AF-03a (Preventive Maintenance On TG Series) For Participan

MAN Truck & Bus Center
Preventive Maintenance
On
MAN TG SERIES TRUCK
PT. Duta Putera Sumatera MAN I Training Center Indonesia AF-03a Rev:00 1
Disclaimer
• 02 October 2012
• Authors: Ejen Jaenudin, ST
• This document is intended solely for use in training and is not subject to the ongoing revision service. © 2012 MAN Truck & Bus
AG. Reproduction, duplication, distribution, editing, translation, microfilming and storage and/or processing in electronic systems
including databases and online services are not allowed without the written approval
of MAN Truck & Bus AG.
 Sangkalan
Penulis: Ejen Jaenudin, ST
Dokumen ini dimaksudkan semata-mata untuk digunakan dalam pelatihan dan tidak tunduk pada layanan revisi. © 2012 MAN Truck &
Bus AG. Reproduksi, duplikasi, distribusi, editing, terjemahan, dan penyimpanan mikrofilm dan / atau pengolahan dalam sistem
elektronik termasuk database dan layanan online tidak diperbolehkan tanpa persetujuan tertulis MAN Truck & Bus AG.
Time Table
08:30 - 10:00 Start of seminar

10:00 – 10:15 Coffee/Tea break
12:00 – 13:00 Lunch break
14:30 – 14:45 Coffee break
Approx. 17:00 End of session
Training Subject
1. Specification Unit
2. Electric Component
3. Preventive Maintenance Unit
4. Specification Oil & Coolant
5. MAN Tips
Vehicle Information
Design Product Door Label on TG
TGA
40.480
TGA: Trucknology Generation A
40: Permissible GVW in Tons
480: Engine Output in Horse Power
Vehicle Information
IDENTITAS KENDARAAN
Vehicle identification , Chassis, & Engine number
Vehicle Information
IDENTITAS KENDARAAN
Vehicle identification , Chassis, & Engine number
Spesifikasi Truck MAN TG series
Engine: MAN-D2066LF07
 Six cylinder in line Diesel Engine, Common Rail, Turbo charging,
Inter cooling.
 Displacement 10.5 liter / 10518cc
 Power Output 360HP(265kW) @ 1900 rpm.
 Torque 1800 Nm @1000 – 1400 rpm
 Emission EURO II
 Clutch
 Single plate clutch diameter 430mm
 Fuel tank capacity: 400L
Gearbox: ZF 16S2520 TO
 16 Speed Synchronized range gearbox & reverse gears.
 Ratio Range: 13.80 – 0.84 : 1
TGS 33.360HP
Front Axel : MAN VOK-07, Dropped, capacity 7.5 Ton.
Rear Axel : MAN HYD1370 / HY 1350, capacity 26 Ton
 Inter axels & Inter Wheel differential lock
Wheel Config : 6x4, BBS-WW  Boggie suspension on tandem axels with stabilizer bar
 Hypoid axel ratio : I: 4,11
GVW:33 Ton /GCW:70 Ton
 Tyre 315/80 R22,5
Brake System : EBS-5 ( Include ABS function), Exhaust Brake non EVB
Cruise Control & Speed Limiter
Inter cooling.
 Displacement 10.5 liter / 10518 cc
 Power Output 400HP(294kW) @ 1900 rpm.
 Torque 1800 Nm @1000 – 1400 rpm
 Clutch
TGS 40.400HP  Ratio Range: 13.80 – 0.84 : 1

Front Axel : MAN VO-09, Straight, capacity 9 Ton.
Rear Axel : MAN HPD1682 / HP 1652, capacity 32 Ton
Wheel Config : 6x4, BB-WW  Inter axels & Inter Wheel differential lock
GVW:40 Ton  Boggie suspension on tandem axels with stabilizer bar
 Hypoid axel ratio : I: 6.28
 Tyre 12.00 R24
Brake System : EBS-5 ( Include ABS function), Exhaust Brake with EVB
 Six cylinder in line Diesel Engine, Common Rail, Turbo charging, Inter
cooling.
 Power Output 480HP(353kW) @ 1700-1900 rpm.
 Torque 2300 Nm @1000 – 1400 rpm
 Clutch
Gearbox: ZF 12 AS 2330 OD, MAN TipMatic
 12 Speed Automated constant-mesh gearbox & reverse.
 Ratio Range: 12.33 – 0.78 : 1
TGA 40.480HP
Transfercase :MAN G 253 P32-L
Front Axel : MAN VO-09-05, Straight, capacity 9 Ton. FA Axel Ratio 5,33:1
Wheel Config : 6x6, BBS-WW  Inter axels & Inter Wheel differential lock
 Boggie suspension on tandem axels with stabilizer bar
GVW:40 Ton
 Hypoid axel ratio : I: 5,33:1
 Tyre 12.00 R24
cooling.
 Torque 2100 Nm @1000 – 1400 rpm
 Clutch
 Twin plate clutch diameter 400mm
TGS 40.440HP  Ratio Range: 13.80 – 0.84 : 1

Transfercase :MAN G 173 Z
Wheel Config : 6x6, BBS-WW Rear Axel : MAN HPD1682 / HP 1652, capacity 32 Ton
GVW:40 Ton  Inter axels & Inter Wheel differential lock
 Tyre 12.00 R24
Inter cooling.
 Torque 2300 Nm @1000 – 1400 rpm
 Clutch
TGA 40.480HP
 Ratio Range: 13.80 – 0.84 : 1
Front Axel : MAN VO-09, Straight, capacity 9 Ton
Wheel Config : 6x4, BBS-WW  Inter axels & Inter Wheel differential lock
GVW:40 Ton  Hypoid axel ratio : I: 6,82:1
 Tyre 12.00 R24
 Six cylinder in line Diesel Engine, Common Rail, Turbocharging,
Intercooling.
 Displacement 12,4 liter / 12400 cc
 Torque 2300 Nm @1000 – 1400 rpm
 Emission EURO III
Clutch
 Single plate clutch MF Z 430
 Clutch plate diameter 430 mm.
Gearbox: ZF 12 AS 2330 OD, MAN TipMatic
 12 Speed Automated constant-mesh gearbox & reverse.
 Ratio Range: 12.33 – 0.78 : 1
Front Axel : MAN VO-09, capacity 9.5 Ton.
TGS 50.480HP
 Hub reduction with inter axels differential lock
 Planetary axel ratio : I: 28/21*4.000: 5,33
Wheel Config : 8x4, BB-WW Tyre 12.00 R24
GVW:41 Ton Brake System : EBS-5 ( Include ABS function), Exhaust Brake with EVB
cooling.
 Torque 2300 Nm @1000 – 1400 rpm
 Clutch
TGS 40.480HP
 Ratio Range: 13.80 – 0.84 : 1
Transfercase :MAN G 253 ZL
Wheel Config : 6x6, BBS-WW Rear Axel : MAN HPD1682 / HP 1652, capacity 32 Ton
GVW:40 Ton  Inter axels & Inter Wheel differential lock
 Tyre 14.00 R24
Engine Information
Engine Information
ENGINE TYPE D2066LF

Engine Information
ENGINE TYPE D2066LF
Electric System Information
Electronic Diesel Control

TGA.40.480-EDC7-C32 (51.25803-7425)
TGA.41.480-EDC7 (51.25803-7119)
TGA.40.400-EDC7 (51.25803-7238)
TGS.40.440-EDC7-C32 (51.25803-7894)
Oil module Charger air pipe

Oil filter & blobby
separator
Unscrewed conduit
Coolant system
Turbocharger Exhaust Valve Brake (EVB)

Y355 (EVB Module),(4.05-97)
TGA 40.400/TGA 41.480
Refrigerant
compressor
Pressure pickup, air filter

sensor (B433)
Cn:15006,16139,31002,
Sh:302-11
Charge air pressure sensor,

(B125)
Cn:60141,60102,61159,
Sh:405-91
Fan clutch / magnetic clutch, blower

(Y273)
Cn:31000, 61304, Sh:302-09
Coolant level sensor, (B139)

Cn:16116,31000, Sh:302-09
Pn:81.27421-0232, R2000.ohm
Fan clutch / magnetic clutch, blower

(Y273).TGA.40.480, D2676
Cn:31000, 61305, 61304,61104,60614
Sh:302-09
Temperature sensor,
charge air (B123)
Cn:60100,60151, Sh:405-91
Steering oil level switch,

(B371)
Cn:92116, 31000 Sh:302-11
Fuel pressure sensor, (B377)

Cn:60158,60155,60137,
Sh:405-91
Temperature sensor,
charge air (B123)
Rail pressure sensor, (B487)
Cn:60100,60151, Sh:405-91
Cn:60162,60160,60161,
Sh:405-89
Metering unit (Mprop) Proportional

valve, fuel, (Y332)
Cn:60374, 60374 Sh:405-89
R2.5-4.5 ohm, SPN:3748
EDC control unit (A435)

Sh:405-89
Oil level sensor &

temperature (B270)
Cn:31027,16138,16129,31027
Sh:3.02-19
Camshaft sensor / Engine speed

segment encoder (B489)
Cn: grbr, gr, Sh:405-91
R:0.926Kohm, SPN:3752.EDC
Water temperature /
coolant sensor (B124)
Cn:60101,60131, Sh:405-
91,SPN:110.EDC
Crankshaft sensor/Engine
speed incremental encoder
(B488), R:0.922-Kohm
Cn:gr-gn,gr-ws, Sh:405-91
SPN:3753.190.EDC
Oil pressure sensor (B104)

Cn:60135,60156,60134,
Sh:405-91,SPN:3082.EDC
Magnetic clutch,
compressor,(Y114)
Cn:23300,31000, Sh:411-07
Exhaust gas temperature (B561)

PTC sensor cn:90115, 90116,
sh:…….
Temperature sensor,
external air (B269)
Cn:60147, 31017,
Sh:302-19
Clutch fluid & level

sensor not available
On TGA Matic
Starting motor (M100)

Cn:30000,30076,60314,3
1321, sh:302-03.
Fuel level sensor (B103)

Cn:16114,31002, Sh:302-17
Pn:81.27203-6020
Periodical Maintenance
Apa itu Preventive Maintenace
Preventive maintenance adalah proses perawatan yang

dilakukan dengan interval waktu yang telah ditetapkan secara
rutin dengan maksud mencegah kerusakan, dengan
mendeteksi secara dini tanda-tanda akan terjadi kegagalan
yang disusul dengan tindakan perbaikan, memperlambat
proses degradasi dan penuaan mesin atau peralatan dan
mencegah atau mengurangi penurunan performance mesin
atau peralatan
Engine
A: Tempat pengisian oli

B: Tempat pengisian air radiator
B A
Penggantian oli Engine

dilakukan setiap 250 Jam atau
10000Km,
Type Oli: 15W-40
Jumlahnya: 42 liters
Termasuk Engine oil filter
(Pn:51.05504-0107) 1 pcs 1 pcs
Engine
Penggantian oli Engine dilakukan setiap 250 Jam atau

10000Km, Type Oli: 15W-40, Jumlahnya: 42 liters,
Termasuk Engine oil filter (Pn:51.05504-0107) 1 pcs
Oil Module, ganti oil filter
disini
Engine
Pengantian filter bahan bakar solar

(racor)
Fuel Separator,
penggantian setiap
250 Jam / 12500Km
Engine
Pengantian filter bahan bakar solar Filter Strainer, di ganti setiap

1000 Jam / 40000Km
Fuel filter setiap 500 jam /
20000Km
Hand fuel pump

Untuk melakukan
bleeding
Engine
Penggantian dilakukan setiap

1000 Jam atau 40000Km,(No:2)
1000 Jam atau 40000Km,(No:3)
Sensor untuk
mendeteksi filter
tersumbat
MAN Truck & Bus Center Preventive Maintenance
Engine
Pengantian Oil Stering

Ganti OLI setiap 1000 Jam / 40000Km, Type OLI
:MAN 339, atau OLI lain yang memiliki
spesifikasi: -ATF DEXTRON 2 / 3, termasuk Oil
filternya P/N: 81.47301-6005, Jumlah oil 4 liters
Expansion tank for

power steering
Oil ATF MAN 339 Type
DE. Qty:4 liters
Transmission
Pengantian Oil transmisi

Ganti OLI setiap 1000 Jam / 40000Km,
quantity lihat tabel, Type OLI :MAN 341,
atau OLI lain yang memiliki spesifikasi;
- API GL 4
- SAE 80W 90
Transfer case
Pengantian Oil transmisi

Ganti OLI setiap 1000 Jam / 40000Km,
quantity lihat tabel, Type OLI :MAN 341,
atau OLI lain yang memiliki spesifikasi;
- API GL 4
- SAE 90
Axel
Pengantian Oil AXEL

ganti OLI setiap 1000 Jam / 40000Km, Type OLI
:MAN 342, atau OLI lain yang memiliki
spesifikasi;
- SAE 85W 90
Rear axle HPD-1682 (MAN) Rear axle HP 1652 (MAN)
Axel
Spesifikasi Oli, & Coolant
Truck MAN TG Series
Oli Mesin
Kuantitas : 42 + 6 liter
Tipe Oli : MAN 3277, atau

oli lain yang memiliki spesifikasi;
- API CH 4
D2066LF06, - API CI 4
- SAE 15W 40
Oli Mesin

- API CH 4
- API CI 4
D2676LF03 - SAE 15W 40
Oli Mesin
Tipe Oli : MAN 3277, atau oli lain yang memiliki spesifikasi;
- API CH 4
- API CI 4
- SAE 15W 40
D2676LF04
Truck MAN TG Series
Oli Mesin

- API CH 4
- API CI 4
D2676LF02 - SAE 15W 40
Oli Mesin
Kuantitas : 30 + 6 liter (Red dipstick)
Tipe Oli : MAN 3277, atau oli lain yang memiliki spesifikasi;
- API CH 4
- API CI 4
D2876LF12 - SAE 15W 40
Truck MAN TG Series
Oli Transmisi
Kuantitas : 13 liter

- SAE 85W 90
ZF 16S2520 OD
Oli Transmisi

ZF 12AS2330 OD oli lain yang memiliki spesifikasi;
- SAE 85W 90
Truck MAN TG Series
Oli Trasfercase
Kuantitas : 8.5 liter

- SAE 85W 90
G 253 P32-L
Oli Trasfercase
Kuantitas : 7 liter

- SAE 85W 90
G 173 Z
Oli Trasfercase
Kuantitas : 5.8 liter

- SAE 85W 90
G 172 P22 - L
Truck MAN TG Series
VP 09-05 / 04
Oli Gardan (Axles)

Kuantitas :
HPD 1682 -VP 09-05 : Mid-section 6L, Planetarydrive: 2x1,5L, Steering
knuckle 4x0,5L = 11 Liter
- HPD1682 : 13,5L Axle + (2x 2,8L) Hub reduction = 19,1 Liter
- HP1652 : 12,1L Axle + (2x 2,8L) Hub reduction = 17,7 Liter
HP1652
- HYD1370 : Axel drive & Power devider= 16 Liter
- HY1350 : Axel drive = 14.5 Liter
HYD 1370 Tipe Oli : MAN 342, atau oli lain yang memiliki spesifikasi;
- SAE 85W 90
- SAE 90
HP1350
Truck MAN TG Series
Grease Bogie (trunion)

Kuantitas : Grease 1 kg
Tipe Oli : MULTIPURPOSE GREASE MAN 283 Li - P2

AGIP LC,NL GI 2
MAN Bogie
Oli Power Steering

Kuantitas : Single steering: 4 liter

MAN Power steering - ATF Dextron 2 atau 3
Radiator Coolant

coolant lain yang memiliki spesifikasi;
- Anti Corrotion (Fleetguard DCA II 0r
MAN Radiator Texaco Havoline XLI ) dengan perbandingan:
Coolant 0,8 -1,5 per 4 liter air
- Air 6,5 – 8,5 pH
Truck MAN TG Series
Clutch Oil
Kuantitas : 1,2 liter
Tipe Oli : Brake Fluid DOT 3 atau DOT 4
MAN Clutch Actuator
Oli Cab Tilt

Kuantitas : 0,75 Liter
MAN Cabin Tilting Tipe Oli : Hydraulic Oil DIN 51524
TIPS Electrical
KERJA PENGELASAN PADA KENDARAAN
Mr. MAN Mengatakan!!

Jika ada “KERJA PENGELASAN PADA
KENDARAAN MAN Truck Anda “, lakukan seperti
penjamperan kabel positive dan negative seperti
gambar di samping
ECU / ECU /
SYSTEM Kabel Positive dan Negative di SYSTEM
Gabungkan
+ - + -
+ - + - + - + -
Baterai Baterai Baterai Baterai
12 V 12 V 12 V 12 V
KONDISI NORMAL KONDISI PENGELASAN
TIPS Electrical
Penambahan Aksesoris Pada Kendaraan
+
+ -
-
MR.MAN Mengatakan:
Jika ada penambahan Aksesoris pada unit MAN,
>Kabel Negative Tidak Di Perbolehkan mengambil dari

Chassis tapi langsung dari negative battery
>Ukuran Kabel Positive dan Negative harus sama

1,5mm
+
+ - -
1,5mm
TIPS Electrical
CARA MELAKUKAN”JUMPER PADA BATERAI”
MR.MAN Mengatakan:
Jika Unit tidak bisa cranking karena Baterai
lemah, Maka:
“ Lakukan jumper kabel seperti
gambar disamping”
Perhatian!
Jika Pemasangan polaritas kabel

baterai terbalik,
Maka akan terjadi kerusakan
pada;
1.ECU Central Cumputer (ZBR)
2.Regulator Fan Blower AC
3.Fuse 125A untuk Alternator putus
4.Fuse 25A untuk EDC putus
TIPS Maintenance
P2H (Pemeriksan dan Perawatan Harian)
MR.MAN Mengatakan:
P2H selayaknya di lakukan sebelum operasi oleh pengguna unit:
TIPS Maintenance
P2H (Pemeriksan dan Perawatan Harian)
TIPS Maintenance
Check & Set up valve Clearance Engine
TDC
Cara Pemeriksaan dan Pengukuran Valve intake dan exhaust:
1. Posisikan Plywheel dengan tanda garis OT di 0 derajat, itu artinya menunjukan Top Dead Center
(TDC) untuk Cylinder no. 1 atau 6.
2. Tentukan apakah saat TDC, itu apakah TOP 1 atau TOP 6, kemudian lakukan pengecekan seperti
prosedur yang sdh ditetapakan , lihat manual book.
3. Siapkan feeler gauge ukuran , 0,50, 0,80 dan 0,60 mm untuk pengkuran.
TIPS Maintenance
TIPS Maintenance
TIPS Maintenance
TIPS Maintenance
Coolant
TIPS Maintenance
Oil Engine
TIPS Maintenance
Oil Engine
TIPS Maintenance
MTC Gear OIL
Terima kasih
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MAN Truck & Bus Center

MAN TG SERIES TRUCK

Penulis: Ejen Jaenudin, ST

08:30 - 10:00 Start of seminar

Design Product Door Label on TG

TGA: Trucknology Generation A

40: Permissible GVW in Tons

480: Engine Output in Horse Power

Spesifikasi Truck MAN TG series

Spesifikasi Truck MAN TG series

TGS 40.400HP  Ratio Range: 13.80 – 0.84 : 1

Spesifikasi Truck MAN TG series

Spesifikasi Truck MAN TG series

TGS 40.440HP  Ratio Range: 13.80 – 0.84 : 1

Spesifikasi Truck MAN TG series

Spesifikasi Truck MAN TG series

Spesifikasi Truck MAN TG series

ENGINE TYPE D2066LF

ENGINE TYPE D2066LF

Electronic Diesel Control

Oil module Charger air pipe

Turbocharger Exhaust Valve Brake (EVB)

Pressure pickup, air filter

Charge air pressure sensor,

Fan clutch / magnetic clutch, blower

Coolant level sensor, (B139)

Fan clutch / magnetic clutch, blower

Steering oil level switch,

Fuel pressure sensor, (B377)

Metering unit (Mprop) Proportional

EDC control unit (A435)

Oil level sensor &

Camshaft sensor / Engine speed

Oil pressure sensor (B104)

Exhaust gas temperature (B561)

Clutch fluid & level

Starting motor (M100)

Fuel level sensor (B103)

Apa itu Preventive Maintenace

Preventive maintenance adalah proses perawatan yang

A: Tempat pengisian oli

Penggantian oli Engine

Penggantian oli Engine dilakukan setiap 250 Jam atau

Pengantian filter bahan bakar solar

Pengantian filter bahan bakar solar Filter Strainer, di ganti setiap

Hand fuel pump

Penggantian dilakukan setiap

Pengantian Oil Stering

Expansion tank for

Pengantian Oil transmisi

Pengantian Oil transmisi

Pengantian Oil AXEL

Rear axle HPD-1682 (MAN) Rear axle HP 1652 (MAN)

Tipe Oli : MAN 3277, atau

Tipe Oli : MAN 3277, atau

Tipe Oli : MAN 3277, atau

Tipe Oli : MAN 341, atau

Tipe Oli : MAN 341, atau

Tipe Oli : MAN 341, atau

Tipe Oli : MAN 341, atau

Tipe Oli : MAN 341, atau

Oli Gardan (Axles)

Grease Bogie (trunion)