Renault Magnum AE / Magnum E-Tech with engines of 12.0 liter, service e-manual (in Russian)

Contents Engine MIPR 06.24.65 Technical data Engine identification plate General characteristics Lubrication system Cooling system Fuel supply system Tightening torques Adhesives, fixing and sealing agents Belt tension General rules before assembling the engine Dimensions and tolerances of engine components Removing and installing engine Removing and installing cylinder head Disassembly and assembly of the gas distribution system Disassembly and assembly of the crank mechanism Lubrication system Disassembly and assembly of the oil pump Dismantling and assembling the oil filter Cooling system Dismantling and assembling the oil cooler Disassembly and assembly of the thermostat Disassembly and assembly of the water pump Fuel injection system Disassembly and assembly of the high pressure fuel pump Adjusting the high pressure fuel pump Disassembly and assembly of the injector Nozzle adjustment Turbocharger Checkout Cleaning Turbocharger problems Brake "J" Removing and installing brake "J" Disassembling and assembling brake "J" MIDR 06.24.65 engine (from May 2000) Technical data EUP System General characteristics Fuel supply system Sensors Adhesives, fixing and sealing agents Tightening torques Dimensions and tolerances of engine components Removing and installing engine Removing and installing cylinder head Disassembly and assembly of the gas distribution system EUP electronic fuel injection System structure Working flowchart Removal and installation of single fuel pump (s) VMAC III System Diagnostics Diagnosis with a warning lamp Diagnosis with RENAULT device Electrical diagrams EE 9 560 VG2 engine Technical data Tightening torques Lubricants and other materials Belt tension Preparing the engine before assembly Valve. Springs, rockers, valve guides - dimensions, clearances Crankshaft - dimensions, clearances Pistons, liners, piston rings - dimensions, clearances Connecting rods, piston pins - dimensions, clearances Camshaft - dimensions, clearances Gas distribution mechanism-dimensions, clearances Valve timing, valve clearances Removing and installing engine Removing and installing cylinder head Disassembly and assembly of the gas distribution mechanism Disassembly and assembly of the crank mechanism Lubrication system Disassembly and assembly of the oil pump Dismantling and assembling the oil filter Disassembly and assembly of the control valve Disassembly and assembly of the breather Cooling system Disassembly and assembly of the radiator (heat exchanger) Disassembly and assembly of thermostats and filter Disassembly and assembly of the water pump Fuel injection system Disassembly and assembly of the high pressure fuel pump Disassembly and assembly of the injector Turbocharger Turbocharger problems Car check Removal and installation of a turbocharger Malfunctions and probable causes Universal tool Engine Electronic Control (VMAC) General information System installation System functioning System performance with limited performance System elements Placement of system elements Tightening torques Engine mode sensor (8261) Fuel pump mode sensor (9262) Supercharged air temperature sensor (8286) Coolant temperature sensor (7362) Fuel pump rack position sensor (9265) Fuel priming pump valve Oil level sensor Clutch pedal adjustment System diagnostics Control lamp Diagnosis with a warning lamp Troubleshooting Defective node or function Checking plugs Microprocessor card of the car Electrical equipment 30 pin connector J 1 A 30-pin connector J 2V 18 pin connector J2 DEUTSCH connector PACKARD connector Diagnostic socket Starting the engine with the cab overturned Schematic diagram of the VMAC system Gearboxes В8, В9 и В18 Technical data Transmission identification Gear ratios Clearances and other indicators Tightening torques Lubricants and other materials Gear kinematics Gearboxes B8, B9 & B18 with TBV remote control Pneumatic circuit diagram Gearbox repair Removal and installation of gearboxes В8, В9 и В18 with remote controltbv Removal and installation of gearboxes В9 and В18 Disassembly and assembly of gearboxes B8, B9 and B18 Adjustment Disassembly and assembly of shafts Main shaft D1 Main shaft D2 Main shaft DZ Input shaft Synchronization Disassembly and assembly of gearshift mechanisms Left-hand gearshift mechanism Right shift mechanism Direct shift mechanism TBV gearshift mechanism Disassembly and assembly of relays Front relays Bearing seat adjustment Synchronization Rear relay ZF gearbox Technical data Transmission identification Tightening torques and clearances Lubricants and other materials How it works Gearbox repair Removing and installing gearbox Removing and installing rear relay Disassembly and assembly of the rear relay Disassembly and assembly of the main crankcase Disassembly and assembly of the oil pump Disassembly and assembly of the input shaft Disassembly and assembly of the intermediate shaft Disassembly and assembly of the output shaft Disassembly and assembly of the VK synchronizer Disassembly and assembly of synchronizer D Gear shifting mechanism Disassembly and assembly of the transmission control unit SERVOSHIFT Servo Drive Removal and Installation Disassembly and assembly of the ECOSPLIT gear shift unit (16 s 221) Cable drive MAGNUM Regulation and control Rear relay axial clearance adjustment Input shaft axial clearance Adjusting the axial clearance of the intermediate shaft Main shaft ring and thrust washer adjustment Adjusting the switch fork of the speed range doubler Checking the pneumatic tightness of the rear cylinder Monitoring the air pressure in the piston and in the doubler cylinder of the speed range Wear limit for synchronizers 3/4 Wear limit for synchronizers 1/2 Hydrodynamic retarder Technical data General recommendations Lubricants and other materials Regulatory data Tightening torques Change oil and oil filter Oil drain Oil filling Replacing the retarder oil filter Repair Electronic speed limiter l1V ASR General provisions Management features Caveats How it works Description of components Pulse generator and electronic control tachograph Computing device ACTIA Speed ??limiter drive Vehicles equipped with VMAC Disassembly and assembly of the control mechanism Car MAGNUM AE 520 Car MAGNUM AE 385 TI and AE 420 TI Checking the electronic speed limiter LIV ASR General check using the DIAGNOSTICA computer Checking with signaling devices Bridges Technical data Bridge identification Tightening torques and clearances Lubricants and other materials Repair of wheel reducers S1.S2 and S5 Hub repair Repair of the central mechanism C4ALL Repair of the C4A2P adapter with two gears Repair of the S4AZR adapter with stirrups Center differential lock repair Interwheel differential lock repair Disassembly and assembly of the interwheel differential locking mechanism Removal and installation of the power cylinder for blocking the interwheel differential Disassembly and assembly of the power cylinder for interwheel differential lock Repair of the front axle EB Technical data Hub repair Trunnion repair Steering Specifications Steering repair Removing and installing steering Steering traction adjustment Removing and installing steering wheel Adjusting the mechanical steering stop Adjusting the hydraulic steering stop Refueling and bleeding the power steering system Checking the steering hydraulics Technical characteristics of hydraulic pumps Control devices Checking the steering box Checking the steering hydraulic pump Faults and remedies Clutch Technical data General information Tightening torques and clearances Lubricants and other materials Clutch mechanism repair Removing and installing release bearing Removing and installing the clutch mechanism Removing and installing engine flywheel Removing and installing plug Clutch actuator adjustment Master cylinder adjustment Adjusting the slave cylinder Check pad wear indicator Pneumatic braking system Vehicle configuration Air brake system components Compressor Air dryer Safety valve Receivers Double axle service brake valve (tandem) Double working brake valve Quick release valve Pressure reducing valve Single aperture camera Self-adjusting lever Cam brake disc S Pneumatic single disc brake Single relay valve Double check valve Relay check valve Double relay valve Reducer Combined pressure reducing valve Brake force regulator Double diaphragm spring camera Parking brake valve Trailer brake valve Parking brake safety valve Double shut-off valve Shut-off valve Check valve Advance trailer brake valve Pressure switches Pneumatic braking system diagrams List of air brake system components Direction designation Hole markings Brake piping designation Checks and adjustments Air dryer Brake force regulator (vehicle with mechanical suspension) Axle brake force regulator (air suspension vehicle) Lifting axle brake force regulator (vehicle with air suspension) Repair of connecting fittings Suspension Air suspension General information Specifications Pneumatic diagram Diagnostics of suspension faults on EURO 2 cars Diagnostics of suspension faults on EURO 3 cars List of fault codes Level sensors adjustment Size check (n) Suspension calibration Parameterisation of the electronic control unit Electronic air suspension EGAS Specifications Equipment placement Schematic diagrams Electro-pneumatic diagrams Functions of ECAS equipment elements The principle of operation of solenoid valves Mechanical system System pre-check Full system check Suspension adjustment Level sensors adjustment Calibration Parameterization Checking the system with a signaling device Cab Removal and installation of the cab Removing and installing air suspension of a cab Cab rollover Replacing the hydraulic fluid Replacing the hydraulic cylinder Cab tipping over with a broken electric motor Removing and installing windshield Replacing the outer panels of the cab Rear shield replacement Replacing the right or left sidebar Replacing the center plate Replacing the right or left side shield Replacing the bottom panel of the door frame Replacing the front door frame panel and roof connection Partial replacement of the windshield frame and hinge reinforcement before joining the roof Replacing the side shield Replacing the subframe reinforcement panel Roof panel replacement Replacing the front half-cross panel Replacing the sidebar Complete roof replacement Replacement of internal elements of the cabin Replacing the curtain of the left door Replacing the curtain of the right door Replacing the upper fixed glass of the door Replacing the door trim Lock replacement Replacing the outside handle Replacing the lock cylinder Switching off relay replacement Replacing the window regulator Replacing the sliding glass Replacing profiled seals Replacing the glass guide Replacing the door Replacing the door opening limiter Seat replacement Removing and installing dashboard Replacing the NEIMAN anti-theft device Replacing the right or left storage compartment Replacing the top shelf for small items Replacing the ventilation hatch curtain Roof upholstery replacement Replacing the mechanically operated windscreen blind Replacing the electrically operated windscreen blind Replacing the wiper motor Replacing the wiper motor assembly with linkage block Replacement of technical platform parts Replacing a right or left rounded corner Replacing the right or left footrest Replacing the right center side trim Replacing the left center side trim Replacing the right or left railing panel Spoiler replacement Checking the dimensions of the cab Checking the geometry of the door frame Checking the geometry of the windshield frame Back panel geometry check Cabin painting Determining the color of the cab paint Determining the type of cabin material Determining the type of cabin painting Methods of painting plastic parts