SERIE TG GERAL ANTERIOR.pdf

Service Training LF-02a TG Series - General Name:___________________________________

May 2008 Florian Hinterscheid

This document is intended solely for use in training and is not covered by the ongoing Amendment Service.

© 2009 MAN Nutzfahrzeuge Aktiengesellschaft Reprinting, reproduction, dissemination, editing, translation, microfilming and storage and/or processing in electronic systems, including databases and online services, is prohibited without the written consent of MAN.

Table of contents Contents

Chapter

Introduction

1

Documentation

2

Frame / Running gear

3

Drivetrain

4

Cab operation

5

Programme for TG Series - General 1. Structure of maintenance and service literature 2. Designations of different vehicle components and their installation locations 3. CAN bus structure and control unit overview 4. Operating instructions for the different vehicle components 5. Functional sequences and interaction of vehicle components

Module Topic

Duration

1

Introduction and presentation of TG series

3.0 hours

2

Structure and presentation of service and maintenance literature,

5.5 hours

including online versions 3

Frame design, including cab suspension, springs, axles, brakes,

8.0 hours

trailer equipment 4

Engine range for TG series with fuel systems, EGR

4.5 hours

5

Clutch

2.0 hours

6

Gearshift variants (Kongsberg and cable pull)

7

Gearbox variants according to model series

2.5 hours

8

Operation of TG vehicles

2.5 hours

9

Group work

6.0 hours

10

Discussion of practical work / Farewell / Online assessment

1.25 hours

Total time:

0.75 hours 36,00 Hrs.

Development history of the TG series

3

TG series

4

Series overview

4

TGL

4

TGA / TGS / TGX

6

Vehicle identification

7

Vehicle identification number VIN

7

Vehicle number

9

LF-02a[1]. TG-allg.-01-EinfÃ¼hrung-0805 FH-en.doc

1.1

1.2


Development history of the TG series

1840

1850

1900


1950

2008

1.3

TG series Series overview TGL

The TGL was presented in 2005. With gross weight ratings from 7.5 to 12 t, the MAN TGL covers the whole range of transport tasks in its application field. The 7.5 t version is a super-light specialist vehicle with high payload intended primarily for use by rental companies, fleets and small companies. The four-cylinder engine with a maximum output of 240 hp and the light C cab are designed to meet the corresponding requirements. 4 fixed wheelbase/overhang combinations are available in this weight class. The complete wheelbase range and the flexible frame rear end are available from a GWR of 8.0 t to permit realisation of all vehicle variants. A crew cab complements the range of cabs for local and long-distance operation. The engine type D08 is used in the TGL.

1.4


TGM

The TGM is in a class of its own with engines of the type D08, offering outputs from 240 hp to 326 hp and weight ratings of between 13 and 26 t. Combined with matching chassis variants, this model range has offered economical and reliable transport solutions since 2005. The crew cab rounds off the range of cabs for local and long-distance operation. The vehicle components are based on the Trucknology® modular system.


1.5

TGA / TGS / TGX

The TGA covers the weight class from 18 tonnes. The MAN TGS / TGX was presented in autumn 2007 and was chosen as "Truck of the Year 2008" at the European Road Transport Show 2007 in Amsterdam.

TGA:

TGS

1.6

TGX


Vehicle identification Vehicle identification number VIN MAN Nutzfahrzeuge Aktiengesellschaft Service Bulletin

Organisation

Date

Publisher

27.07.1999

VSTT

SI Number

442SM

Vehicle Identification No.

vehicle Since 1st July 1999, vehicles have been delivered with a

Modified

modified vehicle identification number.

identification number

The vehicle identification number now has the following format: Characters 1

Characters 4

to 3

to 6

Example:

W

M

A

Characters 7 to 8 Filler character "Z"

H

0 5 Z

Character 9 Check

Z

X

3

Character

Character

Characters

10

11

12 to 17

K

0 0 1 0 2 8

Difference compared with previous vehicle identification number (up to 1999): The 7-digit vehicle number (formerly "planning number") is no longer part of the vehicle identification number. Instead, the vehicle identification number has two "Z" characters as filler characters, a check character and a letter or digit specifying the model year at the corresponding positions.


1.7

Characters 1 to 3

World Manufacturer Identifier (WMI) The World Manufacturer Identifier identifies the company that independently plans, builds and sells the vehicle; also refer to the overview on Pages 1.9 and 2 in the original SI.

Characters 4 to 6

Type code number

Characters 7 and 8

Filler characters "ZZ" (no significance)

Character 9

Check character introduced as from 01.10.2003: The check character allows recognition of any mistakes in transcription of the vehicle identification number and is of no relevance for the service organisation.

Character 10

Model year, see overview on Page 1.10

Character 11

Plant code (assembly line), see overview on Page 1.10

Characters 12 to 17 Sequential number, line-dependent: The sequential number is assigned independently of vehicle type to all vehicles built on a line. The number is assigned in the order in which the vehicles leave the line. It must therefore always be considered in conjunction with the plant code.

1.8


Vehicle number

The vehicle number (formerly "planning number") consists of the type code number and a 4-digit sequential number. The sequential number can also contain letters. It is assigned type-independently when construction of a vehicle is defined, irrespective of the assembly line on which it is then built. This "planning number" was previously part of the vehicle identification number. Since 1st July 1999, the vehicle number can no longer be determined from the vehicle identification number. It is now located on a yellow sticker on the vehicle frame, for example, and on the identification plate (type plate). The vehicle number can be found on the identification plate (e.g. type plate on the door pillar on the passenger's side).


1.9

World

Manufacturer

Identifier:

Model year code:

Plant code:

1.10

WMA

MAN Nutzfahrzeuge AG

VA0 (zero)

MAN Sonderfahrzeuge AG, Vienna, Austria

VAN

MAN Steyr AG, Steyr, Austria

NMA

MAN Türkiye A.S., Ankara, Turkey

SUS

MAN Trucks & Buses sp. z o. o., Starachowice, Poland

SAF

MAN ERF UK Ltd., Swindon, Great Britain

WAG

Neoplan Bus GmbH, Stuttgart, Germany

WVM

Former working partnership MAN-VW (G-series)

Y

01.07.1999 to 30.06.2000

1

01.07.2000 to 30.06.2001

2

01.07.2001 to 30.06.2002

3 to 9

analogous to 1 and 2 for model years 2003 to 2009

A

01.07.2009 to 30.06.2010

B

01.07.2010 to 30.06.2011 etc.

B

Salzgitter, Germany (Bus)

C


F

Starachowize, Poland (Truck, Bus)

G

Salzgitter, Germany (Truck)

H


J


K

Munich, Germany (Truck)

L

Vienna-Liesing, Austria (Truck, Bus)

M

Munich, Germany (Truck)

R

Tarnowo Podgorne, Poland (Bus)

S


T

Ankara, Turkey (Bus)

W

Salzgitter, Germany (Truck)

Y

Steyr, Austria (Truck)

3

Stuttgart, Germany (Neoplan, Bus)

4

Pilsting, Germany (Neoplan, Bus)

5

Plauen, Germany (Neoplan, Bus)

6

Ehrenhain, Germany (Neoplan, Bus)


Documentation

3

Applications of MAN contractual partners

3

Access to the intranet

4

Target group information for sales staff

5

Repair and maintenance manuals

5

Basic workshop equipment

8

Service Information Bulletins

9

Type code

15

Basic vehicle data

16

Information portal EZIS®

19

EZIS via intranet

20

Definition of the most important abbreviations

22

LF-02a[1]. TG-allg.-02-Dokumentation-0805 FH-en.doc

2.1

2.2


Documentation Applications of MAN contractual partners Since MAN contractual partners do not have access to the MAN intranet, a separate access has been set up to the most important information required for service work and customer support: This extranet portal allows users to access the same pages as via the intranet.

The contractual partners can choose different applications. Access to EZIS requires a separate application.


2.3

Access to the intranet Start Internet Explorer browser. 1.

Enter http://mmhyp.mn.man.de/ in the address line.

2.

The start page of the MAN Nutzfahrzeuge intranet portal is now displayed.

3.

Click the hyperlink * Zielgruppen - Infos (Target group information) ÖVertriebs weltweit (Sales worldwide).

Sales worldwide

* Hyperlinks are links which allow the user to click from one document to another without knowing the address of the document. These links allow the user to "click" into a file or a document.

2.4


Target group information for sales staff

Selection area for Service - After Sales

Service Literature Service Information Service Training Center MAN Cats Service Desk

Repair and maintenance manuals

Click

Service Literature


hyperlink.

2.5

Click hyperlink Reparaturanleitungen.

Repair manual

Dear user, This complete directory of Service Literature contains the spare part numbers, available languages and date of publication. Please refer to the current price information of the spare parts organisation for pricing. Please order all publications exclusively through your service workshops or contractual partners.

The service literature is not subject to an automatic distribution service. A list of newly published service literature (updated on a daily basis) can be found in the section "Neuerscheinungen" ("New service literature"). Refer to the PDF files for detailed information.

2.6


An overview of the available service literature and other information portals is displayed in the navigation window as shown below.

Unit / System

Letter symbol

Engine

A

Clutch

B

Manual gearbox - splitter unit, Eaton, Fuller, ZF

C

Transfer case

E

Driven, non-steered axle (rear axle), twin-tyred dummy axle

F

Driven, steered axle (front axle)

G

Nocn-driven axle (front, leading, trailing axle)

H

Circuit diagrams, electrical system

K

Hydraulic steering (steering aids)

L

Electrical components

N

Brake systems, air suspension

P

Axle location, suspension

R

System description

T

Cab

U

Chassis / Frame

V

Removing/installing major components

Y

Seats Recommendations on towing, diesel particulate filter, Beka central lubrication Heating, air-conditioners


2.7

Basic workshop equipment The screen show below also includes the hyperlink "Empfohlene Grundausstattung einer Werkstatt" ("Recommended basic workshop equipment"). It is possible to choose between the following "Vorrichtungen und Werkzeuge" ("Fixtures and tools"): "electrical", "hydro-pneumatic" and "mechanical".

If this hyperlink is selected and opened, a list is displayed showing workshop equipment items which are indispensable for service at a modern and efficient MAN workshop. Display of the above-described link: "Fixtures and tools (electrical)"

2.8


Service Information Bulletins Under this link you can find all the latest information about our systems and subsystems. This includes all newly published measurement sheets and forms, as well as a general overview of manufacturer changes or notifications relating to individual products.

Click

Service

Information

hyperlink.

It is currently possible to choose between twenty-six languages in the screen shown below.

Select the desired user language by clicking the corresponding button with the mouse.


2.9

Further options are available in the following screen. The hyperlinks shown on the right can be clicked and lead to the corresponding information, bulletins, checklists and official texts shown on the left.

Service Information Bulletins Service Bulletins Data collections Forms Measurement sheets Checklists Exemplary Fluke diagrams

2.10

General overview

New service

Service Information for industrial and marine engines

General overview

§ 29 StVZO (German Road Traffic Regulations) and official texts

General overview

Supplier codes

General overview


Service Information Bulletins (SIs) are produced and classified based on vehicle assemblies. Group

Topic/Systems

Sub-systems

0

Engine

2

Electrical system, instruments

3

Gearbox, axles

Clutch, propshafts and mounts/bearings

4

Chassis

Steering, pedal mechanism excluding brake, vehicle lubrication, air suspension

5

Brakes

Wheel-side brake components, actuation

6

Body

10

General, technical publications

11

Service products

12

Maintenance, vehicle handling, special tools

13

Accident prevention, road safety, § 29 / safety inspection

Current topics Service Bulletins

Current SIs for the workshops Tables and value collections

Fluke

Exemplary Fluke diagrams

Forms

Forms for applications, checklists, goodwill

Neoplan Checklists

Unit and type identification, legal issues, warranty

Current topics

Data collections

Measurement sheets

Fuel, intake, exhaust, cooling systems. Air compressor

Tightening torques, fault codes, etc.

Special test and measurement sheets Neoplan Checklists for maintenance

Vehicles before TG

Product Preview of developments development

Service Information Bulletins can be called up via the Intranet / Extranet. VNSTT produced the Service Bulletin SM 700 b on this. In June 1998, the Service Information numbering system was changed from a date-like numbering system with a suffixed group number (e.g. 170698/10) to sequence numbers with suffixed group number. (e.g. 23210) LF-02a[1]. TG-allg.-02-Dokumentation-0805 FH-en.doc

2.11

Note: All Service Information Bulletins, data collections, measurement sheets, checklists etc. can be viewed in their entirety on the screen and printed out if required.

Example 1 1. Group 2

Electrical system

2. All Service Information Bulletins are listed. 3. The respective SI number ( highlighted in blue ) can be opened by clicking on it with the mouse.

Example 2 1. Group 3

Gearbox, axles

2. All Service Information Bulletins are listed. The respective SI number ( highlighted in blue ) can be opened by clicking on it with the mouse.

2.12


Service Information search with the search function The Service Information window also contains an easy-to-use search function. This function allows input of a search term so that all SIs containing this term can be found very quickly. Search function

The search window now opens. The

Search term

can be entered here.

Search

Start and confirm search with the Search button.


2.13

After input of the search term, a list opens showing all the SIs that contain this search term.

Engines D2066LF21, D2066LF22, D20, and D26 Euro 5

The desired Service Information can then be selected by clicking with the left mouse button. 2.14


Type code Information about MAN type codes is available in the sections MAN Home Ö Vertrieb weltweit.Vertrieb weltweit (Worldwide sales).

Type codes

All MAN type codes are listed in these data sheets (screenshot below)


2.15

Basic vehicle data The headings MAN Home Ö Vertrieb weltweit Fahrzeuggrunddaten (Basic vehicle data) also contain a search function.

Basic vehicle data Search and display function for assembly diagrams for the respective vehicle or vehicle type

Click VZ Fahrzeugdaten (VZ vehicle data) ( Suche (Search) ) with the left mouse button. 2.16


Another window opens after you have clicked the "Search" option with the left mouse button.

1

2

3

1.

Here you can enter different chassis numbers in the mask provided.

2.

The check box for M360 must be checked in all cases.

3.

You can then start the search by left-clicking "Suche Starten" ("Start search").


2.17

If the search is successful, the corresponding results are displayed. The assembly order can be displayed by clicking the button "M360 anzeigen" ("Display M360") (delivery status).

In the following window you can copy the corresponding MAN spare part numbers or search for the drawing in the Electronic Drawing Information System (EZIS®) by means of the respective drawing numbers.

2.18


Information portal EZIS®

MAN offers a library of technical drawings in the intranet in "EZIS®" (Electronic Drawing Information System). EZIS® can also be found on MAN Cats® II (if it was ordered). The program is subject to a charge.

The procedure for displaying drawings is described below.

EZIS® drawings and documents

Using EZIS® (Electronic Drawing Information System) it is possible to view or print out drawings and circuit diagrams on a PC.

There are two ways of displaying drawings.

1. The first option is logging in via the intranet. Access authorisation is required to use EZIS®. 2. The second option is via MAN-Cats® II. No access authorisation is needed here as MAN-Cats® II logs in automatically!


2.19

EZIS via intranet Click hyperlink EZIS®.

EZIS® Technical documents

After pressing the button "Login", an input window opens in which it is necessary to enter a user name and password.

User name Password

2.20


Then confirm with OK.

To search for drawings, click the button "Zeichnungen" ("Drawings"). An input window is then displayed in which the drawing number of the required drawing must be entered.

The number of the desired drawing can now be entered. It is possible to enter the drawing number copied from the host / IMS or MAN basic vehicle data directly by clicking with the right mouse button.

81.99......

Reset


Perform search

2.21

When the following screen appears, open the desired drawing by clicking with the mouse in the column "View".

Link to document display

The drawing is displayed on the screen with the installed graphic program.

Definition of the most important abbreviations

PET: Start of production (PET) of the change number (Added)

PAT: End of production (PAT) of the change number (Removed)

2.22


Frame / Running gear Frame design

3 3

Frames for the TGL series

3

Frames for the TGM series

3

Frames for the TGA / S / X series

4

K cross member

5

Front end

5

Rear end cross member

7

Coupling equipment

8

Special frame cases

10

Cab suspension

12

Suspension

16

Leaf-spring suspension

16

Air suspension:

18

LDS Air Spring Damping System

19

Rear axle X-arm

20

ECAS air suspension system

21

ECAS functions

21

Axles

23

Overview of axle type designations

23

Front axles

23

Rear axles

24

Leading and trailing axles

24

Axle overview according to series

25

®

27

MAN HydroDrive

Steering knuckle

29

HUB UNIT

29

Steering gear

30

Adjustment with skew steering wheel

31

LF-02a[1]. TG-allg.-03-Rahmen-Fahrwek-0805 FH-en.doc

3.1

Brake systems Examples

32

System description

38

Special features

39

Disc brake Knorr SN 5

40

Sectional view SN 5

40

Disc brakes Knorr SN 6 and SN 7 Sectional view SN 6 / SN 7

Functional description

41 42

43

Brake clamping

43

Brake release

43

Brake adjustment

44

Disc brake LUCAS-D-Elsa

3.2

32

45


Frame / Running gear Frame design Frames for the TGL series

7.5 t

220 x 70 x 4.0 mm up to wheelbase 4200 mm 220 x 70 x 4.5 mm as from wheelbase 4200 mm

8t

220 x 70 x 4.5 mm

Chassis with tubular cross members based on modular principle with multiple use of parts and subassemblies Material: S 420 MC (acc. to DIN EN149/2, L2000 QSTE 260/340) Inside frame width front/rear 950/850 mm

Frames for the TGM series

10/12 t

220 x 70 x 6.0 mm

15 t

220 x 70 x 7.0 mm

18 t

270 x 70 x 7.0 mm

Chassis with tubular cross members based on modular principle with multiple use of parts and subassemblies Material: S 420 MC (acc. to DIN EN149/2, L2000 QSTE 260/340) Inside frame width front/rear 950/850 mm


3.3

Frames for the TGA / S / X series Rolled longitudinal member, TM500

Tubular cross

Hole spacing same for all variants

Frame

Open front end

Rolled longitudinal members made of

Higher flexural strength, low frame

high-strength steel QSTE 500 TM,

height

270 mm throughout

Frame reinforcements

Reinforcements between the cross members and in the middle section of long wheelbases

Tubular cross members

make the frame torsionally rigid and ensure minimum load transfer to body

Spaced holes in the front

Simple assembly of the different axle

section

guides Single-piece

rear

end

member,

folded

Open front end

Installation of large-area radiators possible

3.4


K cross member

K cross member in the waisted section for increased rigidity. This component provides transverse reinforcement in the middle section and also carries valves and various other components.

K cross member

Front end

The open front end permits installation of large-area radiators


3.5

Front end with underride guard

Maximum crash safety for car passengers thanks to underride guard

Deformation element to Thread for

absorb energy

towing lug The front underride guard with crash elements and integrated step offers the maximum possible safety for car passengers and already meets future safety standards. The integrated step provides a secure footing for safer access.

3.6


Rear end cross member

The single-piece, folded rear end cross member is mounted flush with the longitudinal members on the semitrailer frame. The externally located auxiliary semitrailer frame provides reinforcement in the rear section as well as a wide mounting base for the fifth wheel, while at the same time ensuring the lowest

The height-adjustable rear underride guard permits simple adjustment of the underride guard to accommodate different bodies


3.7

Coupling equipment

Tractor-trailer combination

TGL Ringfeder 2040G145A Ringfeder 2040G145B Tow coupling Ringfeder 6441

Ball head coupling Oris D 85 A Ball head trailer coupling ORIS D125 max. 3500 kg, only in conjunction with the rear end cross member (236AD)

TGM

Ringfeder 2040G145A Ringfeder 2040G145B Tow coupling Ringfeder 6441

TGA

Ringfeder 4040G150 Ringfeder 5050AW

3

Rockinger 400G150A Rockinger 500G6

CAUTION Danger of accidents! When the trailer coupling is fully locked, the pilot pin 3 must be flush with the coupling body. A serious accident may result if the trailer coupling is not fully locked. For this reason, always: • Check whether the pilot pin 3 is projecting at the coupling housing

3.8


Semitrailer TGA / S / X

Jost: JSK 3-2 5 JSK 37 ME140 15 JSK 37 20 JSK 38-2" 28 JSK 38-3 1/2" 36 JSK 50 50 JSK 42 JSK 36 D JSK 42 MK26 18

+GF+ (Georg Fischer) SKS 36.20HG2


3.9

Special frame cases

05X -03S Semitrailer TGX -TGS Tractor unit TS (Tank-Silo)

Weight-optimised tractor unit especially designed for weight-critical applications such as tank and silo transport operation. The modified frame in particular provides a weight saving (approx. 360 kg) for this tractor unit.

3.10


Equipment on the frame for tractor units available ex-works

Ladder behind cab

Walk-on platform up to fifth wheel Storage box on left


3.11

Cab suspension

The cab suspension at the front consists of a rocker element with maintenance-free friction bearings and bearing blocks. The rocker guide permits an increase in the cab tilting angle of 10° compared with the F2000 to more than 65°.

Caution: Danger of accident!!! Always tilt the cab to its end position.

approx.

3.12


The comfort cab suspension is standard for the long-distance cabs L32/ 37/ 40/ 41. The air-sprung 4-point cab suspension allows a maximum spring travel of +/-45mm. The air suspension is controlled by means of 3 level-control valves located at the front right and left and rear right.

Level-control valve mechanical external

Current cab air suspension system A 4-point suspension is also installed, but the spring bags are no longer controlled by means of level-control valves. Instead, the control is integrated in 3 spring bags and is realised by means of a lever on a cam track.

New cab air suspension system Sliding guide for valve control The air spring bag can become trapped between the level control mechanism and rolling piston if it is loaded when not pressurised! For this reason, connect the air supply before loading the air spring.


3.13

Spring extended, venting position, valve to output open

Lever for valve opening at right limit position, valve open

Spring always presses level control mechanism against the upper end stop of the air spring

Ride level, no filling/venting possible, valve closed

Lever for valve opening in middle position, valve closed

Spring compressed, filling position, valve to input open

Lever for valve opening at left limit position, valve open

3.14


It is not possible to fill the air spring if the air spring bag is trapped between the level control mechanism and rolling piston. Cause: Air spring loading with cab weight in unpressurised condition. Remedy: After installing the air spring, connect the air supply and slowly lower the cab with a crane.


3.15

Suspension Leaf-spring suspension

TGL

Type

Front spring

Rear spring

or

7.5 t

1-leaf parabolic

1-leaf parabolic

2-bag air

8t

2-leaf parabolic

1+1-leaf parabolic

2-bag air

10 t

2-leaf parabolic

2+1-leaf parabolic

2-bag air

12 t

2-leaf parabolic

2+1-leaf parabolic

2-bag air

View of single-leaf spring TGL

TGM

Type

Front spring

Rear spring

or

15 t

4x2 2-leaf parabolic

2-leaf parabolic

4-bag air

18 t


1+1-leaf parabolic

4-bag air

4-bag air

3.16

13 t


4-bag air

18 t


2+1-leaf parabolic

26 t


3-leaf parabolic


TGA / S / X

Front axle:

Parabolic spring 2-leaf (7.5 t) or 3-leaf

(8.0 t) (9.0 t) (9.5 t)

Rear axle:

Leaf-spring suspension Parabolic spring 2+1-leaf

(11.5 t)

or 2+1-leaf

(13.0 t)

Trapezoidal spring (6x4)

(26.0 t)

Spring types

Wide-gap parabolic spring

Heavy-duty trapezoidal spring


3.17

Air suspension:

TGL

On TGL vehicles, an air suspension system can be installed only on the rear axle.

TGM

Type

Front spring

Rear spring

or

15 t


2-leaf parabolic

4-bag air

18 t


1+1-leaf parabolic

4-bag air

4-bag air 13 t


4-bag air

TGA / S / X

Air suspension 2-bag

(- 8.5 t)

Air suspension 4-bag

(- 11.5 t) (- 13.0 t)

3.18


LDS Air Spring Damping System

The air spring and shock absorber are combined in one unit (air spring damping system, LDS). The air suspension allows the fully loaded forward-control vehicle to be lowered by 90 mm from ride level and to be raised by 90 mm (the total travel is 280 mm). On a fully loaded low truck - car transporter, the system permits lowering by 60 mm from ride level and lifting by 160 mm (the total travel is 220 mm).


3.19

Rear axle X-arm The X-arm performs all axle guidance tasks (transverse and longitudinal) and also the function of the stabilisers. This means that it is possible to omit trailing arms and A-arms as well as the stabilisers, thereby achieving a weight saving of approx. 45 kg. The X-arm provides extremely precise axle guidance and therefore improves tracking, driving stability and roll stabilisation. The favourable restoring force characteristic improves driving stability in the event of rolling movements.

3.20


ECAS air suspension system The designation ECAS stands for: Electronically Controlled Air Suspension

ECAS is an electronically controlled air suspension system for motor vehicles. ECAS functions ECAS includes the following functions: ⇒ Increased driving comfort and protection of the transported goods through a lower spring rate and low natural frequency. ⇒ Constant vehicle height independent of load. ⇒ Possibility of level adjustment on one side. The following improvements were realised, among others: ⇒ Reduced air consumption while driving. ⇒ Lower installation volume of complex systems. ⇒ Additional functions such as kneeling, overload protection for low-speed traction control. ⇒ Accelerated air filling and venting operations thanks to large valve cross-sections. The control electronics is the heart of the system. Task of the control unit ♦ Permanent monitoring of incoming signals ♦ Comparison of these values (actual values) with stored values (setpoints) ♦ Calculation of required control reaction for every deviation ♦ Activation of the solenoid valves Additional tasks of the control unit ♦ Management and storage of the different setpoints. ♦ Data exchange via the T-CAN and MAN-Cats II ♦ Regular monitoring of the functioning of all system parts ♦ Plausibility check of received signals to detect faults


3.21

The switch "Loading and unloading" present on the series F2000 is no longer fitted on these vehicles. The "Loading and unloading" function is controlled by means of the remote control.

3.22


Axles Overview of axle type designations

V9 - 42 L

Steerable

VOK-08

Series

Nominal axle load (t) Input torque x~100 (Nm)

H9 - 13 120

Nominal axle load (t)

Series

Series

Driven front axle

H = Planetary rear axle HY-13 50

Gross train weight (t)

Non-driven front axle with


drop VO =

Straight front axle

NO =

Rigid trailing axle

NOL =

Steered trailing axle

HY = HYD-13 70


Hypoid rear axle

Double hypoid rear axle with drive-through

HP-13 52 VP-09

Input torque x~100 (Nm)


Nominal axle load (t) VOK =

Input torque x~100 (Nm)

VA7 - 07 50

VA =

HY - 11 75

Nominal axle load (kg x~100)

Gross train weight (t) Nominal axle load (t)

Front axles

With leaf-spring suspension:

With air suspension:


3.23

Rear axles

With leaf-spring suspension:

With air suspension:

Leading and trailing axles

Leading axle (steered)

Trailing axle (steered)

3.24


Trailing axle (not steered, for twin tyres)

Drop: 40 mm

Axle overview according to series

Overview of TGL axles

Front axle


Rear axle

3.25

Overview of TGM axles Front axle

Rear axle

Front axle

Rear axle

Overview of TGA / S / X axles

3.26


MAN HydroDrive®

Special feature of this system: If required, the front wheels are additionally driven at the push of a button. Unlike in the past, when this was achieved by means of a transfer case and propshafts, this is realised here with two hydraulic wheel hub motors. In contrast to vehicles with conventional all-wheel drive, trucks equipped with the MAN HydroDrive® system are also ideally suited for primary use in on-road operation. In normal driving mode, trucks equipped with MAN HydroDrive® drive as usual with rear-wheel drive. However, the transport task may also require the vehicle to be driven off unpaved roads - possibly on difficult terrain or on a construction site - or it may have to cope with difficult driving conditions such as snow or ice. In such situations, the MAN HydroDrive® can be activated in the cab, and the hydrostatic wheel hub motors integrated in the front wheels additionally drive the front axle. Activation of the MAN HydroDrive® even functions under load and up to a speed of 28 km/h. The significantly higher traction provided by four wheels allows stuck vehicles to be moved off again.


3.27

High-pressure connection

Leak

oil

wheel

Leak

oil

wheel

hub

High-pressure connection

Throttle ring Wheel bearing

The wheel bearings are lubricated with the oil of the HydroDrive. A throttle ring is fitted so that the pressure on the rear seal does not become too high.

3.28


Steering knuckle The kingpins have three steps and are inserted from "above" with the axle in installation position. The grease DEA Acron OS3 ( 09.15006.0015 ) is used for initial grease lubrication on assembly. Any grease nipples still present are needed only for production (initial assembly grease filling) and are covered by cap closures. The disc brakes, wheel bearings and axle knuckles are identical for steered front, leading and trailing axles.

HUB UNIT The wheel bearing was also changed with the introduction of "LUCAS D-ELSA" disc brakes. These axles are equipped with "HUB UNIT" wheel bearings. The bearing assembly is provided with for-life lubrication and is encapsulated. There is no need for a prescribed annual grease change. When the disc brakes are replaced, the wheel bearing remains on the axle knuckle as a completely closed unit.


3.29

Steering gear The steering gear is a hydraulically assisted dual-circuit ball-and-nut steering system with variable ratio. The height and rake of the steering wheel are adjustable; the adjusting mechanism is released by compressed air. Steering gear type: ZF 8098/8099- Servocom RBL hydraulically assisted steering C- 700 V The rear axle steering system is a ZF Servocom RAS ec system. (Rear Axle Steering).

Diagnose Versorgung 24V Elektronisches Steuergerät

Fahrzeugtacho

Fehlerlampe

Raddrehzahlsensor

Lenkwinkelsensor Steuerventile

Lenkwinkelsensor Stellzylinder Druckversorgung

The leading or trailing axle is steered hydraulically by means of a hydraulic cylinder. Angle sensors are fitted on the steering gear and on the leading or trailing axle. These sensors measure the steering angle and transmit the values to the control unit and valve block. The hydraulic pressure is 160 - 170 bar. This is generated by a maintenance-free vane pump, which is driven by the air compressor via a cross coupling.

3.30


ZF 8099- Servocom

When replacing the steering gear, fill sleeve with oil ATF MAN 339 Type D/F.

Adjustment with skew steering wheel

If the steering wheel is skew, the steering is not adjusted by moving the steering wheel on the steering spindle. The steering must be in neutral position on the steering gear as shown in Figure 1. Fine adjustment is then performed by means of the thread on the pushrod to the steering arm on the axle knuckle.


3.31

Brake systems

Example: TGA EBS Knorr 2.2/2.3

Examples

3.32



3.33

Example: TG-X/S EBS Knorr 5 3.34



3.35

Example: TG-L/M EBS Wabco 2 3.36



3.37

System description

E B S Electronic Brake System Sub-functions

EPB

ABS

ASR

Electro-Pneumatic

Antilock Braking

Anti Slip

Brake system

System

Regulation

⇒ Fast response

⇒ No wheel locking

⇒ Short braking

⇒ Wheels steerable

distances

when braking

⇒ Low wear

⇒ Traction control prevents wheel spin when accelerating

⇒ Continuous brake deactivation

The Electronic Brake System consists of three sub-functions. The system components are as follows: EBS control unit, service brake module, pressure regulating modules, trailer control module, rotational speed sensor, brake pad wear sensor, axle load sensor. The EBS control unit controls the pressure in the brake cylinders of the brake system with the pressure regulating modules. A connected trailer with ABS is controlled via the brake line with the trailer control module. Trailers with EBS are controlled by the EBS CAN bus via the ABS socket. The deceleration rates of the tractor and trailer are matched to each other by the integrated coupling force control system.

3.38


If the EBS is de-energised, has failed or if there are faults in the system, the system becomes a pure air brake system with two service brake circuits. When the vehicle is braked, the service brake valve builds up pressure in the brake cylinders on the front and rear axles. However, the pressure in the brake cylinders is not regulated and depends only on the brake pedal position.

Special features ¾

EBS Knorr 5 and Wabco 2 do not have an axle load sensor.

¾

The axle loads are detected by way of the slip behaviour.

¾

The trailer control modules do not have any control units.

¾

In the case of Wabco 2, the EBS control unit, service brake module and front axle module are installed as one unit in the central brake module.


3.39

Disc brake Knorr SN 5 Sectional view SN 5 The pneumatic disc brake SN 5 from Knorr is used for the light-duty series with a rim size of 17.5". The SN 5 transfers the brake clamping force by means of one threaded tube. This is in contrast to the SN 6 or SN 7, which use two threaded tubes to transfer the clamping forces.

Cover unit

Brake disc Compression spring

Thrust piece with bellows Threaded tube

Roller bearing Shaft

Wear sensor Lever

Roller chain Chain wheel

Adapter Adjusting unit

3.40


Disc brakes Knorr SN 6 and SN 7 The pneumatic disc brakes SN 6 / SN 7 from Knorr are used for the heavy-duty series with a rim size of 22.5".

The pneumatic brakes SN 6 and SN 7 are also based on the principle of the sliding calliper brake. Brake callipers of this type transfer the clamping forces to the sliding mechanism via two threaded tubes.


3.41

Sectional view SN 6 / SN 7

Thrust piece

Brake carrier

with bellows

Brake calliper Cover unit Brake disc Wear sensor Compression spring Roller chain Retaining bracket

Roller bearing Brake calliper Chain wheel

Guide bushing

Threaded tube

Brass bushing

3.42


Functional description Brake clamping When braking takes place, the force of the brake cylinder (combination or diaphragm brake cylinder) acts on a lever arm. This lever arm transmits the force to the bridge via the roller bearing.

The clamping force acts on the inner brake pad via the threaded tubes and thrust pieces. After the clearance between the brake pad and brake disc has been overcome, the reaction force is transmitted to the outer brake pad via the brake calliper (sliding calliper). The braking torque for the wheel is produced by the brake pad pressure on the brake disc. Brake release When the forces of the brake cylinder are reduced, the compression spring presses the bridge with threaded tubes and the lever arm back to the initial position.


3.43

Brake adjustment The brake is equipped with an automatic, wear-free adjusting device that ensures a constant clearance between the brake pads and the brake disc. Each brake operation also results in operation of the adjuster, which has a positive connection with the lever arm.

Key 6

Lever arm

9

Threaded spindle with thrust piece

10

Chain

12

Shift fork

13

Inner sleeve

14

Ball ramp

15

Spring

In the event of increased clearances due to brake pad and brake disc wear, the threaded tubes are preturned by the adjuster by the wear dimension. The total clearance is 0.6 - 1.1 mm. (total clearance on both sides of the brake disc) A smaller clearance can lead to overheating problems and increased wear!

3.44


Disc brake LUCAS-D-Elsa

All-round disc brake with hub unit Type LUCAS D-Elsa, internally ventilated

used for disc wheels 22.5"

Hub unit


3.45

Drivetrain

3

Overview of engine variants for the TG series

3

TGL engines

3

TGM engines

4

TGA / S / X

5

Engine type plate

7

Fuel injection systems

8

Overview of EDC MS 6.1 Schematic fuel circuit diagram for EDC MS 6.1

Common Rail

8 10

11

Overview of EDC 7

11

Schematic fuel circuit diagram EDC 7 Common Rail on D20 Euro 3

14

Legal introduction dates of emission standards

15

MAN Euro 3 solution

15

MAN Euro 4 solution

17

MAN Euro 5 solution

19

Two-stage turbocharging

21

Clutch

22

Clutch on the D08 engine for TGL

22

Shifting / splitter operation with clutch pedal and Comfort Shift

24

Description of Kongsberg gearshift

25

TGA - Cable-controlled gearshift

26

Gearbox variants

27

TGL

27

TGM

28

TGA / S / X

28

Design of the ZF gearboxes TipMatic mid / TipMatic

30

Internal design of the ZF gearboxes TipMatic mid / TipMatic

30

Transfer case

31

TGL / TGM

31

TGA / S / X

32

New-generation transfer case G172

33

LF-02a[1]. TG-allg.-04-Antrieb-0805 FH-en.doc

4.1

4.2


Drivetrain Overview of engine variants for the TG series TGL engines

The in-line engines of the D08 series underwent significant design modifications for the MAN vehicle series TGL. The measures included realisation of new power output classes with higher outputs and torques as well as high torque rise ratings.

Engine type

KW/ hp

Torque

RPM

4-cylinder D 0834

LFL 40

110 / 150

570

2400

D 0834

LFL 41

132 / 180

700

2400

D 0834

LFL 42

151 / 206

830

2400


4.3

6-cylinder D 0836

LFL 40

176 / 240

925

2400

TGM engines

The in-line engines of the D08 series from 240 hp with new power output classes, higher outputs and torques and high torque rise ratings are used for the MAN vehicle series TGM.

Engine type

KW/ hp

Torque

RPM

6-cylinder

4.4

D 0836

LFL 40

176 / 240

925

2400

D 0836

LFL 41

206 / 280

1100

2400

D 0836

LFL 43

240 / 326

1250

2400


TGA / S / X

D20 engines EURO 4 with EGR + PM-KAT

D2066 LF14 CR (4-V) 228 kW (310 hp) 1550 Nm

1900 rpm

1000 - 1400 rpm

D2066 LF13 CR (4-V) 257 kW (350 hp) 1750 Nm

1900 rpm

1000 - 1400 rpm

D2066 LF12 CR (4-V) 287 KW (390 hp) 1900 Nm

1900 rpm

1000 - 1400 rpm

D2066 LF11 CR (4-V) 316 KW (430 hp) 2100 Nm

1900 rpm

1000 - 1400 rpm

EURO 5 with SCR

D2066 LF22 CR (4-V) 294 KW (400 hp) 1900 Nm

1900 rpm

1000 - 1400 rpm

D2066 LF21 CR (4-V) 321 KW (437 hp)

SCR mixer

2100 Nm

1900 rpm

1000 - 1400 rpm

D26 engines EURO 4 with EGR + PM-KAT

D2676 LF01 CR (4-V) 353 kW (480 hp) 2300 Nm

1900 rpm

1050 - 1400 rpm

EURO 5 with SCR

SCR mixer

D2676 LF12 CR (4-V) 353 KW (480 hp) 2300 Nm

1050 - 1400 rpm

D2676 LF11 CR (4-V) 397 KW (540 hp) 2500 Nm


1900 rpm

1900 rpm

1050 - 1400 rpm

4.5

D28 engines

Only for TGA D2866 LF23 (4-valve + EGR) 228 kW (310 hp) 1800 - 1900 rpm 1500 Nm

900 - 1300 rpm

D2866 LF24 (4-valve + EGR) 265 kW (360 hp) 1800 - 1900 rpm 1700 Nm

900 - 1400 rpm

D2866 LF25 (4-valve + EGR) 301 kW (410 hp) 1900 rpm 1850 Nm

900 - 1300 rpm

D2876 LF03 (4-valve + EGR) 338 kW (460 hp) 1700 - 1900 rpm 2100 Nm

900 - 1300 rpm

D2876 LF12 CR (4-valve + EGR) 353 kW (480 hp) 1900 rpm 2300 Nm

1000 - 1300 rpm

D2876 LF13 CR (4-valve + EGR) 382 kW (530 hp)

1900 rpm 2400 Nm

1000 - 1400 rpm

Only for heavy-duty tractor V10

D2840 LF25 CR (4-valve + EGR) Euro 3 485 kW (660 hp) 2700 Nm

1900 rpm

1000 - 1600 rpm

For V8 heavy-duty tractors and V8 semitrailer tractors

D2868 LF02/03 CR (4-valve + SCR+ AdBlue) Euro 5 with OBD 500 kW (680 hp) 2700 Nm/3000 Nm

4.6

1900 rpm 1200 - 1500 rpm


Engine type plate

MAN - Werk Nürnberg Typ

D2676 LF 03

Motor-Nr. / Engine-no

N I / N II N I / N II Feld

5459170015B2E1

Engine type designation

e.g. D2676 LF 03

D

Fuel type, diesel

26

+ 100 = bore diameter, e.g. 126 mm ∅

7

Designates the stroke 6 = 155 mm, 7 = 166 mm

6

Number of cylinders 6 = 6 cylinders, 0 = 10 cylinders, 2 = 12 cylinders

L

Type of charging, Turbocharging with charge air cooling

F

Engine installation position:

03

F

Truck Forward-control vertical engine

OH

Bus

Rear-installation vertical engine

UH

Bus

Rear-installation horizontal engine

Engine variant; particularly important for spare part supply, technical data and setting values.


4.7

Fuel injection systems Overview of EDC MS 6.1 WasserKraftstoffKraftstoff- temperatur druck Öldruck temperatur

Motor Drehzahl 2

Drehzahl 1

Ladelufttemperatur (Euro3)

Nadelbewegungsfühler Ladedruck

Motorseitiges Steuergerät EDC MS6.1

Klemme 30

Klemme 15

Abgas- Rückführungsventil (EURO3)

Datenverbindung Motor-CAN-Bus

Fahrpedal

Fahrzeugführungsrechner

Kupplung

Lenkstockschalter

Motorbremse

Kombiinstrument, Warnlampe

Instrumenten CAN-Datenbus

Fahrerhaus

Triebstrang CAN-Datenbus

Geschwindigkeit

Bremse

MS61ALG2.CDR

4.8


As with conventional fuel injection systems, the EDC system also consists of an injection pump and a governor. A control sleeve pump is installed in the EDC MS 6.1 (M = fuel delivery control; S = timing adjustment). Both systems are controlled by a microprocessor-based control unit. The program memory of this control unit contains all the maps defined for the engine.

The great advantage of the EDC system is the actuator mechanism, which is always the same irrespective of the map. In other words, the control unit is exclusively responsible for the maps, corrections, etc. On mechanical governors, in contrast, all the components that affect the control characteristic (flyweight parts, spring sets, and compensating devices such as torque control spring capsules, stops, etc) are actually integrated in the governor. If it is wished to change the control characteristic, it is therefore necessary to replace these parts. In the EDC system, there is no mechanical connection between the accelerator and governor. The accelerator has an integrated pedal travel sensor. The driver request is sent to the vehicle management computer via a PWM (pulse-widthmodulated) signal.


4.9

Schematic fuel circuit diagram for EDC MS 6.1

4.10


Common Rail Overview of EDC 7

Fuel pressure ahead of filter Rail pressure sensor Rotational speed sensor Pedal travel sensor Water Temperature

Boost pressure sensor Camshaft sensor

Operating unit High-pressure pump Brake Control unit

CAN

EGR actuator cylinder


FGB/FGRswitch K line

Terminal 15

Injector

Terminal 30

Clutch

Vehicle Management Computer (FFR)

4.11

The CR fuel injection system consists of a quantity-controlled high-pressure pump that can produce a very high fuel pressure (max. 1800 bar) in a fuel reservoir, the "rail". The rail makes this pressure available to the "fuel injector" for finely atomised injection.

The main characteristic of CR systems is therefore the fact that pressure generation and fuel injection from the rail are separated. This time-controlled fuel injection system therefore overcomes the typical restrictions of conventional camcontrolled systems. The increased average fuel injection pressure and injection timing can be freely selected over a wide range independently of the engine operating point. The quantity-controlled high-pressure pump, which is fed by a flanged-on predelivery pump, delivers as much diesel fuel as required to the rail until the desired fuel pressure is reached. This pressure accumulator is connected via hydraulic lines with the fuel injectors. The fuel injectors are controlled by solenoid valves and inject a quantity of the stored fuel defined by the control unit into the combustion chambers of the engine. This allows optimisation of the combustion process.

The hydraulic components of the fuel injection system are monitored by the control unit. The sensors of the control unit continuously measure data relating to engine and vehicle operation. For example, the rail pressure sensor, control unit and quantity-controlled high-pressure pump form a control loop to produce the desired rail pressure. Other sensors, such as coolant temperature sensor, charge air temperature sensor or atmospheric pressure sensor, help to optimally adapt the engine to changing ambient conditions.

4.12


Common rail components

Injector Rail with pressure

Control unit

High-pressure pump with gear delivery pump and fuel metering unit (M PROP) Rail with pressure connections, rail pressure sensor (RDS) and pressure limiting valve (DBV)

Changed valve setting D2876LF12 / 13 and D2066LF… !!!! Intake 0.5 mm Discharge

0.8 mm

EVB

0.6 mm


4.13

Schematic fuel circuit diagram EDC 7 Common Rail on D20 Euro 3

KSC (fuel

Injector

Return channel in cylinder head

service centre) Overflow valve in return line

Rail pressure sensor

Flame

Pressure limiting valve

start

system High-pressure pump with gear delivery pump

4.14


Legal introduction dates of emission standards 2003

2004

2005

2006

2007

2008

2009

10/2005

Euro

4

New types, incl. OBD 1 Durability In use compliance

10/2006

*)

Euro

4

New registrations, incl. OBD 1

*)

Durability In use compliance

10/2008

Euro

5

New types, incl. OBD 2

OBD = On Board Diagnosis

Euro

**)

10/2009

5

New registrations, incl. OBD 2 *)

**)

OBD 1: Monitoring of engine with respect to OBD limits (NOx 7 g/kWh, PM 0.1 g/kWh) Monitoring of exhaust after-treatment for "major functional failure"

**)

OBD 2: Monitoring of engine and exhaust after-treatment with respect to OBD limits (NOx 7 g/kWh, PM 0.1 g/kWh) i.e. catalytic converter efficiency (NOx or NH3 sensor) Monitoring of OBD and emission-relevant information by the interface to vehicle control

units

MAN Euro 3 solution

Comparison of systems for emission reduction internal exhaust retention Charge air 40 °C

• High temperature of cylinder charge

additionally: Required NOxvalues are not achieved

• Low retention 600 °C

• Lower fuel injection rate

• Later start of injection

• Worse efficiency • High consumption • Oil contamination

EURO

rate

Exhaust gas

External cooled exhaust gas recirculation Charge air 40 °C

• Lower temperature of cylinder charge

• High recirculation rate 160 °C

• No further Required NOxvalues are achieved

measures are necessary

• Euro 4

• High efficiency • Low consumption • Clean oil

EURO 3

potential

Cooled exhaust gas LF-02a[1]. TG-allg.-04-Antrieb-0805 FH-en.doc

4.15

Exhaust gas recirculation (EGR)

Cooled and regulated exhaust gas recirculation systems are installed in engines from Euro 3. These systems reduce formation of nitrogen oxide. The exhaust gas mixed with the intake air reduces the oxygen concentration in the charge gas and increases its temperature. Both these factors reduce the combustion temperature and formation of nitrogen oxide. This also reduces the quantity of exhaust gas. If too much exhaust gas is recirculated, soot and carbon monoxide emissions increase due to the lack of oxygen. The recirculated quantity of exhaust gas must be restricted so that sufficient oxygen remains for combustion.

Function: The exhaust gas is routed to the turbocharger in separate exhaust manifolds (cylinders 1,2,3 and 4,5,6). The exhaust gas is routed from 2 outlet points (1st outlet from cylinders 1,2,3 and 2nd outlet from cylinders 4,5,6) in separate pipes through a heat exchanger connected to the cooling circuit. The cooled exhaust flow is brought together only after the check valves at the end of the heat exchanger. This separate exhaust gas routing results in a pulsating exhaust gas flow, which is required to overcome the charge pressure in the intake manifold. The quantity of recirculated exhaust gas can be restricted or interrupted (engine braking mode) by means of the electro-pneumatically controlled shutoff flap. This is controlled by the EDC control unit. The charge air temperature sensor is located in the intake manifold. This is used to switch off EGR as required in order to ensure that the intake air does not become too hot. ChargeEngine

Air

air

filter EGR valve

4.16

Pressure EGR

peak

cooling


MAN Euro 4 solution

New engine generation D20 Common Rail + cooled exhaust gas recirculation + MAN PM-KAT

The MAN PM-KAT filter is a continuously operating particulate matter separating system featuring open channels

Particulate separation is effected by specially triggered turbulence during the deflection of exhaust gases in the separator and their passage through the sintered metal fabric.

The dissolution of the particulates retained in the fabric is the result of the permanent chemical reaction brought about with the aid of the NO2 formed in the upstream oxidising catalytic converter.

As a result, the MAN PM-KAT is maintenance-free and does not clog up. In addition, an above-proportional amount of the smallest particulates (< 40 nm) is eliminated.

Engine

Air

Chargeair

filter

Pressure

EGR valve

EGR cooling

peak valves

PM-

® KAT


4.17

Schematic diagram of the PM-KAT

Chemical conversion in the catalytic converter

V

P

V

Pre-oxidation platinum catalytic converter: 2NO

P

Particulate matter separator: 2NO2+ C Æ CO2+

MAN PM-KAT® system in the TGA

PrePM separator

4.18


MAN Euro 5 solution

Catalytic converter + AdBlue ® (Selective Catalytic Reduction)

In the MAN AdBlue ® solution, the emission control required for Euro 5 is performed using injected aqueous urea in a downstream diesel catalytic converter (SCR catalytic converter) AdBlue® tank

Urea metering system (HDS) AdBlue® mixer O-CAT

AdBlue® mixer

R-CAT

Ammonia formation CO CO(NH2)2+H2O

2NH3 + CO2

R-CAT

NOx reduction

4N 4NO + O2 + 4NH3

4N2 + 6H2O

O-CAT

NH3 oxidation

4NH3 + 3O

2N2 + 6H2O

MAN AdBlue system for Euro 5 in TGA / S / X Injection of AdBlue

AdBlue mixer


Reduction catalytic converter Oxidation catalytic converter 4.19

Installation on engine

Exhaust turbocharger

Exhaust temperature sensor

Metering valve AdBlue mixer

4.20

Urea nozzle


Two-stage turbocharging

The principle of two-stage turbocharging allows generation of very high boost pressures. In the upper rpm range, these pressures would lead to overloading of the engine (particularly cylinder pressure) as well as of the peripheral devices (e.g. charge air cooler). For this reason, it is always necessary to limit the boost pressure. In the simplest case, this is done by a pressure-loaded and springloaded waste gate that limits the boost pressure above a certain fixed value. The D0834 LFL 42 additionally features a boost pressure control valve controlled by the electronic engine controller (EDC). This makes it possible to achieve an optimum boost pressure characteristic.


4.21

Clutch Clutch on the D08 engine for TGL

Clutch MF-362 for D0834 LFL Venting connections

Connection for travel sensor

Travel sensor

Travel sensor The travel sensor is calibrated with MANCATS

This clutch has only a clutch The clutch is pushed upon operation!

slave cylinder and no booster.

The version shown above is installed for gearboxes 6S850 and S5-42; in the case of gearbox 6AS850, clutch operation is via a fork with a clutch master cylinder mounted on the top side. 4.22


Clutch MFZ-395 for D0836 LFL with 6-cylinder engines

Note: As

from

6-cylinder

engines,

clutch

operation is by pulling!! With

clutch

gearboxes

and

booster clutch

for

manual

actuator

for

Clutch booster

Clutch for TipMatic with 6-cylinder engines

A conventional-design dry single-disc clutch is installed. Disengagement is by pulling. This is performed by an electro-pneumatic or pneumatic clutch actuator controlled by the gearbox control unit.

The solenoid valves for filling and venting, a travel sensor and the electronic controller are mounted on the pneumatic actuating cylinder of the clutch actuator.


4.23

Shifting / splitter operation with clutch pedal and Comfort Shift Shift operations can be performed only with the clutch pedal. The pushbutton on the shift lever knob is installed for activation of the Comfort Shift function. The other functions of the gearshift are the same. A mechatronic module is fitted on the shifting device. The clutch master cylinder does not have a solenoid valve. Double master cylinder

Pressure distributor

Old shift lever knob design

Clutch actuation for Comfort Shift

Comfort Shift

Splitter unit

Range unit

New shift lever knob design

Splitter unit switch

ON OFF Range unit switch

4.24


Description of Kongsberg gearshift

HGS (Hydraulic GearShift) The previous mechanical shift linkage has been replaced by a hydraulic gearshift (HGS) from Messrs. Kongsberg. This hydrostatic gearshift consists of a shift transmitter below the shift lever, a compensating reservoir, hydraulic connecting lines (4 control lines: rear gears, front gears, left gate, right gate) to the gearbox and the gear and gate selection cylinders on the gearbox. Bleeding is possible with a bleeding device via the bleeder nipple/screw.

! Only use fluid M 3289! ! Caution: Do not use brake fluid

Hose to the compensating reservoir

Hydraulic master cylinder in the cab

Disconnection point Cab frame

Selection Hydraulic slave cylinders

Shifting


4.25

TGA - Cable-controlled gearshift

The cable gearshift consists of a cab-side shift transmitter, two shift cables with holders and selector levers on the gearbox.

4.26


Gearbox variants TGL

ZF ECOLITE S5-42 OD

i = 5.72 - 0.76

5F/1R

67 kg (150 hp)

6 S 850 OD i = 6.72 - 0.79 6F/1R

111 kg

(180-210 hp)

ZF-ASTronic-LITE (TIPMATIC) 6 AS 850

i = 6.72 - 0.79

6F/1R

(180-210 hp)

EATON FS 8309 DD i = 12.6 - 1.00 9F/1R

FSO 8309 OD 9F/1R

154 kg

(240-280 hp)

i = 9.4 - 0.75 154 kg (240-330 hp)

ZF-ASTronic-MID (TIPMATIC) 12 AS 1210 TO 12F/1R


i = 10.33 - 0.81

190 kg

(240-330 hp)

4.27

TGM EATON FS 8309 DD i = 12.6 - 1.00 9F/1R

154 kg

(240-280 hp)

FSO 8309 OD

i = 9.4 - 0.75 154 kg

9F/1R

(240-330 hp)

ZF-ASTronic-MID (TIPMATIC) 12 AS 1210 TO

i = 10.33 - 0.81

12F/1R

190 kg

(240-330 hp)

TGA / S / X

ZF ECOSPLIT 16S182 OD

i = 13.80 - 0.84

16F/2R 289 kg

16S192 DD

16S222 OD

16S222 DD

16S252 OD

TGA

310/360/410/460 hp

i = 13.80 - 0.84

16F/2R 319 kg

TGA

310/390/430/460 hp

i = 16.41 - 1.00

16F/2R 319 kg

TGA

310/360/410 hp

i = 13.80 - 0.84

16F/2R 317 kg

4.28

310/350/410 hp

i = 16.41 - 1.00

16F/2R 317 kg

TGA

TGA

480/530 hp


MAN TipMatic (ZF) 12 AS 2140 TD

TGA

12F/2R i = 15.86 - 1.00

310 - 460 hp

12 AS 2301 TO

TGA

12F/2R i = 12.33 - 0.78

350 - 460 hp

250 – 260 kg

ZF ECOMAT 5 HP 500

i = 3.43 - 0.83

220 hp

5 HP 590

i = 3.43 - 0.83

280 hp

with retarder + EST18

(optional)

5 HP 600

i = 3.43 - 0.83

310/360 hp

with retarder

i = 5.6 - 0.83

310/360 hp

+ EST18

(optional) 279 - 335 kg

ZF TC-TRONIC WSK 440 + 12 AS 2740 TO i = 12.33 - 0.78


660 hp

Heavy-duty tractor

4.29

Design of the ZF gearboxes TipMatic mid / TipMatic (Function diagram) 6-cylinder

The gearbox has a two-countershaft design. Reaction force Force Reaction force

Second countershaft

Countershaft Main shaft

The reaction forces cancel each other out at the main shaft bearing

Internal design of the ZF gearboxes TipMatic mid / TipMatic

Splitter unit

Reverse gear Gearbox Range unit

brake

Three-speed unit with reverse gear Output flange

The gearbox is designed as a range-change gearbox. 4.30


Transfer case TGL / TGM

MAN transfer case G102 (0.98/1.6 option) with connectable front axle drive or with longitudinal offset

On-road gear:

Weight:

0.983

Off-road gear:

1,607

143 kg 10.xxx

TGL


14.xxx/18.xxx

TGM

4.31

TGA / S / X

MAN transfer case G 172 New, more powerful version, greater axle spacing G 173 With neutral position for PTO G 252 / G253 With connectable front axle drive or with longitudinal offset

G 172/G173 On-road gear:

1.007

0.981

Off-road gear:

1.652

1.583

Weight:

360 kg

up to 430 hp

TGA

4.32

G252/G253

394 kg

41.480

TGS

TGX


New-generation transfer case G172 The increased vertical shaft spacing between the drive shaft and output shaft results in a smaller propshaft deflection angle, reduced noise and a longer service life of the cardan joints. The oil filter removes metal abraded matter from the gear oil, and it was possible to reduce weight by omitting the oil pump.

Oil filter

a


Oil filter

4.33

Cab operation

2

The CAN bus structure

2

Operation at driver's workplace

4

Cab front panel

6

Inspection and maintenance locations

7

Cab tilt mechanism

8

Cab tilting - hydraulic

9

Door modules

12

Auxiliary air conditioning system

13

Switch / pushbutton for intelligent brake coupling

15

Switch: FGR (cruise control) / FGB (speed limiter) / ACC switchover

17

TipMatic gearbox operation

18

Emergency functions in the event of failure

19

Manoeuvring position ("DM" and "RM"):

20

Towing and tow-starting

21

Tow-starting AS-Tronic

21

Roller test bed

21

LF-02a[1]. TG-allg.-05-Fahrerhaus-0805 FH-en.doc

5.1

Cab operation The CAN bus structure Background: Many open-loop and closed-loop control operations must nowadays be performed by electronic control units, since mechanical or electrical control systems do not offer the required level of performance. The electronic control units require information to perform all the tasks reliably, and they receive this from connected sensors as well as from other control units. To minimise the number of sensors required in the vehicle, the goal is to measure each measured value (e.g. water temperature, engine) only once, and to then make this measured value available to all control units.

In the TG series, the control units are connected by means of a data network, the CAN network (CAN = Controller Area Network, BUS = Binary Unit System).

5.2


CAN = Controller Area Network: Drivetrain CAN

CAN Bus = control unit

Engine CAN

networking via data

Instrumentation

Instrument CAN

lines Instrument CAN

Retarder Tachograph

Brake control

Central on-board computer

Drivetrain CAN Vehicle management computer

Engine CAN

Air suspension

Engine control

Transmission control


Air management

5.3

Operation at driver's workplace TGL without multifunction steering wheel

5.4


TGA and TGL / TGM with multifunction steering wheel

TGS / X


5.5

Cab front panel Release for front panel in cab

Press the lever up When tilting the cab, always open the front panel !! (see section on cab tilt mechanism)

5.6


Inspection and maintenance locations

Compensating reservoir for clutch and gearshift operation

Filler neck for engine oil

Filler neck for windscreen washer system

Emergency release connection for spring-type

Filler neck for coolant - exercise caution when the engine is hot


5.7

Cab tilt mechanism The cab tilt mechanism is accessible behind a cover on the right entrance box. An information plate is fitted on the rear of the cover. The rocker guide permits a cab tilting angle of 62°. An electrohydraulic cab tilt mechanism is offered as an option. Information plate for cab tilt mechanism

Move lever 5 up (tilt) or down (lower). Magnetic pushbutton with cap 4a: press for raising and lowering. Magnetic pushbutton without cap 4b: Touch with a metal object (e.g. vehicle key) for raising and lowering.

5.8


Cab tilting - hydraulic

2

1

1 Lever of reversing valve 2 Hexagon for fitting the wheel nut wrench

Caution: Always tilt the cab to its limit position!


5.9

Steering wheel adjustment TG-A , TG-L, TG-M

Press and hold the pushbutton on the driver's seat base with your heel.

Adjust the height of the steering wheel and its distance from your body. Release the pushbutton again.

5.10


Steering wheel adjustment TG-S, TG-X – The supply pressure in the compressed air system must be at a sufficient level for adjustment of the steering wheel. – First adjust the driver's seat and then adjust the steering wheel to the changed

• Press rocker switch 1 at top • Adjust the height of the steering wheel and its distance from your body • Release the rocker switch The steering wheel is locked again after approx. 5 seconds. or • Press rocker switch 1 at bottom The steering wheel is then locked again more quickly.

Switch location:

CAUTION Danger of accident! • Adjust the steering wheel only when the vehicle is stationary and when the parking brake is applied.


5.11

Door modules General

The buttons of the door module on the driver's side can be used to electronically control the window lifters, central locking system, mirror adjustment and mirror heating. The door module on the passenger's side controls only the window lifter on the passenger's side. The door module on the driver's side and the door module on the passenger's side communicate with each other via a data bus.

Switch assignment Mirror heating

Joystick Mirror preselection left / right Mirror selection

2. Mirror position Main mirror, passenger's side

TG A version

Window lifter

Central locking

TG X / S version 5.12


Auxiliary air conditioning system The auxiliary air conditioning system is completely integrated in the driving airconditioning system. This means that existing operating elements for control, delivery, distribution, temperature adjustment and air cleaning can also be used for operation of the auxiliary system when the vehicle is stationary.

Cold accumulator

Expansion tank Air-conditioning unit with heat sink Evaporator unit

Control and distribution unit

The combined driving and auxiliary air-conditioning system increases operating safety and economy in addition to enhancing driver comfort and performance. The best possible air distribution in the cab is achieved with a low noise level through utilisation of the optimised air routing of the vehicle air-conditioning system for the auxiliary system as well. This means that no additional air ducts are necessary.


5.13

Air conditioning during break and waiting times When the engine is switched off, cold is supplied by the accumulator, which stores excess cold while the vehicle is moving. During operation of the auxiliary airconditioning system, the fan and control functions of the vehicle air-conditioning system remain active; this means that the driver does not need to adjust or change anything. Air conditioning while sleeping Sleeping in the vehicle is no longer a problem even during very warm or sultry nights thanks to the auxiliary air-conditioning system, which also de-humidifies the air. In order to ensure that it does not become too cold in the cab as the night temperatures fall, the control system first reduces the cold supply and then fully switches off the accumulator if the temperatures fall further. If this is not sufficient to prevent excessive cooling, the fan is operated only periodically. However, an adequate supply of fresh air is always guaranteed.

Switch for switching the auxiliary air-conditioning system on and off and for charging

Pushbutton for operation of the auxiliary air-conditioning system

5.14


Switching on The air-conditioning system is switched on in driving operation by pressing the AC switch. When the ignition is switched off, the cab can be air-conditioned by switching on the auxiliary air-conditioning system with the auxiliary AC switch.

Switch / pushbutton for intelligent brake coupling

Switch:

Function:

It is possible to select two switch states: • Switch off Retarder operation possible only with the continuous brake momentary switch • Switch on Retarder operation with the continuous brake momentary switch is possible and the following automatic functions can be activated in parallel.

Automatic functions:

Activation in brake pedal lead travel Retarder stages are integrated in the free travel of the brake pedal (approx. 25 % of the total actuating range). The service brake is not yet active in this range. The amount of activated retarder torque depends on the vehicle load. It is a maximum of 50 % of the maximum torque, but without engine brake operation. The retarder icon is additionally shown on the display.


5.15

Automatic braking function with cruise control operating lever

The automatic braking function is used to inform the FFR of a desired speed. In conjunction with the FFR and engine CAN, the EDC system regulates the vehicle speed to the desired speed (as long as the engine power is sufficient for this). The automatic braking function is activated 4km/h above the set cruise control speed. The speed threshold of 2 km/h is defined as part of EOL parameterisation and can be changed by the service organisation. The FFR manages this function and the braking power of the retarder/intarder or of the engine brake is increased, depending on the engine load.

Activation by adaptive braking

A further comfort function is provided by the brake pedal. When the vehicle is braked with the brake pedal, the speed is stored at which the brake pedal is released (= adaptive braking). The speed is stored and is maintained as the new speed by the automatic braking system as long as the required braking torque of the retarder is sufficient. This function is deactivated when the accelerator is pressed or the cruise control stalk is operated.

Activation by the accelerator

A further comfort function is available when the accelerator is in normal position. The current vehicle speed is saved and the vehicle is automatically braked if the speed exceeds the current speed by 4 km/h. This function is deactivated again when the accelerator or brake pedal is pressed or the cruise control stalk is operated.

5.16


Switch: FGR (cruise control) / FGB (speed limiter) / ACC switchover

Function:

The FGR/FGB/ACC (cruise control/speed limiter/ACC) switch is used for switching from the cruise control function to the speed limiter function. Cruise control (FGR): The switch FGR/FGB/ACC (button 10) must be set to the FGR function. It is possible to set a desired speed with the cruise control stalk switch A429. The cruise control function is also deactivated if the driver presses the brake pedal (signal from EBS via T-CAN) or clutch pedal (signal from clutch travel sensor B362).

Speed limiter (FGB)

The switch FGR/FGB/ACC must be switched to the FGB function. Using the cruise control stalk switch A429, it is possible to set a maximum speed that cannot be exceeded. An icon appears on the display when the maximum speed is reached. The speed limiter function is not switched off but is temporarily interrupted when the accelerator is pressed hard (e.g. to overtake, like with kick-down). The speed limiter is activated again when the current vehicle speed falls below the speed limit.


5.17

TipMatic gearbox operation Range selector switch A434 -

Cruise control / gearbox switch A429

Pushbutton

Steering column

Display on instrument cluster

The driving direction and starting gear are selected with the DNR switch. "D" for forward gears, "R" for reverse gears and "N" for neutral. The current position of the DNR switch is forwarded to the transmission control.

5.18


It is possible to switch to automatic mode with the end pushbutton. In this mode, the transmission control shifts gears independently. Automatic mode is switched off again by means of this pushbutton or by manual gear selection. Momentary operation changes to manual operation and shifts up or down by one gear. When driving, the reverse gears are blocked when the direction of travel is forwards, and the forward gears are blocked when reversing. When the vehicle is stopped, the current gear or the gear selected by the DNR switch is maintained as the gear for driving off, depending on which is the lower gear.

Emergency functions in the event of failure Automatic mode is activated if the cruise control/gearbox switch fails. If the DNR switch fails, it is possible to shift from forward gears via neutral to reverse gears and vice versa with the cruise control/gearbox switch. Autoskip function: If the engine speed falls below a certain limit (900 rpm) in manual mode, it is possible to skip several gears by "Downshift" (hold) operation. The gear recommended by the transmission control is then engaged.

In position "D" , the TipMatic selects the starting gear depending on the current vehicle load (standard starting gear = D3)!


5.19

Manoeuvring position ("DM" and "RM"): In Manoeuvring mode, the whole travel of the accelerator is used to close the clutch; the engine speed is limited to 850 rpm. The manoeuvring gears "DM" and "RM" are for extremely slow driving, e.g. when coupling and uncoupling a semitrailer or trailer. Overview of switch variants: Switch, 7-stage, for TipMatic 4x2, 6x2, until May 2004 Buses, rigids also after 2004

Switch, 5-stage, for TipMatic 4x2, 6x2, from June 2004 In position "D", the TipMatic gearbox automatically selects the starting gear depending on the vehicle load (standard starting gear = D3) Switch, 6-stage, for TipMatic 6x4, 8x4, 8x2, 6x2, 4x4, 6x6, refuse collection vehicles

Switch, 6-stage, for TipMatic "Offroad" 4x4, 6x6, 8x6, 8x8

Switch, 6-stage, for TipMatic with torque converter clutch (WSK) (TC Tronic) (DM Starting gear under load via the torque converter clutch) Switch, 5-stage, for TipMatic Fleet

5.20


Towing and tow-starting The drivetrain to the drive axles must always be disconnected for towing! This can be done by removing the propshaft or axle shafts.

Tow-starting AS-Tronic

Tow starting of the engine is not possible!

Roller test bed After driving into the test bed rollers, the gearbox must be shifted to “Neutral”, otherwise the AS-Tronic control unit will detect a “moving vehicle” and close the clutch. The vehicle may then independently drive out of the test bed rollers!

Neutral

D DM

N

R1 RM


5.21

Worksheet on sales designations, wheel configurations and installation plates

What door designation does the training vehicle have? Weight: Power output:

What cab type does the vehicle have?

What wheel configuration does the vehicle have?

In what RAL colour is the cab painted?

What values are entered on the installation plate for the tachograph? L:

W:

K:

When was the tachograph inspection performed?

What K value applies to the vehicle (exhaust-emission check)?

Which item number does MAN prescribe for the air filter insert, and what characteristic does the air filter insert have? No.:

Arbeitsblatt 1 LF-02a-en.doc

Characteristic:

1.1

Worksheet on TG series - Type plates What is the vehicle identification number of the TG vehicle?

Where is the type plate with the VIN located on the vehicle?

Where else can the chassis number be found on the vehicle?

What is the short vehicle number of the vehicle, and where can it be found?

Where was the vehicle manufactured? Vienna ( )

Salzgitter ( )

Munich ( ) Steyr ( )

In what period was the vehicle built?

Find the type plates of the following components on the vehicle and enter the specified data in the table:

Unit

Manufacturer

Type

MAN Item number

Front axle Drive axle Leading/trailing axle Gearbox Air reservoir, circuit 2


1.1

Worksheet on cab tilting and engine type plate

Where can the information plate shown above be found on the vehicle?

Describe the meaning of the individual symbols shown on the information plate. 1. 2. 3. 4. 5. 6. 7. 8. Tilt the cab of the training vehicle and note the information on the engine type plate. MAN - Werk Nürnberg Typ Motor-Nr. / Engine-no


N I / N II

3.1

Station 1 / Tasks on MAN Intranet and MANWIS

2

Station 2 / Tasks for vehicle TGX

6

Station 3 / Tasks for vehicle TGA

9

Time for practical work tasks at the stations For each station and group: 90 minutes

Arbeitsblatt 4 LF-02a Intranet und Fahrzeuge-en.doc

4.1

Station 1 / Tasks on MAN Intranet and MANWIS Task 1: Which MAN item number refers to the maintenance manual for the TGX in German? Item number: Task 2: Which MAN item number does the sticker for ProFit Check II have and how many stickers are supplied for the order quantity 1? Item number / Quantity: Task 3: Which edition of the A 16 Repair Manual is the current one at present? Edition: Task 4: Where can the A16 be found ? Describe the path on the MAN intranet with the corresponding keywords. Path:

Task 5: Which Euro standards do these 3 engines have: D2066LF18, D0834LOH50, OM 502LA ? Euro standards: Task 6: Which wheel configuration does the vehicle type HW6 have? Wheel configuration: Task 7: Which important information is provided in 812AT? Topic:

4.2


Task 8: Is there a Service Information for maintenance of the gearbox 6AS-850? Note the SI number:

Task 9: Enter the word AdBlue as a search term for the Service Information Bulletins. Which SI numbers were found, and what were their contents? Note the numbers and briefly summarise the SI descriptions.

Task 10: You require an EDC circuit diagram for the training vehicle. Find the function diagram number through the MAN basic vehicle data. In which planning period was the vehicle built? Note the function diagram number:

Task 11: Have the diagram displayed using the EZIS application. How many sheets does the circuit diagram have? Briefly describe the procedure. Number of circuit diagram sheets:

Procedure:


4.3

Task 12: Open the "Wartungs- und Betriebsstoffempfehlung" ("Maintenance Recommendations and Service Products") and search for products and works standards in the MAN service products database.

MAN works standard

Manufacturer / Product name

341-Z5

3477

342-S1

Castrol CEO 3291 M

BP Lubricants (manufacturer)

Aqua-Concept GmbH

Liqui Moly Touring High Tech SHPD

4.4


Task 13: Which checklists can be found in MANWIS and what scope of maintenance work do they cover? Note the list designations and the related item number for the vehicle type TGA. List and item number:

Task 14: MANWIS: For RME-operated CR engines, a purchase guarantee must be obtained for fuel injection components. What kinds of damage are covered by the purchase guarantee?

Task 15: MANWIS: What valve clearance is prescribed for the engine D2868 LF02? Intake: Discharge: EVB counterholder:


4.5

Station 2 / Tasks for vehicle TGX Operation Do the window lifters for raising and lowering the side windows have a one-touch function? Yes No What values can be shown on the display of the speedo? Trip mileage, time, mph

Languages German/English

Under which menu item can you find "Diagnose" ("Diagnosis")? Menü – Fahrzeug – Fahrdaten - Diagnose (Menu – Tractor vehicle – Driving data - Diagnosis) Menü – Fahrzeug – Einstellungen - Diagnose (Menu – Tractor vehicle – Settings - Diagnosis) Menü – Fahrzeug – Kontrolldaten - Diagnose (Menu – Tractor vehicle – Monitoring data - Diagnosis) Which control units can be selected for fault finding under the menu item "Diagnosis"? All control units that are installed in the vehicle All control units that have a fault entry Set the service pre-information value to the maximum possible display value. (Menü– Fahrzeug–Einstellungen–Vorinfo-Service)

(Menu–Tractor

vehicle–Settings–Pre-info

Service) What is the maximum value?

How many menu items can be selected for the telephone "Settings"? 1

3

4

6

Under which menu item is the daytime lights function activated? Menü – Fahrzeug – Anzeige aus - Tagfahrlicht (Menu – Tractor vehicle – Display off - Daytime light) Menü – Fahrzeug – Einstellungen - Tagfahrlicht (Menu – Tractor vehicle – Settings - Daytime light) Menü – Fahrzeug – Kontrolldaten - Tagfahrlicht (Menu – Tractor vehicle – Monitoring data - Daytime light) How long does it take before the steering wheel adjustment mechanism locks again after steering wheel adjustment?

How long does it take until the rear view mirror automatically travels back to its basic setting after it has been swivelled out?

4.6


Work outside the cab How many screws have to be undone in order to swivel up the main headlight? 1 screw

3 screws

4 screws

5 screws

Swivel out the main headlight and check the bulb of the direction indicator. What is the designation of this bulb? P 0211

Osram 21 W

PY 21

What colours do the two connectors for the headlight power supply have? red/yellow

white/red

grey/yellow

grey/red

What is the power output of the cornering light? 21 Watt

55 Watt

70 Watt

140 Watt

At what step height is the fastening screw for the lower light band located? bottom step

middle step

top step

In which direction must the mirror glass be pushed when it is removed? to the right


down

up

4.7

Work in the cab

Open the cover panel of the central electrical system (ZE) and determine the spare part number of the ZE. 81.27444.6074

81.25444.7064

81.25444.6074

Where is the bass speaker of the radio system located? under the bunk

under the seat

in the dashboard

How many screws have to be undone in order to remove the radio? 1 screw

2 screws

6 screws

Where is the socket X 200 located?

Can the ZE be folded out on the TGX / S? How many screws have to be undone?

Find the installation locations for the AdBlue filters and note these.

Under what conditions is it possible to tilt the cab of the training vehicle?

4.8


Station 3 / Tasks for vehicle TGA Task 1: Read out the complete diagnostic memory by means of MAN-Cats and save the data on a data medium. Which data media can be used?

Task 2: What must always be done after reading out the complete fault memory?

Task 3: Determine the installation locations of all control units in the vehicle and name the control units with their assigned vehicle components.

Task 4: Program the M1 and M2 buttons of the ECAS remote control and extended after-running for the air suspension. Note the procedure.


4.9

Task 5: Carry out an emergency start on the vehicle. Note the procedure that has to be followed.

Task 6: What dangers exist if an emergency start is performed?

Task 7: Remove the ignition lock and install it again. How do you proceed?

Task 8: Carry out a lighting test and describe the procedure.

Task 9: Which lights are not activated in the test?

4.10


Overview of equipment sorted according to G numbers G 1. Compressors G 2. Pressure regulators G 3. Antifreeze devices G 4. Multi-circuit protection valves G 5. Pressure limiting valves/safety valves G 6. Overflow valves G 7. Service brake valves G 8. Parking brake valves G 9. Precharge valves G 10. Diaphragm/piston cylinders G 11. Double brake cylinders G 12. Spring-loaded cylinders G 13. Shutoff valves G 14. Relay valves G 15. Pressure ratio valves G 16. Brake force regulators G 17. Trailer control valves, 2-line G 18. Trailer control valves, 1-line G 19. Coupling heads, 2-line G 20. Coupling heads, 1-line G 21. Two-way valves G 22. Quick-release valves G 23. Non-return valves G 24. Breather valves G 25. Dewatering devices, air dryers G 26. Differential pressure switching valves G 27. Line filters, noise dampers G 28. Shut-off cocks G 29. Coiled hoses G 30. Brake cables G 31. Metal bellows G 32. G 33. G 34. G 35. G 36. G 37. G 38. G 39. G 40. Tyre pressure valves, automatic G 41. Tyre pressure valves, manual G 42. Switching valves G 43. Rim valves G 44. Wheel bleeder valves G 45. G 46. G 47. G 48. G 49.

G 50. Air reservoirs G 51. Drain/dewatering valves G 52. ALB test valves G 53. Filler connections G 54. Test connections, pneumatic G 55. Pressure switches, pneumatic G 56. Compressed air cylinders G 57. Pressure gauges G 58. Warning indicators G 59. Pressure switches, hydraulic G 60. Mechanical switches G 61. Solenoid valves, filling G 62. Solenoid valves, venting G 63. Solenoid valves, SA G 64. G 65. Load/no-load valves G 66. Pressure sensor valves, electrical G 67. Pressure control valves (ABS) G 68. G 69. Actuator elements for air spring valves G 70. Air spring valves G 71. Switching valves WLS G 72. G 73. Electro-pneumatic valves for electronic air suspension G 74. Control parts for electronic air suspension G 75. G 76. G 77. G 78. G 79. G 80. Main hydraulic cylinders G 81. Compensating reservoirs G 82. Test connections, hydraulic G 83. Wheel brake cylinders, hydraulic G 84. Brake force regulators, hydraulic G 85. Pressure ratio valves, hydraulic G 86. G 87. G 88. G 89. G 89. G 90. G 91. G 92. G 93. G 94. G 95. G 96. G 97. Hoses G 98. Signs, symbols G 99. Miscellaneous

SERIE TG GERAL ANTERIOR.pdf

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