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