Pneumatic diagrams of MAN TGA brake systems since 2000


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Parking brake system

When changing the position of the lever of the manually controlled brake valve 16, the working pressure of the compressed air in the spring energy accumulator of the pneumatic cylinder 19 . In this state, the force on the wheel brake mechanisms is applied due to the elastic forces of the springs of the pneumatic cylinders. At the same time, the air pressure in the line is released in the area from the manually operated 16 17 . When the road train is parked, the trailer is held by applying pressure to the control line. Since the Council Directives of the European Economic Community (ECEC) include the requirement that a goods road train (truck and trailer) can only be held in place by the vehicle's braking system, the pressure in the trailer braking system can be relieved by moving the manually operated brake valve lever to "Control position". This allows you to check whether the parking brake system of the road train meets the requirements of KKEO.

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Interior, structure and markings of cabins

The seats and steering wheel have a lot of different settings, and in addition, there are many devices in the cabin that make it easier to navigate the road:

  • Compact refrigerator;
  • Many different lockers and compartments;
  • Comfortable “sleeping bags”;
  • Glass with a special coating that prevents them from sweating;
  • Mobile oven and independent heater;
  • Multimedia.

The cabin has a special code in its marking - 284 NKW, which indicates that the machine is able to withstand harsh Russian operating conditions and is not afraid of cold weather. Long-haul tractors have “LX” cabs and are divided into two types – XLX and XXL. The length of the “sleeping bags” in such models is 2200x790 cm, and the height is 1975 cm for XLX, and 2200 cm for XXL. There is also the XL model, with more modest indicators, but it has not found sufficient distribution on highways, so it is not taken into account.

A car of this class must have a lot of electronics, so the MAN is equipped with cruise control, an on-board computer, electric windows, and a “bunch” of various electronic assistants that make the driver’s life much easier.

Dashboard (Euro 5)

  1. Hazard warning light switch.
  2. Switch for front and rear fog lights/lights.
  3. Tachometer.
  4. Screen for time and outside temperature/boost pressure/instrument backlight.
  5. Tractor turn signal indicators.
  6. Display.
  7. Control indicators.
  8. Sensor for automatically adjusting the brightness of interior lighting.
  9. Speedometer.
  10. Odometer/trip counter.
  11. Maximum speed indicator.
  12. Light test switch.
  13. Adjuster of the angle of inclination of the optical axis of the headlights.
  14. Fuel level indicator.
  15. Button for confirming “yellow” messages on the display/changing the “km/h” or “mph” display/vehicle menu (in vehicles without a multifunction steering wheel).
  16. Button for permanent display/display switching when there are several displays on the vehicle display/menu (on vehicles without a multifunction steering wheel).
  17. AdBlue reducing agent level indicator.
  18. Indication of differential locks.
  19. Coolant temperature gauge.
  20. Instrument lighting/language selection button.
  21. Button for switching the time and temperature display outside.
  22. Pressure indicator in brake circuit I and II.

1-5. Car/car phone/audio installation menu buttons.

6-9. Cruise control/idle speed/accessory buttons.

10. Cruise control and speed limiter button.

Switches and buttons

Control indicators

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Discounts from the help desk

When you mention ACC you can get discounts on parts and services

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List of repair services

We provide the following services for troubleshooting problems arising in the electronic units of EKAM trucks of MAN TGA:

  • Repair of electronic control board
  • Repair of electrical wiring connecting the ECAM unit to the vehicle environment
  • Replacing a failed unit
  • Programming and firmware of the electronic unit
  • Restoring the CAN bus to the control unit
  • Overhaul, lubricate and clean mechanical valves and modulator air circuits

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Trailer braking in automatic mode (emergency braking)

In the event of a rupture, the pressure in the line instantly drops to atmospheric pressure. As a result, the brake valve 27 and the emergency braking process begins. , a two-way, two-position valve built into the trailer brake control valve 17 11 of the compressed air supply line. Thus, a rupture of the brake system control line will cause a rapid drop in operating pressure and the trailer brake valve will operate within the legally regulated time (no more than two seconds ) . Automatic braking will begin. At the same time, check valve 13 prevents accidental activation of the parking brake system when the pressure in the compressed air supply line to the trailer brake system drops.

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The lineup of MAN trucks

Starting in 2013, restyled versions of the entire MAN TGX, TGS, TGM, TGL range are presented:

  • TGA – the model was discontinued since 2008, was replaced by more modern models of TGX and TGS
  • TGX – tractors and classic “singles” with the maximum level of comfort for the driver, payload from 15 to 70 tons (de facto) and engines from 360 to 680 hp.
  • TGS – truck tractors, classic “singles”, dump trucks and various construction equipment on the MAN chassis with a payload of 18 to 70 tons (de facto) and engines from 360 to 680 liters. from.
  • TGM – medium-tonnage trucks, including classic “singles” and dump trucks with a payload of 7 to 20 tons (de facto) and engines from 240 to 380 liters. from.
  • TGL – low-tonnage trucks for local urban transport with a payload of 5 to 7 tons (de facto) and engines from 150 to 250 liters. from.

In the 1990s. MAN switched to a new range of “2000”, including numerous models with a gross mass from 6 to 50 tons, and in the structure of road trains – up to 180 tons. This family consisted of light, medium and heavy families “L2000”, “M2000” and “F2000” respectively, replacing the series “G90”, “M90” and “F90”. These trucks are widely used electronic devices to regulate the engine, air suspension, the position of the driver's seat, the operation of the air conditioner, as well as anti-lock and traction control systems, etc. All cars have front disc ventilated brakes, steering gear with hydraulic amplifier, pneumatic 2-contour brake system, brake lining with wear sensors.

Wedge brake MAN M 2000

Wedge driven brake

The Simplex wedge brake is pneumatically driven via a chamber with a diaphragm. The mechanism is secured to the brake disc with bolts. The mechanism is equipped with a device for automatic compensation of brake lining wear.

Rice. 7.22. Assembly view of a brake with a wedge drive. 1. Crankcase 2. Spacer 3. Snap ring 4. Spring 5. Retaining plate 6. Snap ring 7. Wedge 8. Wedge mechanism assembly 9. Headless bolt 10. Release spring 11. Brake pad 12. Release spring 13. Disk for fastening

Rice. 7.23. Section of the wedge brake drive mechanism. 1. Snap ring 2. Spring 3. Adjusting ring 4. Adjusting sleeve 5. Adjusting bolt 6. Pushrod with roller 7. Spring 8. Wedge assembly 9. Rubber gasket 10. Snap ring 11. Spacer sleeve 12. Crankcase 13 .Protective cap 14. Control mechanism flywheel 15. Anti-rotation device.

Rice. 7.24. The central bolt in the rear wheel brake mechanisms cancels the action of the spring cylinder.

♦ Place the trestles under the vehicle and remove the wheels.

♦ Remove the cover on the rear surface of the disc (old assembly) and reverse the automatic wear compensation mechanism.

In the latest models, to gain access to the compensation device, you must remove the sheet shield secured to the disk with two bolts.

In rear wheel brakes, before turning the compensation mechanism in the opposite direction, unscrew the central bolt of the cylinder with the spring.

♦ Remove the brake drums using the three jack bolts.

Rice. 7.25. Removing the brake drum 1. Special bolts for removing the drum

Rice. 7.26. Lever for releasing release springs.

Disconnect the release spring from the wedge drive, and then disconnect the second spring.

♦ Remove the two brake pads.

♦ Check the parts, clean the supporting surfaces of the brake disc and brake pads, check the condition of the rubber parts.

Installation of brake pads

♦ Replace release springs.

♦ Adjust the wedge mechanism by first turning the compensating flywheel to the zero mark, and then unscrewing it 1 - 2 turns on each side. Dimension “a” should be about 155.36 mm.

Rice. 7.27. Adjusting the wedge mechanism

Rice. 7.28. Installation of anti-rotation devices. The slots should be parallel to the ribs of the brake pad.

♦ Install anti-rotation devices so that the slots are parallel to the ribs of the brake pad.

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