm)2-freelocati