In detail: do-it-yourself repair of a checkpoint man tga from a real master for the site my.housecope.com.
MAN truck gearboxes are reliable units designed for a long period of operation in various modes and in a wide variety of climatic and road conditions. Despite the built-in margin of safety, malfunctions also occur in them. In most cases, they are the result of violation of the rules of maintenance and operation. Repair of the Man ZF gearbox - Man gearboxes is our main specialization, so we can always provide expert assistance in the shortest possible time.
Control unit maintenance
Replacement of synchronizers, bearings
Replacing the clutch fork repair kit
Assembling an already disassembled checkpoint
The demultiplier carrier burst
Replacing the brake clutches
Replacing the front divider piston o-rings
Replacing the 3-4 gear synchronizer
Differential housing replacement
Shank seal replacement
We determine the cause of the breakdown with 99% accuracy
with the help of a professional
dealer equipment
in 30% of cases, the cause of the breakdown is not in the gearbox itself, but in the adjacent vehicle systems
The cost of repairing which is often much lower than repairing the gearbox itself
Gearbox shift drive mechanism
Control electronics for shift or clutch actuator
Choose your version
- The client formulates his problem
- We carry out diagnostics to determine the true cause of the breakdown
- Dismantling the unit or repairing adjacent systems
- Unit washing. Disassembly, defect detection, budgeting
- Selection and purchase of spare parts
- Repair work
- Assembly and installation of the unit on the car, oil filling
- Test drive, output diagnostics
Video (click to play). |
You know the reason for the breakdown
- Dismantling the unit or repairing adjacent systems
- Unit washing. Disassembly, defect detection, budgeting
- Selection and purchase of spare parts
- Repair work
- Assembly and installation of the unit on the car, oil filling
- Test drive, output diagnostics
- Dismantling the unit
- Unit washing. Disassembly, defect detection, budgeting
- Selection and purchase of spare parts
- Repair work
- Loading the unit
The reason for the most difficult and unpleasant case, when MAN gears are not engaged, is hidden inside the gearbox. The rods and forks of the shift mechanism are strong enough, but they can be deformed or broken during prolonged "power", with crunching and jerking, method of shifting gears. In this case, the only method of "treatment" is disassembly of the gearbox and replacement of damaged parts.
How do tech services cheat their customers?
First of all, we strive to help the client, and then make money.
Therefore, we openly guarantee repairs from the 1st time.
Examples from our practice, when services unfairly profit from clients
1) In the estimate for the repair, they indicate the details of the production of ZF or Euroricambi, and in fact install the details of the production of CEI (cheaper and much lower quality). The benefit can be several tens of thousands of rubles
Examples from our practice, when services unfairly profit from clients
2) In the estimate for the repair, new parts are indicated, and in fact the used parts are installed. The benefit can be several tens of thousands of rubles
Examples from our practice, when services unfairly profit from clients
3) They can cheat when troubleshooting, i.e. slip worn and defective parts from another box, you pay and you will have new parts in the box, and your serviceable ones will be used according to scheme number 2
Examples from our practice, when services unfairly profit from clients
4) Oil fraud schemes are also frequently implemented. Instead of oil of the proper specification, anyone who is at hand or even used oil can be poured! Doesn't fit in your head right? But it fits in the pocket, usually of an ordinary locksmith staff 2-3 thousand rubles.
Thanks to modern European equipment and a high culture of production, you can not think about the quality of repair with us.
Tool storage area, stainless steel workbenches.
Professionalism and the availability of the necessary means of production allow us to maintain a high rate and productivity of labor during disassembly, troubleshooting and assembly of the unit.
Tool storage area, stainless steel workbenches.
Modern electrical equipment allows us to repair any electronic systems of trucks. We also have dealer diagnostic equipment, so you don't have to worry about the accuracy of the breakdown and the quality of repairs.
Press, Goose crane, Stacker
The service is fully equipped with all the necessary, expensive equipment, allowing to carry out repair work of any complexity at the proper level of quality.
Before starting repair work, we wash all the parts of the unit in a special wash, which removes all old oils and dirt from the mechanisms, which will have a beneficial effect on work in the future and greatly simplify the repair process.
Repair of all units is carried out on a special tilter, which fixes the part in a position convenient for access by any tool. At the same time, not a single detail is lying somewhere on the floor, as in most services.
We will prepare all the necessary documents for you, pick up any part within 15 minutes and check its availability in the warehouse. We will also provide you with all the necessary information on the repair and maintenance of your truck.
Message vorzhev "02 Jul 2017, 17:39
Hello everyone.
In general, ECAM on my car ordered to live a long time. For a long time I had been hatching the idea of converting to a 4-circuit system.
For this, a used dehumidifier with a 4-circuit, two limiters for 8.5 and 10 bar was purchased. + 4 sensors, everything is assembled, a 4-liter regeneration receiver, wires, chips, a plastic corrugation, and of course electrical tape.
I cleaned the dehumidifier, went through the restrictive ones with the replacement of the canister and the adjustment for the fur. monometer.
The wiring braid had to be assembled from scratch.
Well, away we go, in general, see for yourself.
I put it in the frame in order to make room for a second tank or under some kind of pallet, it will be seen further.
Gathering everything in a heap, I went to the diagnostician for the firmware of the ZBR unit.
ATTENTION - I hooked up the sensor chip only with the permission of the diagnostician, I was afraid to burn something.
It took about two hours to flash and check the ZBR, and in the end everything worked.
Air pressure began to show from sensors, ECAM dropped out of the list.
For the money, about 45 thousand rubles came out. 4 days of hard work, used spare parts, did everything myself.
Repair and maintenance manual MAN TGA since 2000. The manual contains general information about the device of the car and their modifications, recommendations for operation and maintenance, descriptions of possible malfunctions of the engine, transmission, chassis, steering and brake system. The tips in the manual will help you carry out maintenance and repair both at a service station and on your own. Details (content, specifications, full information) about the book on the official website of the publishing house "Monolit"
Video MAN TGA gearbox repair (first part) channel Publishing house Monolith
We carry out overhaul, diagnostics and restoration of mechanical transmissions ZF, EATON installed on trucks and special equipment MAN F90, F2000, TGA, TGX, TGS, TGL, TGM, NEOPLAN buses
Box repair MAN produced in several stages:
-primary diagnostics and identification of possible causes without removing the gearbox from the car
-remove the gearbox
- removal and inspection of the clutch unit, if necessary, replacement
-disassembly, troubleshooting of faulty parts of the gearbox ZF, EATON
- drawing up a fault finding map
-coordination with the customer of the cost of spare parts to be replaced
-replacement of all necessary spare parts
-assembly and adjustment of the box ZF, EATON
-installation of the check point on the car
- clutch calibration (if required)
-testing of the gearbox on the car
A guarantee is provided for all types of work!
The term of the gearbox repair, if spare parts are available, is 1 day!
By trucks MAN mechanical boxes of series were installed ECOSLIPT ECOMID, ECOLITE, automatic boxes series AS TRONIC, ECOMAT, ECOLIFE and new development TraXon.
The main types of gearboxes installed on MAN vehicles:
ZF 5S42, ZF 9S1310, ZF12AS2330, ZF16S151, ZF16S181, ZF16S221, ZF 16S109 (1304050026), ZF 6S850, ZF 16S1620, ZF 16S1650, ZF 16S1820, ZF 16S1920, ZF16S2220, ZF16S2230, ZF16S2520 (1343002001), ZF16S2523
EATON RTSO 12316 / TSO 11612 / RTO 11613 / FSO 8209 / FSO 5206. Can be installed retarder (Tbrake retarder).
Retarder brake (retarder) - a device designed to reduce the speed of a vehicle without activating the main braking system.
At the installation site, primary retarder brakes are distinguished - installed on the input shaft of the gearbox or on the engine shaft, and secondary ones - on the secondary shaft of the gearbox. If the retarder is combined with a gearbox, it is called integrated: company ZF even introduced a separate name for it - "intarder". It is not connected directly to the output shaft, but through a pair of gears with a gear ratio of approximately 1: 2, so the rotor speed is twice as high here (which improves the braking torque characteristics at low speeds).
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Askar 09 Nov 2017
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question: how to determine by the checkpoint, it or so on without disassembling?
all infa on the nameplate at the checkpoint
TD - direct drive with a gear ratio of 1: 1
TO - direct gear with increased output shaft speed
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many boxes sell without nameplates and the price tag is normal. I had 12as2301to. sell without nameplate and retarder box 2301. how to find out the gear? do not allow to disassemble
but there is no way to find out, just to take and put. If the car drives like it did on the old box, then MOT got caught.
If the speed in top gear at certain rpm is lower, then TD.
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if you lift the control unit, can you see something and determine the gear?
the block will not tell you anything, its business is to manage the korobas. And what kind of gears inside the box are located on the drum control unit.
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I mean by the switch valve block, if you remove it from the box
here's a file for you, study it.
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many boxes sell without nameplates and the price tag is normal. I had 12as2301to. sell without nameplate and retarder box 2301. how to find out the gear? do not allow to disassemble
but there is no way to find out, just to take and put. If the car drives like it did on the old box, then MOT got caught.
If the speed in top gear at certain rpm is lower, then TD. another question, will the miner not get puffed up if he comes across a TD?
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- I do not like
no, on the contrary, it will be a little easier for him.
But the motor will have to be turned more.
before, for example, you drove 90 km / h and the rpm was 1400. With the TD box at such rpm, the speed, for example, will be 80 km / h, that is, to go under 90, you need to turn the engine to, say, 1600-1700.
I invented the numbers out of my head, so to speak, as an example.
- Like
- I do not like
another question, will the miner not get puffed up if he comes across a TD?
no, on the contrary, it will be a little easier for him.
But the motor will have to be turned more.
before, for example, you drove 90 km / h and the rpm was 1400. With the TD box at such rpm, the speed, for example, will be 80 km / h, that is, to go under 90, you need to turn the engine to, say, 1600-1700.
I invented the numbers out of my head, so to speak, as an example. understood. Thank you
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Having removed the control unit, you cannot understand anything, there are shift rods and a gear wheel of the input shaft, the sensor removes revolutions from it.
Behind it there is a large gear, called the Main shaft constant mesh gear. Here it is, if the box is TO at 46 teeth, and if the TD box is at 36. Can it be seen behind the cogwheel? On my own I can not check because everything is disassembled and not by me. Need infa.
- Like
- I do not like
Having removed the control unit, you cannot understand anything, there are shift rods and a gear wheel of the input shaft, the sensor removes revolutions from it.
Behind it there is a large gear, called the Main shaft constant mesh gear. Here it is, if the box is TO at 46 teeth, and if the TD box is at 36. Can it be seen behind the cogwheel? On my own I can not check because everything is disassembled and not by me. Need infa.
- Like
- I do not like
Having removed the control unit, you cannot understand anything, there are shift rods and a gear wheel of the input shaft, the sensor removes revolutions from it.
Behind it there is a large gear, called the Main shaft constant mesh gear. Here it is, if the box is TO at 46 teeth, and if the TD box is at 36. Can it be seen behind the cogwheel? On my own I can not check because everything is disassembled and not by me. Need infa.
And they are visually different. Advertising on photos is not my hands. I did not find any other photos. No warnings needed.
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there will be no warnings, do not worry.
on the contrary, thanks for the info about 36 and 46 teeth. you dug it from the file?
it would also be interesting to know what is the gear ratio of the main pair of the TO box ...
I don’t know how to find out with the gear. About 36 and 46 teeth doped himself partially from the file of that, but the idea was prompted by the guys in Minsk in the trash heap.
PROMPT: there was a box with a retard, I want to stick it in without a retard. Judging by the diagrams of the boxes, they are the same size from the beginning of the bell to the end of the flange. According to the sensors, it turns out that three chips that will just hang out for a retada. This fruit of the German car industry will not be capricious?
We specialize in the repair of gearboxes (gearboxes) MAN: ZF 16 S 151, ZF 16 S 181, ZF 16S221, ZF 16S109, ZF 5S42, EATON, as well as automatic robotic gearboxes "ASTRONIC". These models are installed on the following models: L90, M90, F90, MAN 2 series, MAN 3 series, MAN 4 series, L2000, M2000, F2000, Man TGA, TGM, TGX, TGL, TGS.
The lineup of modern trucks and tractors MAN (MAN):
MAN TGL - light trucks with a capacity of 150-250 HP in C, L, LX cabins or double cabins.
The TGM is a medium-sized truck for urban and suburban transport with a capacity of 250-340 hp. with cabins L or LX
TGX - long-haul tractors with a capacity of 320 hp. up to 680 hp (V8) with XL, XLX, XXL cabins.
MAN TGA - tractors for work in bad road and climatic conditions with engines from 360 hp. (D20 Euro-2) up to 480 hp (D26 Euro-3)
MAN TGS - dump trucks and other heavy equipment for work on construction sites.
Model range of MAN trucks and tractors of the previous generation:
• MAN 2 series
• L90 low-tonnage, up to 7t.
• M90 medium-duty.
• F90 large-capacity.
• MAN 3 series and 4 series
• L2000 low-tonnage, up to 7t.
• M2000 medium tonnage.
• F2000 large-capacity
Carefully following the instructions for use Gearbox Man (TGA, TGA) you can save yourself from the need to repair it for a long time. The long-term operation of your machine is facilitated by such points as regular maintenance and diagnostics. You can carry out these types of work both independently and by contacting a specialized service center.
German tractor units Man are made by one of the oldest European companies for the production of trucks.Repair of a gearbox man begins with the normal wear and tear of the unit, but sometimes there are also problems such as the inability to engage an overdrive or strong etching of air through the relief valve on the control unit.
Man trucks are equipped with various gearboxes, among which are the following: Ecolite, Ecomid, Ecosplit, TGA... One of the most reliable gearboxes for this brand of trucks - 16-speed ZF box... This box mainly requires maintenance only for replacement of sealing elements and renewal of consumables.
You need to carry out all these work very carefully, otherwise you can ruin your checkpoint. Moreover, damage may not be revealed immediately, but some time after the repair, and by the time of detection, some nodes may have already worn out.
Repairing the checkpoint MAN TGA in our service center you can be sure of highly qualified service for your truck. In addition, having our own spare parts warehouse allows us to significantly reduce the repair time for your car. Contact us, and you will be pleasantly surprised by the quality of the work, the deadline for its execution and the prices for services.
Repair and maintenance manual MAN TGA since 2000. The manual contains general information about the device of the car and their modifications, recommendations for operation and maintenance, descriptions of possible malfunctions of the engine, transmission, chassis, steering and brake system. The tips in the manual will help you carry out maintenance and repair both at a service station and on your own. Details (content, specifications, full information) about the book on the official website of the publishing house "Monolith" my.housecope.com/wp-content/uploads/ext/2256/
You can contact the service station or get acquainted with the information in the book catalog / rukovodstvo_po_remontu_man_tga_2000 /
where can i do it and how can i do it
man 8150 for the 2nd does not include
man 8150 papal pile frame
With this situation, it is better to contact the service station.
maz box 12-step cheaty does not work dimplier what can be done maz 13-year-old box shahman
Note
The dismantling and installation of the gearbox is described using the ZF 16 S gearbox as an example. The steps for the other gearbox types are the same. When performing work, it is necessary to be guided by common sense and take into account certain design features.
- Return line of the cooling system.
- Cooling system pressure pipe.
- Input speed sensor connector.
- Reverse gear sensor connector.
- Neutral position sensor connector.
- Hex head bolt (2 pcs.).
- Hex lock nut.
- Fastening bolt.
- Cable traction switching mechanism.
- Hex lock nut.
- Sleeve.
- FFR connector.
- Pneumatic line of the working cylinder.
- Discharge valve connector.
- Pneumatic line of the discharge valve.
- Intarder solenoid valve connector.
- Temperature sensor connector.
- Kitas sensor connector.
- Exhaust pipe.
- Valve block pneumatic line.
1. Disconnect the battery.
2. Relieve the air pressure in the receiver of circuit IV through the water drain valve.
3. Disconnect the propeller shaft from the gearbox (see Chapter 16 "Propeller shaft, axles and wheel hubs").
4. Remove the clutch slave cylinder (see chapter 12 "Clutch").
5. Drain fluid from the cooling system.
6. Drain the transmission oil from the transmission.
7. Remove the bracket (1) for the exhaust pipe.
8. Loosen the two pipe clamps (3) and remove the exhaust pipe (2).
9. Remove the retaining clips (2) and (4) from the top of the gearbox.
10. Loosen the hose clamps (1) of the connecting hoses (5) of the left coolant pipe (3).
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Good day! Prompt the air is leaving through the gearbox control unit! MAN TGA / TGS / TGX ZF 0501 219 311. After a long stay, when you start pumping air into the system, air leaks through the block, you move the flag to the increased leakage stops.As I understand the valve does not hold, how is it possible to eliminate all this without buying a new unit? Thank you all in advance.
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I will unsubscribe here about the leak on the cold one, from the valve block to the checkpoint, I did the same yesterday. on the cold poison until it clicked, the subdued one - increased, it will not stop, it hissed on the hot one when the pressure dropped below 6. The valves were stuck due to dirt and lack of proper air maintenance. the block is disassembled easily, a few bolts for an asterisk and an open-end wrench. remove the front cover and take out the valve. clean and back to assembly. disassemble the valve with a straight screwdriver, the cover, under it the valve that is stuck in the photo can be seen, pour in any solvent, and press on it until it comes out freely. all
Message vorzhev "02 Jul 2017, 17:39
Hello everyone.
In general, ECAM on my car ordered to live a long time. For a long time I had been hatching the idea of converting to a 4-circuit system.
For this, a used dehumidifier with a 4-circuit, two limiters for 8.5 and 10 bar was purchased. + 4 sensors, everything is assembled, a 4-liter regeneration receiver, wires, chips, a plastic corrugation, and of course electrical tape.
I cleaned the dehumidifier, went through the restrictive ones with the replacement of the canister and the adjustment for the fur. monometer.
The wiring braid had to be assembled from scratch.
Well, away we go, in general, see for yourself.
I put it in the frame in order to make room for a second tank or under some kind of pallet, it will be seen further.
Gathering everything in a heap, I went to the diagnostician for the firmware of the ZBR unit.
ATTENTION - I hooked up the sensor chip only with the permission of the diagnostician, I was afraid to burn something.
It took about two hours to flash and check the ZBR, and in the end everything worked.
Air pressure began to show from sensors, ECAM dropped out of the list.
For the money, about 45 thousand rubles came out. 4 days of hard work, used spare parts, did everything myself.
- Like
- I do not like
- Like
- I do not like
- Like
- I do not like
- Like
- I do not like
question: how to determine by the checkpoint, it or so on without disassembling?
all infa on the nameplate at the checkpoint
TD - direct drive with a gear ratio of 1: 1
TO - direct gear with increased output shaft speed
- Like
- I do not like
- Like
- I do not like
- Like
- I do not like
many boxes sell without nameplates and the price tag is normal. I had 12as2301to. sell without nameplate and retarder box 2301. how to find out the gear? do not allow to disassemble
but there is no way to find out, just to take and put. If the car drives like it did on the old box, then MOT got caught.
If the speed in top gear at certain rpm is lower, then TD.
- Like
- I do not like
if you lift the control unit, can you see something and determine the gear?
the block will not tell you anything, its business is to manage the korobas. And what kind of gears inside the box are located on the drum control unit.
- Like
- I do not like
- Like
- I do not like
I mean by the switch valve block, if you remove it from the box
here's a file for you, study it.
- Like
- I do not like
- Like
- I do not like
many boxes sell without nameplates and the price tag is normal. I had 12as2301to. sell without nameplate and retarder box 2301. how to find out the gear? do not allow to disassemble
but there is no way to find out, just to take and put. If the car drives like it did on the old box, then MOT got caught.
If the speed in top gear at certain rpm is lower, then TD. another question, will the miner not get puffed up if he comes across a TD?
- Like
- I do not like
no, on the contrary, it will be a little easier for him.
But the motor will have to be turned more.
before, for example, you drove 90 km / h and the rpm was 1400. With the TD box at such rpm, the speed, for example, will be 80 km / h, that is, to go under 90, you need to turn the engine to, say, 1600-1700.
I invented the numbers out of my head, so to speak, for example.
- Like
- I do not like
another question, will the miner not get puffed up if he comes across a TD?
no, on the contrary, it will be a little easier for him.
But the motor will have to be turned more.
before, for example, you were driving 90 km / h and the rpm was 1400.With a TD box at such speeds, the speed, for example, will be 80 km / h, that is, to drive under 90, you need to turn the engine, say, to 1600-1700.
I invented the numbers out of my head, so to speak, for example. understood. Thank you
- Like
- I do not like
- Like
- I do not like
Having removed the control unit, you cannot understand anything, there are shift rods and a gear wheel of the input shaft, the sensor removes revolutions from it.
Behind it there is a large gear, called the Main shaft constant mesh gear. Here it is, if the box is TO at 46 teeth, and if the TD box is at 36. Can it be seen behind the cogwheel? On my own I can not check because everything is disassembled and not by me. Need infa.
- Like
- I do not like
Having removed the control unit, you cannot understand anything, there are shift rods and a gear wheel of the input shaft, the sensor removes revolutions from it.
Behind it there is a large gear, called the Main shaft constant mesh gear. Here it is, if the box is TO at 46 teeth, and if the TD box is at 36. Can it be seen behind the cogwheel? On my own I can not check because everything is disassembled and not by me. Need infa.
- Like
- I do not like
Having removed the control unit, you cannot understand anything, there are shift rods and a gear wheel of the input shaft, the sensor removes revolutions from it.
Behind it there is a large gear, called the Main shaft constant mesh gear. Here it is, if the box is TO at 46 teeth, and if the TD box is at 36. Can it be seen behind the cogwheel? On my own I can not check because everything is disassembled and not by me. Need infa.
And they are visually different. Advertising on photos is not my hands. I did not find any other photos. No warnings needed.
- Like
- I do not like
- Like
- I do not like
there will be no warnings, do not worry.
on the contrary, thanks for the info about 36 and 46 teeth. you dug it from the file?
it would also be interesting to know what is the gear ratio of the main pair of the TO box ...
I don’t know how to find out with the gear. About 36 and 46 teeth doped himself partially from the file of that, but the idea was prompted by the guys in Minsk in the trash heap.
PROMPT: there was a box with a retard, I want to stick it in without a retard. Judging by the diagrams of the boxes, they are the same size from the beginning of the bell to the end of the flange. According to the sensors, it turns out that three chips that will just hang out for a retada. This fruit of the German car industry will not be capricious?
Repair and maintenance manual MAN TGA since 2000. The manual contains general information about the device of the car and their modifications, recommendations for operation and maintenance, descriptions of possible malfunctions of the engine, transmission, chassis, steering and brake system. The tips in the manual will help you carry out maintenance and repair both at a service station and on your own. Details (content, specifications, full information) about the book on the official website of the publishing house "Monolit"
Books on repair and maintenance of cars, operating instructions and other automotive literature published by "Monolith" at the best prices are always available on the pages of online stores of the largest bookselling companies:
Avtoinform96 (Ukraine)
Autosputnik (Russia)
You can view the full version of the e-book online and purchase it abroad at the following link:
MAN TGA AUTOMATIC TRANSMISSION
What affects the resource for the automatic transmission and which components die ahead of time, Today I will tell you how you Kill the automatic transmission, Automatic automatic transmission, with your own hands and actions. And what is better not to do. C: Moscow, Lyubertsy, st. Transport 16
Video (click to play). |
Problems arising during the installation of the VP-44 MAN injection pump