DIY Renault Magnum repair

When removing the gearbox for repair, I also removed the CCGT. And I had to drain all the brake fluid. So after installing the gearbox and attachments, there was a need pump over the CCGT... To do this, as it turned out in the end, is very simple. Although, having searched through many thematic forums, it became clear to me that this causes difficulties for many. I'll try to help.

As far as I understood from various sources, all CCGT units are pumped from bottom to top. It is not necessary to pour liquid ("brake", Pentosin, ATF) into the expansion tank and try bleed the clutch pedal, periodically bleeding air from the fitting. So far, no one seems to have succeeded. 🙂 It's much easier! I'll be brief ..

We unscrew the cover of the expansion tank. We wrap it with a rag in case there is too much brake fluid and it spills out.

We put on the pump hose on the pumping union of the CCGT unit, having previously removed the nozzle for inflating the tires from the hose. We fix the hose with a clamp or wire. We unscrew the pump cover. We take out the stock. Pour fluid (in my case, brake fluid) into the pump. We tighten the lid.

Fill the brake fluid into the pump.

How to bleed the clutch with a pump?

To pump over the CCGT my car, you need 0.5 liters of "brake". The car hand pump holds the same volume. Those. for me, this is ideal. We will pump the system in one "pumping".

In general, when everything is ready, we begin to press on the pump handle so that the rod slowly but surely pumps liquid into the CCGT system. When the level in the expansion tank reaches the norm, we stop pumping liquid.

By the way, the clutch pedal was in a free state at the time of pumping the psu. That is, it was not pressed.

We tighten the union. Remove the hand pump hose. We tighten the tank lid. The clutch is ready for use!

After this procedure, the clutch pedal should become very tight.

The promised video instruction on how to pump a CCGT unit (a la clutch) in 10 minutes:

1. To be honest, when pumping, I interrupted once when gurgling from the expansion tank started to check the level. But this did not affect the result in any way. I speak so confidently because a month has passed since I bleed the clutch... It squeezes out well.
2. After pumping the pump, it is advisable to repeatedly “blow through” the hand pump with idle “pumping”.
3. Repair manual for Renault Trucks clutches and CCGT units of all models:
   Repair manual for clutch and CCGT
4. Complete list of manuals and repair guides:
   Repair manual Renault Truck

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Hello. give advice. kamaz 6460 otkapitalil gearbox zf16. set. I put the pidal (wabko), I pump it from the bottom to the top. the pidal is tight. everything would be fine. but the clutch is not there, the fag is weakened. and drips from the pid. changed the kit. the same procedure and dripped. thanks in advance.

Hello. Even before 2011, I always pumped through the top (with the pedal). And it always worked out. After that, for a long time, the problem with the clutch was bypassed.
Now there are problems with the PSU. Can you help? Tell me what?
Renault Kerax car, I squeeze the pedal to the middle, throws it out through the upper unloading air. Sometimes to the end, too, straight air into the atmosphere. He took off the piston, cleaned everything, greased it, assembled it, but there was no result. This is not the first time that the PSU was changed twice in two years. How is the top valve supposed to be regulated? How to align the piston? And what can be done at all? Thanks in advance.

Victor Dobriy evening.Need help Scania 420 2006 Arrived from the flight everything was okay stood there for a month I was going to go to the air pumped up, and the gears are not included, the GPU pumped the pump through the bottom of the pidal soft, but with a punch, the code turns off the engine, turns on the gear, the engine starts up, the displacement is found, it switches, and the displacement does not want to.

psu does not reach speed does not turn on

Good evening, guys, I need help machine measures 2433 clutch problem new psu new hose new master cylinder
I am pumping the liquid from below, everything is going well
but the trouble is that the clutch does not work, but if you quickly swing the pedal starts to work, then you don’t swing again for a minute, no, swing the pedal again quickly begins to appear and then disappears again
WHAT TO DO PROMOTE. WHERE TO CLIMATE HOW TO CHECK WHERE WHAT IS WRONG

Hello, I have the same nonsense on a Mitsubishi Fuso on a mixer, I have already changed everything, just how I did not try to swing and nothing comes out, can you tell me what ??

Good evening! Dear I am addressing from Kazakhstan. I have the same problem with the car, can you tell me what the reason was and how was it fixed?

I squeezed out the clutch without air, the gears began to engage poorly and the clutch is driving. What is the reason?

Good afternoon. Tell me what could be the reason. Car DAF XF 95 2004, manual transmission. In the evening, the car set everything up well, started it in the morning, pumped up the air, the clutch pedal became very light (fails). I looked under the car, all the liquid leaked out from the CCGT unit through a plastic fitting, or I don’t know what to call it, it’s only plastic. It is likely that the clutch was squeezed out when there was no air in the system. I don't see any more reasons. Tell me who knows what about this.

Good afternoon. We have such a problem. The stem of the CCGT unit, after a few clicks by half, does not move back. It turns out that the clutch is constantly slipping. The reason for the PSU?

Hello. Tell me please. We started to switch speeds badly, bought a new psu and installed it. pumped the liquid from top to bottom. The clutch pedal at the beginning is soft to the middle and stands stupidly, we are busy for the third day, the result is zero. We are already thinking of removing the box and checking the clutch disc and clutch disc, Tell me what is the reason. thanks in advance.

Good afternoon. Poor gear shifting is a loose concept. There are a lot of reasons: synchronizers, the clutch drive, the clutch itself, the CCGT .. And in each of these reasons there are many sub-reasons. I do not know how your gears were poorly stuck, but if you changed the PSU, then, probably, the cause was diagnosed before that. And if pumping from above did not help, try pumping my way from below. Among other things, the plus of this method is that all the slag from the system goes out (into the tank) (although, it doesn't matter for you, you have a new CCGT unit).
In general, if the pedal got stuck after replacing the CCGT, then the reason is most likely in it. Try to put back the old CCGT unit to identify or exclude this option.

Hello. I have a clutch problem on a Renault premium 340 (1999). Changed the clutch discs. When we tighten the basket onto the flywheel, the petals on the basket move back and the stroke for the crimp is reduced. When we press the pedal it reaches the middle and stands blank, the cage reaches the box. If possible, send √ tel. I would be glad to receive any information.

Hello Rabadan.
In theory, the petals should not leave. There are two options: either it was installed incorrectly, or the wrong clutch disc. And if the release bearing was also changed (which I highly recommend doing while the box is removed), then maybe it is not the same. Have you changed the basket?
I had this this summer - they also changed the clutch (I took it in the assembly: basket, disc, bearing), but at first they did not bring my kit, although the number supposedly fit. There is a nuance in the names of the checkpoint and the manager unknowingly convinced me that he could not be mistaken. I had to find out all the numbers myself, and it turned out that the clutch kit was not mine at all. The parts manager screwed up. But not the point.I can try to help you with information with part numbers.
From you: VIN of the car, full number of the box (example of the number on my box: B18 200L42, written on the nameplate at the checkpoint), numbers of all NEW spare parts that were installed: disk, bearing (if changed), basket (if changed). I will try to clarify whether the correct parts were brought to you or were wrong, as with me.

PS: I will help you as much as I can, but there is no point in giving the phone number, tk. auto repair is not my specialty.

Good evening! I have not changed either the basket, or the clutch plate, or the clutch disc. I just riveted Feredo onto the clutch discs. I suspect the discs are thicker. Riveted disc thickness 12mm. I would like to know the required thickness of the riveted disc. When we put the outer disk on the basket, it flips over the side of the basket.

Maybe you mis-centered when you put the basket? Unfortunately, I can't say anything about the thickness of the disc.

hello! problem with the clutch, the pedal moves easily, the fluid level is normal. what to do ?? auto daf cf 75 2000 onwards

Hello. If not pumped, then pump it. If it does not help, then look at the clutch pedal drive, if it is normal, then remove the CCGT, disassemble, look.

Good afternoon. There is such a problem when you squeeze the clutch everything switches normally, but when you release the air is released through the relief valve, but until the pressure in the system drops, then you have to pump air and press it again. PSU Renault premium. If you can password for the CCGT repair manual

Gregory. As I already wrote, I did not understand the PSU, so I will not help with advice. And he threw the password for the archive on the e-mail.

I also had a knock in the box, but not as strong as yours. But the problems with shifting gears when the air in the system is more than seven atmospheres does not go to the top row and the back one with the turtle is turned on only with the help of a mount until you have to pressurize. Then if you switch from the turtle to the back one, they will switch, but if you stick the first second one there, not the back turtle. What could be?

Ivan, you have a 100% problem in the CCGT unit, namely, the O-rings are worn out, so change them or temporarily you can wind up the fumki under them!

Good day. I also have a Renault premium (as in the example). But it didn’t work to pump from bottom to top (until a certain moment the stock leaves, then it gets up with a stake. I open the union and go to check the pedal. It is weak). I tried to pump from top to bottom (through the pumping hose from the receiver gave pressure to the reservoir). And he looked under the car when it poured out from under the nozzle. Gradually it was tightened all the tighter and applied pressure (periodically poured brakes). As a result, it seems to have "pumped". Came up to the pedal ... Weak .... And the car stood for a couple of days and the TJ periodically leaves the tank, but it is not clear where (there is no puddle under the car, and about a liter has already been filled in the tank). Please contact me by mail. There are a couple more questions about the same car.

Greetings, Constantine.
If the brake does not go through the fitting to the reservoir, then it is logical to assume that the hydraulic part of the CCGT unit is clogged somewhere. This also follows from the fact that the brake fluid does not go through the tank to the fitting.
The fact that the brake fluid was poured from above in an amount of more than 0.5 liters (this is the norm for our system, as well as for many others), it means that it is accumulating somewhere. Alternatively, in the PSU itself.
I disassembled the PSU, but only the pneumatic part. I did not climb into the hydraulics. I think it's worth taking it off and looking inside.
Is everything dry under the car?

What is the root cause of pumping the CCGT unit?

The root cause is the replacement of the CCGT unit. The old bottom valve hissed

The pneumohydraulic booster (PGU) serves to reduce the effort on the clutch pedal. The comfort and safety of the truck operation depends on the serviceability of this system.

The main role in the proper operation of the clutch is played by the amplifier, which participates in all driving operations without unnecessary complications and increases the period of operation of the clutch.

This mechanism can sometimes fail, therefore, if a malfunction is detected, it should be replaced.

• Compressed air does not flow due to swelling of the inlet valve of the pneumatic booster;
• Jamming of the follower piston of the pneumatic booster due to swelling of the follower piston of the sealing ring or rubber ring;
• Worn or deformed cuff of the pneumatic piston of the amplifier;
• Air ingress into the hydraulic system, leakage of working fluid.

If air enters the hydraulic drive for disengaging the clutch, the pedal may "fail" and, as a result, incomplete disengagement of the clutch. It is necessary to remove air bubbles with part of the brake fluid (bleed the clutch). During pumping, it is very important to monitor the fluid level in the reservoir. If there is a significant decrease in the level, you need to top up the liquid.

Autotech center "ZAGORETS" has at its disposal all the necessary equipment for diagnostics and replacement of CCGT units on Renault trucks of small, medium and large carrying capacity, as well as on minibuses. All our work is provided with a 100% guarantee. It is possible for a repair team to leave for diagnostics and minor repairs.

Autotechcenter "ZAGORETS" produces professional diagnostics and replacement of CCGT of commercial vehicles Renault in a short time and with a quality guarantee. Our masters will advise you on all issues related to the operation, prevention, maintenance of trucks.

The main part of the truck is the pneumatic system, the essence of which is to easily squeeze the clutch, and also provide perfect braking, simplify lowering and raising the van to a certain level, and the comfort of the driver's seat (seat).

This type of advantage lies in the presence of additional units and assemblies, they also periodically fail.

The composition of such nodes includes:

1. energy storage;
2. air taps;
3. pneumatic compressor;
4. pneumatic hydraulic booster (PGU).

Such components are important elements in the functioning of any vehicle, and the Renault MAGNUM brand is no exception. In this connection, the cost of the units is quite high, in addition, it will be necessary to hire qualified employees to repair the Renault Magnum CCGT unit. Only this type of repair work is quite dangerous for humans and it is better to contact our specialized service station. Because repairs should be trusted only by professionals.

The service station performs the following repair work:

1. replacement or repair of power accumulators;
2. replacement or repair of CCGT;
3. replacement or repair of automobile pneumatic compressors;
4. replacement or repair of air compressors.

Affordable repair price.

We work only in our premises, so there are no additional rental costs, which significantly reduces the cost of the service.

High quality.

For the repair, modern equipment and techniques are used. Our specialists have many years of experience.

All spare parts are delivered from reliable manufacturers in their original form. After entering the warehouse, all products are passed to the norms and standards of use. Therefore, there is no defective item.

Fast service.

For the needs of the client, we compromise on the work and carry out repairs in the shortest possible time.

For all the work performed, there is a guarantee of operation, which is written out by our administrator during the delivery of the car to the owner.

Diagnostics.

Before starting repair work, our specialists carry out a detailed diagnosis of the vehicle.

Availability of spare parts

On a permanent basis, we have original models of new and used spare parts, and we also carry out the order of the necessary parts at the request of the client.

We carry out disassembly

Clients often turn to trucks, so you don't have to worry, we can easily take on the most difficult work. The quality is guaranteed.

We carry out various repair work on European Renault trucks in the shortest possible time and at a high level of quality.Contact us at any time of the day for an initial qualified consultation and bring your car for consultation. Then we agree on all the points of the repair work. According to the need, an order of a new spare part is carried out or we choose from a large assortment of used spare parts. You will not regret it! We are always glad to see you!

In the lowered position, there is a leak, they switched to high there is no leak at neutral speed, we did all this, after several times they switched from low to high and vice versa, the leak disappeared, tell me what is the reason? Thanks for your feedback! ! !

Good morning, please tell me what is the reason, the situation is like this on the daf when the clutch is pressed, you can hear an air leak in the area of ​​the psu when the leak is released, no what could be the reason?

Tell me how to properly pump the clutch on the Chinese shahman f, otherwise after replacing the psu, I got sick of pumping

Please give me your email

Is a child growing up in your family? Naturally, the kid enjoys decorating the flowers on the wallpaper, tearing them off the wall. You have to periodically wash the wall covering, glue the wallpaper. When the child grows up, you can make repairs to the Renault Magnum with your own hands, which will return the apartment to its original appearance. Modern materials make it possible to bring to life the most interesting solutions, to completely renovate the home.

Life goes by rapidly, one day is similar to another. Do you want variety, a change of scenery? The continuous work schedule provides for constant employment in the service, you have to be at home only in the evenings. An excellent solution would be a contract for the repair of office equipment, a one-time sample of an apartment, which allows you to bring a new note of pleasure into your life. You can contact a specialized company that offers a turnkey service.

How to renovate your apartment or house if there is no time at all? At the moment, the opportunity to contact professionals who are ready to completely revitalize your premises is quite popular. Qualified designers develop projects, companies offer the opportunity to perform turnkey LCD TVs to be repaired. You do not have to buy materials yourself, hire workers, control the process.

Renault Magnum (Renault Magnum) has long become a favorite truck of many carriers. They value this vehicle for its quality, reliability and ease of maintenance. I have already described the advantages of Magnum (you can read it here), its shortcomings (here) and the peculiarities of operation (read here). Today I will tell you about some of the characteristics of spare parts for Renault Magnum.

But first, I want to note that this truck is no longer produced. On June 26, 2013, the last 2 copies of the Magnum rolled off the assembly line in Lyon, France. The largest automaker Renault launched a new line of T Range cars, so it was forced to abandon the services of the famous Magnum. Note that the first Magnums rolled off the assembly line in 1990. But until now, they are actively surfing the vastness of our (and not only) homeland, being one of the most famous European cars.

Fuel filter It is often "covered", since the quality of domestic diesel fuel is poor. It must be changed in pairs. And not only with maintenance. I advise you to change the fuel filters after driving 20 thousand km.

Power steering filter needs to be replaced somewhere after 80-100 thousand km, that is, about once a year. The power steering filter cannot be washed, repaired and extended.

Main belt enough for 2 years (200 thousand km). The rollers change depending on their condition. It is important that they are free of cracks and scuffs. Particular attention should be paid to the belt for those carriers who have cars with high mileage.

Generator serves approximately as long as the engine. But every two years you need to change the brushes. Instead of a new generator, you can purchase a refurbished one, the cost of which is about a third lower.

Air compressor it works normally for about 500 thousand km, then it can drive oil.A repair kit made of gaskets is on sale, but its price is approximately equal to the cost of the compressor. The dryer filter is changed every six months.

Nozzle pump very sensitive to the quality of diesel fuel. Serves in Ukraine for about two years, in Europe - for 5-7 years.

Kingpin repair kit will last about 3 years. Much depends on the condition of the springs. Note that the kit is interchangeable with the Renault Premium repair kit of the same years. The cost is almost the same.

Release bearing serves 400 thousand km, withstanding two clutch replacements. An earlier breakdown often indicates an illiterate driver's actions.

Clutch disc, as a rule, it is enough for 2 years (200,000 km), if, of course, you manage the truck correctly. The part is reliable, the main thing is to skillfully use it.

Working clutch cylinder (PSU) will work for 6-7 years. As practice shows, the repair kit often does not help, so you have to change the whole part, otherwise you will waste your money.

Turbine change as per condition. Usually after 7 years. Its service life directly depends on the quality of the diesel fuel and engine oil used. If there is a lot of moisture in the diesel fuel, the turbine will fly in 2 years.

Caliper repair kit... Basically, the kit with guides is subject to replacement (approximately every 2 years).

Front brake pads nursed also for two years. I recommend changing it depending on their condition. It is better to buy original factory pads, they will last longer.

Rear brake linings will last up to three years. Always clean the drums every time you replace them. You need to change the drums themselves according to their condition. They can come out for 10 years.

Fog lights will work for 5-6 years. Since they are located low in relation to the level of the road, they suffer from rotting of the supply wiring or glass breaks from flying stones.

Cab lift pump serves for a long time and rarely breaks down. The main thing is to add oil. It can come out in a small amount through the tubes. This signals a possible breakdown.

Gas pedal breaks down due to contact with moisture (dirt, snow, road reagents). Refurbishment is not possible.

The pneumohydraulic booster (PGU) serves to reduce the effort on the clutch pedal. The comfort and safety of the truck operation depends on the serviceability of this system.

The main role in the proper operation of the clutch is played by the amplifier, which participates in all driving operations without unnecessary complications and increases the period of operation of the clutch.

This mechanism can sometimes fail, therefore, if a malfunction is detected, it should be replaced.

• Compressed air does not flow due to swelling of the inlet valve of the pneumatic booster;
• Jamming of the follower piston of the pneumatic booster due to swelling of the follower piston of the sealing ring or rubber ring;
• Worn or deformed cuff of the pneumatic piston of the amplifier;
• Air ingress into the hydraulic system, leakage of working fluid.

If air enters the hydraulic drive for disengaging the clutch, the pedal may "fail" and, as a result, incomplete disengagement of the clutch. It is necessary to remove air bubbles with part of the brake fluid (bleed the clutch). During pumping, it is very important to monitor the fluid level in the reservoir. If there is a significant decrease in the level, you need to top up the liquid.

Autotech center "ZAGORETS" has at its disposal all the necessary equipment for diagnostics and replacement of CCGT units on Renault trucks of small, medium and large carrying capacity, as well as on minibuses. All our work is provided with a 100% guarantee. It is possible for a repair team to leave for diagnostics and minor repairs.

Autotechcenter "ZAGORETS" produces professional diagnostics and replacement of CCGT of commercial vehicles Renault in a short time and with a quality guarantee. Our masters will advise you on all issues related to the operation, prevention, maintenance of trucks.

Renault Magnum Red and White ›Logbook› Knorr-Bremse AE 4525 Renault Magnum 4 circuit safety valve repair

The eyes are afraid, but the hands ... But the hands, as it turned out, are not afraid and do. Hello everyone! Today, another uninteresting entry in my BZ, but very useful. It will be very useful for those who have:
a) Renault Magnum,
b) the 4-circuit valve periodically fails,
c) got tired of paying for the bulkhead and replacement to the craftsmen.

Some people call this faucet 6-circuit, some call it 4-circuit. To begin with, I will show what it is and where it is installed on Renault Magnum.

The problem, for me personally, was the following: after repairing the crane, over time, it pumps air worse and worse into one circuit, which is responsible for the clutch, gearbox, seat, steering wheel, cab and trailer cushions. It comes to the point that it was necessary to stuff air into the system for up to half an hour. It is treated by a crane bulkhead using a repair kit (repair kit). Back in Ukraine, in Dnepropetrovsk, I installed a new original crane at a cosmic price at a proprietary station, and it may have helped for a year. A year later, it was necessary to do it again. So I ended up with one crane in reserve, which lies sorted out at the ready, and the second, of course, installed on the tractor.

First, remove the crane. Here, for the sake of interest, I will attach a couple of photos, but I will not explain what and why I will twist. You don't need it, but the one who needs it and who has such a car will figure it out on the spot. Okay, I'll write a few words))

Diagnostics of Renault Magnum pumping sections is carried out by checking the performance in the specified modes and compliance with the BIP signal at the BOSCH EPS815 stand (equipped with CAM847), followed by a printout of the result. Price 1000 R.

Repair always starts with a full-fledged diagnostics, and only after making sure that its parameters do not significantly fit into the standards, we proceed to disassemble the pump section. The repair process consists in achieving leakproofness of the injection control system by restoring the geometric parameters of the guide and seat of the control valve and installing an oversized valve.

After assembly on new seals, the parameters of the productivity of the pumping section in the given modes and the value of the BIP signal are adjusted, with a printout of the results.
All replaced parts are returned to the customer without fail. If necessary, our specialists will explain in detail the reason for replacing each part. To avoid
mistrust, we do not interfere with the presence of the client during testing and troubleshooting of pumping sections.

Repair cost 3500 R. The cost of diagnostics is included in the final cost of the repair, if necessary.

Possible numbers of pumping sections (the list is constantly updated):

0414693001 (0 414 693 001), 0414693006 (0 414 693 006), 0414755002 (0 414 755 002), 0414755003 (0 414 755 003), 0414755006 (0 414 755 006), 7421005584, 7421219977, 74850011590, 5001828 313GC5230M.

Special offer for stand owners CMX3000 previous years of release: we offer to replace old stands with new ones of the latest modification with an additional payment of 599 thousand rubles.
You receive booth CMX3000-V10 with new features, 24-month extended warranty service, and free training at the Dongfang Training Service Center.
Due to limited stocks, the offer is valid until October 31, 2018. See Dongfang Forum for details.

We invite you on November 12-16, 2018 at the Dongfang Training Center in Lyubertsy for the training "Arrangement and repair of Common Rail components". See Dongfang Forum for details.

Are invited to work minders and car mechanic for work with trucks DAF, Iveco, MAN, Mercedes, Renault, Scania, Volvo.
Mandatory requirement: the ability to work with original catalogs for the selection of spare parts. Please contact us by phone +7(909)929-5337 or by calling a free multichannel phone +7(800)700-3773

Renault Magnum MACK - cracks between exhaust valves