MAN TGA Workshop Manual. Electrical System
Complete factory repair manual for MAN TGA trucks. Includes technical specifications, step-by-step instructions, diagrams, tables and recommendations for diagnosing all systems.
📘 What is included in the MAN TGA Manual:
- Repair and maintenance of D20, D26, D28 engines
- ZF gearbox, brake and pneumatic systems
- Electrics and electronics: diagrams, blocks, errors
- Suspension, steering, clutch
- Fault diagnostics and error codes (OBD, FFR)
🚛 Application:
- All MAN TGA modifications: tractors, chassis, dump trucks
- Ideal for service stations, service engineers and equipment owners
📄 Format:
- Convenient PDF file
- For computer, tablet or printing
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MAN TGA - Common Problems and How to Avoid Them
🔋 1. Electrical problems
Symptoms: CAN bus errors, instrument cluster failure, poor starting
Causes: contact corrosion, broken wiring, VECU failure
Prevention:
- Check connectors and ground regularly
- Use moisture protection in connectors
- Clean control units from dirt and moisture
❄️ 2. Cooling system problems
Symptoms: engine overheating, coolant leak
Causes: radiator cracks, thermostat failure, hose wear
Prevention:
- Replace coolant every 2 years
- Inspect hoses and radiator every 50,000 km
- Check thermostat and fan operation
🛠 3. ZF gearbox malfunctions (automatic and manual)
Symptoms: jerking, inability to shift, gearbox errors
Causes: oil contamination, synchronizer wear, electronic failure
Prevention:
- Change oil and filter in the gearbox every 150,000 km
- Diagnose the transmission control unit (TCU)
- Do not delay repairs at the first sign of problems
💨 4. Turbine and turbocharging system
Symptoms: loss of power, smoke, boost pressure error
Causes: wear of bearings, air leaks, coking
Prevention:
- Check pipes and intercooler for leaks
- Timely oil change
- Clean the turbocharger from carbon deposits
🔧 5. Brake system (EBS/ABS)
Symptoms: ABS errors, braking failures, uneven wear of pads
Causes: sensor failure, connector corrosion, wear of calipers
Prevention:
- Cleaning and diagnostics of ABS sensors
- Lubrication supports and guides
- Using original components