DIY car repair

In detail: do-it-yourself man's car repair from a real master for the site my.housecope.com.

This article describes the features of MAN truck repair.

MAN trucks have long been loved by domestic freight carriers. And this is not surprising. German cars, on the hood of which proudly adorn the three large letters MAN, are considered a symbol of quality, reliability and stability. However, this does not mean that these German trucks are devoid of traditional automotive "weaknesses": they can also break down and from time to time have to be repaired by MAN. After all, these trucks work on our domestic roads and on our domestic fuel. Therefore, be sure to download the MAN TGA Baseline Owner's Manual, it will definitely come in handy.

MAN diesel engines are considered one of the best on the planet. They are reliable, environmentally friendly, economical, provide free maintenance of all attachments. Modern engines for MAN dump trucks and truck tractors have more power than motors of the previous series. They meet the standards Euro 5, but at the same time they do not need expensive additives. Modern MAN engines are equipped with common rail injection system... More powerful versions use a dual turbocharging system.

Nevertheless, these engines also need maintenance and overhaul. But before repairing a MAN engine, diagnostics must be carried out, which means:

determination of the degree of wear and deformation of motor parts;
examination of the condition of the crankshaft for the presence of scoring on its journals;
control of the geometry of the cylinder head, cylinder block, motor bolt connections;
testing the cylinder head for tightness of the cooling system;
control of the surface condition, as well as the need for repair or replacement of the gas distribution mechanism;
checking the thermal clearances of the valve and guide, the tightness of their closure.

Video (click to play).

After the diagnostics, the MAN engine is repaired. During the repair, the engine is placed on a special assembly jig, which allows it to be fixed in the required position. This will greatly facilitate and speed up the MAN repair. During assembly, after the engine has been repaired, the tightness of clearances and joints in friction pairs is checked. The weight distribution of connecting rods, pistons, piston pins is also carried out. After the repair, the fasteners of the body parts, covers and pallets of the truck engine are tightened in a specific sequence.

It is advisable to repair a MAN truck in specialized service centers. If the terms of maintenance and the frequency of diagnostics are met, the engine can last a very long time, which will allow the owner of this truck to make good money on the provision of cargo transportation services and at the same time spend less money on repair work. The duration of the overhaul period directly depends on the operating conditions of the equipment, the qualifications of the service personnel, as well as the experience of the vehicle driver.

The chassis of a MAN truck is subject to severe stress. To increase its reliability, safety and increase the turnaround time, manufacturers use the latest technologies and materials in the chassis of modern MAN trucks.

Repair of the MAN undercarriage begins with computer diagnostics, which takes place in several stages:

Express test of the geometry of the truck wheels;
Checking the functioning of the shock absorbers;
Checking the operation of the brake system;
Checking the mechanical part of the suspension: steering rods, tips, ball joints, silent blocks, bushings, etc.

After diagnostics, worn and damaged parts are replaced. In this case, special devices and tools should be used to help improve the quality and reduce the repair time of the MAN truck. For example, replacing hub bearings is usually done by removing the hub and then pressing out the bearing. If you use a set of pullers, you can replace the bearing without removing the hub and without affecting other parts of the chassis, while saving time and money.

After troubleshooting, the repair of the MAN chassis is completed by checking and then adjusting the wheel geometry using a high-precision optical wireless system.

It should be noted that during the repair of the MAN undercarriage there is one big advantage - many of its units and assemblies are interchangeable with spare parts that are produced for other brands of trucks, since they are made by the same manufacturers: WABCO, Knorr, ZF, Telma, Bosch. We also note that you need to closely monitor the timing of the inspection. If, for example, you miss the moment of replacing the pivots, then you can simply throw out the front axle beam.

Trucks of various series and different carrying capacities are equipped with mechanical gearboxes of the brand Eaton and ZF... According to numerous reviews of freight carriers who use MAN vehicles, these gearboxes are the most convenient for domestic operating conditions.

Despite its apparent simplicity, the gearbox or gearbox are rather complex transmission units that do not tolerate carelessness in operation and repair. It would seem nothing complicated: many gears, several shafts and a mechanism that moves all these gears back and forth. But one has only to put something on the wrong side or during assembly to disrupt the sequence of actions - and the driver will not be able to turn on a single gear. If during the repair of the MAN gearbox, the tightening torque is exceeded or a separate unit is loosened, the entire unit may fly apart. Slight wear on bearings and gears can lead to fatal seizure of the gearbox.

Therefore, the repair of the MAN gearbox should be carried out very carefully and accurately. The German manufacturer chose ZF and Eaton boxes for a reason. They are efficient and compact, do not require maintenance, unless, of course, make gross mistakes during operation.

Depending on the wear and the development of the main constituent elements during the repair of the MAN gearbox, these elements are replaced, the gearbox housing or the entire gearbox. If the repair includes the replacement of gears, oil seals and bearings, the gearbox is adjusted.

The hypoid reducer of the MAN rear axle is also highly reliable. This gearbox is well suited for difficult road conditions, it is able to withstand extreme loads without any problems.

The MAN truck, like other trucks, is equipped with electronic control devices for the engine, pneumatic, braking and auxiliary systems. The MAN on-board electrical network includes many control sensors, taps, valves that allow you to regulate the operation of systems. They also require periodic troubleshooting.

It is better to entrust the repair of electrical equipment and wiring MAN (MAN) to professionals, the driver will not be able to figure it out on his own. Repair of electrical equipment and wiring at MAN begins with a comprehensive diagnosis of faults. It can be carried out with the help of special computer software and visually. Only a thorough computer diagnostics of the truck can fully assess the condition of the electrical equipment of the MAN truck. The sensor system will unmistakably determine which nodes are working incorrectly.

Be sure to contact the service center if:

there were difficulties with starting the motor;
the battery is discharged very quickly;
there were problems with the starter;
there are problems with the lighting fixtures;
any relays, switches are indistinctly triggered;
windshield wipers, power windows and other auxiliary equipment do not immediately work or do not turn off.

Most often, electronic engine control systems and fuel supply systems fail. The starter or generator, the ignition system, lighting devices, and passive safety devices often break down. Their breakdown creates huge problems in the operation of the car.

If the cause of the malfunction was found, it remains only to eliminate it, for example, replace the faulty section of the electrical wiring and test the car for operability. Sometimes it is enough to re-solder certain microcircuits of electronic devices, replace transistors, capacitors or resistors that are out of order. In rare cases, it may be necessary to completely replace the electronic part of the truck system.

The pneumatic system is designed to control the chassis of a truck, trailer or semitrailer (air brakes, air suspension, brake system and ABS system). The MAN pneumatic system is highly reliable, but it also requires periodic diagnostics and repairs.

Note that the repair of the MAN pneumatic system is not particularly difficult and is carried out fairly quickly. As a rule, it comes down to the standard replacement of faulty components, while guaranteeing trouble-free operation in the future. The most common pneumatic malfunction on MAN tractors is the fact when, after 50,000 km of run, the compressors begin to drive engine oil into the pneumatic system. After 80-90 thousand km, it sometimes simultaneously breaks through the upper gaskets of the rear heads of the air compressors. Usually, after the breakdown of the gasket, the compressor begins to pump air into the cooling system and the pneumatic system. The incoming air enters the expansion tank. After stopping the engine, the driver can hear the pressure relief valve release excess air pressure from the cooling system. In this case, an urgent repair of the MAN pneumatic system is required.

In conclusion, we note that not all MAN repair work can be performed independently. Therefore, it is better to find a good MAN service center in your city and periodically undergo service there.

Engine overhaul.

Let's go back a little to the Soviet standards that were developed by US.

So, overhaul of an internal combustion engine is an almost complete restoration of the engine's resource, up to the established norm by the engineers of the manufacturer's plant.

Experience from the Soviet times, high-quality engine repair is considered if its operating time is 80%, from the operating time of this engine to overhaul.

A very high-quality criterion that I use when calculating the feasibility of repairs for engines.

Let's take a look at the MAN D20 engine.

We lay down the estimated resource for a new engine of 900 t.km. (this is the average mileage and may differ significantly)

Service life after overhaul 900 t.km *, 8 = 720 t.km

The next step is to decide on the repair.

A new engine costs in Moscow about 2.5 million rubles without a hitch. Here is the stroke, it makes no sense to take a new ICE for MAN.

Now the most important thing is what needs to be changed and how.

This is my experience. If you decide to leave the car for a few more years, then we go over it completely, as expected, otherwise 80% of the initial resource will not work.

A group of parts for 100% replacement.

Any imperfection, during a major overhaul of the internal combustion engine, will reduce the resource several times.
Example: refusal to replace worn-out pump injectors - the result is burned-out pistons after 100 t.km
refusal to pressurize the cylinder head (on the D20 internal combustion engine is rather weak), will also lead to sad consequences

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MAN TGA since 2000 Service and Repair Manual

MAN TGA car repair manual, operation manual, maintenance, device, catalog of spare parts for MAN TGA trucks that went on sale since 2000 and equipped with diesel engines: D0836 with a displacement of 6.9, D2066 with a volume of 10.5, D2866 with a volume of 12.0, D2676 volume 12.4, D2876 volume 12.8, D2840 volume 18.3.

MAN L2000 / F90 / M90 / F2000 Auto manual for repair and operation

Repair manual for MAN F90 / F2000 / L2000 / LE2000 / M2000L / M2000M / ME2000 / M90, as well as instructions for the maintenance and operation of MAN F90 / F2000 / L2000 / LE2000 / M2000L / M2000M / ME2000 / M90 trucks equipped with diesel engines models D02, D08, D25, D28.

Workshop manual MAN L2000

The manual contains information on the repair of the engine, clutch, gearbox, axles, steering, brake system, suspension. Separate sections of the manual include electrical circuits (wiring diagrams) of the car. The book is intended for owners of MAN L2000 cars, service station workers and car services, as well as everyone interested in trucks of this class.

MAN TGL / TGM since 2005 Auto repair and maintenance manual

The presented excellently executed repair manual will always and in any situation provide all the necessary assistance to the owners and users of MAN TGL / MAN TGM trucks, it will be useful to numerous specialists from maintenance stations and technicians from repair shops, as well as many other professionals working in the field auto repair.

MAN TGA since 2000 and since 2005 Repair and maintenance manual

Workshop manual MAN TGA as well as device MAN TGA, operation and maintenance manual MAN TGA. Cars from 2000 release, as well as restyled models from 2005 release. Cars are equipped with diesel power units D2066, D2865, D2866, D2876. The manual will be highly appreciated by the specialists of the service station and repair shops.

MAN TGX / TGS since 2007 Operating Manual and Parts Catalog

The MAN TGX / TGS operating manual, as well as the MAN TGX / TGH truck parts catalog since 2007. This publication contains the operation and maintenance manual for MAN TGX / TGS trucks, as well as a catalog of main parts and assembly units, including Man engines of various modifications.

The manual contains all diagnostic trouble codes and their decryptions. The manual also includes the MAN TGX / TGS operating manual, where the driver of this powerful car will find complete information on how to make driving as comfortable and safe as possible, following all the recommendations of the book guarantees maximum safety of the car and can significantly extend the period of uninterrupted operation of the truck.

MAN F90 / F2000 volume 1 Repair and maintenance manual

The individual sections of the publication include the operating instructions MAN F90 / F2000, recommendations for maintenance and electrical circuits (wiring diagrams) of the vehicle. The book is intended for owners of MAN F90 / F2000 cars, service station workers and mechanics from car services.

MAN TGA volume 2 from 2000, 2005 and 2008 Service and maintenance manual

The presented excellently executed repair manual will always and in any situation provide all the necessary assistance to the owners and users of MAN TG-A trucks, it will be useful to numerous specialists from maintenance stations and technicians from repair shops, as well as many other professionals working in the field of auto repair ... This manual is recommended and will certainly be of interest to all motorists-enthusiasts who are interested in the device of this class of vehicles.

MAN F90 / F2000 Repair book

For the first time, the book describes the repair of in-line engines of Man heavy series cars, there is a table of sizes of all engine assembly parts and repair dimensions of parts, as well as the technical characteristics of the engines and the parameters necessary for their adjustment.The Electrical Equipment section includes detailed wiring diagrams of cars, a list of all electrical components and their location in the car.

MAN TG-A Volume 1 Operation and Maintenance Manual + Parts Catalog

Separate sections of the publication include the operating manual Man TG-A, recommendations for car maintenance.
The book is intended for the owners of Man TGA cars, service station workers and car services, as well as everyone who is interested in trucks of this class.

MAN TG-L Operation and Maintenance Manual. Parts catalog

This publication contains a manual for the operation and maintenance of Man TGL trucks, as well as a catalog of main parts and assembly units, including Man D0834 and Man D0836 engines of various modifications. The book will be useful to all owners of Man TGL trucks, as well as to all those interested in vehicles of this class.

MAN М90 / М2000 Parts catalog

This publication presents a catalog of the main parts and assembly units of the Man cars of the M90 and M2000 series. The illustrations in the manual show the structure of the main components and assemblies of the car. The book will be useful to all owners of Man cars, specialists working in the field of auto repair, as well as everyone interested in trucks of this class.

MAN F90 / F2000 volume 2 Device. Parts catalog

The device of MAN F90 / F2000 vehicles. The book contains a catalog of parts and assembly units of the car. This publication contains a catalog of the main parts and assemblies of the MAN F90 and F2000 series, including the D2840 and D2866 / 76 engines. The book will be useful to all owners of Man cars, specialists working in the field of auto repair, as well as everyone interested in trucks of this class.

MAN M90 Volume 1 Workshop Manual

Workshop manual for Man M 90 equipped with DO 826 diesel engines (F, FO1, TF, LF01, LF, LF02). The book contains information on the repair of the engine, clutch, gearbox, rear axle, front axle, steering, brake system, suspension, electrical equipment. The book will be useful to all owners of Man cars

MAN 19.292, 19.332, 19.362 Repair and maintenance

The book contains the dimensions of the engine assembly parts and the repair dimensions of all parts. There is an extensive reference material on the technical characteristics of motors and the parameters required for their adjustment. The electrical equipment section includes detailed wiring diagrams of cars, a list of all electrical components and their location in the car. The book is a study guide for Maine car owners, and also contains essential information for workshop workers.

MAN M90 / M2000 Operation, repair, engine parts catalog

This publication contains a manual for the operation, maintenance and repair of Man trucks of the M90 and M2000 series, as well as a catalog of the main parts and assembly units for six-cylinder engines of Man M90 cars and four-cylinder engines Man M2000. The separate sections of the publication include electrical circuits (wiring diagrams) of the car.

MAN M90 / M2000L / M2000M / ME2000 / L2000 / LE2000 / F90 / F2000 Workshop Manual Part 2

This auto-manual is the second part of a professional repair manual from the renowned Atlases of cars publisher. The manual will be able to tell its future owner about the procedures for diagnosing car malfunctions, repairing mechanisms, assemblies and systems of the MAN M90 / M2000L / M2000M / ME2000 / L2000 / LE2000 / F90 / F2000 truck. A detailed description will help you quickly identify failed parts and replace them. The step-by-step instructions presented in the book will save time spent on diagnosing and repairing MAN M90 / M2000L / M2000M / ME2000 / L2000 / LE2000 / F90 / F2000.

MAN M2000 Workshop manual

This repair manual for the MAN M2000 contains a step-by-step description of the actions of the technical personnel carrying out repairs and maintenance, the technical equipment required for some operations is described. Recommendations are given and the repair of the engine, clutch, gearbox, front and rear axles, steering, brake system, suspension, electrical equipment is described.

MAN F2000 Operation Manual

Operation and maintenance manual Man F 2000 of the third (and partially 4th) generation, heavy series F-2000 models 19, 26, 27, 32, 33, 35, 41 with engines D2865LF21, D2865LF22, D2865LF23, D2865LF24, D2866LF20, D2866LF21 , D2866LF22, D2866LF31, D2866LF34, D2866LF35, D2876LF02, D2876LF06, D2840LF02, D2840LF06 with a working volume of 10.0, 12.0, 12.8, 18.2 liters.

MAN in-line engines Workshop manual

This manual is intended to assist in the proper repair work on the engines described here. The development of this manual was based on the professional qualifications required to operate diesel engines.

MAN Nutzfahrzeuge Aktiengesellschaft - MAN engine repair manual.
MAN Engine Repair Manual, presents step-by-step repair and operation of MAN industrial and marine engines, Man truck and bus engines.
In the book on engine repair Man, describes the repair of trucks and buses, Man marine engines, Man engines for construction and agricultural machinery.
The information is presented in several languages, including Russian, but the most complete information is presented in German. Information in other languages is much smaller.

There is only one instruction in Russian:
User and Service Documentation / REPAIR INSTRUCTIONS D 2848 LE, D 2840 LE, D 2842 LE.

List of MAN engines for which the repair description is provided:

Year of issue: 2006
Publisher: MAN Nutzfahrzeuge Aktiengesellschaft
Format: PDF
Quality: Originally computer (eBook), Pages scanned
Auto-book language: German, English, Russian, French, Spanish, Italian

This article describes the features of MAN truck repair.

Nevertheless, these engines also need maintenance and overhaul. But before repairing a MAN engine, diagnostics must be carried out, which means:

determination of the degree of wear and deformation of motor parts;
examination of the condition of the crankshaft for the presence of scoring on its journals;
control of the geometry of the cylinder head, cylinder block, motor bolt connections;
testing the cylinder head for tightness of the cooling system;
control of the surface condition, as well as the need for repair or replacement of the gas distribution mechanism;
checking the thermal clearances of the valve and guide, the tightness of their closure.

After the diagnostics, the MAN engine is repaired. During the repair, the engine is placed on a special assembly jig, which allows it to be fixed in the required position. This will greatly facilitate and speed up the MAN repair. During assembly, after the engine has been repaired, the tightness of clearances and joints in friction pairs is checked. The weight distribution of connecting rods, pistons, piston pins is also carried out.After the repair, the fasteners of the body parts, covers and pallets of the truck engine are tightened in a specific sequence.

Repair of the MAN undercarriage begins with computer diagnostics, which takes place in several stages:

Express test of the geometry of the truck wheels;
Checking the functioning of the shock absorbers;
Checking the operation of the brake system;
Checking the mechanical part of the suspension: steering rods, tips, ball joints, silent blocks, bushings, etc.

After troubleshooting, the repair of the MAN chassis is completed by checking and then adjusting the wheel geometry using a high-precision optical wireless system.

The hypoid reducer of the MAN rear axle is also highly reliable.This gearbox is well suited for difficult road conditions, it is able to withstand extreme loads without any problems.

Be sure to contact the service center if:

there were difficulties with starting the motor;
the battery is discharged very quickly;
there were problems with the starter;
there are problems with the lighting fixtures;
any relays, switches are indistinctly triggered;
windshield wipers, power windows and other auxiliary equipment do not immediately work or do not turn off.

In conclusion, we note that not all MAN repair work can be performed independently. Therefore, it is better to find a good MAN service center in your city and periodically undergo service there.

Workshop manual for MAN D28 .. in-line engines for TG-A series, 3rd supplement.
Workshop manual A11 describes the MAN D25 ../ D28 in-line engines.MAN D28… for the TG-A series.

This description is intended to aid in the proper repair of the engines described here.
Includes:
D2555, D2556 ,:
D2565, D2566 ,:
D2865, D2866 ,:
D2876 ,:
D2866LF ... .; 4 valve cylinder head:
D2876LF ... .; 4 valve cylinder head .:

Year of issue: 2007
Publisher: MAN Nutzfahrzeuge Alkiengesellschaft
Format: JPG
Russian language
Size: 140 MB

The list of files for the repair of cars of the MAN company (man).

MAN electric circuits, pneumatic schemes, diagnostic mistakes, instructions, service manuals.wiring diagram.electrical engineering circuit schematic,

electrical schematic diagram,

MAN TG-A ECAS electronically controlled air suspension wiring diagram, repair manual

MAN TG-A EBS error codes EBS full description Wiring diagrams of the entire brake system

MAN TG-A AS-TRONIK error codes complete description Wiring diagrams repair manual

MAN TG-A error codes ZBR 2 central on-board computer, wiring diagrams, codes, repair manual

MAN TG-A error codes FFR vehicle control processor, wiring diagram, repair

MAN TG-A starter control circuits, description of how the engine start authorization occurs

MAN TG-A (2000-2009) wiring diagram detailed, 606 pages

MAN TG-A detailed wiring diagram, page 235

MAN TG-A error codes FFR detailed description and wiring diagrams

MAN TG-A / TG-L pneumatic system PART 3 detailed description of the entire pneumatic system with electrical and pneumatic circuits

ECAS MAN TG-A wiring diagrams and flash (blink) codes

MAN TG-A Operation and maintenance manual in Russian

MAN TG - ZDR ZBR interface wiring diagrams of control units for connections, sensors and actuators of ZDR.ZBR systems.

MAN L2000 detailed wiring diagrams with a description, pinout of sensors and connectors,

MAN F2000 wiring diagrams and descriptions detailed wiring diagrams with descriptions, pinout of sensors and connectors,

MAN F90 F2000. Mounting block designation of relays and fuses

MAN EDS MS 5 F2000F90 Wiring Diagrams and Self-Diagnosis Codes

MAN flesh codes, self-diagnosis by the number of flashing lights

DEUTZ TCD 2012 engine EDC system wiring diagram sensors, connectors, engine control unit repair,

WABCO complete manual includes wiring diagrams, pneumatic diagrams, diagnostic error codes

repair of the gearbox of MAN 16 S 1820 TO ECOSPLIT, 16 S 2223 TD ECOSPLIT, 16 S 2221 TO ECOSPLIT ZF series - repair manual.

Holmer EDC MAN overhaul repair and inspection of control systems

"Advanced" self-diagnosis system that monitors everything and is able to notice and warn about almost NINE THOUSAND deviations from the norm in the car.
MAN TGA systems

Anti Pollution HDS / SCR AdBlue, Exhaust Gas Treatment

Heater Airtronic D1LC - D3LC Compact, Auxiliary heater

Airtronic D2 / D4 heater, auxiliary heater

Heater Hydronic D5W, Auxiliary heater

AS Tronic gearbox, Electronically controlled gearbox

AS Tronic gearbox, Gearbox parameterization

ZF WSK TC2 gearbox, Clutch converter

Climate control ATC, Automatic temperature control

Climate control GKR, Climate control

FFR central computer, Vehicle control unit

Central computer KSM VDO, special parameterization module

Central computer OBDU, On-board diagnostics unit

Central computer ZBR, On-board computer

Central computer ZFR, On-board computer

TPM Wheel Pressure Monitoring, Wheel Pressure Monitoring

EHLA steering, Electro-hydraulic power steering system

Steering RAS EC1, Rear axle control system

Brakes EBS 5, Electronic braking system

Brakes EBS Knorr 2.2-2.3, Electronic braking system

Compressed air preparation ECAM, Electronic control of compressed air flow

INS STON Toolbar, Toolbar

INS VDO Toolbar, Toolbar

Electronic module DM, Door module

CRT engine, Continuous catalyst regeneration

EDC 7 C3 / C32 engine, Electronic Diesel Control (EDC), common rail system

EDC MS 6.1 engine, Diesel high pressure fuel pump

EDC MS5 Engine, Diesel High Pressure Fuel Pump

EDC7 Engine Master / Slave, Engine Management System

Powertrain HydroDrive, Hydrostatic front linkage

ACC safety, Adaptive cruise control

Security AIRBAG, Airbag

LGS Safety, Road Monitoring System

ECAS CAN2 suspension, Electronically controlled suspension system

ECAS NFG suspension, Electronically controlled suspension system

Telematics TBM, Telematics unit

Like any cars nowadays, MAN freely reprograms interchangeable microcircuits, in order to:

1 Reconfiguring the automatic transmission for more difficult driving conditions,
2 Exemption from the speed limit of 90 km / h.
3 Decrease in fuel consumption (through weakening of the engine).
4 Strengthening the engine.
5 Decrease in sensitivity to low-quality fuel.

Video (click to play).

MAN SE is a mechanical engineering company from Germany. The company is specialized in the production of engines, buses and trucks. The company was founded in 1758 with the old name Maschinenfabrik Augsburg-Nurnberg

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